Foton Workshop Manual - Aumark (BJ1099)

POWERED BY

FOTON WORKSHOP MANUAL - AUMARK (BJ1099) 

Table of Contents 

AUMARK MODEL BJ1099 

Pg. 

01 INTRODUCTION 5 

02 PREPARATIONS 39 

03 MAINTENANCE SPECIFICATIONS 71 

04 DIAGNOSTICS 119 

11 FUEL SYSTEM 529 

12 EMISSION CONTROL 545 

13 INTAKE AIR 549 

15 EXHAUST SYSTEM 563 

16 COOLING SYSTEM 575 

21 FRONT SUSPENSION 589 

22 REAR SUSPENSION 601 

23 WHEELS AND TYRES 615 

24 FRONT AXLE 629 

25 REAR AXLE 681 

26 SERVICE BRAKE 727 

27 PARKING BRAKE 775 

31 TRANSMISSION 797 

32 CLUTCH 931 

33 DRIVE SHAFT 969 

41 STEERING MECHANISM 991 

42 POWER STEERING 1015 

51 HEATER AND AIR CONDITIONER 1043 

52 SEAT BELTS 1115 

53 BATTERY 1127 

54 LIGHTING 1153 

55 WIPERS AND WASHERS 1191 

56 AUDIO SYSTEM 1207 

61 CIRCUITRY 1221 

71 COMMUNICATION SYSTEM 1355 

72 WINDSHIELDS, MIRRORS AND GLASS 1361 

73 INSTRUMENT PANEL 1397 

74 SEATS 1421 

75 DOOR LOCKS 1441 

76 BODY TILT, DOORS & CARGO BODY 1459 

77 INTERIOR AND EXTERIOR TRIM 1479 

81 VEHICLE CONTROL SYSTEM 1541 

82 CRUISE CONTROL 1547 

83 REVERSE RADAR 1551 

© 2017 Beiqi Foton Motor Co., Ltd 

All right reserved. No part of this service manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any 

means, electronic, mechanical, photo- copying, recording or otherwise, without the proir written permission of Foton.

Introduction 

How to Use This Manual .................................... 01-1 

Overview ....................................................... 01-1 

Special Notice ............................................... 01-4 

Identification Information .................................. 01-5 

Vehicle Identification Number (VIN) ............. 01-5 

SN ................................................................. 01-6 

01 

General Rules for Maintenance Operations ..... 01-7 

Precautions for Operations ........................... 01-7 

Lifting and Support Positions on the 

Vehicle ........................................................ 01-15 

How to Troubleshoot the Vehicle .................... 01-17 

Overview ..................................................... 01-17 

How to Diagnose and Troubleshoot 

Problems ..................................................... 01-18 

Inspection Procedures for Circuits .............. 01-27

01

How to Use This Manual 

Overview 

1. Overview 

(a) 

Introduction – indentification information 

01-1 

This manual provides general descriptions for you to complete maintenance service. 

Following these descriptions to operate helps ensure quality and efficiency of maintenance 

and repair. 

Tips: 

• This manual does not include information about the engine and its control accessories. 

• For information about the engine and its control accessories, refer to the Service Manual 

for Cummins ISF Series Engines. 

(b) 

(c) 

(d) 

A conventional maintenance operation can be divided into the following 3 parts: 

• Diagnosis 

• Removal and installation (replacement), disassembly and assembly, (on-vehicle) 

inspection, and adjustment, etc. 

• Final inspection 

This manual elaborates “Diagnosis” (refer to “Chapter 04 Diagnosis”) and “Removal and 

Installation (Replacement), Disassembly and Assembly, (On-Vehicle) Inspection, and 

Adjustment, etc.” but does not deal with “Final Inspection”. 

This manual does not describe the following important operations which are essential in 

practical maintenance: 

• Lifting your vehicle using jack or safety support stand 

• Cleaning removed parts as needed 

• Visual inspection 

01 

(e) 

(a) 

Index 

A Glossary Index Table is attached to end of manual to help you in reference. 

3. Preparations 

(a) 

The special tools, recommended tools, facilities, and accessories required for maintenance 

services are listed in Chapter 02 “Preparations” of this manual. Please follow the operation 

procedures strictly for your correct use. 

4. Maintenance procedures 

(a) 

(b) 

Parts diagrams are inserted for system descriptions as required in individual sections. 

In the form of an exploded view, a parts diagram describes assembly relations between 

parts clearly and is followed by a list indicating names of parts.

01-2 

Introduction - indentification information 

Example: 

01 

Assembly relations between parts 

Driven gear 

Cross 

Planetary gear 

Thrust washer, planetary gear 

Side gear 

Thrust washer, side gear 

Inner race, bearing, differential 

Right carrier, differential 

Left carrier, differential 

Part name list

(c) 

(d) 

(e) 

(f) 

Example: 


01-3 

If an installation procedure is the reverse order of the corresponding removal procedure, 

only important parts are described. 

The maintenance procedures in this manual only describe important parts. In addition, 

illustrations are used to represent operation objects and items. In procedure descriptions, 

details of operating procedures, standard values, and precautions for operations are set 

forth. 

Some similar models in this manual may share same illustration. In such a case, the 

relevant content may differ from practical situation. 

An operating procedure shows itself in the following forms: 

• Operating procedure illustration shows “What to do” and “Where to do”. 

• Operating procedure heading shows “What to do”. 

• Operating procedure description shows “How to do” and provides other information 

including “Maintenance specification” and “Warning”. 

01 

Operating procedure illustration Operating procedure heading Operating procedure description 

13. Connecting left front wheel hub with brake 

drum 

(a). 

Tighten the 6 nuts to connect left front wheel 

hub with brake wheel.Torque 

Vehicle mode 

1051 Series 

1061 Series 

1089\1099 Series 

1089 /1099 Series 

Torque 

Notice 

Maintenance 

specification information 

Maintenance warning 

message 

Be sure to replace with new nuts. 

(b). 

Perform thread sealing at 3 places on each nut 

in order to prevent looseness.

01-4 

5. Maintenance specifications 

(a) 


In this manual, maintenance specifications are represented in bold type, so you never need 

to put down your work at hand to search for any of them. Relevant content is also given in 

Chapter 03 “Maintenance Specifications” for your quick search. 

6. “Cautions”, “Notices” and “Tips” 

01 

Caution 

Notice 

Tip 

Expressed in bold type, it indicates a situation that may cause personal 

injury to your or others. 

Expressed in bold type, it indicates a situation that may cause damage to 

repair kits or equipment. 

An additional note provided to help increase maintenance efficiency. 

7. Units-International System of Unit 

(a) 

The “UNITS” given in this manual are expressed as the SI UNITS (International System of Unit). 

Example: 

Torque: 30N•m


Identification Information 

Vehicle Identification Number (VIN) 

01-5 

1. Vehicle identification number 

(a) 

As shown in the figure, vehicle identification 

number (VIN) is printed on vehicle identification 

tag (VIN tag) and stamped on vehicle 

identification plate (VIN plate). 

1: Vehicle identification tag (VIN tag) 

Located at right front corner of instrument panel, 

it can be seen through front windshield. 

2: Vehicle identification plate (VIN plate) 

Located on inside top of B-pillar at left side of 

vehicle body. 

01

01 

01-6 

SN 


1. Rear axle SN 

(a) 

Rear axle SN and final drive ratio are stamped 

on rear axle housing. 

1: Rear axle SN 

2: Final drive ratio 

(b) 

Rear axle name plate is located on the front at 

right side of rear axle. 

2. Front axle SN 

(a) 

Front axle name plate is located at middle on the 

front of front axle. 

3. Drive shaft SN 

(a) 

Drive shaft SN is printed on rear drive shaft.

Introduction-General Rules for Maintenance Operations 

General Rules for Maintenance Operations 

Precautions for Operations 

1. Basic maintenance tips 

(a) Maintenance operation tips 

01-7 

01 

1 Clothing 

2 

3 

4 

Vehicle 

protection 

Safe 

operation 

Tools and 

measuring 

instruments 

preparation 

• Be sure to wear uniform and clean overall. 

• Be sure to wear hard hat and work footwear. 

• Before starting any maintenance operation, get guard rails, shields, seat 

covers, and carpets, etc. ready. 

• When 2 or more persons are operating jointly, they must pay regard to each 

other’s safety. 

• When operating with engine running, make sure the workshop is well ventilated. 

• When operating high-temperature, rotating, moving, or vibrating parts, be 

careful to avoid burn or injury. 

• Your vehicle can only be jacked up from designated support points. In addition, 

make sure it is firmly supported. 

• When jacking up your vehicle, be sure to use safe and approved apparatuses. 

• Before starting any maintenance operation, be sure to get tool stand, special 

tools, measuring instruments as well as oils, rags and replacement parts used 

on the vehicle ready.

01-8 


01 

5 

6 

Removal & 

installation 

and 

disassembly 

& assembly 

Removed 

parts 

• Take effective measures after a complete symptom analysis and diagnosis. 

• Before removing a part, check its general situation and for deformation or 

damage, etc. 

• In the case of a complex part, make step records or assembly marks properly 

to avoid impairing its functions. 

• Clean removed parts as needed. Do not install them until a complete inspection 

is finished. 

• Place removed parts in sequence so as to avoid confusing or contaminating 

them. 

• For non-reusable parts including O-rings and self-locking screws, be sure to 

replace them with new ones after removal in accordance with the instructions in 

this manual. 

• Put replaced parts properly in order to show and let the customer know them. 

(b) 

(c) 

Jacking up and supporting your vehicle 

• Be sure to take special care when jacking up and supporting your vehicle and ensure 

that the operations are made at correct positions. (Refer to “Chapter 01 

Introduction-General Rules for Maintenance Operations, Lifting and Supporting 

Positions on Your Vehicle”.) 

Precoated parts 

• Precoated parts refer to the parts (e.g. bolts and nuts) that have been coated with 

sealant before delivery. 

• After a precoated part is loosened, retightened or moved in any way, be sure to 

recoat it with designated sealant. 

• When a precoated part is reused, be sure to clean old sealant and blow-dry using 

compressed air, and then apply designated sealant to its bolts, nuts or threads. 

Notice: 

Check torques according to lower limits of torque requirements. 

(d) 

(e) 

• When using sealant, sometimes you should wait for a period of time until it cures. 

Gaskets and washers 

• Add seal rings on gaskets and washers as needed in order to prevent oil leak. 

Bolts, nuts and screws 

• Tighten using torque wrench in strict accordance with specified tightening torques.

(f) 

Fuses 


01-9 

• When replacing a fuse, make sure current rating of the new one is satisfactory. 

Never use any fuse of unsatisfactory current rating. 

Same current rating 

01 

Illustration Symbol Part name Abbreviation 

Fuse 

Fusible link

01-10 

(g) 

Snap clips 


• The common methods for removal and installation of the snap clips used on the 

vehicle body are illustrated in the table below. 

Tip: 

If a snap clip is damaged in maintenance process, be sure to replace it with a new one. 

01 

Shape(Example) 

Removal/installation 

Pliers 

Clip remover 

Guard band 

Screwdriver 

Guard band 

Scraper 

disassembly 

installation


01-11 

Shape(Example) 

Removal/installation 

disassembly 

installation 

01 

disassembly 

installation 

(h) Removing and installing a vacuum hose 

• When removing and installing a vacuum 

hose, be sure to hold on its end. Never 

pull its middle. 

wrong 

right 

• When disconnecting a vacuum hose 

connector, mark it with a label for 

identification during line connection. 

• After a removal and installation is 

completed, be sure to check the vacuum 

hose carefully for correct connection. 

• In the case of an oversize connector 

when a vacuum pressure gauge is used, 

never connect the vacuum hose with the 

gauge directly. Instead, you must use a 

special adapter to adjust. Once the 

vacuum hose is expanded, air leak may 

result.

01-12 


01 

(i) 

Using a torque wrench with extension handle 

• When a torque wrench with special 

service tool or extension handle is used, 

it indicates that the actual torque has 

been excess if the torque indication on 

the wrench reaches the specified value. 

• In this manual, only the torque values 

requiring special explanations are 

described. When such a wrench is used, 

please calculate its torque value 

according to the following formula. 

• Formula: T’ = T × L2 / (L1 + L2) 

T’ Torque wrench reading (N•m) 

T 

L1 

L2 

Actual torque (N•m) 

Length of special service tool or extension 

handle (mm) 

Length of torque wrench (mm) 

2. Electric control 

(a) 

Disconnecting and connecting battery negative 

cable 

• Before starting an electrical maintenance 

work, be sure to disconnect battery 

negative (-) cable in order to prevent 

burning accident caused by short circuit, 

etc. 

• Before disconnecting and connecting a 

battery cable, be sure to turn off ignition 

and lighting switches and loosen fixing 

nuts of the cable completely. Never twist 

and pry it. 

• After the battery cable is disconnected, 

records of clock and radio, etc. will be 

cleared. Therefore, you should check 

such facilities as clock and radio and 

make corresponding records before such 

an operation.


01-13 

(b) 

Operating electrical components 

• If not specially needed, never open control 

module housing (if you touch an IC pin 

inadvertently, it may be damaged by static 

electricity). 

• When disconnecting a harness 

connector, be sure to pull it instead of 

harness. 

• Operate with care. Never drop any 

electrical component (e.g. sensor or 

relay). If dropped to a hard ground 

inadvertently, be sure to replace without 

reusing it. 

01 

wrong 

3. Removal and installation of fuel control system parts 

(a) 

(b) 

Worksite notices for removal and installation of fuel system parts 

• When cleaning your engine using steam, 

be sure to protect electrical components, 

air cleaner, and emission control system 

related components from being affected 

by water vapor. 

• Never use an impact wrench to removal 

and install any temperature control switch or 

temperature sensor. 

• When checking continuity of a harness 

connector, be careful to insert a probe so 

as to avoid pin distortion or damage. 

• After replacement of an electrical 

component is completed, be sure to 

check its functions in order to ensure its 

normal functioning. 

• Be sure to select a well-ventilated place where there is not any facilities or objects 

that may cause open flames around, including welding, grinding machine, electric 

drill, electric motor and oven. 

• Never select a refueling station or a place around it because evaporative fuel may 

have occupied the whole space. 

Removal and installation of fuel system parts 

• Be sure to get fire extinguishers ready before any operation. 

• To prevent generation of static electricity, be sure to ground the vehicle and fuel 

tank, etc. In addition, do not splash water so as to prevent contact from sliding. 

• Never use any electric appliances like an electric motor or work light so as to avoid 

generation of sparks or high temperature. 

• Never use an iron hammer in order to prevent generation of sparks. 

• When discarding things, be sure to separate rags from fuel.

01 

01-14 


4. Removal and installation of engine intake system parts 

(a) 

If any metal scraps are entrained into intake pipe, engine and turbocharger will be seriously 

damaged. 

(b) 

When removing and installing an intake system 

part, seal air passage openings on the part 

removed using clean rag or sealing tape. 

(c) 

When installing intake system parts, make sure 

they are free of any metal scraps. 

5. Hose hoop operation 

(a) 

(b) 

(c) 

(d) 

Before removing a hose, check depth of 

insertion of its connecto Hose hoop r and 

location of its hoop for accurate reinstallation. 

If the hoop is deformed or dented, replace. 

If the hose can be reused, be sure to let the 

hoop clamp the impression previously left. 

In the case of a spring hoop, its clamping force 

can be adjusted by applying a force in the 

direction shown by the arrow after its installation 

is completed. 

6. Vehicles equipped with selective catalytic reduction (SCR) device 

Cautions: 

A large amount of unburned fuel flowing into catalytic reduction device may cause excess 

temperature resulting in fire hazard. To prevent such an accident, the following precautions 

must be abided by during operation. 

(a) 

(b) 

(c) 

(d) 

(e) 

Hoop clam 

inpression 

Spring hoop 

Be sure to use lead-free diesel oil only. 

Avoid extended idling. Avoid idling your engine for more than 20 minutes. 

Avoid spark test. 

• If not specially needed, never perform any spark test. If such a test is a must, be 

sure to complete it as quickly as possible. 

• During a spark test, never idle your engine. 

Avoid prolonged engine stress test. An engine stress test must be completed as quickly as 

possible. 

Never run your engine when fuel in fuel tank is about to be used up so as to avoid engine 

shutdown adding extra load to catalytic reduction device.


Lifting and Support Positions on the Vehicle 

1. Paying attention to condition of your vehicle when you jack it up 

(a) 

(b) 

01-15 

Principle: Be sure to jack up your vehicle in light condition. Never perform this operation with 

your vehicle laden. 

After heavy parts such as engine and transmission are removed, center of gravity of your 

vehicle will shift. Be sure to place balance weights to prevent your vehicle from turnover or 

support it at specified lifting positions using jack. 

2. Precautions for uses of jack and safety support stand 

(a) 

(b) 

(c) 

(d). 

(e) 

(f) 

Be sure to follow the instructions in this manual to operate safely. 

Never attempt to use a pry bar to raise tires so as to avoid damage to wheels and tires. 

Park your vehicle on a flat road and set parking brake. 

Switch shift lever to reverse position. 

Be sure to block the wheel at diagonal corner of the place to be lifted using stopper. 

Jack up your vehicle using jack with rubber pad. 

Caution: 

• Never lift entire vehicle so as to avoid damage to it, otherwise even personal safety 

will be jeopardized. 

• Be sure to jack up your vehicle at specified jacking points. 

01

01-16 

(g) 


After your vehicle is jacked up, you can support it with a safety stands with rubber pad as needed. 

Caution: 

• Never lift entire vehicle so as to avoid damage to it, otherwise even personal safety 

will be jeopardized. 

• Be sure to jack up your vehicle at specified jacking points. 

01

Introduction-How to Troubleshoot the Vehicle 

How to Troubleshoot the Vehicle 

Overview 

01-17 

The maintenance personnel should have certain electricity knowledge base and they should study 

the circuits in this manual one by one. (Refer to “Chapter 61 Circuitry”.) 

After having a good knowledge of the diagnostic system in this manual (refer to “Chapter 04 

Diagnosis”), the maintenance personnel can troubleshoot problems by means of accurate 

diagnosis and necessary operations. 

This manual is compiled based on the above principle in order to provide maintenance technicians 

with accurate and effective troubleshooting solutions. Please see the text hereunder for details on 

trouble diagnosis and troubleshooting procedures. 

01 

System 

Refer to 

ABS 

A/C system 

Lighting System 

Wipers and Washers 

Audio System 

Power Windows 

Combination Meter 

Power Door Locks 

Chapter 04 Diagnosis-ABS 

Chapter 04 Diagnosis-A/C System 

Chapter 04 Diagnosis-Lighting System 

Chapter 04 Diagnosis-Wipers and Washers 

Chapter 04 Diagnosis-Audio System 

Chapter 04 Diagnosis-Power Windows 

Chapter 04 Diagnosis-Combination Meter 

Chapter 04 Diagnosis-Power Door Locks 

About use of a hand-held diagnostic tester 

Tips: 

• Before using a diagnostic tester, be sure to read its operation manual carefully. 

• Connect the diagnostic tester with the on-vehicle diagnostic interface, and turn ignition 

switch to ON position. If the tester can not communicate with the control module normally, it 

indicates that the vehicle or tester is malfunctioning. 

• If normal communication is enabled when this tester is connected with other vehicles, 

you should check power circuits of vehicle diagnostic data cable or control module. 

• If neither is normal communication enabled when this tester is connected with other 

vehicles, it indicates that the tester itself may be malfunctioning. Please operate 

according to the self-diagnostic procedure in the operation manual of the tester.

01 

01-18 


How to Diagnose and Troubleshoot Problems 

Tips: 

• Only basic operation procedures are listed here briefly. 

• Please perform trouble diagnosis and troubleshooting according to the operation procedures 

described hereunder. 

• For each circuit, the most effective trouble diagnosis and troubleshooting descriptions are 

available in this manual. (Refer to “Chapter 04 Diagnosis”.) 

• Before starting any maintenance operation, be sure to determine trouble diagnosis and 

troubleshooting procedures for related circuits first. 

1. Faulty vehicle check-in 

2. Analysis of customer complaints 

(a) 

Inquire the customer about the vehicle condition and environment-related information when 

the malfunction occurred. 

3. Identifying symptoms and checking diagnostic trouble code/blink code (DTC/BC) 

(a) 

(b) 

(c) 

(d) 

Check battery voltage. 

Voltage: 11~14V (engine off) 

Visually check harnesses, connectors, and fuses for open or short circuit. 

Start the engine and warm it up until its normal operating temperature. 

Search in symptoms chart and list of DTC/BC according to symptoms and set conditions. 

Is it found in symptoms chart or list of DTC/BC? 

Symptoms chart > Go to step 5. 

List of DTC > Go to step 4. 

4. List of DTC/BC 

(a) 

Check the data obtained in step 3 and then determine the inspection procedures of the 

systems or parts to be checked using list of DTC/BC. 

Go to step 6 directly. 

5. Symptoms chart 

(a) 

Check the data obtained in step 3 and then determine the inspection procedures of the 

systems or parts to be checked using symptoms chart. 

6. Circuits and parts inspection 

(a) Identify circuits of the systems or parts determined in steps 4 and 5. 

7. Maintenance 

(a) Repair damaged systems or parts according to the instructions in step 6. 

8. Validation test 

(a) 

(b) 

After the maintenance and repair work is completed, be sure to confirm if the trouble has 

been eliminated. 

If the trouble persists, perform a vehicle validation test by simulating the vehicle and 

environmental conditions of the vehicle when this malfunction occurred for the first time. 

9. Finish


Analysis of customer complaints 

Tips: 

01-19 

• In trouble diagnosis and troubleshooting processes, be sure to eliminate all biases and 

judge accurately in order to identify symptoms. 

• In order to identify symptoms accurately, it is necessary to inquire the customer about the 

vehicle condition and environment-related information when the malfunction occurred. 

• When analyzing customer complaints, you should usually pay more attention to the 

following 5 items. 

Key points for analysis of customer complaints 

01 

Which? 

When? 

Where? 

Conditions? 

How does it happen? 

Model number and system name 

Date, time, and incidence 

Road conditions 

Operating conditions, driving conditions, and climate conditions 

Symptoms 

Some malfunctions and maintenance experiences that seem unrelated can also help your 

malfunction analysis sometimes, so you should collect information as much as possible. The 

symptom related information can serve as reference for your trouble diagnosis and 

troubleshooting.

01 

01-20 


Identifying symptoms and checking diagnostic trouble code/ 

blink code (DTC/BC) 

Tips: 

• The Foton AUMARK diagnostic system has many functions. 

• The first function is to check DTC/BC. Trouble signals in control module circuit will 

be stored in memory of the module in the form of codes for easy call. 

• The other function is to check input signals. Check if signals from switches have 

been sent to the control module accurately. 

• Uses of these functions help narrow troubleshooting scope rapidly and increase 

trouble diagnosis and troubleshooting efficiencies. 

System 

DTC/BC 

Checking input 

signals (sensor 

check) 

Diagnostic test 

mode (quick test) 

ABS ○ ○ ○ 

A/C system - - - 

Lighting system - - - 

Wipers and washers - - - 

Audio system - - - 

Power windows - - - 

Combination meter - - - 

Power door locks - - - 

• During DTC/BC, it is extremely important to judge if the malfunction represented by this 

code is taking place or has occurred and now has restored to normal. In addition, 

verification must be performed in symptom check whether the malfunction represented by a 

DTC / BC is directly related to a symptom. Therefore, you must perform DTC/BC check both 

before and after symptom identification in order to judge current state of your vehicle. 

Otherwise, inessential trouble diagnosis and troubleshooting to normal systems will take 

place to increase troubleshooting difficulty or cause some unrelated maintenance operations. 

So you must follow operation procedures to check DTC/BC. 

• The flow by which you can perform trouble diagnosis and troubleshooting using DTC/BC 

check is shown in the figure below. This flow shows how to inspect efficiently using DTC/BC. 

Finally, this flow shows how to perform trouble diagnosis and troubleshooting by using 

DTC/BC and symptoms chart. 

1. DTC/BC check 

2. Making records and clearing the DTC/BC displayed 

3. Symptom identification 

Whether the symptom persist? 

Yes > Go to step 4. 

No > Go to step 5. 

4. Checking by means of symptom simulation

5. DTC/BC check 


Whether a DTC / BC occurs? 

Yes > Diagnose and troubleshoot the malfunction represented by the DTC/BC. 


6. Symptom identification 

Whether a symptom exists? 


No > The system is OK. 

01-21 

Tip: 

If a DTC is displayed in initial DTC/BC inspection, it indicates that harnesses or connectors in this 

circuit section may be malfunctioning. Then, please check related harnesses or connectors. (Refer 

to “Chapter 01 Introduction-How to Troubleshoot the Vehicle, Inspection Procedures for Circuits”.) 

7. Performing trouble diagnosis and troubleshooting using symptoms chart 

01

01-22 


Symptom simulation check 

01 

Tips: 

• The most difficult situation you may encounter in trouble diagnosis and troubleshooting is 

that no faults are found. In such a case, you must perform a thorough analysis to customer 

complaints, and then simulate the vehicle and environmental conditions when the 

malfunction occurred. A maintenance technician, no matter how experienced and skilled 

he/she it, will certainly overlook some important information in maintenance operations and 

make wrong guesses which will do nothing but leading to a stagnant situation if he/she does 

not identify symptoms during trouble diagnosis and troubleshooting. For example, those 

problems that may only occur when engine is cold or that are caused by bumpy roads 

during vehicle travel will never be found when the engine is hot or the vehicle is stationary. 

Vibration, overheat, and water leak (dampness), etc. are also common causes of troubles 

but they are difficult to be reproduced, so a symptom simulation check method is described 

here for obtaining effective check results by simulating external factors with vehicle parked. 

• Key points in symptom simulation: 

• First, you must identify symptoms and locate faulty sections or parts. To achieve this, you 

should connect a hand-held diagnostic tester first and minimize troubleshooting scope of 

the faulty circuit according to symptoms before the symptom simulation check. 

• Then, conduct a symptom simulation test to judge whether the circuit tested is 

damaged or not and, at the same time, to identify symptoms. Browse symptoms 

charts of systems in order to narrow scope of possible causes of this symptom. 

gentle rocking 


1. Vibration method: Used when vibration is 

the first cause of the trouble. 

(a) 

Parts and sensors 

• Gently rock the suspected sensor with 

your fingers and check if the trouble 

occurs. 

Tip: 

Gently rocking a relay may result in its open. 

(b) 

(c) 

Connectors 

• Gently rock the connector both 

horizontally and vertically. 

Harnesses 

• Gently rock the harness both horizontally 

and vertically. Joints of harnesses and 

connectors are the main areas where 

require careful check. 


2. Heating method: The trouble will always 

occur after a suspected area is heated. 

(a) 

Heat the suspected part with such articles as a 

blower and check if the trouble occurs. 

Notices: 

• Never allow heating temperature to exceed 

60℃. Be sure to limit heating temperature 

so as to avoid damage to the part. 

• Never heat any part in the control module 

directly.


01-23 

3. Drenching method: The trouble will occur 

only in rainy days or damp environments. 

(a) 

Sprinkle water on your car, and check if the 

trouble occurs. Notices: 

Notice: 

• Never sprinkle water directly on any engine 

component. You can spray water to front 

face of radiator so that engine temperature 

and humidity are changed indirectly. 

• Never sprinkle water directly on any 

electrical component. 

Tip: 

In the case of water leak from the vehicle, the liquid 

leakage may damage the control module. Be sure to 

pay attention to this when you perform a rain test to 

your vehicle. 

01 

4. Others: The trouble will occur in case of 

circuit overload 

(a) 

Turn on all electrical equipment including air 

conditioner, headlights, and interior lights to 

check if the trouble occurs.

01-24 

List of DTC/BC 


The list of BC of ABS is taken as an example here (as shown in the table below). 

This table shows each BC and its corresponding inspection procedure. Performing trouble 

diagnosis and troubleshooting based on these can greatly increase efficiency and accuracy. 

01

Symptoms chart 


01-25 

A symptoms chart is used to show possible causes (e.g. circuits or parts) of each symptom (as 

shown in the table below). If the malfunction persists when a hand-held diagnostic tester indicates 

normal system, you can perform trouble diagnosis and troubleshooting using the symptoms chart. 

The SNs in the table represents check sequence of circuits or parts. 

Tip: 

If a symptom really exists when no malfunction is detected by the vehicle diagnostic system, it 

indicates that the existing malfunction is beyond the detection range of the system. 

01

01-26 

Circuit Inspection 


The following table shows you the way to read and use the circuit inspection section in this manual. 

01 

Descriptions of malfunction 

blink codes and diagnostic 

trouble codes 

Description 

Descriptions are made based on 

circuit f eatures, diagnostic flows, 

and parts and components. 

5-1 ABS Sensor Signal Unstable (Right Front Wheel) 

Circuit diagram 



ABS control unit 

B014 


brown 

brown 

Tip: 

Since the 4 ABS sensors use same control mode, the diagnostic procedure for ABS sensors of 

left front, right rear, and left rear wheels is the same as that for the sensor of right front wheel. 

Left front wheel 

speed 

sensor 

A005 

black 

black 

Description 

brown 

brown 

Rotor 

speed sensor 

magnet 

coil 

to ABS ECU 

low 

speed 

High 

speed 

1. Speed sensor detects wheel speed and transmits 

signals to ECU. These signals are used to control 

ABS control system. Both front and rear rotors are 

provided with a serration. 

2. When a rotor rotates, the magnetic field formed by 

the permanent magnet on the speed sensor will 

generate an alternating voltage. 

3. Frequency changes of this alternating voltage is 

directly proportional to rotor speed, so ECU can 

use this frequency to detect speed of each wheel. 

Right front 

wheel speed 

sensor 

A002 

Left rear wheel 

speed 

sensor 

A006 


speed 

sensor 

A006 

black 

brown 

black 

black 

brown 

black 

brown 

brown 

Diagnostic procedure 

It comprises caption, description 

and judgment of a diagnostic 

procedure. 


To distinguish and identify a large 

number of electric wires, each 

wire is marked with either 

monocolor or bicolor for your 

reference. 

Right rear wheel 

speed 

sensor 

A008 


black 

1. Checking (right) front wheel 

(a) Check if (right) front wheel size is within specifications. 

(b) Check (right) front wheel rim for deformation. 

(c) Check (right) front wheel steering knuckle lock nut for looseness. 

(d) Check (right) front wheel bearing for looseness. 

Is diagnosis result normal? 


No > Adjust, repair, or replace loose, deformed, and damaged parts and 

components. 

black


Inspection Procedures for Circuits 

1. Basic inspection 

(a) 

Resistance measurement conditions for electric components 

01-27 

• All resistance measurement operations are made under an ambient temperature of 20℃, 

unless specifically stated otherwise. 

• High temperature will be produced when your vehicle is running, so resistances 

measured under such a temperature may exceed the specified range. Therefore, 

resistance measurement must be made when your engine is cold. 

Wire core 

Pull lightly 

Loose curling 

Bended pin 

(b) 

Precautions for connector operations 

• To remove a connector with latch, 

squeeze the connector slightly along its 

junction direction and then depress its 

hasp gently to open the latch. 

• When removing a connector, be sure to 

hold it instead of its harness. 

• When connecting a connector, be sure 

to check it for deformation, damage, or 

missing pin. 

• When connecting a connector with latch, 

a “clatter” must be heard to ensure firm 

connection. 

• When checking a connector using 

special tester, be sure to check on back 

(harness side) of the connector with a 

microprobe. 

Notices: 

• A waterproof connector can not be checked 

from its back, so please do the job after 

connecting an auxiliary harness. 

• Be careful when moving the probe. Never 

damage any connector pin. 

(c) 

Key points for connector inspection 

• Check during connector connection: 

Hold the connector and check its 

insertion and locking (i.e. junction). 

• Check during connector disconnection: 

Pull the harness gently to check for missing 

pin, bended pin, and broken center harness. 

Visually check the connector for rust, 

entrained metal scraps, water entry and 

bended or rusty pin, entrained foreign 

materials or deformation. 

Notice: 

When inspecting a gold-plated female plug, a 

gold-plated male plug must be used. 

01

01-28 


• Check contact pressure of pin: 

Get a male plug ready, and then insert it into a 

female plug to check its junction and sliding 

resistance. 

01 

Material same as that for 

male plug is used. 

Correct 

Incorrect 

Incorrect 

(d) 

(e) 

Maintenance method for connector pins 

• If a contact is stained with oil, be sure to 

clean it with an air gun or rag. Never use 

a sand cloth to polish it, otherwise its 

electro-deposited coating may be 

damaged. 

• If contact pressure is abnormal, replace 

female plug. At this time, be sure to 

replace with a gold-plated female plug if 

the male plug is gold-plated; be sure to 

replace with a silver-plated female plug if 

the male plug is silver-plated. 

Precautions for harness operations 

• Before starting to remove a harness, be 

sure to check locations of the harness 

and its ties for accurate reinstallation. 

• If unnecessary, never twist, pull, or 

loosen the harness. 

• Never allow the harness to contact any 

hot, rotating, moving, vibrating, or sharp 

(e.g. panel edge and screw tip) part. 

• When installing a part, never squeeze or 

pinch its harness. 

• Never cut or break insulation sheath of any 

harness. In the case of inadvertent 

breakage, be sure to replace the harness or 

bind up the breakage with insulating cloth. 

Sensor 

Open circuit 

2. Open-circuit check 

(a) 

The circuit is shown in the left figure. Perform 

continuity check and voltage check in steps (b) 

and (c) respectively in order to locate open.


01-29 

sensor 

sensor 

(b) 

Continuity check 

• Disconnect connectors A and C and 

measure the resistance between them. 

Resistance:

01-30 


01 

sensor 

(c) 

Voltage check 

• When a circuit is energized, you can 

determine if its loop is open-circuited by 

checking its voltage. 

Take this circuit as an example. All connectors 

are still connected. Sequentially measure 

voltages to ground of pins 1 of connectors Aand 

B at 5V output pin of the control module 

respectively. 

voltages to ground of pins 1 of 

connectorsC 

If the measurement results are as follows: 

5 V: voltage to ground of pin 1 of connector A 

5 V: voltage to ground of pin 1 of connector B 

0 V: voltage to ground of pin 1 of connector C 

Then you can judge that there is an open circuit 

between pins 1 of connectors B and C. 

sensor 

Short circuit 

3. Short-circuit check 

(a) 

A harness ground short circuit is shown in the 

left figure. In step (b), continuity between it and 

ground is checked in order to locate short circuit.


01-31 

sensor 

sensor 

(b) 

Continuity check 

• Disconnect connectors A and C, and 

measure resistances to ground of pins 1 

and 2 of connector A respectively. 

Resistance: >1MΩ 

Tip: 

Gently rock the harness both horizontally and vertically, 

and measure its resistance. 

Take this circuit as an example: 

If the resistance to ground of pin 1 of connector 

A is less than 2Ω; 

and the resistance to ground of pin 2 of 

connector A is greater than 1MΩ; 

then you can judge that there is a short circuit 

between pins 1 of connectors A and C. 

• Disconnect connector B, and measure 

resistances to ground of connectors A 

and B2 respectively. 

Take this circuit as an example: 

If the resistance to ground of pin 1 of connector 

A is greater than 1MΩ; 

and the resistance to ground of pin 1 of 

connector B2 is less than 2Ω; 

then you can judge that there is a short circuit 

between pins 1 of connectors B2 and C. 

01

Preparations 

Diagnosis ........................................... 02-1 

Preparations .................................. 02-1 

Fuel ..................................................... 02-3 

Preparations .................................. 02-3 

Intake .................................................. 02-4 

Preparations .................................. 02-4 

Exhaust............................................... 02-5 

Preparations .................................. 02-5 

Cooling ............................................... 02-6 

Preparations .................................. 02-6 

Front Suspension .............................. 02-7 

Preparations .................................. 02-7 

Rear Suspension ............................... 02-8 

Preparations .................................. 02-8 

Wheels and Tires ............................... 02-9 

Preparations .................................. 02-9 

Front Axle ......................................... 02-10 

Preparations ................................ 02-10 

Rear Axle .......................................... 02-12 

Preparations ................................ 02-12 

Service Brake ................................... 02-14 

Preparations ............................... .02-14 

Parking Brake .................................. 02-16 

Preparations ................................ 02-16 

Transmission ................................... 02-17 

Preparations ................................ 02-17 

Clutch ............................................... 02-19 

Preparations ................................ 02-19 

Drive shaft ........................................ 02-20 

Preparations ................................ 02-20 

Steering Mechanism ........................ 02-22 

Preparations ................................ 02-22 

Power Steering ................................ 02-23 

Preparations ................................ 02-23 

Heater and Air Conditioner ............. 02-24 

Preparations ................................ 02-24 

Seat Belts ......................................... 02-26 

Preparations ................................ 02-26 

Battery .............................................. 02-27 

Preparations ................................ 02-27 

Windshields/Window/Mirrors.........02-28 

Preparations ................................ 02-28 

Seats ................................................. 02-29 

Preparations ................................ 02-29 

Body Tilt/Doors/Cargo Body ........... 02-30 

Preparations ................................ 02-30 

Interior/Exterior Trims ..................... 02-31 

Preparations ................................ 02-31 

Vehicle Control System ................... 02-32 

Preparations ................................ 02-32 

02

02

Diagnosis 

Preparations 

Special tool 

Preparations-Diagnosis 

02-1 

Sensor and pressure switch 

socket 

Engine control system 

A/C system 

02 

Recommended tools 

Digital multimeter 

Test wire set 

Manifold pressure gauge 

ABS 

A/C system 

Lighting system 

Wiper and washer 

Audio system 

Power window 

Combination meter 

Central lock 

ABS 

A/C system 


Wiper and washer 

Audio system 

Power window 


Central lock 

Refrigerant 

Compressor assembly 

Vacuum pump 

Refrigerant 

Compressor assembly

02-2 

Facilities 

PC: WABCO (version E)246 301 637 0 

WABCO diagnostic tester: 446 300 320 0 

Preparations-Diagnosis 

ABS 

ABS 

Portable diagnostic tester (version E): 446 300 430 0 

ABS 

02 

Accessories 

Item Capacity Specification 

ABS grease - Silicon grease 

Refrigerant 550 ± 50 g R134a 

A/C refrigeration oil 180 ml PAG100

Fuel 

Preparations 

Special tool 

Preparations-Fuel 

02-3 

Special tool for fuel filter 

Fuel filter 

02 

Recommended tool 

Torque wrench 

Accessory 

Item Quantity Specification 

Diesel oil - -

02-4 

Intake 

Preparations 


Preparations-Intake 

02 

Torque wrench

Exhaust 

Preparations 


Preparations-Exhaust 

02-5 

Copper bar 

Exhaust pipe 

02 

Hammer 

Exhaust pipe 

Torque wrench

02-6 

Cooling 

Preparations 


Preparations-Cooling 

02 

Torque wrench 

Accessories 


Antifreeze - - 

Sealant for junction surface of 

surge tank connecting pipe 

Sealant for junction surface of 

radiator water pipe 

- - 

- -

Front Suspension 

Preparations 


Preparations-Front Suspension 

02-7 

Micrometer 

Rear drive shaft spline 

02 

Hammer 

Leaf spring pin bushing 

Copper bar 


Vernier caliper 


Shackle pin bushing 

Grease gun 

Leaf spring 

Shackle pin 

Torque wrench 

Accessories 


Leaf spring grease - 2# lithium base grease 

Leaf spring pin grease - 2# lithium base grease 

Shackle pin grease - 2# lithium base grease

02-8 

Rear Suspension 

Preparations 


Preparations-Rear Suspension 

02 

Micrometer 


Hammer 


Copper bar 




Shackle pin bushing 

Grease gun 

Leaf spring 

Shackle pin 

Torque wrench 

Accessories 


Leaf spring grease - 2# lithium base grease 

Leaf spring pin grease - 2# lithium base grease 

Shackle pin grease - 2# lithium base grease

Wheels and Tires 

Preparations 


Preparations-Wheels and Tires 

02-9 

Tire pressure gauge 

Wheel and tire 

02 

Torque wrench 

Facilities 

Dynamic balancer 

Inflator

02-10 

Front Axle 

Preparations 


Preparations-Front Axle 

02 

Tire pressure gauge 

Wheel and tire 

Toe-in gauge 

Front wheel toe-in 

Sharp nose pliers 

Front wheel hub oil seal 

Copper bar 

Front wheel hub bearing 

Steering linkage 

Hammer 



Dial indicator 

Micrometer 

Spring balance 


Tie rod 

Steering knuckle 

Knuckle pin 


Steering knuckle bushing 

Knuckle pin 

Steering knuckle adjusting 

washer 

Rotation starting force of front 

wheel hub 

Test prod 

Fore axle 

Puller 

Front wheel hub 

Front wheel hub oil seal ring

Preparations-Front Axle 

02-11 

Grease gun 


Torque wrench 

Facilities 

02 

Turning angle gauge 

V-bench 

Table vice 

Accessories 


Front wheel hub grease - 2# lithium base grease 

Red lead powder - -

02-12 

Rear Axle 

Preparations 


Preparations-Service Brake 

02 

Measuring tape 

Rear axle assembly 

Puller 




Half axle 

Rear wheel hub 

Rear wheel hub oil seal ring 

Main reducing gear 

Driving gear bearing 

Half axle 


Driving gear 

Driven gear 

Planetary gear 

Side gear 

Rear axle housing 

Adjusting washer of driving gear 

bearing seat 

Adjusting washer of driving gear 

bearing 

Thrust washer of planetary gear 

Thrust washer of side gear 

Rear wheel hub oil seal 

Driving gear oil seal 

Copper bar 

Hammer 

Half axle 


Rear wheel hub bearing 

Differential assembly 

Half axle 



Hydraulic jack 


Clearance gauge 

Side gear 

Differential wrench 

Differential adjusting nut


02-13 



Driving gear 

Driven gear 

Circlip pliers 

Guide bearing of driving gear 

Grease gun 


02 

Torque wrench 

Accessories 

Item Quantity specification 

Rear axle gear oil for 1051series models 



3.5L Hypoid gear oil GL-5 85W/90 





Rear wheel hub grease for 1051 series 

models 5.0L Hypoid gear oil GL-5 85W/90 

Rear wheel hub grease for 1061 series 

models 280g(each wheel hub) 2# lithium base grease 

Rear wheel hub grease for 1089series 



models 

210g±10g(each wheel 

hub) 

2# lithium base grease 

Red lead power 

_ 

_ 

Sealant for junction surface of final drive 

on rear axle housing 

Sealant for assembly threads of main 

reducing gear 

Sealant for assembly threads of driven 

gear 

Sealant for assembly threads of 

differential gear 

Differential bearing lubricant 

Driving gear guide bearing lubricant 

Driving gear bearing lubricant 

_ 

_ 

_ 

_ 

_ 

_ 

_ 

1587 silicone rubber sealant 

605 mechanical sealant 

GY-340 anaerobic adhesive 

GY-340 anaerobic adhesive 

Hypoid gear oil GL-5 85W/90 

Hypoid gear oil GL-5 85W/90 

Hypoid gear oil GL-5 85W/90

02-14 


02 

Service Brake 

Preparations 


Puller 




Front wheel hub oil seal ring 

Rear wheel hub oil seal ring 

Half axle 




Front wheel brake shoe lining 

Rear wheel brake shoe lining 


Front wheel hub oil seal 

Rear wheel hub oil seal 

Copper bar 

Hammer 






Half axle 





Half axle 


Return spring 

Grease gun 



Torque wrench


02-15 

Facility 

Table vice 

Accessories 

Front wheel hub grease for 1051 series 

_ 

models 



_ 

models 


Front wheel hub grease for 1089series 

_ 

models 



_ 

models 







models 420g (each wheel hub) 2# lithium base grease 


models 

210g±10g(each wheel 

hub) 


02

02-16 

P Preparations-Parking Brake 

Parking Brake 

Preparations 


Measuring tape 

Central brake shoe 


Central brake drum 

Copper bar 

Central brake 

02 

Hammer 

Central brake 


Central brake drum 


Return spring 

Torque wrench 

Facility 

Table vice 

Accessory 


Hub grease - 2# lithium base grease

02-18 

Clutch 

Preparations 


Preparations-Transmission 

02 


Driven plate 

Pressure plate 


Driven plate 


Clutch master cylinder 

Clutch slave cylinder booster 

Clutch pedal 


Pressure plate 

Driven plate 



Grease gun 

Release bearing 


Torque wrench 

Facility 

Table vice 

Accessories 


Release bearing grease - 2# lithium base grease 

Clutch oil - V-3 brake fluid

Drive shaft 

Preparations 


Preparations- Drive shaft 

02-19 


Dial gauge 

Intermediate drive shaft 

Rear drive shaft 

Cross 

Needle bearing 

Universal joint fork 

Joint cross 

Needle bearing 

02 



Hammer 

Universal joint 

Intermediate drive shaft flange 

Intermediate bearing 

Copper bar 

Universal Joint 

Intermediate drive shaft flange 



Joint cross 



Torque wrench

02-20 

Facilities 

Preparations- Drive shaft 

V-bench 

Table vice 

Bench press 

02 

Accessories 


Universal joint grease - 2# lithium base grease 

Intermediate bearing grease - 2# lithium base grease

Steering Mechanism 

Preparations 


Preparations-Steering Mechanism 

02-21 


Steering wheel 

02 


Steering column return spring 

Dial gauge 

Steering column cross 

Torque wrench 

Facility 

V-bench

02-22 

Power Steering 

Preparations 


Preparations-Steering Mechanism 

02 

Torque wrench 

Puller 

Steering arm 

Accessories 


Steering fluid - ATF-Ⅲ-Q/SH 038.531 

Hydraulic circuit sealant - Loctite 567 sealant

Preparations-Heater and Air Conditioner 

Heater and Air Conditioner 

Preparations 


02-23 

Manifold pressure gauge 

Refrigerant 


02 

Refrigerant filling hose 

Refrigerant 


Quick connector 

Tee fitting 

Refrigerant 


Refrigerant 


Service tank 

Refrigerant 


Vacuum pump adapter 

Refrigerant 


Gas leak detector 

Refrigerant 


Heater and A/C system lines 

Thermometer 

Ambient temperature 

Thermistor thermometer 

Air outlet temperature 

Belt tension gauge 

Belt

02-24 


Refrigerant filling and recycling 

unit 

Refrigerant 


Vacuum pump 

Refrigerant 


02 

Accessories 


Refrigerant 550 ± 50 g R-134a 

refrigerant oil 180 ml PAG100

Seat Belts 

Preparations 



02-25 

Torque wrench 

02

02-26 

Battery 

Preparations 


Preparations- Seat Belts 

02 

High-rate discharge gauge 

Battery 

Hydrometer 

Battery 

Torque wrench 

Accessories 


Pure water - JB/T 10053-1999 

Concentrated sulfuric acid - GB 4554-1984

Preparations-Battery 

Windshields/Windows/Mirrors 

Preparations 


02-27 

Plastics scraper 

Window 

02 

Facilities 

Guard band 

Wood block 

Plastic paper 

Torque wrench 

Small-gauge wire 

Nylon cord 

Tape 

Accessories 


Primer - Black reactive polyurethane primer 

Glass cement - Black polyurethane glue

02-28 

Seats 

Preparations 


Preparations-Windshields/Window glasses/Rear-View Mirror 

02 

Torque wrench

Preparations-Seats 

Body Tilt/Doors/Cargo Body 

Preparations 


02-29 


Cab locking mechanism 

Cab titling mechanism 

02 

Copper bar 


Hammer 


Grease gun 

Torque wrench 

Cab locking mechanism 


Door 

Facilities 

banch vice 

hanger 

Accessories 

items quanlity Specification 

lubricating grease - 2 lithium grease

02-30 

Interior/Exterior Trims 

Preparations 


Preparations-Body Tilt/Doors/Cargo Body 

02 

Torque wrench

Vehicle Control System 

Preparations 


Preparations-Interior/Exterior Trims 

02-31 


Ignition switch assembly 

02

Maintenance Specifications 

Fuel ................................................ 03-1 

Service Data ............................. 03-1 

Torque Requirements ............. . 03-2 

Intake.............................................. 03-3 

Torque Requirements ............... 03-3 

Exhaust .......................................... 03-4 


Cooling. .......................................... 03-5 

Service Data ............................. 03-5 


Front Suspension ......................... 03-7 

Service Data ............................. 03-7 


Rear Suspension ........................... 03-9 

Service Data ............................. 03-9 

Torque Requirements ............. 03-10 

Wheels and Tires ........................ 03-11 

Service Data ........................... 03-11 


Front Axle .................................... 03-13 

Service Data ........................... 03-13 


Rear Axle ..................................... 03-18 

Service Data ........................... 03-18 


Service Brake .............................. 03-23 

Service Data ........................... 03-23 


Parking Brake .............................. 03-27 

Service Data ........................... 03-27 


Clutch ........................................... 03-30 

Service Data ........................... 03-30 


Drive shaft.. .................................. 03-33 

Service Data ........................... 03-33 


Steering Mechanism ................... 03-35 

Service Data ........................... 03-35 


Power Steering ............................ 03-37 

Service Data ........................... 03-37 


Heater and Air Conditioner.. ....... 03-39 

Service Data ........................... 03-39 

Torque Requirements ........... 03-40 

Seat Belts ..................................... 03-41 


Lighting ...................................... 03-42 


Wipers and washers ................... 03-43 

Service Data ........................... 03-43 

Instrument Panel..........................03-44 


Seats............................................. 03-45 


Body Tilt/Doors/Cargo Body ...... 03-46 


Interior/Exterior Trims ................ 03-47 


03

Fuel 

Service Data 

Maintenance Specifications-Fuel 

03-1 

Fuel tank capacity 

1051 series models 


1089series models 


80L 

120L 

200L 

120L 

03

03-2 

Torque Requirements 

Maintenance Specifications-Fuel 

03 

Fastener 

Fuel tank pulling strip welded unit × fuel tank bracket 





Fuel return pipe joint × fuel sensor 


Front fuel delivery pipe joint × fuel sensor 


Fuel filter inlet pipe joint nut 


Fuel filter outlet pipe joint nut 


N•m 

21~25 

41~51 

41~51 

41~51 

21~25 

41~51 

21~25 

21~25 

21~25 

182 ~ 222 

41~51 

182 ~ 222 

Fuel filter base seat × frame 41~51

Intake 


Maintenance Specifications-Intake 

03-3 

Fastener 

N•m 

Intake hose hub × high mounted intake pipe 9~11 

Fixing bolt of high mounted intake pipe assembly 21~25 

Air cleaner assembly × air cleaner bracket 21~25 

03 

Air cleaner × intake hose (clamp) 9~11 

Intake nozzle × bracket 21~25

03-4 

Exhaust 


Maintenance Specifications-Exhaust 

03 

Fastener 

Hoop of exhaust pipe welded unit × bracket of 

exhaust pipe welded unit 

Exhaust pipe welded unit × exhaust manifold 

(clamp) 

Hoop of exhaust muffler × bracket of exhaust 

muffler 

N•m 

21~25 

9~11 

41~51 

Exhaust muffler × exhaust pipe welded unit 41~51

Cooling 

Service Data 

Coolant 

Maintenance Specifications-Cooling 

03-5 

Capacity - 

Specification - 

Surge tank 

03 

Capacity 

4L

03-6 


Maintenance Specifications-Cooling 

Fastener 

N•m 

Cowl × radiator 9~11 

Intercooler × radiator 21~25 

Radiator, intercooler, cowl × frame 73~89 

03 

Radiator rod × radiator 21~25 

Radiator rod × frame 21~25 

Intercooler × engine intake hose (clamp) 9~11 

Intercooler × turbocharger steel tube (clamp) 9~11 

Radiator × engine water inlet hose (clamp) 9~11 

Radiator × engine water outlet hose (clamp) 9~11 

Cooling fan × fan pulley hub 60~65 

Surge tank × bracket 21~25

Front suspension 

Service Data 


Maintenance Specifications-Front Suspension 

3-7 

Front steel plate spring assembly 

Outside diameter of steel plate spring pin at 

front end 

Standard value 

Limit value 

25 mm 

24.981 ~ 24.956 mm 

03 

Inside diameter of bushing ofsteel plate spring 

pin at front end 


Limit value 

25 mm 

25.095 ~ 25.065 mm 

Outside diameter of shackle pin at rear end 


Limit value 

25 mm 

24.981 ~ 24.956 mm 

Free height of steel plate spring assembly 


Limit value 

25 mm 

100 ~ 112 mm 


Front steel plate spring assembly 


front end 


Limit value 

25 mm 

25 ~ 24.979 mm 

Inside diameter of bushing of steel plate 

spring pin at front end 


Limit value 

25 mm 

25 ~ 25.025 mm 



Limit value 

25 mm 

25 ~ 24.979 mm 



Limit value 

Left 122 mm/116 ~ 128 mm 

Right 122 mm/107 ~ 119 mm



03-8 

Maintenance Specifications-Front Suspension 

Fastener 

N•m 

Top of shock absorber × frame 45~55 

Bottom of shock absorber × frame 78~96 

U-bolt × front axle 199~243 


Fastener 

N•m 


03 


U-bolt × front axle 199~243

Rear suspension 

Service Data 


Maintenance Specifications-Rear Suspension 

03-9 

Rear steel plate spring assembly 


front end 


Limit value 

30 mm 

30 ~ 29.979 mm 

03 


spring pin at front end 


Limit value 

30 mm 

30~ 30.25 mm 



Limit value 

30 mm 

30 ~ 29.979 mm 

Inside diameter of shackle pin bushing at 

rear end 


Limit value 

30 mm 

30.~ 30.2 mm 


spring pin at rear end 


Limit value 

30 mm 

30~ 30.25 mm 

Free height of assist spring of steel plate 

spring 


Limit value 

56mm 

50 ~ 62 mm 



Limit value 

115 mm 

109 ~ 121 mm

03-10 



Maintenance Specifications-Rear Suspension 

Fastener 

N•m 



03 

U-bolt × front axle 396~465 


Fastener 

N•m 

Top of shock absorber × frame 199~ 243 

Bottom of shock absorber × frame 199~ 243 

U-bolt × front axle 396 ~ 46


Service Data 

Maintenance Specifications-Wheels and Tires 

03-11 

Tire size 

Tire pressure 

1051 series model 




7.00-16 

215/75R17.5 

0.67mPa 

0.76mpa 

03

03-12 


Maintenance Specifications-Wheels and Tires 

Tire nut 

Fastener 



N·m 

250~300 

396~465 

03

Front Axle 

Service Data 


Front wheel alignment 

Maintenance Specifications-Front Axle 

03-13 

Camber angle 


Limit value 

Caster angle 3° 

1° 

45'~1°15' 

03 

Inclination angle 

Toe-in 

Maximum steering angle 


Rotation starting force 


Radial runout at middle of tie rod 


Diameter of knuckle pin 

Diameter of knuckle pin hole 

Inside diameter of steering 

knuckle bushing 

Knuckle pin to knuckle bushing 

clearance 

Steering knuckle to fore axle 

clearance (without adjusting 

washer) 


clearance (with adjusting 

washer) 

Adjusting shim specification 

(outside diameter × inside 

diameter × thickness) 

Starting force 

Fore axle 

Rated load 

Sink 


Limit value 

Radial ply tire 

Bias tire 

Inner wheel 

Outer wheel 


Limit value 


Limit value 


Limit value 


Limit value 

8° 

7°45'~8°15' 

1~3 mm 

2~4 mm 

35° 

27° 

20~30 N 

≤ 3 mm 

32.000 mm 

31.984~32.000 mm 

32.000 mm 

32.000~32.039 mm 

32.000 mm 

32.025~32.064 mm 

0.025~0.080 mm 

2.0 mm 

2.3~2.9 mm 

≤ 0.1 mm 

56 × 32.5 × (2.30~2.85) mm 

10~60 N 

2200 Kg 

70 + 34 mm

03-14 


I beam specification(height×upper×lower width 

68×70×60mm 

Suspension distance 


Limit value 

750mm 

749-751mm 

03


Front wheel alignment 


03-15 

Camber angle 


Limit value 

1° 

45'~1°15' 

Caster angle 3°30’ 


Toe-in 


Limit value 

Radial ply tire 

Bias tire 

8° 

7°45'~8°15' 

1~3 mm 

2~4 mm 

03 

Maximum steering angle 

Inner wheel 

Outer wheel 

35° 

27° 



25~35 N 


Radial runout at middle of tie rod 

≤ 3 mm 


Diameter of knuckle pin 


Limit value 

32.000 mm 

31.984~32.000 mm 

Diameter of knuckle pin hole 


Limit value 

32.000 mm 

32.000~32.025 mm 

Inside diameter of steering 

knuckle bushing 


Limit value 

32.000 mm 

32.025~32.064 mm 

Knuckle pin to knuckle bushing 

clearance 

0.025~0.080 mm 


clearance (without adjusting 

washer) 


Limit value 

2.5mm 

2.3~2.9 mm 


clearance (with adjusting 

washer) 

≤ 0.1 mm 

Adjusting shim specification 

(outside diameter × inside 

diameter × thickness) 

56 × 32.5 × (1.30~2.85) mm 

Starting force 

10~60 N 

Fore axle 

Rated load 

2500 Kg 

Sink 

85 + 35 mm

03-16 


I beam specification(height×upper×lower width 

68×70×60mm 



Limit value 

800mm 

799-801mm 

03


1051 series mosels 


03-17 

Fastener 

N•m 

Front wheel hub × front brake drum 287~336 

Steering knuckle nut 140~150 

Front wheel hub cap pad 12~20 

03 

Drag link × front end assembly 30~35 

Tie rod × left and right end assemblies 40~50 

Steering knuckle × steering arm 230~280 

Steering knuckle × steering knuckle arm 230~280 

Steering arm × tie rod 230~280 

Steering knuckle arm × drag link 180~220 

Steering arm × drag link 180~220 

Steering knuckle × latch 25~40 

Steering knuckle × knuckle pin cap 12~20 


Fastener 

N•m 

Front wheel hub × front brake drum 396 ~ 465 

Steering knuckle nut 165 ~ 180 

Front wheel hub cap pad 12~20 

Drag link × front end assembly 

Tie rod × left and right end assemblies 

70 ~90 

70 ~90 

Steering knuckle × steering arm 230~280 

Steering knuckle × steering knuckle arm 230~280 

Steering arm × tie rod 230~280 

Steering knuckle arm × drag link 200~260 

Steering arm × drag link 200~260 

Steering knuckle × latch 50~70 

Steering knuckle × knuckle pin cap 12~20

03-18 

Rear Axle 

Service Data 


Maintenance Specifications-Rear Axle 


03 

Load 

Rating 

Limit value 

5000 Kg 

12500 Kg 

Diameter Maximum 332 mm 

Wheel track 


Total play 

Diameter of rear leaf spring 

locating hole 

Half axle 

Radial runout at middle 

Runout of inside face of flange 

Wear in thickness of spline tooth 

Spline tooth profile skewness 


Wear on journal at end of axle sleeve 

Verticality of journal at end of axle 

sleeve 

Face runout of joint surface of rear 

wheel hub and half axle flange 




Wear limit 

1590 mm 

952 mm 

≤ 6 mm 

18.5 mm 

≤ 1.0 mm 

≤ 1.0 mm 

≤ 0.15 mm 

≤ 0.2 mm 

≤ 1 mm 

≤ 0.08 mm 

≤ 1.5 mm 

≤ 0.15 mm 

31.3~52.3 N 

Number of teeth of driving gear 9 

Number of teeth of driven gear 37 

Final drive ratio 4.11 

Deflection limit of driven gear 

Tooth flank clearance between 

driving and driven gears 


End gap of side gear 

Rotation starting torque of driven gear 


planetary gear and side gear 



Limit value 

0.07 mm 

0.18~0.23 mm 

0.05~0.24 mm 

0.686~1.586 N 

0~0.09 mm 

0.18 mm


03-19 

Radial clearance between cross and planetary 

gear 

Radial clearance between side gear and 

differential carrier 

Clearance between side gear and half axle 

spline 


Limit value 


Limit value 


Limit value 

0~0.04 mm 

0.09 mm 

0~0.08 mm 

0.16 mm 

0~0.55 mm 

1.11 mm 

Thickness of thrust washer of planetary gear 

Thickness of thrust washer of side gear 

Driving gear assembly 

Distance from flange plane to medium line of 

axle housing 


Specification of adjusting washer of driving 

gear bearing 


gear bearing seat 

0.92 ~ 1.00 mm 

1.35 ~ 1.45 mm 

296 mm 

9.8~19.6 N 

0.05, 0.10, 0.20, 0.40, 0.50 mm 

0.10, 0.15, 0.40 mm 

03

03-20 




Load 

Rating 

Limit value 

5000 Kg 

Diameter Maximum 450 mm 

03 

Wheel track 


Total play 

1615 mm 

952 mm 

≤ 6 mm 

Diameter of rear leaf spring 

locating hole 

Half axle 

Radial runout at middle 

Runout of inside face of flange 

Wear in thickness of spline tooth 

Spline tooth profile skewness 


Wear on journal at end of axle sleeve 

Verticality of journal at end of axle 

sleeve 

Face runout of joint surface of rear 

wheel hub and half axle flange 




Wear limit 

21 mm 

≤ 1.0 mm 

≤ 0.06 mm 

≤ 0.15 mm 

≤ 0.2 mm 

≤ 1 mm 

≤ 0.05 mm 

≤ 1.5 mm 

≤ 0.15 mm 

30 ~ 55N 

Number of teeth of driving gear 8 

Number of teeth of driven gear 39 

Final drive ratio 4.33 

Deflection limit of driven gear 


driving and driven gears 


End gap of side gear 


0.07 mm 

0.30 ~ 0.40 mm 

0.15 ~ 0.30 mm 

Rotation starting torque of driven gear 

0.686~1.586 N 


planetary gear and side gear 


Limit value 

0.15 ~ 0.30mm 

0.30mm


03-21 

Radial clearance between cross and planetary 

gear 

Radial clearance between side gear and 

differential carrier 

Clearance between side gear and half axle 

spline 


Limit value 


Limit value 


Limit value 

0.105 mm 

0 ~ 0.22 mm 

0.45 mm 

0.030 mm 

0.217 mm 

Thickness of thrust washer of planetary gear 

Thickness of thrust washer of side gear 


Distance from flange plane to medium line of 

axle housing 



gear bearing 

1.5mm 

2mm 

321 mm 

9.8~19.6 N 

0.05/0.08/0.12/0.20/0.50mm 

03 


gear bearing seat 

0.05/0.08/0.15/0.35/0.50/0.70 mm

03-22 




Fastener 

N•m 

Rear wheel hub × half axle 37~75 

03 

Rear wheel hub × rear brake drum 287~346 

Rear axle housing × final drive 78~115 

Differential right carrier × driven gear 108~161 

Differential left carrier × differential right carrier 54~70 

Differential carrier × bearing cap 134~174 

Main reducer flange nut 250~280 

Main reducer housing × driving gear bearing seat 80~104 


Fastener 

N•m 

Rear wheel hub × half axle 108~161 

Rear wheel hub × rear brake drum 396~480 

Rear axle housing × final drive 178~235 

Differential right carrier × driven gear 178~235 

Differential left carrier × differential right carrier 178~235 

Differential carrier × bearing cap 380~467 

Main reducer flange nut 350~450 

Main reducer housing × driving gear bearing seat 105~156

Service brake 

Service Data 


Maintenance Specifications-Service Brake 

03-23 

Free travel of brake pedal 

Height of brake pedal 

Brake pedal reserve 

Inside diameter of front wheel 

brake drum 

10~15 mm 

160~165 mm 

45~50 mm 

310 mm 

03 

Rear wheel braking lining to rivet 

head depth 

Thickness of rear wheel braking 

lining 


Limit value 


Wear limit 

8.0 mm 

7.7 mm 

12 mm 

4.6 ± 0.2 mm 


Free travel of brake pedal 

Height of brake pedal 

Brake pedal reserve 

Push rod stroke of front wheel 

brake chamber 

Inside diameter of front wheel 

brake drum 

Front wheel brakeing lining to 

rivet head depth 

Thickness of front wheel braking 

lining 

Free lengh of front wheel brake 

shoe return spring 

Front wheel brake shoe return 

spring load / load length 

Push rod stroke of rear wheel 

brake chamber 

Inside diameter of rear wheel 

brake drum 

Rear wheel brakeing lining to 

rivet head depth 

Thickness of front wheel braking 

lining 

Free lengh of rear wheel brake 

shoe return spring 

Rear wheel brake shoe return 


Limit value 


Wear limit 


Limit value 


Wear limit 

10~15 mm 

160~165 mm 

45~50 mm 

51 

310 mm 

12.2 mm 

12.5mm 

16mm 

4.6 ± 0.2 mm 

148mm 

440 N / 168 mm 

45mm 

310mm 

10.0 mm 

9.7 mm 

14 mm 

4.6 ± 0.2 mm 

138mm 

440 N / 168 mm

03-24 


spring load / load length 

Operating angle of exhaust brake 

control valve 

Exhaust brake valve to valve 

body clearance 

64° 

≤ 0.13 mm 

03


03-25 

Torque requirements 


Fastener 

N.M 

Lock nut of brake light awitch 20 ± 5 

Brake pedal pin bolt 45 ~ 55 

Pedal suspension fixing bolt 40 ~ 45 

03 

Pedal suspension ×cab front wall 

Pedal suspension ×cab floor 

Nut of connecting air pipe joint of 

combined drier 

Fixing bolt of combined drier bracket 



Nut of connecting air pipe joint of air 

reservoir 

Air reservoir bracket ×frame 

Nut of connecting air pipe joint of relay 

valve 

Realy valve bracket×frame 

Nut of connecting air pipe joint of quick 

release valve 

Realy valve bracket × frame 

Nut of connecting air pipe joint of quick 

release valve 

Fixing bolt of combined drier bracket 



25 ~30 

55 ~66 

25 ~ 30 

49 ~59 

32 ~42 

49 ~59 

49 ~59 

32 ~ 42 

25 ~30 

32 ~ 42 

49 ~59 

25 ~ 30 

49 ~59 

32 ~ 42 

Front brake chamber × bracket 32 ~ 42 

Nut of connecting air pipe joint of front 

brake chamber 

Front wheel brake drum × wheel hub 

32 ~ 42 

396 ~465

03-26 


03 

Front wheel brake bottom plate streering 

knuckle 

Fixing bolt of wheel hub cap of rear 

brake 

Nut of connection air pipe joint of rear 

brake chamber (contral brake) 

Nut of connection air pipe joint of rear 

brake chamber (air cut-off brake) 

Rear brake chamber × bracket (contral 

brake) 

Rear brake chamber ×bracket (air 

cut-off brake) 

126 ~ 154 

12 ~ 20 

32 ~ 42 

32 ~ 42 

150 ~ 210 

150 ~ 210 

Rear wheel brake drum hub brake drum 396 ~ 465 

Fixing bolt of brake bottom plate of rear 

wheel brake drum 

126 ~ 154 

Half axle fixing bolt 37 ~ 75 

Fixing bolt of pneumatic cylinder of 

exhaust brake valve 

49 ~ 59

Parking Brake 

Service Data 

Maintenance Specifications-Parking Brake 

03-27 

Inside diameter of central brake 

drum 

Thickness of brake lining 


Limit value 

178 mm 

207 mm 

6 mm 

Braking lining to brake drum 

clearance 

Free length of brake shoe return 

spring 

0.6 mm 

76.5 mm 

03

03-28 


Maintenance Specifications-Parking Brake 

Fastener 

N•m 

Fixing bolt of parking brake handle 20~24 

Brake cable × parking brake handle (lock nut) 9~11 

Fixing bolt of brake bottom plate 89~118 

03 

Output shaft flange nut 393~500 

Hand brake cable × bracket 21~25 

Hand brake cable × cab floor 20~24 

Hand brake valve × bracket 21~25 

Nut of air pipe joint of hand brake valve 21~25

03-30 

Clutch 

Service Data 


Height of clutch pedal 

Maintenance Specifications-Clutch 

160~165 mm 

03 

Free travel of clutch pedal 

Push rod stroke of clutch master cylinder 

Piston stroke of pneumatic cylinder of 

clutch slave cylinder booster 

15~25 mm 

28 ± 2 mm 

28 ± 1 mm 

Driven plate surface to rivet head depth Limit value 1.3 mm 

Radial runout of driven plate 

Fit clearance between driven plate and 

input shaft spline 


Limit value 

0.8 mm 

0.075 mm 

0.025~0.125 mm 

Wear-away thickness of pressure plate Limit value 1.0 mm 

Height of diaphragm spring tip Pressed 56 ± 1.5 mm 

1099series mosels 

Height of clutch pedal 

Free travel of clutch pedal 

Push rod stroke of clutch master cylinder 

Piston stroke of pneumatic cylinder of 


160~165 mm 

15~25 mm 

28 ± 2 mm 

28 ± 1 mm 

Driven plate surface to rivet head depth Limit value 18.-2.4 

Radial runout of driven plate 

Fit clearance between driven plate and 

input shaft spline 


Limit value 

1.0 mm 

0.078 mm 

0.033~0.123 mm 

Wear-away thickness of pressure plate Limit value 1.0 mm 

Height of diaphragm spring tip Pressed 61.5mm/(61.5±1.5)mm


03-31 



Fastener 

Plug of bleed valve of clutch slave 

cylinder booster 


Limit value 

N•m 

6 

4~8 

Lock nut of clutch switch 20 ± 5 

Nut of oil outlet pipe joint of clutch 

master cylinder 

22~24 

Clutch pedal × pedal suspension 20 ± 3.5 

Bolt of clutch pedal pin 20 ± 3.5 

Lock nut of push rod of clutch master 

cylinder 

17.5 ± 2.5 

Clutch master cylinder × clutch support 20 ± 3.5 

Nut of oil inlet pipe joint of clutch slave 


Nut of intake pipe joint of clutch slave 


Clutch slave cylinder booster bracket × 

transmission housing 

22~24 

21~25 

40 ± 3.5 

Clutch slave cylinder booster × bracket 20 ± 3.5 

Fixing bolt of hydraulic piston chamber of 


Nut of control air pipe joint of pneumatic 

cylinder of clutch slave cylinder booster 



17.5 ± 2.5 

22~24 

20 ± 3.5 

Fixing bolt of clutch pressure plate 50~63 

Clutch release fork × clutch release fork 

shaft 

Clutch release fork arm × clutch release 

fork shaft 


Fastener 

Plug of bleed valve of clutch slave 



Limit value 

40 ± 5 

20 ± 3.5 

N•m 

6 

4~8 

Lock nut of clutch switch 20 ± 5 

Nut of oil outlet pipe joint of clutch 


22~24 

Clutch pedal × pedal suspension 20 ± 3.5 

Bolt of clutch pedal pin 20 ± 3.5 

Lock nut of push rod of clutch master 

cylinder 

17.5 ± 2.5 

Clutch master cylinder × clutch support 20 ± 3.5 

Nut of oil inlet pipe joint of clutch slave 


22~24 

03

03-32 


03 

Nut of intake pipe joint of clutch slave 


Clutch slave cylinder booster bracket × 

transmission housing 

21~25 

40 ± 3.5 

Clutch slave cylinder booster × bracket 20 ± 3.5 

Fixing bolt of hydraulic piston chamber of 


Nut of control air pipe joint of pneumatic 

cylinder of clutch slave cylinder booster 



17.5 ± 2.5 

22~24 

20 ± 3.5 

Fixing bolt of clutch pressure plate 65~75 

Clutch release fork × clutch release fork 

shaft 

Clutch release fork arm × clutch release 

fork shaft 

41~51 

41~51

Drive shaft 

Service Data 


Drive shaft assembly 

Maintenance Specifications- Drive shaft 

03-33 

Radial runout of drive shaft 

Fit clearance between spline 

shaft and splined hub 


Limit value 


Limit value 

0.5 mm 

0.6 mm 

0.1 mm 

0.3 mm 

03 


Cross journal 


Wear limit 

21.94 mm 

0.10 mm 

Cross to needle bearing 

clearance 

0.012~0.061 mm 

Universal joint fork to needle 

bearing clearance 

0.29~0.61 mm 

Axial clearance of cross 

≤ 0.25 mm 


Drive shaft assembly 

Radial runout of drive shaft 


Limit value 

0.5 mm 

0.7 mm 

Fit clearance between spline 

shaft and splined hub 


Limit value 

0.1 mm 

0.3 mm 


Cross journal 


Wear limit 

25 mm 

0.10 mm 

Cross to needle bearing 

clearance 

0.016~0.071 mm 

Universal joint fork to needle 

bearing clearance 

0.15~0.4 mm 

Axial clearance of cross 

≤ 0.25 mm

03-34 



Maintenance Specifications- Drive shaft 

Fastener 

N•m 

Transmission output shaft × intermediate drive shaft 58~70 

Parking brake drum × intermediate drive shaft 58~70 

03 

Frame cross member × intermediate bearing 

support 

130~160 

Intermediate drive shaft × rear drive shaft 58~70 

Final drive × rear drive shaft 146~205 

Slotted nut of intermediate bearing 440 


Fastener 

N•m 

Transmission output shaft × intermediate drive shaft 130 ~ 160 

Parking brake drum × intermediate drive shaft 130 ~ 160 

Frame cross member × intermediate bearing 

support 

130 ~ 160 

Intermediate drive shaft × rear drive shaft 130 ~ 160 

Final drive × rear drive shaft 130 ~ 160 

Slotted nut of intermediate bearing 440


Service Data 

1051/1099 series models 

Maintenance Specifications-Steering Mechanism 

03-35 


Diameter 

425 mm 

Free travel ± 10° 

03 

Number of turns 4.8 

Longitudinal adjustable angle 8° 

Vertical adjustable distance 

Steering effort 

30 mm 

22~55 N 

Steering column assembly 

Straightness of steering shaft 

Cross specification (journal × length) 

Cross to journal clearance 

≤ 1.5 mm 

16 × 40 mm 

≤ 0.25 mm

03-36 


1051/1099 series model 

Maintenance Specifications-Steering Mechanism 

Fastener 

N•m 

Fixing nut of steering wheel 40~50 

03 

Steering gear × steering column 41~51


Service Data 


Maintenance Specifications-Power Steering 

03-37 

Steering fluid 

Operating temperature -40~120 ℃ 

Liquid level rise Engine idle → shut down ≤ 5 mm 

03 

Steering gear 

Length of stay of steering wheel at 

extreme position 

< 5 s 

Net mass 

18.5 Kg 

Drive ratio 18.85 

Number of turns of screw 4.8 

Working pressure Maximum 10.3 MPa 

Direction of spiral of cycle raceway 

Diameter of cycle pair 

Left-handed 

72 mm 

Number of recirculating balls 30 

Diameter of recirculating ball 

7.14 mm

03-38 



Maintenance Specifications-Power Steering 

Fastener 

N•m 

Steering gear support × steering gear 105~128 

Steering gear × rocker arm 

197~246 (M27×1.5) 

03 

Hydraulic circuit connection 46~56 

Frame × low pressure oil pipe assembly 2 9~11

Maintenance Specifications-Heater and Air Conditioner 


Service Data 

03-39 

Fill capacity of refrigeration 

oil 

At compressor replacement 

At evaporator replacement 

At liquid reservoir 

180ml refrigeration oil comes with the 

compressor. No adding required. 

40 ~ 60 ml 

10 ~ 30 ml 

03 

At condenser replacement 

At hose replacement 

3 pressure switches 

Pressure at low pressure 

side 

Pressure at medium 

pressure side 

Pressure at high pressure 

side 

Temperature control switch 

No trace of oil leakage 

Trace of oil leakage found 

No trace of oil leakage 

Trace of oil leakage found 

ON 

OFF 

ON 

OFF 

ON 

OFF 

10 ~ 30 ml 

40 ~ 60 ml 

Do not add. 

40 ~60 ml 

0.196 ± 0.02 MPa 

0.025 MPa 

1.37 ± 0.12 MPa 

1.77 ± 0.08 MPa 

0.59 ± 0.2 MPa 

3.14 ± 0.2 MPa 

Zero-power resistance 4 ℃ 

25 ℃ 

3.967 ± 6% KΩ 

1.487 ± 4% KΩ

03-40 


Maintenance Specifications-Heater and Air Conditioner 

Fastener 

N•m 

Φ9 aluminum pipe 15 ± 5 

Φ12 aluminum pipe 23 ± 3 

Φ16 aluminum pipe 30 

03 

Tightening torque of pressure switch 10.8 

Fixing bolt of A/C compressor 46 ± 5 

Fixing bolt of compressor refrigeration pipe 28 ± 3 

Fixing bolt of evaporator 23 ± 2 

Fixing bolt of condenser 23 ± 2

Seat Belts 


Maintenance Specifications- Seat Belts 

03-41 

Fastener 

N•m 

Fixing bolt of seat belt 41 ~51 

03

03-42 

Lighting 


Maintenance Specifications-Lighting 

Fastener 

N•m 

Fixing bolt of headlight assembly 9~11 

03 

Fixing bolt of fog light assembly 9~11 

Fixing bolt of taillight assembly 9~11


Service Data 

Maintenance Specifications-Wipers and Washers 

03-43 

Blade 

Pressing force of left blade 

Pressing force of right blade 

7.0 ± 0.5 N 

6.6 ± 0.5 N 

03

03-44 

Maintenance Specifications-Instrument Panel/Combination Meter/Cigarette Lighter 

Instrument Panel 


Fastener 

N•m 

Fixing bolt of instrument panel 7.7~10.0 

03

Seats 


Maintenance Specifications-Seats 

03-45 

Fastener 

N•m 

Fixing bolt of seat 21~25 

03

03-46 

Maintenance Specifications-Body Tilt/Doors/Cargo Body 

Body Tilt/Doors/Cargo Body 



Fastener 

N•m 

03 

Fixing bolt of control mechanism assembly 26~30 

Fixing bolt of left lock body 21~25 

Fixing bolt of right lock body 21~25 

Left carriage × bracket 26~30 

Right carriage × bracket 26~30 

Fixing bolt of left front support 48~52 

Fixing bolt of right front support 48~52 

Fixing bolt of left front door hinge 26~30 

Fixing bolt of right front door hinge 26~30 

Cargo body × frame (U-bolt) 

70~75 


Fastener 

N•m 

Fixing bolt of control mechanism assembly 41~51 

Fixing bolt of left lock body 21~25 

Fixing bolt of right lock body 21~25 

Left carriage × bracket 41~51 

Right carriage × bracket 41~51 

Fixing bolt of left front support 160 ~ 195 

Fixing bolt of right front support 160 ~ 195 

Fixing bolt of left front door hinge 

Fixing bolt of right front door hinge 

Cargo body × frame (U-bolt) 

28~34 

28~34 

92~95

Interior/Exterior Trims 


Maintenance Specifications-Interior/Exterior Trims 

03-47 

Fastener 

N•m 

Fixing bolt of cab inside-view mirror 9 ~ 11 

Bumper body × bumper frame 41 ~ 51 

Bumper assembly × frame 41 ~ 51 

03 

Front wheel rear mud guard × stiffener 21 ~ 25 

Stiffener of front wheel rear mud guard × bracket 21 ~ 25 

Fixing bolt of engine left lower mud guard 21 ~ 25 

Front door check × door 21 ~ 25 

Fixing bolt of pedal 21 ~ 25 

Cargo body guardrail × cargo body 70 ~ 75 

Rear wheel rear mud guard × cargo body 21 ~ 25 

Rear wheel rear mud guard × bracket 21 ~ 25 

Rear wheel rear mud guard bracket × cargo body 21 ~ 25 

Rear wheel front mud guard × cargo body 21 ~ 25 

Rear wheel front mud guard × bracket 21 ~ 25 

Rear wheel front mud guard bracket × cargo body 21 ~ 25 

Rear guardrail × frame 70 ~ 75

Diagnostics 

ABS ........................................................... 04-1 

Precautions .......................................... 04-1 

Parts diagram ...................................... 04-2 

ABS Diagnosis Descriptions ................ 04-4 

ABS Control Unit Terminals ................. 04-6 

Reading and Clearing a Diagnostic 

Trouble Code (DTC) ............................ 04-8 

Basic Checks ..................................... 04-14 

Symptoms Chart ................................ 04-16 

DTC List ............................................. 04-17 

2- ABS Solenoid Valve ..................... 04-19 

2-1 (Right Front Wheel) 

2-2 (Left Front Wheel) 

2-3 (Right Rear Wheel) 

2-4 (Left Rear Wheel) 

3- ABS Sensor Gap - Large.............. 04-24 





4- ABS Sensor - Shorted ...................04-27 





5- ABS Sensor - Unstable .................04-32 





6- ABS Ring Gear - Damaged .......... 04-38 





7-4 ABS Malfunction Indicator Light ... 04-40 

8-1 ABS Control Unit Voltage Low ..... 04-45 

8-2 ABS Control Unit Voltage High .... 04-50 

8-3 Internal Fault of ABS Control Unit ..04-51 

ABS Does Not Work............................ 04-52 

ABS Can Not Work Effectively............. 04-57 

ABS Malfunction Indicator Light 

Always Lighted Up ............................. 04-59 

ABS Malfunction Indicator Light 

Does Not Come On ........................... 04-63 

ASR (ABS) Blink Code Indicator 

Light Always Lighted Up .................... 04-67 

ASR (ABS) Blink Code Indicator 

Light Does Not Come On ................. . 04-71 

Heater and Air Conditioner .................... 04-76 

Precautions ........................................ 04-76 

Basic Checks ..................................... 04-79 

Symptoms Chart ................................ 04-80 

Air Output Is Normal but Compressor 

Does Not Run .................................... 04-85 

No Air Output from Blower ................. 04-91 

Compressor Runs Intermittently......... 04-95 

Lighting ................................................... 04-99 

Precautions ........................................ 04-99 

Basic Checks ................................... 04-100 

Symptoms Chart .............................. 04-101 

Low Beam at One Side Does Not 

Come On ............. ........................... 04-109 

Low Beam at Neither Side 

Comes On ....................................... 04-111 

Low Beams at Both Sides 

Always Lighted Up ........................... 04-114 

High Beam at One Side Does 

Not Come On ................................... 04-116 

High Beam at Neither Side 

Comes On ....................................... 04-119 

High Beam at One Side Always 

Lighted Up ....................................... 04-122 

High Beams at Both Sides Always 

Lighted Up ....................................... 04-124 

Neither High Beam nor Low 

Beam at One Side Comes On.......... 04-126 

Neither High Beam nor Low 

Beam at Neither Side Comes On ..... 04-129 

Both High and Low Beams at One 

Side Always Lighted Up ................... 04-132 

Both High and Low Beams at 

Both Sides Always Lighted Up ......... 04-134 

Front Fog Light at One Side Does 

Not Come On ................................... 04-136 

Front Fog Light at Neither Side 

Comes On ....................................... 04-138 

Front Fog Lights Always 

Lighted Up ....................................... 04-141 

Rear Fog Light at One Side Does 

Not Come On ................................... 04-143 

04

04 

Rear Fog Light at Neither Side 

Comes On ....................................... 04-145 

Rear Fog Lights Always Light Up ....04-148 

Neither Steering Warning Light nor 

Hazard Warning Light Comes On .... 04-150 

Neither of Turn Lights Comes On .... 04-153 

Turn Light at One Side Does Not 

Come On ......................................... 04-155 

Turn Light at Neither Side 

Comes On ....................................... 04-157 

Hazard Warning Light Always 

Lighted Up ........... .............................04-159 

Turn Lights Always Lighted Up ..... .. 04-161 

Brake Light at One Side Does Not 

Come On ......................................... 04-163 

Brake Light at Neither Side 

Comes On ....................................... 04-164 

Brake Lights Always Lighted Up ...... 04-166 

Backup Light at One Side Does Not 

Come On ......................................... 04-168 

Backup Light at Neither Side 

Comes On ....................................... 04-169 

Backup Lights Always 

Lighted Up ....................................... 04-172 

License Light Does Not 

Come On ......................................... 04-174 

Interior Light at One Side Does 

Not Come On ................................... 04-176 

Interior Light at Neither Side 

Comes On ....................................... 04-177 

Interior Lights Always 

Lighted Up ....................................... 04-179 

Courtesy Light at One Side Does 

Not Come On ................................... 04-181 

Courtesy Light at Neither Side 

Comes On ....................................... 04-183 

Courtesy Lights Always 

Lighted Up ....................................... 04-185 

Neither Interior Lights nor 

Courtesy Lights Come On ................ 04-187 

Combination Meter Illumination 

Does Not Shine ............................... 04-189 

Radio Cassette Player Illumination 

Does Not Shine ............................... 04-191 

Rear Fog Light Switch Illumination 

Does Not Shine ............................... 04-193 

Cigarette Lighter Illumination Does 

Not Shine ......................................... 04-195 

Hazard Warning Switch Illumination 

Does Not Shine ............................... 04-197 

A/C Switch Illumination Does 

Not Shine ......................................... 04-199 

Blower Switch Illumination 

Does Not Shine ...............................04-201 

ABS Diagnostic Switch 

Illumination Does Not Shine .............04-203 

Left Front Position Light Does 

Not Come On ................................... 04-205 

Right Front Position Light Does 

Not Come On .................................. .04-207 

Left Front Marker Light Does 

Not Come On ................................... 04-209 

Right Front Marker Light Does 

Not Come On ................................... 04-211 

Left Rear Marker Light Does Not 

Come On ......................................... 04-213 

Right Rear Marker Light Does 

Not Come On ................................... 04-215 

Left Combination Taillight Does 

Not Come On ................................... 04-217 

Right Combination Taillight Does 

Not Come On ................................... 04-219 

None of Interior Small Lights and 

Exterior Outline Marker Lights 

Comes On ....................................... 04-222 

Wipers and Washers ............................ 04-225 

Precautions ...................................... 04-225 

Basic Checks ................................... 04-226 


Wiper Does Not Work After 

Switched On ................. ...................04-229 

Wiper Sluggish.. ................................04-232 

Wiper Can Not Stop ......................... 04-234 

Wiper Does Not Work In 

Intermittent Position (INT) ................ 04-236 

Wiper Does Not Work In Low 

Speed Position (LO)....................... 04-238 

Wiper Does Not Work In High 

Speed Position (HI)....... ...................04-240 

Wiper Can Not Return To Original 

Position After Switched Off .............. 04-242 

Washer Does Not Work While 

Wiper Is Normal ............................... 04-244 

Washer Fluid Can Not Be Sprayed ..04-246 

Audio System ....................................... 04-248 

Precautions ...................................... 04-248 

Parts diagram .................................. 04-260 

Audio Unit Terminals........................ 04-261 

Basic Checks .................................. .04-262 


Audio Unit Does Not Work ............... 04-264 

Speaker Is Soundless in All Modes .. 04-270

Speaker Tone Quality Is Poor in 

All Modes ......................................... 04-273 

Speaker Volume Is Low in All 

Modes ............................................. 04-275 

Speaker Tone Quality Is Poor Only 

When Playing CD or MP3 ................ 04-278 

Failure to Receive Radio Broadcast 

or Reception is Poor ...................... 04-279 

CD Can Not Be Inserted/Played or 

Immediately Ejected After Inserted .. 04-281 

CD Sound Jump .............................. 04-283 

MP3 Can Not Be Inserted/Played .... 04-284 

MP3 Sound Jump ............................ 04-285 

Power Windows .................................... 04-286 

Precautions ..................................... 04-286 

Basic inspection ............................... 04-287 

Malfunction Symptom Table ........... 04-288 

Horn does not ring ........................... 04-289 

Horn keeps ringing .......................... 04-292 

Parts diagram .................................. 04-294 

Left front door control switch 

assembly terminals .......................... 04-295 

Right front door electric glass 

switch terminals ............................... 04-296 

Basic checks ................................... 04-297 

Malfunction symptoms table ............ 04-298 

None of power windows works ........ 04-299 

Left front door power window does 

not work ........................................... 04-308 

Left front door power window can 

not drop ........................................... 04-311 

Left front door power window can 

not lift ............................................... 04-314 

Right front door power window 

does not work .................................. 04-317 


does not work (when right front 

door electric glass switch is used) .... 04-321 


does not work (when left front door 

control switch is used) ..................... 04-324 

Combination Meter ............................... 04-328 

Notes ............................................... 04-328 

Parts diagram .................................. 04-329 

Instrumentation descriptions ............ 04-330 

Instrument terminals ........................ 04-333 

Basic checks ................................... 04-337 

Symptoms chart ............................... 04-338 

Whole combination meter does 

not work ............................................ 04-342 

Speedometer malfunction ................ 04-346 

Tachometer Malfunction .................. 04-350 

Fuel gauge malfunction ................... 04-352 

Coolant temperature gauge 

malfunction ...................................... 04-355 

Brake (or clutch) fluid level warning 

light is always lighted up/does not 

come on ........................................... 04-358 

Low pressure warning light is 

always lighted up/does not come 

on .................................................... 04-362 

Oil pressure indicator light is 


on .................................................... 04-366 

Parking brake indicator light is 


on (air cut-off brake) ........................ 04-370 

Parking brake indicator light is 


on (central drum) ............................. 04-374 

Coolant level indicator light is 


on .................................................... 04-378 

Air cleaner indicator light is always 

lighted up/does not come on ............ 04-382 

Exhaust brake indicator light is 


on .................................................... 04-386 

Fuel indicator light is always lighted 

up/does not come on ....................... 04-390 

Central lock ...................................... 04-394 

Central lock is inoperative ................ 04-399 

Right front door can not be locked ... 04-408 

Right front door can not be 

unlocked .......................................... 04-412 

04

04

ABS system 

Precautions 

1. Power off. 

(a) 

(b) 

Diagnose- ABS system 

04-1 

Before you remove or install any electrical device or when tools or equipment are accessible 

to bare electrical terminals, be sure to disconnect battery negative cable first in order to 

prevent personal injury or vehicle damage. 

Ignition switch must be turned OFF unless specifically stated otherwise. 

Tip: 

If a central door lock is equipped, please do not leave your car key in your vehicle before battery 

negative cable is disconnected so as to avoid locking doors. 

2. Removing combination meter or disconnecting battery negative cable will clear day 

odometer and clock on combination meter. 

Tip: 

Total odometer will not be cleared. 

3. Disconnecting battery negative cable will cause audio system to lose saved settings. 

Tip: 

After battery negative cable is reconnected, you need to reset audio system. (Refer to “Operation 

Manual of the Audio System” in Chinese and English.) 

4. Ignition switch expressions 

04 

Ignition switch (position) 

LOCK 

ACC 

ON 

START 

Ignition switch expression 

Ignition switch OFF 

Ignition switch in ACC 

Ignition switch ON 

Engine start 

5. Precautions for troubleshooting 

(a) 

(b) 

(c) 

(d) 

(e) 

In the case of terminal contact or part installation fault, removing and reinstalling the 

suspected part may allow the system to return to normal completely or briefly. 

To locate a trouble, you must check vehicle condition when the problem occurs. For 

example, check through DTC output and record these conditions before you disconnect 

each connector or remove and install a part. 

Unless specified otherwise in check steps, be sure to remove and install ABS control unit, 

ABS solenoid valves, and stand-alone sensors with ignition switch OFF. 

When reassembling the ABS control unit, or any ABS solenoid valve or sensor that has 

been removed and reinstalled, you must check the system for normal operation after the 

assembly is completed. You can either use a special tester to check DTC (diagnostic trouble 

code) or read it through BC (blink code). 

Do not use a multimeter to measure any ABS control unit terminal directly.

04-2 

Parts diagram 


04


04-3 

1 ABS sensor (left front wheel) 

2 ABS solenoid valve (left front wheel) 

3 ABS control unit 

4 ABS solenoid valve (right front wheel) 

6 ABS solenoid valve (right rear wheel) 

7 ABS sensor (right rear wheel) 

8 ABS sensor (left rear wheel) 

9 ABS solenoid valve (left rear wheel) 

5 ABS sensor (right front wheel) 

04

04 

04-4 


ABS Diagnosis Descriptions 

The ABS control unit has a fault self-diagnosis feature. Once the unit detects a brake system 

malfunction, it will light up malfunction light and, at the same time, generate a corresponding DTC 

and store it in memory, and then the system will enter different fail-safe procedures automatically 

according to severity level of the malfunction. 

1. Two ways available to read DTC after an ABS system malfunction occurs 

(a) 

(b) 

• Read through BC on ASR (ABS) blink code light. 

• Read using a special tester. 

Blink code 

• DTC obtained by means of flicker frequency of ASR (ABS) blink code light on the 

meter. 

• After a malfunction blink code appears, you can perform troubleshooting according to 

the code and its corresponding trouble description. 

• Blink codes sometimes appear and are read inaccurately in real processes and 

deviations will occur to bring untruth to your trouble diagnosis. Therefore, you had 

better use a trouble diagnosis tester to perform diagnosis. 

• You should delete corresponding malfunction blink code as quickly as possible after 

a trouble is cleared. 

SAE code 

• Such a code can only be read using a dedicated trouble detector. 

• When troubleshooting a vehicle equipped with on-board diagnostics (OBD), you must 

connect the vehicle to special diagnostic equipment with OBD function and then read 

out various data output from the ABS control unit on your vehicle. When the ABS 

control unit detects a malfunction, OBD rules require the on-board computer to light 

up the malfunction indicator light on the instrument panel. 

• If a malfunction represented by a DTC recorded in the ABS control unit does not 

reappear in 3 successive stroke tests, the ABS malfunction indicator light will go out 

automatically, but the DTC will still be recorded in memory of the unit. 

2. Checking battery voltage 

(a) 

(b) 

Battery voltage: 9.6-14V. 

If the voltage is below 9.6V, be sure to replace battery before entering the next step. 

3. Checking ABS malfunction indicator light


Operation of ABS malfunction indicator light is shown in the table below: 

04-5 

Ignition switch 

status 

ABS malfunction indicator 

light status 

Description 

The light shines for an instant 

(approx. 3 seconds) and then 

goes out. 

ABS is normal. 

Ignition switch: ON 

Shines all the time. 

Does not come on. 

If the light goes out when vehicle speed is 

greater than 7km/h, it indicates ABS is normal. 

If the light does not go out when vehicle speed 

is greater than 7km/h, it indicates an ABS 

malfunction or indicator light line failure. 

Indicator light line failure or ABS control unit 

malfunction 

04 

Tip: 

The ABS indicator light must not go out until vehicle speed is greater than 7km/h (if the system is 

OK) after the vehicle is started for the first time or the system has been diagnosed. Conditions after 

ignition switch is turned on for the second time are shown in above table.

04-6 

ABS Control Unit Terminals 


04 

Terminal number Wiring color Description 

1 Brown Connected to right front ABS solenoid valve 

2 Brown Connected to left rear ABS solenoid valve 

3 Brown Connected to left front ABS solenoid valve 

4 Blue Connected to right front ABS solenoid valve 

5 Blue Connected to left rear ABS solenoid valve 

6 Blue Connected to left front ABS solenoid valve 

7 - - 

8 Brown Connected to right rear ABS solenoid valve 

B014 (18 pins) 

9 Blue Connected to right rear ABS solenoid valve 

10 Brown Connected to right front ABS sensor 

11 Brown Connected to left rear ABS sensor 

12 Brown Connected to left front ABS sensor 

13 Black Connected to right front ABS sensor 

14 Black Connected to left rear ABS sensor 

15 Black Connected to left front ABS sensor 

16 - - 

17 Brown Connected to right rear ABS sensor 

18 Black Connected to right rear ABS sensor


04-7 


1 - - 

2 - - 

3 - - 

4 White-black Ground 

5 - - 

6 - - 

7 Yellow 

Connected to IG power relay (power supply of ABS 

control unit) 

04 

B013 (15 pins) 

8 Red 

Connected to battery (power supply of solenoid 

valves) 


10 White Connected to detection interface 

11 - - 

12 - - 

13 Orange 

Connected to ABS diagnostic switch and ASR (ABS) 

blink code indicator light on combination meter 

14 - - 

15 Yellow 

Connected to ABS malfunction indicator light on 

combination meter

04 

04-8 


Reading and Clearing a Diagnostic Trouble Code (DTC) 

1. Malfunction is ABS failure detected by ABS control unit and stored in memory. A 

system malfunction can be either actual or stored. 

(a) 

(b) 

Actual malfunction: currently exists in ABS (e.g. left front wheel sensor line broken). An 

actual malfunction must be repaired, otherwise it can not be cleared from memory and nor 

can other malfunctions continue to be shown. 

Stored malfunction: comes in two ways. 

• A repaired malfunction that has not been cleared from ABS control unit yet. 

• A malfunction that has ever appeared but no longer exists (e.g. poor wire contact). 

There is no need to repair it before it is cleared from memory because a stored 

malfunction is not an actual one. 

2. Using flashes of ASR (ABS) blink code indicator light to read DTC 

(a) 

Ignition switch: ON. 

(b) Press and hold ABS diagnostic switch for 1-3 

seconds and then release it. 

Tip: 

• In the case of a current malfunction, the ABS 

control unit will show it by means of flash; if 

more malfunctions exist, the latest detected one 

will be shown by means of blink code flashes. 

As long as it is an actual malfunction, ASR 

(ABS) blink code indicator light will flash to show 

it repeatedly. 

• If no current malfunction exists, the last 4 

memorized malfunctions will be shown in 

reverse order (i.e. the last found one is flashed 

first) only once. 

(c) 

Refer to flash modes of DTCs 7-1 and 4-2 in the following figure.


04-9 

diagnosis requiement 

switch on 

off 

0.5 seconds 

0.5 seconds 

1.5 seconds 

2.5 

seconds 

repeat 

4 seconds 

ASR(ABS)blink code 

indicator no lighting 

ASR(ABS)blink code indicator 

no lighting 

1.5 

seconds 

Codes 71 Codes 42 

04 

3. Using flashes of ASR (ABS) blink code indicator light to clear DTC 

(a) 


(b) Press and hold ABS diagnostic switch for 3-6.3 

seconds and then release it. 

(c) 

Observe flicker frequency of ASR (ABS) blink 

code indicator light.

04-10 


Tip: 

If ASR (ABS) blink code indicator light gives 8 fast blinks and then flashes system structure code (2 

blinks), it indicates a successful clear and that the ABS malfunction has been cleared from memory. 

If ASR (ABS) blink code indicator light does not give 8 blinks and only flashes system structure 

code, it indicates that an actual malfunction persists in ABS and that it must repaired before 

corresponding DTC is cleared. 

(d) 

If the clear is successful, the ASR (ABS) blink code indicator light will flash as shown in the 

following figure. 

04 

diagnosis requiement 

switch on 

off 

4 seconds 

repeat 

4 seconds 

ASR (ABS) blink code 

indicator light comes on 

ASR (ABS) blink code indicator 

light goes out 

1.5 

seconds 

8 fast blinks 

System structure code 

(e) 

In some cases, the system requires reconfirmation. At this time, the following method can 

be used: In clear mode, ground indicator light 3 times with duration of each grounding longer 

than 0.5 second after 3 system code flashes, and then there will be 4 fast blinks followed by 

code of the new system. See the following figure for its flicker frequency. 

>0.5seconds 

diagnosis 

requiement switch on 

off 

Malfunction light 

comes on 

>3seconds 

2 

seco 

nds 

< 

3se 

con 

ds 

Retarder configuration 

Confirm retarder connection 

Malfunction light 

goes out 

System code

4. Diagnostic procedure for BCs 


04-11 

Mode Step System response Operation 

Diagnos 

is 

1. Ignition switch: ON. If ABS malfunction 

indicator light shines for an 

instant and then goes out, 

it indicates normal system. 

If ABS malfunction 

indicator light does not 

come on, it indicates line 

failure or bulb damaged. 

No actual malfunction exists in ABS, so no 

action should be taken. 

Go to symptoms table. 

If ABS malfunction 

indicator light shines all the 

time, it indicates one or 

more malfunctions in the 

system. 

Go to step 2. 

04 

2. Depress ABS 

diagnostic switch and 

hold for 1 second. 


indicator light starts to 

flash 2 groups of codes. 

Determine whether the malfunction is 

actual or stored: 

Actual malfunction: The light will show a 

code repeatedly. 

Stored malfunction: The light will show 

code of malfunction at each storage and 

then go out. The malfunction will be 

displayed only once. 

3. Determine BC 

according to number of 

flashes. 

1 st digit: 1-8 flashes 

2 nd digit: 1-6 flashes 

Interval between displays 

of 1 st and 2 nd digits is 1.5 

second. 

Go to DTC list. 

4. Correct and record 

malfunction. 

In the case of an actual 

malfunction 

Make necessary repairs. Repeat steps 1 

through 3 until the system is OK. 

In the case of a stored 

malfunction 

Record for your future reference. 

Notice: 

The malfunction displayed first is the one 

last stored in ABS control unit. 

Clear 

5. Clear a DTC from ABS. 

Depress ABS diagnostic 

switch and hold for at 

least 3 seconds. 


indicator light gives at least 

8 blinks. 


indicator light does not 

give 8 blinks. 

The light should go out after all DTCs 

have been cleared. 

The actual malfunction persists. Then 

repeat steps 1 through 5. 

5. Using a special diagnostic tester to read and clear DTCs 

(a) Ignition switch: OFF. 

(b) Insert the diagnostic wire having a 9-pin plug into corresponding interface on the diagnostic tester. 

(c) Connect the other end of the diagnostic wire with the diagnostic interface. 

(d) Turn on ignition switch. 

(e) “888” will be displayed immediately on display screen of the diagnostic tester. 

(f) “ABS” will be displayed after approx. 1 second. 

(g) The diagnostic tester is connected with ABS successfully.

04 

04-12 

(h) 

(i) 

Reading a DTC: 


• After the diagnostic tester is connected with ABS successfully, depress “ERROR” key 

and hold for approx. 1 second. 

• After “ERROR” key is released, the malfunction will be displayed on the screen in 3 

groups of digits. 

Position 1 Position 2 Position 3 

Failure path Failure mode Occurrence number 

For example, 411 mean excessive sensor gap of wheel D and 1 occurrence. 

• The current malfunction identified by ABS control unit is displayed first and then “old” 

will appear after the above display is completed. Then you can depress and release 

“ERROR” key to display stored malfunctions subsequently. 

• After all malfunctions have been displayed, “ABS” will be displayed. 

Clearing a DTC: 

• The prerequisite for DTC clear: No current malfunction exists. 

• Depress (and hold for more than 0.5 second) and release “CLEAR” key. 

• “Clr” will be displayed on the screen. 

• Then screen display “ABS” will appear. 

• Ignition switch: OFF. 

• Ignition switch: ON. 

• All stored malfunctions are deleted. 

6. System display 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

Ignition switch: OFF. 

Insert the diagnostic wire having a 9-pin plug into corresponding interface on the diagnostic 

tester. 

Connect the other end of the diagnostic wire with the diagnostic interface. 

Turn on ignition switch. 

“888” will be displayed immediately on display screen of the diagnostic tester. 

“ABS” will be displayed after approx. 1 second. 

The diagnostic tester is connected with ABS successfully. 

Depress and release “SYSTEM” key. 

Type of the ABS will be displayed on the screen. For example: “4-3” indicates a 4S/3M ABS 

while “4-4” indicates a 4S/4M ABS.

7. System formatting 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

(j) 



04-13 

Insert the diagnostic wire having a 9-pin plug into corresponding interface on the diagnostic 

tester. 

Connect the other end of the diagnostic wire with the diagnostic interface. 

Turn on ignition switch. 

“888” will be displayed immediately on display screen of the diagnostic tester. 

“ABS” will be displayed after approx. 1 second. 

The diagnostic tester is connected with ABS successfully. 

Depress and release “SYSTEM” key. 

Type of the ABS will be displayed on the screen. For example, “4-3” indicates a 4S/3M ABS. 

Depress “SYSTEM” key and hold for more than 2 seconds, the display will be deleted and a 

new system will be displayed in a short time to show a successful formatting. If the system 

can not be formatted for some reason, “---” will be displayed immediately on the screen after 

“SYSTEM” key is depressed for the second time. In addition, you can also perform such 

operations as systematic inspection using portable diagnostic tester (see owner's manual of 

the portable diagnostic tester for details). 

04

04 

04-14 

Basic Checks 


1. When a fault can not be recognized through a DTC check, perform a troubleshooting 

analysis to all circuits that are considered to have potentially led to the malfunction. 

2. In many cases, the fault cause can be located quickly and effectively by performing 

the basic checks for ABS shown in the following list. Therefore, it is essential to use 

this test method in ABS troubleshooting. 

Notice: 

ABS malfunctions do not necessarily mean electronic or circuital problems. In most cases, 

they are the same mechanical and brake line related problems as those occur in a regular 

brake system; then, the ABS malfunction indicator light will not come on and the operator 

can handle the problems according to his/her own experience. However, when the ABS 

malfunction indicator light comes on, it generally indicates an electronic or electrical 

problem; then, the operator must not perform any maintenance work without permission if 

he/she is not a specially trained serviceman/servicewoman and instead he/she should drive 

the vehicle to a Foton authorized service center as soon as possible for maintenance. 

Step Check item Measures 

1 Checking battery voltage 

• Turn off all electrical equipment. 

• Turn ignition switch OFF. 

Battery voltage >9.6V? 

2 Checking all brake lines 

• For damage, leakage, cracks, 

clogging, etc. 

Is check result normal? 

3 Checking ABS sensors for dirt 

• If ABS sensors are installed correctly. 

• ABS sensors for dirt. 

• ABS sensors for damage and 

deformation. 

Are check results normal? 

4 Checking ABS solenoid valves 


• Wait until ABS malfunction indicator 

light goes out. 

• Listen to sound cycle of ABS 

solenoid valves: Solenoid valves will 

make 4 self-check sounds: 

1-Right front wheel 

2-Left rear wheel 

3-Left front wheel 

4-Right rear wheel 


Y Go to step 2 

N 

Replace battery. 


N 

Repair or replace brake lines. 


N 

Reinstall, clear dirt, or replace ABS 

sensors. 


N 

Go to symptoms table.


04-15 

Step Check item Measure 

5 Checking ABS for normal operation 

• Apply emergency brake on a 

broad and flat road with vehicle speed 

greater than 40km/h, and then observe 

braking trace. If no braking drag marks 

exist, it indicates that the ABS works; if 

drag marks are seen on all wheels or 

one wheel and, at the same time, the 

ABS indicator light is always lighted 

up, it indicates that the ABS does not 

work or the ABS unit on the wheel 

does not work. When this happens, 

you must diagnose and service the 

ABS on your vehicle or the ABS 

feature on the wheel. 



N 

Go to symptoms table. 

04 

6 Checking ABS electrical connectors 

• Check ABS electrical connectors 

for firm installation. 

• Check ABS electrical connectors 

for dirt. 


Y 

N 

Go to related DTC diagnostics or 

symptoms table. 

Reinstall, clear dirt, or replace 

connectors.

04-16 


Malfunction Symptoms Table 

1. If a malfunction persists while a normal code is displayed during DTC check, you 

should check circuits for symptoms according to the order given in the following 

table and then enter relevant troubleshooting pages to troubleshoot the problem. 

Tip: 

When replacing ABS control unit, solenoid valves, or sensors, turn ignition switch OFF and 

disconnect battery negative cable. 

Use of the table below will help you find causes of problems. The SNs show possibilities sorting of 

causes of problems. Check each part according to this order and replace as needed. 

04 

ABS does not work. 

Symptom Suspected area Refer to 

1. Make sure DTC output is 

system normal code. 

2. Power supply and ground 

circuit 

3. Brake line for leakage. 

4. ABS control unit 

Chapter 04 Diagnosis-ABS, ABS 

Does Not Work 

ABS can not work effectively. 

ABS malfunction indicator light 

always lighted up. 

ABS malfunction indicator light 

does not come on. 


light always lighted up. 


light does not come on. 

1. Make sure DTC output is 

system normal code. 

2. Front wheel speed sensor 

circuit 

3. Rear wheel speed sensor 

circuit 

4. ABS solenoid valve 

5. Brake line for leakage, 

breakage, deformation, etc. 


1. ABS malfunction indicator 

light circuit 


1. ABS malfunction indicator 

light circuit 


1. ASR (ABS) blink code 

indicator light circuit 


1. ASR (ABS) blink code 




Can Not Work Effectively 


Malfunction Indicator Light 

Always Lighted Up 


Malfunction Indicator Light Does 

Not Come On 

Chapter 04 Diagnosis-ABS, ASR 

(ABS) Blink Code Indicator Light 

Always Lighted Up 

Chapter 04 Diagnosis-ABS, ASR 

(ABS) Blink Code Indicator Light 

Does Not Come On

DTC List 


Tips: 

• A malfunction blink code consists of 2 digits. 

• The first one indicates faulty component while the second one indicates fault location. 

04-17 

Malfunction blink 

code 

DTC description 

Refer to 

2 - 1 ABS solenoid valve (right front wheel) 

2 - 2 ABS solenoid valve (left front wheel) 

2 - 3 ABS solenoid valve (right rear wheel) 

2 - 4 ABS solenoid valve (left rear wheel) 

3 - 1 Sensor gap large (right front wheel) 

3 - 2 Sensor gap large (left front wheel) 

Chapter 04 Diagnosis-ABS, 2-1 ABS 

Solenoid Valve (Right Front Wheel) 


Solenoid Valve (Left Front Wheel) 


Solenoid Valve (Right Rear Wheel) 


Solenoid Valve (Left Rear Wheel) 


Sensor Gap Large (Right Front 

Wheel) 


Sensor Gap Large (Left Front Wheel) 

04 

3 - 3 

3 - 4 

4 - 1 

4 - 2 

4 - 3 

4 - 4 

5 - 1 

5 - 2 

5 - 3 

Sensor clearance large (right rear 

wheel) 

Sensor clearance large (left rear 

wheel) 

Sensor broken/shorted (right front 

wheel) 

Sensor broken/shorted (left front 

wheel) 

Sensor broken/shorted (right rear 

wheel) 

Sensor broken/shorted (left rear 

wheel) 

sensor signal unstable (right front 

wheel) 

sensor signal unstable (left front 

wheel) 

ensor signal unstable (right rear 

wheel) 


Sensor Gap Large (Right Rear 

Wheel) 


Sensor Gap Large (Left Rear Wheel) 

Chapter 04 Diagnosis-ABS, 4-1 

Sensor Broken/Shorted (Right Front 

Wheel) 


Sensor Broken/Shorted (Left Front 

Wheel) 


Sensor Broken/Shorted (Right Rear 

Wheel) 


Sensor Broken/Shorted (Left Rear 

Wheel) 


Sensor Signal Unstable (Right Front 

Wheel) 


Sensor Signal Unstable (Left Front 

Wheel) 


Sensor Signal Unstable (Right Rear 

Wheel)

04-18 


Malfunction blink 

code 

DTC description 

Refer to 

5 - 4 ensor signal unstable (left rear wheel) 


Sensor Signal Unstable (Left Rear 

Wheel) 

6 - 1 

Ring gear damaged (right front 

wheel) 


Ring Gear Damaged (Right Front 

Wheel) 

04 

6 - 2 Ring gear damaged (left front wheel) 

6 - 3 Ring gear damaged (right rear wheel) 

6 - 4 Ring gear damaged (left rear wheel) 

7 - 4 ABS malfunction indicator light 

8 - 1 ABS control unit voltage low 

8 - 2 ABS control unit voltage high 

8 - 3 Internal fault of ABS control unit 


Ring Gear Damaged (Left Front 

Wheel) 


Ring Gear Damaged (Right Rear 

Wheel) 


Ring Gear Damaged (Left Rear 

Wheel) 


Malfunction Indicator Light 


Control Unit Voltage Low 


Control Unit Voltage High 


Internal Fault of ABS Control Unit


04-19 

2 - 1 ABS Solenoid Valve (Right Front Wheel) 

2 - 2 ABS Solenoid Valve (Left Front Wheel) 

2 - 3 ABS Solenoid Valve (Right Rear Wheel) 

2 - 4 ABS Solenoid Valve (Left Rear Wheel) 

Tip: 

Since the 4 ABS solenoid valves use same control mode, the diagnostic procedure for ABS 

solenoid valves of left front, right rear, and left rear wheels is the same as that for the valve of right 

front wheel. 

Description 

1. The solenoid valves are mounted on frame. 

The connecting pipes between them and 

brake chambers should be as short as 

possible (maximum length ≤ 1.5m; diameter 

of air pipe > 9mm). Port 1 is connected to air 

supply while port 2 is connected to a brake 

chamber. Exhaust port of each solenoid 

valve is down (deviation: ±30°). 

04

04-20 

Circuit Diagram 


ABS control unit B014 

green-yellow 

brown 

brown 

blue 

blue 


solenoid valve A004 

04 

green-yellow 

brown 

brown 

blue 

blue 

Right front wheel 


green-yellow 

brown 

brown 

blue 

blue 



green-yellow 

brown 

brown 

blue 

blue 

green-yellow 



1. Checking self-check of ABS solenoid valves 

(a) 

(b) 

(c) 


Wait until ABS malfunction indicator light goes out. 

Listen to sound cycle of ABS solenoid valves: 4 self-check sounds from solenoid valves 

should be heard. 

• 1-Right front wheel 

• 2-Left rear wheel 

• 3-Left front wheel 

• 4-Right rear wheel 


Yes > Clear malfunction blink code after it is recorded. Perform another road test. If 

malfunction blink code reappears, replace ABS solenoid valve. 

No > Go to step 2.


2. Checking ABS solenoid valves 


04-21 

(b) 

Disconnect connector of (right) front ABS 

solenoid valve. 

Tip: 

Turn the ABS solenoid valve connector approx. 45° 

counterclockwise and then take it off. 

Notice: 

Take care not to damage any ABS solenoid valve 

connector. 

04 

(c) 

Use a multimeter to measure resistances 

between pins 1 and 2 and between pins 1 and 3 

of the ABS solenoid valve respectively. 

Resistance: 14~15.5Ω 



No > Replace (right) front ABS solenoid valve. 

3. Checking ABS solenoid valve control circuit 

(a) 

Disconnect ABS control unit connector.

04-22 


(b) Use a multimeter to measure resistance 

between connector pin 4 of ABS control unit 

B014 and connector pin 3 of (right) front ABS 

solenoid valve A003. 

Resistance: ≤2Ω 

04 

(c) Use a multimeter to measure resistance 







No > Repair line open from connector pins 1 and 4 of ABS control unit to connector pins 2 

and 3 of (right) front ABS solenoid valve A003. 

4. Checking ABS solenoid valve control circuit 

(a) 

Use a multimeter to measure resistances to 

ground of connector pins 2 and 3 of (right) front 

ABS solenoid valve A003 respectively. 



between connector pins 2 and 3 of (right) front 

ABS solenoid valve A003. 

Resistance: >1MΩ


04-23 

(c) 

(d) 


Use a multimeter to measure voltages to ground 

of connector pins 2 and 3 of (right) front ABS 

solenoid valve A003 respectively. 

Voltage: 0V 



No > Repair line short from connector pins 1 and 4 of ABS control unit to connector pins 2 

and 3 of (right) front ABS solenoid valve A003. 

04 

5. Checking ABS solenoid valve ground circuit 

(a) 


(b) 

Use a multimeter to measure resistance to 

ground of connector pin 1 of (right) front ABS 




Yes > Replace ABS control unit. 

No > Repair line open between connector pin 1 of (right) front ABS solenoid valve A003 

and ground.

04 

04-24 


3-1 ABS Sensor Gap Large (Right Front Wheel) 

3-2 ABS Sensor Gap Large (Left Front Wheel) 

3-3 ABS Sensor Gap Large (Right Rear Wheel) 

3-4 ABS Sensor Gap Large (Left Rear Wheel) 

Tip: 

Since the 4 ABS sensors use same control mode, the diagnostic procedure for ABS sensors of left 

front, right rear, and left rear wheels is the same as that for the sensor of right front wheel. 

Description 

Rotor 

High speed 

speed sensor 

coil 

low speed 

magnet 

to ABS ESU 

1. Speed sensor detects wheel speed and 

transmits signals to ABS control unit. These 

signals are used to control ABS control 

system. Both front and rear rotors are 


2. When a rotor rotates, the magnetic field 

formed by the permanent magnet on the 

speed sensor will generate an alternating 

voltage. 

3. Frequency changes of this alternating 

voltage is directly proportional to rotor 

speed, so the ABS control unit can use this 

frequency to detect speed of each wheel.



04-25 


brown 

brown 

Left front wheel speed 

sensor 

A005 

black 

black 

brown 

brown 

04 

Right front wheel speed 

sensor 

A002 

black 

black 

brown 

brown 

Left rear wheel speed 

sensor 

A006 

black 

black 

brown 

brown 

Right rear wheel speed 

sensor 

A008 

black 

black 

Diagnostic Procedure 

1. Checking ABS sensor of (right) front wheel 

(a) 

Ignition switch: OFF.

04-26 


(b) 

(c) 

Check if ABS sensor of (right) front wheel gets 

loose as shown in the figure. 

Check ABS sensor of (right) front wheel for 

damage and deformation. 

04 



No > Reinstall ABS sensor of (right) front wheel. 


(a) 

(b) 

(c) 

As shown in the figure, check ABS sensor of 

(right) front wheel for correct installation. 

There should be no clearance between the 

sensor and its mount. 

The fit clearance between the sensor and the 

ring gear should be less than 0.7mm. 


Yes > Replace ABS sensor of (right) front wheel. Clear malfunction blink code and perform 

a road test. If the malfunction blink code persists, replace ABS control unit. 

No > Reinstall ABS sensor of (right) front wheel.


4-1 ABS Sensor/Shorted (Right Front Wheel) 

4-2 ABS Sensor/Shorted (Left Front Wheel) 

4-3 ABS Sensor/Shorted (Right Rear Wheel) 

4-4 ABS Sensor/Shorted (Left Rear Wheel) 

04-27 

Tip: 



Description 

Rotor 

High speed 

speed sensor 

coil 

magnet 

low speed 

to ABS ECU 









voltage. 




frequency to detect speed of each wheel. 

04

04-28 




brown 

brown 


sensor 

A005 

black 

black 

04 

brown 

brown 


sensor 

A002 

black 

black 

brown 

brown 


sensor 

A006 

black 

black 

brown 

brown 


sensor 

A008 

black 

black 



(a) 



04-29 

(b) 

Disconnect (right) front ABS sensor connector. 

04 

(c) 

Use a multimeter to measure resistance 

between pins 1 and 2 of (right) front ABS 

sensor. 

Resistance: 1,110~1,250Ω 



No > Replace (right) front ABS sensor. 

2. Checking signal circuit of ABS sensor of (right) front wheel 

(a) 


04-30 


(b) 



ABS sensor A002 respectively. 


04 



ABS sensor A002. 


(d) 

(e) 




sensor A002 respectively. 

Voltage: 0V 



No > Repair line short from connector pins 10 and 13 of ABS control unit to connector pins 

1 and 2 of (right) front ABS sensor A002.


3. Checking for signal circuit open of ABS sensor of (right) front wheel 

04-31 

(a) 


(b) 




sensor A002. 


04 

(a) 




sensor A002. 




No > Repair line open from connector pins 10 and 13 of ABS control unit to connector pins 

1 and 2 of (right) front ABS sensor A002.

04 

04-32 



5-2 ABS Sensor Signal Unstable (Left Front Wheel) 

5-3 ABS Sensor Signal Unstable (Right Rear Wheel) 

5-4 ABS Sensor Signal Unstable (Left Rear Wheel) 

Tip: 



Description 

Rotor 

High speed 

speed sensor 

coil 

magnet 

low speed 

to ABS ECU 









voltage. 




frequency to detect speed of each wheel.



04-33 


brown 

brown 


sensor 

A005 

black 

black 

brown 

brown 

04 


sensor 

A002 

black 

black 

brown 

brown 


sensor 

A006 

black 

black 

brown 

brown 


sensor 

A008 

black 

black 


1. Checking (right) front wheel 

(a) 

(b) 

(c) 

(d) 

Check if (right) front wheel size is within specifications. 

Check (right) front wheel rim for deformation. 

Check (right) front wheel steering knuckle lock nut for looseness. 

Check (right) front wheel bearing for looseness. 



No > Adjust, repair, or replace loose, deformed, and damaged parts and components.

04-34 



(a) 


(b) 

Disconnect (right) front ABS sensor connector. 

04 


between pins 1 and 2 of (right) front ABS 

sensor. 

Resistance: 1,110~1,250Ω 



No > Replace (right) front ABS sensor.


3. Checking installation of ABS sensor of (right) front wheel 

04-35 

(a) 

(b) 

(c) 

(d) 

As shown in the figure, check ABS sensor of 

(right) front wheel for correct installation. 

There should be no clearance between the 

sensor and its mount. 

The fit clearance between the sensor and the 

ring gear should be less than 0.7mm. 

The sensor can not rotate freely in its mounting 

hole. 

04 



No > Reinstall ABS sensor of (right) front wheel. 


(a) 


(b) 

(c) 

(d) 

Remove ABS sensor of (right) front wheel. 


foreign materials. 


deformation and damage. 



No > Clear foreign materials; if ABS sensor of (right) front wheel is deformed and damaged, 

replace with a new one.

04-36 


5. Checking ABS ring gear of (right) front wheel 

(a) 

(b) 

(c) 

(d) 

Check the ABS ring gear for looseness. Its installation should be an interference fit. 

Check the ABS ring gear for deformation. 

Check the ABS ring gear for foreign materials. 

Installation fit of the ABS ring gear and ABS sensor should comply with the following figure. 

04 

ABS sensor 

ring gear 



No > Clear foreign materials or replace ABS ring gear of (right) front wheel. 

6. Checking signal circuit of ABS sensor of (right) front wheel 

(a) 



04-37 

(b) 



ABS sensor A002 respectively. 


(c) 



ABS sensor A002. 


04 

(d) 

(e) 




sensor A002 respectively. 

Voltage: 0V 


Yes > Replace (right) front ABS sensor. Clear malfunction blink code. 

If the malfunction blink code persists after a road test, replace ABS control unit. 

No > Repair lines from connector pins 10 and 13 of ABS control unit to connector pins 1 

and 2 of (right) front ABS sensor A002.

04 

04-38 


6-1 ABS Ring Gear Damaged (Right Front Wheel) 

6-2 ABS Ring Gear Damaged (Left Front Wheel) 

6-3 ABS Ring Gear Damaged (Right Rear Wheel) 

6-4 ABS Ring Gear Damaged (Left Rear Wheel) 

Tip: 



Description: 

Rotor 

High speed 

speed sensor 

coil 

magnet 

low speed 

to ABS ECU 









voltage. 




frequency to detect speed of each wheel. 


1. Checking ABS ring gear of (right) front wheel 

(a) 

(b) 

(c) 

(d) 

Check the ABS ring gear for looseness. Its installation should be an interference fit. 

Check the ABS ring gear for deformation, missing teeth, and fracture. 

Check the ABS ring gear for foreign materials. 

Installation fit of the ABS ring gear and ABS sensor should comply with the following figure.


04-39 

ABS sensor 

ring gear 

04 


Yes > Clear malfunction blink code and perform a road test. 

If the malfunction blink code persists, replace ABS control unit. 

No > Clear foreign materials or replace ABS ring gear of (right) front wheel.

04-40 


7-4 ABS Malfunction Indicator Light 

Description 

1. Generally, you can judge if the ABS works normally by observing ABS malfunction 

indicator light and emergency brake application with vehicle speed greater than 

40km/h. 

04 

2. Operation of ABS malfunction indicator light is shown in the table below. 


status 


light status 



goes out. 

Description 


Ignition 

ON 

switch: 


If the light goes out when vehicle speed is greater 

than 7km/h, it indicates ABS is normal. 

If the light does not go out when vehicle speed is 

greater than 7km/h, it indicates an ABS 




malfunction 

Tip: 

The ABS indicator light must not go out until vehicle speed is greater than 7km/h (if the system is 

OK) after the vehicle is started for the first time or the system has been diagnosed. Conditions after 

ignition switch is turned on for the second time are shown in above table.



04-41 


Combination meter B032 

Malfunctio 

n light 

yellow 

White-black 

04 

White-black 

White-black 


1. Checking ABS malfunction indicator light circuit 

(a) 


(b) 


04-42 


(c) 

(d) 


Observe ABS malfunction indicator light. It 

should come on. 

04 




2. Checking control and ground circuits of ABS malfunction indicator light 

(a) 

Use a multimeter to measure voltage between 

connector pins 15 and 9 and voltage to ground 

of pin 15 of ABS control unit B013 respectively. 

Voltage: battery voltage 


Yes > Repair or replace connector harness of ABS control unit B013. 

No > If battery voltage is not available in either case, go to step 3. 

If battery voltage is not available only between connector pins 15 and 9 of ABS 

control unit B013, repair line open between connector pin 9 of the unit and ground.


3. Checking for ABS malfunction indicator light circuit open 

04-43 

(a) 

Use a multimeter to measure voltage to ground 

of connector pin 14 of combination meter B032. 



Yes > Repair line open between connector pin 14 of combination meter B032 and connector 

pin 15 of ABS control unit B013. 

No > Replace combination meter assembly. 

04 

4. Checking for ABS malfunction indicator light circuit short 

(a) 

Insert a plastic insulation insert into connector 


ABS malfunction indicator light goes out? 


No > Repair line to ground short between connector pin 14 of combination meter B032 and 

connector pin 15 of ABS control unit B013.

04-44 



(a) 


(b) 

Disconnect connector of combination meter 

B032. 

04 

(c) 


(d) 


of connector pin 15 of ABS control unit B013. 

Voltage: 0V 



No > Repair line to power short between connector pin 14 of combination meter B032 and 



8-1 ABS Control Unit Voltage Low 


04-45 

Body fuse block B050 

Ignition switch B026 

White-blue 

Black-White 

IG Power 

relay 

R14 


Yellow 

04 

Red 

White-blue 

White 

White 

White-blue 

White-red 

White-blue 

White- Black 

ABS 

Detection 

interface 

B023 

White- Black 

Chassis fuse box 1 

White- Black 

White- Black 

White 

White- Black 

Battery 

White- 

Black 

White- 

Black

04-46 



1. Checking power fuse of ABS control unit 

(a) 


(b) 

Check if fuse F21 (5 A) and F23 (15 A) in body 

fuse block have been blown. 

04 



No > If fuse F21 (5A) is blown, go to step 2. 

If fuse F23 (15A) is blown, go to step 4. 

2. Checking circuit of fuse F21 (5A) 

(a) 

Disconnect ABS control unit connector. 

(b) 

Use a multimeter to measure resistance between fuse F21 (5A) and connector pin 7 of ABS 

control unit B013. 

Resistance: ≤2Ω


04-47 



No > Repair line open between fuse F21 (5A) and connector pin 7 of ABS control unit B013. 


(a) 

Use a multimeter to measure resistance to ground of connector pin 7 of ABS control unit 

B013. 



Yes > Replace fuse F21 (5A), clear malfunction blink code, and perform a road test. If the 

fuse is reblown, replace ABS control unit. 

No > Replace fuse F21 (5A) and repair line to ground short between the fuse and connector 



04 

(a) 


(b) 

Use a multimeter to measure resistance between fuse F23 (15A) and connector pin 8 of 

ABS control unit B013. 




No > Repair line open between fuse F23 (15A) and connector pin 8 of ABS control unit B013. 


(a) 


B013. 



Yes > Replace fuse F23 (15A), clear malfunction blink code, and perform a road test. 

If the fuse is reblown, replace ABS control unit.

04-48 


No > Replace fuse F23 (15A) and repair line to ground short between the fuse and 

connector pin 8 of ABS control unit B013. 

6. Checking power circuit of ABS control unit 

(a) 


04 

(b) 


of connector pins 7 and 8 of ABS control unit 

B013 respectively. 

Voltage: ≥ 18 V 



No > If both voltages are below 18V, check battery and charging system. (Refer to 

“Chapter 53 Battery” and Service Manual for Cummins ISF Series Engines.) 

If only voltage to ground of connector pin 7 of ABS control unit B013 is below 18V, 

go to step 8. 

If only voltage to ground of connector pin 8 of ABS control unit B013 is below 18V, 

go to step 9. 

7. Checking ground circuit of ABS control unit 

(a) 


(b) 


ground of connector pins 4 and 9 of ABS control 

unit B013 respectively. 




No > Repair lines between connector pins 4 and 9 of ABS control unit B013 and ground.

8. Checking power circuit of fuse F21 (5A) 


04-49 

(a) 

Use a multimeter to measure voltage to ground of fuse F21 (5A). 



Yes > Repair line open between fuse F21 (5A) and connector pin 7 of ABS control unit B013. 

No > Repair line open between F21 (5A) and power relay IG. 

9. Checking power circuit of fuse F23 (15A) 

(a) 




Yes > Repair line open between fuse F21 (5A) and connector pin 7 of ABS control unit B013. 

No > Repair line open between F21 (5A) and power relay IG. 

04

04-50 


8-2 ABS Control Unit Voltage High 


1. Checking power supply of ABS control unit 

(a) 

Inspect if battery voltage is below 14V. Is check result normal? 


No > Replace with a new battery. 

04 

2. Checking charging system 

(a) Start the engine. 

(b) Inspect if charging voltage is greater than 12V and less than 14V. 



No > Service charging system. (Refer to Service Manual for Cummins ISF Series Engines.)


8-3 Internal Fault of ABS Control Unit 



04-51 

(a) 

Start the engine. 

(b) 




Voltage: Replace ABS control unit. 

No > Service battery and charging system. (Refer to “Chapter 53 Battery” and Service 

Manual for Cummins ISF Series Engines.)

04-52 

ABS Does Not Work 

Description 

1. Symptom determination 

(a) 

(b) 


Generally, you can judge if the ABS works normally by observing ABS malfunction indicator 

light and emergency brake application with vehicle speed greater than 40km/h. 


04 


status 


light status 



goes out. 

Description 


Ignition switch: 

ON 


If the light goes out when vehicle speed is greater 

than 7km/h, it indicates ABS is normal. 

If the light does not go out when vehicle speed is 

greater than 7km/h, it indicates an ABS 




malfunction 

Tip: 

• The ABS indicator light must not go out until vehicle speed is greater than 7km/h (if the 

system is OK) after the vehicle is started for the first time or the system has been diagnosed. 

Conditions after ignition switch is turned on for the second time are shown in above table. 

• If ABS malfunction indicator light shines all the time, you should read DTC first and then 

diagnose according to corresponding DTC. 

• If no DTC exists, conduct an emergency brake test. 

(c) 

Apply emergency brake on a broad and flat road with vehicle speed greater than 40km/h, 

and then observe braking trace. If no braking drag marks exist, it indicates that the ABS 

works; if drag marks are seen on all wheels or one wheel and, at the same time, the ABS 

indicator light is always lighted up, it indicates that the ABS does not work or the ABS unit 

on the wheel does not work. Follow the steps below to perform troubleshooting. 

Notice: 

The emergency brake test must be carried out in a no man's land in good road conditions.



04-53 

Body fuse block B050 


White-blue 

Black-White 

IG Power 

relay 

R14 


Yellow 

Red 

04 

White-blue 

White 

White 

White-blue 

White-red 

White-blue 

White- Black 

ABS 

Detection 

interface 

B023 

White- Black 


White- Black 

White- Black 

White 

White- Black 

Battery 

White- 

Black 

White- 

Black

04-54 



• Check brake line for leakage. 


Yes > Repair brake line. (Refer to “Chapter 26 Service Brake-Brake System, On-Vehicle 

Inspection”.) 


1. Checking power fuse of ABS control unit 

04 

(a) 


(b) 

Check if fuse F21 (5 A) and F23 (15 A) in body 




No > If fuse F21 (5A) is blown, go to step 2. 

If fuse F23 (15A) is blown, go to step 4. 


(a) 


(b) 


04-55 

Use a multimeter to measure resistance between fuse F21 (5A) and connector pin 7 of ABS 

control unit B013. 




No > Repair line open between fuse F21 (5A) and connector pin 7 of ABS control unit 

B013. 


(a) 


B013. 



Yes > Replace fuse F21 (5A), and perform a road test. 

If the fuse is reblown, replace ABS control unit. 

No > Replace fuse F21 (5A) and repair line to ground short between the fuse and connector 


04 


(a) 


(b) 

Use a multimeter to measure resistance between fuse F23 (15A) and connector pin 8 of 

ABS control unit B013. Resistance: ≤2Ω 



No > Repair line open between fuse F23 (15A) and connector pin 8 of ABS control unit 

B013. 


(a) 


B013. 

Resistance: >1MΩ

04-56 



Yes > Replace fuse F23 (15A), and perform a road test. 

If the fuse is reblown, replace ABS control unit. 




(a) 


04 

(b) 







No > Repair line open between power relay IG and connector pin 7 of ABS control unit B013. 

Repair line open between F/L1 (50A) and connector pin 8 of ABS control unit B013. 


(a) 


(b) 


ground of connector pins 4 and 9 of ABS control 





No > Repair lines between connector pins 4 and 9 of ABS control unit B013 and ground.


ABS Can Not Work Effectively 

Description 


(a) 

(b) 

04-57 





status 


light status 



goes out. 

Description 


04 










malfunction 

Tip: 






• If no DTC exists, conduct an emergency brake test. 

(c) 

Apply emergency brake on a broad and flat road with vehicle speed greater than 40km/h, 

and then observe braking trace. If no braking drag marks exist, it indicates that the ABS 

works; if drag marks are seen on all wheels or one wheel and, at the same time, the ABS 

indicator light is always lighted up, it indicates that the ABS does not work or the ABS unit 

on the wheel does not work. Follow the steps below to perform troubleshooting. 

Notice: 

The emergency brake test must be carried out in a no man's land in good road conditions.

04-58 



• Check brake line for leakage, breakage, and deformation, etc. 


Yes > Repair brake line. (Refer to “Chapter 26 Service Brake-Brake System, On-Vehicle 



1. Checking ABS sensors 

04 

(a) 

(b) 

(c) 

Refer to “Chapter 04 Diagnosis-ABS, 3-1 Sensor Gap Large (Right Front Wheel)”. 

Refer to “Chapter 04 Diagnosis-ABS, 4-1 Sensor Broken/Shorted (Right Front Wheel)”. 

Refer to “Chapter 04 Diagnosis-ABS, 5-1 Sensor Signal Unstable (Right Front Wheel)”. 



No > Perform troubleshooting according to diagnostic procedures in above reference 

sections. 

2. Checking ABS ring gears 

(a) 

(b) 

(c) 

(d) 

Refer to “Chapter 04 Diagnosis-ABS, 6-1 Ring Gear Damaged (Right Front Wheel)”. 

Refer to “Chapter 04 Diagnosis-ABS, 6-2 Ring Gear Damaged (Left Front Wheel)”. 

Refer to “Chapter 04 Diagnosis-ABS, 6-3 Ring Gear Damaged (Right Rear Wheel)”. 

Refer to “Chapter 04 Diagnosis-ABS, 6-4 Ring Gear Damaged (Left Rear Wheel)”. 




sections. 

3. Checking ABS solenoid valves 

(a) 

(b) 

(c) 

(d) 

Refer to “Chapter 04 Diagnosis-ABS, 2-1 ABS Solenoid Valve (Right Front Wheel)”. 

Refer to “Chapter 04 Diagnosis-ABS, 2-2 ABS Solenoid Valve (Left Front Wheel)”. 

Refer to “Chapter 04 Diagnosis-ABS, 2-3 ABS Solenoid Valve (Right Rear Wheel)”. 

Refer to “Chapter 04 Diagnosis-ABS, 2-4 ABS Solenoid Valve (Left Rear Wheel)”. 


Yes > Check brake system. (Refer to “Chapter 26 Service Brake-Brake System, On-Vehicle 


If brake system is normal, replace ABS control unit. 


sections.

Diagnosis-ABS system 

ABS Malfunction Indicator Light Always Lighted Up 

Description 


(a) 

04-59 



04 

(b) 



status 



light status 



goes out. 



Description 








malfunction 

Tip: 






• If no DTC exists, follow the steps below to perform troubleshooting.

04-60 




B013 

combination 

meter B032 

ABS 

malfunctio 

n light 

yellow 

04 

white-black 

white-black 

white-black 



(a) 


(b) 



04-61 

(c) 

(d) 




04 





(a) 


(b) 


ground of connector pin 9 of ABS control unit 

B013. 




No > Repair the line between connector pin 9 of ABS control unit B013 and ground.

04-62 



(a) 


(b) 

Insert a right-sized plastic insulation insert into 


04 

ABS malfunction indicator light goes out? 





ABS Malfunction Indicator Light Does Not Come On 

Description 


(a) 

04-63 



04 

(b) 



status 



light status 



goes out. 



Description 








malfunction 

Tip: 







04-64 




B013 

combination 

meter B032 

ABS 

malfunctio 

n light 

yellow 

04 

white-black 

white-black 

white-black 



(a) 


(b) 



04-65 

(c) 

(d) 




04 




2. Checking control and ground circuits of ABS malfunction indicator light 

(a) 



of pin 15 of ABS control unit B013 respectively. 




No > If battery voltage is not available in either case, go to step 3. If battery voltage is not 

available only between connector pins 15 and 9 of ABS control unit B013, repair line 

open between connector pin 9 of the unit and ground.

04-66 


3. Checking for ABS malfunction indicator light circuit open 

(a) 




04 


Yes > Repair line open between connector pin 14 of combination meter B032 and 


No > Replace combination meter assembly.


ASR (ABS) Blink Code Indicator Light Always Lighted 

Up 

Description 


(a) 

Operation of ASR (ABS) blink code indicator light is shown in the table below: 

04-67 


status 



(depress ABS 

diagnostic switch 

and hold) 


(depress ABS 


and release) 


indicator light status 



goes out. 





Flash in different frequency 

modes. 

Does not flash. 

Description 



malfunction 

ABS diagnostic switch malfunction 


malfunction 

ASR (ABS) blink code indicator light line is 

normal. 

Indicator light line failure or ABS diagnostic 

switch malfunction 


normal. 


malfunction 


04 

(b) 



(c) 

If ASR (ABS) blink code indicator light is always 

lighted up, make sure if ABS malfunction 

indicator light comes on first.

04-68 


(d) Operation of ABS malfunction indicator light is shown in the table below: 


status 


light status 

Description 



goes out. 


04 










malfunction 

Tip: 









04-69 

combination 

meter B033 


(ABS) blink 

code 

indicator 

light. 

orange 

ABS diagnostic 

switch 

B046 

orange 

04 

white-black 


1. Checking ABS diagnostic switch 

(a) 

(b) 

(c) 


Disconnect ABS diagnostic switch connector. 


(d) 

Observe ASR (ABS) blink code indicator light. 

Check if ASR (ABS) blink code indicator light goes out. 

Yes > Replace ABS diagnostic switch. 

No > Go to step 2.

04-70 


2. Checking control circuit of ASR (ABS) blink code indicator light 

(a) 


(b) 


04 

(c) 

(d) 


Observe ASR (ABS) blink code indicator light. 

Check if ASR (ABS) blink code indicator light goes out. 




Repair line to ground short between connector pin 7 of combination meter B033 and 

connector pin 1 of ABS diagnostic switch B046.


ASR (ABS) Blink Code Indicator Light Does Not Come 

On 

Description 


(a) 

Operation of ASR (ABS) blink code indicator light is shown in the table below: 

04-71 


status 



(depress ABS 


and hold) 


(depress ABS 


and release) 


indicator light status 



goes out. 





Flash in different frequency 

modes. 

Does not flash. 

Description 



malfunction 



malfunction 


normal. 

Indicator light line failure or ABS diagnostic 

switch malfunction 


normal. 


malfunction 


04 

(b) 



(c) 

If ASR (ABS) blink code indicator light does not 

come on, make sure if ABS malfunction 

indicator light comes on first.

04-72 


(d) Operation of ABS malfunction indicator light is shown in the table below: 


status 


light status 

Description 



goes out. 


04 










malfunction 

Tip: 









04-73 

combination 

meter B033 

(ABS) blink 

code 

indicator 

light. 

orange 


switch 

B046 


orange 

04 

white-black 


1. Checking for ASR (ABS) blink code indicator light control circuit open 

(a) 

(b) 

(c) 


Disconnect ABS diagnostic switch connector. 


(d) 


connector pins 1 and 3 and voltage to ground of 

pin 1 of ABS diagnostic switch B046. 





If battery voltage is not available only between connector pins 1 and 3 of ABS 

diagnostic switch B046, repair line open between connector pin 3 of the switch and 

ground.

04-74 



(a) 




04 



pin 1 of ABS diagnostic switch B046. 


3. Checking ABS diagnostic switch 

(a) 


(b) 

Press and hold ABS diagnostic switch. 


between pins 1 and 3 of ABS diagnostic switch. 




No > Replace ABS diagnostic switch.



04-75 

(a) 


04 

(b) 

(c) 



of connector pin 13 of ABS control unit B013. 




No > Repair line open between connector pin 7 of combination meter B033 and connector 

pin 13 of ABS control unit B013.

04-76 


Notes 

1. Ignition switch expression 

Diagnosis-Heater and Air Conditioner 

04 


LOCK 

ACC 

ON 

START 





Engine start 

2. Power off. 

(a) 


to bare electrical pins, be sure to disconnect battery negative cable first in order to prevent 

personal injury or vehicle damage. 

Tip: 



(b) 


3. Disconnecting battery negative cable will clear day odometer and clock on 

combination meter. 

Tip: 



Tip: 



5. Never work in a closed place or a place 

where is close to a fire source. 

6. Never perform welding operation on parts and components filled with refrigerant. 

7. Please always wear goggles.


04-77 

8. Never allow liquid refrigerant to enter your 

eyes or contact your skin. 

If this happens: 

(a) 

Flush contact site with plenty of cold water. 

Notice: 

Never rub your eyes or skin. 

(b) 

(c) 

Apply clean Vaseline. 

Please see a doctor immediately. 

9. Never heat any tank or place it on an open flame. 

10. Never drop or hit it. Handle with care! 

04 

13. Take care and never overfill the refrigeration system. 

11. Never operate the compressor when there is not 

enough refrigerant in the refrigeration system. 

Without adequate refrigerant in the refrigeration system, 

poor oil lubrication will occur and the compressor may be 

burned out. Please take care to avoid this. 

12. Never open high-pressure line when the 

compressor is running. 

If high-pressure valve is opened, refrigerant will flow reversely 

to result in compressor cylinder block fracture. Therefore, 

only low-pressure valve can be opened and closed. 

Refrigerant overfill will result in such problems as insufficient cooling, poor fuel economy, and engine overheat. 

14. Do not open the system when there are puddles around or in rainy days. 

15. After the refrigeration system is opened, be sure to cap or bind and seal it promptly in 

order to prevent entry of water vapor or foreign substances in air. 

16. Refrigeration oil must be always covered with brand labeled. Hybrid use of refrigeration 

oils of different brands is not allowed so as to avoid reduction in oil quality and viscosity. 

17. When installing the refrigeration system, the reservoir must be installed last. 

18. After refrigerant is changed, you must refill the system with refrigeration oil first and then 

fill refrigerant. 

19. Repair tools must be clean and dry. Installation and repair sites should also be clean. 

20. Various seal cushions (washers) must be made of rubber sealing materials having good 

compatibility with the refrigerant used. 

21. Connection hoses must be made of the materials intended for refrigeration. Connection 

hoses suited to R-134a should use nylon linings. 

22. Refrigerant must be drained slowly so as to avoid refrigeration oil being taken out. Do not 

allow refrigeration oil to contact any glossy metal surface. 

23. Do not fill liquid refrigerant from low pressure end. Do not start up the compressor when 

filling refrigerant from high pressure end. 

24. Do not clean condenser and evaporator with steam. Use cold water or compressed air 

only. 

25. When repairing the refrigeration system, protect your car with such articles as protection pads. 

26. Do not start the compressor when the refrigeration system is not filled with refrigerant yet. 

27. To prevent corrosion during a long-term storage of the compressor (used), be sure to 

bleed air in the compressor completely and then fill it with refrigerant or dry nitrogen.

04-78 


04 

28. Before vacuum pumping process, you must check sealing carefully and handle leaky 

sites properly first. After installation is finished, check components of your car for 

normal motions, cooling pipe, cooling system and circuits for sound conditions, and 

air conditioner for good performance. 

29. When you install parts and components of your car, be sure to check clearances 

between them. Do not allow them to contact or approach. Be sure to separate each 

part from others with dielectrics. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

Clearance between fan housing and condenser (or radiator) >5mm 

Clearance between cooling fan (steel) and condenser or radiator >15mm 

Clearance between cooling fan (plastic) and condenser or radiator >20mm 

Clearance between cooling fan and fan housing >15mm 

Clearances between cooling fan and crankshaft and tensioner >4mm 

Clearance between cooling fan and condenser hose >15mm 

Clearance between slack side of V-belt and A/C hose >20mm 

30. When installing metal parts and components, spring washers must be added. 

31. Parts and components installed on the engine must be tightened to specified torques. 

32. If suspension bodies installed for assemblies are different or have nonuniform 

vibrations, they can not be connected using hard tubes. 

33. Notes related to wires 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

(j) 

To prevent wire short, battery negative connection (or ground wire) must be removed before 

you start to install any part. 

Wires must be connected securely and fixed firmly. 

If a wire has to pass through body metal plate, a rubber grommet should be added (to 

protect the wire). 

If other lines are detached or moved away in a repair process, they must be restored after 

the repair. 

Wires must be fixed in original harnesses of your car using plastic adhesive tape or original 

fasteners. 

When installing other A/C parts and components, take care not to pinch any harness. 

When welding to original wires, leads of equal diameters must be used and junctions must 

be wrapped up using adhesive tape. 

Wires can not be close to moving or high temperature components (e.g. engine exhaust 

pipe and cylinder block). They must be more than 50mm away from any heat source. 

Wires must be separated from fuel pipe for more than 100mm. 

Check wires carefully for contact with sharp objects or moving components.

Diagnosis-illlumination 

04-79 

Basic Checks 


1 Checking for presence of refrigerant 

• Screw off protective cover of service valve of A/C 

refrigeration system, and press valve core. 


2 Checking A/C switch 

• Turn on air conditioner. 

• Visually check if A/C working indicator light comes 

on. 


Y Go to step 2. 

N 

Add refrigerant. 


N Go to malfunction 

sympotoms table. 

04 

3 

4 

Checking electromagnetic clutch 

• Check electromagnetic clutch for normal pick-up. 


Checking driving belt 

• Check driving belt for slip. 








5 Checking compressor 

• If abnormal sound is heard when compressor is 

working. 


6 Checking condenser 

• Check between condenser and radiator for foreign 

materials. 

• Check condenser fan for normal operation. 

Check if condenser is normal. 

7 Checking refrigerant volume 

• Through sight hole, view volume of refrigerant in the 

system. 


8 Checking lines and circuits 

• Check lines and circuits for bending or kinks that will 

cause blocking. 


9 Checking high and low-pressure lines 

• Touch A/C line. The low-pressure pipe between 

evaporator outlet and compressor should feel cold; 

the high-pressure pipe between compressor and 

condenser should feel hot; the pipe sections from 

condenser to receiver drier and before receiver 

drier-expansion valve should feel warm; the pipe 

sections before and after expansion valve should 

have a significant temperature difference. 


10 Checking junctions 

• Check junctions between condenser, refrigerant pipe 

and other lines for oil traces. 






N 

Clear foreign materials or 

replace condenser fan. 





N Lay lines and circuits 

again. 




Y Go to malfunction 


N 

Perform a leakage test.

04-80 

Diagnosis-illuminaiton 

Malfunction sympotoms table 



1. Refrigeration System Does Not Achieve Refrigeration 


1. Fuse (damaged) - 

2. Belt (too loose) - 

04 

3. Electromagnetic clutch (damaged) - 

4. A/C cut-off relay (damaged) - 

5. A/C switch (damaged) Chapter 73 Instrument Panel/ 

Combination Meter/Cigarette 

Lighter-Instrument 

Panel, 

Replacement 

6. Tri-state pressure switch 

(damaged) 

Chapter 51 Heater and Air 

Conditioner-Reservoir, Replacement 

Air output is normal but 

compressor does not run. 

7. Sensing bulb (damaged) Chapter 51 Heater and Air 

Conditioner-Evaporator, 

Replacement 

8. A/C amplifier (damaged) - 

9. Electromagnetic clutch relay 

(damaged) 

- 

10. A/C relay (damaged) - 

11. ECM (damaged) - 

12. Harness (open or short to ground) - 

13. Compressor (damaged) Chapter 51 Heater and Air 

Conditioner-A/C Compressor, 

Replacement 



No air output from blower 

3. Air output switch (damaged) Chapter 73 Instrument 

Panel/Combination Meter/Cigarette 

Lighter-Instrument 

Panel, 

Replacement 

4. Governor resistor (damaged) Chapter 51 Heater and Air 

Conditioner-Blower, Replacement 

5. Blower (damaged) Chapter 51 Heater and Air 


With compressor running, air 

output is normal but insufficient 

cooling occurs. 

1. Serious refrigerant leak Chapter 51 Heater and Air 

Conditioner-Refrigerant, On-Vehicle 

Inspection 

2. Compressor damaged Chapter 51 Heater and Air 


Replacement 

3. Reservoir clogged Chapter 51 Heater and Air 

Conditioner-Reservoir, Replacement

2. Intermittent Refrigeration 


04-81 


1. Harness (contact poor) - 

2. Relay (contact poor) - 

Intermittent air output 

Compressor runs intermittently. 

Blower and compressor run 

normally but intermittent 

refrigeration occurs. 


Panel/Combination 

Meter/Cigarette Lighter-Instrument 

Panel, Replacement 



5. Blower (contact poor internally) Chapter 51 Heater and Air 


6. Air duct (clogged) Chapter 51 Heater and Air 

Conditioner-Air 

Duct, 

Replacement 

1. Belt (slip) - 

2. Electromagnetic clutch (slip) - 

3. A/C switch (damaged) Chapter 73 Instrument 




4. Tri-state pressure switch 

(damaged) 


Conditioner-Reservoir, 

Replacement 

5. Sensing bulb (damaged) Chapter 51 Heater and Air 


Replacement 

6. A/C amplifier (damaged) - 



Replacement 


1. Sensing bulb (loose) Chapter 51 Heater and Air 


Replacement 

2. Expansion valve (frozen up) Chapter 51 Heater and Air 


Replacement 

04 

3. System intermittently clogged 

by foreign materials 

-

04-82 

3. Insufficient Refrigeration 


04 

Air output abnormal 


Air output is normal but 

compressor is out of order. 

Pressures at both high and low 

pressure sides low 

Pressures at both high and low 

pressure sides high 

High pressure is low while low 

pressure is high. 


2. Relay (contact poor) - 







5. Blower (contact poor internally) Chapter 51 Heater and Air 


6. Air duct (clogged) Chapter 51 Heater and Air 


Duct, 

Replacement 

1. Electromagnetic clutch (slip) - 

2. Belt (slip) - 




Replacement 

5. Reservoir (clogged) Chapter 51 Heater and Air 


Replacement 

1. Refrigerant (leak) Chapter 51 Heater and Air 

Conditioner-Refrigerant, 

On-Vehicle Inspection 

2. Expansion valve (opening too 

small or clogged) 



Replacement 

3. Reservoir (outlet clogged) Chapter 51 Heater and Air 


Replacement 

4. Evaporator (frosting) Chapter 51 Heater and Air 



1. Refrigerant (excessive) Chapter 51 Heater and Air 



2. Air entrained in system Chapter 51 Heater and Air 



3. Condenser (surface covered 

with dirt) 

4. Expansion valve (opening 

excessive) 

- 



Replacement 



Replacement


04-83 


1. Reservoir (inlet or internally 

clogged) 



Replacement 

High pressure is too high while 

low pressure is too low. 

2. Condenser (clogged) Chapter 51 Heater and Air 

Conditioner-Condenser, 

Replacement 

Other 

3. Compressor outlet-reservoir 

line (clogged) 

1. Temperature control switch 

(damaged) 

2. Cooling and heating air doors 

(damaged) 


Conditioner-A/C 

Pipe, 

Replacement 



Pipe, 

Replacement 



Pipe, 

Replacement 

04 

4. Refrigeration System Noise Heavy 


1. Belt (too loose) - 

2. Compressor bracket (damaged) - 



Replacement 

External noise of system 

4. Refrigeration oil (insufficient or 

starvation) 

- 

5. Electromagnetic clutch (slip) Chapter 51 Heater and Air 


Replacement 

Internal noise of system 

6. Blower (bearing damaged or 

fan contact with other 

components) 

1. Refrigerant (excessive or 

insufficient) 

2. Water vapor in system causing 

expansion valve noise (slip) 

3. Too high pressure at high 

pressure side causing compressor 

shock 











On-Vehicle Inspection

04-84 

5. No Heating or Insufficient Heating 



1. Blower (damaged) Chapter 51 Heater and Air 


2. Blower relay (damaged) - 

3. Heater duct (coming off) Chapter 51 Heater and Air 


Duct, 

Replacement 

04 

No heating supply 

4. Temperature control air door 

(damaged) 


Conditioner-Heater Box, 

Replacement 

5. Water valve (damaged) Chapter 51 Heater and Air 

Conditioner-Water Hose, 

Replacement 

6. Control panel cable (coming off) Chapter 73 Instrument 




1. Coolant (insufficient or blocked) - 

Insufficient heating 

2. Heater core fin (deformed) Chapter 51 Heater and Air 

Conditioner-Heater Box, 

Replacement 

3. Heater line (scaling or having 

air inside) 


Conditioner-Water Hose, 

Replacement


Air Output Is Normal but Compressor Does Not Run 


04-85 

Ignition switch·B026 

white-blue 

black-white 

body fuse block B050 

04 

IG power 

relay 

R14 

starting 

system 

white-blue 

A/C cut-off 

relay 

R35 

A/C main 

relay 

R36 

black-red 

black-red 

engine control 

unit 

C033 

green 

green 

compressor 

electromagnetic clutch 

C006 

white 

white-red 

chassis fuse block 1 

C051 

white 

battery 

self-grou 

nding

04-86 


1. Checking fuse 


(a) 


(b) 

Check fuse F22 (10A) in body fuse block. 

04 

Check if the fuse is OK. 


No > Replace fuse. 

2. Checking compressor belt 

(a) 

Check compressor belt and its tension. 



No > Replace belt or adjust its tension. 

3. Checking electromagnetic clutch 

(a) 

(b) 

Connect compressor positive (+) with battery positive (+) and its negative (-) with body 

ground. 

Check if the electromagnetic clutch picks up. 



No > Replace compressor assembly.

4. Checking A/C cut-off relay 


04-87 



No > Replace A/C cut-off relay. 

5. Checking A/C switch 

(a) Check A/C cut-off relay R35. 

Standard values: 

Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 

Normal 1 - 2 Continuity 

Apply supply 

voltage between 

pins 1 and 2. 

3 - 5 Continuity 

04 

(a) 

Remove A/C switch (refer to “Chapter 73 Instrument Panel/Combination Meter/Cigarette 

Lighter-Instrument Panel, Replacement"). 

(b) 

Check A/C switch. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 

OFF 4 - 6 > 1 MΩ 

ON 4 - 6 ≤ 2 Ω 



No > Replace A/C switch.

04-88 


04 

6. Checking tri-state pressure switch 

(a) 

low pressure side high pressure side 

ON (conducted) 

OFF (non-conducted) OFF (non-conducted) 

Electromagnetic clutch control: 

Check pressure switch operation. 

• Install a manifold pressure gauge on the 

line. 

• Connect positive (+) of a multimeter (in 

ohms range) to pin 4 and its negative (-) 

to pin 1. 

• When refrigeration system pressure 

changes, check make and break 

between pins as shown in the figure. 

OFF 

(non-conducted) 

ON 

(conducted) 

(b) 

Cooling fan control: 




to pin 3. 


changes, check make and break 

between pins as shown in the figure. 



No > Replace pressure switch. 

7. Checking sensing bulb 

(a) 

Remove sensing bulb (refer to “Chapter 51 Heater and Air Conditioner-Evaporator, 

Replacement”). 

(b) 

Check sensing bulb resistance. 


Condition 

Use a 

multimeter to 

connect pins 

Specified value 

4 ℃ 1 - 2 3.967 KΩ ± 6% 

25 ℃ 1 - 2 1.487 KΩ ± 4% 



No > Replace sensing bulb.


04-89 

8. Checking electromagnetic clutch relay 



No > Replace dimmer relay. 

9. Checking A/C amplifier 

(a) Check electromagnetic clutch relay R15. 


Condition 

Use a multimeter 

to connect pins 

Specified 

value 


Apply supply 


pins 85 and 86. 


04 

(a) 

Turn on A/C switch to start air conditioner. 

(b) 

Check output voltage of A/C amplifier. 


Condition 

Turn on refrigeration 

system 

Use a 

multimeter to 

connect pins 

4-ground 

Specified 

value 

24 V 



No > Replace A/C amplifier.

04 

04-90 

10. Checking A/C main relay 



No > Replace A/C main relay. 

11. Checking ECM 


(a) Check A/C main relay R36. 


Condition 



Specified 

value 


Apply supply 


pins 1 and 2. 


(a) 

(b) 

Replace with an ECM known as trouble-free one. 

Turn on A/C system and check if compressor works. 

Is check result “working”? 

Yes > Replace ECM. 


12. Checking harness 

(a) 

Use a multimeter to measure resistance of the harness between pin 5 of A/C main relay 

R36 and pin 1 of A/C compressor. 


(b) Use a multimeter to measure resistance to ground of pin 5 of A/C main relay R36. 



Yes > Replace compressor. 

No > Replace harness.

No Air Output from Blower 



04-91 


white-blue 

black-white 


04 

IG power 

relay 

R14 

starting 

system 

white- black 

A/C cut-off 

relay 

R35 

A/C main 

relay 

R36 

blue -white 

blue –black 

white 

Blower 

B007 

white-red 

black-white 

blue 

–black 

Speed adjusting 

resistorB005 

blue 

-white 


C051 

blue-orange 

blueorang 

e 

blueyellow 

blue -white 

white 

battery 

blower switch 

B042 

white-black

04-92 




(a) 


(b) 


04 




2. Checking heater relay 

(a) Check heater relay R13. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 






No > Replace heater relay.

3. Checking blower switch 


04-93 

(a) 

Remove blower switch (refer to “Chapter 73 Instrument Panel/Combination Meter/Cigarette 


(b) 

Check blower switch. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 

OFF 

9 - 12 

9 - 1 

9 - 8 

9 - 11 

> 1 MΩ 

04 

LO 9 - 12 ≤ 2 Ω 

M1 9 - 1 ≤ 2 Ω 

M2 9 - 8 ≤ 2 Ω 

HI 9 - 11 ≤ 2 Ω 



No > Replace blower switch.

04-94 

4. Checking governor resistor 


(a) 

Disconnect governor resistor plugs. 

04 

(b) 

Check governor resistor. 


Condition 

Normal 



1 - 2 

1 - 3 

1 - 4 

Specified 

value 

Continuity 



No > Replace governor resistor. 


(a) 

(b) 

Use a multimeter to measure resistance of the harness between pin 87 of heater relay R13 

and pin 1 of blower. 


Use a multimeter to measure resistance to ground of pin 1 of blower. 



Yes > Replace blower. 



Compressor Runs Intermittently 


04-95 


white- blue 

white- blue 


04 

IG power 

relay 

R14 

white-black 

starting system 

A/C 

cut-off 

relay 

R35 

A/C main 

relay 

R36 

black –red black –red engine control unit 

C033 

green 

green 

compressor 

electromagnetic clutch 

C066 

white 

white –red 


white 

battery 

self-grounding

04-96 


1. Checking compressor belt 


(a) 

Check compressor belt and its tension. 



No > Replace belt or adjust its tension. 

2. Checking electromagnetic clutch 

04 

(a) 

(b) 

Connect compressor positive pole with battery positive pole and its negative pole with body 

ground. 

Check if the electromagnetic clutch picks up. 



No > Replace compressor assembly. 

3. Checking A/C switch 

(a) 

Remove A/C switch (refer to “Chapter 73 Instrument Panel/Combination Meter/Cigarette 


(b) 

Check A/C switch. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 

OFF 4 - 6 > 1 MΩ 

ON 4 - 6 ≤ 2 Ω 



No > Replace A/C switch.

4. Checking tri-state pressure switch 


04-97 

low pressure side high pressure side 

ON (conducted) 

OFF (non-conducted) OFF (non-conducted) 

(a) 



• Install a manifold pressure gauge on the 

line. 



to pin 1. 


changes, check make and break between 

pins as shown in the figure. 

04 

OFF 


ON 

(conducted) 

(b) 

Cooling fan control: 




to pin 3. 


changes, check make and break between 

pins as shown in the figure. 



No > Replace pressure switch. 

5. Checking sensing bulb 

(a) 

Remove sensing bulb (refer to “Chapter 51 Heater and Air Conditioner-Evaporator, 


(b) 

Check sensing bulb resistance. 


Condition 

Use a 

multimeter to 

connect pins 


4 ℃ 1 - 2 3.967 KΩ ± 6% 

25 ℃ 1 - 2 1.487 KΩ ± 4% 



No > Replace sensing bulb.

04-98 

6. Checking A/C amplifier 


(a) 

Turn on A/C switch to start air conditioner. 

04 

(b) 

Check output voltage of A/C amplifier. 


Condition 

Turn on 

refrigeration system 

Use a 

multimeter to 

connect pins 

4-ground 

Specified 

value 

24 V 



No > Replace A/C amplifier. 


(a) 

Check installation and resistances of harnesses. 


Yes > Replace harness. 

No > Replace compressor.

Illumination 

Notes 

1. Power off. 

(a) 


04-99 


to bare electrical pins, be sure to disconnect battery negative cable first in order to prevent 

personal injury or vehicle damage. 

Tip: 

Please do not leave your car key in your vehicle before battery negative cable is disconnected so 

as to avoid locking doors. 

(b) 




Tip: 



Tip: 

After battery negative cable is reconnected, you need to reset audio system (refer to “Operation 

Manual of the Audio System” in Chinese and English). 

4. Replacing bulbs with care 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

If oil stains are left on surface of a halogen bulb, the bulb’s life will also be shortened and it 

will be burned out due to overheat. 

Great care must be taken when handling a halogen bulb because high pressure exists 

inside it. Dropping, hitting or damaging it may result in explosion and fracture. 

When replacing a halogen bulb, be sure to wear safety goggles. 

When taking a bulb, hold its lamp holder only and avoid contact with glass. 

Keep a bulb ready for immediate replacement because the bulb’s reflector will absorb dust 

and water vapor if the used bulb has been removed from your vehicle for a prolonged time 

during replacement. 

Replace with a bulb of equal power. 

After bulb replacement is completed, reinstall lamp holder firmly. If water vapor near lamp 

holder enters the reflector, the reflector may become blurred. 

04

04-100 

Basic Checks 



04 


• Battery voltage should not be below 

21V. 


2 Checking night light 

• Use combination switch to turn on 

night light. 


3 Checking low beam 


• Use combination switch to turn on low 

beam. 


4 Checking high beam 


high beam. 


5 Checking passing light 


passing light. 


6 Checking turn light 

• Use combination switch to turn on turn 

light. 


7 Checking hazard warning light 

• Use hazard warning switch to turn on 

hazard warning light. 



N 

Charge the battery or replace. Refer to 

“Chapter 53 Battery-Battery”. 


N 

Go to malfunction sympotoms table. 


N 



N 



N 



N 



N 


8 Checking interior light 

• Use interior light switch to turn on 

interior light. 


Y 

N 

Check harness. 

Go to malfunction sympotoms table.


Malfunction sympotoms table 

04-101 



1. Headlights 


Low beam at one side does not 

come on. 

Low beam at neither side 

comes on. 

Low beam at one side always 

lighted up. 

Low beams at both sides 


High beam at one side does not 

come on. 

High beam at neither side 

comes on. 

High beam at one side always 

lighted up. 

1. Fuse (damaged) 

2. Bulb (damaged) 

3. Harness (open or short to 

ground) 



3. Dimmer relay (damaged) 


ground) 

5. Combination switch (damaged) 

1. Bulb harness (to power short) - 



3. Combination switch (shorted) 

4. Harness (shorted) 

1. Fuse 


3. High beam relay (damaged) 


ground) 




ground) 



- 

Chapter 54 Illumination- 

Combination Headlight Bulb, 

Replacement 

- 

- 



Replacement 

- 

- 

Chapter 41 Steering Mechanism- 

Combination Switch, Replacement 

- 

- 



- 

- 



Replacement 

- 

- 



Replacement 



- 

- 

- 

04

04-102 



High beams at both sides 






- 


- 

04 

Passing light does not come on. 



ground) 




- 

- 

Neither high beam nor low 

beam at one side comes on. 



ground) 



Replacement 

- 


- 


- 

Neither high beam nor low 

beam at neither side comes on. 



ground) 



Replacement 

- 

4. Illumination relay (damaged) 

- 




Both high and low beams at one 

side always lighted up. 





- 

Both high and low beams at 

both sides always lighted up. 





- 

Headlight dim 

1. Bulb (aging) 



Replacement 

2. Harness (contact poor) 

-

2. Taillights 


04-103 


Only combination taillight at one 

side does not come on. 


2. Harness (open) 


Combination Taillight Bulb, 

Replacement 

- 

Combination taillight at neither 

side comes on (combination 

headlight normal). 

Combination taillight at neither 

side comes on (combination 

headlight abnormal). 



ground) 



ground) 

- 

- 



- 

04 

3. Fog lights 


Front fog light at one side does 

not come on. 

Front fog light at neither side 

comes on. 

Front fog lights always lighted 

up. 

Rear fog lights do not come on. 

Rear fog lights always lighted 

up. 





3. Fog light relay (damaged) 



ground) 


2. Front fog light relay 



2. Rear fog light switch (damaged) 

3. Three-in-one controller 

(damaged) 


ground) 

1. Rear fog light switch (damaged) 


(damaged) 


Chapter 54 Illumination-Fog Light 

Bulb, Replacement 

- 

- 

Chapter 54 Illumination-Fog Light 

Bulb, Replacement 

- 



- 



- 

- 



Replacement 

- 

- 

- 

- 

- 

-

04-104 


4. Turn lights and hazard warning light 


04 

Neither turn lights nor hazard 

warning light comes on. 

Neither of turn lights comes 

on. 

Hazard warning light does 

not come on. 

Turn light at one side does 

not come on. 

Turn light at neither side 

comes on. 

A bulb does not come on. 

Hazard warning light always 

lighted up. 

Turn lights always lighted up. 


2. Three-in-one controller (damaged) 

3. Hazard warning switch (damaged) 

4. Harness (open or short to ground) 





















- 

- 

Chapter 73 Instrument Panel/ 


Lighter-Instrument Panel, 

Replacement 

- 

- 



- 

Chapter 73 Instrument 






- 

- 



- 

- 



Replacement 

- 





- 

- 



- 

-

5. Brake lights 


04-105 


Brake light at one side does not 

come on. 





Replacement 

- 


- 

Brake light at neither side 

comes on. 

2. Brake light switch (damaged) 


ground) 

Chapter 26 Service Brake-Brake 

Pedal, Replacement 

- 

04 

Brake lights always lighted up. 

1. Brake light switch (damaged) 

2. Bulb harness (to power short) 

Chapter 26 Service Brake-Brake 

Pedal, Replacement 

- 

6. Backup lights 


Backup light at one side does 

not come on. 

Backup light at neither side 

comes on. 

Backup lights always lighted up. 

7. Front ceiling lights 



ground) 



3. Backup light switch (damaged) 


ground) 

1. Backup light switch (damaged) 




Replacement 

- 

- 



Replacement 

Chapter 31 Transmission- 

Transmission Assembly, 

Replacement 

- 

Chapter 31 Transmission- 

Transmission Assembly, 

Replacement 

- 


Interior light at one side does 

not come on. 

Interior light at neither side 

comes on. 



1. Front ceiling light switch 

(damaged) 


ground) 

Chapter 54 Illumination-Front 

Ceiling Light Bulb, Replacement 

- 


Ceiling Light, Replacement 

-

04-106 



Interior lights always lighted 

up. 

1. Front ceiling light switch 

(damaged) 

2. Door light switch (damaged) 



Chapter 54 Illumination-Door Light 

Switch, Replacement 


- 

04 

Courtesy light at one side 

does not come on. 

Courtesy light at neither 

side comes on. 



1. Courtesy light switch (damaged) 




- 






- 

Courtesy lights always 

lighted up. 

1. Courtesy light switch (damaged) 







- 


- 

Neither interior lights nor 

courtesy lights come on. 





- 

8. Interior small lights illumination 



illumination does not shine. 

Radio cassette player 


Rear fog light switch 


Cigarette lighter illumination 

does not shine. 

Hazard warning switch 


1. LED (damaged) 

2. Harness (damaged) 

1. Radio cassette player assembly 

(damaged) 




1. Cigarette lighter (damaged) 





Combination Meter/Cigarette Lighter- 

Combination Meter, Replacement 

- 

Chapter 56 Audio System-Audio 

Unit, Replacement 

- 



Instrument Panel, Replacement 

- 



Cigarette Lighter, Replacement 



Instrument Panel, Replacement 

-


04-107 


A/C switch illumination does not 

shine. 

Blower switch illumination does 

not shine. 

ABS diagnostic switch 











Replacement 

- 




Replacement 

- 




Replacement 

- 

04 

9. Exterior outline marker lights 


Left front position light does not 

come on. 

Right front position light does not 

come on. 

Left outline marker light does not 

come on. 

Right outline marker light does 

not come on. 










Position Light Bulb, Replacement 

- 

- 


Position Light Bulb, Replacement 

Chapter 54 Illumination-Outline 

Marker Light Bulb, Replacement 

- 

Chapter 54 Illumination-Outline 

Marker Light Bulb, Replacement 

-

04-108 



Left rear marker light does not 

come on. 





Replacement 

- 

Right rear marker light does not 

come on. 





Replacement 

- 

04 

Left rear position light does not 

come on. 





Replacement 

- 

Right rear position light does not 

come on. 





Replacement 

- 


- 

None of interior small lights and 

exterior outline marker lights 

comes on. 

2. Small light relay (damaged) 


- 


Combination Switch, 

Replacement 


ground) 

-

Diagnosis- illumination 

Low Beam At One Side Does Not Come On 

04-109 

block B050 

left relay 

body fuse 

R30 

blue-black 

front left combined 

lamps 

B018 

Main 

beam 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

front right 

combined lamps 

B012 

04 

red-blue 

Dipped 

beam 

high beam 

right relay 

R31 

Main 

beam 

bluewhite 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 

red-white red-white red-yellow red-green 

white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery

04-110 


1. Checking fuses 

Diagnosis-illumination 

(a) 


(b) 

Check fuses F9 (15A) and F10 (15A) in body 

fuse block. 

04 

Check if the fuses are OK. 


No > Replace fuses. 

2. Checking harnesses 

(a) 

(b) 

Use a multimeter to measure resistances of harnesses between dimmer relay R11 and left 

and right combination headlights. 


Use a multimeter to measure resistances of harnesses between positive electrodes of left 

and right combination headlights and ground. 



Yes > Replace bulbs. 

No > Repair or replace harnesses.


Low Beam At Neither Side Comes On 


04-111 

block B050 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

04 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

red-blue 

front right 


B012 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery

04-112 




(a) 


(b) 


fuse block. 

04 




2. Checking dimmer relay 

(a) Check dimmer relay R11. 


Condition 

Use a 

multimeter 

to connect 

pins 



Apply supply 

voltage 

between pins 

85 and 86. 




No > Replace dimmer relay.


04-113 


(a) 

(b) 

Use a multimeter to measure resistances of harnesses between dimmer relay R11 and left 

and right combination headlights. 


Use a multimeter to measure resistances of harnesses between pins 1 of left and right 

combination headlights and ground. 




No > Repair or replace harnesses. 

4. Checking combination switch 

04 

(a) 

Check combination switch. 

Resistances: 

Condition 

Low beam switch 

OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

9 - 3 > 1 MΩ 

9 - 3 ≤ 2 Ω 


Yes > Replace bulb. 

No > Replace combination switch.

04-114 


Low Beams At Both Sides Always Lighted Up 


block B050 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

04 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

red-blue 

front right 


B012 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery


1. Checking dimmer relay 


04-115 

(a) Check dimmer relay R11. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 




04 



No > Replace dimmer relay. 


(a) 


Resistances: 

Condition 


OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

9 - 3 > 1 MΩ 

9 - 3 ≤ 2Ω 



No > Replace combination switch. 


(a) 

Use a multimeter to measure resistances of harnesses between pin 11 of dimmer relay and 

pins 1 of left and right low beams. 



Yes > Low beam to power short 


04-116 


High Beam At One Side Does Not Come On 


block B050 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

04 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

red-blue 

front right 


B012 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery




04-117 

(a) 


(b) 

Check fuses F7 (15A) and F8 (15A) in body fuse 

block. 

04 




2. Checking high beam relay 

(a) 

Check high beam relay R30/R31. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 


pins 1 and 2. 




No > Replace high beam relay.

04-118 



04 

(a) 

(b) 

Use a multimeter to measure resistances of harnesses between high beam relay R30/R31 

and left and right combination headlights. 


Use a multimeter to measure resistance of harness between high beam relay R30/R31 and 

ground. 






High Beam At Neither Side Comes On 


04-119 

block B050 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

04 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

red-blue 

front right 


B012 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery

04-120 




(a) 


(b) 


fuse block. 

04 




2. Checking high beam relays 

(a) Check high beam relays R30 and R31. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 


pins 1 and 2. 




No > Replace high beam relays.



04-121 

(a) 

(b) 

Use a multimeter to measure resistances of harnesses between high beam relays R30 and 

R31 and left and right combination headlights. 


Use a multimeter to measure resistances of harnesses between high beam relays R30 and 

R31 and ground. 





04 


(a) 


Resistances: 

Condition 

High beam switch 

OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

9 - 12 > 1 MΩ 

9 - 12 ≤ 2 Ω 




04-122 


High Beam At One Side Always Lighted Up 


block B050 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

04 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

front right 


B012 

red-blue 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery




04-123 

(a) Check high beam relay R30 and R31. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 


pins 1 and 2. 


04 


Yes > Repair or replace harnesses. 


04-124 


High Beams At Both Sides Always Lighted Up 


block B050 

04 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

beam relay 

high beam 

R11 

redyellow 

red-blue 

Dipped 

beam 

front right 


B012 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery




04-125 

(a) 


Resistances: 

Condition 


OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

9 - 12 > 1 MΩ 

9 - 12 ≤ 2 Ω 

04 





(a) Check high beam relay R30 and R31. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 


pins 1 and 2. 





04-126 


Neither High Beam Nor Low Beam At One Side Comes 

On 


block B050 

04 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

red-blue 

front right 


B012 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery




04-127 

(a) 


(b) 

Check fuses F7 (15 A), F8 (15 A), F9 (15 A), 

and F10 (15 A) in body fuse block. 

04 





(a) 

(b) 

(c) 

(d) 

Use a multimeter to measure resistances of harnesses between pins 3 of combination 

headlights B017 and B011 and ground. 

Use a multimeter to measure resistance of harness between pin 5 of high beam relay 

R30/R31 and combination headlight B017/B011. 

Use a multimeter to measure resistances of harnesses between pin 87 of dimmer relay R11 

and pins 1 of combination headlights B017 and B011. 


Use a multimeter to measure resistance to ground of pin 5 of high beam relay R30/R31. 





04 

04-128 



Yes > Replace headlight bulbs. 

No > Replace high beam relays. 


(a) Check high beam relays R30 and R31. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 


pins 1 and 2. 

3 - 5 Continuity


04-129 

Neither High Beam Nor Low Beam At Neither Side 

Comes On 


block B050 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

04 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

red-blue 

front right 


B012 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery

04-130 




(a) 


(b) 

Check fuses F7 (15 A), F8 (15 A), F9 (15 A), 

and F10 (15 A) in body fuse block. 

04 




2. Checking illumination relay 

(a) Check illumination relay R10. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 






No > Replace illumination relay.



04-131 

(a) 

(b) 

Use a multimeter to measure resistance between pin 85 of illumination relay R10 and pin 

14 of combination switch. 

Use a multimeter to measure resistance between pin 9 of combination switch and ground 

B028. 


(c) Use a multimeter to measure resistance to ground of pin 85 of illumination relay R10. 





04 


(a) 


Resistances: 

Condition 


OFF 


ON 


OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

9 - 3 > 1 MΩ 

9 - 3 ≤ 2 Ω 

9 - 12 > 1 MΩ 

9 - 12 ≤ 2 Ω 




04-132 


Both High And Low Beams At One Side Always Lighted 

Up 


block B050 

04 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

front right 


B012 

red-blue 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery


1. Checking high beam relay 


04-133 

(a) 

Check high beam relay R30/R31. 


Condition 



Specified 

value 


Apply supply 


pins 1 and 2. 


04 


Yes > Repair or replace harness. 

No > Replace high beam relay.

04-134 


Both High And Low Beams At Both Sides Always 

Lighted Up 


block B050 

04 

left relay 

body fuse 

R30 

blue-black 


lamps 

B018 

Main 

beam 

beam relay 

high beam 

R11 

redyellow 

Dipped 

beam 

red-blue 

front right 


B012 

Dipped 

beam 

high beam 

right relay 

R31 

bluewhite 

Main 

beam 

white-black 

lighting 

relay 

R10 

bluewhite 

combination 

meter 

B034 

whiteblack 

white-blue 


white-black 

white-black 

white-blue 

chassis fuse 

block 1 

C051 

connect 

or 

h 

(position) 

hea 

dlig 

ht 

Dipped 

beam 

Main 

beam 

overtake 

cubicle 

switch 

B025 

whiteblack 

white-black 

white 

white-black 

battery




04-135 

(a) 


Resistances: 

Condition 


OFF 


ON 


OFF 


ON 



Specified 

value 

9 - 3 > 1 MΩ 

9 - 3 ≤ 2 Ω 

9 - 12 > 1 MΩ 

9 - 12 ≤ 2 Ω 

04 





(a) 

(b) 

Use a multimeter to measure resistances of harnesses between pin 87 of dimmer relay R11 

and pins 1 of left and right combination headlights. 

Use a multimeter to measure resistances of harnesses between pin 5 of high beam relay 

R30/R31 and pins 2 of left and right combination headlights. 



Yes > Both left and right combination headlights to power short 


04-136 


Front Fog Light At One Side Does Not Come On 


04 

front 

fog light 

relay 

R33 

small 

light 

relay 

R32 

body fuse block 

B050 

white-blue 

green-red 

greenblue 

bluered 

green 

red-black 

connec 

tor 

switch 

(position) 

small light 

fog light 

cubicle 

switch 

B025 

white-black 

red-blue 

three-in-one 

controller 

redgreen 

red-yellow 

three-in-one 

controller 

B004 

blue-red 

white-blue 

rear fog light 

switch 

B041 

whiteblack 

chassis 

block 1 

C051 

fuse 

white-black 

left front fog light B021 

blue-red 

white-black 

white 

red-yellow 

right front fog light B010 

blue-red 

combination meter 

B032, B034 

white-black 

battery 

red-yellow 

right rear combined 

light J005 

red-yellow 

red-yellow red-yellow red-yellow 

white-black 

white-black 

left rear combined 

light J002



(a) 

(b) 


04-137 

Use a multimeter to measure resistances of harnesses between pin 2 of front fog light and 

grounds B206 and B207. 

Use a multimeter to measure resistance of harness between pin 5 of front fog light relay 

R33 and pin 1 of front fog light. 


(c) Use a multimeter to measure resistance to ground of pin 5 of front fog light relay R33. 



Yes > Replace front fog light bulb. 


04

04-138 


Front Fog Light At Neither Side Comes On 


04 

front 

fog light 

relay 

R33 

small 

light 

relay 

R32 


B050 

white-blue 

green-red 

greenblue 

bluered 

green 

red-black 

connec 

tor 

switch 

(position) 

small light 

fog light 

cubicle 

switch 

B025 

white-black 

red-blue 

three-in-one 

controller 

redgreen 

red-yellow 

three-in-one 

controller 

B004 

blue-red 

white-blue 


switch 

B041 

whiteblack 

chassis 

block 1 

C051 

fuse 

white-black 


blue-red 

white-black 

white 

red-yellow 


blue-red 


B032, B034 

white-black 

battery 

red-yellow 


light J005 

red-yellow 


white-black 

white-black 


light J002




04-139 

(a) 


(b) 

Check fuses F7 (15 A), F8 (15 A), F9 (15 A), and 

F10 (15 A) in body fuse block. 

04 

Check if the fuses are OK ? 



2. Checking front fog light relay 

(a) Check front fog light relay R33. 


Condition 



Specified 

value 


Apply supply 


pins 1 and 2. 




No > Replace front fog light relay.

04-140 



(a) 


Resistances: 

Condition 

Fog light switch 

OFF 



Specified 

value 

2 - 7 > 1 MΩ 

Fog light switch ON 2 - 7 ≤ 2 Ω 

04 





(a) 

(a) 


R33 and pin 1 of left front fog light B021. 


R33 and pin 1 of right front fog light B010. 


(b) Use a multimeter to measure resistance to ground of pin 5 of front fog light relay R33. 

Resistance: > 1MΩ 


Yes > Replace front fog light bulbs. 



Front Fog Lights Always Lighted Up 


04-141 

front 

fog light 

relay 

R33 

small 

light 

relay 

R32 


B050 

04 

white-blue 

green-red 

greenblue 

bluered 

green 

red-black 

connec 

tor 

switch 

(position) 

small light 

fog light 

cubicle 

switch 

B025 

white-black 

red-blue 

three-in-one 

controller 

redgreen 

red-yellow 

three-in-one 

controller 

B004 

blue-red 

white-blue 


switch 

B041 

whiteblack 

chassis 

block 1 

C051 

fuse 

white-black 


blue-red 

white-black 

white 

red-yellow 


blue-red 


B032, B034 

white-black 

battery 

red-yellow 


light J005 

red-yellow 


white-black 

white-black 


light J002

04-142 


1. Checking front fog light relay 


(a) Check front fog light relay R33. 


Condition 



Specified 

value 


04 

Apply supply 


pins 1 and 2. 




No > Replace front fog light relay. 


(a) 


Resistances: 

Condition 

Fog light switch 

OFF 

Use a 

multimeter to 

connect pins 

Specified 

value 

2 - 7 > 1 MΩ 

Fog light switch ON 2 - 7 ≤ 2 Ω 





Rear Fog Light at One Side Does Not Come On 


04-143 

front 

fog light 

relay 

R33 

small 

light 

relay 

R32 


B050 

04 

white-blue 

green-red 

greenblue 

bluered 

green 

red-black 

connec 

tor 

switch 

(position) 

small light 

fog light 

cubicle 

switch 

B025 

white-black 

red-blue 

three-in-one 

controller 

redgreen 

red-yellow 

three-in-one 

controller 

B004 

blue-red 

white-blue 


switch 

B041 

whiteblack 

chassis 

block 1 

C051 

fuse 

white-black 


blue-red 

white-black 

white 

red-yellow 


blue-red 


B032, B034 

white-black 

battery 

red-yellow 


light J005 

red-yellow 


white-black 

white-black 


light J002

04-144 




04 

(a) 

(b) 

Use a multimeter to measure resistances of harnesses between pin 12 of connector J101 

and pins 4 of left combination taillight J002 and right combination taillight J005. 

Use a multimeter to measure resistances of harnesses between pin 2 of three-in-one 

controller and pins 6 of left combination taillight J002 and right combination taillight J005. 



Yes > Replace rear fog light bulbs. 



Rear Fog Light at Neither Side Comes On 


04-145 

front 

fog light 

relay 

R33 

small 

light 

relay 

R32 


B050 

04 

white-blue 

green-red 

greenblue 

bluered 

green 

red-black 

connec 

tor 

switch 

(position) 

small light 

fog light 

cubicle 

switch 

B025 

white-black 

red-blue 

three-in-one 

controller 

redgreen 

red-yellow 

three-in-one 

controller 

B004 

blue-red 

white-blue 


switch 

B041 

whiteblack 

chassis 

block 1 

C051 

fuse 

white-black 


blue-red 

white-black 

white 

red-yellow 


blue-red 


B032, B034 

white-black 

battery 

red-yellow 


light J005 

red-yellow 


white-black 

white-black 


light J002

04-146 


1. Checking rear fog light switch 


(a) 

Remove rear fog light switch (refer to “Chapter 73 Instrument Panel/Combination 

Meter/Cigarette Lighter-Instrument Panel, Replacement"). 

04 

(b) 

Check rear fog light switch. 

Resistances: 

Condition 

Rear fog light 

switch OFF 


switch ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

9 - 6 > 1 MΩ 

9 - 6 ≤ 2 Ω 



No > Replace rear fog light switch. 


(a) 

(b) 

(c) 

(d) 

(e) 

Use a multimeter to measure resistance of harness between pin 2 of three-in-one controller 

B004 and pin 1 of B105. 

Use a multimeter to measure resistance of harness between pin 1 of C105 and pin 4 of 

C102. 

Use a multimeter to measure resistances of harnesses between pin 4 of C102 and pins 6 of 

left and right combination taillights J002 and J005. 

Use a multimeter to measure resistances of harnesses between pins 4 of left and right 

combination taillights J002 and J005 and ground. 


Disconnect connectors of left and right combination taillights J002 and J005, and use a 

multimeter to measure resistance to ground of pin 2 of three-in-one controller B004. 

Resistance: > 1MΩ 




3. Checking three-in-one controller 


04-147 

(a) Disconnect connectors of left and right 

combination taillights J002 and J005, turn on 

rear fog light switch, and measure output 

voltage on pin 2 of three-in-one controller. 

Voltage: 12V 


Yes > Replace rear fog light bulbs. 

No > Replace three-in-one controller. 

04

04-148 


Rear Fog Lights Always Lighted Up 


04 

front 

fog light 

relay 

R33 

small 

light 

relay 

R32 


B050 

white-blue 

green-red 

greenblue 

bluered 

green 

red-black 

connec 

tor 

switch 

(position) 

small light 

fog light 

cubicle 

switch 

B025 

white-black 

red-blue 

three-in-one 

controller 

redgreen 

red-yellow 

three-in-one 

controller 

B004 

blue-red 

white-blue 


switch 

B041 

whiteblack 

chassis 

block 1 

C051 

fuse 

white-black 


blue-red 

white-black 

white 

red-yellow 


blue-red 


B032, B034 

white-black 

battery 

red-yellow 


light J005 

red-yellow 


white-black 

white-black 


light J002


1. Checking rear fog light switch 


04-149 

(a) 

Remove rear fog light switch (refer to “Chapter 73 Instrument Panel/Combination 

Meter/Cigarette Lighter-Instrument Panel, Replacement"). 

(b) 

Check rear fog light switch. 

Resistances: 

Condition 


switch OFF 


switch ON 



Specified 

value 

9 - 6 > 1 MΩ 

9 - 6 ≤ 2 Ω 

04 



No > Replace rear fog light switch. 


(a) Disconnect connectors of left and right 

combination taillights J002 and J005, turn off 

rear fog light switch, and measure output 

voltage on pin 2 of three-in-one controller. 

Voltage: 0V 



No > Replace three-in-one controller. 


(a) 

Use a multimeter to measure resistances of harnesses between pin 2 of three-in-one 

controller and pins 6 of left and right combination taillights J002 and J005. 



Yes > Both left and right combination taillights to power short 


04-150 


Neither Steering Warning Light nor Hazard Warning 

Light Comes On 



white-blue 

black-white 

04 

IG 

power 

relay 

R14 


B050 

white 

white-blue 

connec 

tor 

switch 

(position) 

OFF 

ON 

hazard warning 

switch 

B037 

green-yellow 

green-black blue green-white connec 

tor 

switch 

(position) 

three-in-one 

controller 

three-in-o 

ne 

controller 

B003 

left 

right 

cubicle 

switch 

B025 

white-red 

white-blue 

green-yellow 

green-yellow 

green-black 

white-black 

white-black 

right rear combined light 

J005 

green-black 

white-black 

right front combined light (right front turn light) 

green-black 

green-black 

white-black 

white-black 

chassis 

block 1 

C051 

fuse 

green-yellow 

green-black 

green-black 

turn light of right door side 

white-black D006 

right front combined light 

(right side turn light) 

B0111 

white-black 

white 

green-black 

white-black 


B032, B033 

green-black 

green-black 

left front combined light (left side turn light) 

B017 

white-black 

white-black 

battery 

green-black 

turn light of left door side 

E006 

white-black 

left front combined light (left front turn light) 

B019 

green-black 

green-black 

green-black 

white-black 

white-black 

left rear combined light 

J002




04-151 

(a) 


(b) 


fuse block. 

04 

Check if the fuses are OK? 



2. Checking hazard warning light switch 

(a) 

Check hazard warning light switch. 

Resistances: 

Condition 

Hazard warning 

light OFF 


light ON 



Specified 

value 

7 - 10 ≤ 2Ω 

7-8 

5 - 9 - 6 

≤ 2Ω 



No > Replace hazard warning light switch

04-152 



(a) 

Check three-in-one controller. 

Voltage: 

Condition 


light ON 



12-ground 

Specified 

value 

12 V 

04 



No > Replace hazard warning light switch. 


(a) Use a multimeter to measure resistances of grounds B204, B205, B237, and B238. 

(b) 


Use a multimeter to measure resistances to ground of pins 8 and 10 of hazard warning 

switch B037. 



Yes > Replace turn light bulbs. 



Neither of Turn Lights Comes On 


04-153 


white-blue 

black-white 

IG 

power 

relay 

R14 


B050 

04 

white 

white-blue 

connec 

tor 

switch 

(position) 

OFF 

ON 


switch 

B037 

green-yellow 


tor 

switch 

(position) 

three-in-one 

controller 

three-in-o 

ne 

controller 

B003 

left 

right 

cubicle 

switch 

B025 

white-red 

white-blue 

green-yellow 

green-yellow 

green-black 

white-black 

white-black 


J005 

green-black 

white-black 


green-black 

green-black 

white-black 

white-black 

chassis 

block 1 

C051 

fuse 

green-yellow 

green-black 

green-black 





B0111 

white-black 

white 

green-black 

white-black 


B032, B033 

green-black 

green-black 


B017 

white-black 

white-black 

battery 

green-black 


E006 

white-black 


B019 

green-black 

green-black 

green-black 

white-black 

white-black 


J002

04-154 




04 

(a) 


Resistances: 

Condition 

Left turn light switch 

OFF 


ON 

Right turn light 

switch OFF 


switch ON 



Specified 

value 

5 - 1 > 1 MΩ 

5 - 1 ≤ 2 Ω 

1 - 8 > 1 MΩ 

1 - 8 ≤ 2 Ω 





Turn Light at One Side Does Not Come On 


04-155 


white-blue 

black-white 

IG 

power 

relay 

R14 


B050 

04 

white 

white-blue 

connec 

tor 

switch 

(position) 

OFF 

ON 


switch 

B037 

green-yellow 


tor 

switch 

(position) 

three-in-one 

controller 

three-in-o 

ne 

controller 

B003 

left 

right 

cubicle 

switch 

B025 

white-red 

white-blue 

green-yellow 

green-yellow 

green-black 

white-black 

white-black 


J005 

green-black 

white-black 


green-black 

green-black 

white-black 

white-black 

chassis 

block 1 

C051 

fuse 

green-yellow 

green-black 

green-black 





B0111 

white-black 

white 

green-black 

white-black 


B032, B033 

green-black 

green-black 


B017 

white-black 

white-black 

battery 

green-black 


E006 

white-black 


B019 

green-black 

green-black 

green-black 

white-black 

white-black 


J002

04-156 




04 

(a) 


Resistances: 

Condition 


OFF 


ON 


switch OFF 


switch ON 



Specified 

value 

5 - 1 > 1 MΩ 

5 - 1 ≤ 2 Ω 

1 - 8 > 1 MΩ 

1 - 8 ≤ 2 Ω 





Turn Light at Neither Side Comes On 


04-157 


white-blue 

black-white 

IG 

power 

relay 

R14 


B050 

04 

white 

white-blue 

connec 

tor 

switch 

(position) 

OFF 

ON 


switch 

B037 

green-yellow 


tor 

switch 

(position) 

three-in-one 

controller 

three-in-o 

ne 

controller 

B003 

left 

right 

cubicle 

switch 

B025 

white-red 

white-blue 

green-yellow 

green-yellow 

green-black 

white-black 

white-black 


J005 

green-black 

white-black 


green-black 

green-black 

white-black 

white-black 

chassis 

block 1 

C051 

fuse 

green-yellow 

green-black 

green-black 





B0111 

white-black 

white 

green-black 

white-black 


B032, B033 

green-black 

green-black 


B017 

white-black 

white-black 

battery 

green-black 


E006 

white-black 


B019 

green-black 

green-black 

green-black 

white-black 

white-black 


J002

04-158 




04 

(a) 


Resistances: 

Condition 

Left turn light 

switch OFF 

Left turn light 

switch ON 


switch OFF 


switch ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

5 - 1 > 1 MΩ 

5 - 1 ≤ 2 Ω 

1 - 8 > 1 MΩ 

1 - 8 ≤ 2 Ω 

Are check results normal ? 




Hazard Warning Light Always Lighted Up 


04-159 


white-blue 

black-white 

IG 

power 

relay 

R14 


B050 

04 

white 

white-blue 

connec 

tor 

switch 

(position) 

OFF 

ON 


switch 

B037 

green-yellow 


tor 

switch 

(position) 

three-in-one 

controller 

three-in-o 

ne 

controller 

B003 

left 

right 

cubicle 

switch 

B025 

white-red 

white-blue 

green-yellow 

green-yellow 

green-black 

white-black 

white-black 


J005 

green-black 

white-black 


green-black 

green-black 

white-black 

white-black 

chassis 

block 1 

C051 

fuse 

green-yellow 

green-black 

green-black 





B0111 

white-black 

white 

green-black 

white-black 


B032, B033 

green-black 

green-black 


B017 

white-black 

white-black 

battery 

green-black 


E006 

white-black 


B019 

green-black 

green-black 

green-black 

white-black 

white-black 


J002

04-160 


1. Checking hazard warning light switch 


04 

(a) 

Check hazard warning light switch. 

Resistances: 

Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 

OFF 5 - 9 - 6 > 1 MΩ 

ON 5 - 9 - 6 ≤ 2 Ω 



No > Replace hazard warning light switch.


Turn Lights Always Lighted Up 


04-161 


white-blue 

black-white 

IG 

power 

relay 

R14 


B050 

04 

white 

white-blue 

connec 

tor 

switch 

(position) 

OFF 

ON 


switch 

B037 

green-yellow 


tor 

switch 

(position) 

three-in-one 

controller 

three-in-o 

ne 

controller 

B003 

left 

right 

cubicle 

switch 

B025 

white-red 

white-blue 

green-yellow 

green-yellow 

green-black 

white-black 

white-black 


J005 

green-black 

white-black 


green-black 

green-black 

white-black 

white-black 

chassis 

block 1 

C051 

fuse 

green-yellow 

green-black 

green-black 





B0111 

white-black 

white 

green-black 

white-black 


B032, B033 

green-black 


B017 

green-black 

white-black 

white-black 

battery 

green-black 


E006 

white-black 


B019 

green-black 

green-black 

green-black 

white-black 

white-black 


J002

04 

04-162 




(a) 


Resistances: 

Condition 

Turn light switch 

OFF 

Turn light switch 

ON 

Use a 

multimeter to 

connect pins 

5 - 1 

8 - 1 

5 - 1 

8 - 1 

Specified 

value 

> 1 MΩ 

≤ 2 Ω 





Brake Light At One Side Does Not Come On 


04-163 


white-blue 

black-white 


IG power 

relay 

R14 

backup light switch 

B015 

04 

bule-yellow 

Yellow- green 

white 

Yellow- green 

white-red 

Yellow- green 

chassis fuse 

block 1 

C051 

white-black 

Yellow- green 

left combination 

taillight 

J002 

Yellow- green 

right combination 

taillight 

J005 

white 

white-black 

white-black 

white-black 

battery 

white-black 



(a) 

(b) 

Use a multimeter to measure resistances of harnesses between pin 3 of J101 and pins 2 of 

left combination taillight J002 and right combination taillight J005. 

Use a multimeter to measure resistances of harnesses between pins 4 of left combination 

taillight J002 and right combination taillight J005 and pin 12 of J101. 





04-164 


Brake Light At Neither Side Comes On 



white-blue 

black-white 


04 

IG power 

relay 

R14 


B015 

bule-yellow 

Yellow- green 

white 

Yellow- green 

white-red 

Yellow- green 

chassis fuse 

block 1 

C051 

white-black 

Yellow- green 


taillight 

J002 

Yellow- green 


taillight 

J005 

white 

white-black 

white-black 

white-black 

battery 

white-black 



(a) 



04-165 

(b) 

Check fuse F14 (7.5A) in body fuse block. 

04 




2. Checking brake light switch 

(a) 

Remove brake light switch (refer to “Chapter 26 Service Brake-Brake Pedal, Replacement”). 

(b) Check brake light switch B105. 

Resistances: 

Condition 

Brake light switch 

OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

1 - 2 > 1 MΩ 

1 - 2 ≤ 2 Ω 



No > Replace brake light switch. 


(a) 

(b) 

Use a multimeter to measure resistance between pin 2 of brake switch B015 and pin 3 of 

J101. 

Use a multimeter to measure resistances between pin 12 of J101 and grounds C237 and 

C238. 





04-166 


Brake Lights Always Lighted Up 



white-blue 

black-white 


04 

IG power 

relay 

R14 


B015 

bule-yellow 

Yellow- green 

white 

Yellow- green 

white-red 

Yellow- green 

chassis fuse 

block 1 

C051 

white-black 

Yellow- green 


taillight 

J002 

Yellow- green 


taillight 

J005 

white 

white-black 

white-black 

white-black 

battery 

white-black


1. Checking brake light switch 


04-167 

(a) 

Remove brake light switch (refer to “Chapter 26 Service Brake-Brake Pedal, Replacement”). 

(b) Check brake light switch B105. 

Resistances: 

Condition 


OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

1 - 2 > 1 MΩ 

1 - 2 ≤ 2 Ω 

04 



No > Replace brake light switch.

04-168 


Backup Light At One Side Does Not Come On 



white-blue 

black-white 


04 

IG power 

relay 

R14 


C032 

red-yellow 

green-yellow 

green-red 

white 

green-red 

green-red 

white-red 

chassis fuse 

block 1 

C051 

white-black 

combinatio 

n meter 

B032, 

B034 

green-red 

left 

combination 

taillight 

J002 

green-red 

right 

combinati 

on taillight 

J005 

white 

white-black 

white-black 

white-black 

white-black 

battery 

white-black 



(a) 

(b) 


combination taillights J002 and J005. 

Use a multimeter to measure resistances of harnesses between pins 4 of combination 

taillights J002 and J005 and pin 12 of J101. 





Diagnosis – Illumination 

Backup Light At Neither Side Comes On 


04-169 


white-blue 

black-white 


04 

IG power 

relay 

R14 


C032 

red-yellow 

green-yellow 

green-red 

white 

green-red 

green-red 

white-red 

green-red 

green-red 

chassis fuse 

block 1 

C051 

white-black 

combinatio 

n meter 

B032, 

B034 

left 

combination 

taillight 

J002 

right 

combinati 

on taillight 

J005 

white 

white-black 

white-black 

white-black 

white-black 

battery 

white-black

04-170 




(a) 


(b) 


04 

Check if the fuse is OK? 



2. Checking backup light switch 

(a) Remove backup light switch (refer to “Chapter 31 Transmission-Transmission, 


(b) Check backup light switch C032. 

Resistances: 

Condition 

Backup light switch 

OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

1 - 2 > 1 MΩ 

1 - 2 ≤ 2 Ω 



No > Replace backup light switch.



04-171 

(a) 

(b) 

(c) 

(d) 

Use a multimeter to measure resistance of harness between pin 87 of IG power relay R14 

and pin 1 of B104. 

Use a multimeter to measure resistance of harness between pins 1 of C106 and backup 

light switch C032. 

Use a multimeter to measure resistance of harness between pin 2 of backup light switch 

C032 and pin 9 of C102. 


left and right combination taillights J002 and J005. 





04

04-172 


Backup Lights Always Lighted Up 



white-blue 

black-white 


04 

IG power 

relay 

R14 


C032 

red-yellow 

green-yellow 

green-red 

white 

green-red 

green-red 

white-red 

chassis fuse 

block 1 

C051 

white-black 

combinatio 

n meter 

B032, 

B034 

green-red 

left 

combination 

taillight 

J002 

green-red 

right 

combinati 

on taillight 

J005 

white 

white-black 

white-black 

white-black 

white-black 

battery 

white-black


1. Checking backup light switch 


04-173 

(a) Remove backup light switch (refer to “Chapter 31 Transmission-Transmission, 


(b) Check backup light switch C032. 

Resistances: 

Condition 


OFF 


ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

1 - 2 > 1 MΩ 

1 - 2 ≤ 2 Ω 

04 



No > Replace backup light switch.

04-174 


License Light Does Not Come On 


green 

green 

F004 right outline 

marker light 

04 

green 

F003 left outline 

marker light 

white-blu 

e 

white-blue 

right front combination 

taillight B011 

white-blue 

green 

white-blu 

e 

left front combination 

lightB017 

white-blue 

green green green 


B050 


taillight J005 

small 

light 

relay 

R32 

green 

green 



white-blue 

rear licence light 

J003 

white-blue 

green-blue 

green 

white-blue 

white-red 

connect 

or 

switch 

(position) 

small light 

cubicle switch 

B025 

green 

green 

right marker light 

C024 

left marker light 

C025 

white-blue 

white-blue 

white-blue 

white-blue 

right front 

marker light C02 

white-blue 

chassis fuse 

block 1 

C051 

green 

left front marker 

light C036 

white-blue 

white-blue 

white 

green 

white-blue 

white-blue 

rear outline 


white-blue 

battery 

green 

green 

white-blue 

right rear outline 

marker light G002 

white-blue 

left rear outline 

marker light G003



(a) 

(b) 

(c) 

(d) 


04-175 

Use a multimeter to measure resistance of harness between pin 5 of small light relay R32 



C102. 

Use a multimeter to measure resistance of harness between pins 1 of J101 and license 

light J003. 


license light J003. 





04

04-176 


Interior Light At One Side Does Not Come On 



B050 

yellow 

red-yellow 

04 

white-blue 

door 

courtesy 

off 

off 

front ceiling 

light 

F002 

white-blue 

on 

on 

chassis fuse 

block 1 

C051 

red-white 

green 

white 

green 

green 

green 

green 

battery 

left door light 

switch 

L001 

right door light 

switch 

H001 

self-grounding 




(a) 

Use a multimeter to measure resistance of harness between pin 1 of front ceiling light F002 

and bulb positive (+). 


(b) Use a multimeter to measure resistance to ground of pin 1 of front ceiling light F002. 






Interior Light At Neither Side Comes On 


04-177 


B050 

yellow 

red-yellow 

white-blue 

04 

door 

courtesy 

off 

off 

front ceiling 

light 

F002 

white-blue 

on 

on 

chassis fuse 

block 1 

C051 

red-white 

green 

white 

green 

green 

green 

green 

battery 


switch 

L001 


switch 

H001 


self-grounding

04-178 


1. Checking front ceiling light switch 


(a) 

Remove front ceiling light (refer to “Chapter 54 Illumination-Front Ceiling Light, 


04 

(b) 

Check front ceiling light switch. 

Resistances: 

Condition 

Front ceiling light 

switch OFF 


switch ON 



Specified 

value 

1 - 2 > 1 MΩ 

1 - 2 ≤ 2 Ω 



No > Replace front ceiling light switch.


Interior Lights Always Lighted Up 


04-179 


B050 

yellow 

red-yellow 

white-blue 

04 

door 

courtesy 

off 

off 

front ceiling 

light 

F002 

white-blue 

on 

on 

chassis fuse 

block 1 

C051 

red-white 

green 

white 

green 

green 

green 

green 

battery 


switch 

L001 


switch 

H001 


self-grounding

04-180 


1. Checking front ceiling light switch 


(a) 

Remove front ceiling light (refer to “Chapter 54 Illumination-Front Ceiling Light, 


04 

(b) 

Check front ceiling light switch. 

Resistances: 

Condition 


switch OFF 


switch ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

1 - 2 > 1 MΩ 

1 - 2 ≤ 2 Ω 



No > Replace front ceiling light switch.


Courtesy Light At One Side Does Not Come On 


04-181 


B050 

yellow 

red-yellow 

white-blue 

04 

door 

courtesy 

off 

off 

front ceiling 

light 

F002 

white-blue 

on 

on 

chassis fuse 

block 1 

C051 

red-white 

green 

white 

green 

green 

green 

green 

battery 


switch 

L001 


switch 

H001 


self-grounding

04-182 


1. Checking door light switch 


04 

(a) 

Check door light switch. 

Resistances: 

Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 

Pressed 1-ground > 1 MΩ 

Released 1-ground ≤ 2 Ω 



No > Replace door light switch. 


(a) 

Use a multimeter to measure resistance of harness between pin 1 of front ceiling light F002 

and bulb positive (+). 


(b) Use a multimeter to measure resistance to ground of pin 1 of front ceiling light F002. 






Courtesy Light At Neither Side Comes On 


04-183 


B050 

yellow 

red-yellow 

white-blue 

04 

door 

courtesy 

off 

off 

front ceiling 

light 

F002 

white-blue 

on 

on 

chassis fuse 

block 1 

C051 

red-white 

green 

white 

green 

green 

green 

green 

battery 


switch 

L001 


switch 

H001 


self-grounding

04-184 


1. Checking courtesy light switch 


(a) 

Remove front ceiling light assembly (refer to “Chapter 54 Illumination-Front Ceiling Light 

Assembly, Replacement”). 

04 

(b) 

Check courtesy light switch. 

Resistances: 

Condition 


switch OFF 


switch ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

1 - 2 > 1 MΩ 

1 - 2 ≤ 2 Ω 



No > Replace front ceiling light assembly. 


(a) 


Resistances: 

Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 





No > Replace door light switch.


Courtesy Lights Always Lighted Up 


04-185 


B050 

yellow 

red-yellow 

white-blue 

04 

door 

courtesy 

off 

off 

front ceiling 

light 

F002 

white-blue 

on 

on 

chassis fuse 

block 1 

C051 

red-white 

green 

white 

green 

green 

green 

green 

battery 


switch 

L001 


switch 

H001 


self-grounding

04-186 


1. Checking courtesy light switch 


(a) 

Remove front ceiling light assembly (refer to “Chapter 54 Illumination-Front Ceiling Light 

Assembly, Replacement”). 

04 

(b) 

Check courtesy light switch. 

Resistances: 

Condition 


switch OFF 


switch ON 

Use a 

multimeter to 

connect pins 

Specified 

value 

1 - 2 > 1 MΩ 

1 - 2 ≤ 2 Ω 



No > Replace front ceiling light assembly. 


(a) 


Resistances: 

Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 





No > Replace door light switch.


04-187 

Neither Interior Lights Nor Courtesy Lights Come On 



B050 

yellow 

red-yellow 

white-blue 

04 

door 

courtesy 

off 

off 

front ceiling 

light 

F002 

white-blue 

on 

on 

chassis fuse 

block 1 

C051 

red-white 

green 

white 

green 

green 

green 

green 

battery 


switch 

L001 


switch 

H001 


self-grounding

04-188 




(a) 


(b) 


04 





(a) Use a multimeter to measure resistance of harness between pin 1 of B103 and fuse F15. 

(b) Use a multimeter to measure resistance of harness between fuse F15 and pin 2 of B112. 

(c) 

Use a multimeter to measure resistance of harness between pin 2 of F101 and pin 1 of 

front ceiling light F002. 






Combination Meter Illumination Does Not Shine 


04-189 

green 

white-black 


B032,B034 

04 


B050 

green 


switch B046 

white-black 

small 

light 

relay 

R32 

green 

blower switch 

B042 

white-black 

green 

white-black 

white-blue 

green-blue 

A/C switch 

B043 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 


switch B037 

white-black 

green 

white-black 

chassis fuse 

block 1 

C051 

Cigarette Lighter 

Illumination B039 

green 

white-black 

white 

white-blue 

rear fog switch 

B041 

green 

white-black 

Radio cassette 

player illumination 

B045 

battery 

green 

white-black 

igniting switch 

Illumination B027

04-190 




04 

(a) 

(b) 

(c) 


and pin 15 of combination meter B034. 

Use a multimeter to measure resistances of harnesses between pin 12 of combination 

meter B034 and grounds B204 and B205. 


Use a multimeter to measure resistance of harness between pin 15 of combination meter 

B034 and ground. 



Yes > Replace combination meter assembly. 



Radio cassette player illumination does not shine. 


04-191 

green 

white-black 


B032,B034 

04 


B050 

green 


switch B046 

white-black 

small 

light 

relay 

R32 

green 

blower switch 

B042 

white-black 

green 

white-black 

white-blue 

green-blue 

A/C switch 

B043 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 


switch B037 

white-black 

green 

white-black 

chassis fuse 

block 1 

C051 



green 

white-black 

white 

white-blue 


B041 

green 

white-black 



B045 

battery 

green 

white-black 


Illumination B027

04-192 




04 

(a) 

(b) 

(c) 


and pin 10 of radio cassette player B045. 

Use a multimeter to measure resistances of harnesses between pin 7 of radio cassette 

player B045 and grounds B208 and B209. 


Use a multimeter to measure resistance of harness between pin 10 of radio cassette player 




Yes > Repair or replace audio unit. 



Rear Fog Light Switch Illumination Does Not Shine 


04-193 

green 

white-black 


B032,B034 

04 


B050 

green 


switch B046 

white-black 

small 

light 

relay 

R32 

green 

blower switch 

B042 

white-black 

green 

white-black 

white-blue 

green-blue 

A/C switch 

B043 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 


switch B037 

white-black 

green 

white-black 

chassis fuse 

block 1 

C051 



green 

white-black 

white 

white-blue 


B041 

green 

white-black 



B045 

battery 

green 

white-black 


Illumination B027

04-194 




04 

(a) 

(b) 

(c) 


and pin 2 of rear fog light switch B041. 

Use a multimeter to measure resistances of harnesses between pin 7 of rear fog light 

switch B041 and grounds B208 and B209. 


Use a multimeter to measure resistance of harness between pin 2 of rear fog light switch 




Yes > Replace rear fog light switch. 



Cigarette Lighter Illumination Does Not Shine 


04-195 

green 

white-black 


B032,B034 

04 


B050 

green 


switch B046 

white-black 

small 

light 

relay 

R32 

green 

blower switch 

B042 

white-black 

green 

white-black 

white-blue 

green-blue 

A/C switch 

B043 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 


switch B037 

white-black 

green 

white-black 

chassis fuse 

block 1 

C051 



green 

white-black 

white 

white-blue 


B041 

green 

white-black 



B045 

battery 

green 

white-black 


Illumination B027

04-196 




04 

(a) 

(b) 

(c) 


and pin 1 of cigarette lighter illuminating light B039. 

Use a multimeter to measure resistances of harnesses between pin 2 of cigarette lighter 

illuminating light B039 and grounds B208 and B209. 


Use a multimeter to measure resistance of harness between pin 1 of cigarette lighter 

illuminating light B039 and ground. 



Yes > Replace cigarette lighter assembly. 



Hazard Warning Switch Illumination Does Not Shine 


04-197 

green 

white-black 


B032,B034 

04 


B050 

green 


switch B046 

white-black 

small 

light 

relay 

R32 

green 

blower switch 

B042 

white-black 

green 

white-black 

white-blue 

green-blue 

A/C switch 

B043 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 


switch B037 

white-black 

green 

white-black 

chassis fuse 

block 1 

C051 



green 

white-black 

white 

white-blue 


B041 

green 

white-black 



B045 

battery 

green 

white-black 


Illumination B027

04-198 




04 

(a) 

(b) 

(c) 


and pin 2 of hazard warning switch B037. 

Use a multimeter to measure resistances of harnesses between pin 3 of cigarette lighter 

illuminating light hazard warning switch B037 and grounds B208 and B209. 


Use a multimeter to measure resistance of harness between pin 2 of hazard warning switch 




Yes > Replace hazard warning light switch. 



A/C Switch Illumination Does Not Shine 


04-199 

green 

white-black 


B032,B034 

04 


B050 

green 


switch B046 

white-black 

small 

light 

relay 

R32 

green 

blower switch 

B042 

white-black 

green 

white-black 

white-blue 

green-blue 

A/C switch 

B043 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 


switch B037 

white-black 

green 

white-black 

chassis fuse 

block 1 

C051 



green 

white-black 

white 

white-blue 


B041 

green 

white-black 



B045 

battery 

green 

white-black 


Illumination B027

04-200 




04 

(a) 

(b) 

(c) 


and pin 3 of A/C switch B043. 

Use a multimeter to measure resistances of harnesses between pin 1 of A/C switch B043 

and grounds B208 and B209. 


Use a multimeter to measure resistance of harness between pin 3 of A/C switch B043 and 

ground. 



Yes > Replace A/C switch. 



Blower Switch Illumination Does Not Shine 


04-201 

green 

white-black 


B032,B034 

04 


B050 

green 


switch B046 

white-black 

small 

light 

relay 

R32 

green 

blower switch 

B042 

white-black 

green 

white-black 

white-blue 

green-blue 

A/C switch 

B043 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 


switch B037 

white-black 

green 

white-black 

chassis fuse 

block 1 

C051 



green 

white-black 

white 

white-blue 


B041 

green 

white-black 



B045 

battery 

green 

white-black 


Illumination B027

04-202 




04 

(a) 

(b) 

(c) 


and pin 7 of blower switch B042. 

Use a multimeter to measure resistances of harnesses between pin 6 of blower switch 

B042 and grounds B208 and B209. 


Use a multimeter to measure resistance of harness between pin 7 of blower switch B042 

and ground. 



Yes > Replace LED. 



ABS Diagnostic Switch Illumination Does Not Shine 


04-203 

green 

white-black 


B032,B034 

04 


B050 

green 


switch B046 

white-black 

small 

light 

relay 

R32 

green 

blower switch 

B042 

white-black 

green 

white-black 

white-blue 

green-blue 

A/C switch 

B043 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 


switch B037 

white-black 

green 

white-black 

chassis fuse 

block 1 

C051 



green 

white-black 

white 

white-blue 


B041 

green 

white-black 



B045 

battery 

green 

white-black 


Illumination B027

04-204 




04 

(a) 

(b) 

(c) 


and pin 6 of ABS diagnostic switch B046. 

Use a multimeter to measure resistances of harnesses between pin 2 of ABS diagnostic 

switch B046 and grounds B208 and B209. 


Use a multimeter to measure resistance of harness between pin 6 of ABS diagnostic switch 




Yes > Replace ABS diagnostic switch. 



Left Front Position Light Does Not Come On 


04-205 

green 

green 

right outline marker 

light F004 

green 

left outline marker 

light F003 

white-black 

white-black 

04 



white-black 

green 

white-black 


lightB017 

white-black 


B050 

green 

green 



green 

small 

light 

relay 

R32 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 

green 


C024 


C025 

white-black 

white-black 

white-black 

white-black 

right front marker 

light C021 

white-black 

chassis fuse 

block 1 

C051 

green 

left front marker light 

C036 

white-black 

white-black 

white 

green 

white-black 

white-blue 

rear outline marker 

light C030 

white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003

04-206 




04 

(a) 

(b) 

(c) 


and pin 1 of left combination headlight B017. 

Use a multimeter to measure resistances of harnesses between pin 2 of left combination 

headlight B017 and grounds B204 and B205. 


Use a multimeter to measure resistance of harness between pin 1 of left combination 

headlight B017 and ground. 






Right Front Position Light Does Not Come On 


04-207 

green 

green 

right outline marker 

light F004 

green 


light F003 

white-black 

white-black 

04 



white-black 

green 

white-black 


lightB017 

white-black 


B050 

green 

green 



green 

small 

light 

relay 

R32 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

white-red 

connec 

tor 

switch 

(position) 

small light 

cubicle 

switch 

B025 

green 

green 


C024 


C025 

white-black 

white-black 

white-black 

white-black 


light C021 

white-black 

chassis fuse 

block 1 

C051 

green 

left front marker light 

C036 

white-black 

white-black 

white 

green 

white-black 

white-blue 

rear outline marker 

light C030 

white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003

A/C cut-off relay 

R35 

04-208 




04 

(a) 

(b) 

(c) 


and pin 1 of right combination headlight B011. 

Use a multimeter to measure resistances of harnesses between pin 2 of right combination 

headlight B011 and grounds B204 and B205. 


Use a multimeter to measure resistance of harness between pin 1 of right combination 

headlight B011 and ground. 






04-209 

Left front marker light does not come on 


green 

green 

right outline 

marker light 

F004 

white-black 

green 


light F003 

white-black 

04 



white-black 

green 

white-black 


lightB017 

white-black 





small 

light 

relay 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

conne 

ctor 

switch 

(position) 

cubicle 

switch 

green 


C024 

white-black 

white-black 

white-red 

small light 

green 


C025 

white-black 

white-black 


light C021 

white-black 

1 chassis fuse block 1 

green 

white-black 


light C036 

white-black 

white 

green 

white-black 

white-blue 

rear outline 


white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003

04 

04-210 



(a) 

(b) 


Use a multimeter to measure resistance of harness between pin 3 of C105 and pin 1 of left 

front marker light C036. 

Use a multimeter to measure resistance of harness between pin 2 of left front marker light 

C036 and ground C237. 


(c) Use a multimeter to measure resistance to ground of pin 1 of left front marker light C036. 






04-211 

Right front marker light does not come on 


green 

green 

right outline 

marker light 

F004 

white-black 

green 


light F003 

white-black 

04 



white-black 

green 

white-black 


lightB017 

white-black 





small 

light 

relay 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

conne 

ctor 

switch 

(position) 

cubicle 

switch 

green 


C024 

white-black 

white-black 

white-red 

small light 

green 


C025 

white-black 

white-black 


light C021 

white-black 


green 

white-black 


light C036 

white-black 

white 

green 

white-black 

white-blue 

rear outline 


white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003

04 

04-212 



(a) 

(b) 


Use a multimeter to measure resistance of harness between pin 3 of C105 and pin 1 of right 

front marker light C021. 

Use a multimeter to measure resistance of harness between pin 2 of right front marker light 



(c) Use a multimeter to measure resistance to ground of pin 1 of right front marker light C021. 






Left rear marker light does not come on 


04-213 

green 

green 

right outline 

marker light 

F004 

white-black 

green 


light F003 

white-black 

04 



white-black 

green 

white-black 


lightB017 

white-black 





small 

light 

relay 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

white-red 

con 

nect 

switch or 

(position 

) 

small light 

cubicle 

switch 

green 

green 


C024 


C025 

white-black 

white-black 

white-black 

white-black 


light C021 

white-black 


green 

white-black 


light C036 

white-black 

white 

green 

white-black 

white-blue 

rear outline 


white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003

04 

04-214 



(a) 

(b) 


Use a multimeter to measure resistance of harness between pin 3 of C105 and pin 1 of left 

rear marker light C025. 

Use a multimeter to measure resistance of harness between pin 2 of left rear marker light 



(c) Use a multimeter to measure resistance to ground of pin 1 of left rear marker light C025. 






04-215 

Right rear marker light does not come on 


green 

green 

right outline 

marker light 

F004 

white-black 

green 


light F003 

white-black 

04 



white-black 

green 

white-black 


lightB017 

white-black 





small 

light 

relay 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

conne 

ctor 

switch 

(position) 

cubicle 

switch 

green 


C024 

white-black 

white-black 

white-red 

small light 

green 


C025 

white-black 

white-black 


light C021 

white-black 


green 

white-black 


light C036 

white-black 

white 

green 

white-black 

white-blue 

rear outline 


white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003

04 

04-216 



(a) 

(b) 


Use a multimeter to measure resistance of harness between pin 3 of C105 and pin 1 of right 

rear marker light C024. 

Use a multimeter to measure resistance of harness between pin 2 of right rear marker light 



(c) Use a multimeter to measure resistance to ground of pin 1 of right rear marker light C024. 






04-217 

Left combination taillight does not come on 


green 

green 

right outline 

marker light 

F004 

white-black 

green 


light F003 

white-black 

04 



white-black 

green 

white-black 


lightB017 

white-black 





small 

light 

relay 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

white-red 

conne 

ctor 

switch 

(position) 

small light 

cubicle 

switch 

green 

green 


C024 


C025 

white-black 

white-black 

white-black 

white-black 


light C021 

white-black 


green 

white-black 


light C036 

white-black 

white 

green 

white-black 

white-blue 

rear outline 


white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003

04 

04-218 



(a) 

(b) 

(c) 


Use a multimeter to measure resistance of harness between pin 1 of J101 and pin 3 of left 

combination taillight J002. 

Use a multimeter to measure resistance of harness between pin 4 of left combination taillight 

J002 and pin 12 of J101. 


Use a multimeter to measure resistance of harness between pin 3 of left combination taillight 

J002 and ground. 






04-219 

Right combination taillight does not come on 


green 

green 

right outline 

marker light 

F004 

white-black 

green 


light F003 

white-black 

04 



white-black 

green 

white-black 


lightB017 

white-black 





small 

light 

relay 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

white-red 

conne 

ctor 

switch 

(position) 

small light 

cubicle 

switch 

green 

green 


C024 


C025 

white-black 

white-black 

white-black 

white-black 


light C021 

white-black 


green 

white-black 


light C036 

white-black 

white 

green 

white-black 

white-blue 

rear outline 


white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003

04 

04-220 



(a) 

(b) 

(c) 


Use a multimeter to measure resistance of harness between pin 1 of J101 and pin 3 of right 

combination taillight J005. 


taillight J005 and pin 12 of J101. 



taillight J005 and ground. 





04-222 


None of interior small lights comes on 


green 

green 

right outline 

marker light 

F004 

04 

green 


light F003 

white-black 

white-black 



white-black 

green 

white-black 


lightB017 

white-black 





small 

light 

relay 

green 

green 



white-black 


J003 

white-blue 

green-blue 

green 

white-black 

white-red 

conne 

ctor 

switch 

(position) 

small light 

cubicle 

switch 

green 

green 


C024 


C025 

white-black 

white-black 

white-black 

white-black 


light C021 

white-black 


green 

white-black 


light C036 

white-black 

white 

green 

white-black 

white-blue 

rear outline 


white-black 

battery 

green 

green 

white-black 



white-black 


marker light G003




04-223 


(b) Check fuse F12 (10A) in body fuse block. 

04 

Check if the fuse is OK? 



2. Checking small light relay 

(a) Check small light relay R32. 


Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 


Apply supply 


pins 1 and 2. 




No > Replace small light relay.

04-224 



(a) Check combination switch. 

Resistances: 

Condition 

Use a 

multimeter to 

connect pins 

Specified 

value 

04 

Small light switch 

OFF 

Small light switch 

ON 

11 - 2 > 1 MΩ 

11 - 2 ≤ 2 Ω 





(a) 



(b) Use a multimeter to measure resistances of grounds C237 and C238. 





Wipers and washers 

Notes 

1. Power off. 

(a) 

Diagnosis- Wipers and washers 

04-225 




Tip: 

Please do not leave your car key in your vehicle before battery negative cable is disconnected so as 

to avoid locking doors. 

(b) 




Tip: 



Tip: 

After battery negative cable is reconnected, you need to reset audio system (refer to “Operation 

Manual of the Audio System” in Chinese and English). 

04

04-226 

Basic checks 



04 



22V. 


2 Checking intermittent position (INT) of 

wiper 

• Use combination switch to set wiper 

to INT. 


3 Checking low speed position (LO) of wiper 



to LO. 


4 Checking high speed position (HI) of wiper 


to HI. 



N 




N 

Go to symptoms chart. 


N 



N 


5 Checking washer 


washer. 


Y 

N 


Go to symptoms chart.


04-227 






- 

Wiper does not work after 

switched on. 


7. Wiper motor (damaged) 


ground) 

Chapter 41 Steering 

Mechanism-Combination Switch, 

Replacement 

Chapter 55 Wipers and 

Washers-Wiper Motor Assembly, 

Replacement 

- 

04 

1. Wiper arm (loose) 

- 

Motor rotates but wiper arm does 

not move. 

2. Worm gear (getting loose) 

3. Linkage mechanism (getting 

loose) 

- 


Washers-Linkage Mechanism, 

Replacement 

1. Battery (voltage too low) 

- 

2. Harness (contact poor) 

- 

Wiper sluggish 

3. Motor bearing and reduction 

gear (lubrication poor) 

- 



Washers-Wiper Motor Assembly, 

Replacement 

1. Glass (stained with oil and car 

wax) 

- 

2. Wiper arm and blade (type 

incorrect) 


Washers-Wiper Arm and Blade, 

Replacement 

Wiping effect poor 

3. Wiper arm and blade (rubber 

damaged) 


Washers-Wiper Arm and Blade, 

Replacement 

4. Wiper arm (damaged) 


Washers-Wiper Arm Assembly, 

Replacement 

5. Wiper arm (spring force drop) 


Washers-Wiper Arm Assembly, 

Replacement 

1. Worm gear and worm (not 

lubricated) 

- 

Abnormal sound 

2. Linkage mechanism (distorted) 

3. Linkage joint (worn) 



Replacement 



Replacement 

Wiper can not stop. 

1. Combination switch (damaged) Chapter 41 Steering 


Replacement

04-228 



Wiper does not work in 

intermittent position (INT). 



ground) 



Replacement 

- 


(damaged) 

- 

04 

Wiper does not work in low speed 

position (LO). 



ground) 



Replacement 

- 


(damaged) 

- 

Wiper does not work in high 

speed position (HI). 



ground) 



Replacement 

- 


(damaged) 

- 

Wiper can not return to original 

position after switched off. 


ground) 

2. Cam switch junction (contact 

poor) 

- 

- 

1. Washer fluid (insufficient) 

- 

2. Nozzle (clogged) 


Washers-Nozzle, Replacement 

Washer does not work while wiper 

is normal. 

3. Hose (damaged) 


- 



Replacement 

5. Washer motor (damaged) 


Washers-Washer, Replacement 

6. Harness 

- 

1. Nozzle (clogged) 


Washers-Nozzle, Replacement 

2. Hose (damaged) 

- 

Washer fluid can not be sprayed. 

3. Washer motor (damaged) 



Washers-Washer, Replacement 



Replacement 


ground) 

-


Wiper does not work after switched on 


04-229 

ignition switch 

White-blue 

black - white 

IG 

power 

relay 

car body fuse box 

04 

blue blue blue blue 

white 

blue 

three-in-one controller 

three-in-one 

controller 

whitered 

Chasiss fuse block 1 

whiteblack 

temin 

al 

switch 

(position) 

intermittent 

blueyellow 

blue-greenblack 

cubicle 

switch 

bluered 

blue 

Low shaft 

white 

High shaft 

blue-black 

blue-orange 

battery 

white-black 

wiper-motor 

white-black

04-230 





(b) 


04 




2. Checking wiper motor 

(a) 

(b) 

(c) 

Checking function in LO 

• Connect battery positive (+) to connector 

pin 2 and negative (-) to connector pin 3, 

and check if the motor runs in LO. 

Checking function in HI 



and check if the motor runs in HI. 

Checking auto stop function 



and disconnect pin 2 when the motor is 

running in LO unless it is at any position 

for auto stop.


04-231 



No > Replace wiper motor. 


(a) 

• Restart the motor by connecting pins 2 

and 5 and connecting battery positive (+) 

and pin 6, and run it in LO. 

• Check if auto stop position is correct. 



Switch position 

Use a 

multimeter to 

connect pins 

Standard 

value 

OFF 4 - 7 ≤ 2 Ω 

INT 

4 - 7 

12 - 16 

≤ 2 Ω 

LO 7 - 18 ≤ 2 Ω 

HI 13 - 18 ≤ 2 Ω 

04 


Yes > Replace harnesses. 


04-232 

Wiper Sluggish 




White-blue 

black - white 

04 

IG 

power 

relay 



white 

blue 


three-in-one 

controller 

whitered 

blueyellow 

blue-greenblack 

teminal 


whiteblack 

switch 

(position) 

intermittent 

cubicle 

switch 

bluered 

blue 

Low shaft 

white 

High shaft 

blue-black 

blue-orange 

battery 

white-black 

wiper-motor 

white-black


04-233 


1. Checking battery voltage 

(a) 

Use a multimeter to measure battery voltage. 



No > Charge or replace battery. 


(a) 

Checking function in LO 

04 



and check if the motor runs in LO. 

(b) 

Checking function in HI 



and check if the motor runs in HI. 

(c) 




and disconnect pin 2 when the motor is 

running in LO unless it is at any position 

for auto stop. 

• Restart the motor by connecting pins 2 

and 5 of the motor and connecting 

battery positive (+) and pin 6, and run it 

in LO. 




No > Replace wiper motor. 

3. Checking motor bearing and reduction gear 

(a) 

(b) 

Remove wiper motor (refer to “Chapter 55 Wipers and Washers-Wiper Motor Assembly, 


Check lubrication of motor bearing and reduction gear. 



No > Lubricate.

04-234 

Wiper can not stop 




White-blue 

black - white 

04 

IG 

power 

relay 



white 

blue 


three-in-one 

controller 

whitered 

teminal 

blueyellow 

blue-green 

- black 


whiteblack 

switch 

(position) 

intermittent 

cubicle 

switch 

bluered 

blue 

Low shaft 

white 

High shaft 

blue-black 

blue-orange 

battery 

white-black 

wiper-motor 

white-black




(a) 




Use a 

multimeter to 

connect pins 

04-235 

Standard 

value 

OFF 4 - 7 ≤ 2 Ω 

INT 4 -7 12 - 16 ≤ 2 Ω 

04 

LO 7 - 18 ≤ 2 Ω 

HI 13 - 18 ≤ 2 Ω 




04-236 


Wiper does not work in intermittent position 



White-blue 

black - white 

04 

IG 

power 

relay 



white 

blue 


three-in-one 

controller 

whitered 

teminal 

blueyellow 

blue-green 

- black 


whiteblack 

switch 

(position) 

intermittent 

cubicle 

switch 

bluered 

blue 

Low shaft 

white 

High shaft 

blue-black 

blue-orange 

battery 

white-black 

wiper-motor 

white-black




(a) 




Use a 

multimeter to 

connect pins 

04-237 

Standard 

value 

OFF 4 - 7 ≤ 2 Ω 

INT 4 -7 12 - 16 ≤ 2 Ω 

04 





(a) 

LO 7 - 18 ≤ 2 Ω 

HI 13 - 18 ≤ 2 Ω 


and pin 16 of combination switch. 



Yes > Replace three-in-one controller. 


04-238 


Wiper does not work in low speed position 



White-blue 

black - white 

04 

IG 

power 

relay 



white 

blue 


three-in-one 

controller 

whitered 

teminal 

blueyellow 

blue-green 

- black 


whiteblack 

switch 

(position) 

intermittent 

cubicle 

switch 

bluered 

blue 

Low shaft 

white 

High shaft 

blue-black 

blue-orange 

battery 

white-black 

wiper-motor 

white-black




(a) 




Use a 

multimeter to 

connect pins 

04-239 

Standard 

value 

OFF 4 - 7 ≤ 2 Ω 

INT 4 - 7 12 - 16 ≤ 2 Ω 

04 

LO 7 - 18 ≤ 2 Ω 

HI 13 - 18 ≤ 2 Ω 




04-240 


Wiper does not work in high speed position 



White-blue 

black - white 

04 

IG 

power 

relay 



white 

blue 


three-in-one 

controller 

whitered 

teminal 

blueyellow 

blue-green 

- black 


whiteblack 

switch 

(position) 

intermittent 

cubicle 

switch 

bluered 

blue 

Low shaft 

white 

High shaft 

blue-black 

blue-orange 

battery 

white-black 

wiper-motor 

white-black




(a) 




Use a 

multimeter to 

connect pins 

04-241 

Standard 

value 

OFF 4 - 7 ≤ 2 Ω 

INT 4 - 7 12 - 16 ≤ 2 Ω 

04 

LO 7 - 18 ≤ 2 Ω 

HI 13 - 18 ≤ 2 Ω 




04-242 


Wiper can not return to original position after switched 

off 



White-blue 

black - white 

04 

IG 

power 

relay 



white 

blue 


three-in-one 

controller 

whitered 

teminal 

blueyellow 

blue-green 

- black 


whiteblack 

switch 

(position) 

intermittent 

cubicle 

switch 

bluered 

blue 

Low shaft 

white 

High shaft 

blue-black 

blue-orange 

battery 

white-black 

wiper-motor 

white-black


04-243 



(a) 

(b) 


and pin 5 of wiper motor. 

Use a multimeter to measure resistance of harness between fuse F20 and pin 6 of wiper 

motor. 




No > Replace harnesses. 

04 


(a) 

Remove wiper motor (refer to “Chapter 55 Wipers and Washers-Wiper Motor Assembly, 


(b) 


• Connect battery positive (+) to 

connector pin 2 and negative (-) to 

connector pin 3, and disconnect pin 2 

when the motor is running in LO 

unless it is at any position for auto 

stop. 

• Restart the motor by connecting pins 

2 and 5 of the motor and connecting 

battery positive (+) and pin 6, and run 

it in LO. 



Yes > Replace three-in-one controller. 

No > Replace wiper motor assembly.

04-244 


Washer does not work while wiper is normal 



white-blue 

black - white 

04 

IG 

power 

relay 

car body fuse 

block 

Washer motor 

blue 

blue-white 

white 

blue-white 

white-red 

teminal 

switch 

(position) 

cubicle 

switch 


white-black 

white-black 

white 

battery


04-245 


1. Checking washer fluid 

(a) 

Check washer fluid level. 

Check if washer fluid is sufficient. 


No > Add washer fluid. 

2. Checking nozzle 

(a) 

Check nozzle. 

Check if nozzle is unobstructed. 


No > Replace nozzle. 

04 

3. Checking hose 

(a) 

Check leakage from hose. 

Check hose for leakage. 

Yes > Replace hose. 


4. Checking washer motor 

(a) 

Functional inspection 

• Pour water into the washer pot 

containing washer motor. 

• Connect battery positive (+) to pin 2 of 

washer motor and negative (-) to pin 1 of 

the motor. Check if water can flow out of 

washer pot. 


(a) 




Use a 

multimeter to 

connect pins 

Standard 

value 

OFF 4 - 7 ≤ 2 Ω 

SPRAY 12 - 8 ≤ 2 Ω 




04-246 


Washer fluid can not be sprayed 



white-blue 

black - white 

04 

IG 

power 

relay 

car body fuse 

block 

Washer motor 

blue 

blue-white 

white 

blue-white 

white-red 

teminal 

switch 

(position) 

cubicle 

switch 


white-black 

white-black 

white 

battery


04-247 


1. Checking nozzle 

(a) 

Check nozzle. 

Check if nozzle is unobstructed. 


No > Replace nozzle. 

2. Checking hose 

(a) 

Check leakage from hose. 

Check hose for leakage. 

Yes > Replace hose. 


04 

3. Checking washer motor 

1. Washer motor 

(a) 

Functional inspection 

• Pour water into the washer pot 

containing washer motor. 

• Connect battery positive (+) to pin 1 of 

washer motor and negative (-) to pin 2 of 

the motor. Check if water can flow out of 

washer pot. 



No > Replace washer motor. 


(a) 




Use a 

multimeter to 

connect pins 

Standard 

value 

OFF 4 - 7 ≤ 2 Ω 

SPRAY 12 - 8 ≤ 2 Ω 




04-248 

Diagnosis- Audio System 

Audio System 

Notes 

1. It is strictly forbidden to refit this audio system or add other audio equipment to it. 

2. This audio system uses the following radio bands. 

04 

Radio wave AM FM 

Method of 

modulation 

Amplitude modulation 

Frequency modulation 

Wave band AM1 AM2 FM1 FM2 FM3 

Frequency 

range 

3. Notes for CD player 

522~1620 KHz 87.5~108 MHz 

Notices: 

Do not view the laser head directly because the CD player uses invisible laser beams. Be 

sure to follow instructions to operate the player. 

(a) 

A CD player uses a laser head to read digital signals recorded on CDs. It plays music and 

other items by converting digital signals into analog signals. 

(b) 

The CD player can only play the CDs with this 

identification (ID). 

(c) 

Notes for use of CDs 

• This CD player is of single-disc type. Never put multiple CDs in it at the same time, 

otherwise it will be damaged. 

• This CD player uses 120±0.03 mm CDs. 

• Failure to play CDs may result due to characteristics of CDs or damage, dirt or aging, 

etc. caused by extended placement in the vehicle. 

• Keep CDs free from dirt. Take care not to damage CDs or leave your finger marks on 

them. 

• Keep labeled surface of a CD up, and take it by gripping its outer edge and center 

hole. 

• Exposing part of a CD out of slot long after the disc eject button is depressed may 

cause CD deformation and render it disabled. 

• If adhesive tape, sticker, or paste marks of any similar labels are left on a CD, the CD 

will not be ejected or CD player breakdown will result. 

• Avoid exposing CDs to direct sunlight. (Exposure to direct sunlight may result in CD 

deformation which will render CDs disabled.) 

• Do not use CDs of odd shapes, otherwise CD player breakdown may result.


04-249 

• Do not use any CD of which the burning part is transparent or semitransparent, 

because the machine may not be able to load, eject, or normally play such a CD. 

(d) 

The CDs listed below can not be used; otherwise audio unit may be damaged. 

1. 

尺寸 

Undersize 

过小以及 

and 

形状 

irregularly 

不规则的 

shaped 

光碟 

CDs 

04 

光 CD 碟 Angular 角形光碟 CD 

Square 方形光 CD 碟箭 Arrow 形光 CD 碟等 Etc. 等 

2. 超 Thickness 出厚度的光 excessive 碟 CDs 

With self-made label With matching printing 

贴有 

affixed 

自制标签贴有 label 配套 affixed 印刷标签加 Sealed 封口 Plastic 加 cemented 塑胶 

3. 3. 坏碟 Damaged CDs 

Twisted, 扭曲、有 notched 缺口或 or 裂 cracked 缝的光碟 CD 

CD 边 with 缘有 burrs 毛边的 on 光 edge 碟 

Tips: 

• In cold or rainy days, fog and condensation may also be developed in the CD player if 

windows are foggy. In such a case, CD sound jump or halfway stop during playing may take 

place. Before using the CD player, ventilate or dehumidify vehicle inside for a period of time. 

• When your vehicle is running on a rough road or a similar uneven road, CD sound jump may 

take place in case the CD player encounters strong vibration. 

(e) 

Cleaning 

• If surfaces of a CD are dirty, wipe radially 

from inside to outside with a dry soft cloth 

(e.g. glasses cleaning cloth for plastic 

lenses).


04-259 

Notices: 

• Do not use any lens cleaner because it may result in CD player laser head 

malfunction. 

• Wiping a CD by hand or using coarse cloth may scratch CD surfaces. 

• Use of CD spraying agent, antistatic agent, alcohol, benzene, thinner, and so on, or 

chemical dipped cloth may damage CDs and render them disabled. 

4. Precautions for MP3 

(a) 

An audio unit with MP3 is provided with a USB 

interface for connection with external media 

sources. 

04 

(b) 

(c) 

Only files with suffix “.mp3” can be identified as MP3 files and be played. 

If files other than MP3 files are saved as files with suffix “.mp3”, these files will be mistaken 

as MP3 files and be played, but they may not able to be played or sharp noise will be made 

during playing and thus speakers may be damaged. 

5. Power off. 

(a) 

(b) 






Tip: 


Manual of the Audio System” in Chinese and English.)

04-260 

Parts diagram 


04 

1 Antenna 3 CD player (or MP3) assembly 

2 Left speaker 4 Right speaker

Audio unit terminals 


04-261 

04 


1 Blue-black Right front speaker (+) 

2 Green-black Left front speaker (+) 

3 Gray Ignition switch: ACC 

4 Yellow Battery (+) 

5 Blue Right front speaker (-) 

6 Green Left front speaker (-) 


8 - - 

9 - - 

10 Green Instrument illumination

04-262 

Basic checks 



1 

Checking battery voltage 

• Battery voltage should not be below 21V. 



N 



04 

2 Checking antenna 

• For extension to its maximum length. 

• For covering of foreign materials. 

• For bending and deformation. 


3 Checking audio unit 

• Depress power switch of sound system 

and check LCD screen for display. 


4 Checking audio unit 

• Turn up to above 5 VOL and check if 

speaker makes sounds. 



N 

Repair or replace antenna. Refer to 

“Chapter 56 Audio System-Antenna”. 


N 

Go to malfunction symptoms table. 


N 


5 Radio wave check 

• Coverage areas of AM and FM 

broadcastings differ greatly. Sometimes, 

AM broadcasting can be received clearly 

while FM stereo can not. FM stereo has 

minimum coverage area and is susceptible 

to interference of electromagnetic wave. 

• If your vehicle receives two radio signals 

from one and the same transmitting tower 

at night, phasing interference will take 

place. (One signal is received from the 

tower directly while the other is obtained 

through ionospheric reflection.) 

• Check around your vehicle for tall buildings 

or high mountains which will block part of 

signals between transmitting towers and 

your vehicle. 

• Check around your vehicle for large-scale 

transformer substations and transmission 

stations. Strong electromagnetic waves 

they give off will result in broadcast signal 

reception failure. 

• Some buildings will reflect broadcast 

signals due to their materials so that two 

signals will be received to produce 

interference. 


Y 

N 


Move your vehicle to a place where 

has good signal reception conditions.


Malfunction symptoms table 

04-263 




Audio unit does not work. 

1. Power and ground circuits 

2. Audio unit itself 


Unit Does Not Work 

Speaker is soundless in all 

modes. 

1. In mute mode 

2. Speaker circuit 

3. Speaker 


Operation Manual of the Audio 

System (in Chinese and English) 

Chapter 04 Audio System-Speaker 

Is Soundless In All Modes 

04 

Speaker tone quality is poor in 

all modes. 

1. Audio unit settings improper 


3. Speaker 




Tone Quality Is Poor In All Modes 

Speaker volume is low in all 

modes. 

1. Audio unit settings improper 


3. Speaker 





Volume Is Low In All Modes 

Speaker tone quality is poor 

only when playing CD or MP3. 

1. Tone quality of media source file 

poor 



Tone Quality Is Poor Only When 

Playing CD Or MP3 

Failure to receive radio 

broadcast or reception is poor. 

1. Peripheral interference of 

electromagnetic wave too strong 

2. Antenna 


Chapter 04 Audio System-Failure 

to Receive Radio Broadcast or 

Reception Is Poor 

CD can not be inserted/played 

or immediately ejected after 

inserted. 

1. CD recognition failure 


Chapter 04 Audio System-CD Can 

Not Be Inserted/Played or 

Immediately Ejected After Inserted 

CD can not be ejected. 

1. Use of unknown CD 




(Replacing audio unit) 


Unit, Replacement 

CD sound jump 

1. Tone quality of CD source file 

poor 


Chapter 04 Audio System-CD 

Sound Jump 

MP3 can not be 

loaded/played. 

1. Format of audio source file 

incorrect 


Chapter 04 Audio System-MP3 

Can Not Be Loaded/Played 

MP3 sound jump 

1. Tone quality of media source file 

poor 


Chapter 04 Audio System-MP3 

Sound Jump 

LCD screen has no display 

while audio system works 

normally. 


(Replacing audio unit) Chapter 56 

Audio System-Audio Unit, 

Replacement

04-264 

Audio unit does not work 



receiver 

04 

Left front 

speaker 

green-black 

green 

green-black 

green 

Right front 

speaker 

blue -black 

blue 

blue -black 

blue 


Write-blue 

blue –red 

Car body fuse box 

gray 

yellow 

Write 

Write-blue 

Write-red 

Write-blue 

Chasiss 

fuse box 1 

Interior 

small light 

green 

Write 

Write-black 

Battery


1. Checking power fuses of audio system 

(a) 



(b) 

04-265 


fuse block. 

04 



No > If fuse F6 (15A) is blown only, go to step 3. 

If fuse F15 (10A) is blown only, go to step 2. 

2. Checking fuse of audio unit 

(a) 

Disconnect audio unit connector. 

Notice: 

Take care not to drop audio unit.

04-266 


(b) 


ground of connector pin 4 of audio unit B045. 


04 


Yes > Replace CD and MP3 audio units. 


connector pin 4 of audio unit B045. 


(a) 


Notice: 

Take care not to drop audio unit. 

(b) 


ground of connector pin 3 of audio unit B045. 





connector pin 3 of audio unit B045.


(a) 


Remove audio unit. (Refer to “Chapter 56 Audio System-Audio Unit, Replacement”.) 

(b) 

04-267 

Remove fuse of audio unit in the direction 

shown in the figure. 

04 

good 

(c) 

As shown in the figure, check if fuse of audio 

unit has been blown. 

bad 



No > Replace with a new (10A) fuse, and turn on audio unit. If the fuse is reblown, replace 

CD and MP3 audio units.

04-268 


5. Checking power and ground circuits of audio system 

(a) 


(b) 


Notice: 

Take care not to drop audio unit. 

04 

(c) 


(d) 



pin 4 of audio unit B045 respectively. 




No > If battery voltage is not available in either case, repair line open between fuse F15 

(10A) and connector pin 4 of audio unit B045. 

If battery voltage is not available only between connector pins 4 and 7 of audio unit 

B045, repair line open between connector pin 7 of the unit and grounds B208 and 

B209.

6. Checking power circuit of audio system 


(a) 

04-269 


of connector pin 3 of audio unit B045. 




No > Repair line open between connector pin 3 of audio unit B045 and connector pin 7 of 

ignition switch B026. 

04

04-270 


Speaker is soundless in all modes 


receiver 

04 

Left front 

speaker 

green-black 

green 

green-black 

green 

Right front 

speaker 

blue -black 

blue 

blue -black 

blue 


Write-blue 

blue –red 


gray 

yellow 

Write 

Write-blue 

Write-red 

Write-blue 

Chasiss 

fuse box 1 

Interior 

small light 

green 

Write 

Write-black 

Battery



• Depress power switch of audio unit. 

• Turn up audio unit to above 5 VOL. 

• Check and make sure MUTE key is OFF. 

Check if speaker makes sounds. 

Yes > Audio unit settings are incorrect. 


1. Checking speakers 

(a) 

(b) 

(c) 



04-271 

Remove left and right speakers. (Refer to “Chapter 56 Audio System-Speaker, 

Replacement”.) 

Check speaker cone for breakage. 

(d) 


between connector pins 1 and 2 of left and right 

speakers E002 and D002 respectively. 

Resistance: 8Ω 

04 



No > Replace speaker. 

2. Checking signal circuit of speaker 

(a) 

Disconnect audio unit connector.

04-272 


(b) 


between connector pins 2 and 6 and 1 and 5 of 

audio unit B045 respectively. 


04 



No > Repair signal line short between connector pins 2 and 6 and 1 and 5 of audio unit 

B045. 

3. Checking for speaker signal circuit short 

(a) 


ground of connector pins 1, 2, 5, and 6 of audio 





No > Repair lines to ground short between connector pins 1, 2, 5, and 6 of audio unit B045 

and connector pins 1 and 2 of left and right speakers E002 and D002. 

4. Checking for speaker signal circuit short 

(a) 

(b) 



of connector pins 1, 2, 5, and 6 of audio unit 


Voltage: 0V 


Yes > Replace CD or MP3 audio unit. 

No > Repair lines to power short between connector pins 1, 2, 5, and 6 of audio unit B045 

and connector pins 1 and 2 of left and right speakers E002 and D002.


Speaker tone quality is poor in all modes 


1. Checking audio unit settings 

(a) 

(b) 

(c) 

(d) 

(e) 


Depress power switch of audio unit. 

Turn up audio unit to above 5 VOL. 

04-273 

Set “BAS” (bass), “TRE” (treble), and “BAL” (balance) to their respective initial settings; or 

set “BAS” and “TRE” to 0~3 and “BAL” to 0. 

Press “VOL” (volume control key) and hold for more than 2 seconds to enable loudness 

function. 

Check speakers for normal tone quality. 

Yes > CD or MP3 audio unit settings are incorrect. 



(a) 

(b) 

(c) 

(d) 

(e) 


Remove left and right speakers. (Refer to “Chapter 56 Audio System-Speaker, 

Replacement”.) 

Check left and right speakers for foreign material absorption. 

Check left and right speaker cones for excessive dust accumulation inside. 

Check left and right speaker cones for breakage. 

(f) 





04 



No > Clear foreign materials or dust, or replace speakers.

04-274 


3. Comparing with models of the same kind 

(a) 

(b) 

Set “BAS”, “TRE”, and “BAL” of audio unit to the same level. 

Compare with models of the same kind. 

Check speakers for uniform tone quality. 

Yes > End of check 

No > Replace CD or MP3 audio unit. 

04


Speaker volume is low in all modes 


04-275 

receiver 

Left front 

speaker 

green-black 

green 

green-black 

green 

04 

Right front 

speaker 

blue -black 

blue 

blue -black 

blue 


Write-blue 

blue –red 


gray 

yellow 

Write 

Write-blue 

Write-red 

Write-blue 

Chasiss 

fuse box 1 

Interior 

small light 

green 

Write 

Write-black 

Battery

04 

04-276 



(a) 

(b) 

(c) 




(d) Set “BAL” to 0. 


Check speakers for normal volume. 




(a) 

(b) 


Check left and right speaker cones for breakage. 

(c) 







No > Replace speakers. 

3. Checking speaker circuits 

(a) 

Disconnect audio unit connector.


04-277 

(b) 


between connector pins 2 and 6 of audio unit 

B045 and connector pins 1 and 2 of left speaker 

E002 respectively. 


(c) 


between connector pins 1 and 5 of audio unit 

B045 and connector pins 1 and 2 of right 

speaker D002 respectively. 


04 



No > Repair line open between connector pins 1, 2, 5, and 6 of audio unit B045 and 

connector pins 1 and 2 of left and right speakers E002 and D002. 

4. Comparing with models of the same kind 

(a) 

(b) 

Set “BAS”, “TRE”, and “BAL” of audio unit to the same level. 

Compare with models of the same kind. 

Check speakers for uniform volume. 

Yes > End of check 

No > Replace CD or MP3 audio unit.

04 

04-278 


Speaker tone quality is poor only when playing CD or 

MP3 


1. Checking source file of CD or MP3 media 

(a) 

Replace with a known genuine CD or MP3 source file and play. 


Yes > Please use genuine CD or MP3. 



(a) 

(b) 

(c) 

(d) 

(e) 

(f) 




Set “BAS”, “TRE”, and “BAL” to their respective initial settings. 

Press “VOL” (volume control key) and hold for more than 2 seconds to enable loudness 

function. 

In CD mode, press “CD” key in turn to select sound field mode according to genre of the 

music to be played: “FLAT” (flat), “JAZZ” (jazz), “POP” (popular), “CLASSIC” (classical), 

“ROCK” (rock-and-roll), and “VOCAL” (vocal music). 





04-279 

Failure to receive radio broadcast or reception is poor 



(a) 

(b) 

(c) 

(d) 

(e) 




Press “AM/FM” (band selection key) repeatedly to select frequency band “FM1”. 

Briefly press “∧” or “∨” (TUNE key) at left/right side to search radio stations automatically. 

Auto search function of audio unit is normal? 

Yes > Replace CD or MP3 audio unit. 


2. Checking antenna of audio unit 

(a) 

(b) 

(c) 

Check if antenna has been stretched to its highest position. 

For covering of foreign materials. 

For bending and deformation. 



No > Replace antenna. (Refer to “Chapter 56 Audio System-Antenna, Replacement”.) 

3. Checking audio unit 

(a) 


(b) 

Pull out antenna plug of sound system. 

04

04-280 


04 

(c) 

(d) 

(e) 

(f) 

(g) 




Press “AM/FM” (band selection key) repeatedly 

to select frequency band “FM1”. 

Put a screwdriver and a thin wire or other 

hardware on antenna socket of audio unit, and 

check and make sure you can hear radio 

broadcast. 

Check if audio unit can receive radio broadcast. 

Yes > Replace antenna. (Refer to “Chapter 56 Audio System-Antenna, Replacement”.) 



04-281 

CD can not be inserted/played or immediately ejected 

after inserted 


1. Checking if an appropriate CD has been inserted 

(a) 

Ensure that the CD is an audio CD which is free of deformation, defects, dirt, scratches, or 

failure. 

Tips: 

• Semitransparent or exotic CDs can not be played. 

• Do not play CDs with sticker label. 

• Commercial audio CDs can be played. 

• For more information about playable CDs, please refer to “Operation Manual of the Audio 

System (in Chinese and English)”. 



No > Replace and use an appropriate CD. 

2. Checking if an CD is inserted correctly 

(a) 

Check if the CD is inserted upside down. 



No > Please insert the CD correctly. (Refer to “Operation Manual of the Audio System” in 

Chinese and English.) 

3. Checking a CD 

(a) 

Check if the CD is too dirty. 

(b) 

If too dirty, wipe and clean it radially from inside 

to outside with a soft cloth as shown in the 

figure. 

Notice: 

Do not use any common CD cleaner or antistatic 

protectant. 

04 

(c) 

Insert the CD. 

Check audio unit for normal play. 

Yes > Please use a clean CD. 

No > Go to step 4.

04 

04-282 

4. Checking source file of CD media 

(a) 


Replace with a known genuine CD source file and play. 


Yes > Please use a genuine CD. 



(a) 

(b) 

(c) 

Check deck for foreign materials inside. 

Check deck for presence of a CD inside. 

Check if deck has been in disc loaded state due to incorrect operation. If so, press EJECT 

key long to reset deck. 


Yes > Replace CD audio unit. 

No > Take out existing CD to reset deck. 

If foreign materials exist, please send the machine to a designated maintenance 

station for service.

CD sound jump 



04-283 

Tip: 

Sometimes, CD sound jump will take place when your vehicle is running on a rugged road. This is 

normal. 

1. Checking a CD 

(a) 

Ensure that the CD is free of deformation, dirt, and scratches. 

(b) 

If too dirty, wipe and clean it radially from inside 

to outside with a soft cloth as shown in the 

figure. 

Notice: 

Do not use any common CD cleaner or antistatic 

protectant. 

04 

(c) 

Insert the CD. 


Yes > Please use a clean CD which is free of deformation, dirt, and scratches. 


2. Checking source file of CD media 

(a) 

Replace with a known genuine CD or MP3 source file and play. 


Yes > Please use a genuine CD. 



(a) 

(b) 

(c) 

Check audio unit for correct installation. 

Check if fixing bolts of audio unit have been tightened. 

Check if circumstances of audio unit are kept away from dust. 


Yes > Replace CD audio unit. 

No > Reinstall audio unit and keep it away from dust.

04-284 


MP3 can not be loaded/played 


1. Checking USB interface 

(a) 

Check USB interface of U-Disk for deformation, damage, and oxidation, etc. 

(b) 

Check USB converter port of MP3 audio unit for 

deformation, damage, and oxidation, etc. 

04 



No > In the case of a U-Disk problem, replace the disk. 

In the case of deformation or damage of USB converter port of MP3 audio unit, 

replace the unit. 

In the case of oxidation of USB converter port of MP3 audio unit, simply insert and 

pull out U-Disk repeatedly. 

Notice: 

In the case of oxidation of USB converter port of MP3 audio unit, never treat any metal pin 

with a scraper or sand paper. 

2. Checking source file of MP3 media 

(a) 

Replace with known source file of definite format “*.mp3” and play. 


Yes > Please use source file of correct format. 


3. Checking U-Disk 

(a) 

(b) 

Make sure read function of U-Disk is not locked. 

Replace with a U-Disk which is known normally usable. 


Yes > Replace U-Disk. 

No > Replace MP3 audio unit.

MP3 sound jump 



04-285 

Tip: 

Sometimes, MP3 interruption will take place when your vehicle is running on a rugged road. This 

is normal. 

1. Checking source file of MP3 media 

(a) 

Check and confirm if sound jump occurs on all source files of “*. mp3” format during playing. 

Check result is as mentioned above? 


No > Please use genuine source files of correct “*.mp3” format. 

2. Checking U-Disk 

(a) 

(b) 

Make sure the source files in the U-Disk are “*. mp3” source files which can be normally 

played. 

Replace with a U-Disk which is known normally usable. 


Yes > Replace U-Disk. 

No > Replace MP3 audio unit. 

04

04-286 

Power Windows 

Precautions 

Diagnosis-Power Windows 

04 



LOCK 

ACC 

ON 

START 

2. Power off. 





Engine start 

(a) 




Tip: 



(b) 




Tip: 



Tip: 



Basic inspection 


04-287 

Step No. Check content Measures 

1 Check the battery voltage 

• The battery voltage shall be no less 

than 11V. 

Is the check result is normal? 

2 Check the horn 


• Press the horn button. 

Does the horn ring? 

Yes go to step 2 

No 

Charge or replace the battery. 

Refer to “Chapter 53 Battery - 

Battery” 

Yes Go to step 3 

No 

Go to Malfunction Symptom 

Table 

04 

3 Check the horn button 

• Press the horn button. 

• Relieve the horn button. 

Does the horn ring? 

Yes 

No 

Go to Malfunction Symptom 

Table 

Replace the horn

04-288 


Malfunction Symptom Table 

The table below will help you find out the cause of failures. The serial number indicates the 

sequence of failure cause possibility. Check each part according to this sequence and replace if 

necessary. 

Failure symptom Possible position Reference 

3. Horn (damaged) 

Chapter 71 Information system – 

Horn, replacement 

04 

Horn does not ring 

4. Combination switch 

(damaged) 

5. Horn button (damaged) 

Chapter 41 Steering gear – 

combination switch, replacement 


steering wheel, inspection and 

repair 


- 

1. Combination switch 

(damaged) 


combination switch, replacement 

Horn keeps ringing 

2. Horn button (damaged) 


steering wheel, inspection and 

repair 


-


04-289 

Horn does not ring 


Vehicle body fuse box B050 

Horn 1 

Horn 

R34 

relay 

04 

Blue-white 

Blue-white 

White-black 

White-blue 

Horn 2 

White-blue 

Chassis 

box 1 

fuse 

Combination 

switch (horn 

switch) B025 

White-black 

White 

Battery 

Self grounding 

Diagnosis steps 

1. Check the fuse 

(a). Ignition switch: OFF.

04-290 


(b). 

Check the fuse in vehicle body fuse box: F11 

(15 A). 

04 

Is the check result normal? 


No > Replace the fuse. 

2. Check the horn relay 

(a). Check the horn relay R34. 

Standard value: 

Condition 

Multimeter 

connection pin 

Specified 

value 

Constant 1 – 2 Conductive 

Apply supply 


pins 1 and 2 

3 - 5 Conductive 



No > Replace the horn relay. 

3. Check the horn 

(a). 

Remove the horn (refer to “chapter 71 Information system – Horn, replacement”) 

(b). 

Check the horn. 

Resistance: 

Multimeter connection 

pin 


1 – 2 4 Ω


04-291 



No > Replace the horn. 

4. Check the harness 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

(g). 

(h). 

(i). 

(j). 

Measure the harness resistance between B103 and F11 with multimeter. 

Measure the harness resistance between F11 and pin 2 and 3 of horn relay R34 with 

multimeter. 

Measure the harness resistance between pin 1 of horn relay R34 and pin 10 of combination 

switch with multimeter. 

Measure the resistance of inner harness of horn button with multimeter. 

Measure the harness resistance between pin 5 of horn relay R34 and B106 with multimeter. 

Measure the harness resistance between C105 and pin 1 of horn with multimeter. 

Measure the harness resistance between pin 2 of horn and C237 with multimeter. 

Resistance: ≤ 2 Ω 

Measure the harness resistance between B 103 and grounding with multimeter. 

Measure the harness resistance between pin 2 of horn relay R34 and grounding with 

multimeter. 

Measure the harness resistance between C105 and grounding with multimeter. 

Resistance: > 1 MΩ 


Yes > Replace the horn. 

No > Repair or replace the harness. 

04

04-292 


Horn keeps ringing 


Vehicle body fuse box B050 

Horn 1 

04 

Horn 

R34 

relay 

Blue-white 

Blue-white 

White-black 

White-blue 

Horn 2 

White-blue 

Chassis 

box 1 

fuse 

Combination 

switch (horn 

switch) B025 

White-black 

White 

Battery 

Self grounding


04-293 

Diagnosis steps 

1. Check the horn relay 

(a). Check the horn relay R34. 


Condition 

Multimeter 

connection pins 

Specified 

value 

Normal 1 – 2 Conductive 

Apply supply 


pins 1 and 2 

3 - 5 Conductive 

04 



No > Replace the horn relay. 

2. Check the harness 

(a). 

(b). 

Release the horn button. 

Measure the harness resistance between combination switch pin 10 and grounding of horn 

button with multimeter. 

Resistance: > 10 MΩ 


Yes > Repair the horn button or replace the steering wheel. 

No > Repair or replace the harness.

04-294 


Parts diagram 

04 

1 

2 


assembly 

Left front door glass lifter 

assembly-electric 

5 Power window fuse 

6 

Right front door glass lifter 

assembly-electric 

3 IG power relay 7 Right front door electric glass switch 

4 Power window relay


Left front door control switch assembly terminals 

04-295 

04 


1 - - 

2 Green-yellow 

Connected to right front door electric glass 

switch (drop) 

3 Blue-red Connected to power window relay 

4 Green-black 

Connected to right front door electric glass 

switch (lift) 

5 - - 


7 - - 

8 - - 

9 Blue-yellow 

10 Blue-black 

Connected to left front door glass lifter 

assembly-electric (drop) 

Connected to left front door glass lifter 

assembly-electric (lift)

04-296 


Right front door electric glass switch terminals 

04 


1 Blue-yellow 

2 Green-black 

3 Blue-black 


Connected to right front door glass lifter 

assembly-electric (drop) 

Connected to left front door control switch 

assembly 

Connected to right front door glass lifter 

assembly-electric (lift) 

Connected to left front door control switch 

assembly 

5 Blue-red Connected to power window relay

Basic checks 


04-297 




11V. 


2 Checking left front door glass lifter 


• Use left front door control switch to 

control lift and drop of left front door 

glass lifter. 


3 Checking right front door glass lifter 

• Use left front door control switch to 

control lift and drop of right front door 

glass lifter. 


4 Checking right front door glass lifter 

• Use right front door electric glass 

switch to control lift and drop of right 

front door glass lifter. 


5 Checking window lock switch 

• Depress the window lock switch on 

left front door control switch. 




Check if right front door glass lifter works. 


N 


“Chapter 53 Battery-Battery, Replacement”. 


N 



N 



N 

Y 


Replace right front door electric glass 

switch. Refer to “Chapter 77 

Interior/Exterior Trims-Door Inner Trim 

Panel, Replacement (Electric Glass)” 

N Go to step 6. 

04 

6 Checking window lock switch 

• Depress the window lock switch on 

left front door control switch again. 




Check if right front door glass lifter works. 

Y 

N 


Replace right front door electric glass 

switch. Refer to “Chapter 77 

Interior/Exterior Trims-Door Inner Trim 

Panel, Replacement (Electric Glass)”

04-298 






None of power windows 

works. 


2. Left front door control switch 

3. Left and right front door glass lifters 

4. Harness line 

Chapter 04 Diagnosis-Power 

Windows, None of Power 

Windows Works 

04 

Left front door power window 

does not work. 


2. Left front door glass lifter 



Windows, Left Front Door 

Power Window Does Not Work 


can not drop. 





Power Window Can Not Drop 


can not lift. 





Power Window Can Not Lift 

Right front door power 

window does not work. 



3. Right front door electric glass switch 

4. Right front door glass lifter 



Windows, Right Front Door 



window does not work (when 

right front door electric glass 

switch is used). 








(When Right Front Door 

Electric Glass Switch Is Used) 


window does not work (when 

left front door control switch 

is used). 







(When Left Front Door Control 

Switch Is Used)


None of power windows works 


04-299 

right front door for electric glass switch 


Switch 

position 

termi 

nal 

Right Front door 

up 

off 

dow 

n 

green-black 

green-black 

green-black 

termi 

nal 

Switch 

position 

Left front door 

up 

off 

dow 

n 

right front door 

up 

dow 

n 

dow 

n 

Window lock 

Green –yellow Green –yellow Green –yellow 

blue -black 

blue 

-black 

04 

blue -yellow 

up Right front 

Door glass 

lifter 

do D004 

wn 

blue 

-yellow 


Door glass 

lifter 

do E004 

wn 

blue –red 

blue –red 

blue –red 

blue –red 

Car body fuse box B050 

Power windowrelay 

R12 

Write-blue 

Write 

Write-black 

IG power relay 

R14 

Write-blue 

Write-red 


Write-blue 

Chaiss fuse box1 

Write-black 

Write 

Write-black 

Battery 

Write-black

04-300 



1. Checking power fuse of power window 


(b) Check fuse F4 (20A) in body fuse block. 

04 




2. Checking power window power fuse circuit 

(a) 

Disconnect connector of left front door control 

switch E003. 

(b) 

Disconnect connector of right front door electric 

glass switch D003.

(c) 


Use a multimeter to measure resistance to ground of fuse F4 (20A). 


04-301 



No > Repair lines to ground short between fuse F4 (20A) to connector pin 3 of left front 

door control switch E003 and connector pin 5 of right front door electric glass switch. 

3. Checking left front door control switch 

04 

(a) 

Measure resistances according to the values listed in the following table. 

Use a multimeter to 

connect terminals 

Switch status 

Resistance 

3 - 10 Left front window lift ≤ 2 Ω 


6 - 9 - 10 Left front window still (i.e. switch in natural position) ≤ 2 Ω 

6 - 10 Left front window drop ≤ 2 Ω 


3 - 4 Right front window lift ≤ 2 Ω 


2 - 4 - 6 

Right front window still (i.e. switch in natural 

position) 

≤ 2 Ω 

4 - 6 Right front window drop ≤ 2 Ω 


2 - 9 Window lock switch depressed > 1MΩ 

4 - 9 Window lock switch depressed > 1MΩ 



No > Replace left front door control switch.

04-302 


4. Checking right front door electric glass switch 

04 

(a) 



to connect 

terminals 

Switch status 

Resistance 



2 - 3 Right front window still (i.e. switch in natural position) ≤ 2 Ω 

1 - 4 Right front window still (i.e. switch in natural position) ≤ 2 Ω 





No > Replace right front door electric glass switch. 

5. Checking left front door control switch to right front door electric glass switch circuit 

(a) Use a multimeter to measure resistance 

between connector pins 2 and 4 of left front door 

control switch E003. 


(b) 


ground of connector pins 2 and 4 of left front 

door control switch E003 respectively. 

Resistance: >1MΩ


04-303 



No > Repair line short between connector pins 2 and 4 of left front door control switch 

E003 and connector pins 2 and 4 of right front door electric glass switch D003. 

6. Checking left front door glass lifter circuit 

(a) 

Disconnect left front door glass lifter connector. 

04 



glass lifter E004. 


(c) 



door glass lifter E004 respectively. 





E003 and connector pins 2 and 1 of left front door glass lifter E004.

04-304 

7. Checking left front door glass lifter 




glass lifter E004. 

Resistance: approx. 11Ω 

04 



No > Replace left front door glass lifter. 

8. Checking right front door glass lifter circuit 

(a) 

Disconnect right front door glass lifter connector. 


between connector pins 1 and 2 of right front 

door glass lifter D004. 


(c) 



door glass lifter D004 respectively. 





D003 and connector pins 2 and 1 of left front door glass lifter D004.

9. Checking right front door glass lifter 


04-305 


between connector pins 1 and 2 of right front 

door glass lifter D004. 

Resistance: approx. 11Ω 


Yes > Replace fuse F4 (20A). 

No > Replace left front door glass lifter. 

10. Checking power circuit of power window 

(a) 

(b) 







11. Checking output supply of power window relay 

(a) 

Use a multimeter to measure voltage to ground of pin 87 of power window relay. 



Yes > Repair line open between pin 87 of power window relay and F4 (20A). 


12. Checking power and ground circuits of power window relay 

(a) 

(b) 

(c) 

(d) 

(e) 


Take off power window relay. 


Use a multimeter to measure voltage between pins 86 and 85 and voltage to ground of pin 

86 of power window relay R12 respectively. 


Use a multimeter to measure voltage to ground of pin 30 of power window relay. 


04

04 

04-306 



Yes > Replace power window relay. 

No > If battery voltage is not available between pins 85 and 86 of power window relay only, 

repair line open between pin 86 of the relay and ground. 

If battery voltage is not available between pin 85 of power window relay and ground 

only, repair the line between IG power relay and pin 85 of power window relay. 

If battery voltage is not available between pin 30 of power window relay and ground 

only, repair line open between fuse F/L2 (50A) and pin 30 of power window relay. 

13. Checking power and ground circuits of left front door control switch 

(a) 



pin 3 of left front door control switch E003 

respectively. 




No > If battery voltage is not available in either case, repair line open between fuse F4 (20A) 

and connector pin 3 of left front door control switch E003. 

If battery voltage is not available between connector pins 3 and 6 of left front door 

control switch E003 only, repair line open between connector pin 6 of the switch and 


14. Checking control circuit of left front door glass lifter 


Yes > Replace left front door glass lifter. 


(a) 

(b) 

(c) 


connector pins 1 and 2 of left front door glass 

lifter E004. 

Depress left front door control switch (left front 

window). 


Pull up left front door control switch (left front 

window). 

Voltage: battery voltage



(a) 

(b) 

(c) 

04-307 


connector pins 9 and 10 of left front door control 

switch E003. 


window). 



window). 



Yes > Repair line open between connector pins 9 and 10 of left front door control switch 

E003 and connector pins 2 and 1 of left front door glass lifter E004. 

No > Replace left front door control switch. 

04

04-308 


Left front door power window does not work 




Switch 

position 

termi 

nal 


up 

off 

dow 

n 

green-black 

green-black 

green-black 

termi 

nal 

Switch 

position 


up 


off dow up dow 

n 

n 

dow 

n 

Window lock 

04 


blue -black 

blue 

-black 

blue -yellow 


Door glass 

lifter 

do D004 

wn 

blue 

-yellow 


Door glass 

lifter 

do E004 

wn 

blue –red 

blue –red 

blue –red 

blue –red 



R12 

Write-blue 

Write 

Write-black 


R14 

Write-blue 

Write-red 


Write-blue 


Write-black 

Write 

Write-black 

Battery 

Write-black



1. Checking power circuit of left front door control switch 

(a) 


(b) 

04-309 


of connector pin 3 of left front door control 

switch E003. 


04 



No > Repair line open between fuse F4 (20A) and connector pin 3 of left front door control 

switch E003. 





(a) 

(b) 

(c) 


connector pins 1 and 2 of left front door glass 

lifter E004. 


window). 



window). 

Voltage: battery voltage

04 

04-310 



(a) 

(b) 

(c) 


connector pins 9 and 10 of left front door control 

switch E003. 


window). 



window). 



Yes > Repair line open between connector pins 9 and 10 of left front door control switch 

E003 and connector pins 2 and 1 of left front door glass lifter E004. 



Left front door power window can not drop 


04-311 



Switch 

position 

termi 

nal 


up 

off 

dow 

n 

green-black 

green-black 

green-black 

termi 

nal 

Switch 

position 


up 

off 

dow 

n 


up 

dow 

n 

dow 

n 

Window lock 


blue -black 

blue 

-black 

04 

blue -yellow 


Door glass 

lifter 

do D004 

wn 

blue 

-yellow 


Door glass 

lifter 

do E004 

wn 

blue –red 

blue –red 

blue –red 

blue –red 



R12 

Write-blue 

Write 

Write-black 


R14 

Write-blue 

Write-red 


Write-blue 


Write-black 

Write 

Write-black 

Battery 

Write-black

04-312 



(a) 



(b) 


switch. 

04 

(c) 




Switch status 

Resistance 









04-313 



(a) Disconnect left front door glass lifter connector. 

(b) 


ground of connector pin 2 of left front door glass 

lifter E004. 


04 



No > Repair the line between connector pin 9 of left front door control switch E003 and 

connector pin 2 of left front door glass lifter E004.

04-314 


Left front door power window can not lift 




Switch 

position 

termi 

nal 


up 

off 

dow 

n 

green-black 

green-black 

green-black 

termi 

nal 

Switch 

position 


up 



n 

n 

dow 

n 

Window lock 

04 


blue -black 

blue 

-black 

blue -yellow 


Door glass 

lifter 

do D004 

wn 

blue 

-yellow 

up 

do 

wn 

Right front 

Door glass 

lifter 

E004 

blue –red 

blue –red 

blue –red 

blue –red 



R12 

Write-blue 

Write 

Write-black 


R14 

Write-blue 

Write-red 


Write-blue 


Write-black 

Write 

Write-black 

Battery 

Write-black



(a) 



(b) 

04-315 


switch. 

04 

(c) 




Switch status 

Resistance 









04-316 



(a) 

Disconnect left front door glass lifter connector. 

04 

(b) 


ground of connector pin 1 of left front door glass 

lifter E004. 




No > Repair the line between connector pin 10 of left front door control switch E003 and 

connector pin 1 of left front door glass lifter E004.

Diagnosis-power windows 

Right front door power window does not work 


04-317 



Switch 

position 

termi 

nal 


up 

off 

dow 

n 

green-black 

green-black 

green-black 

termi 

nal 

Switch 

position 


up 



n 

n 

dow 

n 

Window lock 


blue -black 

blue -yellow 

up 

do 

wn 

Right front 

Door glass 

lifter 

D004 

blue - 

black 

blue 

-yellow 

up 

do 

wn 

Right front 

Door 

glass lifter 

E004 

04 

blue –red 

blue –red 

blue –red 

blue –red 



R12 

Write-blue 

Write 

Write-black 


R14 

Write-blue 

Write-red 


Write-blue 


C051 

Write-black 

Write 

Write-black 

Battery 

Write-black

04-318 




(a) 


(b) 


switch. 

04 

(c) 



to connect 

terminals 

Switch status 

Resistance 



2 - 4 - 6 


position) 

≤ 2 Ω 



2 - 9 Window lock switch depressed > 1 MΩ 






04-319 

2. Checking control circuit from left front door control switch to right front door electric 

glass switch 

(a) 

Disconnect connector of right front door electric 

glass switch. 

04 

(b) 



control switch E003 and connector pins 4 and 2 

of right front door electric glass switch D003 

respectively. 




No > Repair line open between connector pins 2 and 4 of left front door control switch 

E003 and connector pins 4 and 2 of right front door electric glass switch D003. 


(a) 



to connect 

terminals 

Switch status 

Resistance 


3 -5 Right front window lift ≤ 2 Ω 

2 -3 Right front window still (i.e. switch in natural position) ≤ 2 Ω 

1 - 4 Right front window still (i.e. switch in natural position) ≤ 2 Ω

04-320 



to connect 

terminals 

Switch status 

Resistance 



04 



No > Replace right front door electric glass switch. 

4. Checking control circuit of right front door glass lifter 

(a) 

Disconnect right front door glass lifter connector. 


between connector pin 1 of right front door 

electric glass switch D003 and connector pin 2 

of right front door glass lifter D004. 



between connector pin 3 of right front door 

electric glass switch D003 and connector pin 1 

of right front door glass lifter D004. 



Yes > Replace right front door glass lifter. 

No > Repair line open between connector pins 1 and 3 of right front door electric glass 

switch D003 and connector pins 2 and 1 of right front door glass lifter D004.


04-321 

Right front door power window does not work (when 

right front door electric glass switch is used) 




Switch 

position 

termi 

nal 


up 

off 

dow 

n 

green-black 

green-black 

green-black 

termi 

nal 

Switch 

position 


up 



n 

n 

dow 

n 

Window lock 


04 

blue -black 

blue -yellow 

up 

do 

wn 

Right front 

Door glass 

lifter 

D004 

blue - 

black 

blue 

-yellow 

up 

do 

wn 

Right front 

Door 

glass lifter 

E004 

blue –red 

blue –red 

blue –red 

blue –red 



R12 

Write-blue 

Write 

Write-black 


R14 

Write-blue 

Write-red 


Write-blue 


C051 

Write-black 

Write 

Write-black 

Battery 

Write-black

04-322 



1. Checking power circuit of right front door electric glass switch 

(a) 


(b) 


of connector pin 5 of right front electric glass 

switch D003. 


04 



No > Repair line open between fuse F4 (20A) and connector pin 5 of right front door 

electric glass switch D003. 


(a) 


(b) 

Disconnect connector of right front electric glass 

switch.


04-323 

(c) 



to connect 

terminals 

Switch status 

Resistance 


04 


1 - 5 

2 - 4 


position) 


position) 

≤ 2 Ω 

≤ 2 Ω 




Yes > Reconnect connector of right front door electric glass switch. 

If the symptom persists, replace right front door electric glass switch. 

No > Replace right front door electric glass switch.

04-324 


Right front door power window does not work (when 

left front door control switch is used) 




Switch 

position 

termi 

nal 


up 

off 

dow 

n 

green-black 

green-black 

green-black 

termi 

nal 

Switch 

position 


up 



n 

n 

dow 

n 

Window lock 

04 


blue -black 

blue -yellow 

up 

do 

wn 

Right front 

Door glass 

lifter 

D004 

blue - 

black 

blue 

-yellow 

up 

do 

wn 

Right front 

Door 

glass lifter 

E004 

blue –red 

blue –red 

blue –red 

blue –red 



R12 

Write-blue 

Write 

Write-black 


R14 

Write-blue 

Write-red 


Write-blue 


C051 

Write-black 

Write 

Write-black 

Battery 

Write-black




04-325 

(a) 


(b) 


switch. 

04 

(c) 



to connect 

terminals 

Switch status 

Resistance 










04-326 



(a) 

Disconnect connector of right front electric glass 

switch. 

04 

(b) 



to connect 

terminals 

Switch status 

Resistance 



1 - 5 

2 - 4 


position) 


position) 

≤ 2 Ω 

≤ 2 Ω 





No > Replace right front door electric glass switch.


04-327 

3. Checking control circuit from left front door control switch to right front door electric 

glass switch 

(a) 



control switch E003 and connector pins 4 and 2 

of right front door electric glass switch D003 

respectively. 


04 

(b) 


ground of connector pins 2 and 4 of right front 

door electric glass switch D003 respectively. 



Yes > Reconnect connectors of left front door control switch and right front door electric 

glass switch. If the symptom persists, replace left front door control switch and right 

front door electric glass switch. 

No > Repair lines between connector pins 2 and 4 of left front door control switch E003 

and connector pins 4 and 2 of right front door electric glass switch D003.

04 

04-328 


Notes 

Diagnosis- combination meter 

1. Power off. 

(a) Before you remove or install any electrical device or when tools or equipment are accessible 



(b) 


2. Removing combination meter or disconnecting battery negative cable will clear day 

odometer and clock on combination meter. 

Tip: 



Tip: 





LOCK 

ACC 

ON 

START 





Engine start

Parts diagram 

Diagnosis- Combination meter 

04-329 

04 

1 Combination mete r 4 Oil pressure alarm switch 

2 Coolant temperature sensor 5 Fuel sensor 

3 Speedometer sensor

04-330 


Instrumentation descriptions 

04 

Meters and gauges 

SN Item Description 

10 Speedometer 

20 Tachometer 

21 Fuel gauge 

Indicates current vehicle speed according to pulse signals 

received from vehicle speed sensor. 

Indicates engine speed according to signals received from 

ECM. 

Indicates fuel level according to signals sent out from fuel 

sensor. 

22 

43 

Urea meter indicator 

light 

Coolant temperature 

gauge 

Indicates urea level through 4 indicator lights according to 

signals sent out from urea level sensor. 

Indicates temperature range (40~120℃) of engine coolant 

according to signals received from coolant temperature 

sensor. 

44 Air pressure gauge 

Indicates current air pressure in brake system according to 

gas pressure in brake line.

Warning/indicator lights 


04-331 


1 

Vacuum warning indicator 

light (optional) 

Comes on when vacuum booster switch is turned ON. 

2 Preheat indicator light Lighted up by ECM during intake manifold warm-up. 

3 Parking brake indicator light Comes on when parking brake switch is turned ON. 

4 

Left turn signal indicator 

light and hazard warning 

indicator light 

Comes on when turn light switch or hazard warning switch 

is turned ON. 

5 

Brake malfunction indicator 

light 

Comes on when brake malfunction alarm switch is turned 

ON. 

04 

6 

Door ajar warning light 

(optional) 

Comes on when door ajar alarm switch is turned ON. 

7 High beam indicator light 

8 Exhaust brake indicator light 

9 Front fog light indicator light 

11 Rear fog light indicator light 

Lighted up according to signals received from high beam 

relay when high beam is turned ON. 

Lighted up through ECM when exhaust brake switch is 

turned ON. 

Lighted up according to signals received from front fog light 

relay when front fog light switch is turned ON. 

Lighted up according to signals received from two-in-one 

controller when rear fog light switch is turned ON. 

12 

Seat belt indicator light 

(optional) 

Lighted up according to signals received from seat belt 

reminder alarm switch. 

13 Oil pressure indicator light 

14 Backup indicator light 

15 Coolant level indicator light 

Lighted up according to signals received from oil pressure 

alarm switch. 

Lighted up according to signals received from backup light 

switch. 

Lighted up according to signals received from coolant level 

alarm switch. 

16 

17 

19 

18 

23 

Right turn signal indicator 

light and hazard warning 


Oil level warning light 

(optional) 

Cab lock warning indicator 


Engine malfunction indicator 

light 

Tire pressure warning 

indicator light (optional) 

Comes on when turn light switch or hazard warning switch 

is turned ON. 

Lighted up according to signals received from oil level alarm 

switch. 

Lighted up according to signals received from cab lock 

alarm switch. 

Lighted up by ECM in the case of engine electronic control 

system problem. 

Lighted up by TPMS when tire pressure is below 75% or 

above 125% standard value. 

24 Urea warning indicator light 

Lighted up by DCU according to signals received from urea 

level sensor. 

25 

Airbag warning indicator 


Lighted up by airbag module in the case of SRS 

malfunction.

04-332 



26 

27 

Rear-view mirror 

defrost/defog indicator light 

(optional) 

Brake system low pressure 

warning indicator light 

Lighted up according to signals received from rear-view 

mirror defrost/defog switch. 

Lighted up according to signals received from low pressure 

alarm switch. 

28 Engine stop indicator light 

Lighted up by ECM according to malfunction rating in the 

case of engine electronic control system malfunction. 

04 

29 

31 

Low brake (or clutch) fluid 

level warning indicator light 

Water sedimentation 

indicator light (optional) 

Lighted up as low brake (or clutch) fluid level alarm switch is 

turned ON when brake (or clutch) fluid level is below 

minimum scale line. 

Lighted up as water sedimentation switch installed in 

oil-water separator is turned ON when water sedimentation 

in diesel oil filter element from the separator reaches a 

certain volume. 

32 


light 

Lighted up by ABS control unit in the case of ABS 

malfunction. 

33 Generator indicator light Lighted up in the case of charging system malfunction. 

34 

35 

ASR blink code indicator 

light (ABS blink code 

indicator light) 

Coolant temperature 

warning indicator light 

In the case of ABS malfunction, ABS control unit will light up 

ASR blink code indicator light through which malfunction 

blink code is output. 

Lighted up when coolant temperature is above 102℃. 

36 Fuel indicator light 

38 SVS warning light 

Lighted up as fuel alarm switch is turned ON when fuel in 

fuel tank is below calibration scale. 

When ECM detects a general failure in the system, this light 

will come on and is always lighted up with diagnostic switch 

in OFF position until the trouble is cleared. 

39 

Air cleaner clogging warning 


Comes on when intake system is obstructed. 

40 EBD warning light (optional) 

42 ESP warning light (optional) 

41 PTO indicator light (optional) 

Lighted up by ABS control unit in the case of EBD system 

malfunction. 

Lighted up by ABS control unit in the case of ESP system 

malfunction. 

Comes on when PTO switch is turned ON to allow PTO to 

work. 

LCD screens 

30 Reset button Sets and resets LCD screen signals. 


37 

Clock 

Odometer 

Displays time, in addition, allows time settings and switching 

between day odometer and clock through reset button. 

Displays total kilometrage of vehicle (this information can 

not be reset).

Instrument terminals 


04-333 

04

04-334 



1 - - 

2 Green-yellow Fuel gauge signal, connected to fuel sensor 

3 Blue-black 

4 Red-black 

Coolant temperature gauge signal, connected to 

coolant temperature sensor 

Buzzer alarm signal, connected to low pressure alarm 

switch 

04 

5 Yellow-red 

Urea indicator light signal, connected to engine control 

unit 

6 - - 

7 - - 

8 Yellow-black 

Urea meter liquid level indicator light signal, 

connected to after treatment control unit (DCU) 

9 Black-red Connected to ignition switch (ON/START) 

B032 

10 White-red 


Engine malfunction indicator light signal, connected to 

engine control unit 

Right turn signal indicator light and hazard warning 

indicator light signals, connected to combination 

switch and hazard warning switch 

12 White-black Indicator light ground 

13 - - 

14 Yellow 

ABS malfunction indicator light signal, connected to 


15 - - 

16 Blue-white 

17 Red 

18 Red-black 

Low brake (or clutch) fluid level warning indicator light 

signal, connected to low brake (or clutch) fluid level 

alarm switch 

Engine stop indicator light signal, connected to engine 

control unit 

Low pressure warning indicator light signal, connected 

to low pressure alarm switch


04-335 


1 Green-black 

Left turn signal indicator light and hazard warning 

indicator light signals, connected to combination 

switch and hazard warning switch 

2 Yellow Connected to battery (+) 

3 White-black Left and right turn signal indicator lights ground 

4 White-black Instrument sensor ground 

5 White-black Instrument sensor ground 

6 White-red 

7 Orange 

Generator indicator light signal, connected to 

generator 

ASR blink code indicator light (ABS blink code 

indicator light) signal, connected to ABS control unit 

and ABS diagnostic switch 

04 

8 Blue-white Tire pressure warning indicator light signal 

9 Green-white 

Fuel warning indicator light signal, connected to fuel 

sensor 

B033 

10 Blue Connected to ignition switch (ON/START) 

11 Black-red Connected to ignition switch (ON/START) 

12 Red-blue 

13 Yellow-red 

14 Yellow-red 

Preheat indicator light signal, connected to engine 

control unit 

Speedometer signal, connected to speedometer 

sensor 

Vacuum warning indicator light signal, connected to 

vacuum booster switch 

15 White-blue Tachometer signal, connected to engine control unit 

16 - - 

17 - - 

18 - - 

19 Blue-red 

20 Blue-yellow 

Air cleaner clogging warning indicator light signal, 

connected to air cleaner clogging warning indicator 

light switch 

SVS warning light signal, connected to engine control 

unit

04-336 



1 - - 

2 - - 

04 

3 Black-red 


5 Blue-red 

6 Red-yellow 

Power supply of exhaust brake indicator light, 

connected to ignition switch (ON/START) 

Exhaust brake indicator light signal, connected to 

combination switch 

Front fog light indicator light signal, connected to front 

fog light relay 

Rear fog light indicator light signal, connected to 


7 - - 

B034 

8 Green-red 

9 Red-black 

10 White-red 

11 Red-yellow 

12 Blue-white 

Backup indicator light signal, connected to backup 

light switch 

Coolant level indicator light signal, connected to 

coolant level alarm switch 

Oil pressure indicator light signal, connected to oil 

pressure alarm switch 

Parking brake indicator light, connected to parking 

brake indicator light switch 

High beam indicator light signal, connected to right 

high beam relay 

13 White-black High beam indicator light signal ground 

14 Yellow-black 

Speedometer power output, connected to 

speedometer sensor 

15 Green Instrument illumination, connected to small light relay 

16 - - 

17 - - 

18 - - 

19 - - 

20 - -

Basic checks 


04-337 

Notice: 

When you perform basic checks, the engine must reach its operating temperature. Any road 

test must be carried out by two or more persons. 


1 Checking air pressure gauge 

• Indicated pressure ≥ 0.6Mpa. 

• Air pressure should rise from 0 to 0.4MPa in 4 

minutes (at the same time, low pressure 

alarm buzzer should stop alarm) with engine 

at 75% nominal power speed (1,500r/min). 

• Vehicle driving is forbidden when air pressure 

gauge pointer is in red zone. 


2 Checking tachometer 

• Connect a diagnostic tester, and select 

engine speed. 

• Observe tachometer readings at 700r/min, 

1,000r/min, 1,500r/min, and 2,000r/min 

respectively. 

• Error should be within ±70~200r/min. 


3 Checking speedometer 

• Connect a diagnostic tester, and select 

vehicle speed. 

• Observe speedometer readings at 40km/h, 

60km/h, and 80km/h respectively. 

• Error should be within ±5km/h. 

• Pointer should not throb at constant speed or 

uniform acceleration. 

Notice: 

Both tire wear and overinflation or 

underinflation will result in error. 


4 Checking oil pressure indicator light 


• Oil pressure indicator light should come on. 

• After the engine is started, oil pressure 

indicator light should go out. 



N Go to symptoms chart. 







04 

5 Checking generator indicator light 

• Ignition switch: ON (ACC). 

• Generator indicator light should come on. 

• After the engine is started, generator indicator 

light should go out. 


Y 

N 


Refer to Service Manual for 

Cummins ISF Series Engines.

04-338 


Overall system 



Whole combination meter does 

not work. 

4. Power and ground lines 

5. Combination meter itself 

Chapter 04 

Diagnosis-Combination Meter, 

Whole Combination Meter Does 

Not Work 

04 

No background illumination on 

whole combination meter 

1. Instrument illumination circuit 

2. Combination meter itself 

Chapter 04 Diagnosis-Lighting 

System 



Lighter-Combination Meter, 

Replacement 

Meters and gauges 


Air pressure gauge malfunction 

Speedometer malfunction 

Tachometer malfunction 

Fuel gauge and urea meter 

malfunctions 

Coolant temperature gauge 

malfunction 

1. Air brake system 

2. Air pressure gauge itself 

1. Vehicle speed sensor 

2. Tachometer circuit 

3. Tachometer itself 

1. Speed sensor 

2. Tachometer circuit 

3. Tachometer itself 

1. Fuel sensor 

2. Urea level sensor 

3. Fuel gauge circuit 

4. Urea meter circuit 

5. Fuel gauge and urea meter 

themselves 

1. Coolant temperature sensor 

2. Coolant temperature gauge 

circuit 


itself 

Chapter 26 Service Brake 




Replacement 

Chapter 04 Diagnosis- 

Combination 

Meter, 

Speedometer Malfunction 

Chapter 04 


Tachometer Malfunction 


Combination Meter, Fuel Gauge 

Malfunction 

The Service Manual for Cummins 

ISF Series Engines 


Combination Meter, Coolant 

Temperature Gauge Malfunction

Warning lights 


04-339 


Engine malfunction light does not 

come on/is always lighted up. 

1. Engine electronic control 

system 

2. Engine malfunction light 

circuit 

3. Combination meter assembly 



Brake (or clutch) fluid level 

warning light is always lighted 

up/does not come on. 

ABS malfunction warning light 

does not come on/is always 

lighted up. 

1. Brake (or clutch) fluid level 

alarm switch 

2. Brake (or clutch) fluid level 

warning light circuit 


1. ABS malfunction 

2. ABS malfunction warning 

light circuit 


Chapter 04 


Brake (Or Clutch) Fluid Level 

Warning Light Is Always Lighted 

Up/Does Not Come On 

Chapter 04 Diagnosis-ABS, 

Symptoms Chart 

04 

ASR blink code light does not 


1. ABS malfunction 

2. ASR blink code light circuit 


Chapter 04 Diagnosis-ABS, 


Door open warning light does not 


1. Door light switch 

2. Door open warning light 

circuit 







Replacement 

Low pressure warning light does 

not come on/is always lighted up. 

1. Low pressure alarm 

2. Low pressure warning light 

circuit 


Chapter 04 


Low Pressure Warning Light 

Does Not Come On/Is Always 

Lighted Up 

Coolant temperature warning light 

does not come on/is always 

lighted up. 





Meter/Cigarette 


Replacement 

1. Oil level sensor 

2. Oil level warning light circuit 



Oil level warning light does not 






Replacement

04-340 

Indicator lights 



Water sedimentation indicator light 

does not come on/is always lighted 

up. 

1. Water sedimentation switch 

2. Water sedimentation indicator 

light circuit 







Replacement 

04 

Oil pressure indicator light does not 


1. Oil pressure switch 

2. Oil pressure indicator light 

circuit 


Chapter 04 Diagnosis-Combination 

Meter, Oil Pressure Indicator Light 


Lighted Up 

Parking brake indicator light does 


1. Parking brake switch 

2. Parking brake indicator light 

circuit 



Meter, Parking Brake Indicator 

Light Does Not Come On/Is Always 

Lighted Up 

Fuel indicator light does not come 

on/is always lighted up. 

1. Fuel alarm switch 

2. Fuel indicator light circuit 



Meter, Fuel Indicator Light Does 

Not Come On/Is Always Lighted Up 

Preheat indicator light does not 


1. Electronic control system 

(ECM) 

2. Preheat indicator light circuit 







Replacement 

Generator indicator light does not 


1. Charging system 

2. Generator indicator light circuit 







Replacement 

Air cleaner indicator light does not 


1. Air cleaner clogging alarm 

switch 

2. Air cleaner indicator light 

circuit 



Meter, Air Cleaner Indicator Light 


Lighted Up 

Exhaust brake indicator light does 


1. Combination switch assembly 

2. Exhaust brake indicator light 

circuit 



Meter, Exhaust Brake Indicator 


Lighted Up 

Rear-view mirror defrost/defog 

indicator light does not come on/is 


1. Rear-view mirror defroster 

switch 

2. Rear-view mirror defrost/defog 



Chapter 72 Windshields/Window 

glasses/Rear-View Mirror-Outside 

Rear-View Mirror Defrost System, 


Coolant level indicator light does 


1. Coolant level sensor 

2. Coolant level indicator light 

circuit 



Meter, Coolant Level Indicator 


Lighted Up


04-341 


Turn signal and hazard warning 

indicator light does not come on/is 


1. Fuse 


3. Hazard warning switch 

4. Flasher 

5. Turn signal and hazard warning 




System, Symptoms Chart (If 

external turn signal and hazard 

warning light works normally, 

service line open or replace 

combination meter assembly.) 

High beam indicator light does not 


1. Fuse 



4. High beam indicator light circuit 




external high beam works normally, 



04 

Backup indicator light does not 


1. Fuse 

2. Backup light switch 

3. Backup indicator light circuit 




backup light works normally, 



Front fog light indicator light does 


1. Fuse 


3. Front fog light indicator light 

circuit 



System, Symptoms Chart (If front 

fog light indicator light works 

normally, service line open or 

replace combination meter 

assembly.) 

Rear fog light indicator light does 


1. Fuse 


3. Rear fog light switch 


5. Rear fog light indicator light 

circuit 



System, Symptoms Chart (If rear 

fog light indicator light works 

normally, service line open or 

replace combination meter 

assembly.) 

LCD screens 


No clock display or display blurred 

Clock setting failed 

Switching between clock and 

total/day odometer failed 

No odometer display or display 

blurred 

1. LCD screen 

1. Current selection incorrect 

2. Reset button 

1. Reset button 

1. LCD screen 




Replacement 

Switching to clock using reset 

button 




Replacement 




Replacement 




Replacement

04-342 


Whole combination meter does not work 




Black-white 

White-blue 


Black-red 

Black-red 


electric power 



Black-red 



04 

IG electric 

Power 

relay 

R14 

blue 

yellow 



battery electric 

power 

white 

White-blue 

White-red 

White-blue 

White-black 

White-black 

Transimission 

grounding 

Transimission 

grounding 

Chasiss fuse box 1 

White-black 

White-black White-black 

groundin 

g 

grounding 

white 

battery 

White-blac 

k 

White-black 

Step 

1. Checking power circuit of combination meter 

(a) 

Ignition switch: ON.


04-343 

(b) 

Check if fuse F15 (10 A) and F17 (7.5 A) in body 


04 




2. Checking power circuit of combination meter 

(a) 


B033. 

(b) 


of connector pins 2 and 10 of combination meter 





No > If battery voltage is not available on connector pin 2 of combination meter B033, 

repair line open from fuse F15 (10A) to connector pin 2 of the meter. 

If battery voltage is not available on connector pin 10 of combination meter B033, 

repair line open from fuse F17 (7.5A) to connector pin 10 of the meter.

04-344 


3. Checking ground circuit of combination meter 


(c) 


ground of connector pins 4 and 5 of combination 

meter B033 respectively. 


04 



No > Repair lines between connector pins 4 and 5 of combination meter B033 and ground. 

4. Checking for combination meter to power short 

(a) 


(b) 

Disconnect 3 connectors of combination meter.


04-345 

(c) 


ground of connector pin 9 of combination meter 

B032. 


(d) 


ground of connector pins 2, 10, and 11 of 

combination meter B033 respectively. 


04 

(e) 


ground of connector pin 3 of combination meter 

B034. 




No > Repair lines to ground short between fuse F17 (7.5A) and connector pins 9, 10, 11, 

and 3 of combination meters B032, B033, and B034; repair line to ground short 

between fuse F15 (10A) and connector pin 2 of combination meter B033.

04-346 

Speedometer malfunction 



Combination meter B033, B034 

04 

Speedometer 

sensor C048 

Yellow-black 

Yellow-red 

Yellow-black 

Yellow-red 

Speedometer 

sensor 

Water temperature sensor 

Speedometer 

message 

White-black 


1. Checking working voltage of speedometer sensor 

(a) 


(b) 

Disconnect connector of speedometer sensor 

C048. 

(c) 



04-347 

(d) 



pin 1 of speedometer sensor C048 respectively. 

Voltage: 8.5~13.5V 



No > If voltage is not available in either case, go to step 2. 

If voltage to ground of pin 1 is available, repair line open between connector pin 2 of 

speedometer sensor C048 and ground C238. 

04 

2. Checking supply circuit of speedometer sensor 

(a) 



Voltage: 8.5~13.5V 


Yes > Repair line open between connector pin 14 of combination meter B034 and 

connector pin 1 of speedometer sensor C048. 


3. Checking supply circuit of speedometer sensor 

(a) 


(b) 


B034.

04-348 


(c) 


ground of connector pin 1 of speedometer 

sensor C048. 


04 


Yes > Replace combination meter. 

No > Repair line to ground short between connector pin 14 of combination meter B034 

and connector pin 1 of speedometer sensor C048. 

4. Checking speedometer sensor 

(a) 

Remove speedometer sensor. 

(b) 

Turn spindle of speedometer sensor. 


between connector pins 2 and 3 of speedometer 

sensor C048. 

Pulse signals: 8 pulse resistance signals per 

turn 



No > Replace speedometer sensor. 

5. Checking signal circuit of speedometer sensor 

(a) 


ground of connector pin 3 of speedometer 

sensor C048. 

Resistance: >1MΩ


04-349 


between connector pin 3 of speedometer sensor 

C048 and connector pin 13 of combination 

meter B033. 




No > Repair signal line between connector pin 3 of speedometer sensor C048 and 

connector pin 13 of combination meter B033. 

04

04-350 

Tachometer Malfunction 



Combination metter B033 

Motor control unit 

C033 

White-blue 

Yellow-red 

tachometer 

04 


Tip: 

Engine galloping will result in tachometer pointer jump. 

Check if the vehicle can start normally. 



1. Checking tachometer signal 

(a) 


(b) Disconnect connector of combination meter B033.


04-351 

(c) 

(d) 




Voltage: approx. 0V 

(e) 

Start the engine and wait until its normal temperature is reached. 

(f) 

Use a multimeter to measure pulse signals on 


Signal value: 100~200 Hz (at idle) 

04 



No > If speed signal is not available, go to step 2. 

If speed signal is available, repair the line between connector pin 15 of combination 

meter B033 and connector pin 9 of ECM C033. 

2. Checking tachometer signal circuit 

(a) 

(b) 


Disconnect battery negative cable. 

(c) Disconnect connector of ECM C033. 

(d) Use a multimeter to measure resistance 

between connector pin 15 of combination meter 

B033 and connector pin 9 of ECM C033. 

(e) 



ground of connector pin 15 of combination 

meter B033. 



Yes > Replace ECM. (Refer to Service Manual for Cummins ISF Series Engines.) 

No > Repair the line between connector pin 15 of combination meter B033 and connector 

pin 9 of ECM C033.

04-352 

Fuel gauge malfunction 




Fuel sensor C038 

Blue-yellow 

Green-yellow 

Fuel meter 

04 

Blue-red 

Green-white 

Fuel meter 

White-black 


1. Checking fuel sensor 

(a) 


(b) 

Disconnect connector of fuel sensor.


04-353 


between connector pins 2 and 3 of fuel sensor 

C038. 

(d) 

Remove fuel sensor, and simulate the states 

with fuel tank empty, half-full, and full 

respectively. 

Resistance: approx. 110 Ω, 32.5 Ω, 3 Ω 



No > Replace fuel sensor. 

04 

2. Checking signal and ground circuits of fuel sensor 

(a) 


(b) 



pin 3 of fuel sensor C038 respectively. 





If voltage is not available between connector pins 3 and 2 of fuel sensor C038 only, 

repair ground line open between connector pin 2 of the sensor and ground C238. 

3. Checking signal circuit of fuel sensor 

(a) 



Voltage: approx. 5V

04-354 




pin 3 of fuel sensor C038. 


4. Checking for fuel sensor signal circuit short 

(a) 


(b) 


B032. 

04 

(c) 


ground of connector pin 3 of fuel sensor C038. 




No > Repair signal line to ground short between connector pin 3 of fuel sensor C038 and 

connector pin 2 of combination meter B032.


Coolant temperature gauge malfunction 


04-355 

Combination sensor B032 

Water temperature 

sensor C007 

Blue-black 

Blue-black 

Water 

temperature 

04 

Self- grounding 


1. Checking coolant temperature sensor 

(a) 

(b) 


Remove coolant temperature sensor. 

Caution: 

Removal of coolant temperature sensor should be made with engine cold (or coolant temperature 

≤ 40℃). 

(c) 

Use a multimeter to measure resistances of coolant temperature sensor under different 

temperatures. The reference values should conform to the following table. 

Temperature (℃) 40 60 90 102 

Resistance (Ω) 287.4 ± 30 134 ± 13.5 51.2 ± 4.3 38.5 ± 1 



No > Replace coolant temperature sensor.

04-356 


2. Checking signal circuit of coolant temperature sensor 

(a) 


(b) 

Disconnect connector of coolant temperature 

sensor. 

04 

(c) 


(d) 


of connector pin 1 of coolant temperature sensor 

C007. 





3. Checking signal power supply of coolant temperature sensor 

(a) 



Voltage: approx. 5V


04-357 



pin 1 of coolant temperature sensor C007. 


4. Checking for coolant temperature sensor signal circuit short 

(a) 


(b) 


B032. 

04 

(c) 


ground of connector pin 1 of coolant 

temperature sensor C007. 




No > Repair signal line to ground short between connector pin 1 of coolant temperature 

sensor C007 and connector pin 3 of combination meter B032.

04-358 


Brake (or clutch) fluid level warning light is always 

lighted up/does not come on 



Brake fuild position 

warning switch B022 

04 

Blue-white 

Brake fuild position 

warning light 

White-black 


• Check if brake (or clutch) fluid level is too low. If so, add designated special brake (or clutch) 

fluid. 

• Apply parking brake. 

• Start the engine. 

Check whether brake (or clutch) fluid level warning light is always lighted up or does not 

come on. 

Yes > (Always lighted up) go to step 1. 

No > (Does not come on) go to step 3. 

1. Checking signal and ground circuits of brake (or clutch) fluid level warning light 

(a) 

(b) 


Apply parking brake.


04-359 

(c) 

Disconnect connector of brake (or clutch) fluid 

level alarm switch. 

04 

(d) 


Check if brake (or clutch) fluid level warning light goes out. 

Yes > Replace brake (or clutch) fluid level alarm switch. 


2. Checking signal circuit of brake (or clutch) fluid level warning light 

(a) 


(b) 


B032. 

(c) 


ground of connector pin 1 of brake (or clutch) 

fluid level alarm switch B022. 




No > Repair signal line to ground short between connector pin 1 of brake (or clutch) fluid 

level alarm switch B022 and connector pin 16 of combination meter B032.

04-360 


3. Checking signal and ground circuits of brake (or clutch) fluid level warning light 

(a) 

(b) 


Apply parking brake. 

(c) 

Disconnect connector of brake (or clutch) fluid 

level alarm switch B022. 

04 

(d) 


(e) 



pin 1 of brake (or clutch) fluid level alarm switch 




Yes > Replace brake (or clutch) fluid level alarm switch. 


If battery voltage is not available between connector pins 1 and 2 of brake (or clutch) 

fluid level alarm switch B022 only, repair line open from connector pin 2 of the 

switch to grounds B208 and B209.


04-361 

4. Checking signal circuit of brake (or clutch) fluid level warning light 

(a) 


(b) 


B032. 

04 


between connector pin 1 of brake (or clutch) 

fluid level alarm switch B022 and connector pin 

16 of combination meter B032. 

(d) 



ground of connector pin 1 of brake (or clutch) 

fluid level alarm switch B022. 




No > Repair the signal line between connector pin 1 of brake (or clutch) fluid level alarm 

switch B022 and connector pin 16 of combination meter B032.

04-362 


Low pressure warning light is always lighted up/does 

not come on 


combinatiom meter B032 

Warner of pressure too low 1 

04 

Red-black 

Red-black 

Warning indicator 

pressure low 

Warner of pressure 

too low2 



• Start the engine, and observe air pressure gauge. 

• When air pressure gauge reading is not greater than 0.4±0.025 MPa, low pressure warning 

light should come on. 

• When air pressure gauge reading is greater than 0.4±0.025 MPa, low pressure warning light 

should go out. 

Check whether low pressure warning light is always lighted up or does not come on. 



1. Checking for low pressure warning light signal circuit short 

(a) 



04-363 

(b) 

Disconnect connectors of low pressure alarms 

C027 and C037 on front and rear air reservoirs 

respectively. 

04 

Check if low pressure warning light goes out. 

Yes > Replace with low pressure alarms that make low pressure warning light go out. 


2. Checking for low pressure warning light signal circuit short 

(a) 


(b) 


B032. 

(c) 


ground of connector pins 1 of low pressure 

alarms C027 and C037 respectively. 




No > Repair signal line to ground short between connector pins 1 of low pressure alarms 

C027 and C037 and connector pin 18 of combination meter B032.

04-364 


3. Checking for low pressure warning light signal circuit open 

(a) 


(b) 

Disconnect connectors of low pressure alarms 

C027 and C037 respectively. 

04 

(c) 


(d) 


of connector pins 1 of low pressure alarms C027 

and C037 respectively. 



Yes > Replace low pressure alarms. 

No > Go to step 4.


04-365 

4. Checking for low pressure warning light signal circuit open 

(a) 





Yes > Repair signal line open between connector pins 1 of low pressure alarms C027 and 

C037 and connector pin 18 of combination meter B032. 


04

04-366 

Diagnosis- Combination Meter 

Oil pressure indicator light is always lighted up/does 

not come on 



04 

Engine oil pressure 

warning switch C040 

White-red White-red Engine oil 

pressure warning 

Self-ground 


• When ignition switch is in ON position, this indicator light should come on. 

• After the engine is started, this indicator light should go out. 

• When oil pressure is not greater than 0.050± 0.011 MPa, this indicator light should come 

on. 

• When oil pressure is greater than 0.050± 0.011 MPa, this indicator light should go out. 

Notice: 

If this indicator light keeps lighted up after the engine is started, stop the engine 

immediately and check oil level. If the oil level is abnormal, clear the trouble first. (Refer 

to Service Manual for Cummins ISF Series Engines.) 

Check whether oil pressure indicator light is always lighted up or does not come on. 



1. Checking for oil pressure indicator light signal circuit short 

(a) 



04-367 

(b) 

Disconnect connector of oil pressure alarm 

switch. 

04 

(c) 


Check if oil pressure indicator light goes out. 

Yes > Replace oil pressure alarm switch. 


2. Checking for oil pressure indicator light signal circuit short 

(a) 


(b) 


B034. 

(c) 


ground of connector pin 1 of oil pressure alarm 

switch C040. 




No > Repair signal line to ground short between connector pin 1 of oil pressure alarm 

switch C040 and connector pin 10 of combination meter B034.

04-368 


3. Checking for oil pressure indicator light signal circuit open 

(a) 


(b) Disconnect the connector connecting oil 

pressure alarm switch C040. 

04 

(c) 


(d) 


of connector pin 1 of oil pressure alarm switch 

C040. 



Yes > Replace oil pressure alarm switch. 

No > Go to step 4.


4. Checking for oil pressure indicator light signal circuit open 

(a) 

04-369 





Yes > Repair signal line open between connector pin 1 of oil pressure alarm switch C040 

and connector pin 10 of combination meter B034. 


04

04-370 


Parking brake indicator light is always lighted up/does 

not come on (air cut-off brake) 



04 

Parking brake 

indicator switch C026 

Red-yellow 

Red-yellow 

Parking brake 

indicator 

Black-white 


• This indicator light should come on when air pressure is below 0.02~0.05MPa with ignition 

switch in ON position and hand brake pulled up. 

• This indicator light should go out when air pressure is not less than 0.02~0.05MPa with 

ignition switch in ON position and hand brake pulled down. 

Tip: 

If the parking brake is of air cut-off type, abnormal pressure in brake system will result in parking 

brake indicator light malfunction. If air pressure in brake system is abnormal, troubleshoot brake air 

circuit first. (Refer to “Chapter 26 Service Brake”.) 

Check whether parking brake indicator light is always lighted up or does not come on. 



1. Checking for parking brake indicator light signal circuit short 

(a) 

(b) 


Release parking brake. 

Caution: 

Before releasing parking brake, block the 4 wheels with wedges first to avoid vehicle sliding.


04-371 

(c) 

Disconnect connector of parking brake indicator 

light switch. 

04 

(d) 


Check if parking brake indicator light goes out. 

Yes > Replace parking brake indicator light switch. 



(a) 


(b) 


B034. 

(c) 


ground of connector pin 1 of parking brake 

indicator light switch C026. 




No > Repair signal line to ground short between connector pin 1 of parking brake indicator 

light switch C026 and connector pin 11 of combination meter B034.

04-372 


3. Checking for parking brake indicator light signal and ground circuits open 

(a) 


(b) 


light switch. 

04 

(c) 


(d) 



pin 1 of parking brake indicator light switch C026 

respectively. 



Yes > Replace parking brake indicator light switch. 


If battery voltage is not available between connector pins 1 and 2 of parking brake 

indicator light switch C026 only, repair line open between connector pin 2 of the 

switch and ground B038.


4. Checking for parking brake indicator light signal circuit open 

(a) 

04-373 





Yes > Repair signal line open between connector pin 1 of parking brake indicator light 

switch C026 and connector pin 11 of combination meter B034. 


04

04-374 


Parking brake indicator light is always lighted up/does 

not come on (central drum) 


Combination 

meter B034 

04 

Parking brake 

indicator switch C026 

Red-yellow 

Red-yellow 

Parking brake 

indicator 

Self-grounding 


• This indicator light should come on when hand brake is pulled up with ignition switch in ON 

position. 

• This indicator light should go out when hand brake is pulled down with ignition switch in ON 

position. 

Check whether parking brake indicator light is always lighted up or does not come on. 




(a) 

(b) 


Put down hand brake. 

Caution: 

Before putting down hand brake, block the 4 wheels with wedges first to avoid vehicle 

sliding.


04-375 

(c) 

Disconnect the parking brake indicator light 

switch connector at the bottom of parking brake 

control handle assembly. 

04 

(d) 


Check if parking brake indicator light goes out. 

Yes > Replace parking brake control handle assembly. 



(a) 


(b) 


B034. 

(c) 


ground of connector pin 1 of parking brake 

indicator light switch L002. 




No > Repair signal line to ground short between connector pin 1 of parking brake indicator 

light switch L002 and connector pin 11 of combination meter B034.

04-376 


3. Checking for parking brake indicator light signal and ground circuits open 

(a) 

(b) 

Pull up hand brake. 


(c) 


light switch. 

04 

(d) 


(e) 


of connector pin 1 of parking brake indicator light 

switch L002. 



Yes > Replace parking brake control handle assembly. 

No > Go to step 4.


4. Checking for parking brake indicator light signal circuit open 

(a) 

04-377 





Yes > Repair signal line open between connector pin 1 of parking brake indicator light 

switch L002 and connector pin 11 of combination meter B034. 


04

04-378 


Coolant level indicator light is always lighted up/does 

not come on 


Combination 

meter B334 

04 

Water position 

warning switch C039 

red-black 

red-black 

Coolant position 

warning 

White-black 


• Make sure coolant level is within standard scale range. 


Check whether coolant level indicator light is always lighted up or does not come on. 


No > (Does not come on) go to step 3.


1. Checking for coolant level indicator light signal circuit short 

(a) 


04-379 

(b) Disconnect coolant level alarm switch 

connector. 

04 

(c) 


Check if coolant level indicator light goes out. 

Yes > Replace coolant level alarm switch. 


2. Checking for coolant level indicator light signal circuit short 

(a) 


(b) 


B034. 

(c) 


ground of connector pin 1 of coolant level alarm 

switch C039. 

Resistance: >1MΩ

04-380 




No > Repair signal line to ground short between connector pin 1 of coolant level alarm 


3. Checking for coolant level indicator light signal and ground circuits open 

(a) 


(b) Disconnect coolant level alarm switch 

connector. 

04 

(c) 


(d) 



pin 1 of coolant level alarm switch C039 

respectively. 



Yes > Replace coolant level alarm switch. 


If battery voltage is not available between connector pins 1 and 2 of coolant level 

alarm switch C039, repair line open between connector pin 2 of the switch and 

ground C211.


4. Checking for coolant level indicator light signal circuit open 

(a) 

04-381 





Yes > Repair signal line open between connector pin 1 of coolant level alarm switch C039 

and connector pin 9 of combination meter B034. 


04

04-382 


Air cleaner indicator light is always lighted up/does 

not come on 


Combination 

Meter B033 

04 

Air filter jam warning 

Switch C011 

Blue-red Blue-red Air filter jam 

warning indicator 

White- black 


• Confirm if air cleaner is too dirty. If so, replace with a new one. 

• Check intake system for excessive intake resistance. If so, clear this trouble first. (Refer to 

Service Manual for Cummins ISF Series Engines-Intake System.) 


Check whether air cleaner indicator light is always lighted up or does not come on. 



1. Checking for air cleaner indicator light signal circuit short 

(a) 



04-383 

(b) 

Disconnect connector of air cleaner clogging 

warning light switch. 

04 

(c) 


Check if air cleaner indicator light goes out. 

Yes > Replace air cleaner clogging warning light switch. 


2. Checking for air cleaner indicator light signal circuit short 

(a) 


(b) 


B033. 

(c) 


ground of connector pin 1 of air cleaner clogging 

warning light switch C011. 




No > Repair signal line to ground short between connector pin 1 of air cleaner clogging 

warning light switch C011 and connector pin 19 of combination meter B033.

04-384 


3. Checking for air cleaner indicator light signal and ground circuits open 

(a) 


(b) 



04 

(c) 


(d) 



pin 1 of air cleaner clogging warning light switch 

C011 respectively. 



Yes > Replace air cleaner clogging warning light switch. 


If battery voltage is not available between connector pins 1 and 2 of air cleaner 

clogging warning light switch C011, repair line open between connector pin 2 of the 

switch and ground C238.


4. Checking for air cleaner indicator light signal circuit open 

(a) 

04-385 





Yes > Repair signal line open between connector pin 1 of air cleaner clogging warning light 



04

04-386 


Exhaust brake indicator light is always lighted up/does 

not come on 


Combination 

Meter B032 

04 

Combination 

Switch B029 

Exhaust brake 

switch 

Green- yellow 

Exhaust brake 


Blue- yellow 

Yellow-green 

Blue- yellow 

Yellow-green 

Engine Control 

Unit C003 



• Move exhaust brake switch back and forth. 

Check whether exhaust brake indicator light is always lighted up or does not come on. 



1. Checking for exhaust brake indicator light signal circuit short 

(a) 


(b) 

Disconnect connector of combination switch 

B029. 

(c) 



Check if exhaust brake indicator light goes out. 

Yes > Replace combination switch assembly. 


2. Checking for circuit short from exhaust brake indicator light signal to ECM 

(a) 

(b) 

(c) 

(d) 

(e) 



Disconnect ECM connector. 

Reinstall battery negative cable. 


Check if exhaust brake indicator light goes out. 



04-387 

3. Checking for circuit short from exhaust brake indicator light signal to combination meter 

(a) 


(b) 


B034. 

04 

(c) 


ground of connector pin 10 of combination 

switch B029. 




No > Repair lines to ground short from connector pin 10 of combination switch B029 to 

connector pin 4 of combination meter B034 and connector pin 13 of ECM (58-pin) 

C033.

04-388 


4. Checking for exhaust brake indicator light signal and ground circuits open 

(a) 


(b) 

Disconnect connector of combination switch 

B029. 

04 

(c) 


(d) 



of pin 10 of combination switch B029 

respectively. 



Yes > Replace combination switch assembly. 


If battery voltage is not available between connector pins 1 and 10 of combination 

switch B029, go to step 5. 

5. Checking ground circuit from combination switch to ECM signal 

(a) 


(b) 


ground of connector pin 1 of combination switch 

B029. 




No > Go to step 6.


6. Checking ground circuit from combination switch to ECM signal 

04-389 


between connector pin 1 of combination switch 

B029 and connector pin 29 of ECM (58-pin) 

C033. 




No > Repair line open between connector pin 1 of combination switch B029 and connector 

pin 29 of ECM (58-pin) C033. 

7. Checking for exhaust brake indicator light signal circuit open 

(a). 


(b) 




04 


Yes > Repair signal line open between connector pin 10 of combination switch B029 and 


No > Replace combination meter assembly.

04-390 


Fuel indicator light is always lighted up/does not come 

on 


Combination 

Meter B032 

04 

Fuel Sensor C038 

Blue-Yellow 

Green-Yellow 

Fuel Table 

Blue- Red 

Green- White 

Fuel Alarm 

White-black 


• Confirm there is sufficient fuel in fuel tank (greater than 1/4 fuel level) when ignition switch is 

in ON position. 

• When fuel level in fuel tank is below 345mm (i.e. less than 7~10L) or fuel sensor resistance 

is greater than 89Ω, this indicator light should come on. 

• When fuel level in fuel tank is above 345mm (i.e. greater than 7~10L) or fuel sensor 

resistance is less than 89Ω, this indicator light should go out. 

Tip: 

Fuel indicator light will come on occasionally when your vehicle is making a sharp turn. This is 

normal. 

Check whether fuel indicator light is always lighted up or does not come on. 



1. Checking for fuel indicator light signal circuit short 

(a) 



04-391 

(b) 

Disconnect connector of fuel sensor. 

04 

Check if fuel indicator light goes out. 

Yes > Replace fuel sensor. 


2. Checking for fuel indicator light signal circuit short 

(a) 


(b) 


B033. 

(c) 


ground of connector pin 1 of fuel sensor C038. 




No > Repair signal line to ground short between connector pin 3 of fuel sensor C038 and 

connector pin 9 of combination meter B033.

04-392 


3. Checking for fuel indicator light signal circuit open 

(a). Ignition switch: OFF. 

(b) Disconnect connector of fuel sensor. 

04 

(c) 


(d) 



pin 1 of fuel sensor C038 respectively. 



Yes > Replace fuel sensor. 


If battery voltage is not available between connector pins 1 and 2 of fuel sensor C038 

only, repair line open between connector pin 2 of the sensor and ground C238.


4. Checking for fuel indicator light signal circuit open 

(a) 

04-393 





No > Repair signal line open between connector pin 1 of fuel sensor C038 and connector 

pin 9 of combination meter B033. 


04

04 

04-394 

Central lock 

Precautions 



LOCK 

ACCS 

ON 

START 

Diagnosis- Central Lock 





Engine start 

2. Power off. 

(a) 




Tip: 

Please do not leave your car key in your vehicle before battery negative cable is disconnected so 

as to avoid locking doors. 

(b) 




Tip: 



Tip: 



Component drawing 


04-395 

04 

1 Left front door lock actuator 3 Left front door lock actuator 

2 Central lock controller

04-396 


Central lock controller terminals 

04 

Terminal 

number 

Wiring color 

Description 

1 White-black Central lock controller ground 

2 Blue-yellow Connected to right front door lock actuator 

3 Purple Connected to battery (+) 

4 Blue-black Connected to right front door lock actuator 

5 - - 

6 Purple 

Connected to left front door lock actuator (left front door lock 

switch) 

7 - - 

8 - - 

9 - - 

10 - -

Basic checks 


04-397 




21V. 


2 Checking left front door 

• Open left front door with car key. 

Tip: 

• If central lock is equipped, only left 

front door is equipped with lock 

cylinder. 

• In the case of a right hand drive 

model, only right front door is 

equipped with lock cylinder. 

Check if left front door is unlocked. 

3 Checking right front door 

• Observe right front door while left 

front door is opened. 

Check if right front door is unlocked. 

4 Checking left front door switch 

• Depress vertical bar of left front door 

lock. 

Check if right front door is locked. 


N 




N 

Repair or replace left front door lock body 

assembly. Refer to “Chapter 75 Door 

Locks-Door Lock, Replacement”. 


N 



N 


04 

5 Checking right front door dock body 

• Depress and pull up vertical bar of 

right front door dock repeatedly. 

Check vertical bar of right front door dock 

for smart motion. 

Y 

N 


Repair or replace left front door lock body 

assembly. Refer to “Chapter 75 Door 

Locks-Door Lock, Replacement”.

04-398 






04 

Central lock is inoperative. 


locked. 


2. Left front door lock actuator 

(left front door switch) 

3. Right front door lock actuator 

4. Central lock controller 




Chapter 04 Diagnosis-Central 

Lock, Central Lock Is Inoperative 


Lock, Right Front Door Can Not 

Be Locked 


unlocked. 




Lock, Right Front Door Can Not 

Be Unlocked

Central lock is inoperative 



04-399 

central locking 

controller B0035 

Violet 

Blue -Black 

Blue -Black 

White-blue 

Body fuse 

block B050 

Lock 

Open 

Right Front Door 

Lock 

04 

Blue -yellow 

Blue -yellow 

White-blue 



lock E005 

Left Door Lock 

Switch 

Violet 

Violet 

White 

White- Black 

White- Black 

Battery 

White- Black

04-400 



1. Checking power fuse of central lock controller 

(a) 


(b) Check fuse F/L2 (50A) in chassis fuse block 1 

and F13 (15A) in body fuse block respectively. 

04 



No > If fuse F/L2 (50A) is blown only, go to step 4. 

If fuse F13 (15A) is blown only, go to step 2. 

2. Checking fuse F13 (15A) to central lock controller circuit 

(a) 


ground of connector pin 3 of central lock 

controller B035. 




No > Go to step 3.

04-401 


3. Checking fuse F13 (15A) to central lock controller circuit 

(a) Disconnect central lock controller connector. 

04 

(b) 






Yes > Replace fuse F13 (15A) and central lock controller assembly. 


connector pin 3 of central lock controller B035. 

4. Checking fuse F/L2 (50A) to fuse F13 (15A) circuit 

(a) 

Disconnect C101 connector.

04-402 


(b) 


ground of connector pin 1 of C101. 


04 



No > Replace fuse F/L2 (50A) and repair line to ground short between the fuse and 

connector pin 1 of C101. 

5. Checking fuse F/L2 (50A) to fuse F13 (15A) circuit 

(a) 


ground of connector pin 1 of B103. 



Yes > Replace fuse F/L2 (50A). 

No > Replace fuse F/L2 (50A) and repair line to ground short between connector pin 1 of 

B103 and fuse F13 (15A).

04-403 


6. Checking power and ground circuits of central lock controller 

(a) Disconnect central lock controller connector. 

04 

(b) 



pin 3 of central lock controller B035 respectively. 




No > f battery voltage is not available in either case, repair line open between fuse F/L2 

(50A) and connector pin 3 of central lock controller B035. 

If battery voltage is not available only between connector pins 3 and 1 of central lock 

controller B035, repair line open between connector pin 1 of the controller and 


7. Checking left front door lock actuator (left front door lock switch) 

(a) 

(b) 

(c) 


Remove (left) door outer trim panel assembly. (Refer to “Chapter 77 Interior/Exterior 

Trims-Replacement”.) 

Remove (left) door rainproof curtain shield. 

Tip: 

Only part of (left) door rainproof curtain shield needs to be lifted.

04-404 


(d) 

Disconnect connector of left front door lock 

actuator (left front door lock switch). 

04 

(e) Use a multimeter to measure resistance 


lock actuator (left front door lock switch) E005. 

(f) 

(g) 

Depress vertical bar of left front door lock. 


Pull up vertical bar of left front door lock. 




No > Replace left front door lock actuator assembly. 

Locks-Door Lock, Replacement”.) 

(Refer to “Chapter 75 Door


04-405 

8. Checking signal and ground circuits of left front door lock actuator (left front door 

lock switch) 

(a) 

Connect central lock controller connector. 

04 

(b) 



pin 1 of left front door lock actuator (left front 

door lock switch) E005 respectively. 





If voltage is not available between connector pins 1 and 2 of left front door lock 

actuator (left front door lock switch) E005 only, repair line open between connector 

pin 2 of the actuator and grounds B208 and B209. 

9. Checking signal circuit of left front door lock actuator (left front door lock switch) 

(a) 


of connector pin 6 of central lock controller 

B035. 

Voltage: approx. 12V

04-406 



Yes > Repair line open between connector pin 6 of central lock controller B035 and 

connector pin 1 of left front door lock actuator (left front door lock switch) E005. 

No > Replace central lock controller assembly. 

10. Checking control circuit of right front door lock actuator 

(a) 


(b) Connect connector of left front door lock actuator (left front door lock switch) E005. 

(c) 

Disconnect central lock controller connector. 

04 

(d) Disconnect connector of right front door lock actuator D005. 

(e) Use a multimeter to measure resistance 

between connector pins 4 and 2 of central lock 

controller B035 and connector pins 1 and 2 of 

right front door lock actuator D005 respectively. 


(f) 


ground of connector pins 1 and 2 of right front 

door lock actuator D005 respectively. 

Resistance: >1MΩ


04-407 



No > Repair the line between connector pins 4 and 2 of central lock controller B035 and 

connector pins 1 and 2 of right front door lock actuator D005. 


(a) 

Connect central lock controller connector. 

04 

(b) 

(c) 

(d) 


Yes > Replace right front door lock actuator. 

No > Replace central lock controller. 


connector pins 1 and 2 of right front door lock 

actuator D005. 


Voltage: battery voltage (duration: approx. 

0.3~1.1s) 



0.3~1.1s)

04-408 


Right front door can not be locked 




Violet 

Blue -Black 

Blue -Black 

04 

White-blue 

Body fuse 

block B050 

Lock 

Open 


Lock 

Blue -yellow 

Blue -yellow 

White-blue 



lock E005 


Switch 

Violet 

Violet 

White 

White- Black 

White- Black 

Battery 

White- Black


1. Checking right front door lock actuator 


(a) 

(b) 

04-409 






0.3~1.1s) 

04 





(a) 

(b) 


Disconnect connector of right front door lock actuator. 

(c) 

(d) 


of connector pin 2 of right front door lock 




0.3~1.1s) 



No > Go to step 3.

04-410 


3. Checking supply circuit of right front door lock actuator 


(b) Disconnect central lock controller connector. 

04 


between connector pins 2 of central lock 

controller B035 and right front door lock actuator 

D005. 


(d) 


ground of connector pin 2 of right front door lock 




Yes > Replace central lock controller. 

No > Repair the line between connector pins 2 of central lock controller B035 and right 

front door lock actuator D005.


4. Checking control and ground circuits of right front door lock actuator 

(a) 


(b) 

04-411 





04 




5. Checking control and ground circuits of central lock controller 

(a) 







connector pin 1 of right front door lock actuator D005. 

No > Replace central lock controller.

04-412 


Right front door can not be unlocked 




Violet 

Blue -Black 

Blue -Black 

04 

White-blue 

Body fuse 

block B050 

Lock 

Open 


Lock 

Blue -yellow 

Blue -yellow 

White-blue 



lock E005 


Switch 

Violet 

Violet 

White 

White- Black 

White- Black 

Battery 

White- Black 


1. Checking right front door lock actuator 

(a) 

(b) 






0.3~1.1s)






(a) 

(b) 


Disconnect connector of right front door lock actuator. 

(c) 

(d) 

04-413 


of connector pin 1 of right front door lock 




0.3~1.1s) 

04 




3. Checking supply circuit of right front door lock actuator 

(a) 


(b) 

Disconnect central lock controller connector.

04-414 



between connector pin 4 of central lock 

controller B035 and connector pin 1 of right front 

door lock actuator D005. 


04 

(d) 






Yes > Replace central lock controller. 

No > Repair the line between connector pin 4 of central lock controller B035 and connector 

pin 1 of right front door lock actuator D005. 

4. Checking control and ground circuits of right front door lock actuator 

(a) 


(b) 







No > Go to step 5.


5. Checking control and ground circuits of central lock controller 

(a) 

04-415 







connector pin 2 of right front door lock actuator D005. 

No > Replace central lock controller. 

04

Fuel 

Fuel system .................................................... 11-1 

Precautions ................................................ 11-1 

Fuel tank ......................................................... 11-2 

Parts diagram ............................................ 11-2 

Replacement .............................................. 11-4 

Purification ................................................. 11-8 

Fuel filter ......................................................... 11-9 

Parts diagram ............................................ 11-9 

Replacement ............................................ 11-10 

11 

Fuel sensor ................................................... 11-13 

Replacement ............................................ 11-13

11

Fuel system 

Precautions 

Fuel- Fuel system 

1. Before checking and servicing the fuel system, disconnect battery negative cable. 

11-1 

2. Fuels are combustible materials. When you operate on the fuel system, cigarettes, 

open flames, indicator lights, arc equipment, and switches must be kept away from 

the work area where should be equipped with ventilation facilities so as to avoid 

personal injury even death. 

3. The high-pressure fuel line and fuel rail of the fuel pump contain high pressure fuel. In 

order to avoid personal injury, never loosen any fuel pipe joint when the engine is 

running. 

4. Keep fuel away from rubber or leather components. 

5. Diesel injection equipment is manufactured in accordance with very accurate 

tolerances and clearances, so it is very important to have an absolutely clean working 

environment when you operate on the fuel system. All openings must be sealed with 

special plug caps. 

6. Residual oil pressure in the fuel system will still persist for a long time after your car is 

shut down. Before servicing the fuel system, you must release fuel pressure first. 

Failure to comply with these tips may result in personal injury. 

7. Before disconnecting any fuel system line, you should check and make sure there is 

no dirt or foreign substances around the fuel pipe joint. If any, clean it up. Dirt or 

foreign substances may damage the fuel system or engine. 

8. Do not allow cleanser to enter any fuel pipe joint; otherwise the fuel system may be 

damaged. 

9. Do not bend or twist any fuel pipe in the fuel system hard. 

10. Before connecting fuel system lines, make sure no fuel pipe joints are damaged. If any 

is found damaged or cracked, replace the fuel pipe assembly. Ensure that connecting 

surfaces of fuel pipes are free of dirt. 

Releasing fuel system pressure 

(a) 

(b) 

(c) 

(d) 

Disconnect connection harness connector of fuel pump. 

Start the engine and remain idle until engine shutdown. 

Restart the engine and wait approx. 5 seconds to make sure the pressure in fuel injection 

supply manifold has been completely released. 

Connect fuel pump harness connector. 

Fuel tank drainage 

(a) 

(b) 

(c) 


Screw off fuel tank cap. 

Use an appropriate fuel tank drainage facility to drain the fuel tank. 

11

11-2 

Fuel tank 

Parts diagram 

Fuel- Fuel tank 

11


11-3 

1 Front fuel delivery pipe assembly 

2 Rubber grommet 

3 Fuel return pipe assembly 

4 Fuel sensor assembly 

5 Fuel tank assembly 

6 Fuel tank cap 

8 Plain washer 

9 Spring washer 

10 Hexagon nut 

11 Fuel tank band 

12 Hexagon bolt 

13 Fuel tank bracket 

7 Fuel tank strap welded unit 

11

11 

11-4 

Replacement 


1. Releasing fuel pressure (refer to “Chapter 11 Fuel, Precautions”) 

2. Draining fuel tank (refer to “Chapter 11 Fuel, Precautions”) 

3. Disconnecting battery negative cable 

4. Disconnecting fuel sensor 

(a) 


Tip: 

There is usually dirt on the fuel sensor connector. When 

it is difficult to disconnect, you can lightly tap it for 

several times with an appropriate tool before the 

operation. 

5. Disconnecting front fuel delivery pipe 

(a) 

Loosen front fuel delivery pipe joint nut. 

6. Disconnecting fuel return pipe 

(a) 

Loosen fuel return pipe joint nut. 

7. Removing cargo body guardrail assembly (refer to “Chapter 77 Interior/Exterior 

Trims-Cargo Body Guardrail, Replacement”)


11-5 

8. Removing fuel tank assembly 

(a) 

(b) 

(c) 

Loosen the 2 nuts connecting fuel tank strap 

welded unit with fuel tank bracket. 

Take off fuel tank strap welded unit. 

Remove fuel tank assembly. 

Notices: 

• Before starting this operation, check and 

make sure there are no lines, harnesses or 

other foreign materials around the fuel tank. 

When necessary, clean up. 

• When you lift off the fuel tank, operate using 

appropriate tools or with aid from others 

when necessary because it is large. 

• The fuel tank is an aluminum alloy part, so 

collision should be avoided during removal, 

handling, and installation. 

11 

9. Removing fuel sensor assembly 

(a) 

(b) 

Loosen sealing gland of fuel sensor using fuel 

sensor special tool. 

Rotate it until an appropriate angle, and then 

take out fuel sensor assembly gently. 

Notices: 

• Before starting this operation, check and 

make sure there is no dirt or other foreign 

materials around the fuel sensor. When 

necessary, clean up. 

• When removing the fuel sensor, be sure to 

rotate it until an appropriate angle and then 

take it out. 

• There is a grommet in the sealing gland. 

Never damage it during the removal. 

10. Installing fuel sensor assembly 

(a) 

(b) 

Rotate fuel sensor to an appropriate angle and 

install it to its correct position on the fuel tank. 

Tighten sealing gland of fuel sensor using fuel 


Notice: 

When installing the fuel sensor, be sure to rotate it 

to an appropriate angle before entry. Do not cause 

bending and deformation. 

11. Installing fuel tank assembly 

(a) 

Install fuel tank assembly onto fuel tank bracket 

and fix it to correct position.

11-6 


(b) 

Tighten the nuts connecting fuel tank strap 

welded unit with fuel tank bracket. 

Torques: 

Fuel tank capacity (L) 

Torque (N•m) 

80 21~25 

4 

11 

Notices: 

• Tighten the nuts connecting fuel tank strap 

welded unit with fuel tank bracket to the 

specified torque simply. Over torque will 

cause fuel tank deformation. 

• The fuel tank should be connected securely 

without abnormal shock. 

• Rubber band pads should be even and flat. 

12. Connecting fuel return pipe 

(a) 

(b) 

Connect fuel return pipe of fuel tank, and tighten 

fuel return pipe joint nut. 

Torque: 21~25 N•m 

After the connection is completed, lightly pull 

junction of fuel pipe and fuel sensor outlet to 

check for firm connection.


11-7 

13. Connecting front fuel delivery pipe 

(a) 

(b) 

Connect front fuel delivery pipe of fuel tank, and 

tighten front fuel delivery pipe joint nut. 


After the connection is completed, lightly pull 

junction of fuel pipe and fuel sensor outlet to 

check for firm connection. 

14. Connecting fuel sensor 

(a) 

(b) 

Connect connector of fuel sensor. 

Secure the harness to frame and prevent it from 

interference with any moving part. 

11 

15. Bleeding fuel system 

(a) 

Bleed the fuel system by pressing the manual 

pump handle on the fuel filter several times. 

16. Connecting battery negative cable 

17. Inspection 

After making sure all connectors have been connected properly, turn on ignition switch to check fuel 

gauge on the meter for normal display and start the engine and check fuel pipe joints of the fuel 

system for oil ooze and leak. 

18. Installing cargo body guardrails (refer to “Chapter 77 Interior/Exterior Trims-Cargo 

Body Guardrail, Replacement”)

11-8 

Purification 


1. Fuel drainage 

(a) 

Open fuel tank cap and screw off drain plug of 

fuel tank. After residual fuel is drained, clean up 

stains on the plug and then reinstall it. 

11 

2. Filling clean fuel 

(a) 

Fill fuel tank with fuel until fuel level is approx. 

15~20mm from bottom of the tank. 

4. Cleaning fuel tank repeatedly 

(a) 

3. Cleaning fuel tank assembly 

(a) 

Insert a hose with spray head to bottom of the 

fuel tank. 

(b) Connect compressed air hose with the 

purpose-made spray head. (The spray head is a 

metal tube of 12mm outside diameter and 

approx. 250mm length. 4~5 Ø1mm apertures 

are drilled on its one end which has been seal 

welded. Its other end is simply connected with 

the hose.) 

(c) 

Seal oil filler with clean cloth veil. Turn on 

compressed air switch and flush with air 

pressure maintained at 0.382~0.594MPa. During 

flushing, change positions of the spray head to 

allow deposits and burs to stir with fuel. 

Notice: 

When using compressed air, wear suitable goggles 

and face shield. Flying chips and dirt will cause 

personal injury. 

After flushing the whole fuel tank with spray head, screw off drain plug to discharge dirty fuel. 

Repeat thus 2~3 times to clean the tank up. 

5. Checking fuel tank 

(a) 

After cleaning the fuel tank, check it for breakage. If any, handle promptly. 

6. Checking fuel tank cap 

(a) 

compress 

ed air 

Check if the fuel tank cap is in good condition. In the case of valve spring damage or rust, 

service or replace it.

Fuel filter 

Parts diagram 

Fuel- Fuel filter 

11-9 

11 

1 Gasket (for installation) 5 Case assembly 

2 Gasket 6 Spring 

3 Screw cover assembly 7 Pressure plate 

4 Filter element assembly

11 

11-10 

Replacement 




3. Disconnecting fuel filter harness 

(a) 

Disconnect the 2 connectors of fuel filter 

harness. 

Tip: 

There is usually dirt on the fuel filter harness 

connectors. When they are difficult to disconnect, you 

can lightly tap them for several times with an 

appropriate tool before the operation. 

4. Removing fuel filter element 

(a) 

Remove fuel filter element by twisting it 

counterclockwise with a filter wrench. 

5. Checking fuel filter holder 

(a) 

Check fuel filter holder for such defects as cracks, scratches, or noticeable damage. If any of 

above defects is found, replace with a new fuel filter holder and go to steps 6 and 7. 

6. Removing fuel filter holder 

(a) 

Loosen fuel inlet pipe joint nut of fuel filter. 

(b) 

Loosen fuel outlet pipe joint nut of fuel filter.


11-11 

(c) 

Remove fixing bolts and nuts of fuel filter holder. 

7. Installing fuel filter holder 

(a) Install fixing bolts and nuts of fuel filter holder. 


11 

(b) 

Connect fuel outlet pipe of fuel filter, and tighten 

fuel pipe joint nut. 


(c) 

Connect fuel inlet pipe of fuel filter, and tighten 

fuel pipe joint nut. 

Torque: 41~51 N•m

11-12 


8. Installing fuel filter element 

(a) 

(b) 

Coat fuel filter seal ring with a little lubricant. 

Tighten fuel filter element clockwise using fuel 

filter wrench. 

Notice: 

Overtightening a fuel filter will cause thread 

deformation and damage to filter element gasket or 

filter tank. 

11 

9. Connecting fuel filter harness 

(a) 

As shown in the figure, connect the 2 connectors 

of the fuel filter harness. 



(a) 




After making sure all connectors have been connected properly, turn on ignition switch to check fuel 

gauge on the meter for normal display and start the engine and check fuel pipe joints of the fuel 

system for oil ooze and leak. 

Tips: The maintenance method of the other fuel filter is same as the above. In maintenance, the two 

filters are put together for check.

Fuel sensor 

Replacement 

Fuel- Fuel sensor 



3. Disconnecting fuel sensor 

(a) 


11-13 

Tip: 

There is usually dirt on the fuel sensor connector, so 

you can lightly tap it for several times with an 

appropriate tool before the operation when it is difficult 

to disconnect. 

11 

4. Disconnecting front fuel delivery pipe 

(a) 

Loosen front fuel delivery pipe joint nut. 

5. Disconnecting fuel return pipe 

(a) 

Loosen fuel return pipe joint nut.

11-14 

Fuel- Fuel sensor 

11 

6. Removing fuel sensor 

(a) 

(b) 

Loosen sealing gland of fuel sensor using fuel 


Take off fuel sensor assembly. 

Tip: 

If the fuel sensor can not be taken out due to restricted 

space, you can loosen the welding-on nut of fuel tank 

strap and turn fuel tank assembly a certain angle 

outward or lift out the tank, and then take off the sensor. 

Notices: 

• Before starting this operation, check and make 

sure there is no dirt or other foreign materials 

around the fuel sensor. When necessary, clean 

up. 

• There is a grommet in the sealing gland of the 

fuel sensor. Never damage it during the 

removal. 

• Rotate the fuel sensor until an appropriate 

angle, and then take it out gently. 

7. Installing fuel sensor 

(a) 

(b) 

Install fuel sensor onto its correct position on fuel 

tank. 

Tighten sealing gland of fuel sensor using fuel 


Notice: 

When installing the fuel sensor, be sure to rotate it to 

an appropriate angle before entry. Do not cause 

bending and deformation of fuel sensor. 

8. Connecting fuel sensor 

(a) 

Connect connector of fuel sensor. 

Notice: 

After the fuel sensor is installed, check sealing of 

its seal ring and ensure that no leakage exists. 


(a) 





(a) 

After making sure all connectors have been 

connected properly, turn on ignition switch to 

check fuel gauge on the meter for normal display 

and start the engine and check fuel pipe joints of 

the fuel system for oil ooze and leak.

Emission control 

Fuel tank cap .................................................. 12-1 

Inspection .................................................. 12-1 

12

12

Fuel tank cap 

Inspection 

Emission Control- Fuel tank cap 

1. Checking fuel tank cap assembly 

(a) 

12-1 

Visually check fuel tank cap and washer for 

deformation or damage. When necessary, 

replace fuel tank cap. 

(b) Remember to lubricate rotating parts 

periodically. 

12

12 

- Memo –

Intake 

Intake system .. ...............................................13-1 

Precautions ..... ...........................................13-1 

High mounted intake pipe ............................. 13-2 

Parts diagram ............................................ 13-2 

Replacement .............................................. 13-4 

Air cleaner assembly ......................................13-6 

Parts diagram ............................................ 13-6 

Replacement .............................................. 13-8 

13

13

Intake system 

Precautions 

Intake- Intake system 

13-1 

1. Engine intake must be filtered in order to prevent entry of dirt and chips into engine. In 

the case of intake pipe damage or looseness, unfiltered air will enter the engine and 

cause premature engine wear. 

2. Connection port of intake hose and high mounted intake pipe should be firm and 

secure without light leak and looseness, etc. 

3. Intake pipe should be connected firmly and securely with its support. Its exterior 

should be free of cracks and no air leak should occur at the joint of intake hose and it. 

4. Cushions should be bonded securely to intake pipe support. 

13

13-2 

Intake- High mounted intake pipe 

High mounted intake pipe 

Parts diagram 

13


13-3 

1 

Connection hose of intake 

connector 

6 Bracket 

2 Type A worm drive hose hoop 7 Intake hose assembly 

3 Type 1 hexagon nut 8 Hoop 

4 Intake nozzle 1 9 Hexagon flange nut 

5 

Unit-hexagon bolt, spring washer 

and plain washer 

10 Cushion unit 

11 High mounted intake pipe 

13

13-4 

Replacement 


1. Removing high mounted intake pipe 

assembly 

(a) 

(b) 

As shown in the figure, remove the bolts and 

nuts connecting high mounted intake pipe with 

cab. 

Take off high mounted intake pipe assembly. 

13 

2. Removing intake hose 

(a) 

Loosen the hoop connecting intake hose with 

high mounted intake pipe, and take off the hose.


13-5 

3. Installing intake hose assembly 

(a) 

Install intake hose to its correct position on high 

mounted intake pipe, and then tighten the fixing 

hoop. 


Notice: 

Before installing the intake hose, check it for 

fracture, air leak, etc. When necessary, replace 

intake hose assembly. 

13 

4. Installing high mounted intake pipe 

(a) 

(b) 

Install cushion unit onto high mounted intake 

pipe support. 

Install high mounted intake pipe onto its correct 

position on cab, and tighten fixing nuts and bolts. 

Torque: 21~25 N•m

13-6 

Intake-Air cleaner assembly 

Air cleaner assembly 

Parts diagram 

13

Intake- Air cleaner assembly 

13-7 

1 

Unit-hexagon bolt, spring washer 

and plain washer 

8 Intake hose of turbocharger 

2 Air cleaner bracket assembly 9 Type A worm drive hose hoop 

3 Type 1 hexagon nut 10 Type A worm drive hose hoop 

4 Assembling bolt 11 Intake hose support of air pump 

5 

Air cleaner clogging warning light 

switch 

12 Intake hose of air pump 

6 Air cleaner assembly 13 Type A worm drive hose hoop 

7 Type A worm drive hose hoop 14 Intake connector of air compressor 

13

13 

13-8 

Replacement 

1. Tilting Cab 



3. Disconnecting air cleaner clogging warning 

light switch 

(a) 



Tip: 

There is usually dirt on the sensor connector, so you 

can lightly tap it for several times with an appropriate 

tool before the operation when it is difficult to 

disconnect. 

4. Disconnecting intake air temperature sensor 

(a) 

Disconnect connector of intake air temperature 

sensor. 

5. Removing air cleaner assembly 

(a) 

Disconnect the clamp connecting air cleaner 

assembly with turbocharger intake hose. 

Notice: 

Do not allow sealing materials and any other 

materials to enter intake hose nozzle where should 

be sealed with a special plug cap. 

(b) Remove the 2 bolts connecting intake nozzle 1 

of air cleaner assembly with bracket.


13-9 

(c) 

As shown in the figure, remove the 4 bolts and 

nuts connecting air cleaner assembly with air 

cleaner bracket, and take off the assembly. 

6. Disassembling air cleaner assembly 

(a) 

Remove snap clips of lower sealing gland of air 

cleaner assembly, and take off the gland. 

13 

(b) 

(c) 

As shown in the figure, take out air cleaner 

cartridge assembly. 

When cleaning up the air cleaner cartridge 

removed, blow off dust on it from inside outward 

with compressed air while rotating the cartridge 

by hand. Compressed air pressure should be 

below 0.07MPa. 

Notices: 

• Pick and place air cleaner cartridge with 

care. Do not damage it. 

• When using compressed air, wear suitable 

goggles and face shield. Flying chips and 

dirt will cause personal injury.

13-10 


7. Assembling air cleaner assembly 

(a) 

Install air cleaner cartridge into air cleaner, and 

align the former. 

Tip: 

After the air cleaner cartridge is installed, make sure it 

is seated at correct position in the air cleaner properly. 

13 

(b) 

Install lower sealing gland of air cleaner 

assembly, and fix the gland with snap clips. 

Notices: 

• After the air cleaner is assembled, check it 

for good sealing. No looseness and air leak 

are allowed. 

• After the installation is finished, direction of 

dust bag must be correct. 

8. Installing air cleaner assembly 

(a) 

Install the 4 bolts connecting air cleaner 

assembly with air cleaner bracket, and tighten 

them. 

Torque: 73~89 N•m


13-11 

(b) 

(c) 

Connect air cleaner assembly with intake hose, 

and tighten the clamp. 


Check that junctions of intake line are tight and 

firm without looseness and air leak, etc. The 

clamp bolt should be installed in such a direction 

that it will not interfere with other places on the 

body after tightened. 

(d) 

Install the 2 bolts connecting intake nozzle 1 of 

air cleaner assembly with bracket, and tighten 

them. 


Notice: 

Air cleaner assembly should be connected firmly 

and securely with its bracket. Its exterior should be 

free of cracks and no looseness and air leak should 

occur at the joint. 

13 

9. Connecting air cleaner clogging warning 

light switch 

(a) 

Connect connector of air cleaner clogging 


10. Connecting intake air temperature sensor 

(a) 

Connect connector of intake air temperature 

sensor. 

11. Connect battery negative cable 

12. Tilting down cab

13 

- Memo –

Exhaust 

Exhaust pipe ................................................... 15-1 

Parts diagram ............................................ 15-1 

Replacement .............................................. 15-3 

15

15

Exhaust pipe 

Parts diagram 

Exhaust- Exhaust pipe 

15-1 

15

15-2 


1 Exhaust pipe joint clamp 17 Muffler clamp 

2 Exhaust pipe welded unit 18 Type 1 hexagon nut 

3 Hexagon bolt 19 Type 1 hexagon nut 

4 Exhaust pipe support 20 Large washer 

5 Type 1 hexagon nut 21 Rubber cushion 

6 Spring washer 22 Bushing 

7 Plain washer 23 Hanger plate 

8 U-trim on roof 24 Hexagon bolt 

9 Hexagon bolt 25 Rubber cushion 

10 Hexagon flange bolt 26 Hexagon bolt 

15 

11 Plain washer 27 Type 1 hexagon nut 

12 Type 1 hexagon nut 28 Spring washer 

13 Exhaust processing unit 29 Plain washer 

14 Type 1 hexagon nut 30 Support plate 

15 Spring washer 31 Hexagon bolt 

16 Plain washer

Replacement 



Caution: 

The exhaust pipe is hot, so you should not operate on it until it has completely cooled down. 

2. Disconnecting exhaust brake valve 

(a) 

Disconnect harness connector of exhaust brake valve. 

15-3 

15 

(b). Disconnect harness connector of exhaust brake valve. 

(c). Disconnect vacuum hose of exhaust brake valve.

15-4 


3. Disconnecting exhaust temperature sensor (refer to Service Manual for Cummins ISF 

Series Engines) 

4. Disconnecting nitrogen oxide sensor (refer to Service Manual for Cummins ISF Series 

Engines) 

5. Removing secondary muffler assembly (optional) 

(a)Remove the 4 bolts and nuts connecting exhaust muffler with exhaust pipe welded unit. 

15 

(b) 

(c) 

Remove exhaust brake valve assembly and fix it with a suspension hook. 

Remove the bolts and nuts connecting exhaust muffler clamp with bracket hanger plate. 

(d). Removing exhaust muffler assembly 

Notice: 

When you take off the exhaust muffler, operate using appropriate tools or with aid from 

others when necessary. 

(e). Check exhaust muffler for excessive corrosion, cracks, and air leak, etc. When necessary, 

replace.


6. Removing exhaust pipe welded assembly 

(a) 

15-5 

Loosen the clamp connecting exhaust pipe welded 

unit with exhaust manifold. 

Notice: 

Exhaust pipe welded unit is hot, so do not operate until 

making sure exhaust pipe has completely cooled down. 

15

15-6 


(b) Remove the bolts and nuts securing exhaust pipe welded unit to the bracket. 

15 

(c). Take off exhaust pipe welded assembly. 

(d) Check exhaust pipe welded unit for excessive corrosion, cracks, and air leak, etc. When 

necessary, replace.


15-7 

7. Removing exhaust temperature sensor (refer to Service Manual for Cummins ISF Series 

Engines) 

8. Removing nitrogen oxide sensor (refer to Service Manual for Cummins ISF Series 

Engines) 

9. Installing exhaust temperature sensor (refer to Service Manual for Cummins ISF 


10. Installing nitrogen oxide sensor (refer to Service Manual for Cummins ISF Series 

Engines) 

11. Installing exhaust pipe welded assembly 

(a) 

Install the bolts securing exhaust pipe welded unit to bracket temporarily. Do not tighten the 

fixing bolts until the joint clamp has been fastened. 


15 

(b) 

Install the clamp connecting exhaust pipe 

welded unit with exhaust manifold, and tighten 

the fixing clamp. 


12. Installing exhaust muffler assembly 

(a) 

Install the bolts securing exhaust muffler to bracket hanger plate temporarily. Do not tighten 

the fixing bolts until all joint clamps have been fastened. 

Torque: 41~51 N•m

-Memo- 

15 

13. Installing exhaust brake valve assembly 

(a) 

Install fixing bolts of exhaust brake valve (bolts connecting exhaust pipe welded unit with 

exhaust muffler), and tighten them to specified torque. 


Notice: 

Replace gasket with a new one. 

14. Connecting exhaust brake valve pipeline and harness connector

(a) Connecting vacuum hose at the tail end of exhaust brake valve. 

(b) 

Connecting the brake speed limiting connector. 

Fixing the harness with the bindings. 

16 

15. Checking exhaust pipe for exhaust gas leak 

(a) In the case of exhaust gas leak, tighten necessary parts to stop leak. 

damaged parts. 

If necessary, replace

15 

-Memo-

Cooling 

Cooling system .............................................. 16-1 

Precautions ............................................... 16-1 

On-vehicle inspection ................................ 16-2 

Radiator .......................................................... 16-3 

Parts diagram ............................................ 16-3 

Replacement ............................................. 16-5 

16 

Cooling fan ................................................... 16-11 

Replacement ........................................... 16-11

Cooling system 

Precautions 

Cooling- Cooling system 

16-1 

1. When disconnecting a cooling system line, collect residual coolant using a special 

vessel. If not reused, dispose of coolant as required. 

2. When disconnecting a cooling system line, never allow chips to enter it. Otherwise, 

the cooling system and engine may be damaged. 

3. When disconnecting a cooling system line joint, be sure to seal its nozzle with a 

special plug cap in order to prevent entry of dirt or foreign substances. 

4. Coolant is noxious, so keep it away from children and pets and dispose of it as 

required if it will not be reused. 

16

16 

16-2 

On-vehicle inspection 

1. Checking coolant level in surge tank 

(a) 

(b) 

Cooling- Cooling system 

Visually check that the coolant level in surge tank is between lines MIN (minimum) and MAX 

(maximum) with engine cold. 

If engine coolant level is too low, check cooling system for leakage and add “Foton 

special-purpose long-acting coolant” or similar high-quality long-acting hybrid organic acid 

technology based ethylene glycol coolant (free of silicate, amine, nitrite, and borate) to the 

MAX line. 

Notice: 

Never use water as coolant only. 

2. Checking cooling system for leakage (refer to Service Manual for Cummins ISF Series 

Engines) 

3. Checking quality of engine coolant 

Caution: 

Never open the pressure cap with engine hot. Wait and do not open the cap until coolant 

temperature drops below 50℃, otherwise ejecting hot coolant or steam may cause personal 

injury. 

(a) 

(b) 

(c) 

(d) 

Open surge tank cap. 

Put a vessel under radiator outlet to hold discharged coolant. 

Loosen water drain valve of radiator to drain a little engine coolant, and check round the 

valve for excessive rust or scale deposit. In addition, coolant can not contain engine oil. In 

the case of excessive dirt, clean the cooling system and change coolant. 

Install water drain valve of radiator, at the same time, check coolant level in surge tank. 

When necessary, add coolant to specified position. 

4. Cleaning cooling system (refer to Service Manual for Cummins ISF Series Engines)

Radiator 

Parts diagram 

Cooling-Radiator 

16-3 

16

16-4 


16 

1 Aluminum radiator with cowl assembly 


3 Large gasket 

4 Support cushion of radiator 



7 Radiator tie rod assembly 



10 Large washer 

11 Type 1 hexagon nut 

12 Tie rod adjustment cushion 




16 Type A worm drive hose hoop 


18 Engine outlet hose 

19 Radiator outlet hose 

20 Water inlet four way welding assembly 

21 Engine inlet hose 



24 Surge tank outlet hose 

25 Lower air deflector of radiator 


27 Radiator escape hose

Replacement 

1. Tilting up cab 


2. Draining cooling system (refer to Service Manual for Cummins ISF Series Engines) 

3. Disconnecting surge tank hose 

(a) 

16-5 

Loosen the fixing clamp of the hose connecting 

radiator with surge tank, and separate surge 

tank hose. 

4. Disconnecting radiator inlet hose 

(a) 

Loosen radiator inlet hose clamp, and separate 

the hose. 

16 

5. Disconnecting radiator outlet hose 

(a) Loosen radiator outlet hose clamp, and 

separate the hose. 

6. Disconnecting intercooler 

(a) 

Loosen the clamp of the hose between 

intercooler and intake steel pipe, and separate 

the pipe.

16-6 


(b) 

Loosen the fixing clamp between intercooler and 

engine intake hose, and separate the hose. 

7. Removing radiator tie rod assembly 

(a) 

Remove the nut securing radiator tie rod to 

radiator. 

16 

8. Disconnecting related components on radiator 

(a) 

Disconnect other related components connected to radiator. 

(b) 

Remove the nut securing radiator tie rod to 

frame.


16-7 

9. Removing radiator, intercooler, and cowl 

assembly 

(a) 

Loosen the nut securing radiator, intercooler, 

and cowl assembly to left side of frame. 

(b) 

Loosen the nut securing radiator, intercooler, 

and cowl assembly to right side of frame. 

(c) Take out radiator, intercooler, and cowl 

assembly. 

Notice: 

When you remove and install radiator, intercooler, 

and cowl assembly, never scratch surfaces of 

radiator and intercooler. 

16 

10. Disassembling intercooler, radiator, and 

cowl assembly 

(a) 

Remove the 4 bolts securing intercooler to 

radiator. 

(b) 

Remove the 6 bolts securing cowl to radiator.

16-8 


11. Assembling intercooler, radiator, and cowl 

assembly 

(a) 

Install cowl to radiator, and tighten the 6 fixing 

bolts. 


16 

(b) Install intercooler to radiator, and tighten the 4 

fixing bolts. 


Notices: 

• Before assembling intercooler, radiator, and 

cowl, check that there are no noticeable 

indentation and scratches, etc. on radiator 

surface. It is required that radiator inside be 

clean without foreign materials and weld 

zone be welded properly. If necessary, 

replace. 

• It is required that junction of radiator and 

cowl be sealed properly without air leak. 

12. Installing radiator, intercooler, and cowl 

assembly 

(a) 

Install the bolt securing radiator, intercooler, and 

cowl assembly to right side of frame, and tighten 

the fixing bolt temporarily. Tighten the bolt after 

the assembly has been completely fixed. 


Notice: 

The radiator assembly must be installed to correct 

position and a certain amount of fit clearance must 

be left between the assembly and the support in 

order to prevent radiator twist and deformation. 

(b) 

Install the bolt securing radiator, intercooler, and 

cowl assembly to left side of frame, and tighten 

the fixing bolt temporarily. Tighten the bolt after 

the assembly has been completely fixed. 

Torque: 73~89 N•m


16-9 

13. Installing radiator tie rod assembly 

(a) 

Install the nut securing radiator tie rod to 

radiator and tighten it to specified torque. 


(b) 

Install the nut securing radiator tie rod to frame 

and tighten it to specified torque. 


16 

14. Connecting intercooler assembly 

(a) 

Connect intercooler with engine intake hose, 

and tighten the fixing clamp. 


(b) 

Connect intercooler with intake steel pipe, and 

tighten the fixing clamps. 

Torque: 9~11 N•m

16-10 


15. Connecting radiator outlet hose 

(a) 

Connect radiator outlet hose, and tighten the 

fixing clamp. 


16 

16. Connecting radiator inlet hose 

(a) 

Connect radiator inlet hose, and tighten the 

fixing clamp. 


17. Connecting surge tank hose 

(a) 

Connect surge tank hose to radiator, and tighten 

the clamp. 


18. Connecting related components on radiator 

(a) 

Connect other related components to radiator. 

19. Filling coolant and bleeding cooling system (refer to Service Manual for Cummins ISF 


20. Tilting down cab

Cooling Fan 

Replacement 

1. Tilting up cab 

2. Removing radiator, intercooler, and cowl assembly (refer to “Chapter 16 

Cooling-Radiator, Replacement”) 

3. Removing cooling fan assembly 

(a) 

(b) 

Remove the bolts connecting cooling fan with 

belt and fan hub. 

Take off fan assembly. 

Tip: 

Before removing fan assembly, mark fan and belt 

and fan hub for easier assembly. 

4. Installing cooling fan assembly 

(a) 

Install fan assembly onto belt and fan hub 

according to the marks, and tighten fixing bolts. 


Notice: 

After the assembly, the fan should be able to rotate 

smoothly without abnormal sound and seizure. 

16 

5. Installing radiator, intercooler, and cowl assembly (refer to “Chapter 16 

Cooling-Radiator, Replacement”) 

6. Filling coolant and bleeding cooling system (refer to Service Manual for Cummins ISF 


7. Tilting down cab

16

Front Suspension 

Front Suspension Assembly...........................21-1 

Malfunction symptoms table.......................21-1 

Parts diagram .............................................21-2 

On-Vehicle Inspection ................................21-3 

Front Shock Absorber...................................... 21-4 

Overhaul ....................................................21-4 

Front leaf spring assembly ..............................21-6 

Overhaul ....................................................21-6 

21

Front Suspension-Front Suspension Assembly 

Front Suspension Assembly 


21-1 


1. Lubricant (excessive) 

- 

Oil leakage from shock 

absorber 

2. Sealing member (failure or 

damage) 

3. Shock absorber (failure) 

- 

Chapter 21 Front 

Suspension-Front Shock 

Absorber, Overhaul 





Noise from suspension unit 

2. Leaf spring (wear or 

damage) 

3. Bushing (wear or damage) 


Suspension-Front Leaf Spring 

Assembly, Overhaul 




21 

4. Bolt and nut fastening shock 

absorber to leaf spring 

assembly (loose or 

damaged) 




1. Leaf spring pin, bushing, 

shackle (wear excessive) 




Body tilts when the vehicle is 

running or parked. 

2. U-bolt (loose) 

3. Leaf springs (elastic force 

drop or stiffness 

nonuniformity) 







4. Leaf spring (broken) 



Assembly, Overhaul

21-2 

Parts diagram 


21 



3 Locating bolt of spring pin 




7 Shackle pin 

8 Shackle 



11 Connector-type forced filling oil cup 

12 Front leaf spring pin 

13 Hexagon bolt-fine thread 





18 Shock absorber pin bush 



21 Shock absorber with sleeve assembly 

22 Lower bracket of shock absorber 

23 Front U-bolt 

24 Stopper 


26 Nut 

27 Front leaf spring cover 

28 Front leaf spring assembly


1. Check shock absorber for oil leak. 


21-3 

2. Check rubber bushing of shock absorber eye for aging, cracking, and deformation. 

When necessary, replace with a new one. 

3. Remember to replace leaf spring eye bushings and leaf spring pins on a regular basis. 

4. Check U-bolts for deformation and cracks and threads for damage. When necessary, 

replace with new ones. 

5. U-bolts should be tightened in an even and cross manner. Increase tightening torque 

gradually until specified value. Leaf springs fit tightly when your vehicle is fully 

loaded; as a result, you need to retighten nuts of U-bolts. When tightening the nuts, 

prevent failure to hold down leaf springs due to bolt and nut rust causing an illusion 

of large torque. When necessary, perform a retapping until bolts and nuts fit properly. 

6. In the case of a sliding plate leaf spring, apply a layer of grease between the spring 

and its shackle bracket in order to reduce its wear. 

21

21-4 

Front Shock Absorber 

Overhaul 

Front Suspension- Front Shock Absorber 

1. Removing left front shock absorber 

(a) 

Loosen the fixing nut on its top. 

Tip: 

If the shock absorber top is a lug structure, remove in 

the same way, i.e. remove the fixing nut from the top. 

(b) 

Loosen the fixing nut on its bottom. 

21 

2. Checking shock absorber for oil leak 

(a) 

Check shock absorber for oil leak. If any, replace with a new one. 

3. Checking connecting pieces of shock absorber 

(a) 

Check connecting pieces of shock absorber such as connecting links and rubber bushings 

for damage. If any, replace with new ones. 

4. Shock absorber performance inspection 

(a) 

Press and pull the shock absorber to and fro for 2~3 times. You can deem it acceptable if its 

travel is normal and uniform without noticeable idle travel, seizure, and resistance variations 

in each whole reciprocating process and no oil leakage are found after a 24-hour horizontal 

placement; otherwise, replace with a new one.

Front Suspension- Front Shock Absorber 

21-5 

5. Installing left front shock absorber 

(a) Tighten the fixing nut on its bottom. 

1051 /1061series torques:45~55 N•m 

1099 series torques: 122~149N•m 

(b) 

Tighten the fixing nut on its top. 

1051 /1061/1089series torques:45~55 N•m 

1099 series torques: 122~149N•m 

21 

6. After-mounting shock absorber inspection 

(a) 

After shock absorbers are mounted on your vehicle, drive your car on a poor road for approx. 

10km and then stop to touch surfaces of shock absorbers. If there is a great temperature 

difference between the two shock absorbers, it means resistances on them also differ greatly 

and the one of lower temperature has smaller resistance. If surface temperature of any one 

is not above the air temperature, it means that the shock absorber has no resistance and is 

out of action, and then you should replace it with a new one. 

7. Removing right front shock absorber 

Tip: 

Follow the same removal steps for left front shock absorber to remove right front shock absorber.

21-6 

Front Suspension- Front Leaf Spring Assembly 

Front Leaf Spring Assembly 

Overhaul 

1. Removing left front shock absorber (refer to “Chapter 21 Front Suspension-Front 

Shock Absorber, Overhaul”) 

2. Removing left front leaf spring assembly 

(a) 

(b) 

Loosen nuts of U-bolts, and remove the bolts, 

front leaf spring cover, and stopper. 

Jack down slowly to lower fore axle to the 

ground smoothly. 

Notice: 

Check each U-bolt. If such damages as deformation 

and cracks are found, replace with a new one 

promptly. 

21 

(c) 

Loosen locating bolts and nuts of front-end leaf 

spring pin. 

(d) 

Remove front-end leaf spring pin and front end 

of leaf spring assembly. 

Tip: 

If the front end is a structure without leaf spring pin 

fixing bolt, you can simply remove front end of leaf 

spring assembly after the front-end leaf spring pin is 

removed.


21-7 

(e) 

Loosen fixing nuts of rear-end shackle pin. 

(f) 

Remove rear-end lower shackle pin and rear 

end of front leaf spring assembly. 

Tip: 

If a structure of shackle with sleeve assembly is 

installed at the rear end, you can not remove rear-end 

shackle pin until leaf spring pin fixing bolt is loosened 

first. 

(g) 

Remove rear-end shackle pin and shackle. 

21 

3. Measuring outside diameter of front-end leaf 

spring pin 

Vehicle model 

Outside diameter 

Standard value Limit value 

1051 series 25 mm 24.981~24.956 mm 

1061/1089 series 25mm 25~24.979 mm 

1099 series 25mm 25~24.979 mm 

If out of specification, replace leaf spring pin.

21-8 


4. Measuring inside diameter of front-end leaf 

spring pin bushing 

Vehicle model 

Inside diameter 


1051 series 25 mm 25.095~25.065 mm 

1061 series 25 mm 25.250~25 mm 

1089 series 25 mm 25.195~25.065 mm 

1099 series 25 mm 25~25.025 mm 

If out of specification, replace leaf spring pin bushing. 

5. Measuring outside diameter of rear-end 

shackle pin 

Vehicle model 



1051 series 25 mm 24.981 ~24.956 mm 

1061 series 25 mm 25 ~24.979 mm 

1089 series 25 mm 25 ~24.979 mm 

1099 series 25 mm 25 ~24.979 mm 

If out of specification, replace rear-end shackle pin. 

21 

6. Checking leaf spring for aging, cracks, breakdown, and severe rust (If any of such 

cases is found, replace the assembly.) 

7. Free camber of leaf spring assembly 

Vehicle model 

Free camber 


Limit value 

1051 series 106 mm 100~112 mm 

1061 series 122mm 112~ 128 mm 

1089 series 135mm 127 ~ 141 mm 

1099 series 128mm 

Left 122 mm/116 ~ 128 mm 

Right 122 mm/107 ~ 119 mm 

Notice: 

The left-right camber deviation should not be greater than 4mm, otherwise vehicle tilt will 

result.


21-9 

8. Installing left front leaf spring assembly 

(a) 

Install rear-end shackle and its pin. 

(b) 

(c) 

Apply a layer of grease to lower shackle pin. 

Grease: 2# lithium base grease 

Align rear eye end of front leaf spring assembly 

with the shackle, and install lower shackle pin. 

Tip: 

If a structure of shackle with sleeve assembly is 

installed, you need to install lower shackle pin fixing 

bolt after the pin is installed. When installing, align the 

half slot on the pin with the locating bolt hole. 

21 

(d) 

Tighten shackle pin fixing nuts. 

(e) 

Lift up front end of leaf spring assembly and put 

it into the bracket, and install front leaf spring pin 

and its fixing bolts. 

Tip: 

If the front end is a structure without leaf spring pin 

fixing bolt, simply install front-end leaf spring pin.

21-10 


(f) 

(g) 

Jack up front axle slowly, and slip head of leaf 

spring center bolt into front axle locating hole. 

Install stopper, front leaf spring cover, and 

U-bolts, and tighten nuts of the bolts. 

1051/1061 series torques:199~243 N•m 

1089 series torques:287~366 N•m 

21 

9. Installing left front shock absorber (refer to “Chapter 21 Front Suspension-Front 

Shock Absorber, Overhaul”) 

10. Retighten nuts of U-bolts after a 3~5km travel. 



11. Removing right front leaf spring assembly 

Tip: 

Follow the same removal steps for left front leaf spring assembly to remove right front leaf spring 

assembly.

Rear Suspension 

Rear Suspension Assembly .............................22-1 

Malfunction symptoms table .......................22-1 

Parts diagram.............................................. 22-2 

On-Vehicle Inspection................................. 22-3 

Rear Shock Absorber .......................................22-4 

Overhaul .....................................................22-4 

Rear Leaf Spring Assembly ............................. 22-6 

Overhaul .....................................................22-6 

22

22

Rear Suspension- Rear Suspension Assembly 

Rear Suspension Assembly 


22-1 


1. Lubricant (excessive) 

- 

Oil leakage from shock 

absorber 

2. Sealing member (failure or 

damage) 


- 

Chapter 22 Rear Suspension-Rear 

Shock Absorber, Overhaul 




Noise from suspension unit 

2. Leaf spring (wear or damage) 

3. Bushing (wear or damage) 


Leaf Spring Assembly, Overhaul 



4. Bolt and nut fastening shock 

absorber to leaf spring 

assembly (loose or damaged) 



Body tilts when the vehicle is 

running or parked. 

1. Leaf spring pin, bushing, 

shackle (wear excessive) 

2. U-bolt (loose) 

3. Leaf springs (elastic force drop 

or stiffness nonuniformity) 







22 

4. Leaf spring (broken) 


Leaf Spring Assembly, Overhaul

22-2 

Parts diagram 


22 



3 Type 1 hexagon nut-fine thread 





8 

Rear shock absorber assembly with 

sleeve 

9 Leaf spring pin 

10 Through-type forced filling oil cup 


13 Rear leaf spring pressure plate 


15 Hexagon thick nut 

16 Washer 



19 Shackle with sleeve assembly 





12 Rear leaf spring U-bolt


1. Check shock absorber for oil leak. 


22-3 

2. Check rubber bushing of shock absorber eye for aging, cracking, and deformation. 

When necessary, replace with a new one. 

3. Remember to replace leaf spring eye bushings and leaf spring pins on a regular basis. 

4. Check U-bolts for deformation and cracks and threads for damage. When necessary, 

replace with new ones. 

5. U-bolts should be tightened in an even and cross manner. Increase tightening torque 

gradually until specified value. Leaf springs fit tightly when your vehicle is fully 

loaded; as a result, you need to retighten nuts of U-bolts. When tightening the nuts, 

prevent failure to hold down leaf springs due to bolt and nut rust causing an illusion 

of large torque. When necessary, perform a retapping until bolts and nuts fit properly. 

6. In the case of a sliding plate leaf spring, apply a layer of grease between the spring 

and its shackle bracket in order to reduce its wear. 

22

22-4 

Rear shock absorber 

Overhaul 

Rear Suspension- Rear shock absorber 

1. Removing left rear shock absorber 

(a) Loosen the fixing nut on its top. 

(b) 

Loosen the fixing nut on its bottom. 

22 

2. Checking shock absorber for oil leak 

(a) 

Check shock absorber for oil leak. If any, replace with a new one. 

3. Checking connecting pieces of shock absorber 

(a) 

Check connecting pieces of shock absorber such as connecting links and rubber bushings 

for damage. When necessary, replace with new ones.

4. Shock absorber performance inspection 

(a) 

Rear Suspension- Rear shock absorber 

22-5 

Pull and press the shock absorber to and fro for 2~3 times. You can deem it acceptable if its 

travel is normal and uniform without noticeable idle travel, seizure, and resistance variations 

in each whole reciprocating process and no oil leakage are found after a 24-hour horizontal 

placement; otherwise, replace with a new one. 

5. Installing left rear shock absorber 

(a) 

Tighten the fixing nut on its bottom. 




1099 series torques: 199~243 N•m 

(b) 

Tighten the fixing nut on its top. 





22 

6. After-mounting shock absorber inspection 

(a) 

After shock absorbers are mounted on your vehicle, drive your car on a poor road for approx. 

10km and then stop to touch surfaces of shock absorbers. If there is a great temperature 

difference between the two shock absorbers, it means resistances on them also differ greatly 

and the one of lower temperature has smaller resistance. If surface temperature of any one 

is not above the air temperature, it means that the shock absorber has no resistance and is 

out of action, and then you should replace it with a new one. 

7. Removing right rear shock absorber 

Tip: 

Follow the same removal steps for left front shock absorber to remove right rear shock absorber.

22-6 

Rear Suspension- Rear Leaf Spring Assembly 

Rear Leaf Spring Assembly 

Overhaul 

1. Removing left rear shock absorber (refer to “Chapter 22 Rear Suspension-Rear Shock 

Absorber, Overhaul”) 

2. Removing left rear leaf spring assembly 

(a) 

(b) 

Loosen nuts of U-bolts, and remove the bolts 

and rear leaf spring cover. 

Jack down slowly to lower rear axle to the 

ground smoothly. 

Notice: 

Check each U-bolt. If such damages as deformation 

and cracks are found, replace promptly. 

(c) 

Loosen locating bolts of front-end leaf spring pin. 

22 

(d) 

Remove front-end leaf spring pin and front end 

of leaf spring assembly.


22-7 

(e) 

Loosen locating bolts of rear-end leaf spring pin. 

(f) 

Remove rear-end leaf spring pin and rear end of 

rear leaf spring assembly. 

(g) 

Remove shackle with sleeve assembly and 

shackle pin. 

22 

3. Measuring outside diameter of front-end leaf 

spring pin 

Vehicle model 



Limit value 

1051 25 mm 24.981~24.959 mm 

1061 30mm 30 ~ 29.979 mm 

1089 30mm 24.980~ 24.979 mm 

1099 30mm 30 ~ 29.979 mm 

If out of specification, replace leaf spring pin.

22-8 


4. Measuring inside diameter of front-end leaf 


Vehicle model 



1051 25 mm 25.195~25.065 mm 

1061 30mm 30.250 ~ 30 mm 

1089 30mm 30.230~30.080 mm 

1099 30mm 30~ 30.25 mm 

If out of specification, replace leaf spring 

pin bushing. 

5. Measuring outside diameter of rear-end 

shackle pin 

Vehicle model 



1051 25 mm 24.981~24.959 mm 

1061 30mm 30 ~29.979 mm 

1089 30mm 30 ~29.979 mm 

1099 30mm 30 ~29.979 mm 

22 

If out of specification, replace shackle pin. 

6. Measuring inside diameter of shackle pin 

bushing 

Vehicle model 



1051 25 mm 25.250~25mm 

1061 30mm 30.250~30 mm 

1089 30mm 30.033~30 mm 

1099 30mm 30.~ 30.2 mm 

If out of specification, replace bushing.


22-9 

7. Measuring inside diameter of leaf 


Vehicle 


model Standard value Limit value 

1051 25 mm 25.072~25.020 mm 

1061 30mm 30.020~30.100 mm 

1089 30mm 30.033~30 mm 

1099 30mm 30~ 30.25 mm 

If out of specification, replace bushing. 

8. Checking main and assist springs of leaf spring for aging, cracks, breakdown, and 

severe rust (If any, replace the assembly.) 

9. Free camber of assist spring of leaf spring 

Vehicle model 


Camber 

Limit value 

1051 67 mm 61~73 mm 

1061 56mm 50~62 mm 

1089 40mm 34~56 mm 

1099 56mm 50~62 mm 

Notice: 

The left-right camber difference should not be greater than 4mm, otherwise body tilt will result. 

22 

10. Free camber of main spring of leaf spring 

Vehicle model 


Camber 

Limit value 

1051 125 mm 119~131 mm 

1061 115mm 109~121 mm 

1089 123mm 117~129 mm 

1099 115mm 109~121 mm 

Notice: 

The left-right camber difference should not be greater than 4mm, otherwise body tilt will result.

22-10 


11. Installing rear leaf spring assembly 

(a) 

Install shackle with sleeve assembly and shackle 

pin. 

22 

(b) 

(c) 

Apply a layer of grease to leaf spring pin. 


Align rear eye end of leaf spring assembly with 

shackle with sleeve assembly, and install leaf 

spring pin. 

Notice: 

When reeving leaf spring pin, align the half slot on 

the pin with the locating bolt hole. 

(d) 

Tighten leaf spring pin locating bolt. 

(e) Lift up front end of leaf spring assembly and put it 

into the bracket, and install rear leaf spring pin. 

Notice: 

When reeving leaf spring pin, align the half slot on 

the pin with the locating bolt hole.


22-11 

(f) 

Tighten leaf spring pin locating bolt. 

(g) 

(h) 

Jack up rear axle slowly, and slip head of leaf 

spring center bolt into rear axle locating hole and 

rear leaf spring center hole. 

Install rear leaf spring cover and U-bolts, and 

tighten nuts of the bolts. 





22 

12. Installing left rear shock absorber (refer to “Chapter 22 Rear Suspension-Rear Shock 

Absorber, Overhaul”) 

13. Retighten nuts of U-bolts after a 3~5km travel. 

Torques:396~465 N•m 

14. Removing right rear leaf spring assembly 

Tip: 

Follow the same removal steps for left rear leaf spring assembly to remove right rear leaf spring 

assembly.

22 

-Memo-


Wheel and Tire Assembly .................................23-1 

Precautions ................................................23-1 

Malfunction symptoms table ......................23-2 

On-Vehicle Inspection ...............................23-3 

Adjustment ................................................23-6 

Front Wheel and Tire .........................................23-7 

Parts diagram ............................................23-7 

Replacement .............................................23-8 

Rear Wheel and Tire .........................................23-10 

Parts diagram .........................................23-10 

Replacement ..........................................23-11 

23

23

Wheels and Tires-Wheel and Tire Assembly 

Wheel and Tire Assembly 

Precautions 

23-1 

1. The special tool must be used when you remove and install a tire. It is not allowed to 

remove and install a tire by knocking on it using a sledge hammer or by using other 

sharp tools. 

2. Mixed use of tires of different specifications, ply ratings, tread patterns, pressures, 

and loads is not allowed. 

3. When installing a directional tread pattern tire, pay attention to its mark of rolling 

direction. 

4. In the case of a double tire, remember to align vent holes of the 2 wheels, stagger the 

2 tire valves 180°, and leave the tire normal to the shoe to hub clearance inspection 

hole on the brake hub. 

5. Be sure to perform tire rotation every 5,000~6,000km travel in order to achieve even 

wear of tires. 

6. After a tire rotation, readjust tire pressure according to requirements for 

corresponding tire position. 

7. Tire inflation should be made according to the standard pressure specified in the 

owner’s manual for this model and be measured with an air pressure gauge with tires 

cold; before inflation, check if valve core and valve fit flatly, and wipe dust; charged 

air should not contain moisture and oil mist. After inflation, check for air leak, and 

tighten tire valve cap. 

8. Have a good knowledge of inflation standard, check air pressure and recharge in 

good time, and keep tire pressure moderate. 

9. Check and adjust front wheel toe-in periodically to avoid unnecessary increases in 

running resistance and fuel consumption which could even accelerate tire wear. 

23

23-2 




23 

Abnormal tire wear 

Front wheel shimmy or jitter 

Bad ride during travel 

Front wheel sideslip 

1. Tire toe-in (out of specification) 

2. Tire (pressure out of 

specification) 

3. Wheel (unbalance) 

4. Steering mechanism 

(deformation) 

1. Front wheel (pressure different) 

2. Wheel (unbalance) 


4. Steering mechanism (seriously 

worn) 

1. Tire (pressure too high) 


3. Leaf spring (failure) 

1. Tire toe-in (out of specification) 

2. Tire (pressure out of 

specification) 

Chapter 24 Front Axle-Front 

Wheel Alignment, Adjustment 

Chapter 23 Wheels and 

Tires-Wheel and Tire Assembly, 




Adjustment 


Mechanism-Steering Stand, 

Replacement 






Adjustment 





Mechanism-Steering Stand, 

Replacement 














Chapter 24 Front Axle-Front 

Wheel Alignment, Adjustment 



On-Vehicle Inspection


1. Checking tread pattern depth 

Depth: ≥ 1.6 mm 


If tread pattern depth is out of limits, replace with a new tire. 

Notice: 

Be sure to replace tires at left and right sides in pairs. 

2. Checking for abnormal tire wear 

(a) 

23-3 

Check tire shoulder for wear. If any, check for 

tire inflation underpressure and frequent 

overload. Perform tire rotation after a pressure 

adjustment. 

Underinflation 

Tire shoulder wear 

(b) 

Check middle of tire tread for wear. If any, check 

for tire overinflation. Perform tire rotation after a 

pressure adjustment. 

23 

Overinflation 

Tread middle wear

23-4 


(c) 

Check tire inside for wear. If any, take 

care to avoid turning at high speed. 

Check suspension components for 

looseness and for normal camber angle. 

Perform tire rotation after an adjustment. 

Inside 

Inside wear 

(d) 

Check tire outside for wear. If any, take 

care to avoid turning at high speed. 

Check suspension components for 

looseness and for normal camber angle. 

Perform tire rotation after an adjustment. 

Inside 

23 

Outside wear 

Direction of travel 

(e) 

Check tire for feather wear. If any, check 

toe-in and adjust. Perform tire rotation 

after the adjustment. 

Slip 

direction 

of tire 

Inside 

Inside 

Toe-in wear


23-5 

(f) 

Check tire for ripple wear. If any, check tire for 

standard inflation pressure and correct camber 

angle and toe-in, and wheel bearing for 

looseness or wear, and adjust. Perform tire 

rotation after the adjustment. 

Direction of 

rotation 

3. Inspecting inflation pressure of a cold tire 

Tire size 

Inflation pressure 

8.5R17.5 

0.625Mpa 

215/75R17.5 

0.760Mpa 

8.25R20 0.830 MPa 

8.25R16 0.670 MPa 

7.50R16 0.770 MPa 

7.00R16 0.670 MPa 

If tire size or inflation pressure is nonconforming, adjust or replace as needed. 

4. Checking crown, shoulder, and sidewall of a tire 

If such defects as internal damage, delamination, bulging and deformation are found at crown, 

shoulder, or sidewall of a tire, the tire must be replaced with a new one. 

5. Checking tire valve 

If a valve core is found leaky, replace promptly. 

6. Checking rim and circlip 

If deformation or rust causing damage is found, replace promptly. 

7. Checking tire bolts 

If not tightened, retighten them one by one according to the standard. 





23

23-6 

Adjustment 


1. Tire rotation 

(a) 

(b) 

(c) 

Figure A shows the case that spare tire is not 

involved in rotation. 

Figure B shows the case that spare tire is 

involved in cycle rotation. 

Figure C shows the case that spare tire is 

involved in cross rotation. 

23 

2. Dynamic balancing of a tire 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

(j) 

(k) 

Clear the wheel to be tested of dust, stones and 

used weights. 

Check tire pressure and adjust to original 

requirement. 

Select a cone according to size of rim center 

hole. Install the wheel carefully and tighten using 

quick nut. 

Power on dynamic balancer. 

Measure rim width. 

Measure rim diameter. 

Measure rim edge to dynamic balancer distance. 

Drop wheel shield, and start the test. 

Wait until the test is finished, and then install 

weights firmly according to the unbalanced 

positions and unbalances indicated by the 

machine. 

Test again, and adjust until dynamic balance is 

satisfactory. 

Remove the tire. 

3. Front wheel toe-in (refer to “Chapter 24 Front Axle-Front Wheel Alignment, 

Adjustment”)

Front Wheel and Tire 

Parts diagram 

Wheels and Tires-Front Wheel and Tire 

23-7 

1. Rim assembly 3. Tire 

23 

2. Tire nut 4. Circlip

23-8 

Replacement 


1. Pulling up hand brake and choking rear wheel with wedges 

2. Jacking up front end of vehicle 

3. Removing left front wheel 

(a) Loosen left front tire nut. 

(a) 

Remove left front wheel. 

23


23-9 

4. Installing front wheels 

(a) 

Install left front wheel. 

(b) 

Tighten left front tire nut. 


23 

5. Removing wedges 

6. Removing right front wheel 

Tip: Follow the same removal steps for left front wheel to remove right front wheel.

23-10 

Rear Wheel and Tire 

Parts diagram 

Wheels and Tires-Rear Wheel and Tire 

23 

1 wheel rim assy 

2 tire 


4 Air noizzle extention pipe and helmet 

5 Tire nuts

Replacement 


1. Pulling up hand brake and choking front wheel with wedges 

2. Jacking up front end of vehicle 

3. Removing left rear wheel 

(a) 

23-11 

Loosen left rear outer tire nut, and remove left 

rear outer wheel. 

(b) 

Remove left rear inner wheel. 

23

23-12 


4. Installing left rear wheel 

(a) 

Install left rear inner wheel. 

23 

(b) 

Install left rear outer wheel, and tighten left rear 

outer tire nut. 





5. Lowering rear end of vehicle 

6. Removing right rear wheel 

Tip: Follow the same removal steps for left rear wheel to remove right rear wheel.

Front Axle 

Front Axle Assembly ...................................... 24-1 

Malfunction symptoms table ....................... 24-1 

Front Wheel Alignment ................................... 24-4 

Adjustment .................................................. 24-4 

Front Wheel Hub Bearing ............................. 24-10 

On-Vehicle Inspection ............................... 24-10 

Front Wheel Hub with Brake Drum Assy.... 24-12 

Parts diagram ........................................... 24-12 

Overhaul ................................................... 24-13 

Steering Linkage ........................................... 24-21 

Parts diagram ........................................... 24-21 

Overhaul ................................................... 24-24 

Steering Knuckle ........................................... 24-37 

Parts diagram ........................................... 24-37 

Overhaul ................................................... 24-42 

Front Axle ....................................................... 24-49 

Overhaul ................................................... 24-49 

24

24

Front Axle Assembly 

Front Axle-Front Axle Assembly 


24-1 



Symptom Suspected area Reference 

Steering 

heaviness 

1. Fore axle (overload) 

2. Tire (wear) 

3. Tire (pressure too low) 

4. Front wheel alignment (incorrect) 

5. Steering fluid (lack) 

6. Ball pin (too tight or too loose) 

7. Steering shaft (bending or bearing 

too tight) 

8. Steering gear (wear or damage) 

9. Front wheel bearing (installed 

oppositely) 

10. Knuckle pin (clearance too small) 

- 

Chapter 23 Wheels and Tires-Wheel and 

Tire Assembly, On-Vehicle Inspection 



Chapter 24 Front Axle-Front Wheel 

Alignment, Adjustment 

Chapter 42 Power Steering-Power Steering 

System, On-Vehicle Inspection 

Chapter 42 Power Steering-Steering Fluid, 

Replacement 

Chapter 24 Front Axle-Steering Linkage, 

Overhaul 

Chapter 41 Steering Mechanism-Steering 

Column Assembly, Overhaul 

Chapter 42 Power Steering-Steering Gear 

with Rocker Arm Assembly, Overhaul 

Chapter 24 Front Axle-Front Wheel Hub with 

Brake Drum Assembly, Overhaul 

Chapter 24 Front Axle-Steering Knuckle, 

Overhaul 

24

24-2 



24 


jitter 

Uncomfortable 

ride 

1. Tire (pressure different) 


3. Shock absorber (damage) 

4. Front leaf spring (looseness or damage) 

5. Wheel and tire assembly (unbalance or 

wear) 

6. Steering gear (looseness or damage) 

7. Brake drum (unbalance) 

8. Front wheel bearing (wear) 

9. Knuckle pin (too tight) 

10. Steering knuckle (deformation) 

11. Frame (deformation) 

1. Tire (type incorrect) 

2. Tire (pressure too high) 


4. Caster angle (incorrect) 

5. Leaf spring (failure) 

6. Steering gear (abnormal) 





Chapter 21 Front Suspension-Front Shock 


Chapter 22 Rear Suspension-Rear Shock 


Chapter 21 Front Suspension-Front 

Suspension Assembly, On-Vehicle 

Inspection 

Chapter 21 Front Suspension-Front Leaf 

Spring Assembly, Overhaul 




Tire Assembly, Adjustment 



Chapter 26 Service Brake-Front Wheel 

Brake, Overhaul 

Chapter 24 Front Axle-Front Wheel Hub 

with Brake Drum Assembly, Overhaul 


Overhaul 


Overhaul 

- 













Chapter 22 Rear Suspension-Rear Leaf 



with Rocker Arm Assembly, Overhaul


24-3 


Vehicle pulls to 

one side during 

travel 

Abnormal sound 

during travel 

Abnormal tire 

wear 

1. Tire (size different) 

2. Tire (pressure different) 


4. Brake (grab) 

5. Shock absorber (damage) 

6. Front leaf spring (fatigue or damage) 

7. Front wheel bearing (loose) 

8. Fore axle (bending) 

9. Rear axle housing (deformation) 

1. Shock absorber (loose) 

2. Drag link end (wear or damage) 

3. Steering gear (looseness or wear) 

4. Front wheel bearing (loose) 

1. Vehicle (overload) 

2. Driving mode (bad) 

3. Tire (pressure incorrect) 

4. Wheel and tire assembly (eccentric or 

deformed) 


6. Ball pin (too tight or too loose) 

7. Front wheel bearing (looseness or wear) 

8. Knuckle pin (too tight or too loose) 

9. Steering knuckle (bending or 

deformation) 

Chapter 23 Wheels and Tires-Wheel and Tire 

Assembly, On-Vehicle Inspection 





Chapter 26 Service Brake-Front Wheel Brake, 

Overhaul 

Chapter 26 Service Brake-Rear Wheel Brake, 

Overhaul 





Chapter 21 Front Suspension-Front 

Suspension Assembly, On-Vehicle Inspection 




Bearing, On-Vehicle Inspection 

Chapter 24 Front Axle-Fore Axle, Overhaul 

Chapter 24 Rear Axle-Rear Axle Assembly, 







Overhaul 





- 

- 




Assembly, Adjustment 




Overhaul 




Overhaul 


Overhaul 

24

24-4 

Front Wheel Alignment 

Adjustment 

Front Axle-Front Wheel Alignment 

1. Preparations for checking front wheel alignment 

(a) 

(b) 

(c) 

(d) 

Park your vehicle. 

• Be sure to keep your vehicle idle and park it on a firm and flat road. 

Check wheel and tire assembly. 

• Check tire pressure and adjust as needed. (Reference “Chapter 23 Wheels and 

Tires-Wheel and Tire Assembly, On-Vehicle Inspection”.) 

• Check tire wear. (Reference “Chapter 23 Wheels and Tires-Wheel and Tire Assembly, 

On-Vehicle Inspection”.) 

• Check rim deformation. 

Check frame. 

• Check frame for distortion or bending. 

Check front axle. 

• Check front axle and ensure that its axis is normal to vehicle heading. 

2. Checking camber angle, and knuckle pin caster angle and inclination angle 

(a) 

Park your vehicle and make heights of rear wheel and turning angle gauge equal. 

(b) 

Right steering wheel to set front wheel straight 

ahead. 

24 

(c) Check tire pressure. (Reference “Chapter 23 

Wheels and Tires-Wheel and Tire Assembly, 


(d) 

(e) 

Position front wheel to center of turning angle 

gauge dial slowly, and adjust reading of the 

gauge to “zero”. 

Remove front wheel hub cap, and install a front 

wheel alignment meter onto rim horizontally.


24-5 

(f) 

View center of bubble on camber gauge, and 

read out camber angle. 

Standard value: 1° 

Limit value: 45’~1°15’ 

If camber angle is out of limits, check: 

• Wear of knuckle pin and bushing 

• Wheel hub bearing clearance 

• Front axle bending 

Service or replace as needed. 

(g) 

Tips: 

Turn steering wheel slowly to change wheel 

angle from 0° to 20°. 

• If left wheel is measured, turn steering wheel to 

the left. 

• If right wheel is measured, turn steering wheel to 

the right. 

(h) 

View center of bubble on caster gauge, and read 

out knuckle pin caster angle. 

Caster angle: 1051 series 3° 

1061 series 2°24' 

1089/1099 series 3°30' 

If knuckle pin caster angle is nonconforming to standard 

value, check: 





24

24-6 


3. Checking front wheel toe-in 

(a) 

With your vehicle unladen, park it on a flat road. 

(i) 

View center of bubble on inclination gauge, and 

read out knuckle pin inclination angle. 

Inclination angle:1051/1061/1099 series 

stardard value 8°; Limit value 7°45’~8°15’ 

Inclination angle:1089 series stardard value 

7°30’; Limit value 7°15’~7°45’ 

If knuckle pin inclination angle is out of limits, check: 





(b) 


ahead. 

24 

(c) Check tire pressure. (Reference “Chapter 23 

Wheels and Tires-Wheel and Tire Assembly, 


(d) 

Using toe-in gauge, mark centers (on treads) of 

fore parts of the 2 front wheels respectively, and 

measure the distance between the 2 mark points 

(designated S1).


24-7 

(e) 

(f) 

Push your vehicle slowly to allow front wheel to 

roll 1/2 turn forward exactly. At this time, the 2 

mark points have turned to rear part of front 

wheel. 

Using toe-in gauge, remeasure the distance 

between the 2 mark points (designated S2). 

(g) 

The difference between the two values is front 

wheel toe-in (S=S2-S1). 

Radial ply tire: 1~3 mm 

Bias tire: 2~4 mm 

If front wheel toe-in is out of the specified range, be 

sure to adjust. 

Notices: 

• If toe-in is out of the range, running 

resistance and fuel consumption will 

increase so that tire wear is aggravated. 

• Front wheel toe-in will change with knuckle 

pin wear, so you must check and adjust it 

periodically. 

24

24-8 


4. Adjusting front wheel toe-in 

(a) 


ahead. 

(b) 

Loosen fastening nut of tie rod left end 

assembly. 

24 

(c) 

Loosen fastening nut of tie rod right end 

assembly. 

Tip: 

Follow the same steps for loosening fastening nut of tie 

rod left end assembly to loosen fastening nut of tie rod 

right end assembly. 

(d) 

Hold tie rod shaft and turn it until front wheel toe-in 

is adjusted to within the specified range. 

Radial ply tire: 1~3 mm 

Bias tire: 2~4 mm 

(e) 

Tighten fastening nut of tie rod left end 

assembly. 

1051/1061 series torques: 40~50 N•m 

1089/1099 series torques: 70~90 N•m


24-9 

5. Checking steering locking angle of front wheel 

(a) 

(b) 

(f) 

Turn steering wheel to the left and right. 

Tighten fastening nut of tie rod right end 

assembly. 

Tip: 

Follow the same steps for tightening fastening nut of tie 

rod left end assembly to tighten fastening nut of tie rod 

right end assembly. 

Measure both leftward and rightward steering locking angles of front wheel 

1051/1089/1099 series steering locking angle: Inner wheel 35° ; Outer wheel 27° 

1061 series Inner wheel 35°Outer wheel 28° 

If steering locking angles of front wheel are nonconforming to the specified values, adjust. 

(Reference “Chapter 24 Front Axle-Steering Knuckle, Overhaul”.) 

6. Adjusting steering locking angles of front wheel 

(a) 

Turn steering wheel to the left and right. 

(b) 

Screw steering knuckle stopper bolt to 

adjust steering locking angles of front 

wheel. 

Steering locking angles: 

1051/1089/1099 series Inner wheel 35° ; 

Outer wheel 27° 

1061 series Inner wheel 35°Outer wheel 28° 

Tip: 

When front wheel reaches its steering locking 

angle, steering knuckle stopper bolt should be 

held by the boss on fore axle. 

24 

(c) Tighten fastening nut of steering 

knuckle stopper bolt. 

Torque: 80~100 N•m

24-10 

Front Axle-Front Wheel Hub Bearing 

Front Wheel Hub Bearing 


1. Checking noise from front wheel hub bearing 

(a) 

Perform road test on a flat road surface, and make sharp left or right turns during straight 

driving to check if front wheel hub bearing produces noise. 

Tips: 

• If your vehicle produces noise during right turn, it indicates that you may need to replace left 

front wheel hub bearing with a new one. Then, check left front wheel hub bearing clearance. 

• If your vehicle produces noise during left turn, it indicates that you may need to replace right 

front wheel hub bearing with a new one. Then, check right front wheel hub bearing 

clearance. 

• If your vehicle produces noise during both left turn and right turn, check the side with heavier 

noise in the same way above. 

2. Checking left front wheel hub bearing clearance 

(a) 

Park your vehicle on a firm and flat road. 

(b) 

Swing upper and lower ends of left front wheel to 

check wheel bearing for looseness. 

24 

(c) 

Rotate left front wheel quickly by hand to check 

that it should rotate smoothly without noise.

Front Axle-Front Wheel Hub Bearing 

24-11 

3. Checking right front wheel hub bearing clearance 

(d) Remove left front wheel and tire 

assembly. (Reference “Chapter 23 


Assembly, Replacement”.) 

(e) 

(f) 

Secure a dial indicator to the bracket and 

allow it to come into contact with side face 

of left front wheel hub. 

Push and pull left front wheel hub 

horizontally to check for displacement. 

Tip: 

There should be no displacement, otherwise 

replace with a new left front wheel hub bearing. 

(Reference “Chapter 24 Front Axle-Front Wheel 

Hub with Brake Drum Assembly, Overhaul”.) 

Tip: 

Follow the same steps for checking left front wheel hub bearing clearance to check right front wheel 

hub bearing clearance. 

24

24-12 

Front axle-front wheel hub with brake drum assembly 

Front Wheel Hub with Brake Drum Assembly 

Parts diagram 

24 

1 Oil seal ring 

2 Oil seal 

3 Outer tapered roller bearing 

4 Brake caliper assy 

5 Brake drum 

6 Front wheel hub 

10 Tyre nut 

11 Locking washer 

12 Split pin 

13 Steering knuckle nut 

14 Front wheel hub cap 

15 Mud cover assy 

7 Wheel hub connecting belt , indented bolt 

8 Outer tapered roller bearing 

9 Wheel hub bolt

Overhaul 


24-13 

1. Removing front wheel and tire assembly (reference “Chapter 23 Wheels and 

Tires-Front Wheel and Tire Assembly, Replacement”) 

2. Removing left front wheel hub with brake 

drum assembly 

(a) 

Pry off dust cover, and remove left front wheel 

hub cap. 

(b) 

Remove split pin and nut of front steering 

knuckle lock nut. 

Notice: 

Be sure to keep them clean during storage. 

(c) 

Take off .steering knuckle nut locking washer. 

Notice: 

Do not reuse removed split pin. 

24 

(d) 

Take off outer taped roller bearing.

24-14 


(e) 

Take off inner race of outer tapered roller 

bearing of left front wheel hub. 

Notice: 

Be sure to store it with care. Never drop it from a 

height so as to avoid damage to bearing. 

(f) 

Remove left front wheel hub with brake drum 

assembly. 

3. Removing right front wheel hub with brake drum assembly 

Tip: 

Follow the same removal steps for left front wheel hub with brake drum assembly to remove right 

front wheel hub with brake drum assembly. 

4. Separating left front wheel hub from brake 

drum 

(a) 

Loosen the 5 nuts, and separate left front wheel 

hub from brake drum. 

Notice: 

Do not reuse removed nuts. 

24 

5. Separating right front wheel hub from brake drum 

Tip: 

Follow the same steps for separating left front wheel hub from brake drum to separate right front 

wheel hub from brake drum. 

6. Removing front brake assembly (reference “Chapter 26 Service Brake-Front Wheel 

Brake, Overhaul”) 

7. Removing left front wheel hub oil seal 

(a) 

Using sharp nose pliers, take off the oil seal 

from left front wheel hub. 

Notice: 

Do not reuse removed oil seal.


24-15 

(b) 

Using puller, remove left front wheel hub oil seal 

ring. 

• At the same time, take off inner race of 

inner tapered roller bearing of left front 

wheel hub. 

Notice: 

Do not reuse removed oil seal ring. 

8. Removing left front wheel hub bearing 

(a) 

Take off inner race of inner tapered roller 

bearing of left front wheel hub from left steering 

knuckle. 

(b) 

Using copper bar, take off outer race of outer 

tapered roller bearing from left front wheel hub. 

24 

(c) 

Using copper bar, take off outer race of inner 

tapered roller bearing from left front wheel hub. 

9. Removing right front wheel hub oil seal 

Tip: 

Follow the same removal steps for left front wheel hub oil seal to remove right front wheel hub oil seal. 

10. Removing right front wheel hub bearing 

Tip: 

Follow the same removal steps for left front wheel hub bearing to remove right front wheel hub 

bearing.

24-16 

11. Checking front wheel hub 

(a) 

(b) 


Check front wheel hub for cracking and loose thread. 

If any of above defects is found, replace with a new front wheel hub. 

Check wear of support necks of inner and outer bearings of front wheel hub. 

Standard: Inner and outer support necks and outer races of inner and outer bearings 

of front wheel hub form tight fit respectively without looseness. 

If loose fit is found between a support neck and corresponding bearing outer race, correct or 

replace as needed. 

12. Checking front brake drum 

(a) 

Check wear of front brake drum, and replace with a new one as needed. 

13. Connecting left front wheel hub with brake 

drum 

(a) 

tighten 5 nuts and connect left front wheel hub 

with brake drum . 

1051 series torques:287~336N•m 

1061/1089/1099 series torques:396~465N•m 

Notice: 

Be sure to replace with new nuts. 

(b) 

Do thread sealing at 3 places on each nut in 

order to prevent looseness. 

24 

14. Connecting right front wheel hub with brake drum 

Tip: 

Follow the same steps for connecting left front wheel hub with brake drum to connect right front 

wheel hub with brake drum. 

15. Installing left front wheel hub bearing 

(a) 

Grease outer race of inner tapered roller 

bearing, and press it onto left rear wheel hub 

using copper bar. 

Grease: 2# lithium base grease


24-17 

(b) 

Grease outer race of outer tapered roller 

bearing, and press it onto left rear wheel hub 

using copper bar. 


(c) 

Fill left front wheel hub with plenty of grease 

until 1/3 volume of its chamber is occupied. 


16. Installing left front wheel hub oil seal 

(a) 

Heat oil seal ring to allow it to expand, and 

press it onto left steering knuckle using special 

die. 

• At the same time, press inner race of 

inner tapered roller bearing onto left 

steering knuckle using copper bar, and 

apply grease. 


Notice: 

Be sure to replace with new oil seal ring. 

(b) 

Coat oil seal with grease, and install it onto left 

front wheel hub using sharp nose pliers. 


Notice: 

Be sure to replace with new oil seal. 

24 

17. Installing right front wheel hub bearing 

Tip: 

Follow the same installation steps for left front wheel hub bearing to install right front wheel hub 

bearing. 

18. Installing right front wheel hub oil seal 

Tip: 

Follow the same installation steps for left front wheel hub oil seal to install right front wheel hub oil 

seal.

24-18 


19. Installing front brake assembly (reference “Chapter 26 Service Brake-Front Wheel 


20. Installing left front wheel hub with brake 

drum assembly 

(a) 

Put left front wheel hub with brake drum 

assembly on left steering knuckle. 

Tip: 

Slip left steering knuckle through centers of inner and 

outer tapered roller bearings of left front wheel hub. 

(b) 

(c) 

(d) 

Grease inner race of outer tapered roller bearing 



Install inner race of outer tapered roller bearing 


Grease left steering knuckle threads and 

lockwasher of left steering knuckle nut. 


(e) 

Install left steering caliper. 

24 

(f) 

Install left steering knuckle nut. 

Tip: 

In this step, simply tighten left steering knuckle nut, but 

torque value is not required. 

(g) 

(h) 

Rotate left front wheel hub 2~3 turns by hand in 

order to allow front wheel hub bearing to enter 

correct position. 

Tighten left steering knuckle nut, and insert split 

pin. 



• After tightening, return approx. 30° to 

align split pin hole with left steering 

knuckle nut notch. 

• Be sure to replace with a new split pin.


24-19 

(i) 

(j) 

(k) 

Check left front wheel hub bearing clearance. 

(Reference “Chapter 24 Front Axle-Front Wheel 

Hub Bearing, On-Vehicle Inspection”.) 

Adjust brake drum to brake shoe lining 

clearance of left front wheel. (Reference 

“Chapter 26 Service Brake-Front Wheel Brake, 

Adjustment”.) 

Check left front wheel hub bearing preload. 

• Rotate left front wheel hub 2~3 turns by 

hand. 

• Using spring balance, measure rotation 

starting force of left front wheel hub. 

1051/1061 rotation starting forces: 20~30 N 

1089/1099 rotation starting forces: 25~35 N 

If rotation starting force is out of limits, adjust by 

turning left steering knuckle nut. 

(l) 

Smear plenty of grease on surface of left 

steering knuckle nut until the whole left front 

wheel hub cap is filled. 


(m) 

Install left front wheel hub cap pad. 

24 

(n) 

Fill filler hole at each end of left steering knuckle 

with grease. 

Grease: 2# lithium base grease

24-20 


(o) 

(p) 

Fill left front wheel hub cap with grease. 


Usage: 25~35g 

Install left front wheel hub cap by tightening the 

4 bolts. 


21. Installing right front wheel hub with brake drum assembly 

Tip: 

Follow the same installation steps for left front wheel hub with brake drum assembly to install right 

front wheel hub with brake drum assembly. 

22. Installing front wheel and tire assembly (reference “Chapter 23 Wheels and 


24


Parts diagram 

Front axle-steering linkage 

24-21 

24

24-22 

1 Left steering knuckle 

2 Stud 

3 Steering knuckle arm 

4 Slotted nu 

5 Bolt 

6 Drag link front end assembly 

7 Nut 


9 Drag link end clamp 


12 Right steering knuckle 

13 Right steering trapezium arm 

14 Tie rod right end assembly 

15 Tie rod 

16 Tie rod assembly 

17 Tie rod end clamp 


19 Nut 

20 Tie rod left end assembly 

10 Drag link with rear end riveted unit 

11 Drag link assembly 

21 Left steering trapezium arm 

22 Bolt 

24


Extension series vehicle Models 

24-23 

24 


2 Nut 


4 Bolt 

5 Drag link front end assembly 

6 Nut 


8 Drag link end clamp 

9 Drag link assembly 



13 Tie rod 

14 Bolt 



17 Slotted nut 

18 Split pin 

19 Nut 



11 Right steering trapezium arm

24-24 

Overhaul 


1. Removing drag link 

(a) 

Separate drag link from steering arm. 

• Pull out split pin, and loosen hexagon 

slotted nut. 

Notice: 


• Using hammer and copper bar, knock on 

drag link front end assembly axially to 

separate drag link from steering arm. 

24 

(b) 

Separate drag link from steering knuckle arm. 

1051 series and 1061 series models: 


slotted nut. 

Notice: 



drag link rear end assembly axially to 

separate drag link from steering knuckle 

arm. 

1089 series models: 


slotted nut. 

Notice: 




separate drag link from steering knuckle 

arm. 

Tip: 

Steps for separating drag link from steering knuckle 

arm on 1089 series models and those for doing the 

same job on 1051 series and 1061 series models are 

the same. (Only appearances of steering knuckle arms 

differ.)


24-25 

2. Removing steering knuckle arm 

(a) 

Separate drag link from steering knuckle arm. 



slotted nut. 

Notice: 




take it off from under steering knuckle 

arm. 



slotted nut. 

Notice: 




take it off from under steering knuckle 

arm. 

Tip: 

Steps for separating drag link from steering knuckle 

arm on 1089 series models and those for doing the 

same job on 1051 series and 1061 series models are 

the same. (Only appearances of steering knuckle arms 

differ.) 

24 

(b) 

Separate steering knuckle arm from left steering 

knuckle. 


• Pull out the 2 split pins, and loosen the 2 

hexagon slotted nuts. 

Notice: 



steering knuckle arm to take it off from 

behind left steering knuckle. 


• Loosen the nut. 

Notice: 



steering knuckle arm axially to take it off 

from behind left steering knuckle.

24-26 


24 

3. Removing tie rod 

(a) 

Separate tie rod from left steering trapezium 

arm. 


slotted nut. 

Notice: 


(b) 


tie rod left end assembly axially to take it 

off from under left steering trapezium arm. 

Separate tie rod from right steering trapezium 

arm. 

Tip: 

Follow the same steps for separating tie rod from left 

steering trapezium arm to separate tie rod from right 

steering trapezium arm. 

4. Removing left steering trapezium arm 

(a) 

Separate tie rod from left steering trapezium 

arm. 


slotted nut. 

Notice: 



tie rod left end assembly axially to take it 

off from under left steering trapezium arm. 

(b) 

Separate left steering trapezium arm from left 

steering knuckle. 


• Pull out the 2 split pins, and loosen the 2 

hexagon slotted nuts. 

Notice: 



left steering trapezium arm to take it off 

from inside of left steering knuckle. 


• Loosen the nut. 

Notice: 



steering trapezium arm axially to take it 

off from behind left steering knuckle.

5. Removing right steering trapezium arm 


24-27 

Tip: 

Follow the same removal steps for left steering trapezium arm to remove right steering trapezium arm. 

contact area covering not 

greater than 3/4 length of 

whole tapered 

6. Checking joints 

(a) 

Check contact area of tie rod left end assembly 

and left steering trapezium arm. 

• Coat tapered shaft of tie rod left end 

assembly and inside surface of mounting 

hole of left steering trapezium arm with red 

lead powder evenly. 

• Insert tapered shaft of tie rod left end 

assembly into mounting hole of the steering 

trapezium arm, and then take it out to check 

contact indentation. 

Standard: Uniform contact with contact area 

covering not greater than 3/4 length of 

whole tapered shaft. 

In the case of nonuniform contact or contact area 

covering greater than 3/4 length of whole tapered 

shaft, replace with new tie rod left end assembly and 

left steering trapezium arm. (Reference “Chapter 24 

Front Axle-Steering Linkage, Overhaul”.) 

contact area covering 


whole tapered 

contact area covering 

greater than 3/4 length 

of whole tapered 

(b) Check contact area of tie rod right end assembly 

and right steering trapezium arm. 

Tip: 

Follow the same check steps for tie rod left end 

assembly and left steering trapezium arm to check tie 

rod right end assembly and right steering trapezium 

arm. 




In the case of nonuniform contact or contact area covering 

greater than 3/4 length of whole tapered shaft, replace with 

new tie rod left end assembly and left steering trapezium 

arm. (Reference “Chapter 24 Front Axle-Steering Linkage, 

Overhaul”.) 

(c) Check contact area of drag link front end 

assembly and steering arm. 

Tip: 


assembly and left steering trapezium arm to check 

drag link front end and steering arm. 






shaft, replace with new drag link front end assembly 

and steering arm. (Reference “Chapter 24 Front 

Axle-Steering Linkage, Overhaul” and “Chapter 42 

Power Steering-Steering Gear with Rocker Arm 

Assembly, Overhaul”.) 

24

24-28 


24 










(d) Check contact area of drag link rear end 

assembly and steering knuckle arm. 

Tip: 



drag link rear end assembly and steering knuckle arm. 






shaft, replace with new drag link rear end assembly 

and steering knuckle arm. (Reference “Chapter 24 

Front Axle-Steering Linkage, Overhaul”.) 

(e) Check contact area of steering knuckle arm and 

steering knuckle (1089 series models). 

Tip: 



steering knuckle arm and steering knuckle. 






shaft, replace with new steering knuckle arm and 

steering knuckle. (Reference “Chapter 24 Front 


Front Axle-Steering Knuckle, Overhaul”.) 

(f) Check contact area of steering trapezium arm 

and steering knuckle (1089 series models). 

Tip: 



steering trapezium arm and steering knuckle. 






shaft, replace with new steering trapezium arm and 

steering knuckle. (Reference “Chapter 24 Front 


Front Axle-Steering Knuckle, Overhaul”.)


24-29 

7. Removing end assemblies 

(a) 

Remove tie rod left end assembly. 

• Loosen fastening nut of tie rod left end 

assembly. 

• Hold tie rod shaft, and turn and take off 

left end assembly. 

(b) 

Remove tie rod right end assembly. 

Tip: 

Follow the same removal steps for tie rod left end 

assembly to remove tie rod right end assembly. 

(c) 

Remove drag link front end assembly. 

• Loosen fastening nut of drag link front 

end assembly. 

• Hold drag link shaft, and turn and take off 

front end assembly. 

24

24-30 


8. Installing end assemblies 

(a) 

Install drag link front end assembly. 

• Hold drag link shaft, and turn front end 

assembly until whole sleeve of front end 

assembly almost enters drag link shaft. 

Tip: 

If tapered shaft of drag link rear end assembly is placed 

upward, then tapered shaft of front end assembly should 

be normal to it and face to outside of the vehicle. 

• Tighten fastening nut of drag link front 

end assembly. 

1051/1061 series torques: 30~35 N•m 

1061/1089/1099 series torques:70~90 N•m 

24 

(b) 

Install tie rod left end assembly. 

• Hold tie rod shaft, and turn left end 

assembly until whole sleeve of left end 

assembly almost enters tie rod shaft. 

Tip: 

Record number of turns of left end assembly. 

• Tighten fastening nut of tie rod left end 

assembly. 


1089/1099 series torques:70~90 N•m


24-31 

(c) 

Install tie rod right end assembly. 

Notice: 

Be sure to install according to the number of turns 

recorded. Make sure number of turns of tie rod right 

end assembly equals that of left end assembly. 

Tip: 

Follow the same installation steps for tie rod left end 

assembly to install tie rod right end assembly. 



9. Installing left steering trapezium arm 

(a) 

Check left steering trapezium arm for deformation, bending, cracks, and other damages. 

If any of above defects is found, replace with a new left steering trapezium arm. 

(b) 

Connect left steering trapezium arm with left 

steering knuckle. 



left steering trapezium arm to install it 

onto left steering knuckle from inside. 

• Tighten the 2 hexagon slotted nuts, and 

insert the 2 split pins. 


Notice: 

Be sure to replace with new split pins. 

Tip: 

After tightening, return approx. 30° to align split pin hole 

with left steering knuckle nut notch. 

1089/1099 series models: 


left steering trapezium arm axially to 

install it onto left steering knuckle from 

behind. 

• Tighten the nut and curl to lock. 


Notice: 

Be sure to replace with a new nut. 

24

24-32 


(c) 

10. Installing right steering trapezium arm 

Connect tie rod with left steering trapezium arm. 


tie rod left end assembly axially to install it 

onto left steering trapezium arm from 

under. 

• Tighten hexagon slotted nut, and insert 

split pin. 


Notice: 

Be sure to replace with a new split pin. 

Tip: 

Follow the same installation steps for left steering trapezium arm to install right steering trapezium 

arm. 

11. Installing tie rod 

(a) 

(b) 

Check tie rod for cracks, threads disorder, and other damages. 

If any of above defects is found, replace with a new tie rod. 

Using V-bench and dial indicator, measure radial runout at middle of tie rod. 

Standard value: ≤ 3 mm 

If radial runout is out of limits, replace with a new tie rod. 

24 

(c) 

Connect tie rod with left steering trapezium arm. 


tie rod left end assembly axially to install it 

onto left steering trapezium arm from 

under. 


split pin. 


Notice: 


(d) 

Connect tie rod with right steering trapezium 

arm. 

Tip: 

Follow the same steps for connecting tie rod with left 

steering trapezium arm to connect tie rod with right 

steering trapezium arm.

12. Installing steering knuckle arm 

(a) 


Check steering knuckle arm for deformation, bending, cracks, and other damages. 

If any of above defects is found, replace with a new steering knuckle arm. 

24-33 

(b) 

Connect steering knuckle arm with left steering 

knuckle. 



steering knuckle arm to install it onto left 

steering knuckle from behind. 

• Tighten the 2 hexagon slotted nuts, and 

insert the 2 split pins. 


Notice: 

Be sure to replace with new split pins. 

Tip: 



1089 /1099series models: 


steering knuckle arm axially to install it 

onto left steering knuckle from behind. 

• Tighten the nut and curl to lock. 


Notice: 

Be sure to replace with a new nut. 

24

24-34 


(c) 

Connect drag link with steering knuckle arm. 




install it onto steering knuckle arm from 

under. 


split pin. 


Notice: 


Tip: 



24 





under. 


split pin. 


Notice: 


Tip: 

• After tightening, return approx. 30° to align split 

pin hole with left steering knuckle nut notch. 

• Steps for connecting drag link with steering 

knuckle arm on 1089 series models and those 

for doing the same job on 1051 series and 1061 

series models are the same. (Only appearances 

of steering knuckle arms differ.)


24-35 

13. Installing drag link 

(a) 

Check drag link for cracks, threads disorder, and other damages. 

If any of above defects is found, replace with a new drag link. 

(b) 

Connect drag link with steering knuckle arm. 





under. 


split pin. 


Notice: 


Tip: 







under. 


split pin. 


Notice: 


Tip: 

• After tightening, return approx. 30° to align split 

pin hole with left steering knuckle nut notch. 

• Steps for connecting drag link with steering 

knuckle arm on 1089 series models and those 

for doing the same job on 1051 series and 1061 

series models are the same. (Only appearances 

of steering knuckle arms differ.) 

24

24-36 


(c) 

Connect drag link with steering arm. 

• Right steering wheel. 

• Move front wheels at both sides by hand 

to set them straight ahead. 

• Loosen fastening bolt of drag link front 

end assembly, and turn front end 

assembly until its tapered shaft and 

mounting hole of steering arm are 

concentric. 

Tip: 

Number of turns of drag link front end assembly must 

be a natural number (e.g. 1, 2, 3……). 

24 


drag link front end assembly axially to 

install it onto steering arm from inside. 


split pin. 

Torques: 180~220 N•m 

Notice: 


Tip: 

After tightening, return approx. 30° to align split pin 

hole with left steering knuckle nut notch. 

14. Checking front wheel toe-in (reference “Chapter 24 Front Axle-Front Wheel Alignment, 

Adjustment”) 

15. Adjusting front wheel toe-in (reference “Chapter 24 Front Axle-Front Wheel Alignment, 

Adjustment”)

Steering Knuckle 

Front axle-steering knuckle 

Parts diagram 

1051 series and 1061 series models 

24-37 

24 


2 Slotted nut 

3 Stud 


5 Knuckle pin cap pad 

6 Steering knuckle pin cap 

7 Oil cup 

8 Bolt 


10 Knuckle pin 


12 Adjusting washer 

13 Fore axle 

14 Bolt 



17 Nut 

18 Stopper bolt 

19 Right steering trapezium arm 

20 Tie rod right end assembly

24-38 

21 Tie rod 


23 Tie rod end clamp 


25 Nut 



27 Knuckle pin plug cap 

28 Bolt 

29 Thrust bearing 

30 Latch 


32 Nut 

24


24-39 

Extension series vehicle Models 

24 


2 Nut 


4 Bolt 

5 Knuckle pin cap 

6 Knuckle pin cap pad 

7 Knuckle pin 


9 Latch 

10 Adjusting washer 

11 Fore axle 



15 Tie rod 


17 Bolt 



20 Nut 



23 Bolt 

24 Oil cup 

25 Nut 

13 Right steering trapezium arm 26 Stopper bolt

24-40 


27 Slotted nut 

28 Split pin 

29 Thrust bearing 



32 Nut 

24

24-42 

Overhaul 


1. Removing front wheel and tire assembly (reference “Chapter 23 Wheels and 


2. Removing front wheel hub with brake drum assembly (reference “Chapter 24 Front 

Axle-Front Wheel Hub with Brake Drum Assembly, Overhaul”) 

3. Removing front brake assembly (reference “Chapter 26 Service Brake-Front Brake 

Assembly, Overhaul”) 

4. Removing steering linkage (reference “Chapter 24 Front Axle-Steering Linkage, 

Overhaul”) 

5. Removing left knuckle pin cap 

(a) 


• Loosen the 3 bolts, and remove left 

knuckle pin cap. 

• Take off oil cup from left knuckle pin cap. 

• Take off left knuckle pin cap pad. 

Notice: 

Do not reuse removed knuckle pin cap pad. 

24 

6. Removing right knuckle pin cap 

Tip: 

Follow the same removal steps for left knuckle pin cap to remove right knuckle pin cap. 

7. Removing left knuckle pin plug cap 

Tip: 

Follow the same removal steps for left knuckle pin cap to remove left knuckle pin plug cap. 

8. Removing right knuckle pin plug cap 

Tip: 

Follow the same removal steps for left knuckle pin plug cap to remove right knuckle pin plug cap.


24-43 

9. Removing left steering knuckle latch 

(a) 

(b) 

Loosen the nut. 

Using hammer and copper bar, knock on the 

latch axially to take it off. 

Notice: 

Do not reuse removed latch. 

10. Removing right steering knuckle latch 

Tip: 

Follow the same removal steps for left latch to remove right latch. 

11. Removing left knuckle pin 

(a) 

Using hammer and copper bar, knock on left 

knuckle pin axially to take it off. 

12. Removing right knuckle pin 

Tip: 

Follow the same removal steps for left knuckle pin to remove right knuckle pin. 

24 

13. Removing left steering knuckle 

Tip: 

Take off thrust bearing and adjusting washer of steering 

knuckle at the same time. 

14. Removing right steering knuckle 

Tip: 

Follow the same removal steps for left steering knuckle to remove right steering knuckle.

24-44 


15. Checking knuckle pin and steering knuckle 

(a) 

Using micrometer, measure diameter of knuckle pin. 

Diameters: 

Vehicle model 


Diameter 

Limit value 

1049 series 32.000 mm 31.984~32.000 mm 

1061 series 32.000 mm 31.984~32.000 mm 

1089 series 40.000 mm 40.000~40.025 mm 

1099 series 32.000 mm 31.984~32.000 mm 

If knuckle pin diameter is out of limits, replace with a new knuckle pin. 

(b) 

Using micrometer, measure inside diameter of steering knuckle bushing. 

Inside diameters: 

Vehicle model 


Diameter 

Limit value 

1049 series 32.000 mm 32.025~32.064 mm 

1061 series 32.000 mm 32.025~32.064 mm 

1089 series 40.000 mm 40.051~40.078 mm 

1099 series 32.000 mm 32.025~32.064 mm 

If inside diameter of steering knuckle bushing is out of limits, replace with a new steering knuckle 

bushing. 

24 

(c) 

Using dial indicator, measure knuckle pin to steering knuckle bushing clearance. 

• Fix steering knuckle with a table vice, and insert knuckle pin into steering knuckle 

bushing. 

• Push knuckle pin radially by hand to check knuckle pin to steering knuckle bushing 

clearance. 

Clearances: 

Vehicle model 

Torque 

1049 series 0.025~0.080 mm 

1061 series 0.025~0.080 mm 

1089 series 0.026~0.078 mm 

1099 series 0.025~0.080 mm 

If knuckle pin to steering knuckle bushing clearance is out of limits, measure diameter of knuckle pin 

and inside diameter of steering knuckle bushing respectively, and replace as needed. 

(d) 

Check steering knuckle. 

• Using magnaflux, check such places as knuckle journal and upper and lower ears for 

cracks. 

• Check threads on end of knuckle spindle for damage (especially when more than 2 

threads are damaged). 

• Check knuckle journal for serious wear. 

If any of above defects exists, replace with a new steering knuckle.

(e) 


Using dial indicator, measure steering knuckle to fore axle clearance. 

Clearances (without adjusting washer): 

Vehicle model 

Clearance (without adjusting washer) 


Limit value 

1049 series 2.0 mm 2.3~2.9 mm 

1061 series 2.0 mm 2.3~2.9 mm 

1089 series 3.0 mm 2.9~3.5 mm 

1099 series 2.5 mm 2.3~2.9 mm 

24-45 

If steering knuckle to fore axle clearance is out of limits, replace with a new steering knuckle. 

16. Installing left steering knuckle 

(a) Install left steering knuckle onto fore axle. 

• Grease left steering knuckle hole. 


(b) 

Install thrust bearing of steering knuckle. 

• Grease thrust bearing of steering knuckle. 


• Make sure bearing shell faces up. 

24 

Up parts 

Down parts 

(c) 

Install adjusting washer (s) of left steering knuckle. 

Specifications of adjusting washer of steering knuckle: 

Vehicle model 

Specification of adjusting washer of steering knuckle 

(outside diameter × inside diameter × thickness) 

1049 series 56 × 32.5 × (2.30~2.85) mm 

1061 series 56 × 32.5 × (2.30~2.85) mm 

1089 series 64 × 42.5 × (2.85~3.45) mm 

1099 series 56 × 32.5 × (1.30~2.85) mm 

Number of adjusting washers of steering knuckle: ≤ 2 (single side)

24-46 


(d) 

Using dial indicator, remeasure steering knuckle to fore axle clearance. 

Clearances (with adjusting washer): ≤ 0.1 mm 

17. Installing right steering knuckle 

Tip: 

Follow the same installation steps for left steering knuckle to install right steering knuckle. 

18. Installing left knuckle pin 

(a) 

(b) 

Using hammer and copper bar, lightly tap left 

knuckle pin to insert it into left steering knuckle 

bushing. 

• Grease left knuckle pin. 


• Be sure to align the key groove on left 

knuckle pin with the latch hole. 

Check left steering knuckle for smart rotation. 

19. Installing right knuckle pin 

Tip: 

Follow the same installation steps for left knuckle pin to install right knuckle pin. 

20. Installing left steering knuckle latch 

24 

(a) 

Using hammer and copper bar, lightly tap latch 

axially until it is seated in place completely. 

Notice: 

Be sure to replace with a new latch. 

(b) 

Tighten the nut. 

Torques: 

Vehicle model 

Torque 

1049 series 25~40 N•m 

1061 series 25~40 N•m 

1089 series 50~70 N•m 

1099 series 25~40 N•m 

(c) 

Using spring balance, measure starting force of 

steering knuckle at the split pin hole on knuckle 

journal. 

Starting force: 10~60 N

21. Installing right steering knuckle latch 


24-47 

Tip: 

Follow the same installation steps for left steering knuckle latch to install right steering knuckle 

latch. 

22. Installing left knuckle pin cap 

(a) 

(b) 

Smear plenty of grease on both ends of knuckle pin. Be sure to fill up the whole space. 


Install left knuckle pin cap pad. 

Notice: 

Be sure to replace with a new left knuckle pin cap pad. 

(c) 


• Install left knuckle pin cap by tightening 

the 3 bolts. 


• Install oil cup onto left knuckle pin cap. 

(d) 


• Install left knuckle pin cap by tightening 

the 2 bolts. 


24 

23. Installing right knuckle pin cap 

Tip: 

Follow the same installation steps for left knuckle pin cap to install right knuckle pin cap. 

24. Installing left knuckle pin plug cap 

Tip: 

Follow the same installation steps for left knuckle pin cap to install left knuckle pin plug cap. 

25. Installing right knuckle pin plug cap 

Tip: 

Follow the same installation steps for left knuckle pin plug cap to install right knuckle pin plug cap.

24-48 


26. Installing steering linkage (refer to “Chapter 24 Front Axle-Steering Linkage, 

Overhaul”) 

27. Checking steering locking angle of front wheel (refer to “Chapter 24 Front Axle-Front 

Wheel Alignment, Adjustment”) 

28. Adjusting steering locking angle of front wheel (refer to “Chapter 24 Front Axle-Front 

Wheel Alignment, Adjustment”) 

29. Installing front brake assembly (refer to “Chapter 26 Service Brake-Front Wheel Brake, 

Overhaul”) 

30. Installing front wheel hub with brake drum assembly (refer to “Chapter 24 Front 


31. Installing front wheel and tire assembly (refer to “Chapter 23 Wheels and Tires-Front 

Wheel and Tire Assembly, Replacement”) 

24

Front Axle 

Overhaul 

Front axle-fore axle 

24-49 

1. Removing front wheel and tire assembly (refer to “Chapter 23 Wheels and Tires-Front 

Wheel and Tire Assembly, Replacement”) 

2. Removing front wheel hub with brake drum assembly (refer to “Chapter 24 Front 


3. Removing front brake assembly (refer to “Chapter 26 Service Brake-Front Wheel 


4. Removing steering linkage (refer to “Chapter 24 Front Axle-Steering Linkage, 

Overhaul”) 

5. Removing steering knuckle (refer to “Chapter 24 Front Axle-Steering Knuckle, 

Overhaul”) 

6. Removing front leaf spring U-bolt (refer to “Chapter 21 Front Suspension-Front Leaf 

Spring Assembly, Overhaul”) 

7. Removing fore axle 

Suspend a line of the 

test prods. 

horizontal 

bending of fore 

axle 

8. Checking fore axle 

(a) 

Insert 1 test prod in each knuckle pin hole. 

(b) Suspend a line between centers of the 2 

test prods. 

(c) 

Check for horizontal bending of fore axle. 

• Overlook fore axle from right above, 

and check if the line suspended and 

the tie line of center bolt holes of the 

2 leaf springs are aligned. 

If not aligned, it indicates horizontal bending of 

fore axle. Then you should correct it using a 

press under room temperature. 

24 

(d) 

Check for fore axle distortion. 

• Observe from one side, and check if 

the 2 test prods are upright and 

overlapped. 

If not, it indicates fore axle distortion. Then 

correct. 

(e) Check for vertical bending of fore axle. 

• Check if the 2 leaf spring seats of fore axle are in the same plane. 

If not, it indicates vertical bending of fore axle. Then correct or replace with a new fore axle.

24-50 

(f) 

Front axle-fore axle 

Using micrometer, check knuckle pin hole of fore axle. 

• Measure diameter of knuckle pin hole. 

Diameters: 

Vehicle model 


Diameter 

Limit value 

1049 series 32.000 mm 32.000~32.039 mm 

1061 series 32.000 mm 32.000~32.039 mm 

1089 series 40.000 mm 40.026~40.051 mm 

1099 series 32.000 mm 32.000~32.025 mm 

If diameter of knuckle pin hole is out of limits, replace with a new fore axle. 

• Measure inclination angle of knuckle pin hole. 

Inclination angles: 

Vehicle model 



Limit value 

1049 series 8° 7°45’~8°15’ 

1061 series 8° 7°45’~8°15’ 

1089 series 7°30’ 7°15’~7°45’ 

1099 series 8° 7°45’~8°15’ 

24 

If inclination angle of knuckle pin hole is out of limits, replace with a new fore axle. 

(g) 

• Check upper and lower ports of knuckle pin hole for serious wear (bell mouth). 

Replace with a new fore axle as needed. 

• Check upper and lower faces of knuckle pin hole for serious wear. Replace with a new 

fore axle as needed. 

Check fore axle for cracks or leaf spring seat for wear and serious sink. If any of above 

defects exists, replace with a new fore axle. 

9. Installing fore axle 

10. Removing front leaf spring U-bolt (refer to “Chapter 21 Front Suspension-Front Leaf 

Spring Assembly, Overhaul”) 

11. Removing steering knuckle (refer to “Chapter 24 Front Axle-Steering Knuckle, 

Overhaul”) 

12. Removing steering linkage (refer to “Chapter 24 Front Axle-Steering Linkage, 

Overhaul”) 

13. Removing front brake assembly (refer to “Chapter 26 Service Brake-Front Wheel 


14. Removing front wheel hub with brake drum assembly (refer to “Chapter 24 Front 


15. Removing front wheel and tire assembly (refer to “Chapter 23 Wheels and Tires-Front 

Wheel and Tire Assembly, Replacement”)

Rear Axle 

Rear axle assembly ....................................... 25-1 

Notes ........................................................ 25-1 

Malfunction symptom table ....................... 25-3 

Inspection on vehicle ................................ 25-4 

Overhaul ................................................... 25-5 

Rear axle gear oil .......................................... 25-6 

Replacement ............................................. 25-6 

Half axle ......................................................... 25-7 

Overhaul ................................................... 25-7 

Rear wheel hub with brake drum Assy........25-9 

Parts diagram ........................................... 25-9 

Overhaul ................................................. 25-11 

Main reducing gear assembly .................... 25-19 

Parts diagram ......................................... 25-19 

Inspection ............................................... 25-20 

Replacement ........................................... 25-22 

Differential assembly .................................. 25-24 

Parts diagram ......................................... 25-24 

Inspection ............................................... 25-25 

Overhaul ................................................. 25-27 

Drive gear assembly ................................... 25-36 

Parts diagram ......................................... 25-36 

Inspection ............................................... 25-37 

Overhaul ................................................. 25-38 

25


Notes 

Rear axle- Rear axle assembly 

1. Notes for the maintenance with rear axle gear oil 

(a) The designated rear axle gear oil must be used, don’t mix it with other oil. 

Gear oil: 

Gear oil 

Vehicle 

Specification 

Dosage 

25-1 

(b). 

(c). 

1051 series 

3.5 L 

Hypoid gear oil 

1061/1099 series GL-5 85W/90 

5.0L 

1089 series 6.5L 

Rep lacing with new rear axle gear oil must be required at regular intervals. 

• Replacing with new gear oil must be required while carrying out second-class maintenance 

for the first time. 

• Replacing with new gear oil must be required after driving for 40,000 Km or 24 months first. 

(Refer to “chapter 25 rear axle-rear axle gear oil, replacement) 

• Replacing with new gear oil must be required after driving for 80,000 Km or 48 months, 

thereafter, the gear oil shall be replaced each 50,000Km first. (Refer to “chapter 25 rear 

axle -rear axle gear oil, replacement”) 

Regular inspection must be carried out, at least once for every four times of second-class 

maintenance. 

• Inspect the quality of the lubricant oil and see whether it goes bad such as: changes color, 

turns thin etc. (refer to “chapter 25 rear axle -rear axle gear oil, replacement”) 

• Replacing with new gear oil must be required if the above-mentioned defects exist. (refer 

to “chapter 25 rear axle -rear axle gear oil, replacement”) 

2. Notes for the maintenance of rear axle assembly 

(a). 

Regular inspection must be carried out on the air 

plug of rear-axle housing and the dirt and dust on it 

shall be cleaned. 

• Remove it for cleaning during the first-class 

maintenance so as to keep the air passage 

open. 

Hint: 

• The blockage of air plug will cause the increase of 

pressure in the rear-axle housing and lead to the 

oil leakage at the driving gear oil seal and the joint. 

• The level of the gear oil inside the rear-axle 

housing shall be inspected during the cleaning of 

air plug. 

(b). 

(c). 

The rear axle can be removed and the inner 

chamber and the main reducing gear assembly 

can be cleaned during the three-class 

maintenance, the bolts and nuts of all the parts 

shall be screwed down in accordance with the 

specified torque. 

The brake shoe lining and the brake drum must be 

inspected for wear regularly. Rear axle-rear axle 

assembly 

25

25-2 


• The brake shoe lining and the brake drum must 

be inspected for wear after driving for 40,000 

Km or 24 months. 

• Measure the thickness of the wear at the most 

serious part of the brake shoe lining. 

Thickness: 

Vehicle type 

Standard 

Thickness 

Limit 

1051 series 13 mm 4.6 ± 0.2 mm 

1061 series 13 mm 4.6 ± 0.2 mm 

1089/1099 series 16 mm 4.6 ± 0.2 mm 

3. NOTES for the maintenance of rear axle assembly. 

(a). 

(b). 

(c). 

If the thickness of brake shoe lining is less than the limit 

value, the replacement of a new one is required. 

If one of the mating parts needs to be replaced, the complete set of parts must be replaced. 

All the rubber parts (such as O-ring, oil seal, gasket, etc.) can not be used again after removing. 

Check the appearance of all the parts carefully through visual inspection, using red lead 

powder or other designated methods to see whether the following shortcomings exist: 

Irregular wear Partial wear Abrasion Crack 

Deformity Flexural deformation Looseness Rusting 

Color changes or 

unsmooth blockage 

Lose effectiveness or 

weaken (spring) 

Abnormal 

(bearing) 

noises 

Transformation (brake 

shoe lining) 

25 

(d). 

Make sure that all the parts are clean without oil stain or iron chips during the assembly and 

installation of main reducing gear assembly. Unless otherwise specified, No. 10 engine oil shall be 

used for lubrication before operation. 

4. Notes for the use of vehicles 

(a). 

(b). 

Do not overload, the loading of the vehicle shall not exceed the maximum loading weight. 

Do not allow increase the obstacle clearance ability through the abrupt lifting of clutch during 

the driving. 

Hint: 

The abrupt lifting of clutch during the driving may cause impact on the gear so as to result in damage.



25-3 

Use the table below to help you find the cause of the malfunction. Sequence number indicates the 

probability of the cause of the malfunction. Inspect each part in order. If necessary, replace these parts. 

Symptom Suspect Area Reference 

Continuous 

knocking sound 

(Turning) 

1. Planet gear thrust washer (Worn) 

2. Planet gear (Worn) 

chapter 25 rear axle-differential assembly, overhaul 

chapter 25 rear axle-differential assembly, overhaul 

Continuous 


(High-speed 

driving) 

1. Driving gear and driven gear (The 

clearance is too big or worn) 


clearance is too small) 

chapter 25 rear axle–main reducing gear 

assembly, inspection 



Continuous 


(Speeding up) 









Intermittent 


(Driving) 

1. Half axle spline (The clearance is too big) 



3. Rear-axle housing (Mixed with impurities) 

chapter 25 rear axle–differential assembly, 

inspection 



chapter 25 rear axle – rear axle gear oil, 

replacement 

1. Air vent (Blocked) 

chapter 25 rear axle–rear axle assembly, 

precautions 

2. Bolt (Loose or worn) 

- 

Oil leakage of 

rear-axle housing 

3. Rear axle gear oil (Too much) 

chapter 25 rear axle–rear axle gear oil, 

replacement 

4. Seal washer (Damaged or does not work) 

5. Rear-axle housing (Cracked or blistered) 

- 

chapter 25 rear axle–rear axle assembly, 

on-vehicle inspection 

25 

The gear oil 

soaks in the rear 

wheel hub 

and brake drum. 

1. Rear axle gear oil (Too much) 

2. Rear wheel hub outer oil seal (Damaged) 

3. Rear wheel hub inner oil seal (Damaged) 


replacement 

chapter 25 rear axle–rear wheel hub with brake 

drum assembly, overhaul 

chapter 25 rear axle–rear wheel hub with brake 

drum assembly, overhaul 

1. Rear axle gear oil (Too little) 


replacement 





Overheating 

rear axle 

of 

3. Differential bearing (Too tight) 

chapter 25 rear axle–differential assembly, 

overhaul 

4. Differential oil seal (Too tight) 

chapter 25 rear axle –differential assembly, 

overhaul 

5. Rear wheel brake (Grabbed) 

chapter 26 service brake-rear wheel brake, 

overhaul

25-4 

Inspection and repair 


1. Check the total clearance of the rear axle. 

(a). 

(b). 

(c). 

Park the vehicle on flat road. 

Set the transmission to neutral and tighten the parking brake. 

Lift the vehicle and support it with safety bench. 

(d). Separate the rear transmission shaft from main reducing gear. (Refer to “chapter 33 

transmission shaft - transmission shaft assembly, replacement”) 

(e). 

Rotate the flange of the main reducing gear 

counterclockwise to the limit position of the side 

and make matched marks on the flange and the 

case of main reducing gear. 

25 

Total 

clearance 

of the rear 

axle 

(f). 

Measure the total clearance of the rear axle. 

The total clearance of the rear axle: ≤ 6 mm 

If the total clearance of the rear axle exceeds the limit 

range, then the gear clearance of the rear axle is too 

big, the main reducing gear must be removed to 

adjustment. 

Hint: 

Rotate the flange of the main reducing gear clockwise 

to the limit position of the other side and measure the 

distance between the two matched marks made on the 

flange and the case of main reducing gear. This 

distance is the total clearance of the rear axle. 

2. Check the rear-axle housing 

(a). 

Check whether the rear-axle housing cracks or leaks oil and weld up it if necessary.

Overhaul 


25-5 

1. Brain oil rear axle gear oil (refer to “chapter 25 rear axle -rear axle gear oil, 

replacement”) 

2. Remove the rear wheels and tire assembly (refer to “chapter 23 wheels and tires – 

rear wheels and tire assembly, replacement”) 

3. Remove the u bolts of rear plate spring (refer to “chapter 22 rear suspension – rear 

plate spring assembly, overhaul”) 

4. Remove the rear axle assembly 

5. Check the rear axle assembly 

(a). 

Check the location hole diameter of the rear axle plate spring seat. 

Diameter: 

Vehicle 

Standard 

Diameter 

Limit 

1051 series 18.5 mm ≤ 1.0 mm 

1061 series 21.0 mm ≤ 1.0 mm 

1089/1099 series 21.0 mm ≤ 1.0 mm 

If the wear exceeds the limit value, calibrate it and replace with new rear-axle housing if necessary. 

6. Check the rear wheel hub with brake drum assembly 

(a). 

(b). 

Check whether the rear wheel hub leaks oil. 

Check whether the rear brake drum leaks oil. 

7. Install rear axle assembly 

8. Install the u bolts of rear plate spring. (refer to “chapter 22 rear suspension – rear 

plate spring assembly, overhaul”) 

9. Install rear wheels and tire assembly. (refer to “chapter 23 wheels and tires – rear 

wheels and tire assembly, replacement”) 

10. Fill rear axle gear oil. (refer to “chapter 25 rear axle -rear axle gear oil, replacement”) 

25

25-6 

Rear axle gear oil 

Replacement 

Rear axle- Rear axle gear oil 

1. Drainage oil 

(a). 

(b). 

(c). 

Rotate the drain plug counterclockwise and 

remove it. 

Exhaust the rear axle gear oil. 

Screw down the drain plug clockwise. 

2. Filling 

(a). 

(b). 

Rotate the oiling plug counterclockwise and 

remove it. 

Fill gear oil into the rear-axle housing. 

Gear oil: 

Vehicle type 

Specification 

Gear Oil 

Dosage 

25 

1051 series 

3.5 L 

1061/1099 series 

Hypoid gear oil 

GL-5 85W/90 

5.0L 

1089 series 6.5L 

(c). 

Screw down the oiling plug clockwise.

Half axle 

Rear axle- Half axle 

25-7 

Overhaul 

1. Remove the left half axle 

(a). Fix the wheels with sleepers to prevent the movement of the vehicle. 

(b). 

Loosen the half-axle bolt. 

(c). 

Remove the left half axle. 

Hint: 

• If the half axle is too tight to be removed, knock 

the flange surface of the half axle lightly with a 

hammer and copper bar to make the half axle 

loose, and then remove it. 

• If it still can’t be removed, pull the flange of the 

half axle with a puller and remove it after 

separating the half axle and the rear wheel hub. 

2. Remove the right half axle. 

Hint: 

The steps for the removal of the right half axle are the same with those for the left half axle. 

25 

3. Check half axle 

(a). 

Measure the radial runout in the middle of the 

half axle and the end face runout inside the 

flange with V-shaped tables and dial indicators. 

Radial jumpiness: ≤ 1.0 mm 

End face jumpiness: ≤ 0.15 mm 

If the radial jumpiness and end face jumpiness are 

beyond the limit values, calibrate them and replace 

with a new half axle if necessary. 

(b). 

(c). 

Check whether the half axle has cracks through 

magnetic crack detection. 

Check whether the spline at the end of the half 

axle is worn seriously and whether there are 

significant distortion and cracks. 

Wear of tooth thickness: ≤ 0.2 mm 

Skew of tooth form: ≤ 1 mm 

half axle if the tooth thickness wear of spline and the 

skew of tooth form are over the limit values.

25-8 

Rear axle- Rear axle gear oil 

4. Install the left half axle 

(a). 

Insert the left half axle into the left 

half-axle bushing. 

(b). 

Screw down the half-axle bolt. 

1051 Series torque:37 ~ 75 N•m 

1061 Series torque:75 ~113 N•m 



5. Install the right half axle 

Hint: 

The steps for the installation of the right half axle are the same with those for the left half axle. 

25

Rear axle- Rear wheel hub with brake drum assembly 

25-9 

Rear wheel hub with brake drum assembly 

Parts diagram 

25

25-10 


1 Rear Wheels and Tire Assembly 

2 Wheel Nut 

3 Half-shaft Bolt 

4 Spring Washer 

5 Half-axle 

6 Outer Oil Seal 

7 Hexagon Head Nut 


9 Locking Washer 

11 Outer Tapered Roller Bearing 

12 Rear Wheel Hub 

13 Brake Drum 

14 Inner Tapered Roller Bearing 

15 Inner Oil Seal 

16 Nut 

17 Wheel Bolt 

18 

Rear Wheel Hub With Brake Drum 

Assembly 

19 Rear-axle Housing Assembly 

10 Wheel Hub Bearing Lock Nut 

25

Overhaul 


25-11 

1. Remove the rear wheels and tire assembly. (refer to “chapter 23 wheels and tires – rear 

wheels and tire assembly, replacement”) 

2. Drain rear axle gear oil. (refer to “chapter 25 rear axle -rear axle gear oil, replacement”) 

3. Remove the left half axle 

(a). 

Loosen the half-shaft bolts. 

(b). 

Remove the left half axle. 

Hint: 

• If the half axle is too tight to be removed, knock 

the flange surface of the half axle lightly by a 

hammer and a copper bar to make the half axle 

loose, and then remove it. 

• If it still can’t be removed, pull the flange of the half 

axle with a puller and remove it after separating the 

half axle and the rear wheel hub. 

4. Remove the right half axle 

Hint: 

The steps for the removal of the right half axle are the same with those for the left half axle. 

5. Remove the left rear wheel hub with brake 

drum assembly 

(a). 

Remove outer oil seal of the left half axle. 

25 

(b). 

Loosen the two bolts and remove the left rear 

wheel hub bearing locking washer.

25-12 


(c). 

Remove the lock nut of the left rear wheel hub 

bearing by the lock nut wrench of wheel hub 

bearing. 

(d). 

Remove the inner ring of the outer tapered roller 

bearing of left rear wheel hub. 

(e). Remove the left rear wheel hub with brake drum 

assembly. 

• If the left rear wheel hub with brake drum 

assembly is too tight to be removed, remove it 

by a rear wheel hub puller. 

25 

6. Remove the right rear wheel hub with brake drum assembly. 

Hint: 

The steps for the removal of the right rear wheel hub with brake drum are the same with those for 

the left rear wheel hub with brake drum. 

7. Separate the left rear wheel hub and the 

brake drum 

(a). 

Remove the 6 nuts, separate the left rear wheel 

hub and the brake drum. 

Notice: 

The nuts removed and can’t be used again. 

8. Separate the right rear wheel hub and the brake drum 

Hint: 

The steps for the separation of the right rear wheel hub and the brake drum are the same with those 

for the left rear wheel hub and the brake drum.


25-13 

9. Remove the inner oil seal of the left rear 

wheel hub 

(a). 

Remove the inner oil seal from the left rear 

wheel hub by sharp-nose pliers 

Notice: 

The inner oil seal removed and can’t be used 

again. 

(b). 

Remove the inner oil seal of the left rear wheel 

hub with a puller. 

• Remove the inner ring of the inner tapered 

roller bearing of the left rear wheel hub at 

the same time. 

Notice: 

The inner oil seal ring removed and can’t be used 

again. 

10. Remove the left rear wheel hub bearing. 

(a). 

Remove the outer ring of the outer tapered roller 

bearing from the left rear wheel hub with a 

hammer and a copper bar. 

(b). 

Remove the outer ring of the inner tapered roller 

bearing from the left rear wheel hub with a 

hammer and a copper bar. 

25 

11. Remove the inner oil seal of the right rear wheel hub. 

Hint: 

The steps for the removal of the inner oil seal of the right rear wheel hub are the same with those for 

the inner oil seal of the left rear wheel hub. 

12. Remove the right rear wheel hub bearing 

Hint: 

The steps for the removal of the right rear wheel hub bearing are the same with those for the left 

rear wheel hub bearing.

25-14 


13. Check the rear-axle housing deformation 

(a). 

(b). 

(c). 

Measure the shaft journal worn at the end of the half-axle bushing. 

Wear: ≤ 0.08 mm 

Replace with new rear-axle housing if the worn is beyond the limit range. 

Measure the verticality of the half-axle bushing shaft journal on both sides based on the front 

end of the rear-axle housing. 

Verticality: ≤ 1.5 mm 

Calibrate if the verticality is beyond the limit range and replace with new rear-axle housing if 

necessary. 

Check whether cracks are on the welding positions of the half-axle bushing and the rear-axle 

housing and worn at the shaft journal of the wheel hub oil seal, and then calibrate or replace 

if necessary. 

14. Check the rear wheel hub 

(a). 

(b). 

(c). 

Check whether the rear wheel hub has cracks or loose screw. 

If the defects above are found out, replace with new rear wheel hub. 

Check the wear of the inner and outer bearing support necks of the rear wheel hub. 

Standard: The inner and outer support necks of the rear wheel hub shall be coordinated 

with the outer ring of the inner and outer bearings closely without looseness. 

If the coordination between the support necks and the outer ring of the bearings are loose, 

calibrate them and replace with a new rear wheel hub if necessary. 

Check the end face runout of the joint surface between the rear wheel hub and the half axle flange. 

End face runout: ≤ 0.15 mm 

Replace with a new rear wheel hub if the end face jumpiness is beyond the limit value. 

15. Check the rear brake drum 

(a). 

Check the wear of the rear brake drum, replace with a new one if necessary. 

25 

16. Connect the left rear wheel hub and the 

brake drum 

(a). 

Screw down the 6 nuts, and connect the left rear 

wheel hub and the brake drum. 

1051 series torque:287 ~ 346 N•m 

1061/1089/1099 series torque 396 ~ 480 N•m 

17. Connect the right rear wheel hub and the brake drum 

Notice: 

New nuts must be replaced . 

(b). Make three places of tooth density for each nut 

to prevent them from loosening. 

Hint: 

The steps for the connection of the right rear wheel and the brake drum are the same with those for the left rear 

wheel hub and the brake drum.


25-15 

18. Install the left rear wheel hub bearing 

(a). 

Apply lubricating grease on the outer ring of the 

inner tapered roller bearing and press it to the 

left rear wheel hub with a hammer and a copper 

bar. 

Lubricating grease: Lithium Grease No. 2 

(b). 

Apply lubricating grease on the outer ring of the 

outer tapered roller bearing and press it to the left 

rear wheel hub with a hammer and a copper bar. 


(c). 

Fill a large amount of lubricating grease inside 

the left rear wheel hub. 

Usage amount of lubricating grease (single wheel 

hub): 1051 series :280 g 

1061/1089 series :420g 

1099 series :420g 

19. Install the left rear wheel hub oil seal 

(a). 

Heat the inner oil seal ring to make it expand 

and use special press mold to press it on the left 

half-axle bushing. 

Notice: 

A new inner oil seal ring must be replaced 

25 

(b). 

At the same time, press the inner ring of the 

inner tapered roller bearing on the left half-axle 

bushing with a hammer and a copper bar and 

apply lubricating grease on it. 

Lubricating grease: Lithium Grease No. 2

25-16 


(c). 

Apply lubricating grease on the oil seal and install it 

on the left rear wheel hub with sharp-nose pliers. 


Notice: 

A new oil seal must be replaced. 

20. Install the right rear wheel hub bearing 

Hint: 

The steps for the installation of right rear wheel hub bearing are the same with those for the left rear 

wheel hub bearing. 

21. Install the right rear wheel hub oil seal 

Hint: 

The steps for the installation of right rear wheel hub oil seal are the same with those for the left rear 

wheel hub oil seal. 

22. Install the left rear wheel hub with brake 

drum assembly 

(a). 

Sets of the left rear wheel hub with brake drum 

assembly is fixed on the left half-axle bushing. 

Hint: 

Make the left half-axle bushing pass through from the 

center of the inner and outer tapered roller bearing of 

the left rear wheel hub. 

25 

(b). 

(c). 

Apply lubricating grease on the outer tapered roller 

bearing inner ring of the left rear wheel hub. 


Install the inner ring for the outer tapered roller 

bearing of the left rear wheel hub. 

(d). 

Apply lubricating grease on the screw thread of 

the left half-axle bushing and the lock nut of the 

left rear wheel hub. 

Lubricating grease: Lithium Grease No. 2


25-17 

(e). 

Install the lock nut of the left rear wheel hub bearing 

with a lock nut wrench of wheel hub bearing. 

Hint: 

It is no need to screw down the lock nut of the left rear 

wheel hub bearing at this step. 

(f). 

(g). 

Turn the left rear wheel hub for 2 to 3 rings with 

hand and make the rear wheel hub bearing 

enter into the correct position. 

Operate with the lock nut wrench of wheel hub 

bearing again to screw down the lock nut of the 

left rear wheel hub bearing. 

Hint: 

Loosen the lock nut of the left rear wheel hub bearing 

reversely for 1/8 to 1/6 revolution after screwing down. 

(h). 

(i). 

Adjust the clearance between the left rear brake 

drum and the brake shoe lining. (Refer to “chapter 

26 service brake – rear wheel brake, adjustment”) 

Check the pre-stressing force of the left rear 


• Rotate the left rear wheel hub for 2 to 3 rings 

by hand. 

Standard: Rotate freely 

If the defects of turning blockage and unsmoothness 

are found out, rotate the lock nut of the left rear wheel 

hub bearing for adjustment. 

• Measure the rotary breakout force of the 

left rear wheel hub with spring balance. 

Rotary breakout force: 

1051 series:31.3 ~ 52.3 N 

1061 /1089/1099series:30 ~ 55 N 

If the rotary breakout force is beyond the limit range, adjust 

rotate the lock nut of the left rear wheel hub bearing t. 

(j). 

(k). 

Apply lubricating grease on the locking washer of the 

left rear wheel hub bearing. 


Screw down 2 bolts and install the locking washer of 

the left rear wheel hub bearing. 

Hint: 

• If the mounting hole on the locking washer of the left rear 

wheel hub bearing doesn’t align with the threaded hole 

on the lock nut of the left rear wheel hub bearing, turn 

over the locking washer. 

• If the locking washer still doesn’t align with the 

threaded hole, then rotate the lock nut, it is 

necessary to adjust. 

25

25-18 


(l). 

Install the outer oil seal of the left half axle. 

23. Install the right rear wheel hub with brake drum assembly 

Hint: 

The steps of the installation of right rear wheel hub with brake drum assembly are the same with 

those for the left rear wheel hub with brake drum assembly. 

24. Check the half axle (refer to “chapter 25 rear axle-half axle, overhaul”) 

25. Install the left half axle 

(a). 

Insert the left half axle into the left half-axle 

bushing. 

25 

(b). 

Screw down the half-axle bolt. 

Torque: 

1051 /1099 series:37 ~ 75 N•m 

1061 series:75 ~ 113 N•m 

1089 series:108 ~ 161 N•m 

26. Install the right half axle. 

Hint: 

The steps for the installation of right half axle are the same with those for the left half axle. 

27. Fill rear axle gear oil (refer to “chapter 25 rear axle -rear axle gear oil, replacement”) 

28. Install rear wheels and tire assembly. (refer to “chapter 23 wheels and tires – rear 

wheels and tire assembly, replacement”)

Rear axle- Main reducing gear assembly 

Main reducing gear assembly 

Parts diagram 

25-19 

25 

1 housing of Main Reducing Gear 

2 pilot Bearing Baffle 

3 

Adjusting Washer of Driving Gear 

Bearing Seat 


5 Bolt 

6 Driving Gear Assembly 

7 Bolt 

8 Outer Ring of Pilot Bearing 

9 Nut 

10 Adjusting nut 

11 Outer Ring of Differential Bearing 

12 Bearing Cover 

13 Driven Gear and Differential Assembly 

14 Bearing Cover Bolt 

15 Hexagon Head Bolt 

16 Locking Plate for Adjusting Nut

25-20 

Inspection 


1. Inspect the driven gear jumpiness 

(a). 

Measure the jumpiness from the back of the 

driven gear with a dial indicator. 

Limit value: 0.07 mm 

If the jumpiness of the driven gear is beyond the limit 

value, replace with a new driven gear. 

25 

2. Inspect the meshing marks of driving gear 

and driven gear 

(a). 

(b). 

Check the meshing marks of the driven gear by 

red lead powder. 

Correct meshing marks of the driven gear 

Position: At the higher part of the tooth 

surface of the driven gear and slightly 

deflect to the small end. 

Length: ≥ 60% of the tooth surface 

Width: ≥ 50% of the tooth surface 

If the meshing marks of the driving gear and the 

driven gear are not correct, adjust them by changing 

the number of the washers through the increase or 

decrease of the driving gear bearing seat and 

adjusting the nuts through the rotation of the 

differential bearing. (Refer to “chapter 25 rear 

axle-differential assembly, overhaul”, and “chapter 

25 rear axle- driving gear assembly, overhaul”) 

Notice: 

Ensure that the ring number of the adjusting nuts 

screwed in on the differential side is the same with 

that screwed out to maintain the same 

pre-stressing force of the differential bearing, and 

then fasten the locking plates.


3. Adjust the meshing marks of driving gear and driven gear 

25-21 

Meshing marks of the driven 

gear 

Causes 

The driving gear is too far from 

the driven gear. 

The driving gear is too close to 

the driven gear. 

The driven gear is too close to the 

driving gear. 

The driven gear is too far from the 

driving gear. 

Procedures of adjustment 

1. Adjust the driven gear to keep it 

away from the driving gear. 

2. Adjust the driving gear to make 

it close to the driven gear. 

1. Adjust the driven gear to make 

it close to the driving gear. 

2. Adjust the driving gear to keep 

it away from the driven gear. 

1. Adjust the driven gear to keep it 

away from the driving gear. 

2. Adjust the driving gear to keep 

it away from the driven gear. 

1. Adjust the driven gear to make 

it close to the driving gear. 

2. Adjust the driving gear to make 

it close to the driven gear. 

Hint: 

• Step 1, adjust the gear tooth meshing of the driving and driven gears. (Rotate the differential bearing 

for the adjustment of nuts, refer to “chapter 25 rear axle-differential assembly, overhaul”) 

• Step 2, adjust the tooth surface clearance between the driving gear and the driven gear. (Adjust the 

washer through the increase and decrease of driving gear bearing seat, refer to “CHAPTER 25 REAR 

AXLE-DRIVING GEAR ASSEMBLY, OVERHAUL”) 

• Check the meshing marks of the driving gear and the driven gear again after adjustment, until getting 

the correct meshing marks of the driving gear and the driven gear. 

4. Inspect the tooth surface clearance of driving 

gear and driven gear 

(a). 

Measure the tooth surface clearance between the 

driving gear and the driven gear by a dial indicator. 

Hint: 

• Measure respectively on the four positions that 

uniformly distribute along the circumference of the 

driven gear. 

• Make sure that the head of the dial indicator must be 

perpendicular to the surface of the point being 

measured. 

Tooth surface clearance: 

1051/1061 series 0.18 ~ 0.23 mm 

1089 series 0.3 ~ 0.4 mm 

1099 series 0.15-0.30mm 

If the tooth surface clearance of the driven gear is beyond the 

standard value or the variation quantity is beyond the limit value, 

adjust the washer through the increase or decrease of the 

driving gear bearing seat. (refer to “chapter 25 rear axle-driving 

gear assembly, overhaul”) 

25

25-22 

Replacement 


1. Drain rear axle gear oil. (refer to “chapter 25 rear axle -rear axle gear oil, replacement”) 

2. Separate the rear transmission shaft and the main reducing gear. (refer to “chapter 33 


3. Remove the half axle. (refer to “chapter 25 rear axle –half axle, overhaul”) 

4. Remove the main reducing gear assembly. 

(a). 

Loosen 12 bolts. 

(b). 

(c). 

Take out the main reducing gear assembly from 

the rear-axle housing by a puller. 

Transport the main reducing gear assembly to 

the work bench by a hydraulic jack. 

25


25-23 

5. Install the main reducing gear assembly 

(a). 

(b). 

(c). 

Transport the main reducing gear assembly to the 

front of the rear-axle housing with a hydraulic jack. 

Apply sealant on the installation surface of the 

rear-axle housing and the main reducing gear. 

Sealant: 1587 silicone rubber sealant 

Push the main reducing gear assembly into the 

rear-axle housing. 

(d). Apply sealant on the screw thread of the 12 

bolts and inside the threaded hole of the 

rear-axle housing. 

(e). 

Sealant: 605 mechanical sealant 

Screw down 12 bolts. 

Torque: 

1051/1061 series:78 ~ 115 N•m 

1089 series:178 ~ 235 N•m 

1099 series:78 ~ 115 N•m 

6. Install the half axle. (refer to “chapter 25 rear axle –half axle, overhaul”) 

7. Connect the rear transmission shaft and the main reducing gear. (refer to “chapter 33 


8. Fill rear axle gear oil. (refer to “chapter 25 rear axle -rear axle gear oil, replacement”) 

25

25-24 


Components 

Rear axle- Differential assembly 

25 

1 Driven Gear 

2 Cross Shaft 

3 Planetary Gear 

4 Planetary Gear Thrust Washer 

6 Half-axle Gear Thrust Washer 

7 Inner Ring of Differential Bearing 

8 Right Case of Differential 

9 Left Case of Differential 

5 Half-axle Gear

Inspection 


25-25 

1. Inspect the end clearance of half-axle 

gear 

(a). 

Inspect the end clearance of half-axle 

gear by a clearance gauge. 

Hint: 

The inspection methods for the end clearance of 

the left half-axle gear and the right half-axle gear 

are the same. 

End clearance:1051 series:0.05 ~ 0.24 mm 

1061 series:0 ~ 0.18 mm 

1089/1099 series:0.1 ~ 0.23 mm 

If the end clearance is beyond the limit value or 

the differential makes too much noise while the 

vehicle turns, disassemble the differential 

assembly and replace a new half-axle gear 

thrust washer. 

If the end clearance doesn’t exceed the limit 

value and the differential doesn’t make too much 

noise while the vehicle turns, it is no need to 

disassemble the differential assembly. 

2. Adjust the pre-stressing force of 

differential bearing 

(a). 

Loosen the bolt and remove the locking 

plate. 

25 

(b). 

Measure the rotary breakout force of the 

driven gear by spring balance. 

Moment of rotary breakout force: 

0.686~1.586 N•m 

If the rotary breakout force of the driven gear is 

beyond the limit range, screw the adjusting nut 

for adjustment.

25-26 


(c). 

Screw the adjusting nut with a differential 

wrench. 

(d). 

Measure the rotary breakout force of the driven 

gear again and repeat Step (b) and Step (c) if 

necessary. 

Notice: 

Ensure that the driven gear has no axial clearance 

after the completion of adjustment. 

(e). 

Install the locking plate and screw down the bolt. 

25

Overhaul 


1. Remove the main reducing gear assembly. (refer to “chapter 25 rear axle –main 

reducing gear assembly, replacement”) 

2. Remove the bearing cover 

(a). 

(b). 

25-27 

Make matchmarks on the bearing cover and 

the differential case. 

Make matchmarks on the bearing cover and 

the adjusting nut. 

(c). 

Loosen the bolt and remove the locking plate. 

(d). 

Remove the adjusting nut with a differential 

wrench. 

Notice: 

Make sure that the bolt of bearing cover is slightly 

loosened before carrying out this step. 

25 

(e). 

Loosen 2 bolts of bearing cover and remove 

the bearing cover. 

• Remove the outer ring of the differential 

bearing at the same time. 

Hint: 

The steps are same for the removal of the bearing 

covers on both sides. 

Notice: 

Make sure that the parts for the left side and the 

right side of the differential are placed separately 

and label on them to indicate the left and the right.

25-28 


3. Remove the differential assembly 

(a). 

Lift The differential assembly of and a copper 

bar and a hoister and take out the differential 

assembly from the case of main reducing gear. 

4. Inspect the end clearance of half-axle gear. (refer to “chapter 25 rear axle –differential 

assembly, inspection”) 

End clearance: 

Vehicle type 

End clearance 

1049 series 0.05 ~ 0.24 mm 

1061 series 0 ~ 0.18 mm 

1089/1099 series 0.10 ~ 0.23 mm 

If the end clearance is beyond the limit value or the differential makes too much noise while the vehicle 

turns, disassemble the differential assembly and replace with a new half-axle gear thrust washer. 

If the end clearance doesn’t exceed the limit value and the differential doesn’t make too much noise 

when the vehicle turns, it is no need to disassemble the differential assembly. 

5. Disassemble the differential assembly 

(a). 

Make matchmarks on the left and right housing 

of the differential. 

25 

(b). 

Loosen 8 bolts to separate the left and the right 

housing of the differential.


25-29 

(c). 

Disassemble the right half-axle gear and the 

thrust washer of the half-axle gear. 

(d). 

Measure the tooth surface clearance between 

the planetary gear and the half-axle gear with a 

dial indicator. 

Notice: 

Make sure to compact the cross shaft of the 

planetary gear to avoid sliding. 

Hint: 

More than 3 points shall be measured at this step. 

Tooth surface clearance: 

Vehicle type 

Tooth surface clearance 

Standard 

Limit 

1049 series 0 ~ 0.09 mm 0.18 mm 

1061 series 0 ~ 0.09 mm 0.18 mm 

1089/1099 series 0 ~ 0.15 mm 0.30 mm 

If the tooth surface clearance is beyond the limit value, 

check the wear of the thrust washer, planetary gear and 

the half-axle gear and replace them if necessary. 

25 

(e). 

(f). 

Remove the planetary gear and the cross shaft 

assembly (including the planetary gear thrust 

washer). 

Remove the planetary gear and the planetary 

gear thrust washer from the cross shaft.

25-30 


(g). 

Measure the radial clearance of the cross shaft 

and the planetary gear by a bench screw and a 


Radial clearance: 

Vehicle type 

Radial clearance 

Standard 

Limit 

1049 series 0 ~ 0.04 mm 0.09 mm 

1061 series 0 ~ 0.04 mm 0.09 mm 

1089 series 0 ~ 0.12 mm 0.25 mm 

1099 series 0.105mm 

If the radial clearance is beyond the limit value, check 

the worn of the cross shaft and the planetary gear and 

replace them if necessary. 

Notice: 

Make sure to wrap the cross shaft with a soft cloth 

and then clamp it with a bench screw so as to avoid 

damage. 

(h). 

Measure the radial clearance of the half-axle 

gear and the differential case by bench screw 

and a dial indicator. 

Radial clearance: 

Vehicle type 

Standard 

Radial clearance 

Limit 

25 

1049 series 0 ~ 0.08 mm 0.16 mm 

1061 series 0 ~ 0.08 mm 0.16 mm 

1089/1099series 0 ~ 0.22 mm 0.45 mm 

If the radial clearance is beyond the limit value, check 

the worn of the half-axle gear and the differential 

housing and replace them if necessary. 

(i). Measure the clearance of the half-axle gear and 

the half-axle spline by bench screw and dial 

indicator. 

Clearance: 

Clearance 

Vehicle type 

Standard Limit 

1049 series 0 ~ 0.55 mm 1.11 mm 

1061 series 0 ~ 0.55 mm 1.11 mm 

1089/1099series 0.030 ~ 0.217 mm 1.11 mm 

If the clearance is beyond the limit value, check the 

worn of the half-axle gear and the half-axle spline , 

replace them if necessary.


25-31 

(j). 

Measure the thickness of the planetary gear and 

the half-axle gear thrust washers and check the 

wear of them. 

• Planetary gear thrust washer 

Thickness: 

Vehicle type 

Thickness 

1049 series 0.92 ~ 1.00 mm 

1061 series 1.42 ~ 1.50 mm 

1089 series 1.00 mm 


• Half-axle gear thrust washer 

Thickness: 

Vehicle type 

Thickness 

1049 series 1.35 ~ 1.45 mm 

1061 series 1.92 ~ 2.00 mm 

1089 series 1.42 ~ 1.50 mm 


If the thickness of the planetary gear and the half-axle 

gear thrust washers is beyond the limit value and the 

differential makes too much noise when the vehicle 

turns, replace with new thrust washers. 

Notice: 

The sets of thrust bearings must be replaced 

together. 

25 

(k). 

Remove the left half-axle gear and the half-axle 

gear thrust washers. 

6. Remove the driven gear 

(a). 

Loosen 12 nuts and separate the driven gear 

and the left housing of the differential.

25-32 

7. Check the driven gear 

(a). 


Check the tooth surface of the driven gear damage and wear. 

• Repairing is needed if slight damage is found on the tooth surface. 

• If the defects of scuffing, peeling, spot corrosion, cracks or excessive wear are found 

on the tooth surface, replace with a new driven gear. 

Notice: 

The sets of driving gear and driven gear must be replaced together. 

8. Remove the differential bearing 

(a). 

Remove the inner ring of the differential bearing 

from the left and right housing of the differential 

by a puller. 

Notice: 

Make sure that the inner ring of the differential 

bearing and the adjusting nuts and bearing cover 

removed are placed together and the parts of the 

left side are separated from those on the right 

side. 

9. Install the differential bearing 

(a). 

Install the inner ring of the differential bearing 

on the left and right housing of the differential. 

Notice: 

Make sure the installation is carried out in 

accordance with the left and right labels. 

25 

10. Install the driven gear 

(a). Sealant is daub on the screw thread of the 12 bolts and inside the threaded hole of the driven gear. 

Sealant: GY-340 anaerobic adhesive 

(b). 

Screw down the 12 bolts in order and connect 

the driven gear and the left housing of the 

differential. 

Torque: 

Vehicle 

Torque 

1049 series 108 ~ 161 N•m 

1061 series 182 ~ 245 N•m 

1089 series 178 ~ 235 N•m 

1099 series 199 ~ 270 N•m


25-33 

11. Assemble the differential assembly 

(a). 

Install the left half-axle gear and the half-axle 

gear thrust washer. 

(b). 

Install the planetary gear and the cross shaft 

assembly (including the planetary gear thrust 

washer). 

(c). 

Install the right half-axle gear and the half-axle 

gear thrust washer. 

(d). 

Screw down the 2 bolts on the cross and connect 

the left and right housing of the differential. 

Notice: 

Make sure that the installation is carried out in 

accordance with the matchmarks. 

Hint: 

It is no need to screw down all the bolts at this step, 

only a group of bolts on any diagonal line is enough. 

25

25-34 


(e). 

Check the end clearance of the half-axle gear. 

(Refer to “chapter 25 rear axle –differential 


End clearance: 

Vehicle type 

End clearance 

1049 series 0.05 ~ 0.24 mm 

1061 series 0 ~ 0.18 mm 

1089 /1099series 0.10 ~ 0.23 mm 

If the end clearance is beyond the limit value, disassemble 

the differential assembly again and replace with a new 

half-axle gear thrust washer and repeat this step. 

If the end clearance is not beyond the limit value, go 

on the next step. 

(f). 

Loosen the two bolts is screwed down on the 

cross. 

25 

(g). Apply sealant on the screw thread of the 12 

bolts and inside the threaded hole of the 

differential housing. 

Sealant: GY-340 anaerobic adhesive 

(h). 

Screw down the 8 bolts in order and connect the 

left housing and right housing of the differential. 

Notice: 


accordance with the matchmarks. 

Torque: 

Vehicle type 

Torque 

1049 series 54 ~ 70 N•m 

1061 series 182 ~ 245 N•m 

1089 series 178 ~ 235 N•m 

1099 series 199 ~ 270 N•m


25-35 

12. Install the differential assembly 

(a). 

Lift the differential assembly with a copper bar 

and a hoister and put it into the housing of main 

reducing gear. 

13. Install the bearing cover 

(a). 

(b). 

Fill rear-axle gear oil between the inner ring and the outer ringer of the differential bearing. 

Gear oil: hypoid gear oil GL-5 85W/90 

Close the bearing cover and the differential housing freely and screw the adjusting nut into 

the mounting hole by hand. 

• Install the outer ring of the differential bearing at the same time. 

Notice: 

Make sure that the installation is carried out in accordance with the matchmarks. 

Hint: 

The adjusting nut is only needed to be screwed to rotate freely at this step. 

(c). 

Screw down 2 bolts of bearing cover and fasten 

the bearing cover. 

Torque: 

Vehicle type 

Torque 

1049 series 134 ~ 174 N•m 

1061 series 186 ~ 242 N•m 

1089 series 380 ~ 467 N•m 

1099 series 182 ~ 245 N•m 

25 

(d). 

Screw down the adjusting nut with a differential 

wrench. 

14. Adjust the pre-stressing force of differential bearing. (refer to “chapter 25 rear 

axle-differential assembly, inspection”) 

15. Inspect the driven gear defection. (refer to “chapter 25 rear axle- main reducing gear 


16. Inspect the meshing marks of driving gear and driven gear. (refer to “chapter 25 rear 

axle- main reducing gear assembly, inspection”) 

17. Inspect the tooth surface clearance of driving gear and driven gear. (refer to “chapter 

25 rear axle- main reducing gear assembly, inspection”) 

18. Install the main reducing gear assembly. (refer to “chapter 25 rear axle- main reducing 

gear assembly, replacement”)

25-36 

Rear axle- Driving gear assembly 


Parts diagram 

25 

1 Flange Nut 

2 Flange Gasket 

3 Flange 

4 Driving Gear Oil Seal 

5 Outer Bearing 

6 Bearing Seat 

7 Adjusting Washer of Bearing Seat 

8 O Ring 

9 Bearing Spacer 

10 Adjusting Washer of Driving Gear 

11 Inner Bearing 

12 Driving Gear 

13 Pilot Bearing 

14 Retaining Ring of Pilot Bearing

Inspection 


25-37 

1. Inspect the pre-stressing force of driving 

gear bearing 

(a). 

(b). 

Rotate the driving gear for five rings by hand in 

the same direction. 

Measure the rotary breakout force of the driving 

gear with bench screw, special fixture and 

spring balance. 

Rotary breakout force: 9.8~19.6 N 

If the rotary breakout force of the driving gear is 

beyond the limit range, adjust it by adjusting the 

washer through the increase or decrease of driving 

gear bearing. 

Specification (thickness): 0.05, 0.10, 0.20, 

0.40, 0.50 mm 

Notice: 

Measure the rotary breakout force of the driving 

gear and make sure that the measurement is 

carried out after the disassembly of driving gear oil 

seal and the driving gear bearing is fully 

lubricated. 

25

25-38 

Overhaul 


1. Remove the driving gear assembly 

(a). 

Make matchmarks on the flange to ensure that 

the direction of the flange will not change during 

the installation. 

(b). 

Loosen the 7 bolts of the driving gear bearing 

seat. 

(c). 

Take out the driving gear assembly from the 

housing of main reducing gear. 

25 

(d). 

Remove the adjusting washer of the driving 

gear bearing seat. 

Notice: 

The adjusting washer of the driving gear bearing seat 

removed and can’t be used again. 

2. Disassemble the driving gear assembly 

(a). 

Pull out the cotter pin and loosen the flange nut.


25-39 

(b). 

(c). 

Remove the flange gasket. 

Pull out the flange. 

(d). 

Remove the driving gear oil seal (1) with 

sharp-nose pliers. 

Notice: 

The driving gear oil seal removed and can’t be 

used again. 

(e). Remove the inner ring of the outer bearing (4). 

(f). 

Press out the driving gear with bench press. 

(g). Remove the outer ring of the inner bearing (3) 

and the outer ring of the outer bearing (2) from 

the driving gear bearing seat with a hammer 

and a copper bar. 

25 

(h). 

Remove the bearing adjusting washer and the 

bearing sleeve from the driving gear. 

Notice: 

The bearing sleeve removed and can’t be used 

again.

25-40 


(i). 

Remove the inner ring of the inner bearing from 

the driving gear with a puller. 

(j). 

Disassemble the elastic damping ring with 

spring pliers and sharp-nose pliers. 

Notice: 

The elastic damping ring removed can’t be used 

again. 

(k). 

Remove the inner ring of the pilot bearing from 

the driving gear with a puller. 

HINT: 

Remove the outer ring of the pilot bearing after 

removing the differential and the pilot bearing baffle. 

25 

3. Inspect the driving gear 

(a). 

(b). 

Inspect the tooth surface damage and the wear of the driving gear. 

Repairing is needed if slight damage is found on the tooth surface. 

scuffing, peeling, spot corrosion, cracks or excessive wear such as defects the defects are 

found on the tooth surface, replace with a new driving gear. 

Inspect the wear of the driving gear bearing journal and the elastic damping ring groove. 

If serious damage is found, replace with a new driving gear. 

Notice: 

The sets of driving gear and driven gear must be replaced together. 

4. Assemble the driving gear assembly 

(a). 

(b). 

Press the inner ring of the pilot bearing on the 

driving gear and apply gear oil on it. 

Gear oil: GL-5 85W/90 

Install the elastic damping ring with spring pliers 

and sharp-nose pliers. 

Notice: 

A new elastic damping ring must be replaced to 

ensure install it into the groove.


25-41 

(c). 

Press the inner ring of the inner bearing on the 

driving gear with a bench press. 

(d). 

Set the bearing spacer and the bearing 

adjusting washer on the driving gear. 

Notice: 

A new bearing spacer must be replaced with. 

(e). 

(f). 

Clean the driving gear bearing seat and apply 

gear oil on the installation surface of the driving 

gear oil sea and the outer ring of the outer 

bearing. 


Install the outer ring of the inner bearing (3) and 

the outer ring of the outer bearing (2) on the 

driving gear bearing seat with a hammer and a 

copper rod and apply gear oil on them. 


25 

(g). 

Press the bearing seat on the driving gear with a 

bench press.

25-42 


(h). 

Install the inner ring of the outer bearing of 

driving gear (4). 

(i). 

(j). 

Install the flange. 

Install the flange gasket. 

(k). 

Screw down the flange nut and insert the cotter 

pin. 

Torque: 

Vehicle type 

Torque 

1049 series 250 ~ 280 N•m 

1061 series 323 ~ 408 N•m 

25 

1089 series 350 ~ 450 N•m 

1099 series 323 ~ 480 N•m 

(l). 

(m). 

(n). 

Inspect the pre-stressing force of driving gear 

bearing. (Refer to “chapter 25 rear axle –driving 

gear assembly, inspection”) 

Make matchmarks on the ends of flange nut and 

driving gear. 

Pull out the cotter pin and loosen the flange nut.


25-43 

(o). 

(p). 

Remove the flange gasket. 

Pull out the flange. 

(q). 

Install the driving gear oil seal (1) with 


(r). 

(s). 

Install the flange. 

Install the flange gasket. 

(t). 

Screw down the flange nut and insert the cotter 

pin. 

Torque: 

25 

Vehicle type 

Torque 

1049 series 250 ~ 280 N•m 

1061 series 323 ~ 408 N•m 

1089 series 350 ~ 450 N•m 

1099 series 323 ~ 480 N•m 

Notice: 


accordance with the matchmarks.

25-44 

5. Install the driving gear assembly 

(a). 


Install the adjusting washer of the driving gear bearing seat. 

Specification (thickness): 0.10, 0.15, 0.40mm 

Notice: 

Make sure a new adjusting washer of the driving gear bearing seat is replaced with. 

Hint: 

The number of the adjusting washer of the driving gear bearing seat shall ensure to get correct 

meshing marks of driving and driven gears. (Refer to “chapter 25 rear axle –main reducing gear 


(b). 

Insert the driving gear assembly into the 

housing of main reducing gear. 

Notice: 

Make sure that the installation is carried out 

in accordance with the matchmarks. 

(c). 

Screw down 7 bolts and fasten the driving 

gear bearing seat. 

Torque: 

Vehicle type 

Torque 

1049 series 80 ~ 104 N•m 

1061 series 80 ~ 104 N•m 

25 

1089/1099 series 105 ~ 156 N•m 

6. Inspect the meshing marks of driving gear and driven gear. (refer to “chapter 25 rear 

axle- main reducing gear assembly, inspection”) 

7. Inspect the tooth surface clearance of driving gear and driven gear. (refer to “chapter 

25 rear axle- main reducing gear assembly, inspection”)

Braking 

Brake system ........................................................ 26-1 

Notes ................................................................ 26-1 

Malfunction Symptoms Table ........................... 26-2 

Component inspection ..................................... 26-4 

Brake system bleeding ..................................... 26-5 

Brake pedal ............................................................ 26-7 

Adjustment ....................................................... 26-7 

Parts diagram ................................................... 26-9 

Replacement .................................................. 26-10 

Vacuum booster with brake master cylinder ......... 26-17 

Component drawing ....................................... 26-17 

Detection ........................................................ 26-18 

Replacement .................................................. 26-19 

Vacuum tank ........................................................ 26-25 

Component drawing ....................................... 26-25 

Replacement .................................................. 26-26 

Front wheel brake ................................................. 26-28 

Parts diagram ................................................. 26-28 

Overhaul ........................................................ 26-29 

Overhaul ........................................................ 26-31 

Rear wheel brake ................................................. 26-37 

Parts diagram ................................................. 26-37 

Overhaul ........................................................ 26-38 

26

26

Brake system 

Notes 

1. Brake system operation notes 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

(g). 

Braking-brake system 

26-1 

Care must be taken to replace each part properly. Improper installation could affect the 

performance of the brake system and result in person security 

Replace all parts with parts which are original pure parts. 

Keep all parts and the work area clean. 

Brake pipes are important safety parts, if a leak is detected, they must be repaired or 

replaced if necessary. 

When operate brake pipes, use a cap on the pipe orifice in order to prevent dust, dirt and 

other foreign materials from entering into the pipe. 

Do not bend the brake pipes or deform them during the removal or installation. 

The buckles or cable tie removed can not be used again. 

2. Brake system maintenance notes 

(a). Inspect regularly, inspect the following parts every 5.000 Km. 

Inspect the clearance of brake shoe lining and brake drum. 

Inspect the brake shoe lining for wear. 

Inspect brake pedal stroke and pedal free play. 

Inspect the damage of brake pipes. 

Inspect the looseness of each connection. 

Inspect whether the functions of brake system are normal. 

26

26-2 


Malfunction Symptoms Table 

Use the table below to help you find the cause of malfunction. The numbers indicate the probability 

of the cause of the malfunction. Check each part in order. If necessary, replace these parts. 

Symptom Possible position Measure reference 

Brake failure 

1. Master cylinder (no brake fluid or 

severely shortage) 

2. Master cylinder (severe master 

cylinder wearing or damage of cup of 

master and wheel cylinder) 

3. Brake fuel pipe (rupture or severe 

damage of connector) 

4. Master cylinder pushrod (drop-off) 

Properly fill the brake fluid 

Chapter 26 Service brake - vacuum booster with 

brake master cylinder, replacement 

Repair or replace the brake oil pipe 

Repair 

Brake malfunction 

1. Brake system (air in brake pipeline or 

oil leakage) 

2. Brake pedal (excess free path) 

3. Rear brake (excess clearance 

between brake drum and friction 

wafer) 

4. Rear brake (swelling blockage of 

brake cup) 

5. Rear brake (excessive wearing, poor 

contact or oil of friction wafer) 

6. Rear brake (out of round of brake drum, 

unqualified wearing coefficient) 

7. Brake hose (ageing) 

Chapter 26 Service brake - Brake system, brake 

system bleeding 

Chapter 26 Service brake - brake pedal, 

adjustment 

Chapter 26 Service brake - rear wheel brake, 

inspection and repair 







Replace the hose 

1. Brake shoe (clearance difference of 

left and right brake shoes) 

2. Brake system (blockage of individual brake 

Adjust the clearance 

Dredge the pipeline, bleed the brake system 

26 

Braking deflection 

hose connector and air in the pipeline) 

3. Rear brake wheel cylinder cup (swelling 

blockage of individual cup) 

4. Brake shoe friction wafer (oil stain or 

damage of individual wheel brake 

shoe friction wafer) 

5. Tyre (pressure difference of left and 

right tyres) 

6. Rear wheel brake drum (out of round 

of individual brake drum) 

7. Rear wheel brake drum (deformation 

after assembly of brake drum and tyre) 

8. Rear wheel brake drum (difference of 

friction coefficient of left and right 

brake drum) 

9. Brake drum (difference of effect time of 

left and right brake force) 

10. Frame (severe deformation of frame, 

non-parallel wheelbase) 

Replace the leather cup 

Grind or replace the shoe 

Make up the pressure 

Repair or replace 

Measure and check after assembly of brake drum 

and tyre 

Replace with the brake drum of same friction 

wafer coefficient 

Find out the cause, make the judgment and 

adjust 

Measure and adjust 

Brake grab (simultaneous 

grab of all wheels) 

1. Brake master cylinder (slow return) 

2. brake pedal (too less free path) 

3. Brake pipeline (blockage, unsmooth oil 

return) 

Repair or replace the master cylinder 

Chapter 26 Service brake - brake pedal, 

adjustment 

Dredge the pipeline


26-3 

Symptom Possible position Measure reference 

Brake 

grab 

(simultaneous grab of 

few wheels) 

1. rear wheel brake (too small 

clearance of brake drum and 

friction wafer) 

2. rear wheel brake (weakness of 

brake shoe return spring) 

3. Rear brake wheel cylinder (leather 

cup swelling or piston jamming) 

4. Brake pipeline (blockage) 

Adjust the clearance 

Replace the spring or adjust the support pin or 

eccentric spring 

Replace or repair 

Dredge the pipeline 

1. Rear wheel brake drum (out of 

Repair or replace the brake drum 

Abnormal brake noise 

round or uneven wearing) 

2. rear wheel brake friction wafer (dirt 

or damage) 

3. rear wheel brake (brake shoe 

brake drum 

4. rear wheel brake friction wafer 

(excessive wearing or damage) 







Gradual go-down of 

brake pedal 

1. Brake pipeline (oil leakage or air) 

2. Brake master cylinder (wearing of 

leather cup or ring, oil flowing 

between front and rear part during 

brake) 

3. Brake wheel cylinder (leather cup 

overturn) 

Chapter 26 Service brake – service brake 

system, brake system bleeding 

Chapter 26 Service brake – vacuum booster 

with brake master cylinder, inspection and 

repair 



Gradual rise of brake 

pedal 

1. Brake master cylinder (blockage of 

master cylinder oil supply hole or 

the leather cup can not cover the 

oil hole and the surplus brake fluid 

can not return the reservoir) 

2. Brake master cylinder (too small 

free clearance of master pump 

pushrod) 

Dredge the oil supply hole and re-adjust 

Re-adjust 

26 

Too heavy of brake pedal 

1. Vacuum booster (diaphragm air 

leakage or spring rupture) 

2. Vacuum booster (oil leakage of 

control valve diaphragm) 

3. Vacuum booster (not tightly closed 

of vacuum valve of control valve) 

4. Vacuum pipeline (air leakage) 

Chapter 26 Service brake - Vacuum booster 


repair 



repair 



repair 



repair

26-4 

Component inspection 


1. Check the damage of vacuum booster with brake master cylinder assembly or oil 

leakage 

(a). 

(b). 

Check the oil leakage between brake master cylinder and booster. 

Check the damage or oil leakage of pipeline connectors around the brake master cylinder 

and booster. 

2. Check the damage or oil leakage of brake hose 

(a). 

(b). 

(c). 

Check the damage or oil leakage of pipeline connector and integral bolting connector. 

Check the oil leakage of hose and pipeline. 

Check the excessive torsion or curve of pipeline. 

3. Check the damage or oil leakage of front brake caliper 

(a). 

(b). 

(c). 

Check the piston sealness. 

Check the damage or oil leakage of integral bolting connector. 

Check the oil leakage of drain valve screw. 

4. Check the damage or oil leakage of rear brake wheel cylinder 

(a). 

(b). 

(c). 

Check the damage or oil leakage of rear brake wheel brake cylinder. 

Check the damage or oil leakage of integral bolting connector. 

Check the oil leakage of drain valve screw. 

5. Check the damage or oil leakage of ABS HECU assembly 

(a). 

(b). 

Check the damage or oil leakage of pipeline connector near ABS HECU assembly. 

Check the damage of HECU assembly. 

26

Brake system bleeding 

Note: 

 

 

 

 

 


The brake fluid bleeded can not be re-used. 

It is definitely necessary to use proper brake fluid. 

26-5 

Confirm the brake fluid shall not be polluted by the dirt or other foreign matters. 

Do not spatter the brake fluid on the vehicle since it will damage the paint. If the 

brake fluid has spattered on the paint, immediately clean with water. 

When the bleeding starts, the level of reservoir of brake master cylinder must be 

at the maximum level mark position. It must be checked after bleeding for each 

brake caliper or brake wheel cylinder. Refill adequate brake fluid according to 

the requirement. 

1. Confirm the brake fluid level in reservoir is at 

maximum level position. 

2. Unscrew down the right front bleeding screw 

cap. 

26 

3. Slide a transparent plastic hose onto the right 

front bleeding screw and then insert the other 

end into the container filled with new brake fluid.

26-6 


4. Ask the assistant to slowly step down the brake 

pedal for several times and then apply a stable 

pressure onto the pedal. 

5. Loosen the right front brake bleeding screw to 

emit the air from the brake system, and then 

tighten the bleeding screw. 

6. Conduct above mentioned operations in 

sequence to each brake until there is no air 

bubble in the drain pipe. 

Note: 

Bleeding sequence: 1 right front ----- 2 Left front ---- 

3 Left rear ---- 4 Right rear 

26 

7. Fill the brake reservoir again to the maximum 

level line.

Brake pedal 

Adjustment 

Rear axle- Brake pedal 

1. Inspect and adjust brake pedal height 

(a). 

(b). 

Turn over the floor carpet in the driving cab. 

Inspect the brake pedal height. 

Brake pedal height: 

26-7 

1051/1061/1089/1099series :Standard value:160 mm 

Limit value: 165 mm 

Pedal height 

Front boarding 

(c). 

Adjust the brake pedal height. 

 

Disconnect the connector from the brake 

lamp switch. 

26 

 

Loosen the brake lamp lock nut, adjust 

the pedal height to standard value by 

turning the brake lamp switch.

26-8 


 

Tighten the brake lamp switch lock nut. 

Torque: 20 ± 5 N•m 

Hint: 

Do not rotate brake lamp switch when tightening the 

brake lamp switch lock nut. 

Connect the brake lamp switch 

connector. 

Pedal free 

stroke 

2. Inspect brake pedal free stroke 

(a). 

Stop the engine and depress the brake pedal 

gently until slight resistance is felt. 

1051/1061/1089/1099series pedal free stroke: 

Standard value:10 mm 

Limit value: 15 mm 

26 

Front 

boarding 

Pedal reserve route 

3. Inspect the brake pedal reserve stroke 

(a). 

(b). 

Loosen the parking brake. 

When the engine is running, depress the brake 

pedal and measure the pedal reserve distance. 

1051/1061/1089/1099series pedal stroke reserve: 

Standard value:50mm 

Limit value: 45 mm

Parts diagram 


26-9 

26 

1 Bolt 5 washer 

2 Spring washer 6 Spring Washer 

3 Washer 7 Nut 

4 Clutch brake pedal assy

26-10 

Replacement 

1. Disconnect battery negative cable 


2. Remove combination meter assembly (refer to “chapter 73 instrument 

desk/meter/cigar lighter-instrument panel, replacement”) 

3. Remove instrument panel installation crossbar welding assembly (refer to “chapter 51 

heater and air conditioning-heater housing assembly, overhaul”) 

4. Disconnect the connector from clutch switch (refer to “chapter 32 clutch-clutch pedal, 


5. Disconnect the connector from brake lamp switch (refer to “chapter 26 service 

brake-brake pedal, adjustment”) 

6. Drain clutch fluid 

7. Disconnect clutch master cylinder oil inlet 

pipe 

(a). 

Loosen the clutch master cylinder oil inlet hose 

hoop with a screw-driver and disconnect the 

clutch master cylinder oil inlet hose. 

Notice: 

Use a dedicated container to recover the clutch 

fluid remained; don’t make it stick to any painted 

surface, wash the fluid off with a large amount of 

water immediately if it comes into contact with the 

skin. 

26 

8. Disconnect clutch master cylinder oil outlet 

pipe 

(a). 

Loosen the terminal nuts of clutch master 

cylinder oil outlet pipe, disconnect the clutch 

master cylinder oil outlet pipe.


26-11 

9. Disconnect brake vacuum booster 

connecting pipe 

(a). 

Loosen brake vacuum booster vacuum hose 

fixing clamp, separate vacuum booster vacuum 

hose. 

10. Disconnect brake master cylinder 

connecting pipe 

(a). 

Loosen two inlet hose fixing clamp of brake 

master cylinder, separate brake master cylinder 

inlet hose. 

NOTICE: 

Special container must be used for recycling relic 

brake oil; brake oil shall not be attached on the 

surface of the paints. If the brake oil is attached on 

the skin, clean with water. 

(b). 

Loose two outlet oil locking bolts of brake 

master cylinder, separate brake master cylinder 

oillet tube line. 

11. Remove brake pedal assembly 

(a). 

Remove two connecting bolts of pedal assy and 

cab. 

26 

(b). 

Remove two connecting bolts of pedal assy and 

cab.

26-12 


(c). 

take off brake clutch pedal assy. 

Notice: 

There are too many harnesses at this location, 

donot snap down or damage harness. 

12. Install brake pedal assembly 

(a). 

(b). 

loose brake lamp switch locking nut and take off 

brake lamp switch. 

Remove clutch vacuum booster rod pin shaft 

split pin and take out pin shaft. 

26 

(c). 

Remove clutch vacuum booster with clutch 

master cylinder assy fixing nut, and take off 

vacuum booster with clutch master cylinder 

assy. 

(d). 

Remove brake vacuum booster rod pin split pin, 

and take off pin shaft.


26-13 

(e). 

Remove brake vacuum booster with brake 

master cylinder fixing nut and take off clutch 

vacuum booster with clutch master cylinder 

assy. 

13. Install pedal suspension assembly 

(a). 

(b). 

Put upper brake vacuum booster with brake 

master cylinder assy. 

Install brake vacuum booster with brake master 

cylinder assy fixing nut. 


(c) 

Install brake vacuum booster push rod locking 

pin and split pin and lock it. 

(d). 

(e). 

Put upper clutch vacuum booster with clutch 

master cylinder assy. 

Install clutch vacuum booster fixing nut. 


26 

(f). 

(g). 

install clutch vacuum booster push rod locking 

pin and split pin and lock it 

Install brake lamp switch , pre-lock nut tightly 

and screw nut tightly after adjusting correctly 

brake pedal height. 

Torque: 20 ± 5 N•m

26-14 


14. Install brake clutch pedal assy 

(a). 

put the brake clutch pedal assy in the 

installation position. 

Notice: 

There are many harnesses in this position and the 

harness shall not be pulled apart or damaged 

harness. 

(b). 

Screw two connecting bolts of pedal assy and 

cab floor 

Torque: 73 - 89 N•m 

(c). 

screw tightly two connecting bolt of pedal assy 

and cab. 

Torque: 21 ~ 25 N•m 

26 

15. Connect the clutch master cylinder oil outlet 

pipe 

(a). 

Connect the clutch master cylinder oil outlet 

pipe and screw down the collar nuts. 

Torque: 25-30 N•m


26-15 

(b) . 

connect two oil inlet hose of brake master 

cylinder and install hose spring clamp. 

Hint: 

Check if spring clamp is plastic and hose is installed 

correctly. 

(c). 

connect brake vacuum booster hose and install 

hose spring clamp. 

Hint: 


correctly. 

16. Connect the clutch master cylinder oil inlet 

pipe 

(a). 

Connect the clutch master cylinder oil inlet hose 

and tighten the hoop. 

Torque: 22- 24 N•m 

26 

(b). 

connect clutch master cylinder oil inlet hose and 

clutch vacuum booster hose and install hose 

spring clamp 

hint: 


correctly.

26-16 


17. Install instrument panel installation crossbar welding assembly (refer to “chapter 51 

heater and air conditioning-heater housing assembly, overhaul”) 

18. Install combination meter assembly (refer to “chapter 73 instrument desk/meter/cigar 

lighter-instrument panel, replacement”) 

19. Connect the connector to the brake lamp switch (refer to “chapter 26 service 

brake-brake pedal, adjustment”) 

20. Connect the connector to the clutch switch (refer to “chapter 32 clutch-clutch pedal, 



22. Fill with clutch fluid and remove the air in the clutch system (refer to “chapter 32 

clutch-clutch fluid, air exhaust”) 

23. Adjust the brake pedal height (refer to “chapter 26 service brake-brake pedal, 

adjustment”) 

24. Inspect and adjust the height of clutch pedal (refer to “chapter 32 clutch-clutch pedal, 


25. Brake system seal tightness test (refer to “chapter 26 service brake-brake system, 

on-vehicle inspection”) 

26

Service brake – Vacuum booster with brake master cylinder 

26-17 

Vacuum booster with brake master 

cylinder 


26 

1 

vacuum booster with brake master 

cylinder assembly 

4 Cotter pin 

2 Washer 5 Washer 

3 Nut 6 Lockpin

26-18 

Detection 

Rear axle- Vacuum booster with brake master cylinder 

1. First step down the brake pedal for several 

times when the engine does not start. Check 

and confirm the travel margin of brake pedal 

does not change. 

2. Step down the brake pedal and start the engine. If the brake pedal further slightly moves 

down, it means operation is normal. 

3. Shut down the engien after started for 1 to 2 minutes. Slowly step down the brake pedal for 

several times. If the pedal tavel stepped down at first time is large, and the brake pedal slowly 

and slightly rises up at second and three times, it means the sealness of vacuum booster is 

sound. 

4. Step down the brake pedal when the engine is running and then shut down the engine with 

the brake pedal stepped down. If the brake pedal margin does not change within in 30 

seconds, it measn the sealness of vacuum booster is sound; otherwise the sealness of 

vacuum booster shall be carefully checked. 

26

Replacement 


1. Disconnect the battery negative cable 

26-19 

2. Remove the combination instrument assembly (see “Chapter 73 instrument 

panel/instrument/cogarette lighter – instrument panel, replacement”) 

3. Remove the mounting cross beam welding assembly of instrument panel (see 

“Chapter 51 Heating and air conditioning – heating box, inspection and repair”) 

4. Disconnect the clutch switch connector assembly (see “chapter 32 Clutch – clutch 

pedal, replacement”) 

5. Disconnect the brake lamp switch connector assembly (see “chapter 26 Service brake 

- brake pedal, adjustment ”) 

6. Drain the clutch oil 

7. Disconnect the oil inlet pipe and vacuum 

hose of clutch master cylinder. 

(a). 

Unclamp the tie hoop of oil inlet hose of clutch 

master cylinder and fixing hoop of vacuum 

hose, and separate the hose. 

Notice: 

The residual clutch oil must be reclaimed with 

special container. Do not make the clutch oil 

touching the paint surface. If the skin contacts the 

clutch oil, immediately flush with water. 

8. Disconnect the oil outlet pipe of clutch 


(a). 

Loosen the oil outlet pipe connector nut of 

clutch master cylinder and separate the oil 

outlet pipe of clutch master cylinder. 

26

26-20 


9. Disconnect the connection pipeline of brake 

vacuum booster 

(a). 

Unclamp the fixing hoop of brake vacuum 

booster vacuum hose and separate the vacuum 

booster vacuum hose. 

10. Disconnect the brake master cylinder 

connection pipeline 

(a). 

Unclamp two inlet hose fixing hoops of brake 

master cylinder and separate the inlet hose of 

brake master cylinder. 

Note: 

The residual brake oil must be reclaimed with 

special container. Do not make the brake oil 

touching the paint surface. If the skin contacts the 

brake oil, immediately flush with water. 

(b). 

Unscrew the two oil outlet hose lock nut of brake 

master cylinder and separate the oil outlet 

pipeline of brake master cylinder. 

26 

11. Take out the brake clutch pedal assembly 

(a). 

Remove two connecting bolts of pedal assembly 

and cab. 

(b). 

Remove 2 connecting bolts of pedal assembly 

and cab floor.


26-21 

(c). 

Take out the brake clutch pedal assembly. 

Note: 

Do not break or damage the harness since there 

are many harnesses at this position. 

12. Remove the vacuum booster with brake 

master cylinder assembly 

(a). 

Remove the cotter pin of brake vacuum booster 

pushrod lock pin and take out the lock pin. 

(b). 

Remove the fixing nut of brake vacuum booster 

with brake master cylinder assembly and take 

the clutch vacuum booster with clutch master 

cylinder assembly. 

26 

13. Separate the vacuum booster and brake 


(a). 

Remove the connection fixing nut of vacuum 

booster and brake master cylinder assembly 

and separate the vacuum booster and brake 

master cylinder.

26-22 


14. Assemble the vacuum booster and brake 


(a). 

Install the connection fixing nut of vacuum 

booster and brake master cylinder and 

assemble the vacuum booster and brake 

master cylinder. 

Torque: 45 to 55 N•m 

15. Assemble the brake clutch pedal assembly 

(a). 

(b). 

Place the brake vacuum booster with brake 

master cylinder assembly. 

Install the fixing nut of brake vacuum booster 

with brake master cylinder assembly. 


(c). 

Install the lockpin of brake vacuum booster 

pushrod; install the cotter pin and lock. 

26 

16. Install the brake clutch pedal assembly 

(a). 

Place the brake clutch pedal assembly into the 

installation position. 

Note: 

Do not break or damage the harness since there 

are many harnesses at this position.


(b). 

26-23 

Tighten two connecting bolts of pedal assembly 

and cab floor. 


(c). 

Tighten two connecting bolts of pedal assembly 

and cab 


17. Connect the brake master cylinder pipeline 

(a). 

Connect the outlet pipeline of brake master 

cylinder and tighten the connector nut. 


(b). 

Connect two inlet hoses of brake master 

cylinder and install the hose spring hoop. 

Tip: 

It is necessary to check the certain elasticity of 

spring hoop and whether the hose is installed in 

place. 

26 

(c). 

Connect the brake vacuum booster hose and 

install the hose spring hoop. 

Tip: 



place.

26-24 


18. Connect the clutch master cylinder 

connection pipeline 

(a). 

Connect the oil outlet pipeline of clutch master 

cylinder and tighten the nut of oil outlet pipe. 


(b). 

Connect the clutch master cylinder oil inlet hose 

and clutch vacuum booster hose and install the 

hose spring hoop. 

Tip: 



place. 

26 

19. Install the mounting crossbeam welding assembly of instrument panel (see “chapter 

51 heating and air conditioning – heating box, inspection and repair ”) 

20. Install the combination instrument assembly (see “chapter 73 instrument 

panel/instrument/cogarette lighter – instrument panel, replacement ”) 

21. Connect the brake lamp switch connector assembly (see “chapter 26 Service brake - 

brake pedal, adjustment ”) 

22. Connect the clutch switch connector assembly (see “chapter 32 Clutch – clutch pedal, 

replacement ”) 

23. Connect the battery negative cable 

24. Refill the clutch oil and bleed the air in system (see “chapter 32 Clutch – clutch oil, 

bleeding ”) 

25. Adjust the brake pedal height (see “chapter 26 Service brake - brake pedal, 


26. Check and adjust the clutch pedal height (see “chapter 32 Clutch – clutch pedal, 


27. Detect the vacuum booster and brake master cylinder (see “chapter 26 Service brake 

– vacuum booster with brake master cylinder, detection”)

Vacuum tank 


Rear axle- Vacuum tank 

26-25 

1 Vacuum tank 4 Bolt 

26 

2 Washer 5 Nut 

3 Spring washer

26-26 

Replacement 

Rear axle- Series dual-chamber brake valve 

1. Lift the vehicle head (see chapter 76 vehicle body turnover/door/freight box – cab 

locking mechanism, operation) 

2. Disconnect the vacuum tank connection 

hose 

(a). 

(b). 

Unclamp the hose spring hoop. 

Separate the vacuum tank connection hose. 

3. Disconnect the connector assembly of 

vacuum alarm switch harness 

(a). Disconnect the connector of connector 

assembly of vacuum alarm switch harness and 

unscrew down the vacuum alarm switch if 

necessary. 

26 

4. Remove the vacuum tank assembly 

(a). 

(b). 

Remove the vacuum tank assembly fixing bolt 

and nut. 

Take down the vacuum tank assembly. 

5. Install the vacuum tank assembly 

(a). 

(b). 

Place the vacuum tank to installation position. 

Install the fixing bolt and nut of upper vacuum 

tank.

Rear axle- Vacuum tank 

26-27 

6. Install the vacuum alarm switch 

(a). 

(b). 

Install upper vacuum alarm switch. 

Plug the connector of vacuum alarm switch 

harness. 

Tip: 

The “click” sound shall be heard to ensure the harness 

connector is installed in place. 

7. Install the vacuum tank connection hose 

(a). 

(b). 

Connect the vacuum tank connection hose. 

Install the hose spring hoop. 

Tip: 

Check the effectness of spring hoop during and after its 

installation. 

8. Lower down the vehicle head (see chapter 76 vehicle body turnover/door/freight box – 

cab locking mechanism, operation) 

26

26-28 

Front wheel brake 

Parts diagram 

Rear axle- Front wheel brake 

26 

1 Brake drum 6 Retracting spring 

2 Brake caliper 7 Brake plate 

3 piston 8 Brake chassis 

4 Oil seal 9 Brake plate washer 

5 Dust cover

Overhaul 

1. Raise the vehicle with a hoisting jack. 

Rear axle- Rear brake chamber 

26-29 

2. Remove front wheels and tires (refer to “chapter 23 wheels and tires-front wheels and 

tires, replacement”) 

3. Check brake plate 

(a). 

Remove two fixing bolts at the lower end of 

brake caliper. 

(b). 

Pull upward the brake caliper. 

Hints: 

Fix brake caliper pulled upward with iron wires to avoid 

the damage caused by brake caliper collection. 

(c). 

Remove break plate retracting spring of brake 

plate and take off washers at the two ends of 

brake plate. Remove front and rear brake plate. 

26 

(d). 

the thickness of brake plate after and before the 

measurement. 

Front brake plate 


Limit value: 

Rear brake plate 


Limit value: 

If the brake plate does not meet the requirement, replace it.

26-30 


(e). 

Install front and rear brake plates, brake washer 

and retracting spring. 

(f). 

Fold brake caliper. 

(g). 

Install two fixing bolt at the lower end of brake 

caliper. 

Torque: 

26 

4. Check brake disc 

(a). 

measure the runout of brake disc with dial 

gauge. 

Limit value: 

5. Install front wheels and tires (refer to “chapter 23 wheels and tires-front wheels and 


6. Put the jack

Overhaul 



26-31 

2. Remove front wheels and tires (refer to “chapter 23 wheels and tires-front wheels and 


3. Remove the front wheel hub cover 

(a). 

Remove the front wheel hub cover. 

4. Remove the left steering knuckle nut 

(a). 

(b). 

remove the cotter pin from the steering knuckle 

nut. 

Remove steering knuckle nut. 

(c). 

(d). 

Take out locking washer of steering knuckle nut. 

Take out the outer tapered roller bearing. 

26 

5. Remove parts inside brake caliper. 

(a). 

Remove fixing bolt at the lower end of brake 

caliper.

26-32 


(b). 

lift brake caliper 

(c). 

Remove brake plate locking pieces. 

(d). 

Take out front and rear brake plate. 

26 

(e). 

Take out piston dust cover, piston and piston oil 

seal. 

Hints: 

Generally, The removal of the piston is not required. 

Slowly step brake pedal for several times to push out 

the piston and take out piston oil seal for check and 

replacement. During installation, disconnect pipe line 

connector and push the piston coated with grease 

constantly.


26-33 

6. Remove brake caliper assy 

(a). 

Remove brake caliper assy fixing bolt. 

(b). 

Disconnect pipe line connector and take off 

brake caliper assy. 

7. Remove brake disc assy 

(a). 

Shake brake disc and take out brake disc with 

front wheel hub assy parallelly. 

8. Separate brake disc and front wheel hub 

assy. 

(a). 

(b). 

Remove front wheel hub and brake disc 

connecting bolts. 

Separate front wheel hub and brake disc. 

26 

9. Check brake base board. 

(a). 

Check if the brake base board is cracked. If necessary, replace it.

26-34 


10. Check brake disc 

(a). 

Measure the thickness of brake disc with 

micrometer. 


Limit value” 

Hint” 

Measure from several position and get the average 

value. 

(b). 

Measure the parallelism of brake disc face with 

feeler gauge 

Standard value” 

Limit value” 

Note” 

Measure from both sides and get the average value 

from several sides. 

11. Assemble brake disc and front wheel hub 

assy. 

(a). 

Fold front wheel hub and brake disc. 

(b). Install front wheel hub and brake disc 

connecting bolt. 

26 

12. Install brake disc assy. 

(a). 

Install brake disc and fix the brake disc with 

front wheel hub assy parellelly. 

13. Install brake caliper assy. 

(a). 

Put the brake caliper on the installation position.


26-35 

(b). 

Install brake caliper fixing bolt. 

Torque: 

14. Install inner parts of brake caliper. 

(a). 

Install front and rear brake plate. 

Hint: 

In case of replacing the brake caliper directly, skip the 

step 14. 

(b). 

Install brake plate locking clip. 

(c). 

Install retracting spring and fold brake caliper. 

26 

(d). 

Install bolt at the lower end of brake caliper. 

Torque:

26-36 


15. Connect pipe line joints. 

16. Install front steering knuckle nut 

(a). Install outer tapered roller bearing. 

(b). Install the steering knuckle nut locking washer 

(c). 

(d) 

Install the steering knuckle nut 

Install the steering knuckle nut cotter pin. 

17. Install left front wheel hub cover 

(a). 

Install front wheel hub cover 

26 

18. Install front wheels and tires (refer to “chapter 23 wheels and tires-front wheels and 


19. Lower the vehicle

Rear wheel brake 

Parts diagram 

Rear axle- Rear wheel brake 

26-37 

1 Rear brake pipe assy 

2 Brake pipe clamp 

3 Adjusting hole bleeder screw 

4 Brake shoes pressure spring tie rod 

5 Bolt 

6 Washer 

7 Brake baseboard 

8 Retracting spring 

9 Brake shoes 

10 Brake shoes pressure spring 

11 Brake shoes pressure spring seat 

12 Brake brake cylinder 

13 ABS Sensor 

14 bolt 

26

26-38 

Overhaul 



2. Remove front wheels and tires (refer to “chapter 23 wheels and tires-rear wheels and 


3. Remove the left half-axle assembly 

(a). 

Loosen the half-axle bolt. 

(b). 

Knock the flange face of the half axle gently with 

a copper hammer until the half axle loose. 

(c). 

Remove the half-axle assembly. 

26 

4. Remove the left rear brake drum assembly 

(a). 

Remove the half axle oil seal.


26-39 

(b). 

Loosen the 2 bolts and remove the locking 

washer from the left half-axle oil seal. 

(c). 

Remove the lock nut from the rear wheel hub 

bearing with a lock nut wrench of wheel hub 

bearing. 

(d). 

Remove the inner ring of the outer tapered roller 

bearing from the left rear wheel hub. 

(e). 

Remove the left rear wheel hub assembly. 

Hint: 

Remove with a rear wheel-hub puller if it is too tight to 

remove the left rear wheel hub assembly. 

26 

5. Disconnect the left rear wheel hub and the 

brake drum 

(a). 

Loosen 6 nuts and disconnect the left rear 

wheel hub and the brake drum. 

Notice: 

The nuts removed can not be used again.

26-40 


6. Remove the left rear brake shoe assembly 

(a). 

Remove brake shoe pressure spring and 

pressure spring seat. 

(b). 

Remove the retracing spring from the brake 

shoe. 

(c). 

Remove the brake shoes. 

26 

7. Remove two brake cylinder assembly 

(a). 

(b). 

Disconnect brake cylinder pipe line. 

Remove the brake cylinder fixing bolt and take 

off brake cylinder assy. 

8. Remove brake baseboard 

(a). 

Remove brake baseboard fixing bolt and take off brake baseboard.


26-41 

9. Inspect the brake drum 

(a). 

Inspect the inner diameter working surface of 

the brake drum for any cracks. If the brake drum 

appears grooves or furrows due to the damage, 

repair or replace it, if it appears tiny furrows or 

slight abrasion, it can be used again after 

repairing. 

(b) 

As drawn. Measure the inner diameter of the 

brake drum as shown in the illustration. The 

dimensions of the brake drums on both sides of 

the same axle shall be the same, repair or 


Dia indicator 

(c) 

As drawn. Measure the roundness error (radial 

circular run-out) of brake drums, repair or 


26

26-42 

10. Inspect the brake friction lining 

(a). 


Inspect the brake friction lining for any damage, excessive wear or deformation. If necessary, 

replace the brake friction lining. 

Brake shoe 

Brake friction lining 

(b). 

Inspect the depth from the rivet head to the 

friction lining surface and the damage thickness 

of the friction lining; replace it if they are beyond 

the limit value. 

Wear limit value of friction lining:4.6 ± 0.2 

mm 

11. INSPECT THE BRAKE SHOE RETRACTING 

SPRING 

(a). 

Inspect the retracting spring for any cracks or 

deformation (especially the hooks on both 

ends). Inspect the free length, load and load 

length of the spring. 

Spring load and load length:148 mm 

12. Inspect the brake backing plate 

(a). 

Inspect the brake backing plate for any cracks or deformation, if necessary, replace it. 

26 

13. Install brake baseboard. 

(a). Install brake baseboard fixing bolt. 

Torque: 126 ~ 154 N•m 

14. Install the brake cylinder assy. 

(a). 

(b). 

Install the brake cylinder fixing bolts. 

Connect brake cylinder pipe line joint. 

Hints: 

After the cylinder pipe line joints are installed, tread 

brake pedal and press the moving part at two ends of 

cylinder with hand for the feeling of contraction and 

expansion power.


26-43 

15. Install the left brake shoe. 

(a). 

Put the brake shoes on the installation position. 

(b). 

Install two brake shoe retracing spring 

(c). 

Install brake shoe retracing spring and pressure 

spring seat at the ends of internal pressure 

revolution brake shoes pressure spring tie bar. 

16. Connect left rear wheel drum hub and brake 

drum 

(a). 

Connect the left rear wheel hub to the brake 

drum. Screw down 6 nuts. 

Torque:287 ~ 346 N•m 

Notice: 

New nuts must be replaced with. 

(b). 

Make three places of tooth density for each nut 

to prevent them from loosening. 

26 

17. Install left rear wheel hub with brake drum 

assembly 

(a). 

Install the left rear wheel hub with brake drum 

on the left half-axle bushing. 

Hint: 

Make the left half-axle bushing pass through from the 

inner and outer tapered roller bearing center of the left 

rear wheel hub.

26-44 


(b). 

(c). 

(d). 

Apply lubricating grease on the inner ring of the outer 

tapered roller bearing of the left rear wheel hub. 


Install the inner ring of the outer tapered roller 

bearing of the left rear wheel hub. 

Apply lubricating grease on the thread of left 

half-axle bushing and the lock nut of left rear 



(e). 

Install the lock nut of left rear wheel hub bearing 

with a lock nut wrench of wheel hub bearing. 

Hint: 

It is no need to screw down the front steering knuckle 

nut at this step. 

(f). Rotate the left rear wheel hub for 2~3 

revolutions by hand to make the rear wheel hub 

bearing enter into the correct position. 

(g). 

Screw down the lock nut of the left rear wheel hub 

bearing with a lock nut wrench of wheel hub bearing. 

26 

Hint: 

Loosen the lock nut of the left rear wheel hub bearing reversely for 1/8~1/6 ring after screwing down. 

(h). 

(i). 

(j). 

Adjust the clearance between the left rear wheel brake drum and the brake shoe lining. (refer 

to “chapter 26 service brake-front wheel brake, adjustment”) 

Inspect the pre-stressing force of left rear wheel hub bearing. (Refer to “chapter 25 rear axle 

–rear wheel hub with brake drum assembly, overhaul”) 

Apply lubricating grease on the left half-axle oil seal locking washer. 


(k). 

(l). 

Screw down 2 bolts and install the left half-axle 

oil seal locking washer. 

 

 

If the mounting hole on the left half-axle 

oil seal locking washer doesn’t align with 

the threaded hole on the lock nut of the 

left rear wheel hub bearing, reverse the 

locking washer. 

If it still can’t align with the threaded hole 

after reversal, rotate the lock nut for 

adjustment if necessary. 

Install the outer oil seal of the left half axle.


26-45 

17. Install the left half axle. 

(a). 

Install the left half axle assembly. 

(b). 

Screw down 12 bolts. 

Torque:37 ~ 75 N•m 

18. Install rear wheels and tires (refer to “chapter 23 wheels and tires-rear wheels and 


19. Adjust the rear wheel brake (refer to “chapter 26 service brake-front wheel brake, 


20. Lower the vehicle. 

26

26 

-MEMO-

Parking Brake 

Central braking system ................................ 27-1 

Notes......................................................... 27-1 

Malfunction symptoms tabl ........................ 27-2 

Parts diagram ............................................ 27-3 

Parking brake handle ................................... 27-4 

Adjustment ................................................ 27-4 

Replacement ............................................. 27-5 

Center brake .................................................. 27-8 

Adjustment ................................................ 27-8 

Overhaul.................................................... 27-9 

Hand brake cable ........................................ 27-17 

Replacement ........................................... 27-17 

27

Parking brake-central braking system 

Central braking system 

Notes 

1. notes for the operation of parking brake system 

(a). 

(b). 

(c). 

(d). 

27-1 

Care must be taken to replace each part properly. Improper installation could affect the 

performance of the parking brake system and result in personal sexurity. 

Replace all the parts with original pure parts. 

Keep all the parts and the work area clean. 

The buckles or cable tie removed can not be used again. 

2. Parking brake system maintenance notes 

(a). 

(b). 

(c). 

Check the parking brake handle every 10,000 Km and pull up the parking brake handle with 

500 N force, its normal stroke is 8 to 12 teeth, if its teeth is more than 14, adjust the brake or 

the cable. 

Make sure to check the parking brake cable once every 10,000Km and replace it every 

100,000Km. 

Make sure to inspect regularly, inspect it once every 10,000Km. 

• Check the central braking drum for wear. 

• Check the function of parking brake. 

• Check the stroke of parking brake handle. 

• Check whether the looseness of each connection. 

• Check whether the functions of brake system are normal. 

27

27-2 



Use the table below to help you find the cause of the malfunction. The numbers indicate the 

probability of the cause of the malfunction. Check each part in order. If necessary, replace these 

parts. 


Poor braking efficiency 

The parking brake handle can’t 

locate. 

The brake makes abnormal 

noise. 

1. Center brake clearance (Too 

big) 

2. Brake shoe or brake drum 

(Distorted) 

3. Hand brake cable (Too long) 

1. Parking brake handle pull-rod 

spring (Does not work or 

broken) 

2. Parking brake handle pallet 

and ratchet (Excessive wear) 

3. Parking brake handle 

operating handle (Distorted) 

1. Central braking drum 

(Warped) 

2. Brake shoe retracing spring 

(Does not work) 

Chapter 27 parking brake- center 

brake, adjustment 

Chapter 27 parking brake-center 

brake, overhaul 

Chapter 27 parking brake- hand 

brake cable, replacement 

Chapter 27 parking brake-parking 

brake handle, replacement 






brake,, overhaul 


brake,, overhaul 

27

Parts diagram 


27-3 

1 Handle Shield Fixed Seat 14 Brake Shoe Spring Cover 

27 

2 Handle Shield 15 Brake Shoe Press Springs 

3 Brake Drum 16 Retracing Spring 

4 Brake Alignment Hole Cover 17 Limited Pulling Chip 

5 Bolt 18 Brake Shoe Assembly 

6 Brake Handle 19 Adjusting Screw 

7 Brake Cable 20 Lower Extension Spring 

8 Retainer Ring 21 Brake Arm 

9 Baffle Plate 22 Bolt 

10 Rocker Arm Extension Spring 23 Spring Washer 

11 Retaining Pin 24 Brake Floor Assembly 

12 Brake Shoe Pin 25 Spring Washer 

13 Retracing Spring 26 Nut

27-4 

Parking brake- parking brake handle 

Parking brake handle 

Adjustment 

Lock nut 

Adjusting nut 

1. Adjust the brake handle 

(a). 

(b). 

Release the parking brake and make the 

parking brake handle at the lowest position, 

loosen the lock nut on the parking brake pull rod 

Screw the adjusting nut, adjust the parking 

brake handle and make the handle at normal 

working stroke. 

HINT: 

• Brake begins at the third sound and completes 

at the fifth. 

• The normal stroke of parking brake handle is 8 

to 12 teeth. 

(c). 

Screw up the lock nut after adjusting. 

27

Replacement 

1. Disconnect battery negative pole cable 


27-5 

2. Disconnect the connector from parking 

brake handle 

3. Remove the parking brake handle shield 

(a). 

Remove the 2 fixing bolts of parking brake 

handle shield. 

(b). 

Take down the parking brake handle shield 

assembly. 

27

27-6 


4. Disconnect the hand brake cable 

(a). 

(b). 

Loosen the adjusting nut and lock nut of hand 

brake cable. 

Separate the hand brake cable. 

Lock nut 

Adjusting nut 

5. Remove the parking brake handle assembly 

(a). 

(b). 

Remove the 2 fixing bolts of parking brake 

handle. 

Take down the parking brake handle assembly. 

6. Install parking brake handle 

(a). Install parking brake handle and screw up the 2 

fixing bolts. 


27 

7. Install hand brake cable 

(a). Connect the hand brake cable, pre-tighten the 

adjusting nut and lock nut of hand brake cable 

and screw down the lock nut after adjusting 

the parking brake handle to the correct position. 


Lock nut 

Adjusting nut


8. Inspect and adjust parking brake handle (refer to “chapter 27 parking brake- parking 

brake handle, adjustment”) 

9. Install parking brake handle shield 

(a). 

Install parking brake handle shield. 

27-7 

(b). 

Screw up the 2 fixing screws. 

10. Connect the parking brake handle switch 

connector 

27 

11. Connect the battery negative pole cable

27-8 

Center brake 

Adjustment 

PARKING brake-center brake 

1. Adjust the center brake 

(a). 

(b). 

(c). 

(d). 

Release the parking brake and make the 

parking brake handle at the lowest position. 

Measure the diameter of brake shoe with slide 

calipers, adjust the diameter of brake shoe to 

202mm, and try to be close to the center of the 

shoe plate as possible while using slide 

calipers. 

Install the central braking drum, pull the parking 

brake handle in the driving cab and stop after 

hearing two clicks. 

Rotate the central braking drum until it begins to 

drag. 

(e). 

Put down the parking brake handle, check 

whether the brake drum drags, adjust the 

parking brake handle if necessary. 

27 

2. Inspect the central braking drum 

(a). 

Make the parking brake handle at the lowest 

position after adjustment; the central braking 

drum shall rotate freely without dragging.

Overhaul 

27-9 

Parking brake-center brake 

1. Disconnect the hand brake cable 

(a). Remove the lock nut of hand brake cable. 

(b). 

(c). 

Remove the 2 fixing bolts of hand brake cable. 

Separate the hand brake cable. 

2. Remove the transmission axle (refer to “chapter 33 transmission axle- transmission axle 

assembly, replacement”) 

3. Remove the central braking drum assembly 

(a). 

Take down the central braking drum assembly. 

27 

4. Remove the secondary-axle flange 

(a). Loosen the secondary-axle flange nut. 

(b). Take down the secondary-axle flange.

27-10 

Parking brake- -center brake 

5. Remove the brake shoe 

(a). 

Remove the 2 retracing springs of brake shoe. 

(b). 

Take down the lower extension spring of brake 

shoe. 

27 

(c). 

Take down the adjusting screws of brake shoe.

Parking brake--center brake 

27-11 

(d). 

(e). 

Remove the brake shoe supporting plate. 

Take down two brake shoes. 

6. Remove brake bottom plate 

(a). 

Take down the retracing spring of hand brake 

arm. 

(b). 

Remove the positioning nut of brake cam and 

take down the brake cam. 

27 

(c). 

Remove the 4 fixing bolts of brake bottom plate 

and take down brake bottom plate.

27-12 

7. Inspect the brake shoe 

(a). 


Inspect the brake shoe friction lining for abnormal wear, deep grooves, serious crackles and 

the coking and deterioration caused by the excessive heat, replace if necessary. 

(b). 

Inspect the thickness of brake shoe friction 

lining, the standard value of it is 6mm, replace it 

if necessary. 

8. Overhaul of central braking drum 

(a). 

Inspect the central braking drum for deep 

grooves, cracks and abnormal wear, and 

replace it if necessary. 

27 

(b). 

Inspect the inner diameter of central braking 

drum. 

Standard value: 203.2 mm 

Limit value: 207.0 mm


27-13 

9. Overhaul of retracing spring 

(a). 

Inspect the retracting spring for any cracks or 

deformation (especially the hooks on both 

ends). Replace it if necessary. 

(b). 

Inspect the length of the 2 retracing springs of 

brake shoe, the parameters of the two springs 

shall be the same at the same condition, the 

free length of the retracing springs is 76.5 mm. 

10. Install the backing plate 

(a). 

Install the backing plate and tighten the 4 fixing 

bolts. 

Torque: 130 ~ 160 N•m 

(b). 

Install the brake cam and tighten the fixing nut 

of brake arm. 

27 

(c). 

Install the retracing spring of hand brake arm.

27-14 

11. Install the brake shoe 

(a). Install the two brake shoes. 


(b). 

Install the brake shoe supporting plate as shown 

in the illustration. 

(c). 

Install the 2 retracing springs of the brake 

shoes. 

27 

(d). 

Install the adjusting screws of the brake shoes.


27-15 

(e). 

Install the lower extension spring of brake shoe. 

12. Install the secondary-axle flange 

(a). Install the secondary-axle flange on the 

secondary axle. 

(b) 

tighten the nuts of secondary-axle flange. 

Torque: 393 ~ 500 N•m 

13. Install the central braking drum 

27 

14. Install the transmission axle (refer to “chapter 33 transmission axle - transmission 

axle assembly, replacement”) 

15. Install the hand brake cable 

(a). 

Install the hand brake cable and screw down the 

2 fixing bolts. 

Torque: 21 ~ 25 N•m

27-16 


(b). 

Install the hand brake cable on the hand brake 

arm and screw up the cable lock nut. 

16. Adjust the center brake (refer to “chapter 27 parking brake-center brake, adjustment”) 

17. Adjust the parking brake handle (refer to “chapter 27 parking brake-parking brake 

handle, adjustment”) 

27

Hand brake cable 

Replacement 

Parking brake-hand brake cable 

27-17 

1. Remove the parking brake handle shield (refer to “chapter 27 parking brake-parking 

brake handle, replacement”) 

2. Remove the transmission control shield (refer to “chapter 31 transmission - 

transmission control handle assembly, replacement”) 

3. Remove the hand brake cable 

(a). 

Remove the lock nut and adjusting nut of hand 

brake cable. 

Lock nut 

Adjusting nut 

(b). 

Remove the 2 fixing nuts of hand brake cable. 

27 

(c). 

Remove the lock nuts of hand brake cable and 

hand brake arm.

27-18 


(d). 

(e). 

Remove the 2 fixing bolts of hand brake cable. 

Remove the fixing bolts of hand brake cable and 

frame , take out the hand brake cable assembly. 

4. Install the hand brake cable 

(a). 

Install the hand brake cable assembly according to the correct direction. 

(b). 


2 fixing bolts. 

(c). 

Connect the hand brake cable and screw down 

the lock nut. 

27 

(d). 


2 fixing nuts. 



27-19 

(e). 

Connect the hand brake cable, screw down the 

lock nut after adjusting the parking brake handle 

to the correct position. 


Lock nut 

Adjusting nut 

5. Adjust the parking brake handle (refer to “chapter 27 parking brake-parking brake 

handle, adjustment”) 

6. Install the transmission control shield (refer to “chapter 31 transmission - 

transmission control handle assembly, replacement”) 

7. Install parking brake handle shield (refer to “chapter 27 parking brake-parking brake 

handle, replacement”) 

27

Transmission (646b/651b) 

Transmission control mechanism...................31A-1 

Parts diagram ..............................................31A-1 

Replacement ...............................................31A-2 

Gearshift & Gear Selecting flexible axles .......31A-5 

Parts diagram ..............................................31A-5 

Replacement ...............................................31A-6 

Transmission assembly..................................31A-11 

Notes..........................................................31A-11 

Problem symptoms table........................... 31A-12 

Parts diagram .............................................31A-14 

Replacement ..............................................31A-17 

Overhaul .....................................................31A-24 

Secondary axle assembly ..............................31A-40 


Overhaul .....................................................31A-42 

Intermediate axle assembly...........................31A-58 

Notes...........................................................31A-58 


Replacement ..............................................31A-60 

First axle and reverse gear shaft...................31A-63 


Upper cover assembly....................................31A-65 


Overhaul .....................................................31A-67 

31A

31A

transmission (646b/651b)-transmission control mechanism 

31A-1 

Transmission control mechanism 

Parts diagram 

1 control 8 hexagon 

2 control 9 spring 

3 shield 10 hexagon 

4 control 11 hexagon 

5 plastic 12 flexible 

6 front 13 flexible 

7 all-metal 

31A

31A-2 

transmission (646b/651b)-transmission control mechanism 

Replacement 

1. Remove the control handle ball head 

(a). Screw off the control handle ball head 

counterclockwise. 

2. Remove the control rod shield sleeve 

(a). pull out the control rod shield sleeve. 

31A 

3. Disconnect the connection between the control 

flexible axle and the front transmission control 

mechanism 

(a). Loosen the connecting bolts of the gear selecting 

flexible axle and the gear selecting arm, disconnect 

the connection between the gear selecting flexible 

axle and the gear selecting arm. 

(b). Pull out the cotter pin of gearshift arm and disconnect 

the connection between the gearshift flexible axle 

and the gearshift arm. 

hint: 

Don’t loose the gearshift flexible axle pad. 

4. Remove the front transmission control mechanism 

(a). Loosen the 3 fixing nuts of front transmission control 

mechanism. 

(b). Remove the front transmission control mechanism.

Transmission (646b/651b)-transmission control mechanism 

31A-3 

5. remove the control handle 

(a). Loosen the 2 inner-hexagon bolts and remove the 

control handle. 

Notice: 

Lubricate the plastic bearing of control handle and 

replace it if necessary. 

6. install the control handle 

(a). Screw up the 2 inner-hexagon bolts and install the 


31A 

7. install the front transmission control mechanism 

(a). Screw dpwnthe 3 fixing nuts of front transmission 

control mechanism and install the front transmission 

control mechanism.

31A-4 

Transmission (646b/651b)-transmission control mechanism 

8. connect the control flexible axle and the front 

transmission control mechanism 

(a). screw down the connecting bolts of the gear selecting 

flexible axle and the gear selecting arm, connect the 

gear selecting flexible axle and the gear selecting 

arm. 

(b). insert into the cotter pin of gearshift arm, connect the 

gearshift flexible axle and the gearshift arm. 

9. install the control rod shield sleeve 

(a). set the control rod shield sleeve on. 

10. install the control handle ball head 

(a). Screw down the control handle ball head 

clockwise. 

HINT: 

Apply appropriate amount of anaerobic adhesive (Loctite 

495) during the assembly of control handle ball head and 

the control rod. 

31A

Transmission (646b/651b)-gearshift flexible axle and gear selecting flexible axle 

31A-5 

Gearshift and Gear Selecting Flexible 

Axles 

Parts diagram 

1 Cotter 12 Plastic 

2 Flat 13 Gear 

3 Spring 14 Gearshift 

4 Hexagon 15 Multiple 

5 Locking 16 Cotter 

6 Shield 17 Coupling 

7 Hexagon 18 Spring 

8 Spring 19 Hexagon 

9 Hexagon 20 Flexible 

10 Multiple 21 Hexagon 

11 Air 

31A

31A-6 


Replacement 

1. disconnect the connection to the transmission 

(a). Disconnect the connection to the gearshift flexible 

axle and the gear selecting flexible axle and the 

connection to the transmission gearshift arm and gear 

selecting arm respectively. 

2. disconnect the connection to the support 

(a). Remove the control flexible axle from the flexible 

axle support assembly. 

(b). Remove the control flexible axle from the gearshift 

arm and the gear selecting arm. 

Notice: 

• don’t distort the core of flexible axle. 

• don’t make the flexible axle have sharp turn. 

31A 

3. disconnect the connection to the front speed-shift 

transmission mechanism (refer to “chapter 31 a 

transmission (646b/651b) - transmission control 

mechanism, replacement”)


31A-7 

4. Remove the transmission control protective shell 

(a). Loosen the 5 plastic staple assemblies and remove 

the transmission control protective shell. 

5. Pull up the fixed locking plates of control flexible 

axle 

(a). Pull up the 2 fixed locking plates of control flexible 

axle and separate the control flexible axle and the 

base. 

6. Disconnect the connection from the driving cab 

(a). Remove the flexible axle seal ring pressing plate and 

the flexible axle seal ring. 

31A

31A-8 


7. Disconnect the connections between the control 

flexible axle and the frame 

(a). Loosen the multiple pipe clamping pieces, disconnect 

the connections between the control flexible axle and 

the frame, and remove the control flexible axle. 

8. install the fixed buckle of control flexible axle 

(a). Fasten the control flexible axle on the frame with 

multiple pipe clamping pieces. 

31A 

9. fasten the control flexible axle on the driving cab 

(a). Install the flexible axle seal ring and the flexible axle 

sear ring pressing plate.

Transmission (646b/651b)-transmission assembly 

31A-9 

10. Install the fixed locking plates of control flexible axle 

(a). Insert into 2 fixed locking plates of control flexible 

axle and fasten the control flexible axle on the 

control base assembly. 

11. Install the transmission control protective shell 

(a). Insert into 5 plastic staple assembles and install the 

transmission control protective shells. 

12. Connect the front transmission control 

mechanism (refer to “chapter 31 a transmission 

(646b/651b) - transmission control mechanism, 


Notice: 

When the control mechanism connects with the flexible 

axle, the control handle shall be in a vertical position, 

otherwise, it shall be adjusted, the flexible axle joint 

shall be fastened. 

31A

31A-10 


13. Connect the transmission 

(a). Install the gearshift flexible axle and the gear 

selecting flexible axle on the flexible axle frame 

assembly. 

Notice: 

• Don’t distort the core of flexible axle. 

• Don’t make the flexible axle have sharp turn. 

• Don’t hold the dust cover with hands during the 

operation so as to avoid damaging the internal 

structures. 

• Make sure that all the gears are clear and 

correctafter assembling the control mechanism 

assembly,; the gears can be shifted easily and 

flexibly without clamping or interference. 

(b). Install the gearshift flexible axle and the gear 

selecting flexible axle on the transmission gearshift 

arm and gear selecting arm respectively. 

31A


31A-11 

Transmission assembly 

Notes 

1. Notes for the use of transmission 

(a). Inspect the level of transmission oil regularly and add some transmission oil if it is not enough. 

Hint: 

Park the vehicle on the level road when filling transmission oil, the oil shall be filled to the lower edge of the oil filling 

opening. 

(b). Change the transmission oil for the new transmission every 5,000 kilometers, and change it every 24,000 

Notice: 

kilometers or once a year after the breaking-in period. 

• 80W/90 (GL-5) oil shall be used for the transmission 

• Different brands of transmission oil can’t be used together. 

(c). Maintain the breather plug regularly to ensure its cleanness and smoothness. 

(d). Start with the first gear or the second gear according to the road conditions and the load of vehicles. 

(e). Neutral sliding is not permitted for the transmission, especially when the engine is at flameout state so as to avoid 

burning out the synchronizers and various kinds of bearings. 

(f). The clutch must be separated completely during the gearshift to avoid half linkage state and damage of 

synchronizers and other parts; park the vehicle first and then shift the gear so as to avoid damaging the backward 

gear and the gear ring of the synchronizer. 

(g). When the vehicle needs to be dragged for malfunction, disconnect the transmission axle or drag it above the 

ground, avoid the driving wheels roll and turn the output axis of transmission to rotate so as to burn out the 

bearings and other components. 

2. Notes for the disassembly and assembly of transmission 

(a). The vehicle must be parted on the level and safe place before removing the transmission from the complete vehicle, 

shut off and turn off the power supply, fasten the front and rear wheels with tools to ensure the safety of the 

complete vehicle. 

(b). Clean the outside of the transmission before disassembling it, avoid the dust and impurities entering into the 

transmission during the disassembly of the transmission. 

(c). Don’t knock with a hammer directly while disassembling or assembling the axles, bearings and oil seals and 

fastening the gears, copper hammers or copper rods must be used while knocking to avoid damaging the parts. 

Various special tools shall be used for the disassembly. 

(d). The paper washers and sealant remained on each faying surfaces must be cleaned. 

(e). Clean all the parts in the transmission, unclog the lubricating orifices of each part, and blow off with compressed 

air before assembling. 

(f). Notice the positions and directions of the gear, thrust pad and pad during the assembly. 

(g). Apply clean lubricating oil on all the thrust washers, needle bearings and synchronizer conical surfaces during the 

assembly so as to avoid the damage caused by the dry friction. 

(h). New sealing washer must be used during the assembly; omitted installation of sealing gaskets is not permitted. 

(i). Inspect whether each oil seal lip is damaged, replace with new parts if oil leakage is found. 

(j). Apply sealant uniformly on each gasket to avoid oil leakage, 5699 or 5702 silicone sealant is suggested to be used, 

apply uniformly to avoid breaking. 262 screw-thread retaining compound is suggested to be used during the 

assembly of through-hole bolts. 

(k). Check the important matching parts, especially the interference fit parts and check them carefully before the 

assembly so as to avoid rework. 

31A

31A-12 


Malfunction symptom table 

Use the table below to help you find the cause of the malfunction. The numbers indicate the probability of 

the cause of malfunction. Check each part in order. If necessary, replace these parts. 


1. Lubricating oil (The viscosity is 

too low) 

2. Lubricating oil (Not enough) - 

3. Bearing (Worn or damaged) 

- 

Chapter 31 a transmission 

(646b/651b)-transmission assembly, 

overhaul 

31A 

The abnormal sound or noise is too 

big. 

It is difficult to engage a gear for the 

transmission. 

4. Gear shift fork and synchronizer 

gear (The combination is not 

appropriate) 

5. Synchronizer (Worn or 

damaged) 

6. Gear tooth (Scratched or worn) 

7. Transmission housing (Distorted 

and deformed) 


too big) 

2. Clutch (The separation is not 

complete) 

3. Bearing (Worn or damaged) 

4. Synchronizer (Damaged) 

5. Shift fork catch bolt (Loose) 

6. Gear shift fork (Deformed or 

damaged) 

7. Fork shaft (Deformed or 

damaged) 

8. Lock steel ball (Worn seriously) 


(646b/651b)-secondary-axle 

assembly, overhaul 


(646b/651b)- secondary -axle 




overhaul 



replacement 

- 

Chapter 32 clutch-clutch assembly 

part, overhaul 



overhaul 


(646b/651b)- secondary-axle 



(646b/651b)-upper cover assembly, 

overhaul 



overhaul 



overhaul 



overhaul


31A-13 


The transmission skips gear or gets 

out of gear 

The gears are disordered 

The transmission leaks oil 

1. Flange nut (Loose) Chapter 31 a transmission 

(646b/651b)- transmission assembly, 

overhaul 

2. Gear (The axial clearance is too 

big) 


(646b/651b) - transmission assembly, 

overhaul 

3. Gear meshing end (Worn 

seriously) 



overhaul 

4. Synchronizer (Damaged) Chapter 31 a transmission 

(646b/651b)- secondary -axle 


5. Bearing (Axial movement) Chapter 31 a transmission 

(646b/651b)- transmission assembly, 

overhaul 


damaged) 



overhaul 

7. Self-lock spring (Fractured or 

tired) 



overhaul 

8. Self-lock steel ball (Worn) Chapter 31 a transmission 


overhaul 

1. Interlock steel ball (Worn) Chapter 31 a transmission 


overhaul 

1. Lubricating oil (Excessive) - 

2. Sealing parts (Invalid or 

damaged) 

3. Fastener (Loosened) - 

4. Transmission housing (Distorted 

and deformed) 

5. Sealant is not applied on the bolt 

or the sealant applied is not 

uniform. 

- 

- 



overhaul 

31A

31A-14 


Parts diagram 

31A


31A-15 

31A

31A-16 


1 Clutch Cover Assembly 5 Secondary-axle Assembly 

2 First Axle Assembly 6 Transmission Housing Assembly. 

3 Upper Cover Assembly 7 

Secondary-axle Rear Bearing Cover and 

Reverse Gear Shaft Assembly 

4 Intermediate Axle Assembly 8 Central Braking Drum Assembly 

31A


31A-17 

Replacement 

1. Screw off the oil-discharge plug at the bottom of 

the transmission, exhaust the transmission oil and 

screw up the oil-discharge bolt. 

Torque: 

Model 

Torque 

646B 

98~127N·m 

651B 

98~127N·m 

Notice: 

Recycle the transmission oil with a dedicated container 

when discharging the transmission oil and dispose it as 

the waste according to the prescription. 

Hint: 

• Put the container below the oil drainage port of 

the transmission to hold the transmission oil 

discharged. 

• Discharge the oil after starting the vehicle to 

discharge the transmission oil as far as possible. 

2. Disconnect the connections between the 

transmission and other parts 

(a). Disconnect the connection between the control 

flexible axle and the transmission. (Refer to “chapter 

31 a transmission (646b/651b) -gearshif flexible axle 

and gear selecting flexible axle, replacement”) 

31A

31A-18 


(b). Remove the frame of the control flexible axle. 

(c). Remove the fixed frame of exhaust pipe. (Refer to 

“chapter 15 exhaust pipe, replacement”) 

(d). Remove the back-up light switch. 

31A 

(e). Remove the vehicle speed sensor.


31A-19 

(f). Remove the clutch slave cylinder booster. (Refer to 

“chapter 32 clutch-clutch slave cylinder booster, 


(g). Loosen the 4 connecting nuts of the transmission 

axles and the transmission, take out the transmission. 

(refer to “chapter 33 transmission axle- transmission 


(h). Loosen the 12 bolts of the clutch housing and take 

out the front end of the transmission. 

31A

31A-20 


3. Connect the transmission and other parts 

(a). Screw up the 12 bolts of the clutch housing. 

Torque: 

Model 

Torque: 

646B 

73 ~ 100 N•m 

651B 

73 ~ 100 N•m 

(b). Screw up the 4 connecting nuts of the transmission 

axle and the transmission. (Refer to “CHAPTER 33 

Transmission axle-transmission axle assembly, 


Torque: 

Model 

Torque 

646B 

88 ~ 108 N•m 

651B 

88 ~ 108 N•m 

31A 

(c). Install the clutch slave cylinder booster. (Refer to 

“CHAPTER 32 CLUTCH-CLUTCH SLAVE 

CYLINDER BOOSTER, REPLACEMENT”) 

Torque: 

Model 

Torque 

646B 

33 ~ 42 N•m 

651B 

33 ~ 42 N•m


31A-21 

(d). Install the vehicle speed sensor. 

Torque: 

Model 

Torque 

646B 

73 ~ 100 N•m 

651B 

73 ~ 100 N•m 

(e). Install the reverse lamp 

Torque: 

Model 

646B 

651B 

switch. 

Torque 

29 ~ 49N•m 

29 ~ 49N•m 

(f). Install the fixed frame of exhaust pipe. (Refer to 

“Chapter 15 exhaust pipe-exhaust pipe, 


Torque: 

Model 

Torque 

646B 

73 ~ 100 N•m 

651B 

73 ~ 100 N•m 

31A

31A-22 


(g). Install the control flexible axle bracket. 

Torque: 

Model 

Torque 

646B 

73 ~ 100 N•m 

651B 

73 ~ 100 N•m 

(h). Install the connection between the control flexible 

axle and the transmission. (Refer to “chapter 31 a 

transmission (646b/651b) - gearshift flexible axle and 

gear selecting flexible axle, replacement”) 

31A 

4. Fill transmission oil and screw up the oil filling 

plug 

Torque: 

Model 

Torque: 

646B 

98 ~ 127 N•m 

651B 

98 ~ 127 N•m 

Notice: 

Operate the transmission for a few minutes after filling 

the oil, and then check the level of the oil in the 

transmission again.


31A-23 

5. Transmission breaking-in specification and test 

(a). The rotation speed shall be about 1,500 r/min, the temperature of the oil shall not be less than 15 ℃; no load; the 

operation in neutral gear shall not be less than 15 minutes, and the operation in other gears shall not be less than 20 

minutes. 

(b). Check whether the gearshift is flexible and whether the meshing of gear is completed, no impact sound shall be 

produced by the gear during the gearshift. 

(c). The gearshift level of the transmission shall not have distinct shake. 

(d). No abnormal grinding noise and impact sound shall be produced during the test of transmission. 

(e). The transmission shall not leak oil. 

(f). Drain the transmission oil out and clean the inside of the transmission thoroughly after completing the braking-in 

31A

31A-24 


Overhaul 

1. Put the transmission assembly on the stable working platform 

2. Remove the clutch housing assembly 

(a). Remove the clutch release bearing. (Refer to “chapter 

32 clutch- clutch assembly part, overhaul”) 

(b). Loosen the 6 clutch housing bolts and remove the 

clutch housing. 

3. Remove the center brake assembly. 

(a). Remove the central braking drum. 

(b). Loosen the flange nut and remove the flange. 

Hint: 

Push aside the flange nut spring leaf before loosening the 

flange nut. 

31A 

Notice: 

The secondary-axle flange nut loosened ccan’t be used 

again, replace it with a new one. 

(c). Loosen the 4 bolts and remove the center brake 

assembly with baffle plate. 

HINT: 

The flanges of the non-center brake vehicles can be 

removed directly.


31A-25 

4. Remove the transmission upper cover assembly 

(a). Remove the upper cover assembly. 

5. Measure the axial clearance of each shifting of 

gear of the secondary axle 

(a). Measure the axial clearance of each shifting of gear 

of the secondary axle. 

Gear 

Axial clearance 


Sixth gear 646B 0.26 ~ 0.7 mm 0.8 mm 

651B 0.3 ~ 0.5 mm 

Fourth gear 646B 0.26 ~ 0.7 mm 0.8 mm 

651B 0.3 ~ 0.5 mm 

Third gear 646B 0.26 ~ 0.7 mm 0.8 mm 

651B 0.3 ~ 0.5 mm 

Second gear 646B 0.28 ~ 0.7 mm 0.8 mm 

651B 0.3 ~ 0.5 mm 

First gear 646B 0.28 ~ 0.7 mm 0.8 mm 

Reverse gear 

651B 

646B 

651B 

0.3 ~ 0.5 mm 

0.21 ~ 0.64 mm 

0.3 ~ 0.55 mm 

0.8 mm 

31A

31A-26 


6. Measure the meshing clearance of each pair gear 

(a). Measure the meshing clearance of each pair.gear 

Gear 

Sixth gear 

Fourth gear 

Third gear 

Second gear 

First gear 

646B 

651B 

646B 

651B 

646B 

651B 

646B 

651B 

646B 

651B 

Meshing clearance 

Standard 

0.12 ~ 0.3 mm 

0.12 ~ 0.3 mm 

0.116 ~ 0.292 mm 

0.12 ~ 0.3 mm 

0.132 ~ 0.324 mm 

Hint: 

Apply grease on the fuse that is 1mm in diameter and 

15mm in length so as to make it adhere to the gear face, 

rotate the gear for one revolution and measure and record 

the fit clearance of the gear pair at the trisection places. 

Replace with a new gear pair if it does not conform to the 

provision. 

31A 

7. Inspect the wear of gear and pairgear 

(a). Check the meshing position of the gear with red marks for the gear pair at each gear shift, the middle part of the 

tooth height is the appropriate position, the contact area shall not be less than 60% of the working face of gear, 

otherwise, a new gear pair shall be replaced with. 

(b). The wear length of the gear end surface shall not be over 15% of the gear length, otherwise, a new gear pair shall 

be replaced with. 

8. Remove the secondary-axle rear bearing cover 

(a). Loosen the 8 bolts of the secondary-axle rear bearing 

cover.


31A-27 

(b). Remove the secondary-axle rear bearing cover, paper 

washer of secondary-axle rear bearing cover, 

odometer driven gear, oil seal, and odometer flexible 

axle joint. 

Notice: 

The oil seal can only be removed and replaced with a 

new one after oil leakage is found. 

(c). Remove the odometer driving gear. 

9. Remove the first-axle assembly 

(a). Remove the first-axle cover. 

31A

31A-28 


(b). Remove the first-axle retainer ring and the first-axle 

bearing retainer ring. 

(c). Put the plain-milling position on the first-axle 

synchronous conical ring towards the intermediate 

axle and knock the secondary-axle terminal with a 

hammer and a cooper rod, punch the first-axle 

assembly and then remove it according to the 

position. 

Notice: 

• Don’t remove the first-axle bearing if not 

necessary. 

• Don’t damage the front needle bearing of the 

secondary axle and replace it if necessary. 

31A 

10. Remove the secondary-axle assembly 

(a). Remove the secondary-axle deep groove ball bearing 

retainer ring.


31A-29 

(b). Remove the secondary-axle deep groove ball bearing 

with special tools. 

31A

31A-30 


(c). Measure the internal diameter of the secondary-axle 

deep groove ball bearing. 

Model 

Internal diameter 


646B 45 mm 44.988 ~ 45 mm 

651B 45 mm 44.988 ~ 45 mm 

(d). Hoist the secondary-axle assembly with special 

suspenders and take out the secondary-axle assembly 

from the transmission housing. 

11. Remove the reverse gear shaft 

(a). Remove the locking plate of reverse gear shaft. 

31A 

(b). Remove the cover plate of power take-off hole. 

(c). Take out the reverse gear shaft. 

Hint: 

Take care not to lose the seal ring.


31A-31 

(d). Take out the reverse gear and needle bearing from 

the power take-off hole. 

(e). Detect the diameter of the reverse gear shaft. 

Diameter 

Model 

Standard 

646B 

20 mm 

651B 

20 mm 

If it is out of the clearance, replace with a new reverse 

gear shaft. 

12. Remove the intermediate axle assembly 

(a). Remove the bearing cover of the intermediate axle. 

31A 

(b). Take out the adjusting washer of intermediate axle, 

knock slightly with a cooper rod from inner end and 

punch the front bearing of the intermediate axle.

31A-32 


(c). Measure the front bearing internal diameter of the 

intermediate axle. 

Model 



646B 35 mm 34.988 ~ 35 mm 

651B 35 mm 34.988 ~ 35 mm 

(d). Remove the rear bearing of the intermediate axle. 

(e). Take out the intermediate axle from the housing. 

31A 

(f). Measure the rear bearing internal axle of the 


Model 



646B 35 mm 34.988 ~ 35 mm 

651B 35 mm 34.988 ~ 35 mm


31A-33 

13. Detect the transmission housing 

Hint: 

The primary failure modes of transmission housing are cracks, distortion and bearing hole wear, which are mainly 

caused by the working load and the self gravitation. Repair welding can be carried out on the general cracks, but the 

transmission housing shall be discarded if the cracks are connected to the bearing hole and are at the place for the 

installation of mounting holes. The repairing method for the planes can be file finishing, scraping or grinding. If it is out 

of the clearance, replace with a new part. 

Test item 

Standard 

Planeness errors of the interface between the housing 

and the cover. 

646B 

651B 

0.15 mm 

Parallelism degree errors of cover interface and the 

first-axle and secondary-axle concentric line. 

646B 

651B 

0.1 mm 

Fit clearance of the first-axle bearing seat hole and 

the bearing. 

646B 

651B 

0 ~ 0.069 mm 

Fit clearance of the secondary-axle bearing seat hole 

and the bearing. 

646B 

651B 

0 ~ 0.057 mm 

End circular run-out of the front face of housing to 

the first-axle and secondary-axle concentric line. 

646B 

651B 

0.1 mm 

End circular run-out of the rear face of housing to 

the first-axle and secondary-axle concentric line. 

646B 

651B 

0.1 mm 

Roundness error of each bearing hole 

646B 

651B 

0.007 mm 

Planeness errors of the front face of the housing. 

646B 

651B 

0.1 mm 

31A 

Planeness errors of the rear face of the housing. 

646B 

651B 

0.1 mm 

14. Install the intermediate axle assembly 

(a). Install the intermediate axle assembly into the 

transmission housing.

31A-34 


(b). Install the rear bearing of the intermediate axle. 

(c). Install the front bearing of the intermediate axle and 

the adjusting washer of the intermediate axle. 

HINT: 

Select one or some appropriate adjusting washers and 

install them, the clearance between the adjusting washers 

and the end surface of the transmission housing shall be 

0.2 ~ 0.3 mm, the respective thickness of each adjusting 

washer shall be 0.1 mm, 0.2 mm and 0.3 mm. 

(d). Install the bearing cover of the intermediate axle. 

Torque: 

Model 

Torque 

646B 

21~25 N•m 

651B 

21~25 N•m 

31A 

15. Install the reverse gear shaft 

(a). Install the reverse gear and needle bearing from the 

power take-off hole.


31A-35 

(b). Insert into the reverse gear shaft. 

Notice: 

• Inspect whether the seal ring is aged or cracked 

and replace with a new one if necessary. 

• Make sure that the groove of reverse gear shaft is 

upward to the locking plate of the reverse gear 

shaft. 

(c). Install the cover plate of the power take-off hole and 

screw up the bolts. 

Torque: 

Model 

646B 

651B 

Torque 

57~76 N•m 

57~76 N•m 

Hint: 

Apply sealant while installing the cover plate of the power 

take-off hole. 

(d). Install the locking plate of the reverse gear shaft. 

Hint: 

The locking plate of the reverse gear shaft shall be 

inserted into the groove of reverse gear shaft. 

Torque: 

Model 

646B 

651B 

Torque 

19~25 N•m 

19~25 N•m 

31A 

16. Install the secondary-axle assembly 

(a). Install the secondary-axle assembly into the 

transmission housing.

31A-36 


(b). Knock on the secondary-axle deep groove ball 

bearing slightly with a cooper rod and make it reach 

to its place, and then install the retainer ring. 

17. Install first-axle assembly 

(a). Install first-axle assembly. 

Notice: 

• Put the plain-milling position on the first-axle 

synchronous conical ring towards the 

intermediate axle during the installation of the 

first axle. 

• Be careful not to damage the secondary-axle front 

needle bearing. 

(b). Install the one-axle bearing retainer ring and the 

first-axle retainer ring. 

31A


31A-37 

(c). Install the first-axle cover. 

18. Install the secondary-axle rear bearing cover 

(a). Install the odometer driving gear. Install the driven 

gear, oil seal, odometer flexible axle joint and paper 

pad of secondary-axle rear bearing cover on the 

bearing cover. 

(b). Install the driven gear, oil seal, odometer flexible 

axle joint, and paper washer of secondary-axle rear 

bearing cover on the secondary-axle rear bearing 

cover. 

31A

31A-38 


(c). Screw up the 8 bolts of the secondary-axle rear 

bearing cover. 

Torque: 

Model 

Torque 

646B 

41~45 N•m 

651B 

41~45 N•m 

19. detection after the assembly of transmission axle 

(a). Detect the secondary-axle axial clearance. (Refer to “chapter 31 a transmission (646b/651b)-transmission assembly, 

overhaul”) 

(b). All the first-axle and secondary-axle gears shall be correctly correspond to the positions of intermediate axle gears; 

adjust them through adjusting the adjustable gaskets of the intermediate axle. 

(c). Turn the synchronizer for gear engagement test, the gear shall rotate normally. 

20. Install the transmission upper cover assembly 

(d). Install the upper cover assembly. 

Torque: 

Model 

646B 

651B 

Torque 

33~42 N•m 

33~42 N•m 

HINT: 

Apply sealant while installing the cover plate of the power 

take-off hole. 

31A 

Notice 

Inspect whether there are remains and foreign matters 

in the housing before closing the upper cover of the 

transmission, all the gears and gear shift forks shall be 

at neutral position, take gear engagement test for each 

gear after installation, no abnormality shall be found. 

21. Install the center brake assembly 

(a). Install the center brake assembly with baffle plate. 

Torque: 

Model 

646B 

651B 

Torque 

89~118 N•m 

89~118 N•m


31A-39 

(b). I nstall the central braking drum flange and screw 

up the flange nut. 

Torque: 

Model 

646B 

651B 

Torque 

392~500 N•m 

392~500 N•m 

Hint: 

Press the nut spring into the secondary-axle groove after 

screwing up the flange nut so as to lock up the flange nut. 

(c). Install the central braking drum. 

22. Install the clutch housing assembly 

Torque: 

Model 

646B 

651B 

Torque 

57~75 N•m 

57~75 N•m 

31A

31A-40 


Secondary axle assembly 

Parts diagram 

31A 

1 Needle 19 Third-shifting 

2 Retainer 20 Third-shifting 

3 Fifth-shifting 21 Third-shifting 

4 Fifth-shifting 22 Needle 

5 Synchronizer 23 Retainer 

6 Fifth-shifting 24 Thrust 

7 Fifth-shifting 25 Steel 

8 Secondary-axle 26 Secondary-axle 

9 Needle 27 Needle 

10 Retainer 28 Secondary 

11 Thrust 29 First-shifting 

12 Steel 30 Needle 

13 Secondary-axle 31 Secondary-axle 

14 Needle 32 Reverse-gear 

15 Retainer 33 Reverse-gear 

16 Third-shifting 34 Retainer 

17 Third-shifting 35 Needle 

18 Synchronizer 36 Backward


31A-41 

37 Deep 41 Flange 

38 Retainer 42 O seal ring 

39 Odometer 43 Flange 

40 Flange 

31A

31A-42 

Overhaul 


1. Measure the axial clearance of each shifting of 

secondary-axle gears 

(a). Measure the axial clearance of each shifting of 

secondary-axle gears 

Gear 

Sixth gear 

Fourth gear 

Third gear 

Second gear 

First gear 

Reverse gear 

646B 

651B 

646B 

651B 

646B 

651B 

646B 

651B 

646B 

651B 

646B 

651B 

minor diameter 

Standard 

0.059 ~ 0.100 mm 

0.020 ~ 0.069 mm 

0.020 ~ 0.069 mm 

0.020 ~ 0.069 mm 

0.020 ~ 0.069 mm 

0.020 ~ 0.069 mm 

2. Remove the fifth-shifting and sixth-shifting 

synchronizers 

(a). Remove the synchronizer retainer ring of the fifth 

shifting and the sixth shifting. 

31A


31A-43 

(b). Remove the fifth-shifting and sixth-shifting 

synchronizers from the secondary-axle. 

3. Disassemble the fifth-shifting and sixth-shifting 

synchronizers 

(a). Remove the copper rings of the fifth-shifting and 

sixth-shifting synchronizers. 

HINT: 

Label on the copper rings of the fifth-shifting and 

sixth-shifting synchronizers after removal. 

(b). Separate the springs, slider and retainer rings and 

gear stands of the fifth-shifting and sixth-shifting 

synchronizers. 

31A 

(c). Inspect the two copper rings of the synchronizer 

respectively. (Refer to “chapter 31a transmission 

(646b/651b)-secondary-axle assembly, overhaul”) 

(d). Inspect the gear ring and gear stand of the 

synchronizer. (Refer to “chapter 31a transmission 

(646b/651b)-secondary-axle assembly, overhaul”)

31A-44 


4. Remove the secondary-axle and sixth-shifting gear 

(a). Remove the sixth-shifting gear and the needle 

bearing from the secondary axle. 

5. Remove the secondary-axle and fourth-shifting 

gear attachment 

(a). Remove the retainer ring of the fourth-shifting gear. 

31A 

(b). Remove the thrust washer of the fourth-shifting gear. 

HInt: 

Be careful not to lose the steel ball.


31A-45 

(c). Measure the thrust washer thickness of the 

fourth-shifting gear. 

Model Standard Limit 

646B 6 mm 5.95 mm 

651B 6 mm 5.95 mm 

(d). Remove the fourth-shifting gear attachment and the 

needle bearing from the secondary axle. 

6. Remove the third-shifting and fourth-shifting 


(a). Remove the third-shifting and fourth-shifting 

synchronizer retainer rings. 

31A

31A-46 


(b). Remove the third-shifting and fourth-shifting 

synchronizers from the secondary axle. 

7. Disassemble the third-shifting and fourth- shifting 

synchronizers 

(a). Disassemble the third-shifting and fourth-shifting 

synchronizer copper rings. 

Hint: 

Label on the synchronizer copper rings of the 

third-shifting and fourth-shifting synchronizer after 

removal. 

(b). Remove the third-shifting and fourth-shifting 

synchronizer springs, sliders and synchronizer 

retainer rings and gear stands. 

31A 

(c). Detect the two copper rings of the synchronizer 

respectively. (Refer to “chapter 31a transmission 

(646b/651b)-secondary-axle assembly, overhaul”) 

(d). Inspect the gear ring and gear seat of the 




31A-47 

8. Remove the third-shifting gear attachment 

(a). Remove the third-shifting gear attachment and the 


9. Remove the secondary-shifting gear attachment 

(a). Remove the secondary-axle and secondary-shifting 

gear retainer ring. 

(b). Remove the secondary-shifting gear thrust washer. 

Hint: 

Be careful not to lose the steel ball. 

31A

31A-48 


(c). Measure the thickness of the secondary-shifting gear 

thrust washer. 

Model 

Standard 

Thickness 

Limit 

646B 6 mm 5.95 mm 

651B 6 mm 5.95 mm 

(d). Remove the secondary-shifting gear attachment and 

the needle bearing. 

31A 

10. Remove the first-shifting and secondary-shifting 

lockpin synchronizers 

Hint: 

Remember the installation direction; the conical surface of 

the synchronizer shall be towards the secondary-shifting 

gear.


31A-49 

11. Remove the reverse gear 

(a). Remove the reverse gear attachment and the needle 


12. Remove the reverse-gear synchronizer 

(a). Remove the reverse-gear synchronizer retainer ring. 

(b). Remove the reverse-gear synchronizer assembly 

from the secondary axle. 

13. Disassemble the reverse-gear synchronizer 

(a). Separate the gear ring and gear seat of the 

reverse-gear synchronizer. 

31A 

(b). Detect the gear ring and gear seat of the reverse-gear 



31A-50 


14. Remove the secondary-axle and first-shifting gear 

attachment 

(a). Remove the secondary-axle and first-shifting gear 

attachment and the needle bearing. 

15. Detect the secondary axle 

(a). Measure the secondary-axle circular run-out. 

Model 

Circular run-out 


646B 0.03mm 0.10mm 

651B 0.03mm 0.10mm 

If the circular run-out is beyond the limit value, replace 

the secondary axle. 

31A 

(b). Measure the diameter of the secondary-axle 

main-bearing journal. 

Position of bearing 

journal 

1. 646B 

651B 

2. 646B 

651B 

3. 646B 

651B 

4. 646B 

651B 

5. 646B 

651B 

6. 646B 

651B 

Diameter of bearing 

journal 

Standard 

52 mm 

57 mm 

64 mm 

57 mm 

40 mm 

30 mm 

If the diameter of the main-bearing journal is less than the 

minimum valve, replace the secondary axle.


31A-51 

16. Detect the internal diameters of all the secondaryshifting 

gears 

(a). Measure the internal diameters of all the 

secondary-shifting gears. 


Gear position 

Sixth-shifting gear 

646B 

651B 

Fourth-shifting gear 

646B 

651B 

Third-shifting gear 

646B 

651B 

Second-shifting 

gear 646B 

651B 

First-shifting gear 

646B 

651B 

Reverse gear 646B 

651B 

Standard 

Limit 

40 mm 40.050~40.075 

mm 

58 mm 58.01~58.04 mm 

64 mm 64.01~64.04 mm 

71 mm 71.01~71.04 mm 

64 mm 

70 mm 

0.020 ~ 

0.069 mm 

64.01~64.04mm 

71.01~71.04 mm 

58.01~58.04 mm 

If the value of the internal diameter is beyond the limit 

value, replace the gears. 

17. Detect the copper ring of synchronizer 

(a). Inspect whether there is wear and damage. 

(b). Press the copper ring of synchronizer towards the 

gear and turn towards the same direction, inspect the 

locking effect. If the locking is not enough, apply a 

layer of high-quality grinding paster on the contact 

surfaces of the copper ring and the gear of the 

synchronizer and polish slightly. 

Notice: 

Make sure to clean the grinding paster after polishing. 

(c). Inspect the locking effect of the synchronizer copper 

ring again. 

(d). If the locking effect is still not ideal, detect the 

clearance between the synchronizer ring and the gear. 

31A 

(e). Measure the clearance between the gear and the 

copper ring of synchronizer. 

Position of copper 

Clearance 

ring Standard Limit 

Third-shifting and 

fourth-shifting 646B 

651B 

1.05~2.25 mm 2.75 mm 

Fifth-shifting 

sixth-shifting 

and 

646B 

651B 

0.6~0.8 mm 1.3 mm 

If the actual value is beyond the limit value, replace with a 

new copper ring of synchronizer.

31A-52 


18. Inspect the gear ring and gear seat of 

synchronizer 

(a). Inspect the sliding conditions of the gear ring and 

gear seat. 

(b). Measure the fit clearance of the gear ring and the 

shift fork. 

Model 

Clearance 


646 B 0.1~0.29 mm 1 mm 

651 B 0.1~0.29 mm 1 mm 

If the fit clearance is beyond the limit value, replace the 

relevant gear ring and the shift fork. 

19. Install the secondary-axle and first-shifting gear 

attachment 

(a). Install the first-shifting gear needling bearing. 

(b). Install the secondary-axle and first-shifting gear 

attachment. 

31A 

Notice: 

• The needle steering installed in the gear shall not 

be higher than the end face of the gear; otherwise, 

new needle bearing shall be replaced with. 

• Shake the needle bearing before the installation to 

see whether any needles are missed; if the bearing 

is damaged, replace it in time. 

20. Install the reverse-gear synchronizer 

(a). Install the gear seat of the reverse-gear synchronizer 

into the gear ring of the synchronizer.


31A-53 

(b). Install the reverse-gear synchronizer and the retainer 

ring. 

21. Install the secondary-axle reverse gear 

(a). Install the reverse gear needle bearing. 

(b). Install the reverse gear attachment. 

Notice: 




• Shake the needle bearing before installation to see 

whether any needles are missed; if the bearing is 

damaged, replace it in time. 

22. Install the first-shifting and secondary-shifting 

lockpin synchronizers 

31A 

Notice: 

The conical surface must be towards the 

secondary-shifting gear during the installation, the 

gear can’t be shifted or the transmission will be even 

damaged if installing in the wrong direction.

31A-54 


23. Install the secondary-axle and secondary-shifting 

gear attachment 

(a). Install the secondary-shifting gear needle bearing. 

(b). Install the secondary-shifting gear attachment. 

NOTICE: 







(c). Install the secondary-shifting gear thrust washer. 

Hint: 

The steel balls shall be installed in the groove of the thrust 

washer. 

31A 

(d). Install the secondary-shifting gear retainer ring.


31A-55 

24. install the secondary-axle and third-shifting gear 

attachment 

(a). Install the third-shifting gear needle bearing. 

(b). Install the secondary-axle and third-shifting gear 

attachment. 

Notice: 







25. Install the third-shifting and fourth-shifting 

synchronizers 

(a). Install the gear seat of the synchronizer into the gear 

ring of it. 

(b). Install the third-shifting and fourth-shifting 

synchronizer keys. 

(c). Install the synchronizer spring. 

(d). Install the copper rings of the third-shifting and 

fourth-shifting synchronizers. 

Hint: 

Install according to the marks made during the 

disassembly, mixed installation is not permitted. 

Notice: 

The synchronizer key shall be towards the notch of the 

synchronizer copper ring. 

31A 


synchronizers 

(a). Install the third-shifting and fourth-shifting 

synchronizers on the secondary axle.

31A-56 


(b). Install the retainer rings of the third-shifting and 

fourth-shifting synchronizers. 

27. Install the secondary-axle and fourth-shifting gear 

attachment 

(a). Install the fourth-shifting gear needle bearing. 

(b). Install the fourth-shifting gear attachment. 

Notice: 







31A 

(c). Install the fourth-shifting gear thrust washer. 

Notice: 

The steel balls must be installed into the groove of the 

thrust washer.

Transmission (646b/651b)-secondary axle assy 

31A-57 

30. Install the fifth-shifting and sixthshifting 

synchronizers 

(a). 

Install the fifth-shifting and 

sixth-shifting synchronizers on the 


(b). 

Install the retainer rings of the 

fifth-shifting and the sixth-shifting 


31A

31A-58 

Transmission (646b/651b)- Intermediate axle assy 

Intermediate axle assembly 

Notes 

1. In general, the intermediate axle gear shall not be disassembled, only if it is seriously 

worn or perforated. 

31A


31A-59 

Components 

1 

Adjusting Gasket of Front Roller Bearing 

of Intermediate Axle 

8 Third-shifting Gear of Intermediate Axle 

2 Front Roller Bearing of Intermediate Axle 9 Intermediate Axle 

3 Retainer Ring 10 General Flat Key 

4 Fifth-shifting Gear of Intermediate Axle 11 General Flat Key 

5 Sixth-shifting Gear of Intermediate Axle 12 Half-round Key 

6 Fourth-shifting Gear of Intermediate Axle 13 Rear Roller Bearing of Intermediate Axle 

7 Sleeve Gasket 

31A

31A-60 


Replacement 

1. Remove the fifth-shifting gear of 

the intermediate axle 

(a). 

(b). 

(c). 

Remove the retainer ring. 

Press out the fifth-shifting gear of the 

intermediate axle with a press. 

Take down the short flat key. 

2. Remove the sixth-shifting and 

fourth-shifting gears of the 

intermediate axle 

(a). 

Press out the sixth-shifting and 

fourth-shifting gears of the 

intermediate axle with a press. 

31A 

(b). 

Take down the long flat key and the 

sleeve gasket.


31A-61 

3. Disassemble the third-shifting gear 

of the intermediate axle 

(a). 

(a). 

Press out the third-shifting gear with 

a press. 

Take down the half-round key. 

4. Install the third-shifting gear of the 


(a). 

(b). 

Install the half-round key into the 

groove. 

Press in the third-shifting gear with a 

press and put it into place. 

Notice: 

The long side of the convex plate shall be 

upwards during the installation, the key 

groove shall be aligned with the 

half-round key. 

5. Install the fourth-shifting gear of 

the intermediate axle 

(a). 

Install the sleeve gasket and the long 

flat key. 

31A

31A-62 


(b). 

Press in the fourth-shifting and 

sixth-shifting gears with a press and put 

them into place. 

Notice: 


upwards during the installation. 

6. Install the fifth-shifting gear of the 


(a). 

(b). 

Install the short flat key into the groove. 

Press in the fifth-shifting gear with a 

press and put it into place. 

(c). Install the retainer ring. 

Notice: 


upwards during the installation, the opening 

of the retainer ring shall be staggered to the 

key groove. 

31A

Transmission (646b/651b)- first axle and reverse gear shaft 

First axle and reverse gear shaft 

31A-63 

Components 

1 Retainer Ring 7 Reverse Gear Shaft 

2 Retainer Ring 8 O Ring 

3 R oller Bearing 9 Locking Plate of Reverse Gear Shaft 

4 First Axle 10 Elastic Washer 

5 Needle Bearing 11 Hexagon Nut 

6 Backward Gear 

31A

31A-64 

Transmission (646b/651b)- Replacement 

Replacement 

(Refer to “chapter 31 a transmission (646b/651b)-transmission assy, overhaul”) 

31A

Transmission (646b/651b)- upper cover assy 

31A-65 

Upper cover assembly 

Components 

1 Fifth and Sixth-shifting Shift Fork 19 Blank Cap 

2 Fifth and Sixth-shifting Shift Fork 

Block 

20 Expansion Plug 

3 Fifth and Sixth-shifting Fork Axle 21 Bolt 

4 Shift Fork Catch Bolt 22 Plug Screw 

5 Steel Thread Locking Wire 23 Pressure Spring-1 (Left) 

6 Interlock Pin 24 Pressure Pin 

31A 

7 Third and Fourth-shifting Fork Axle 25 Core plug 

8 Third and Fourth-shifting Shift Fork 26 Straight Pin 

9 First and Second-shifting Block 27 Steel Ball 

10 First and Second-shifting Block 28 Lock Ball Spring (Right Pressure Pin) 

11 First and Second-shifting Fork Axle 29 Plug Screw (Top) 

12 Reverse Shift Fork Axle 30 Spring 

13 Reverse Shift Block 31 Steel Ball 

14 Reverse Shift Fork 32 Air Outlet Valve 

15 Safety Disc-2 (Right) 33 Upper Cover 

16 Guide Plate Assy 34 Spring Circlip for Shaft 

17 Safety Disc-1 (Left) 35 Flat Gasket 

18 Steel Ball 36 Shifting Gear Shaft Oil Seal

31A-66 

Transmission (646b/651b)- Upper cover assy 

37 Internal Gear-select Rocker 

43 Gear-shift Head 

Assembly 

38 Pressure Pin 44 Back-up Lamp Switch 

39 Lock Ball Spring 45 Gear-shift Axle 

40 Pressure Spring-2 (Left) 46 Lock Ball Spring (Fork Shaft) 

41 Plug Screw 47 Gear-shift Armshaft 

42 Shifting Gear Shaft Oil Seal 

31A

Overhaul 


31A-67 

1. Disassemble the fork shaft assy 

(a). Remove each shifting of gear shift fork and the 

steel thread locking wire and catch bolt on the 

gear shift block. 

(b). 

Knock out each shifting of transmission fork 

shaft and take out the each shifting of shift fork, 

self-locking steel ball, lock ball spring and gear 

shift block. 

Hint: 

The lock balls will fly off easily while removing the 

gear shift fork; cover the spring eye of the lock ball 

with rags to prevent the balls from flying off. 

Notice: 

• When the lock ball spring of the fork shaft is 

compressed to 26.1mm, the pressure of the 

spring shall be 80.71 N; if not, replace with a 

new one. 

• All the fork shafts shall be removed in any 

order so as to ensure that the interlock pin is 

at neutral position while removing the lock 

ball spring. 

2. Remove the pressure pin 

(a). Loosen the plug screw. 

31A 

(b). Take out the pressure spring of the pressure pin 

and take out the pressure pin. 

Hint: 

Make marks respectively on the springs of the left and 

right pressure pin springs in order to identify conveniently 

during the installation. 

Notice: 

• When the right pressure spring in the 

illustration is compressed to 34.5 mm, the 

pressure shall be 43.35 N; if not, replace with 

a new one. 

• When the left pressure spring in the 



a new one.

31A-68 


3. Remove the safety disc and the guide plate 

(a). Prize up the four corners of the safety disc and 

loosen the bolt. 

(b). Remove the safety disc and the guide plate. 

(c). Remove the lock ball spring and the steel ball. 

Hint: 

Make marks respectively on the springs of the left and 

right lock ball springs in order to identify conveniently 


Notice: 

• When the right lock ball spring in the 



a new one. 

• When the left lock ball spring in the 



a new one. 

4. Remove the gear-select rocker 

(a). Loosen the nut and remove the external 

gear-select rocker. 

31A 

(b). 

Remove the retainer ring and the pad. 

(c). 

Remove the internal gear-select rocker head.


31A-69 

5. Remove the gear-shift axle assy 

(a). Remove the straight pin. 

(b). 

Remove the gear-shift axle assy. 

6. Measure the clearance between the gear-shift 

head and the block 

Model 

Clearance 


646B 0.7~1.0 mm 1.4 mm 

651B 0.7~1.0 mm 1.4 mm 

If it is beyond the limit, replace with a new gear-shift 

head. 

7. Measure the radial clearance between the 

gear-shift head and the gear-shift axle spline 

Model 

Clearance 

Standard 

Limit 

646B 0.05~0.11 mm 0.5 mm 

651B 0.05~0.11 mm 0.5 mm 

31A 

If it is beyond the limit, replace with a new gear-shift 

head. 

8. Inspect the gearshift fork shaft 

(a). Inspect the gearshift fork shaft, if it is deformed, adjust it at once and replace with a new one 

if the deformation is serious. 

9. Inspect the locking steel ball 

(a). Inspect the locking steel ball, replace with a new one if it is worn.

31A-70 


10. Install the gear-shift axle assy 

(a). Install the gear-shift axle assy. 

Hint: 

The gear-shift head shall be between the two pressure 

pins. 

(b). Install the straight pin. 

Hint: 

The straight pin shall be through the ring groove at the 

head of the gear-shift axle. 

11. Install the gear-shift arm 

(a). Install the internal gear-select rocker head. 

(b). 

Install the pad and retainer ring. 

31A 

(c). 

Install the external gear-select rocker and screw 

up the nut.


31A-71 

12. Install the safety disc and the guide plate 

(a). Install the steel balls and the lock ball springs 

Notice 

The left lock ball spring and the right lock ball 

spring can’t be installed in the opposite side of each 

other. 

(b). 

(c). 

Install the guide plate and the safety disc. 

Screw up the bolt and prize up the four corners 

of the safety disc. 

Torque: 

Model 

Torque 

646B 

16~21 N· m 

651B 

16~21 N· m 

13. Install the pressure pin 

(a). Install the pressure pin and the pressure spring 

of pressure spring. 

Torque: 

Model 

Torque 

646B 

16~21 N· m 

651B 

16~21 N· m 

Notice: 

The left pressure pin spring and the right pressure 

pin spring can’t be installed in the opposite side of 

each other. 

(b). 

Screw up the plug screw. 

31A

31A-72 


14. Install the fork shaft assy 

(a). Install each shifting of transmission fork shaft, 

transmission fork, self-locking steel ball, lock 

ball spring and transmission guide block. 

(b). Install the fork shafts, the interlock steel balls 

and the interlock pins. 

Notice: 

The steel balls and the interlock pins can’t be missed 

during the installation, otherwise, the gears of 

transmission will be confused and the transmission 

will be damaged at the same time. 

(c). Install the catch bolts on each shifting of 

transmission fork and transmission guide block, 

and bind the catch bolt with locking wire. 

31A

Transmission 6g120 

Transmission control mechanism ............. 31B-1 

Components............................................ 31B-1 

Replacement........................................... 31B-2 

Gearshift & gear selecting flexible axles....31B-5 

Components............................................ 31B-5 

Replacement........................................... 31B-6 

Transmission assembly ............................. 31B-11 

Notes..................................................... 31B-11 

Problem symptoms table ...................... 31B-12 

Components.......................................... 31B-14 

Replacement......................................... 31B-17 

Overhaul................................................ 31B-21 

Secondary-axle assembly.......................... 31B-34 

Components.......................................... 31B-34 

Overhaul................................................ 31B-36 

Intermediate axle assembly........................ 31B-51 

Notes...................................................... 31B-51 

Components........................................... 31B-52 

Replacement.......................................... 31B-53 

First-axle and reverse gear shaft............... 31B-56 

Components........................................... 31B-56 

Replacement.......................................... 31B-57 

31B

31B

Transmission 6g120 -transmission control mechanism 

31B-1 

Transmission control mechanism 

Components 

1 Control Handle Ball Head 8 Hexagon Flange Bolt 

2 Control Rod Shield Sleeve 9 Spring Washer 

3 Shield Sleeve Clasp 10 Hexagon Nut-style 1 

5 Control Protective Shell 11 Hexagon Flange Bolt 

5 Plastic Staple Bolt Assy 12 

Flexible Axle Seal Ring Pressing 

Plate 

6 

Front Transmission 

Control Mechanism 

13 Flexible Axle Seal Ring 

7 

All-metal Flange Lock 

Nut 

31B

31B-2 


Replacement 




2. Remove the control rod shield sleeve 

(a). Pull out the control road shield sleeve. 

31B 

3. Disconnect the connection between the 

control flexible axle and the front 

transmission control mechanism 

(a). Loosen the connecting bolt of the gear selecting 

flexible axle and the gear selecting arm, 

disconnect the connection between the gear 

selecting flexible axle and the gear selecting 

(b). 

arm. 

Pull out the cotter pin of gearshift arm and 

disconnect the connection between the gearshift 

flexible axle and the gearshift arm. 

Hint: 

Don’t loose the gearshift flexible axle pad. 

4. Remove the front transmission control 

mechanism 

(a). 

(b). 

Loosen the 3 fixing nuts of front transmission 

control mechanism. 

Remove the front transmission control 

mechanism.


31B-3 

5. Remove the control handle 

(a). Loosen the 2 inner-hexagon bolts and remove the 


Notice: 

Lubricate the ball head of gear shift lever, replace 

the plastic bearing of the control handle if 

necessary. 

6. Install the control handle 

(a). Screw up the 2 inner-hexagon bolts and install the 


31B 

7. Install the control handle assy 

(a). Screw up the 3 fixing nuts of front transmission 

control mechanism and install the front 

transmission control mechanism.

31B-4 


8. Connect the control flexible axle and the 

control handle assy 

(a). Screw up the connecting bolts of the gear 

selecting flexible axle and the gear selecting 

arm, connect the gear selecting flexible axle and 

the gear selecting arm. 

(b). Insert into the cotter pin of gearshift arm, 

connect the gearshift flexible axle and the 

gearshift arm. 

9. Install the control rod shield sleeve 

(a). Set on the gear shift level shield sleeve. 

10. Install the control handle ball head 

(a). Screw up the control handle ball head 

clockwise. 

Hint: 

Apply appropriate amount of anaerobic adhesive 

(Loctite 495) during the assembly of control handle ball 

head and the control rod. 

31B

Transmission 6g120 - gearshift flexible axle and gear selecting flexible axle 

Gearshift and gear selecting flexible 

axle 

31B-5 

Components 

1 Cotter Pin 12 Plastic Clip 

2 Flat Washer 13 Gear Selecting Flexible Axle Assy 

3 Spring Washer 14 Gearshift Flexible Axle Assy 

5 Hexagon Nut-style 1 15 Multiple Pipe Clamping Piece 

5 Locking Plate 16 Cotter Pin 

6 Shield Sleeve 17 Coupling Pin 

7 Hexagon Head Bolt 18 Spring Washer 

8 Spring Washer 19 Hexagon Nut-style 1 

9 Hexagon Nut-style 1 20 Flexible Axle Support Assy 

10 

Multiple Pipe Clamping 

Piece 


11 

Air Conditioning Pipe 

Support 

31B

31B-6 

Replacement 



control flexible axle and the transmission 

(a). Disconnect the connection between the gearshift 

flexible axle and the gear selecting flexible axle 

and the connection between the transmission 

gearshift arm and gear selecting arm 

respectively. 

(b). 

Remove the control flexible axle from the 

gearshift arm and the gear selecting arm. 

Notice: 



31B 


control flexible axle and the control handle 

assy (refer to “chapter 31 b transmission 

6g120 - transmission control mechanism, 

replacement”)


31B-7 

3. Remove the transmission control protective 

shell 

(a). Loosen the 5 plastic staple bolt assemblies and 

remove the transmission control protective 

shell. 

4. Remove the fixed locking plates of control 

flexible axle 

(a). Pull up the 2 fixed locking plates of control 

flexible axle and separate the control flexible 

axle and the control base. 


control flexible axle and the driving cab 

(a). Remove the flexible axle seal ring pressing 

plate and the flexible axle seal ring. 

31B

31B-8 



control flexible axle and the frame 

(a). Loosen the multiple pipe clamping pieces, 

disconnect the connection between the control 

flexible axle and the frame, and remove the 

control flexible axle. 

7. Install the fixed buckle of control flexible 

axle 

(a). Fasten the control flexible axle on the frame 

with multiple pipe clamping pieces. 

31B 

8. Fasten the control flexible axle on the driving 

cab 

(a). Install the flexible axle seal ring and flexible 

axle sear ring pressing plate.


31B-9 

9. Install the fixed locking plates of control 

flexible axle 

(a). Insert into the 2 fixed locking plates of the 

control flexible axle and fasten the control 

flexible axle on the control base assy. 

10. Install the transmission control protective 

shell assy 

(a). Install the transmission control protective shell 

and insert into 5 plastic staple bolt assembles. 

11. Connect the control handle assy (refer to 

“chapter 31 b transmission 6g120 - 

transmission control mechanism, 


Notice: 

When the control mechanism connects with the 

flexible axle, the control handle shall be in a vertical 

position; otherwise, it shall be adjusted, and the 

flexible axle joint shall be fastened after the 

adjustment. 

31B 

12. Connect the control flexible axle and the 

transmission 

(a). Install the gearshift flexible axle and the gear 

selecting flexible axle on the frame assy. 

Notice: 



• Make sure that all the gears are clear and 

correct; the gears can be shifted easily and 

flexibly without clamping or interference.

31B-10 


(b). 

Install the gearshift flexible axle and the gear 

selecting flexible axle on the transmission 

gearshift arm and gear selecting arm 

respectively. 

31B

Transmission 6g120 - transmission assy 

31B-11 

Transmission assembly 

Notes 

1. Notes for the use of transmission 

(a). Inspect the level of transmission oil regularly and add some transmission oil if it is not 

enough. 

Hint: 

Park the vehicle on the level road while filling transmission oil, the oil shall be filled into the lower 

edge of the oil filling opening. 

(b). 

Change the transmission oil for the new transmission every 5,000 kilometers, and change it 

every 24,000 kilometers or once a year after the breaking-in period. 

Notice: 

• 80W/90 (GL-5) oil shall be used for the transmission 

• Different brands of transmission oil can’t be used together. 

(c). 

(d). 

(e). 

(f). 

Maintain the breather plug regularly to ensure its cleanness and smoothness. 

Start with the first gear or the second gear according to the road conditions and the load of 

vehicles. 

Neutral sliding is not permitted for the transmission, especially when the engine is at 

flameout state so as to avoid burning out the synchronizers and various kinds of bearings. 

The clutch must be separated completely during the gearshift to avoid half linkage state and 

damage of synchronizers and other parts; park the vehicle first and then shift the gear so as 

to avoid damaging the backward gear and the gear ring of the synchronizer. 

(g). When the vehicle needs to be dragged for malfunction, disconnect the transmission axle or 

drag it above the ground, avoid the driving wheels roll and turn the output axis of 

transmission to rotate so as the burn out the bearings and other components. 

2. NOTES FOR THE DISASSEMBLY AND ASSEMBLY OF TRANSMISSION 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

(g). 

(h). 

(i). 

(j). 

(k). 

The vehicle must be parted on the level and safe place before removing the transmission 

from the complete vehicle, shut off and turn off the power supply, fasten the front and rear 

wheels with tools to ensure the safety of the complete vehicle. 

Clean the outside of the transmission before disassembling it, avoid the dust and impurities 

entering into the transmission during the disassembly of the transmission. 

Clean all the parts, unclog the lubricating orifices of each part and blow off with compressed air 

before assembling. 

Don’t knock with a hammer directly while disassembling or assembling the axles, bearings 

and oil seals and fastening the gears, copper hammers or copper rods must be used while 

knocking to avoid damaging the parts. Various special tools shall be used for the 

disassembly. 

The paper washers and sealant remained on each faying surfaces must be cleaned. 

Notice the positions and directions of the gear, thrust pad and pad. 

Apply clean lubricating oil on all the thrust washers, needle bearings and synchronizer conical 

surfaces during the assembly so as to avoid the damage caused by the dry friction. 

New sealing gaskets must be used during the assembly; omitted installation of sealing gaskets is 

not permitted. 

Inspect whether each oil seal lip is damaged, replace with new parts if oil leakage is found. 

Apply sealant uniformly on each gasket to avoid oil leakage, 5699 or 5702 silicone sealant is 

suggested to be used, apply uniformly to avoid breaking. 262 screw-thread retaining compound is 

suggested to be used during the assembly of through-hole bolts. 

Check the important matching parts, especially the interference fit parts and check them 

carefully before the assembly so as to avoid rework. 

31B

31B-12 

Problem symptoms table 


Use the table below to help you find the cause of the problem. The numbers indicate the probability of the 

cause of the problem. Check each part in order. If necessary, replace these parts. 



too low) 

2. Lubricating oil (Not enough) 

3. Bearing (Over worn or 

damaged) 

- 

- 


6g120-transmission assy, overhaul 

The abnormal sound or noise is too 

big. 

4. Gear shift fork and 

synchronizer gear (The 

combination is not appropriate) 

5. Synchronizer (Worn or 

damaged) 


6g120-secondary-axle assy, overhaul 


6g120-secondary-axle assy, overhaul 

6. Gear tooth (Scratched or worn) Chapter 31 a transmission 

6g120-transmission assy, overhaul 

7. Transmission housing 

(Distorted and deformed) 


too big) 

2. Clutch (The separation is not 

complete) 


6g120-transmission 

assy, 

replacement 

- 

Chapter 32 clutch-clutch assembly 

part, overhaul 

31B 

It is difficult to engage a gear for the 

transmission. 

3. Bearing (Over worn or Chapter 31 a transmission 

damaged) 

6g120-transmission 

assy, 

replacement 

4. Synchronizer (Damaged) Chapter 31 a transmission 6g120- 

secondary -axle assy, overhaul 

5. Shift fork catch bolt (Loose) Chapter 31 a transmission 

6g120-upper cover assy, overhaul 


damaged) 



7. Fork shaft (Deformed or 

damaged) 



8. Lock steel ball (Over worn) Chapter 31 a transmission 

6g120-upper cover assy, overhaul


31B-13 


The transmission skips gear or gets 

out of gear 

The gears are disordered 

1. Flange nut (Loose) 

2. Gear (The axial clearance is too 

big) 

3. Gear meshing end (Worn 

seriously) 

4. Synchronizer (Damaged) 

5. Bearing (Axial movement) 


damaged) 

7. Self-lock spring (Fractured or 

tired) 

8. Self-lock steel ball (Over worn) 

1. Interlock steel ball (Over worn) 

Chapter 31 a transmission 6g120- 

transmission assy, overhaul 






secondary-axle assy, overhaul 




upper cover assy, overhaul 





Chapter 31 transmission 6g120- 


The transmission leaks oil 

1. Lubricating oil (Excessive) - 

2. Sealing parts (Invalid or 

damaged) 

3. Fastener (Loose) - 

4. Transmission housing 

(Distorted and deformed) 

5. Sealant is not applied on the 

bolt or the sealant applied is not 

uniform. 

- 

- 



31B

31B-14 


Components 

31B


31B-15 

31B

31B-16 


1 Top Head Assy 6 Intermediate Axle Assy 

2 Clutch Cover Assy 7 Reverse Gear Shaft Assy 

3 First Axle Assy 8 Transmission Housing Assy 

5 Secondary-axle Assy 9 

5 

Transmission Mechanism 

Assy 

Flange and Secondary-axle Rear Bearing 

Cover 

31B

Replacement 


31B-17 

1. Screw off the oil-discharge plug at the 

bottom of the transmission, exhaust the 

transmission oil and screw up the 

oil-discharge bolt. 

Torque: 98 ~ 127 N•m 

Hint: 

Discharge the oil after starting the vehicle in order to 

discharge the transmission oil as far as possible. 

2. Disconnect the connections between the transmission and other parts 

(a). Disconnect the connection between the control flexible axle and the transmission. (Refer to 

“chapter 31 b transmission 6g120 -gearshif flexible axle and gear selecting flexible axle, 


(b). Remove the back-up light switch 

(c). 

Remove the vehicle speed sensor. 

31B 

(d). 

Remove the clutch slave cylinder booster. (Refer to “chapter 32 clutch-clutch slave cylinder 

booster, replacement”)

31B-18 


(e). 

Loosen the 4 connecting nuts of the 

transmission axle and the transmission; take out 

the rear end of the transmission. (Refer to 

“chapter 33 transmission axle- transmission axle 

assy, replacement”) 

(f). 

Remove the 12 bolts of clutch housing and take 

out the transmission assy. 

31B 

3. Connect the transmission and other parts 

(a). Screw up the bolts of clutch housing and install 

the front end of the transmission. 

Torque: 

Model 

Torque 

6G120 

73 ~ 100 N•m


31B-19 

(b). 

Screw up the 4 connecting nuts of the 

transmission axle and the transmission. (Refer 

to “chapter 33 transmission axle-transmission 

axle assy, replacement”) 

Torque: 

Model 

Torque 

6G120 

88 ~ 108 N•m 

(c). 

Install the clutch slave cylinder booster. (Refer to “chapter 32 clutch-clutch slave cylinder 

booster, replacement”) 

(d). Install the vehicle speed sensor. 

Torque: 

Model 

Torque 

6G120 

110 ~ 127 N•m 

(e). 

Install the backup light switch. 

Torque: 

Model 

Torque 

6G120 

47.5~ 74.5 N•m 

31B 

(f). 

Install the connection between the control flexible axle and the transmission. (Refer to 

“chapter 31 b transmission 6g120- gearshift flexible axle and gear selecting flexible axle, 

replacement”)

31B-20 


4. Fill transmission oil and screw up the oil 

filling plug 

Torque: 

Model 

Torque 

6G120 

98~ 127 N•m 

Notice: 

Operate the transmission for a few minutes after 

filling the oil, and then check the level of the oil in 

the transmission again. 

5. Transmission breaking-in specification and test 

(a). The rotation speed shall be about 1500 r/min, the temperature of the oil shall not be less than 

15 ℃ ; no load; the operation in neutral gear shall not be less than 15 minutes, and the 

operation in other gears shall not be less than 20 minutes. 

(b). Check whether the gearshift is flexible and whether the meshing of gear is completed, no 

impact sound shall be produced by the gear during the gearshift. 

(c). The gearshift level shall not have distinct shake. 

(d). No abnormal grinding noise and impact sound shall be produced during the test of transmission. 

(e). The transmission shall not leak oil. 

(f). Drain the transmission oil and thoroughly clean the inside of the transmission after 

completing the braking-in and fill transmission oil according to the provision. 

31B

Overhaul 


31B-21 

1. Put the transmission assy on the stable working platform 

2. Remove the clutch housing assy 

(a). Remove the lubricating pipe plug of the clutch. 

(b). 

(c). 

Loosen the set screws on the shift fork of the 

release bearing, punch the release lever and take 

out the spline. 

Take down the release bearing and release fork 

(d). 

Loosen the 10 clutch housing fixing bolts and 

remove the clutch cover assy. 

31B

31B-22 


3. Remove the first-axle cover of the 

transmission 

(a). Loosen the 11 fixing bolts of the first-axle cover 

and remove the first-axle cover. 

(b). 

Remove the first-axle assy. 

4. Remove the front housing of the transmission 

(c). Loosen the 20 front housing bolts and punch the 

2 fixed pins, and remove the front housing of 

the transmission. 

31B 

5. Remove the top head of the transmission 

(a). Loosen the 4 top head bolts and remove the top 

head assy.


31B-23 

6. Remove the secondary-axle rear cover 

(a). Loosen the flange nut locking plate and remove 

the flange nut and the flange. 

(b). 

Loosen the 12 fixing bolts of the secondary-axle 

rear cover and remove the secondary-axle rear 

cover. 

(c). Remove the odometer driven gear, oil seal and 

odometer flexible axle joint from the bearing 

cover. 

Notice: 

The oil seal can only be removed after oil leakage is 

found, replace it with a new part. 

31B

31B-24 


(d). 

Remove the odometer driving gear. 

(e). 

Remove the secondary-axle rear bearing 

retainer ring. 

(f). 

Remove the secondary-axle rear bearing with 

special tools and take down the bearing seat 

retainer. 

31B


31B-25 

(g). 

Measure the internal diameter of the 

secondary-axle rear bearing. 


Model 

Standard 

Limit 

6G120 45 mm 44.988~40 mm 

7. Remove the backward gear 

(a). Loosen the 8 fixing bolts of the reverse gear 

shaft cover and disassemble the reverse gear 

shaft cover. 

(b). Loosen the locking plate of the reverse gear 

shaft. 

(c). Punch the reverse gear shaft. 

Hint: 

Take care not to lose the seal ring. 

31B

31B-26 


(d). 

Take out the backward gear and needle bearing 

from the power take-off hole. 

(e). 

Detect the diameter of the reverse gear shaft. 

Model 

Diameter 

Standard 

6G120 

68 mm 

If it is out of the clearance, replace with a new reverse 

gear shaft. 

8. Remove the fixing bolts of shift fork and 

bushing assy 

(a). Remove the fixing bolts of the left shift fork and 

bushing assy. 

31B 

(b). 

Remove the fixing bolts of the right shift fork 

and bushing assy.


31B-27 

9. Lift gear shift fork assy, secondary-axle assy and 

intermediate axle together with hoisting 

equipment and separate them from the 

tranmission housing 

10. Disassemble the gear-shift mechanism 

(a). Remove the gear shift fork and the bushing assy 

of each shifting. 

Hint: 

Don’t lose gear-shift block. 

(b). 

Remove each shifting of pull rod. 

11. Assemble gear-shift mechanism 

(a). Install each shifting of pull rod. 

31B 

(b). 

Install each shifting of reverse shift fork and 

bushing assy.

31B-28 


12. Install gear shift fork assy, secondary-axle assy 

and intermediate axle together into the 

transmission housing with hoisting equipment 

13. Install the fixing bolts of the shift fork and 

the bushing assy 

(a). Screw up the fixing bolts of the left shift fork 

and the bushing assy. 

(b). 

Screw up the fixing bolts of the right shift fork 

and the bushing assy. 

14. Install the reverse gear 

(a). Install the reverse gear and the needle bearing. 

31B


31B-29 

(b). Install the reverse gear shaft. 

Hint: 

Take care not to lose the seal ring. 

(c). Install the locking plate of the reverse gear 

shaft. 

(d). 

Install the reverse gear shaft cover and screw up 

the 8 fixing bolts of the reverse gear shaft cover. 

Torque: 

Model 

Torque 

6G120 

41~45 N·m 

15. Install the secondary-axle rear cover 

(a). Install the odometer driven gear, oil seal and 

odometer flexible axle joint. 

31B

31B-30 


(b). 

Screw up the 12 fixing bolts of the 

secondary-axle rear cover, and install the 

secondary-axle rear cover. 

Torque: 

Model 

Torque 

6G120 

41~45 N·m 

Notice: 

The oil seal can only be removed after oil leakage is 

found, replace it with a new part. 

(c). 

Install odometer driving gear. 

(d). 

Install secondary-axle rear bearing and the 

bearing seat retainer. 

31B


31B-31 

(e). 

Install the secondary-axle rear bearing retainer 

ring. 

(f). 

Install the flange, screw up the flange nuts and 

fasten the locking plate of the flange nut. 

Torque: 

Model 

6G120 

Torque 

393~500 N·m 

16. Install the top head of the transmission 

(a). Screw up the 4 top head bolts and install the top 

head assy. 

Torque: 

Model 

Torque 

6G120 

41~51 N·m 

31B

31B-32 


17. Install the front housing of transmission 

(b). Screw up the 20 bolts of the front cover, lock 

the 2 fixing pins and install the front housing of 

the transmission. 

Torque: 

Model 

Torque 

6G120 

73~100 N·m 

(c). 

Install the first-axle assy. 

18. Install the first-axle cover of transmission 

(a). Install the first-axle cover, screw up the 11 

fixing bolts of the first-axle cover. 

Torque: 

Model 

Torque 

6G120 

41~45 N·m 

31B

Transmission 6g 120-transmission assembly 

31B-33 

19. Install the clutch housing assembly 

(a). Install the clutch cover assembly and screw down the 

10 fixing bolts of the clutch. 

Torque: 

Model 

6G120 

Torque 

73~100 N·m 

(b). Install the release bearing and release fork. 

(c). Install the release lever and spline, screw down the 

set screws on the release bearing fork. 

(d). Install the lubricating pipe plug of the clutch. 

31B 

20. Inspect after the assembly of transmission axle 

(a). All the first-axle and secondary-axle gears shall be correctly correspond to the positions of intermediate axle gears; 

adjust them through adjusting the adjustable washer of the intermediate axle. 

(b). Turn the synchronizer for gear engagement test, the gear shall rotate normally.

31B-34 

Transmission 6g 120-Secondary axle assembly 

Secondary axle assembly 

Parts diagram 

31B

Transmission 6g 120- Secondary axle assembly 

31B-35 

1 

Secondary-axle Front Bearing Seat Retainer 

Third-shifting and Fourth-shifting 

21 

Ring 

Synchronic Cones 

2 Secondary-axle Front Needle Bearing 22 

Secondary-axle and Third-shifting 

Gear 

3 Secondary-axle Front Bearing Seat ring 23 Third-shifting Gear Needle Bearing 

4 Spring Circlip for Shaft 24 Secondary Axle 

5 

Fifth-shifting and Sixth-shifting 

Secondary-shifting Gear Needle 

25 

Synchronizer Ring 

Bearing 

6 


Secondary-axle 

and 

26 

Synchronizer Gear Ring 

Secondary-shifting Gear 

7 


Synchronizer Gear seat 

27 Secondary-shifting Synchronic Cone 

8 Sixth-shifting Synchronic Cone 28 

First-shifting and Secondary-shifting 

Synchronizer Ring 

9 Sixth-shifting Gear Needle Bearing 29 

First-shifting and Second-shifting 

Synchronizer Gear Seat 

10 Secondary-axle and Sixth-shifting Gear 30 Synchronizer Spring 

11 Spring Circlip for Shaft 31 Synchronizer Thrust Block 

12 Fourth-shifting Gear Thrust Ring 32 Connecting Block 

13 Fourth-shifting Gear Needle Bearing 33 


Synchronizer Gear Ring 

14 Secondary-axle and Fourth-shifting Gear 34 


Synchronic Cones 

15 Fourth-shifting Synchronic Cone 35 First-shifting Gear Needle Bearing 

16 


Secondary-axle and First-shifting 

36 

Synchronizer Rings 

Gear 

17 Circlip for Shaft 37 

Secondary-axle Reverse Gear 

Associative Ring 

18 


Reverse Gear Seat Retainer Needle 

38 

Synchronizer Gear seat 

Bearing 

19 Synchronizer Key 39 Secondary-axle Reverse Gear 

20 


Synchronizer gear Ring 

40 Reverse Gear Bearing Seat 

31B

31B-36 

Overhaul 


1. remove the secondary-axle front needle bearing 

2. remove the fifth-shifting synchronizer ring 

(a). Remove the fifth-shifting synchronizer ring. 

Hint: 

Label for the fifth-shifting synchronizer ring after 

removal. 

(b). Inspect the synchronizer ring. (refer to “chapter 31 b 

transmission 6g 120-secondary-axle assembly, 

overhaul”) 

31B 

3. remove the fifth-shifting and sixth-shifting 

synchronizers from the secondary axle


31B-37 

4. disassemble the fifth-shifting and sixth-shifting 

synchronizer springs, keys and synchronizer gear 

ring and gear seat 

(a). Inspect the synchronizer gear ring and gear stand. 

(refer to “chapter 31 b transmission 6g 

120-secondary-axle assembly, overhaul”) 

5. remove the sixth-shifting synchronizer ring 

(a). Remove the sixth-shifting synchronizer ring. 

Hint: 

Label for the sixth-shifting synchronizer ring after 

removal. 



overhaul”) 

6. remove the sixth-shifting gear 

(a). Remove the sixth-shifting gear and needle bearing 

from the secondary axle. 

31B 

(b). Remove the sixth-shifting needle bearing from the 

secondary axle.

31B-38 


7. Remove the fourth-shifting gear 

(a). Remove the fourth-shifting gear retainer ring. 

(b). Remove the fourth-shifting gear thrust ring and 

fourth-shifting gear. 

(c). Measure the thickness of the fourth-shifting gear 

thrust ring. 

31B 

Thickness 

Model 


6G120 5.2 nn 5.12~5.2 mm 

Replace with a new one if it is beyond the limit value.


31B-39 

(d). Remove the fourth-shifting gear needle bearing from 

the secondary axle. 

8. Remove the fourth-shifting synchronizer ring 

(a). remove the fourth-shifting synchronizer ring. 

hint: 

Label for the fourth-shifting synchronizer ring after 

removal. 

(b). Inspect the synchronizer ring (refer to “chapter 31 b 


overhaul”) 

9. Remove the third-shifting and fourth-shifting 

synchronizers from the secondary axle 

31B

31B-40 


10. Disassemble the third-shifting and fourth-shifting 

synchronizer springs, keys and synchronizer gear 

ring and gear seat 

(a). Inspect the synchronizer gear ring and gear seat. 



11. Remove the third-shifting synchronizer ring 

(a). Remove the third-shifting synchronizer ring. 

Hint: 

Label for the third-shifting synchronizer ring after 

removal. 



overhaul”) 

12. Remove the third-shifting gear 

(a). Remove the third-shifting gear attachment and the 


31B


31B-41 

13. remove the reverse gear 

(a). Remove the reverse gear bearing seat ring, reverse 

gear, reverse gear combined gear ring and needle 


14. remove the first-shifting gear 

(a). Remove the secondary-axle and first-shifting gear 

and needle bearing. 

15. remove the first-shifting synchronzier ring 

(a). Remove the first-shifting synchronizer ring. 

Hint: 

Label for the first-shifting synchronizer ring after removal. 



overhaul”) 

31B

31B-42 


16. remove the first-shifting and secondary-shifting 

synchronizers from the secondary axle 

17. disassemble the first-shifting and 

secondary-shifting synchronizer springs, slides 

and synchronizer gear ring and gear seat. 

(a). Inspect the synchronizer gear ring and gear seat. 



18. remove the secondary-shifting synchronizer ring 

(a). Remove the secondary-shifting synchronizer ring. 

Hint: 

Label for the second-shifting synchronizer ring after 

removal. 

31B 



overhaul”) 

(c). Remove the second-shifting gear and the needle 

bearing. 

19. detect the secondary axle 

(a). Measure the secondary-axle circular run-out. 

Circular run-out 

Model 


6G120 0.03mm 0.10mm 

If the circular run-out is beyond the limit value, replace 

with a new secondary axle.


31B-43 

(b). Measure the diameter of the secondary-axle 

main-bearing 

Position of bearing journal 




Second-shifting gear 

Reverse gear 

Diameter 

Standard 

31 mm 

60 mm 

57 mm 

75 mm 

68 mm 

If the diameter of the secondary-axle main-bearing journal 

is less than the minimum valve, replace with a new 


20. Detect the internal diameters of all the 

secondary-shifting gears 

(a). Measure the internal diameters of all the 

secondary-shifting gears. 

Gear position 




Second-shifting gear 

Reverse gear 


Limit 

50 mm 

68 mm 

83 mm 

83 mm 

76 mm 

If the value of the internal diameter is beyond the limit 

value, replace the gears. 

21. Detect the synchronizer ring 

(a). Inspect whether there is wear and damage. 

(b). Press the copper ring of synchronizer towards the 

gear and turn towards the same direction, inspect its 

locking effect. If the locking is not enough, apply a 

layer of high-quality grinding paster on the contact 

surfaces of the synchronizer ring and the gear and 

polish slightly. 

31B 

Notice: 

Make sure to clean the grinding paster after polishing. 

(c). Inspect the locking effect of the synchronizer ring 

again. 

(d). If the locking effect is still not ideal, detect the 

clearance between the gear and the synchronizer 

ring.

31B-44 


(e). Measure the clearance between the gear and the 

synchronizer ring. 

Position of synchronizer 

First-shifting and 

secondary-shifting 

Third-shifting and 

fourth-shifting 

Fifth-shifting and 

sixth-shifting 

Clearance 

Standard 

1.3~1.7 mm 

1.3~1.7 mm 

1.3~1.7 mm 

If the actual value is beyond the limit value, replace with a 

new synchronizer ring. 

22. Inspect the gear ring and gear seat of the 

synchronizer 

(a). Inspect the sliding conditions of the gear ring and 

gear seat . 

23. Install the secondary-axle and secondary-shifting 

gear 

(a). Install the secondary-shifting gear needling bearing. 

(b). Install the secondary-shifting gear. 

31B 

Notice: 

• The needle bearing installed in the gear shall not 


a new needle bearing shall be replaced with. 




(c). Install the secondary-shifting gear synchronizer ring. 

Hint: 



24. Assemble the first-shifting and secondary-shifting 

synchronizers 

(a). Install the gear seat into the gear ring. 

(b). Install the first-shifting and secondary-shifting 


(c). Install the synchronizer spring.


31B-45 

25. install the first-shifting and secondary-shifting 

synchronizer 

(a). Install the first-shifting and second-shifting 

synchronizers on the secondary axle. 

26. install the first-shifting synchronizer ring 

HINT: 



27. install the secondary-axle and first-shifting gear 

(a). Install the first-shifting gear needle bearing. 

(b). Install the first-shifting gear. 

Notice: 

• The needle bearing installed in the gear shall not 






31B

31B-46 


28. install the reverse gear 

(a). install the reverse gear attachment, needle bearing 

and reverse gear bearing seat retainer. 

notice: 

• the needle bearing installed in the gear shall not 



• shake the needle bearing before installation to see 



29. install the third-shifting gear 

(a). install the third-shifting gear needle bearing. 

(b). install the secondary-axle and third-shifting gear. 

notice: 

• the needle bearing installed in the gear shall not 






30. install the third-shifting synchronizer ring 

31B 

hint: 

install according to the marks made during the 

disassembly, mixed installation is not permitted.


31B-47 

31. Assemble the third-shifting and fourth-shifting 

synchronizers 

(a). Install the gear seat to the gear ring. 

(b). Install the third-shifting and fourth-shifting 


(c). Install the synchronizer spring. 


synchronizers 

(a). Install the third-shifting and fourth-shifting 


33. Install the fourth-shifting synchronizer ring 

Hint: 



31B

31B-48 


(b). Install the fourth-shifting gear needle bearing. 

Notice: 

• The bearing installed in the gear shall not be 

higher than the end face of the gear; otherwise, a 





34. Install the fourth-shifting gear 

(c). Install the fourth-shifting gear and the fourth-shifting 

gear thrust ring. 

Hint: 

The steel ball shall be towards the groove of the thrust 

washer during the installation of thrust washer. 

(d). Install the fourth-shifting gear retainer ring. 

31B


31B-49 

35. Install the sixth-shifting gear 

(a). Install the sixth-shifting gear needle bearing. 

Notice 

• The bearing installed in the gear shall not be 

higher than the end face of the gear; otherwise, a 





(b). Install the secondary-axle and sixth-shifting gear. 

36. Install the sixth-shifting synchronizer ring 

Hint: 



31B 

37. Assemble the fifth-shifting and the sixth-shifting 

synchronizers 

(a). Install the gear seat into the gear ring. 

Notice: 

The direct-gear tooth ring and tooth seat have 

self-releasing prevention structures, they may lose the 

function if being installed in the reversed direction. 

(b). Install the fifth-shifting and sixth-shifting 


(c). Install the synchronizer spring.

31B-50 


38. iinstall the fifth-shifting and sixth-shifting 

synchronizers 

(a). install the fifth-shifting and sixth-shifting 


39. install the fifth-shifting synchronizer ring 

hint: 

install according to the marks made during the 


40. install the secondary-axle front needle bearing 

31B 

notice: 



damaged, replace it in time.

Transmission 6g120-intermediate axle assembly 

31B-51 

Intermediate axle assembly 

Notes 

1. In general, the intermediate axle gear shall not be disassembled, only if it is seriously worn or perforated. 

31B

31B-52 


Parts diagram 

1 Retainer 5 Fourth-shifting 

2 Front 6 Third-shifting 

3 Constant 7 Intermediate 

4 Sixth-shifting 8 Rear 

31B

Replacement 


31B-53 

1. remove the constant mesh retainer ring of 


(a). Remove the retainer ring. 

(b). Press out the constant mesh gear of the intermediate 

axle with a press. 

(c). Take down the short flat key. 

2. remove the sixth-shifting and fourth-shifting gears 

of the intermediate axle 

(a). Press out the sixth-shifting and fourth-shifting gears 

with a press. 

(b). Take down the long flat key and the sleeve gasket. 

31B

31B-54 


3. disassemble the third-shifting gear of the 


(a). Press out the third-shifting gear with a press. 

(b). Take down the half-round key. 

4. install the third-shifting gear of the intermediate 

axle 

(a). Install the half-round key into the groove. 

(b). Press in the third-shifting gear with a press and put it 

into place. 

Notice: 

The long side of the convex plate shall be upwards during 

the installation, the key groove shall be aligned with the 


31B 

5. install the fourth-shifting gear of the intermediate 

axle 

(a). Install the sleeve gasket and the long flat key.


31B-55 

(B). Press in the fourth-shifting gear with a press and put 

them into place. 

Notice: 

The long side of the convex plate shall be upwards 


6. install the constant mesh gear of the intermediate 

axle 

(a). Install the short flat key into the groove. 

(b). Press in the constant mesh gear with a press and put 

it into place. 

(c). Install the retainer ring. 

Notice: 

The long side of the convex plate shall be upwards 

during the installation, the opening of the retainer ring 

shall be staggered to the key groove. 

31B

31B-56 

Transmission 6g120-first axle and reverse gear shaft 

First axle and reverse gear shaft 

Parts diagram 

1 First 5 Reverse 

2 Fifth-axle 6 Reverse 

3 First-axle 7 Reverse 

4 First-axle 8 O 

31B

Replacement 

Transmission 6g120-first axle and reverse gear shaft 

31B-57 

(refer to “chapter 31 a transmission 6g120-transmission assembly, overhaul”) 

31B

Clutch 

Clutch system ...................................... 32-1 

Notes ................................................. 32-1 

Malfunction symptom table. ............... 32-2 

Clutch fluid ........................................... 32-4 

Air exhaust ......................................... 32-4 

Clutch pedal ......................................... 32-5 

Adjustment ......................................... 32-5 

Parts diagram .................................... 32-7 

Replacement ...................................... 32-8 

Clutch master cylinder ...................... 32-15 

Parts diagram .................................. 32-15 

Replacement .................................... 32-16 

Clutch slave cylinder booster ........... 32-20 

Parts diagram .................................. 32-20 

Replacement .................................... 32-22 

Clutch components ........................... 32-27 

Parts diagram .................................. 32-27 

Overhaul .......................................... 32-29 

32

32

Clutch system 

Notes 

Clutch-clutch system 

1. Notes for the operation of clutch system 

(a). 

(b). 

(c). 

32-1 

The descriptions in this manual must be observed during the maintenance operation of the 

clutch system. 

The incorrect operation will affect the performance of the clutch system and vehicle. 

Special plugs shall be used to seal all the openings while disconnecting the pipeline of clutch 

system, don’t make the clutch fluid adhere to the paint surface of the vehicle. 

2. Clutch system maintenance notes 

(a). 

(b). 

(c). 

The clutch fluid appointed must be used, don’t mix different models of clutch fluid together, 

regular inspection and replacement must be carried out for the clutch fluid. 

Clutch fluid: V-3 brake fluid 

The clutch fluid must be inspected every 10,000 Km, new clutch fluid must be replaced with 

after driving the first 40,000 Km, and after that, it must be replaced once every 40,000 Km. 

After driving over 80,000 Km, the clutch fluid must be replaced every 20,000 Km. (Refer to 

“chapter 32 clutch-clutch fluid, air exhaust”) 

Regular inspection must be carried out once every 5,000 Km. 

• Check the clutch pedal journey and the free play. 

• Check whether the hydraulic system of the clutch leaks. 

• Check whether the air pressure system of the clutch leaks. 

• Check the push rod journey of clutch slave cylinder booster and its sealing conditions. 

• Check the looseness of each connection. 

• Check whether the functions of clutch system are normal. 

32

32-2 



Use the table below to help you find the cause of the Malfunction. The numbers indicate the 

probability of the cause of the Malfunction Check each part in order. If necessary, replace these 

parts. 

symptom Suspect Area Reference 

32 

The clutch is slippery 

Clutch doesn’t fully separate 

1. Clutch pedal free play 

(Minimal) 

2. Driven plate (Over worn) 

3. Flywheel (Warped) 

4. Platen (Distorted) 

5. Platen diaphragm spring 


1. Clutch pedal free play (Too 

big) 

2. Platen diaphragm spring 


3. Clutch master cylinder 

(Leaked) 

4. Clutch slave cylinder booster 

(Leaked) 

5. Hydraulic system (Air in it) 

6. Driven plate (Abnormal wear) 

7. Platen (Abnormal wear) 

8. Release bearing (Over worn) 

9. Clutch release fork (Abnormal 

wear) 

Chapter 32 clutch-clutch pedal, 

adjustment 

Chapter 32 clutch-clutch 

components, overhaul 

The service manual with isf of 

cummins engine 






adustment 



Chapter 32 clutch-clutch master 

cylinder, replacement 

Chapter 32 clutch-clutch slave 

cylinder booster, replacement 

Chapter 32 clutch-clutch fluid, air 

exhaust 








components, overhaul


32-3 

Phenomenon Suspect Area Reference 

Noise from clutch 

Clutch shakes 

1. Damper spring (Broken) 

2. Driven plate (Over worn) 

3. Release bearing (Loose) 

4. Clutch pedal (Distorted) 

1. Driven plate (Distorted or 

abnormal wear) 

2. Flywheel (Abnormal wear) 

3. Platen (Abnormal wear) 

4. Damper spring (Broken or 

distorted for fatigue) 

5. Platen Diaphragm Spring 

(Distorted) 

6. Engine support (Loose or 

rubber pad damaged) 








replacement 













32

32-4 

Clutch fluid 

Air exhaust 

Clutch-clutch fluid 

1. fill clutch fluid 

(a). Fill up the oil reservoir with clutch fluid. 

2. Air exhaust of clutch system 

(a). 

(b). 

Install a rubber tube with appropriate length on 

the release valve of the clutch slave cylinder 

booster. 

Put proper container under the rubber tube to 

hold clutch fluid. 

32 

(c). 

(d). 

(e). 

Stamp on the clutch pedal rapidly for some times 

and then stamp the clutch pedal to the lowest 

position and keep still. 

Loosen the drain plug on the release valve to 

discharge the blistery or muddy clutch fluid. 

When the clutch fluid is about to stop 

discharging, screw down the drain plug. 

Repeat the methods above for some times until no 

bubbles in the clutch fluid and the color of the clutch 

fluid is normal, and then screw down the drain plug. 

Standard value: 6 N•m 

Limit value: 4 ~ 8 N•m 

3. Inspect the clutch fluid 

(a). 

Inspect the clutch fluid level in the oil reservoir to 

make the level between the “MAX” and the 

“MIN”, add some if it is not enough.

Clutch pedal 

Adjustment 

Adjust point of pedal free play 

Clutch-clutch pedal 

1. inspect and adjust the clutch pedal 

(a). 

(b). 

Move away the carpet in the driving cab. 

32-5 

Inspect whether the height of clutch pedal is 

correct. 

The height of clutch pedal: 

Adjust point of 

pedal heigh 

Vehicle 

Standard 

Pedal height 

Limit 

1051/1061/1089/1099 

series 

166 mm 171 mm 

Front boarding 

Pedal height 

(c). 

Adjust the height of clutch pedal. 

• Loosen the lock nut, adjust the clutch pedal to 

the correct height and then tighten the lock nut. 

(d). 


Inspect the free play of clutch pedal and the 

push rod journey of clutch master cylinder. 

• Press down the clutch pedal until feeling the 

platen have resistance. 

Free play of clutch pedal: 

Vehicle 

1051/1061/1089/1099 

series 

Pedal height 


15 mm 25 mm 

• Press down the clutch pedal slightly until feeling 

the platen have slight resistance. 

Push rod journey of clutch master cylinder: 

32 

Vehicle 

Pedal height 

Standard 

Limit 

1051/1061/1089/1099series 28 mm 28 ± 2 mm

32-6 


Pedal free play 

(e). 

Adjust the free play of clutch pedal. 

• Loosen the limit bolt and the lock nut of 

clutch push rod; adjust the free play to the 

correct value. 

• Tighten the limit bolt and the lock nut of 

clutch push rod. 

• Inspect the height of clutch pedal after 

adjusting the free play of clutch pedal. 

32

Parts diagram 


32-7 

1 Clutch pedal rubber shield 7 Hexagon nut 

2 Clutch pedal assy 8 Spring washer 

3 Adjusting screw limit rubber pad 9 Clutch master cylinder support assy 

4 Clutch pedal pin bush 10 Clutch pedal pin 

32 

5 Clutch pedal pin bush retainer 11 Hexagon bolt 

6 Flat washer

32-8 

Replacement 

1. Discharge clutch fluid 



3. remove the clutch switch 

(a). 

Disconnect the connector from clutch switch as 

show in the illustration. 

(b). 

Loosen the lock nut of clutch switch and take 

down the clutch switch assembly. 

32 

4. Disconnect the inlet pipe of clutch master 

cylinder 

(a). 

Loosen the oil inlet pipe hoop of clutch master 

cylinder and disconnect the oil inlet pipe of 

clutch master cylinder. 

Notice: 

Use a dedicated container to recycle the clutch 

fluid remained; don’t make it stick to any painted 



skin.


32-9 

5. Disconnect the oil outlet pipe of clutch 


(a). 


cylinder oil outlet pipe; disconnect the oil outlet 

pipe of clutch master cylinder. 

6. Remove the clutch pedal bracket assembly 

(a). 

(b). 

Loosen the 5 fixing bolts of the clutch pedal 

bracket. 

Take out the clutch master cylinder and the 

clutch pedal bracket assembly. 

7. Remove the clutch pedal 

(a). 

Remove the cotter pin as shown in the 

illustration. 

32

32-10 


(b). 

Take down the push rod clevis cotter pin of 

clutch master cylinder. 

(c). 

Loosen the pin bolt of the clutch pedal as shown 


32 

(d). 

(e). 

Take out the clutch pedal pin bolt and the 

retracing spring. 

Take out the clutch pedal assembly.


32-11 

(f). 

Take out the clutch pedal pin bushing as shown 


8. Install the clutch pedal 

(a). 

Install the clutch pedal pin bushing as shown in 

the illustration. 

Hint: 

Apply appropriate amount of grease while installing the 

clutch pedal pin bushing. 

(b). 

Install clutch pedal retracing spring and pin bolt. 

32

32-12 


(c). 

Screw down the clutch pedal pin bolt. 

Torque: 20 ± 3.5 n•m 

(d). 

Install the push rod clevis pin of clutch master 

cylinder. 

32 

(e). 

Install the cotter pin and lock it up as shown in 

the illustration.


32-13 

9. Install the clutch pedal bracket assembly 

(a). 

Install the clutch pedal bracket assembly and 

screw down the 5 fixing bolts. 

Torque: 20 ± 3.5 n•m 

10. Connect the oil outlet pipe of clutch master 

cylinder 

(a). 

Connect the oil outlet pipe of clutch master 

cylinder and screw down the terminal nut of the 

oil outlet pipe. 

Torque: 22 ~ 24 n•m 

11. Connect the oil inlet pipe of clutch master 

cylinder 

(a). 

Connect the oil inlet pipe of clutch master 

cylinder and screw down the oil inlet pipe hoop 


32

32-14 


12. Install the clutch switch assembly 

(a). 

Install the clutch switch assembly and screw 

down the lock nut after adjusting the clutch pedal 

to the correct height. 

Torque: 20 ± 5 n•m 

(b). 

Connect the connector to the clutch switch. 

32 

13. Connect the battery negative pole cable 

14. Fill clutch fluid and remove the air in the clutch system (refer to “chapter 32 


15. Inspect and adjust the height of clutch pedal (refer to “chapter 32 clutch-clutch pedal, 

adjustment”)

clutch-cluch master cylinder 


32-15 

Components 

1 I type hexagon nut 7 Clutch mater cylinder assy 

2 Spring washer 8 Clutch master cylinder oil inlet pipe assy 

32 

3 Flat washer 9 Three-wire tubing clamp 

4 Oil storage assy 10 

5 A type worm drive band type hose hoop 11 Locking piece II 


Clutch master cylinder oil outlet pipe 

assy

32-16 

Replacement 



2. Disconnect clutch master cylinder oil inlet 

pipe 

(a). 

Loosen the clutch master cylinder oil inlet pipe 

hoop and disconnect the clutch master cylinder 

oil inlet pipe. 

Notice: 

Use a dedicated container to recycle the clutch fluid 

remained, don’t make it stick to any painted 



skin. 

3. Disconnect clutch master cylinder oil outlet 

pipe 

(a). 


cylinder oil outlet pipe, disconnect the clutch 

master cylinder oil outlet pipe. 

32 

4. Remove the clutch master cylinder push rod 

(a). 

Remove the push rod clevis cotter pin of clutch 

master cylinder and take down the push rod pin 

of the clutch master cylinder.


32-17 

5. Remove the clutch master cylinder 

(a). 

(b). 

Loosen the 2 fixing bolts of the clutch master 

cylinder as shown in the illustration. 

Take down the clutch master cylinder assembly. 

6. Disassemble the clutch master cylinder 

(a). 

Loosen the push rod lock nut of the clutch 

master cylinder and take down the clutch master 

cylinder clevis. 

(b). 

(c). 

(d). 

Fasten the clutch master cylinder on the bench 

screw as shown in the illustration. 

Push the piston with a push rod according to the 

direction shown in the illustration and take out 

the clamp spring with the spring pliers. 

Move out the push rod and take out the piston 

from the master cylinder of the clutch. 

Notice: 

• The piston may suddenly pop up, so the push 

rod shall be pulled out slowly with welldistributed 

strength during the operation. 

• The piston and its seal ring are precise 

mating parts, don’t contact the external 

surface of the piston or the internal surface 

of the master cylinder. 

32 

7. assemble the clutch master cylinder 

(a). 

(b). 

Apply a little lubricant on the positions shown in 

the illustration in order to install conveniently. 

Install the piston and the whole spring into the 

master cylinder. 

Notice: 

Don’t damage the external surface of the piston and 

the internal surface of the master cylinder.

32-18 


(c). 

Push the piston with a push rod according to the 

direction shown in the illustration and then install 

the clamp spring into the circlip groove with 

spring pliers 

(d). 

Install the push rod clevis of clutch master 

cylinder and screw down the lock nut after 

adjusting the push rod to the correct height. 

Torque: standard value 17.5 n•m 

Limit value 17.5 ± 2.5 n•m 

8. install the clutch master cylinder 

(a). 

Install the clutch master cylinder and screw 

down the 2 fixing bolts. 

Torque: 20 ± 3.5 n•m 

32 

9. install the push rod of clutch master cylinder 

(a). 

Install the push rod clevis pin axle of clutch 

master cylinder and screw down the cotter pin.


32-19 

10. connect the oil outlet pipe of clutch master 

cylinder 

(a). 

Connect the oil outlet pipe of the clutch master 


oil outlet pipe. 


11. connect the oil inlet pipe of the clutch master 

cylinder 

(a). 

Connect the oil inlet pipe of the clutch master 

cylinder and screw down the oil inlet pipe hoop. 


12. Fill with clutch fluid and remove the air in the system (refer to “chapter 32 


13. Inspect and adjust the height of clutch pedal and the height of the cluch master 

cylidner push rod (refer to “chapter 32 clutch-clutch pedal, adjustment”) 

32

32-20 

clutch-clutch slave cylinder booster 


Parts diagram 

32

clutch-clutch slave cylinder booster 

32-21 

1. Connecting hose assy 15 Clutch hose assy 

2 Hexagon thin nut –fine thread 16 Clutch booster assy 

3 External teeth serrated lock wsher 17 Straight thread elbow body 

4 A pipe clamp combination (II) 18 Hexagon thin nut- fine thread 

5 Clutch cylinder oil pipe assy 19 O type seal ring 

6 Hexagon bolt 20 Seal washer 

7 Flat washer 21 Pin 

8 Spring washer 22 Cotter pin 

9 I hexagon nut 23 Flat washer 

10 Hexagon bolt 24 Hexagon nut- fine thread 

11 Clutch hose support 25 Spring washer 

12 Flat washer 26 Clutch booster support 

13 Spring washer 27 I hexagon nut 

14 I hexagon nut 

32

32-22 

Replacement 


clutch-clutch slave cylinder booste 

2. Disconnect the oil inlet pipe from the clutch 

slave cylinder booster 

(a). 

Loosen the oil inlet pipe terminal bolt of the 

clutch slave cylinder booster and disconnect the 


Notice: 

Use a dedicated container to recycle the clutch fluid 

remained and seal up the pipe with a plug so as to 

avoid the entering of foreign matters. 

3. Disconnect the air inlet pipe from the clutch 

slave cylinder booster 

(a). 

loosen the air inlet pipe terminal bolt of the clutch 

slave cylinder booster and Disconnect the air 

inlet pipe. 

4. Remove the clutch cylinder booster 

(a). 

Remove the cotter pin and take out the pin axle 

as shown in the illustration. 

32 

(b). 

Remove the 2 fixing nuts and 1 fixing bolt as 

shown in the illustration.

Clutch-clutch slave cylinder booster 

32-23 

(c). 

Remove the 2 fixing bolts and 1 fixing nut of the 

clutch slave cylinder booster. 

5. Disassemble the clutch slave cylinder 

booster 

(a). 

Remove the retracing spring and take out the 

push rod and the dust cover of the clutch slave 

cylinder booster. 

(b). 

Remove the 5 fixing bolts of the hydraulic piston 

chamber of the clutch slave cylinder and take out 

the hydraulic piston. 

(c). 

Remove the terminal nut of the control air pipe of 

the dynamic cylinder. 

32 

(d). 

Remove the 4 fixing bolts of the dynamic cylinder 

and take out the piston of the dynamic cylinder.

32-24 


6. Inspect the clutch slave cylinder booster 

(a). 

Inspect whether there are distinct cracks or 

damages on the surface of the hydraulic piston and 

the seal ring, replace with a new one if necessary. 

(b). 

Inspect whether there are distinct cracks or aging 

phenomenon on the seal ring of dynamic cylinder 

piston, replace with a new one if necessary. 

7. Assemble the clutch slave cylinder booster 

(a). 

Apply appropriate amount of grease on the seal ring 

of the piston as shown in the illustration. 

(b). 

Install the dynamic cylinder piston and screw down 

the 4 fixing bolts of the cylinder piston. 

Torque: 20 ± 3.5 N•m 

32 

(c). 

Screw down the terminal nut of the control air pipe of 

the dynamic cylinder. 



32-25 

(d). 

Install the hydraulic piston of the clutch slave 

cylinder and screw down the 5 fixing bolts of the 

hydraulic piston chamber of the clutch slave 

cylinder. 

Torque: 17.5 ± 2.5 N•m 

8. Install the clutch slave cylinder booster 

(a). 

Install the clutch slave cylinder booster assembly 

and screw down the 2 fixing bolts and 1 fixing 

nut. 

Torque: 20 ± 3.5 N•m 

(b). 

Screw down the 2 fixing nuts and 1 fixing bolt as 

shown in the illustration. 

Torque: 40 ± 3.5 N•m 

(c). 

Install the pin axle and lock up the cotter pin as 


32 

(d). 

Install the push rod and the dust cover of the 

clutch slave cylinder and install the retracing 

spring.

32-26 


9. connect the oil inlet pipe of clutch slave 


(a). 

Connect the oil inlet pipe of the clutch slave 

cylinder and screw down the terminal bolt of the 


Torque: standard value: 32 n•m 

Limit valued: 30 ~ 34 n•m 

10. connect the air inlet pipe of clutch slave 


(a). 

Connect the air inlet pipe of the clutch slave 


air inlet pipe. 


11. fill with clutch fluid and remove the air in the system (refer to “chapter 32 


12. adjust the clutch slave cylinder booster 

(a). 

(b). 

Inspect and adjust the length of the clutch slave cylinder booster push rod and ensure certain 

clearance of the axle pin of the release fork. 

Inspect and adjust the working stroke of the clutch slave cylinder booster push rod. 

Working stroke of the clutch slave cylinder booster: 

Vehicle 

Standard 

Working stroke 

Limit 

1051 /1061series 13.1 mm 15.3 mm 

32 

1089 series 15.3 mm 17.3 mm 

1099 series 18 mm 24+ 3mm 

13. Tightness test of clutch system 

(a). 

Open the air exhaust of the clutch slave cylinder booster when the air pressure is over 0.4 mpa 

and inspect whether the compressed air leaks. Inspect carefully and clear the faults if there is air 

leakage. 

14. Oil tightness test of clutch system 

(b). 

Inspect whether oil leaks from each pipe fitting while pressing on the clutch pedal, fasten the 

pedal at some position and inspect whether the push rod of the clutch rooster has much 

movement. 

15. Operability test of clutch system 

(a). 

Press down the clutch pedal repeatedly and inspect whether the movement of the push rod 

of the clutch slave cylinder rooster is normal by listening to the noise of the compressed air in 

the exhaust air.

Clutch components 

Parts diagram 

Clutch-clutch components 

32-27 

32

32-28 


1 Hexagon Head Bolt 15 Release Fork 

2 Spring Washer 16 Clutch Release Fork Axle 

3 Clutch Ventilation flap 17 Half-round Key 

4 Clutch Housing 18 Clutch Release Bearing Seat Assembly 

5 Washer 19 Release Bearing 

6 Spring Washer 20 Release Bearing Lubrication Hose Assembly 

7 Hexagon Head Bolt 21 Bend Neck Grease Nipple 

8 Framework Oil Seal 22 Release Fork Arm 

9 First Axle Cover 23 Spring Washer 

10 Spring Washer 24 Hexagon Head Bolt 

11 Hexagon Head Bolt 25 Clutch Platen Assembly 

12 Wire Thread Jamming 26 Clutch Driven Plate Assembly 

13 Half-round Key 27 Flywheel 

14 Needle Bearing 

32

Overhaul 



32-29 

2. Remove the transmission assembly (refer to “chapter 31 transmission-transmission 


3. Remove the release bearing assembly 

(a). 

Remove the release bearing lubrication hose. 

(b). 

Remove the 2 wire thread jamming. 

(c). 

Take out the release bearing assembly. 

32 

4. Remove the release fork axle assembly 

(a). 

Remove the push rod clevis cotter pin of the 

clutch slave cylinder booster and take down the 

coupling pin axle.

32-30 


(b). 

(c). 

Remove the fixing bolt of the release fork arm. 

Take down the release fork arm and take out the 


(d). 

(e). 

Remove the fixing bolt of the clutch release fork 

and take down the clutch release fork. 

Take out the half-round key. 

Assembl 

y 

5. Remove the clutch components 

(a). 

Make matchmarks on the platen and flywheel in 

order to keep the original dynamic balance after 

the reassembly. 

(b). 

Loosen the fixing bolts of the platen respectively 

and uniformly until the membrane spring 

pressure of the platen is completely eliminated. 

32 

(c). 

Take down the 8 fixing bolts of the platen and 

take down the platen slightly. 

Caution: 

Don’t make the platen drop on the floor to prevent 

personal injuries and platen damage.


6. Take out the clutch driven plate assembly 

32-31 

Notice: 

Keep the inside of the driven plate, platen and the flywheel surface away from the oil stain 

and impact. 

7. Overhaul of clutch driven plate 

(a). 

Inspect the contact surface of the driven plate, replace it with a new one if it has distinct 

cracks, oil stains or the damper spring is distorted. 

(b). 

Measure the depth from the surface of the driven 

plate to the rivet head with slide calipers as 

shown in the illustration, if the depth is beyond 

the limit value, replace it with a new one. 

Limit value of depth: 

Vehicle 

Limit 




1099 series 1.8-2.4 mm 

(c). 

Inspect the radial run-out of the working surface 

of the driven plate. As shown in the illustration, if 

the run-out is beyond the limit value, replace the 

driven plate with a new one. 

Radial run-out: 

Vehicle 

Radial run-out 

Limit 

1051/1061 series 0.8 mm 

1089/1099 series 1.0 mm 

32

32-32 


(d). 

Inspect the spline of driven plate for wear as 

shown in the illustration. Install the driven plate 

on the spline axle and measure the fit clearance 

between the driven plate to the spline axle with a 

clearance gauge, replace with a new one if it is 

beyond the limit value of operation. 

Fit clearance between the driven plate and 

the spline: 

Vehicle 

Standard 

Fit clearance 

Limit 

1051/1061series 0.075 mm 0.025~0.125 mm 

1089/1099series 0.078 mm 0.033~0.123 mm 

8. Overhaul of clutch platen 

(a). Inspect whether the platen is burned 

excessively, or whether it is not smooth or has 

distinct scars. Carry out polishing repair on the 

slight burning or unsmooth surface of the platen. 

If it has serious scratches or cracks, replace it 

with a new one. 

(b). 

Inspect the wear thickness of the platen as 

shown in the illustration. If it is beyond the limit 

value, replace it with a new one. 

Wear thickness of the clutch platen: 

Vehicle 

1051/1061/1089/1099 

series 

Wear thickness of the 

platenLimit 

1.0 mm 

32 

(c). 

As it is shown in the illustration, inspect whether 

the spring tops of the platen membrane are at 

the same height.


32-33 

9. Overhaul of release bearing 

(a). 

Fasten the inner edge of the bearing, rotate its 

outer edge, see whether the rotation is not 

smooth and hear whether there are any noises. 

Press on the axial direction, if the bearing has 

distinct clearance or damage, replace it with a 

new one. 

10. Overhaul of clutch release fork 

(a). 

The parts of clutch release fork that are easily 

worn during the operation are shown in the 

illustration, examine and repair the release fork 

of the clutch before the assembly; if serious wear 

or distortion is found, replace or repair it. 

11. Install the clutch components 

(a). 

Install the driven plate of the clutch with special 

tools or insert the first axle into the driven plate 


NOTICE: 

• Make sure that the working surfaces of 

flywheel, clutch driven plate and the clutch 

platen are clean without oil stains; clean all 

the bolt holes with compressed air to ensure 

that there are no foreign matters. 

• Notice the correct position and direction of 

the clutch driven plate; don’t install the 

driven plate in the reverse direction. 

(b). 

Install the clutch platen. 

• Align the clutch platen with the correct 

installation matchmarks that are made during the 

removal, evenly screw down the fixing bolts of 

the platen in batches according to the orders 


Torque: 

32 

Vehicle 

Torque of platen 

Standard 

Limit 

1051/1061 series 56.5 N·m 50~63 N·m 

1089/1099 series 70 N·m 65~75 N·m

32-34 


(c). 

Inspect and adjust the clutch components. 

• Inspect the spring top height of the platen 

membrane with a clearance gauge and special 

tools. Adjust it if it is beyond the limit value. 

Spring top height of the clutch platen 

membrane (compressed state): 

Vehicle 

Spring top height of the membrane 

(compressed state) 

Standard 

Limit 

1051 series 56 mm 56 ± 1.5 mm 

1061/1099 

series 

61.5 mm 61.5 ± 1.5 mm 

1089 series 70 mm 70 ± 1.5 mm 

• If the spring top height of the clutch platen 

membrane is beyond the limit value of the 

operation, adjust the height with special tools to 

make it in the standard scope as shown in the 

illustration. 

Lithium lubricating grease 

12. Assemble the clutch release fork 

(a). 

Apply lubricating grease on the clutch release 

fork as shown in the illustration. 

32 

(b). 

Install the clutch release fork on the axle of the 

clutch release fork and screw down the fixing 

bolt. 

Torque: 40 ± 5 N•m


32-35 

(c). 

Install the release fork of the clutch on the 

transmission and install the release fork arm on 

the release fork axle, screw down the fixing 

bolts. 

Torque: 20 3.5 N•m 

13. install transmission assembly (refer to “chapter 31 transmission-transmission 


14. connect the battery negative pole cable 

15. inspect and adjust the clutch slave cylinder booster (refer to “chapter 32 clutch-clutch 

slave cylinder booster, replacement”) 

16. tightness test of clutch system (refer to “chapter 32 clutch-clutch slave cylinder 


17. oil tightness test of clutch system (refer to “chapter 32 clutch-clutch slave cylinder 


18. operability test of clutch system (refer to “chapter 32 clutch-clutch slave cylinder 


32

32 

- MEMO -

Transmission Axle 

Transmission axle assembly ............................. 33-1 

Malfunction symptom table ............................ 33-1 

Parts diagram ................................................ 33-2 

On-vehicle inspection .................................... 33-3 

Inspection ...................................................... 33-5 

Replacement ................................................. 33-6 

Universal joint .................................................. 33-10 

Parts diagram .............................................. 33-10 

Overhaul ..................................................... 33-11 

Intermediate bearing ........................................ 33-15 

Parts diagram .............................................. 33-15 

Overhaul ..................................................... 33-16 

Sliding foke ...................................................... 33-19 

Parts diagram .............................................. 33-19 

Overhaul ..................................................... 33-20 

33

33

Transmission axle-transmission axle assembly 

33-1 

Transmission axle assembly 



probability of the cause of the Malfunction. Check each part in order. If necessary, replace these 

parts. 


Noise from 

transmission 

axle 

Transmission 

axle vibrates 

The intermediate 

axle heats up 

1. Transmission axle (Loose) 

2. Lubrication (Insufficient) 

3. Universal joint (Worn or damaged) 

4. Intermediate bearing (Worn or damaged) 

5. Sliding spline (Worn) 

1. Transmission axle (Loose) 

2. Transmission axle (The marks are not 

aligned) 

3. Transmission axle (Distorted or bent) 

4. Transmission axle (Unbalanced) 

5. Rubber gasket ring of intermediate 

bearing (Aged or damaged) 

6. Intermediate bearing (Worn or damaged) 

1. Parking brake (Used frequently during 

the driving) 

2. Intermediate bearing bracket (Not 

straight) 

3. Lubrication (Insufficient) 

Chapter 33 transmission axle-transmission 

axle assembly, replacement 

- 

Chapter 33 transmission axle- universal 

joint, overhaul 

Chapter 33 transmission axle- intermediate 

bearing, overhaul 

Chapter 33 transmission axle- transmission 

axle assembly, inspection 

Chapter 33 transmission axle- sliding yoke, 

replacement 






axle assembly, inspection 


axle assembly, on-vehicle inspection 





- 

CHAPTER 33 TRANSMISSION AXLE- 

INTERMEDIATE BEARING, OVERHAUL 

- 

33

33-2 


Parts diagram 

1 Intermediate Transmission Axle Assembly 

2 Flat Washer 


4 Nut 

5 Rear Transmission Axle Assembly 

6 Bolt 

7 Self-locking Nut 

8 Hexagon Bolt 

33


33-3 


1. Inspect the vibration of transmission system 

(a). Inspect the dynamic balance of the front wheels and adjust if necessary (Refer to “chapter 23 

wheels and tires-wheels and tire assembly, adjustment”) 

(b). Inspect the dynamic balance of the rear wheels and adjust if necessary (Refer to “chapter 23 

wheels and tires-wheels and tire assembly, adjustment”) 

(c). 

Carry out driving test, inspect whether the transmission system vibrates during the driving. 

2. Inspect the dynamic balance of transmission axle 

(a). 

(b). 

(c). 

Rotate the rear wheels and make the transmission axle rotate, measure the radial run-out of 

the front, middle and rear parts of the transmission axle. 


Limit value: 

0.5 mm 

0.6 mm 

• If the radial run-outs of the front and middle parts are beyond the limit value, replace with 

a new transmission axle. 

• If the radial run-outs of the front and middle parts are within the limit range, but the radial 

run-out of the rear part is beyond the limit value, mark the high point of the rear end and 

go on the next step. 

• If the radial run-outs of all the parts are within the limit range, go on the next step. 

Rotate the transmission axle and the main reducing gear relatively for 1/2 revolution. (Refer 

to “chapter 05 transmission axle-transmission axle assembly, replacement”) 

• If rotate them for 1/4 revolution, the inspection and adjustment can be carried out more 

accurately. 

Inspect the radial run-out of the rear part of the transmission axle. 

• If the radial run-out of the rear part is beyond the limit value, mark the high point and go 

on the next step. 

• If the radial run-out of the rear part is within the limit range, inspect whether the 

transmission system vibrates during the driving test. If it vibrates, mark the high point 

and go on the next step. 

(d). 

Compare the 2 high points marked in the steps 

above. 

• If the two points are very near and their 

distance is within 20 mm, replace with a new 

transmission axle. 

33 

• If the two high points are at two opposite 

sides of the transmission axle, it means that 

the flange of the main reducing gear is the 

principal cause of the vibration.

33-4 


• The radial run-out of the transmission axle 

shall be within the limit range after 

replacing with a new flange of main 

reducing gear. (Refer to “chapter 25 rear 

axle-rear axle assembly, on-vehicle 

inspection”) 

• Inspect whether the transmission system 

vibrates during the driving test. If it still 

vibrates, balance the transmission axle. 

3. Balance the transmission axle 

(a). 

(b). 

Install one or two hoops at the rear end of the 

transmission axle. 

• Divide the circumferential surface of the 

rear end into nearly four equal parts and 

clamp one of them with the hoop. 

• Inspect whether it vibrates during the 

driving test and change the direction of the 

hoop to ensure the position that can 

produce minimum vibration. Improve the 

vibration of the two adjacent positions and 

make the vibration of them nearly the 

same and then place the hoop in the 

middle of the two positions. 

If vibration still exists, place one more hoop at 

the same position and see if vibration exists in 

the driving test. 

33 

• If the vibration is not improved, rotate the 

hoop to the opposite direction and be 

equidistant with the minimum position of 

the vibration ensured before. Separate the 

two hoops for about 10 cm and inspect 

whether vibration exists by driving test. 

• Increase the space between the two 

hoops and repeat the steps above until 

finding the best position or the acceptable 

level of the vibration reduced.


33-5 

Inspection 

1. Inspect the radial run-out of the 

transmission axle 

• Measure the radial run-out of the 

transmission axle with v-shaped table and 




If the radial run-out is beyond the limit value, calibrate 

it with a press or replace the transmission axle with a 

new one. 

Clearance 

Spline housing 

Spline axle 

2. Inspect the sliding spline clearance of the 


• Measure the fit clearance between the 

spline axle and the spline housing on the 

normal rotation direction with a clearance 

gauge. 



If the clearance of sliding spline is beyond the limit 

value, replace with a new transmission axle. 

33

33-6 

Replacement 


1. Remove the transmission axle of the rear 

axle 

(a). 

Separate the transmission axle of the rear axle 

and the main reducing gear. 

• Inspect the calibration arrows on the 

transmission axle of the rear axle and 

make sure that they are clear and on the 

same axial plane. 

• Make matchmarks on the flange that 

connects the transmission axle of the rear 

axle and the main reducing gear. 

• Loosen the 4 bolts and separate the 

transmission axle and the main reducing 

gear. 

• Put down the rear end of the transmission 

axle of the rear axle. 

(b). 

Separate the transmission axle of the rear axle 

and the intermediate transmission axle. 


connects the transmission axle of the rear 

axle and the intermediate transmission 

axle. 


transmission axle of the rear axle and the 

intermediate transmission axle. 

33 

2. Remove the intermediate transmission axle 

(a). 

Remove the intermediate bearing support. 

• Loosen the 2 bolts and remove the 

intermediate bearing support. 

• Put down the rear end of the intermediate 

transmission axle.


33-7 

(b). 

Air-cut off parking brake: 

Separate the intermediate transmission axle 

and the transmission output axle. 


connects the intermediate transmission 

axle and the transmission output axle. 


intermediate transmission axle and the 

transmission output axle. 

(c). Central drum parking brake: 

Separate the intermediate transmission axle 

and the parking brake drum. 

• Make matchmarks on the connection of 

the intermediate transmission axle and the 

parking brake drum. 

• Loosen the 4 nuts and separate the 


parking brake drum.. 

3. Inspect the transmission axle (refer to “chapter 33 transmission axle-transmission 

axle assembly, inspection”) 

4. Install the intermediate transmission axle 

(a). 

Air-cut off parking brake: 

Connect the intermediate transmission axle 


• New nuts must be replaced with. 

• Screw down the 4 bolts and connect the 


transmission output axle. 

Torque: 1051 series :58~70 N·m 

1061/1089/1099 series :130~160 N·m 

Caution: 

The installation must be carried out in 

accordance with the matchmarks made before. 

33

33-8 


(b). 

Central drum parking brake: 

Connect the intermediate transmission 

axle and the parking brake drum. 


• Screw down the 4 nuts, and connect 

the intermediate transmission axle 



1061/1089/1099 series :130~160 N·m 

Caution: 



(c). 

Install the intermediate bearing support. 

• New bolts must be replaced with. 

• Screw down the 2 bolts and install the 

intermediate axle support. 

Torque: 130 ~ 160 N•m 

5. Install the transmission axle of rear 

axle 

(a). Connect the transmission axle of rear axle 

and the intermediate transmission axle. 


• Screw down the 4 bolts and connect 

the transmission axle of rear axle and 

the intermediate transmission axle. 


Caution: 

1061/1089/1099 series :130~160 N·m 

33 



Hint: 

Notice the direction of the cross shaft grease 

nipple of the universal joint and make it have the 

same direction with the grease nipple of the 

intermediate transmission axle so as to fill 

lubricating grease.


33-9 

(b). Inspect the calibration arrows on the 

transmission axle of the rear axle and make 

sure that they are on the same axial plane. 

(c). 

Connect the transmission axle of the rear axle 

and the main reducing gear. 


• Screw down the 4 bolts and connect the 

transmission axle of rear axle and the 

main reducing gear. 

Torque:1051/1061 series 146~205 N·m 

1089/1099 series 130~160 N·m 

CAUTION: 



33

33-10 

Transmission axle-universal joint 


Parts diagram 

1 Flange Yoke 

2 Needle Bearing 

3 Dust Cover 

5 Retainer Ring 

6 Shaft Fork 

7 Cross bearingt 

4 Grease Nipple 

33

Overhaul 


33-11 

1. remove the transmission axle (refer to “chapter 33 transmission axle-transmission 


2. disassemble the universal joint of sliding 

yoke 

(a). 

Make matchmarks on the flange yoke, cross 

shaft and sliding yoke. 

(b). 

Notice: 

Remove the grease nipple. 

Be careful during the disassembly and don’t 

damage the grease nipple. 

(c). 

Remove the retainer ring with circlip pliers. 

(d). 

Notice: 

Slightly knock on the sliding yoke with a 

hammer and a copper rod, vibrate out the 

needle bearing and the dust cover from the 

outside of the sliding yoke and the flange yoke 

and remove the cross shaft. 

Don’t knock on the transmission axle directly or 

clamp it directly with a bench screw. 

(e). 

Separate the sliding yoke and the flange yoke. 

3. disassemble the universal joint of the intermediate transmission axle 

Hint: 

The steps for the disassembly of the universal joint of intermediate transmission axle are the same with 

those for the universal joint of sliding yoke. 

4. Disassemble the transmission axle universal joint of rear axle 

HINT: 

The steps for the disassembly of the transmission axle universal joint of rear axle are the same with 


33

33-12 


Bearing journal 

5. INSPECT THE CROSS SHAFT 

(a). 

(b). 

Inspect the bearing journal of the cross shaft for 

the surface wear. 

Measure the bearing journal of the cross shaft 

with vernier caliper. 

Bearing journal: 

Vehicle 

Standard 

Bearing journal 

Limit value of 

wear 

1051 series 21.94 mm 0.10 mm 

1061/1099 series 25 mm 0.10 mm 

1089 series 26.68 mm 0.10 mm 

If the wear is beyond the limit range, replace with a new 

cross shaft. 

(c). 

Inspect the clearance between the cross shaft 

and the needle bearing with a bench screw and 


• Don’t clamp the cross shaft directly with a 

bench screw, wrap the place with soft cloth 

to avoid the damage of cross shaft. 

• A new needle bearing shall be used during 

the inspection. 

• Set the needle bearing on the cross shaft, 

move the needle bearing in radial direction 

and measure the clearance between the 

cross shaft and the needle bearing. 

Clearance between the cross shaft and the 

needle bearing: 

33 

Vehicle 

1051series 

1061series 

1089series 

1099series 

Torque 

0.012~0.061 mm 

0.014~0.070 mm 

0.016~0.071 mm 

0.012~0.061 mm 

If the clearance is beyond the limit range, replace with 

a new cross shaft.


33-13 

(d). 

Inspect the clearance between the needle 

bearing and the universal joint fork with a dial 

indicator. 

• Place the needle bearing in the mounting 

hole of the universal joint, move the 

needle bearing in the radial direction and 

measure the clearance between the 

needle bearing and the universal joint fork. 

Clearance between the needle bearing and 

the universal joint fork: 

Vehicle 

Torque 

1051 series 0.29~0.61 mm 

1061 series 0.32~0.58 mm 

1089/1099 series 0.15~0.40 mm 


a new needle bearing. 

(e). 

6. ASSEMBLE THE UNIVERSAL JOINT OF SLIDING YOKE 

(a). 

Inspect the axial clearance of the cross shaft 

with a dial indicator. 

• Set the needle bearing on the cross shaft, 

place the universal joint in the mounting 

hole, move the cross shaft in radial 

direction and measure the axial clearance 

of the cross shaft. 

Axial clearance of the cross shaft: ≤ 0.25 mm 


new cross shaft and needle bearing. 

Apply appropriate amount of lubricating grease on the surfaces of the cross shaft and needle 

bearing. 

• If too much lubricating grease is applied, the difficulty of assembly will be increased. 


(b). 

Knock on the needle bearing slightly with a 

rubber hammer, install it into the ear hole from 

the outside of the flange yoke and the sliding 

yoke and install the cross shaft at the same time. 

• A new needle bearing must be replaced 

with. 

• Dust cover must be installed at the same 

time. 

33 

Caution: 



Hint: 

Notice the direction of the cross shaft grease nipple 

and make it have the same direction with other cross 

shaft grease nipples so as to fill lubricating grease.

33-14 


(c). 

Install the retainer ring with circlip pliers. 

• A new retainer ring must be replaced with. 

(d). 

Install the grease nipple. 

• A new grease nipple must be replaced 

with. 

7. Install the transmission axle universal joint of rear axle 

Hint: 

The steps for the assembly of the transmission universal joint of rear axle are the same with those 

for the universal joint of sliding yoke. 

8. Assemble the universal joint of the intermediate transmission axle 

HINT: 

The steps for the assembly of the universal joint of intermediate transmission axle are the same with 


9. Install the transmission axle (refer to “chapter 33 transmission axle-transmission axle 


33


Parts diagram 

Transmission axle- intermediate bearing 

33-15 

1 Slotted Nut 


3 Flange foke 

4 Oil Seal 


7 Bearing Seat 

8 Rubber Gasket Ring of Intermediate Bearing 

9 Intermediate Transmission 

5 Intermediate bearing 

33

33-16 

Overhaul 


1. Remove the intermediate transmission axle (refer to “chapter 33 transmission 

axle-transmission axle assembly, replacement”) 

2. Remove the flange of intermediate 


(a). 

Notice: 

Pull out the cotter pin and loosen the slotted 

nut. 

The cotter pin removed can’t be used again. 

(b). 

Notice: 

Remove the spring washer. 

the spring washer removed can’t be used again. 

(c). 

Notice: 

Remove the washer. 

the washer removed can’t be used again. 

(d). Make matchmarks on the flange of 


intermediate bearing assembly. 

(e). 

Knock on the edge of the flange slightly with a 

hammer and a copper rod and pull it out from 

the spline axle when the flange is loose. 

3. Remove the rubber gasket ring of 

intermediate bearing 

33 

4. Remove the intermediate bearing assembly 

(a). 

Knock slightly with a hammer and a copper rod and remove the intermediate bearing 

assembly. 

5. Inspect the intermediate bearing assembly 

(a). 

(b) 

Inspect whether the intermediate bearing assembly can rotate freely. 

Replace with a new intermediate bearing assembly if necessary.


33-17 

6. Disassemble the intermediate bearing assembly 

(a). 

(b). 

Disassemble the intermediate bearing assembly into intermediate bearing, bearing seat and 

oil seal with a hammer and a copper rod. 

Inspect whether the intermediate bearing is worn or damaged and replace with a new one if 

necessary. 

7. Assemble the intermediate bearing assembly 

(a). 

(b). 

(c). 

Apply lubricating grease on the intermediate bearing and the oil seal lip. 

Lubricating grease: lithium grease no. 2 

Install the intermediate bearing into the bearing seat. 

Press in the oil seal on both sides. 

8. Install the intermediate bearing assembly 

(a). 

Notice: 

Install the intermediate bearing assembly in place with a hammer and a copper rod. 

Make sure the side with matchmark shall be towards the outside of the spline axle. 

9. Install the rubber gasket ring of intermediate 

bearing 

Hint: 

Make the internal bore groove of the rubber gasket ring 

align with the projecting portion of the intermediate 

bearing. 

10. Install the flange of intermediate 


(a). 

Notice: 

Knock on the edge of the flange with a hammer 

and a copper rod to make it install in place. 

The installation must be carried out in accordance 

with the matchmarks made before. 

(b). Install the washer. 

Notice: 

A new washer must be replaced with. 

(c). Install the spring washer. 

Notice: 

A new spring washer must be replaced with. 

33

33-18 


(d). 

Notice: 

Install the slotted nut of intermediate bearing 

and insert it into the cotter pin. 

Torque: 440 N•m 

A new slotted nut of intermediate bearing must be 

replaced with. 

11. Install intermediate transmission axle (refer to “chapter 33 transmission 


33

Sliding yoke 

Parts diagram 

Transmission axle-sliding yoke 

33-19 

1 Rear Transmission Axle 

2 Oil Seal Cover 

3 Oil Seal Washer 

4 Oil Seal of Sliding Yoke 


6 Sliding foke 

7 Plug 

33

33-20 

Overhaul 

Transmission axle-sliding yoke 

1. Remove the transmission axle of rear axle (refer to “chapter 33 transmission 


2. Inspect the clearance of sliding spline (refer to “chapter 33 transmission 

axle-transmission axle assembly, inspection”) 

3. Remove the spline axle 

(a). 

(b). 

(c). 

Open the oil seal cover of sliding foke. 

Pull out the spline axle from the sliding foke. 

Take down the oil seal, oil seal washer and oil seal cover from the spline axle. 

4. Install the spline axle 

(a). 

(a). 

(b). 

Set the oil seal cover, oil seal washer and oil seal on the spline axle. 

Set the sliding yoke on the spline axle according to the calibration arrows. 

Install the oil seal and oil seal washer and screw down the oil seal cover. 

33


Steering mechanism ........................................... 41-1 

Notes .............................................................. 41-1 


Parts diagram ................................................. 41-3 

On-vehicle inspection ..................................... 41-5 

Steering wheel ..................................................... 41-6 

Overhaul ........................................................ 41-6 

Combination switch assembly .......................... 41-9 

Replacement ................................................. 41-9 

Steering column assembly ............................... 41-13 

Overhaul ...................................................... 41-13 

Steering bracket ................................................ 41-19 

Replacement ................................................ 41-19 

41

41

Steering mechanism 

Notes 

Steering mechanism-steering mechanism 

1. Notes for the operation of steering system 

(a). 

(b). 

41-1 

The descriptions in this manual must be observed and special care must be taken during the 

replacement of parts. 

The incorrect operation may affect the performance of the steering system and even be 

hazardous to personal safety. 

41

41-2 



Use the table below to help you find the cause of the malfunction. The numbers indicate the 

probability of the cause of the malfunction. Check each part in order. If necessary, replace these 

parts. 

Phenomenon Suspect Area Reference 

1. Lock bolt of steering universal joint (Loose) 

Chapter 41 steering mechanism-steering 

column assembly, overhaul 

The free play of 

the steering wheel 

is too big 

2. Steering linkage (Loose) 

3. Steering gear (Loose) 

Chapter 24 front axle-sttering linkage, overhaul 

Chapter 42 power steering-steering gear with 

rocker arm assembly, overhaul 

4. Steering gear (Worn or the adjustment is not 

correct) 

Chapter 42 power steering-steering gear with 

rocker arm assembly, overhaul 

41

Parts diagram 


41-3 

1 Steering Wheel with Horn Button Assembly 

2 Flat Washer 



5 Bolt 

6 Steering Pipe Column Support Welding 

7 Steering Adjustable Support Welding 

8 Spring 

9 Flat Washer 



12 Lower Adjustable Support Welding 

13 Nut 

14 Retainer Ring 

15 Steering Pipe Column Welding 

16 Lock Bolt 

17 Right Limit Bracket 

18 Lock Sleeve 

19 Left Limit Bracket 

20 Regulating Handle 

21 Nut 

22 Check Washer 


24 Fixed Washer 

25 Sliding Block 

26 Hexagon Flange Lock Nut 

41

41-4 


27 Sliding Axle 

28 Hexagon Flange Bolt 

29 Dust Cover 

30 Steering Dust Cover Assembly 

41


41-5 


1. Inspect the free play of the steering wheel 

(a). 

(b). 

Keep the vehicle still. 

Align the steering wheel and make the front 

wheels straightly ahead. 

(c). 

Turn the steering wheel slowly from side to 

side and inspect the free play of the steering 

wheel. 

Free play: ± 10° 

If the free play is beyond the limit value, inspect 

relevant parts. (Refer to “chapter 41 steering 

mechanism-steering mechanism, malfunction 

symptom table”) 

Then, inspect the maximum steering angle of the front 

wheels and adjust it if necessary. (Refer to “chapter 

24 front axle-front wheel alignment, adjustment”) 

41

41-6 


Overhaul 

Steering mechanism-steering wheel 

1. Notes for the operation of steering wheel (refer to “chapter 41 steering 

mechanism-steering mechanism, notes”) 

2. Remove the horn button 

(a). 

Align the steering wheel and make the front 

wheels straightly ahead. 

(b). Take down the steering wheel by hands from 

the left and right sides of the horn button. 

(c). Turn over the horn button and pull out the 2 

harness connectors that are connected to the 

steering wheel. 

41 

3. Remove the steering wheel 

(a). 

(b). 

Loosen and take down the fixing nuts of the 


Take down the retainer ring. 

Notice: 

Store them carefully to prevent loss.


41-7 

(c). 

Notice: 

Make matchmarks on the steering axle and 


Make sure that the matchmarks are visible. 

(d). 

Pull out the steering wheel from the steering 

axle. 

4. Inspect the steering wheel 

(a). 

Inspect whether the flange of the steering wheel is warped or has cracks, break and other 

defects. If the defects above exist, replace with a new steering wheel if necessary. 

5. Install the steering wheel 

(a). 

Caution: 

Install the steering wheel on the steering axle 

according to the assembly matchmarks. 


with the matchmarks made before. 

(b). 

Install the retainer ring and screw down the fixing 

nuts of the steering wheel. 


41

41-8 


6. Inspect the steering force of the steering 

wheel 

(a). 

Pull the outer edge of the steering wheel 

tangentially with a spring balance and measure 

the steering force of the steering wheel. 

Steering force of the steering wheel: 22 ~ 

55 N 

If the steering force of the steering wheel is beyond 

the limit range, inspect and replace with a new 

steering gear if necessary. (Refer to “chapter 42 

power steering-steering gear, overhaul”) 

Hint: 

• Make the left and right front wheels leave the 

ground at the same time and support the 

vehicle with a safety stage. 

• Measure in the scope that the steering wheel 

turns 80° respectively to the left and right sides 

from the middle position. 

7. Install the horn button 

(a). 

Connect the 2 harness connectors. 

(b). 

Press the horn button by hands slightly and 

install it on the steering wheel. 

41

Steering mechanism-combination swtich assembly 

Combination switch assembly 

Replacement 

41-9 

1. Disconnect the battery negative cable (refer to “chapter 53 battery-battery, 


2. Remove the steering wheel (refer to “chapter 41 steering mechanism-steering wheel, 

overhaul”) 

3. Remove the combination switch assembly 

(a). 

Loosen the 4 screws and 1 bolt that fix the 

lower shield of the combination switch. 

(b). 

Push aside the 2 buckles and take down the 

upper shield and lower shield of the 

combination switch. 

41

41-10 


(c). Pull out the connector case of the 

combination switch assembly from the 

support and disconnect the 2 groups of 

connectors. 

(d). 

Loosen the 4 screws and take down the 

combination switch assembly. 

41


41-11 

4. Install the combination switch assembly 

(a). 

Screw down the 4 bolts and fasten the 

combination switch assembly. 

(b). Connect the 2 groups of connectors and install 

the connector case of combination switch 

assembly on the support. 

(c). 

Notice: 

Install the upper shield and lower shield of the 

combination switch and connect the buckle. 

Leave the dustproof rubber pad of the 

combination switch flat. 

HINT: 

The buckle is installed in place with a “click”. 

41

41-12 


(d). 

Screw down the 4 screws and 1 bolt to fasten 

the lower shield of the combination switch. 

5. Install the steering wheel (refer to “chapter 41 steering mechanism-steering wheel, 

overhaul”) 

6. Connect the battery negative pole cable (refer to “chapter 53 battery-battery, 


41

Steering mechanism-steering column assembly 

Steering column assembly 

Overhaul 

41-13 

1. Notes for the operation of steering column assembly (refer to “chapter 41 steering 

mechanism-steering mechanism, notes”) 

2. Remove the steering wheel (refer to “chapter 41 steering mechanism-steering wheel, 

overhaul”) 

3. Remove the combination switch assembly (refer to “chapter 41 steering 

mechanism-combination switch assembly, overhaul”) 

4. Remove the ignition switch assembly (refer to “chapter 81 vehicle control 

system-ignition switch assembly, overhaul”) 

5. Remove the regulating handle 

(a). 

Loosen the bolt and take down the check 

washer. 

cruise 

(b). 

Loosen the nut and take down the regulating 

handle. 

cruise 

6. Remove the left limit bracket 

(a). 

Loosen the bolt and take down the left limit 

bracket. 

cruise 

41 

7. Remove the right limit bracket 

Hint: 

The steps for the removal of right limit bracket are the same with those for the left one.

41-14 


8. Remove the lock sleeve 

cruis 

e 

9. Remove the retracing spring 

(a). 

(b). 

Make the hook on the top of the retracing spring 

pass through from the mounting hole with 


Make the hook at the bottom of the retracing 

spring pass through from the mounting hole and 

take down the retracing spring. 

10. Remove the limit bolt of the sliding axle 

11. Loosen the steering shield assembly 

(a). 

Loosen the 6 screws and loosen the steering 

shield assembly. 

41 

12. Separate the spline housing universal joint of 

steering column and the steering gear 

(a). 

(b). 

Make matchmarks on the spline housing 

universal joint fork of the steering column and 

the steering worm of the steering gear. 

Loosen the bolts and pull out the spline housing 

universal joint fork of the steering column from 

the spline axle at the top of the steering worm of 

steering gear. 

13. Remove the steering column assembly 

(a). 

Pull out the lock bolt of the adjustable support on 

the steering column.


41-15 

(b). 

Take down the steering column welding from the 

steering column assembly. 

(c). 

Take down the precise locating ring from the 

steering column assembly. 

(d). 

Take down the steering column assembly. 

(e). 

At the same time, take down the steering 

column dust cover and the steering shield 

assembly. 

41

41-16 


14. inspect the steering column assembly 

(a). 

(b). 

(c). 

Inspect the steering axle. 

• inspect the straightness of the steering axle. 

Straightness: ≤ 1.5 mm 

If the straightness of the steering axle is beyond the limit value, replace with a new steering 

column assembly. 

Inspect the spline axle, spline housing and universal joint fork. 

• inspect the spline axle, spline housing and universal joint fork spline for corrosion, scars 

or cracks. 

• inspect whether more than 2 gears of the spline are distorted or damaged. If the defects 

above exist, replace with a new steering column assembly. 

Inspect the universal joint of the steering column. 

• inspect whether the bearing surface of the universal joint has the defects of scaling, 

fracture or needle shortage. 

• inspect whether the seal gasket and seal cover of the bearing are invalid. 

• inspect whether the cross shaft bearing journal of the universal joint has the defects of 

impression, scaling, eccentric wear and cracks. 

• inspect whether the universal joint can rotate smoothly. 

If the defects above exist, replace with a new steering column assembly. 

• inspect the clearance between the cross shaft bearing and the bearing journal. 

Clearance: ≤ 0.25 mm 

If the clearance between the cross shaft bearing and the bearing journal is beyond the limit 

value, replace with a new steering column assembly. 

15. Connect the spline housing universal joint of the steering column and the steering 

gear 

(a). 

Set the precise locating ring, steering pipe column welding, steering column dust cover and 

steering shield assembly on the steering column. 

(b). 

Set the spline housing universal joint of the 

steering column completely on the spline axle 

that is on the top of the steering gear steering 

worm and screw down the bolt. 

Torque: 41~51 n•m 

Caution: 

41 



16. install the lock bolt 

(a). 

Make the lock bolt pass through the steering 

adjustable support of the steering column and 

the welding limit hole of the steering pipe 

column.


41-17 

17. Fasten the steering shield assembly 

(a). 

Screw down the 6 screws and fasten the 

steering shield assembly. 

18. Install the steering axle limit bolt 

19. Install the retracing spring 

(a). 

(b). 

Make the hook at one end of the retracing 

spring pass through from the mounting hole at 

the bottom. 

Clamp the hook at the other end of the 

retracing spring with sharp-nose pliers and 

make it pass through the mounting hole at the 

top. 

20. Install the lock sleeve 

cruise 

21. Install the left limit bracket 

(a). 

Screw down the bolt and install the left limit 

bracket. 

cruise 

41 

22. Install the right limit bracket 

Hint: 

The steps for the installation of right limit bracket are the same with those for the left one.

41-18 


cruise 

23. install the regulating handle 

(a). 

Hint: 

Set the regulating handle on the lock bolt and 

screw down the nut. 

• the angle between the regulating handle and the 

steering column shall be about 30° during the 

installation. 

• screw down the nut and make the adjusting 

handle just closely contact the left limit bracket 

and can't rotate freely while turning it slightly. 

cruise 

(b). 

Hint: 

Install the check washer and screw down the 

bolt. 

The end of the check groove shall be aligned with the 

bolt mounting hole on the regulating handle during the 

installation of check washer. 

(c). 

Turn the regulating handle to the lock position; 

inspect the lock state of the steering pipe 

column welding and the steering transmission 

axle assembly. 

Standard value: no looseness 

If the steering pipe column welding and the 

steering transmission axle assembly are found 

loose, repeat step (a). 

41 

24. install the ignition switch assembly (refer to “chapter 81 vehicle control 

system-ignition switch assembly, overhaul”) 

25. install the combination switch assembly (refer to “chapter 41 steering 

mechanism-combination switch assembly, overhaul”) 

26. install the steering wheel (refer to “chapter 41 steering mechanism-steering wheel, 

overhaul”)

Steering bracket 

Replacement 

Steering mechanism-steering bracket 

1. inspect the steering bracket 

(a). 

41-19 

Inspect whether the steering pipe column 

support welding, the steering adjustable 

support welding and the lower adjustable 

support welding are distorted. 

If bending and other defects exist to calibrate 

and replace with a new support if necessary. 

2. remove the steering adjustbale support 

welding 

(a). 

Loosen the 2 bolts and remove the steering 

adjustable support welding. 

41

41-20 


3. Remove the lower adjustable support 

welding 

(a). 

Loosen the 2 bolts and remove the lower 


4. Remove the steering pipe column support 

welding 

(a). 

Loosen the 4 bolts and remove the steering 

pipe column support welding. 

41


41-21 

5. install the steering pipe column support 

welding 

(a). 

Screw down the 4 bolts and install the steering 

pipe column support welding. 

6. install the lower adjustable support welding 

(a). 

Screw down the 2 bolts and install the lower 


41

41-22 


7. install the steering adjustable support 

welding 

(a). 



41


Power steering system ....................................... 42-1 

Notes .............................................................. 42-1 


Parts diagram ................................................. 42-5 


Steering fluid ........................................................ 42-9 

Replacement .................................................. 42-9 

Air bleeding and purification ........................ 42-12 

Steering oil pump assembly ............................. 42-14 

Replacement ................................................ 42-14 

Steering gear with rocker arm assembly ........ 42-15 

Overhaul ...................................................... 42-15 

Hydraulic circuit ................................................ 42-18 

Replacement ................................................ 42-18 

Steering reservoir assembly ............................ 42-23 

Removal installation and decomposition 

assembly ...................................................... 42-23 

42

42

Power steering-power steering system 

42-1 

Power steering system 

Notes 

1. notes for the operation of power steering system 

(a). The descriptions in this manual must be observed and special care must be taken during the 

replacement of parts. 

(b). 

The incorrect operation may affect the performance of the steering system and even be 

hazardous to personal safety. 

2. power steering system maintenance notes 

(a). 

(b). 

(c). 

The steering fluid appointed must be used, don’t mix different models of steering fluid 

together. 

Steering fluid: ATF- Ⅲ 

New steering fluid must be replaced with every 3,000 km for the first time of driving, then 

replace it once every 20,000 km. (refer to “chapter 42 power steering-steering fluid, 


Inspect regularly, at least once every 5,000 km. 

• check the looseness of each connection. 

• check whether the steering function is normal. 

42

42-2 




probability of the cause of the Malfunction. Check each part in order. If necessary, replace these 

parts. 

symptom Suspect area Reference 

1. front axle (overloaded) 

- 

2. tire (worn) 

Chapter 23 wheels and tires-wheels and 

tire assembly, on-vehicle inspection 

3. tire (air pressure is too low) 



4. front wheel alignment (incorrect) 

Chapter 24 front axle-front wheel 

alignment, adjustment 

The steering 

wheel is heavy. 

5. steering fluid (insufficient) 

6. ball pin (too tight or too loose) 

Chapter 42 power steering- power steering 

system, on-vehicle inspection 

Chapter 42 power steering-steering fluid, 

replacement 

Chapter 24 front axle-steering linkage, 

overhaul 

7. steering axle (bent or the bearing is too 

tight) 



42 

8. steering gear (worn or damaged) 

9. front wheel bearing (installed 

reversely) 

Chapter 42 power steering-steering gear 

with rocker arm assembly, overhaul 

Chapter 24 front axle-front wheel hub with 

brake drum assembly, overhaul 

10. steering knuckle pin (clearance too 

small) 

Chapter 24 front axle-steering knuckle, 

overhaul


42-3 

Phenomenon Suspect area Reference 

1. tires (pressure is different) 

2. front wheel alignment (incorrect) 

3. shock absorber (damaged) 


tire assembly, adjustment 



Chapter 21 front suspension-front shock 

absorber, overhaul 

Chapter 22 rear suspension-rear shock 

absorber, overhaul 

4. front plate spring (loose or damaged) 

Chapter 21 front suspension-front plate 

spring assembly, overhaul 

Chapter 22 rear suspension-rear plate 

spring assembly, overhaul 

The steering 

wheel vibrates 

5. wheel and tire assembly (unbalanced 

or worn) 




tire assembly, adjustment 

6. steering gear (loose or damaged) 

Chapter 42 power steering- steering gear 


7. brake drum (unbalanced) 

Chapter 26 braking-front wheel brake, 

overhaul 

8. front wheel bearing (worn) 

9. steering knuckle pin (too tight) 

10. steering knuckle (distorted) 

Chapter 24 front axle- front wheel hub with 

brake drum assembly, overhaul 


overhaul 

11. frame (distorted) 


overhaul 

- 

1. steering drag link (distorted) 


overhaul 

The rotation 

revolutions of 

steering wheel is 

not correct 

2. steering rocker arm (incorrect angle) 

3. steering gear (worn or damaged) 

4. steering knuckle stopper bolt (incorrect 

adjustment) 







42 

1. lock bolt of steering universal joint 

(loose) 



The free play of 

the steering 

wheel is too big 

2. steering linkage (loose) 

3. steering gear (loose) 


overhaul 



4. steering gear (worn or incorrect 

adjustment) 


with rocker arm assembly, overhaul

42-4 



1. steering fluid (insufficient) 



The 

power-assisted 

steering is not 

sufficient 

The steering has 

abnormal sound 

2. steering hydraulic system (mixed into 

air) 

3. steering reservoir (the filter screen is 

blocked) 

4. steering oil pump (worn or damaged) 

5. steering column universal joint (not 

smooth) 

1. steering fluid (incorrect model) 

2. steering hydraulic system (mixed into 

air) 

3. steering gear (loose or worn) 

4. steering oil pump (worn or damaged) 

5. drag link ball joint (worn or damaged) 

6. steering column universal joint (loose) 



Chapter 42 power steering-steering 

reservoir assembly, removal installation 

and decomposition assembly 

Chapter 42 power steering-steering oil 

pump assembly, replacement 




system, notes 





Chapter 42 power steering-steering oil 

pump assembly, replacement 


overhaul 



42

Parts diagram 


42-5 

1 hexagon head bolt 

2 heavy type spring washer 

3 hexagon nut 

13 low pressure oil pipe assembly 2 


15 spring washer 

4 hexagon nut, style 1 



7 steering gear support 

8 steering gear with rocker arm assembly 


10 high pressure oil pipe assembly 1 

11 transmission type hose hoop of type a worm 

gear 



17 flat washer 


19 hexagon nut, style 1 

20 oil pipe bracket welding 



23 steering oil pump with transmission sleeve 

assembly 

24 transmission type hose hoop of type B worm gear 

42

42-6 


25 oil pump oil inlet pipe assembly 

26 plastic spannband 

27 steering reservoir assembly 



30 fixing clip 


32 flat washer 

33 hexagon head nut, style 1 

34 auxiliary water tank bracket 

42


Notice: 


The level of steering fluid must be inspected regularly, at least once every 5,000 km. 

1. Inspect the level of steering fluid 

(a). 

Park the vehicle on the flat road. 

cold 

normal 

cold 

hot 

cold 

hot 

hot 

abnormal 

(b). 

Hint: 

Inspect the level of steering fluid. 

42-7 

• fill the steering fluid if necessary. (refer to 

“chapter 42 power steering –steering fluid, 


Steering fluid: :ATF- Ⅲ -Q/SH 038.531 

• It is no need to start the engine at this step. 

• If the steering fluid is at cold state, inspect 

whether the level is within the scale range of 

level gauge (cold). 

• If the steering fluid is at hot state, inspect 

whether the level is within the scale range of 

level gauge (hot). 

(c). 

(d). 

Notice: 

Start the engine and operate at idle speed. 

Rotate the steering wheel for a few times in 

the limit positions of the left and right sides 

and raise the temperature of steering liquid. 

Steering fluid temperature: 60 ~ 80 ℃ 

The steering wheel shall stay no more than 5 

seconds in the limit position so as to avoid 

damaging the steering gear. 

Hint: 

Make the left and right front wheels leave the 

ground at the same time and support the vehicle 

with a safety stage. 

(e). 

Inspect whether the steering fluid is muddy 

or has bubbles. 

If the steering fluid is found muddy or having 

bubbles, release the gas in it. (refer to 

“chapter 42 power steering - steering fluid, 

air release and purification”) 

42

42-8 


the engine operates 

at idle speed. 

the engine is shut down. 

(f). 

(g). 

(h). 

Make the engine operate at idle speed and 

inspect the level of steering fluid. 

Shut down the engine. 

Wait for a few minutes and inspect the level of 

steering fluid again, and compare it with the level 

obtained at step (f). 

Rise of steering fluid level: ≤ 5 mm 

If the rise distance of the steering fluid level is beyond the 

limit value, release the gas in the steering fluid. (refer to 

“chapter 42 power steering - steering fluid, air release and 

purification”) 

42 

2. inspect the leakage of steering hydraulic system 

(a). 

(b). 

Notice: 

(i). 

Start the engine and make it operate at idle speed. 

Finally, inspect the level of steering fluid and fill 

the steering fluid if necessary. 

Rotate the steering wheel for a few times in the limit positions of the left and right sides and 

raise the temperature of the steering liquid. 

Steering fluid temperature: 60 ~ 80 ℃ 

The steering wheel shall stay no more than 5 seconds in the limit position so as to avoid 


Hint: 

Make the left and right front wheels leave the ground at the same time and support the vehicle with 

a safety stage. 

(c). 

Notice: 

Turn the steering wheel to any side of limit position, apply certain force on it and keep for a 

few seconds. 

The steering wheel shall stay no more than 5 seconds in the limit position so as to avoid 


Hint: 

This step may be repeated for a few times. 

(d). 

Inspect whether the steering hydraulic system leaks. 

• if the oil leaks from the joint, it means the terminal nut loose, screw it at once. 

• if the oil leaks from the joint with hoop, replace with a new hoop. Don’t screw it too tightly 

to avoid damaging.

Steering fluid 

Replacement 

1. Oil discharge 

(a). 

Power steering-steering fluid 

42-9 

Make the left and right front wheels leave the ground at the same time and support the 


(b). Rotate the steering reservoir cap 

counterclockwise and take it down. 

cold 

hot 

(c). 

Loosen the nut and pull out the low pressure 

oil pipe assembly 1 from the return opening of 

the steering gear. 

(d). 

(e). 

(f). 

Notice: 

Start the engine and make it operate at idle 

speed. 

Discharge the steering fluid in the steering oil 

pump and the steering reservoir. 

Rotate the steering wheel for a few times in the 

limit positions of the left and right sides until no 

steering liquid flows out. 




42

42-10 

2. filling 


(a). Apply sealant on the pipe orifice of the low pressure oil pipe assembly 1. 

Sealant: loctite 567 sealant 

(b). 

Insert the low pressure oil pipe assembly 1 into 

the return opening of the steering gear and 

screw down the nut. 


(c). 

Fill steering fluid into the steering reservoir. 

Steering fluid: :ATF- Ⅲ 

(d). 

Make the engine operate at idle speed. 

normal 

abnormal 

(e). 


limit positions of the left and right sides until 

the level of steering fluid in the steering 

reservoir doesn’t drop and no bubbles are 

produced. 

Notice: 




42


42-11 

cold 

hot 

(f). 

Inspect the level of steering fluid. (refer to 

“chapter 42 power steering- power steering 

system, on-vehicle inspection”) 

• refill the steering fluid to the marked 

position of the level gauge. 

Steering fluid: ATF- Ⅲ 

cold 

hot 

hot 

cold 

(g). 

Screw down the steering reservoir cap 

clockwise. 

cold 

42 

cold 

hot 

hot 

(h). 

(i). 


Lower the vehicle.

42-12 


Air bleeding and purification 

1. Air bleeding 

(a). 



(b). 

Rotate the steering reservoir cap 


cold 

hot 

cold 

hot 

(c). 

Start the engine and make it operate at idle 

speed. 

normal 

abnormal 

(d). 


limit positions of the left and right sides until the 

level of steering fluid in the steering reservoir 

doesn’t drop and no bubbles are produced. 

Notice: 

42 


seconds in the limit position, so as to avoid 


(e). 

Inspect the level of steering fluid. (refer to 

“chapter 42 power steering- power steering 

system, on-vehicle inspection”) 

• refill the steering fluid to the marked position 

of the level gauge. 

Steering fluid: atf- Ⅲ -q/sh 038.531


42-13 

(f). Screw down the steering reservoir cap 

clockwise. 

cold 

hot 

cold 

hot 

(g). 

(h). 


Lower the vehicle. 

2. purification 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 



Start the engine and make it operate at idle speed. 

Rotate the steering wheel for a few times in the limit positions of the left and right sides. 

• inspect whether abnormal sound exists in the steering hydraulic system. 

If abnormal sound exists in the steering hydraulic system, release the gas in it. (refer to 

“chapter 42 power steering - steering fluid, air release and purification”) 

Notice: 

The steering wheel shall stay no more than 5 seconds in the limit position, so as to 

avoid damaging the steering gear. 

Repeat step (c) until the abnormal sound disappears. 


Lower the vehicle. 

42

42-14 

Power steering-steering oil pump assembly 

Steering oil pump assembly 

Replacement 

Notice: 

• the steering oil pump assembly is a precision component, don’t disassemble or overhaul it at 

random. 

• if it is damaged, replace with a new steering oil pump assembly. 

1. oil discharge of steering fluid (refer to “chapter 42 power steering - steering fluid, 


2. remove the air jumper pipe (refer to the service manual with isf of cummins engine) 

3. remove the steering oil pump assembly 

(a). 

(b). 

(c). 

Loosen the terminal nut and pull out the high 

pressure oil pipe assembly 3 from the oil outlet 

of the steering oil pump assembly. 

Loosen the hoop and pull out the oil inlet pipe 

assembly of the oil pump from the oil inlet of the 

steering oil pump assembly. 

Loosen the 2 bolts and take down the steering 

oil pump assembly from the air compressor. 

42 

4. install the steering oil pump assembly 

(a). 

(b). 

(c). 

(d). 

Install the steering oil pump assembly on the 

installation plane of the air compressor and 

screw down the 2 bolts. 

Set the oil inlet pipe assembly of the oil pump on 

the oil inlet of the steering oil pump assembly 

and screw down the hoop. 

Apply sealant on the pipe orifice of the high 

pressure oil pipe assembly 3. 


Set the high pressure oil pipe assembly 3 on the 

oil outlet of the steering oil pump assembly and 

screw down the terminal nut. 


5. install the air jumper pipe (refer to the service manual with is of cummins engine) 

6. fill the steering fluid (refer to “chapter 42 power steering - steering fluid, 

replacement”)

Power steering-steering gear with rocker arm assembly 

42-15 

Steering gear with rocker arm assembly 

Overhaul 

Notice: 

• the steering gear is a precision component, don’t disassemble or overhaul it at 

random. 

• if it is damaged, replace with a new steering gear. 



2. separate the spline housing universal joint of steering column and the steering gear 

(refer to “chapter 41 steering mechanism-steering column assembly, overhaul”) 

3. separate the drag link and the steering rocker arm (refer to “chapter 24 front 

axle-steering linkage, overhaul”) 

4. remove the steering gear with rocker arm 

assembly 

(a). 

(b). 

Loosen the terminal nut and pull out the low 

pressure oil pipe assembly 1 from the return 

opening of steering gear. 


pressure oil pipe assembly 1 from the oil inlet of 

steering gear. 

(c). 

Loosen the 4 nuts and take down the steering 

with rocker arm assembly. 

42

42-16 

Power steering- steering gear with rocker arm assembly 

5. Disassemble the steering gear with rocker 

arm assembly 

(a). 

Loosen the fixing nut of steering rocker arm and 

take down the spring washer. 

(b). 

(c). 

Make matchmarks on the steering rocker arm 

and the steering rocker arm axle. 

Take down the steering rocker arm from the 

steering rocker arm axle. 

6. Inspect the steering gear and the steering rocker arm 

(a). 

(b). 

(c). 

Inspect whether cracks are on the steering rocker arm axle and the steering gear housing 

with magnetic crack detection. 

Inspect whether the spline of steering rocker arm axle is distorted or damaged. 

Inspect the steering rocker arm. 

• Inspect whether the steering rocker arm is distorted or cracked. 

• Iinspect whether the splined hole and spline gear of steering rocker arm axle are 

damaged seriously. 

If the defects above exist, replace with new steering gear and steering rocker arm. 

42 

7. Assemble the steering gear with rocker arm 

assembly 

(a). 

Caution: 

Set the steering rocker arm on the steering 

rocker arm axle. 


with the matchmarks made before.

Power steering-steering gear with rocker arm assembly 

42-17 

(b). 

Install the spring washer and screw down the 

fixing nut of steering rocker arm. 

Torque:197~246 n·m 

8. install steering gear with rocker arm 

assembly 

(a). 


gear with rocker arm on the steering gear 

support. 

Torque: 105 ~128 n•m 

(b). 

(c). 

Apply sealant on the pipe orifices of the low 

pressure oil pipe assembly 1 and the high 




the return opening of steering gear and screw 

down the terminal nut. 


(d). Insert the high pressure oil pipe assembly 1 

into the oil inlet of steering gear and screw 



9. connect the drag link and the steering rocker arm (refer to “chapter 24 front 

axle-steering linkage, overhaul”) 

10. connect the spline housing universal joint of steering column and the steering gear 

(refer to “chapter 41 steering mechanism-steering column assembly, overhaul”) 

11. fill steering fluid (refer to “chapter 42 power steering - steering fluid, replacement”) 

42

42-18 

Hydraulic circuit 

Replacement 

Power steering-hydraulic circuit 



2. remove high pressure oil pipe 

(a). 


pressure oil pipe assembly 1 from the oil inlet 

of steering gear. 

(b). 


pressure oil pipe assembly 3 from the oil outlet 

of steering oil pump assembly. 

(c). 

Loosen the 2 pipe clip bolts and take down the 

high pressure oil pipe assembly. 

42 

(d). 

Loosen the terminal nut and separate the high 

pressure oil pipe assembly 1, 2 and 3.


42-19 

3. Remove low pressure oil pipe 

(a). 

Loosen the terminal nut and pull out the low 

pressure oil pipe assembly 1 from the return 

opening of the steering gear. 

(b). 

Loosen the hoop and pull out the low pressure 

oil pipe assembly 3 from the oil inlet of the 

steering reservoir. 

(c). 

Single vehicle type: 

Loosen the 2 pipe clip bolts and take down the 

low pressure oil pipe assembly. 

Half vehicletype: 

Loosen 1 more pipe clip bolt than the single 

vehicle and take down the low pressure oil 

pipe assembly. 

(d). 

Loosen the hoop and separate the low 

pressure oil pipe assembly 1, 2 and 3. 

42

42-20 


4. Remove the oil inlet pipe assembly of oil 

pump 

(a). 


assembly of oil pump from the oil inlet of 

steering oil pump assembly. 

(b). 


assembly of oil pump from the oil outlet of 


(c). 

Take down the oil inlet pipe assembly of oil 

pump. 

5. Install the oil inlet pipe assembly of oil 

pump 

(a). 

Set the oil inlet pipe of the oil pump on the oil 

outlet of the steering reservoir and screw down 

the hoop. 

(b). 

Set the oil inlet pipe of the oil pump on the oil 

inlet of the steering oil pump and screw down 

the hoop. 

42


42-21 

6. install low pressure oil pipe 

(a). 

Set low pressure oil pipe assembly 3 on the oil 

inlet of steering reservoir and screw down the 

hoop. 

(b). 

(c). 

Apply sealant on the pipe orifice of the low 




the return opening of steering gear and screw 



(d). 


Place the low pressure oil pipe assembly 2 on 

the frame beam and screw down the 2 pipe clip 

bolts. 


Half vehicle type: 

Screw down one more pipe clip bolt than the 

single vehicle and fasten the low pressure oil 

pipe assembly 2. 


42 

(e). 

Screw down the hoop and connect the low 

pressure oil pipe assembly 1, 2 and 3.

42-22 

7. Install high pressure oil pipe 

(a). 


Apply sealant on the pipe orifices of the high pressure oil pipe assembly 3 and high pressure 

oil pipe assembly 1. 


(b). 

Set the high pressure oil pipe assembly 3 on 

the oil outlet of the steering oil pump and screw 



(c). Insert the high pressure oil pipe assembly 1 

into the oil inlet of steering gear and screw 



(d). 

Place the high pressure oil pipe assembly 2 on 

the frame beam and screw down the 2 pipe 

clip bolts. 


42 

(e). 

Screw down the terminal nut and connect the 

high pressure oil pipe assembly 1, 2 and 3. 

Torque: 46~ 56 n•m 

8. fill steering fluid (refer to “chapter 42 power steering - steering fluid, replacement”)

Power steering-steering reservoir assembly 

Steering reservoir assembly 

Removal installation and decomposition assembly 

42-23 



2. remove the steering reservoir assembly 

(a). 

(b). 


assembly of the oil pump from the oil outlet of 

the steering reservoir. 

Loosen the hoop and pull out the low pressure 

oil pipe assembly 3 from the oil inlet of the 


(c). 



reservoir assembly. 

Hint: 

Half vehicle type: 



The steps for the removal of single vehicle steering 

reservoir assembly are the same with those for the half 

vehicle steering reservoir assembly, but the operation 

positions are a little different. 

42

42-24 


3. remove the steering reservoir cover 

(a). Turn the steering reservoir cover 


4. install the steering reservoir cover 

(a). Screw down the steering reservoir cap 

clockwise. 

42 

cold 

cold 

hot 

cold 

hot 

hot 

cold 

hot


42-25 

5. install the steering reservoir assembly 

(a). 


Screw down the 2 nuts and fasten the steering 


Half vehicle: 

Screw down the 2 nuts and fasten the steering 


Hint: 

The steps for the installation of single vehicle steering 

reservoir assembly are the same with those for the half 

vehicle steering reservoir assembly, but the operation 

positions are a little different. 

(b). 

(c). 

Set the low pressure oil pipe assembly 3 on the 

oil inlet of the steering reservoir and screw down 

the hoop. 

Set the oil inlet pipe assembly of the oil pump on 

the oil outlet of the steering reservoir and screw 

down the hoop. 

6. Fill steering fluid (refer to “chapter 42 power steering - steering fluid, replacement”) 

42

42 

-MEMO-


Heater and air conditioner .................................. 51-1 

Notes .............................................................. 51-1 



Inspection ..................................................... 51-11 

Air duct of instrument panel ............................. 51-13 

Replacement ................................................ 51-13 

Hot air water pipe .............................................. 51-16 

Parts diagram ............................................... 51-16 

Replacement ................................................ 51-17 

Hot air water tank .............................................. 51-22 

Parts diagram ............................................... 51-22 

Overhaul ...................................................... 51-23 

Refrigerant ......................................................... 51-30 

On-vehicle inspection ................................... 51-30 

Replacement ................................................ 51-36 

Refrigeration oil ................................................ 51-40 

Inspection ..................................................... 51-40 

Replacement ................................................ 51-41 

Air conditioning pipe ........................................ 51-42 

Parts diagram ............................................... 51-42 

Inspection ..................................................... 51-43 

Replacement ................................................ 51-44 

Evaporator ......................................................... 51-51 

Parts diagram ............................................... 51-51 

Overhaul ...................................................... 51-52 

Air-conditioner compressor ............................. 51-57 

Parts diagram ............................................... 51-57 

Overhaul ...................................................... 51-58 

Air blower .......................................................... 51-62 

Replacement ................................................ 51-62 

Condenser ......................................................... 51-63 

Parts diagram ............................................... 51-63 

On-vehicle inspection ................................... 51-64 

Overhaul ...................................................... 51-65 

Liquid Reservoir ............................................... 51-67 

Replacement ................................................ 51-67 

Control mechanism assembly.......................... 51-69 

Parts diagram ............................................... 51-69 

Replacement ................................................ 51-70 

51

51

Heater and air conditioner- heater and air conditioner 

Heater and air conditioner 

51-1 

Notes 

1. ingnition switch description 

Ingnition switch (position) 

Lock 

Acc 

On 

Start 

Ingnition switch description 

Ingnition switch off 

Ingnition switch acc 

Ingnition switch on 

Start the engine 

2. cut off the power 

(a). 

Hint: 

Cut off the battery negative pole cable first before removing or installing any electric 

installation and while the tools or equipment may contact the uncovered electric pin easily so 

as to avoid damaging the people or vehicles. 

If control central lock is equipped with, don’t leave the keys in the vehicle before disconnecting the 

battery negative cable so as to avoid locking the doors. 

(b). 

The ignition switch must be shut off unless it is expressly stated. 

3. the daily odometer and clock in the combination meter will be cleared to zero after 

disconnecting the battery negative pole cable 

Hint: 

The master odometer will not be cleared to zero. 

4. the audio system may lose the settings stored after disconnecting the battery 

negative pole cable 

Hint: 

The audio system shall be reset after connecting the battery negative pole cable again. (refer to 

“chinese and english service manual on audio system”) 

5. don’t operate in an enclosed place or the 

place near the sources of ignition. 

51 

6. don’t carry out welding operation on the parts that are filled with refrigerant 

7. please always put on goggles.

51-2 


8. don’t make the liquid refrigrant enter into 

the eyes or contact the skin 

If the liquid refrigerant enters into the eyes or contacts 

the skin. 

51 

(a). 

Notice: 

Wash the contact part with a large amount of 

cold water. 

Don’t rub the eyes or skin. 

(b). 

(c). 

Apply clean vaseline. 

9. don’t heat up or place the tank body on the open fire. 

Please go to the hospital at once. 

10. don’t make it drop or hit it, and be careful during the movement. 

wrong 

right 

13. don’t fill too much refrigrant in the refrigeration system 

11. don’t operate the compressor while there is 

not enough refrigrant in the refrigeration 

system. 

If there is not enough refrigerant in the refrigeration 

system, the lubrication of engine oil will not be 

enough, the compressor may be burnt out, please be 

careful to avoid this condition. 

12. don’t open the high-pressure pipeline when 

the compressor is operating 

If the high-pressure valve is open, the refrigerant will 

flow backwards, which may break the cylinder body of 

the compressor; therefore, only the low-pressure 

valve can be open and closed. 

If too much refrigerant is filled, the heat radiation will be not enough, the economical efficiency of the 

fuel oil will be poor and the engine will be too hot. 

14. don’t open the system when there are puddles or when it is raining. 

15. the refrigeration system opened shall be covered or wraped up for sealing in time to 

prevent water vapour or foreign matters in the air from entering into it. 

16. the refrigeration oil shall be covered closely at any time and the trademark of the 

refrigeration oil shall be indicated, different trademarks of refrigeration oil can’t be 

used together to avoid reducing the quality or viscosity of the oil. 

17. the reservoir must be installed at last while installing the refrigeration system. 

18. supply refrigeration oil first for the system while replacing with new refrigrant and 

then fill into refrigrant. 

19. the repair tools must be clean and dry, the installation and maintenance site must be clean. 

20. the rubber sealing materials that are used to make various sealing soft pads (washers) 

shall have good compatibility with the refrigerant. 

21. the connection hose must be made of the materials that are specially used for 

refrigeration; nylon shall be used for the lining of connection hose that is applicable to 

r-134a. 

22. the refrigerant must be discharged slowly to avoid discharging refrigeration oil 

together, and it can’t contact the lustrous metal surface. 

23. don’t fill liquid refrigrant into the low-pressure end and don’t start the compressor 

while filling refrigrant into the high-pressure end. 

24. don’t clean the condenser and evaporator with vapour, only cold water or compressed 

air can be used.


51-3 

25. protect the vehicle with retaining washers or other things while repairing the refrigeration 

system. 

26. don’t start the compressor before filling cooling medium into the refrigeration system. 

27. if the compressor (used) shall be kept for a long period to avoid corrosion, discharge 

the air inside the compressor and fill refrigrant or dry nitrogen into it. 

28. inspect the seal conditions carefully and dispose the leakage parts before carrying 

out vacuum-pumping procedure. Check whether the movement of each part is normal, 

whether the cooling pipe, cooling system and electric circuit are in good conditions 

and whether the performance of the air conditioner is good after completing all the 

installation work. 

29. inspect the clearance between the parts during the installation of the automobile parts, 

don’t make them contact or be closed to each other, separate the parts with insulated 

materials. 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

(g). 

The clearance between the fan casing and the condenser (or water tank): > 5 mm 

The clearance between the cooling fan (steel) and the condenser (or water tank): > 15 mm 

The clearance between the cooling fan (plastic) and the condenser (or water tank): > 20 mm 

The clearance between the cooling fan and the fan casing: >15 mm 

The clearance between the cooling fan and the crank axle and tension pulley: >4 mm 

The clearance between the cooling fan and the condenser tube: >15 mm 

The clearance between the looseness side of the triangle belt and the air conditioner 

tube: >20 mm 

30. spring washer must be added while installing metal parts. 

31. the parts installed on the engine must be screwed up in accordance with the 

provision. 

32. don’t connect with hard pipe if the suspension part installed on each assembly is 

different or its vibrations are not the same. 

33. notes on electric wires 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

(g). 

(h). 

(i). 

(j). 

The negative pole cable of the battery (or the earth wire) must be removed before installing 

the parts in order to avoid short circuit. 

The connection of wire must be reliable and the fastness must be firm. 

Rubber retainer shall be added when the wire shall pass through the metal plate of the 

vehicle (in order to protect the wire). 

Other circuits removed or moved away during the repairing must be restored after the 

repairing. 

The wires must be fastened in the original harness of the vehicle with plastic adhesive tape 

or the original fastener. 

Don’t clamp the harness while installing other parts of the air conditioner. 

The lead wires with the same diameter must be used while welding to the original wire and 

the connection points shall be wrapped with adhesive tapes. 

Keep the wires away from the moving parts or high-temperature parts (such as the exhaust 

pipe and cylinder body of the engine), keep over 50 mm away from the heat sources. 

The wire must be separated from the fuel pipe for over 100 mm. 

Inspect carefully whether the wire contacts the sharp objects or moving parts. 

51

51-4 



Use the table below to help you find the cause of the malfunction . The numbers indicate the probability 

of the cause of the malfunction . Check each part in order. If necessary, replace these parts. 

1. the refrigeration system doesn’t work 

Symptom Suspect area Reference 

1. fuse (damaged) 

2. belt (too loose) 

3. electromagnetic clutch (damaged) 

4. air conditioner cut-off relay 

(damaged) 

5. a/c switch (damaged) 

- 

- 

- 

- 

Chapter 73 instrument panel/combination 

meter/cigar lighterinstrument panel, 

replacement 

The air volume is normal, but the 

compressor doesn’t operate. 

6. three-state pressure switch (damaged) 

7. thermal bulb (damaged) 

8. A/C amplifier (damaged) 

9. electromagnetic clutch relay 

(damaged) 

10. air conditioner relay (damaged) 

11. ECM (damaged) 

12. harness (open circuit or 

line-to-ground short circuit) 

13. compressor (damaged) 

Chapter 51 heater and air conditionerreservoir, 

replacement 

Chapter 51 heater and air conditionerevaporator, 

replacement 

- 

- 

- 

- 

- 

Chapter 51 heater and air conditionerair-conditioner 

compressor, replacement 

51 

The air blower has no air volume 1. fuse (damaged) 

2. harness (open circuit or 

line-to-ground short circuit) 

3. air volume switch (damaged) 

4. adjustable resistance (damaged) 

- 

- 

Chapter 73 instrument panel/combination 

meter/cigar lighterinstrument 

panel,replacement 

Chapter 51 heater and air conditionerair 

blower, replacement 

5. air blower (damaged) 

Chapter 51 heater and air conditionerair 


The refrigeration is not enough, 

but the air volume is normal and 

the compressor operates. 

1. the refrigerant leaks seriously. 

2. the compressor is damaged 

3. the reservoir is blocked. 

Chapter 51 heater and air conditionerrefrigerant, 





replacement


51-5 

2. the refrigeration is intermittent 


1. harness (poor contact) 

2. relay (poor contact) 

- 

- 


Chapter 73 instrument 

panel/combination meter/cigar 

lighterinstrument panel,replacement 

The air volume is intermittent. 


Chapter 51 heater and air 

conditionerair blower, replacement 

5. air blower (poor internal contact) 


conditionerair blower, replacement 

6. air flue (blocked) 

1. belt (slippery) 

2. electromagnetic clutch (slippery) 


conditionerair flue, replacement 

- 

- 

3. A/C switch (damaged) 


panel/combination meter/cigar 

lighterinstrument panel,replacement 

Intermittent service of compressor 

4. three-state pressure switch 

(damaged) 

5. thermal bulb (damaged) 

6. a/c amplifier (damaged) 



conditionerreservoir, replacement 


conditionerevaporator, replacement 

- 


conditionerair-conditioner 



1. thermal bulb (loose) 

- 



51 

The air blower and compressor 

operate normally, but the refrigeration 

is intermittent 

2. expansion valve (blocking ice) 

3. intermittent foreign matter 

blocking of system 



-

51-6 


3. the refrigeration is not enough 



2. relay (poor contact) 


- 

- 


panel/combination meter/cigar lighterinstrument 

panel, replacement 

The air volume is abnormal 


Chapter 51 heater and air conditionerair 


5. air blower (poor internal contact) 



The air volume is normal, but the 

compressor doesn’t operate normally. 

6. air flue (blocked) 


2. belt (slippery) 




flue, replacement 

- 

- 

- 


compressor, 

replacement 

5. reservoir (blocked) 

1. refrigerant (leaked) 


replacement 



The pressure at the high-pressure and 

low-pressure sides is low. 

2. expansion valve (the opening is 

too small or blocked) 

3. reservoir (the outlet is blocked) 


replacement 


replacement 

51 

The pressure at the high-pressure and 

low-pressure sides is high. 

The high pressure is low and the low 

pressure is high 

4. evaporator (frosted on the 

surface) 

1. refrigerant (too much) 

2. air is blended into the system 

3. condenser (the surface is covered 

with dirt) 

4. expansion valve (the opening is 

too big) 







- 


replacement 

1. compressor (damaged) Chapter 51 heater and air conditionerair-conditioner 

compressor, 

replacement


51-7 


1. reservoir (the inlet or the inside is 

blocked) 


replacement 

The high pressure is too high and the 

low pressure is too low 

Others 

2. condenser (blocked) 

3. the pipes between the reservoirs 

at the outlet of the compressor 

(blocked) 

1. temperature control switch 

(damaged) 

2. air cooling and heating door 

(damaged) 

Chapter 51 heater and air conditionercondenser, 

replacement 

Chapter 51 heater and air conditioning 

pipe- reservoir, replacement 





4. the noise of the refrigeration system is too big 


1. belt (too loose) 

2. compressor bracket (damaged) 


- 

- 



Noise outside the system 

4. refrigeration oil (the amount is too 

small or no oil at all) 


- 



6. air blower (the bearing is 

damaged and the fan contacts 

with other parts) 

Chapter 51 heater and air conditionerair- 

air blower, replacement 

1. refrigerant (too much or too less) 



Noise inside the system 

2. water vapor is in the system, 

which may cause noise in the 

expansion valve (slippery) 



51 

3. the pressure at the high-pressure 

side is too high, which may cause 

vibration of compressor. 


on-vehicle inspection

51-8 


5. no hot air or hot air is not enough 


1. air blower (damaged) 

2. air blower relay (damaged) 

3. hot air duct (detached) 


conditioner-air blower, replacement 

- 


flue, replacement 

Hot air is not provided. 

4. temperature control ventilation 

door (damaged) 

Chapter 51 heater and air conditionerhot 

air water tank, replacement 

5. water control valve (damaged) 


air water pipe, replacement 

Hot air is not enough 

6. control panel cable (detached) 

1. coolant liquid (not enough or 

blocked) 

2. heater core fin (distorted) 

3. heater pipeline (filth accumulated 

or air in it) 


panel/combination meter/cigar lighterinstrument 

panel, replacement 

- 


air water tank, replacement 


air water pipe, replacement 

51



51-9 

Inspection period 

Inspection item 

Content and object 

Daily 

After 6 months or 

driving for the first 

5,000 km 

After 12 months or 

driving for the first 

10,000 km 

Pipeline 

Bolt type 

The fastness is poor, having 

cracks. 

The connection and the nut 

are loose. 

Loose, detached and having 

cracks 

- ○ ○ 

○ ○ - 

- ○ ○ 

Loose and bent ○ - ○ 

Belt 

Worn, having scars and 

cracks 

Noise, burning smell and 

heating at the same time 

- ○ ○ 

- - ○ 

Condenser 

Air conditioner switch 

and temperature 

control 

The fin is damaged. - - ○ 

Blocked by foreign matter ○ ○ ○ 

Start the temperature control 

inspection and air output. 

○ - ○ 

Changing-over of air outlet - - - 

Leakage of 

refrigerant (including 

the leakage of 

refrigeration oil ) 

Refrigerant amount 

(window) 

Leakage of pipeline 

connections 

Leakage of parts 

(compressor, condenser, 

evaporator and reservoir) 

Inspect whether the 

refrigerant is not enough 

○ ○ - 

- - ○ 

○ - ○ 

Noise (working 

condition) 

Compressor - ○ - 

Idling of pulley - ○ - 

Air motor - ○ - 

Expansion valve - - ○ 

51 

The temperature of 

the outlet pipe of 

reservoir 

Air leakage 

The temperature difference 

is big: the reservoir is 

blocked 

The air outside flows 

backwards to the outlet (from 

the air blower). 

The heat from the hot air 

water tank gets in. 

- - ○ 

- - ○ 

- - ○

51-10 


low-pressure valve 

high-pressure valve 

(conducted) 

(non-conducted) (non-conducted) 

1. inspect the pressure switch 

(a). 


Inspect the operation of pressure switch. 

• install the manifold pressure gauge on the 

pipeline. 

• connect the positive pole of the multimeter 

(ohm grade) to pin 4 and the negative pole 

to pin 1. 

• inspect the switching between pins in 

accordance with the illustration when the 

pressure of refrigeration system changes. 

Replace with a new pressure switch when the operation 

condition doesn’t meet the standard. 


(conducted) 

(b). 

Radiator fan control: 

Inspect the operation of pressure switch. 

• connect the positive pole of the multimeter 

(ohm grade) to pin 2 and the negative pole 

to pin 3. 

• inspect the switching between pins in 

accordance with the illustration when the 

pressure of refrigeration system changes. 

Replace with a new pressure switch when the operation 

condition doesn’t meet the standard. 

2. electromagnetic clutch compressor assembly 

51 

(a). 

(b). 

Connect the positive pole of the compressor to the positive pole of battery and connect the 

negative pole of the compressor to the earthing of the vehicle. 

Inspect whether the electromagnetic clutch responses. 

Replace with a new compressor assembly when the operation condition doesn’t meet the standard.


51-11 

Inspection 

1. Fan switch assembly 

(a). 

Inspect the switching of the fan switch. 

Multimeter 


Switch 

position 


- OFF Non-conducted 

1-6 LO Conducted 

1-6-8 M1 Conducted 

1-5-8 M2 Conducted 

1-4-8 HI Conducted 

Replace with a new fan switch assembly when the 

switching condition doesn’t meet the standard. 

2. Air blower resistance 

(a). 

Measure the resistance value between the 

pins according to the table below. 

Multimeter connection pin 


1-2 2.93 Ω 

1-3 1.03Ω 

1-4 7.49Ω 

Replace with a new blower resistance when the 

resistance value doesn’t meet the standard. 

3. Air blower motor 

(a). 

Connect the positive pole of the battery to Pin 

2 and the negative pole to Pin 1 and inspect 

whether the motor can operate steadily. 

Replace with a new blower motor if the motor doesn’t 

operate normally. 

51 

4. Heater relay 

Multimeter 


Condition 


85-86 Normal Conducted 

30-87 

Input power 

supply voltage 

between Pin 85 

and Pin 85 

Conducted 

Replace with a new blower relay when the switching 

condition doesn’t meet the standard.

51-12 


5. Main relay of air conditioner 

Multimeter 


Condition 


1-2 Normal Conducted 

3-5 

Input power supply 


Pin 1 and Pin 2 

Conducted 

Replace with a new electromagnetic clutch relay when 

the switching condition doesn’t meet the standard. 

6. Hot air water tank 

Check whether there is leakage while filling coolant liquid into the hot air water tank. 

7. Air conditioning pipe 

Water submersion method: 

Fill dry nitrogen inside the pipeline, apply 3.5Mpa of pressure in the high-pressure pipe and 1.67 

Mpa of pressure in the low-pressure pipe, immerse the pipe in the water for 5 minutes and see 

whether bubbles appear on the surface. 

8. Evaporator 

Water submersion method: Seal 1.67 mpa of pressure in the evaporator, immerse it in the water for 

5 minutes and see whether bubbles appear on the surface. 

9. Condenser 

Water submersion method: Seal 3.5 mpa of pressure in the evaporator, immerse it in the water for 3 

minutes and see whether bubbles appear on the surface. 

51

Heater and air conditioner-air duct of instrument panel 

Air duct of instrument panel 

Replacement 

51-13 

1. Remove the instrument panel (refer to “chapter 73 instrument panel/combination 

meter/cigar lighterinstrument panel, replacement”) 

2. Remove the left defrost air duct 

(a). 

Loosen the bolt and remove the left defrost air 

duct. 

3. Remove the middle defrost air duct 

(a). 

Loosen the bolt and remove the middle defrost 

air duct. 

4. Remove the right defrost air duct 

(a). 

Loosen the 2 bolts and remove the right defrost 

air duct. 

51 

5. Remove the left air duct 

(a). 

Loosen the 2 bolts and remove the left air duct.

51-14 


6. Remove the middle air duct 

(a). 

Loosen the 4 bolts and remove the middle air 

duct. 

7. Remove the right air duct 

(a). 

Loosen the bolts and remove the right air duct. 

8. Install the left defrost air duct 

(a). 

Screw down the bolt and install the left defrost air 

duct. 

9. Install the middle defrost air duct 

(a). 

Screw down the bolt and install the middle 

defrost air duct. 

51 

10. Install the right defrost air duct 

(a). 

Screw down the 2 bolts and install the right 

defrost air duct.


51-15 

11. Install the left air duct 

(a). 

Screw down the 2 bolts and install the left air 

duct. 

12. Install the middle air duct 

(a). 

Screw down the 4 bolts and install the middle air 

duct. 

13. Install the right air duct 

(a). 

Screw down the 2 bolts and install the right air 

duct. 

51

51-16 

Hot air water pipe 

Parts diagram 


1 Hot Air Water Pipe 1 

2 Hot Air Water Pipe 2 

51 

3 Hexagon Head Bolt, 

4 Hexagon Nut, Style 1 

5 Heater Pipe Clamp 1 

6 Flat Washer 


8 Hot Air Water Drain Valve 

9 Cross Recess Head Screw 

10 

Transmission Type Hose Hoop of Type B 

Worm Gear 

11 Hot Air Water Pipe


51-17 

Replacement 

1. Discharge coolant liquid 

(a). 

(b). 

Open the hot air water drain valve and discharge 

the coolant liquid in the hot air water pipe. 

Discharge the engine coolant liquid (Refer to 

THE SERVICE MANUAL WITH ISF OF 

CUMMINS ENGINE) 

2. Remove hot air water pipe 1 and hot air water pipe 2 

(a). 

Remove the front mask assembly. (Refer to “chapter 77 internal/external trimming parts front 

mask assembly-replacement”) 

(b). 

Remove the hot air pipe clip. 

(c). 

(d). 

Turn over the driving cab. 

Loosen the 2 hose hoops and remove the hot air 

water pipe 1 and hot air water pipe 2. 

51

51-18 


3. Remove the hot water valve 

(a). 

Loosen the 4 hose hoops and remove the hot water valve. 

4. Remove the hot air water inlet pipe assembly 

(a). 

Loosen the 2 hose hoops and 1 hot air pipe clip and pull out the hot air water inlet pipe 

assembly from the hot air water pipe connector. 

51


51-19 

5. Remove the hot air water outlet pipe assembly 

(a). 

Loosen the 2 hose hoops and 1 hot air pipe clip and remove the hot air water outlet pipe 

assembly. 

6. Install the hot air water outlet pipe assembly 

(a). 

Set on the hot air water outlet pipe and screw down the 2 hose hoops and 1 hot air pipe clip. 

51

51-20 


7. Install the hot air water inlet pipe assembly 

(a). 

Set the hot air water inlet pipe assembly on the hot air water pipe connector and screw down 

the 2 hose hoops and 1 hot air pipe clip 

8. Install the hot water valve 

(a). 

Screw down the 4 hose hoops and install the hot water valve. 

51


51-21 

9. Install hot air water pipe 1 and hot air water pipe 2 

(a). Screw down the 2 hose hoops and install hot air water pipe 1 and hot air water pipe 2. 

(b). 

Install the hot air pipe clip. 

(c). 

Install the front mask assembly. (Refer to 

“chapter 77 internal/external trimming parts 

front mask assembly-replacement”) 

10. Add coolant liquid 

(a). 

Screw down the water drain valve. 

51 

(b). 

Add coolant liquid (Refer to the service manual 

with isf of cummins engine)

51-22 

Hot air water tank 

Parts diagram 

Heater and air conditioner-hot air water tank 

51 

1 12 V Control Mechanism Assembly 

2 AC Switch 

3 Flat Washer 

4 Cross Recessed Pan Head Tapping 

Screws-Type C 

5 Defrost Air Duct 


Screws-Type C 

7 Left Air Outlet Pipe of Hot Air Water Tank 


Screws-Type C 

9 Hot Air Water Tank assembly 



12 Flat Washer 

13 Hexagon Head Bolt, Spring Washer and Flat 

Washer Assembly Part 

14 Transition Air Duct 


Screws-Type C 

16 24V Air Blower Assembly 

17 Flat Washer 



20 12V Sing Row Evaporator Assembly

Overhaul 


1. Discharge coolant liquid 

(a). 

51-23 

Open the hot air water drain valve and discharge 

the coolant liquid in the hot air water pipe. 

(b). 

Discharge the engine coolant liquid (Refer to 

The service manual with isf of cummins engine) 

2. Remove hot air water pipe 1 and hot air water pipe 2 (refer to “chapter 51 heater and 

air conditionerhot air water pipe, replacement”) 

3. Remove the instrument panel (refer to “chapter 73 instrument panel/combination 

meter/cigar lighterinstrument panel,replacement”) 

4. Remove the instrument panel installation cross beam welding assembly 

(a). 

(b). 

(c). 

Remove the clutch fluid reservoir (refer to “chapter 32 clutch-clutch fluid reservoir, 


Remove the central defrost air duct (Refer to “chapter 51 heater and air conditionerair duct, 


Loosen the bolt and remove the instrument panel installation cross beam welding assembly. 

51

51-24 


51


51-25 

5. Remove the air conditioner control mechanism (refer to “chapter 51 heater and air 

conditioner- control mechanism, replacement”) 

6. Remove the evaporator (refer to “chapter 51 heater and air conditionerevaporator, 


7. Remove the transition air duct 

(a). 

Loosen the bolt and remove the transition air 

duct. 

8. Remove the hot air water tank assembly 

(a). 

Loosen the 2 nuts and remove the hot air water 

tank assembly. 

9. Remove the hot air water tank 

(a). 

Loosen the 3 bolts and remove the hot air water 

tank. 

10. Inspect the hot air water tank 

(a). 

Check whether there is leakage while filling 

coolant liquid into the hot air water tank. 

51 

(b). 

Inspect whether the fins of hot air water tank are 

straight, if they are distorted, flattened or collapsed, 

repair them with fin combs.

51-26 


11. Install the hot air water tank 

(a). 

Screw up the 3 bolts and install the hot air 

water tank. 

12. Install the hot air water tank assembly 

(a). 

Screw up the 2 nuts and install the hot air tank 

assembly. 

13. Install the transition air duct 

(a). 

Screw up the bolt and install the transition air 

duct. 

51 

14. Install the evaporator (refer to “chapter 51 heater and air conditionerevaporator, 


15. Install the air conditioner control mechanism (refer to “chapter 51 heater and air 

conditioner-control mechanism, replacement”)


51-27 

16. Install the instrument panel installation cross beam welding assembly 

(a). 

Screw down the bolt and install the instrument panel installation cross beam welding 

assembly. 

51

51-28 


51 

(b). Install the clutch fluid reservoir (Refer to “chapter 32 clutch-clutch fluid reservoir, replacement”)


51-29 

17. Install instrument panel (refer to “chapter 73 instrument panel/combination meter/cigar 

lighterinstrument panel, replacement”) 

18. Install hot air water pipe 1 and hot air water pipe 2 (refer to “chapter 51 heater and air 

conditionerhot air water pipe, replacement”) 

19. Fill coolant liquid 

(a). 

Screw down the hot air water drain valve 

(b). 

Fill coolant liquid of engine (Refer to the service 

manual with isf of cummins engine) 

51

51-30 

Heater and AC-Refrigerant oil 

Refrigerant 

Inspection on vehicle 

It is better to have suitable pressure inside of AC system for leak detection and the pressure should 

reach to at least 0.34MPa. But it is not allowed to charge compressed air into AC system; otherwise 

the moisture, dust and other impurities in the air will increase the burden of dryer or contaminate 

system. There are following methods to check if the refrigerant air is leaking: 

Notes: 

Partial refrigerant will stay inside of refrigerant oil of compressor if AC system is evacuated 

when there is refrigerant left in the system. This kind of left refrigerant will evaporate 

continuously which will cause the reading of pressure meter increases a little during leak 

detection (at most 2 scale divisions); but the increased pressure does not mean there is 

leaking in the AC system. 

1. Measure refrigerant pressure by manifold pressure meter 

(a). 

This method is used to find out where the malfunction is by manifold pressure meter. Read 

the numerical value of manifold pressure meter when the following conditions are met. 

Test conditions: 

Air intake temperature is 30 ~ 35 ℃ 

Engine speed is 1500rpm 

Blower speed is on HI shift 

Thermostat switch is on COOL shift 

AC switch is on ON 

Door is opened completely 

• Normal working conditions of refrigerating 

system. 

Readings of pressure meter: 

Low pressure side: 0.15 ~ 0.25 MPa 

High pressure side: 1.37 ~ 2.37 MPa 

51


• There is vapor inside of the system 

51-31 

Condition: not refrigerated 

continuously 

Phenomenon Possible reasons Diagnosis Measures 

The pressure of low 

pressure side is vacuum 

sometimes and sometimes 

it is normal during running. 

Vapor inside of refrigeration 

system is frozen in the hole 

of expansion valve causing 

the return circuit stops 

working temporarily. It 

resumes working when the 

ice is melt. 

Liquid reservoir is 

supersaturated. 

Vapor is frozen in the hole 

of expansion valve, so the 

refrigeration is blocked. 

1. Replace condenser. 

2. Exhaust the vapor 

inside of circuit by 

compressed air. 

3. Supplement some 

refrigerant. 

• Refrigeration insufficiency 

Condition: effect of refrigeration 

system is insufficient 


The pressures of low 

pressure side and high 

pressure side are low. 

It is expressed as 

refrigeration insufficient. 

There is leak inside of 

refrigeration system. 

Refrigerant is not enough. 

1. Check the leak position 

and repair it as 

necessary 

2. Supplement some 

refrigerant 

3. When connect 

compressortable, 

Evacuate it into 

vacuum afteroverhaul if 

the pressure value 

displayed reaches to 0. 

51

51-32 


• Circulation of refrigerant is not smooth 


system is insufficient 




pressure side are low. 

Condenser is frosted 

Condition: refrigeration system 

is not working (sometimes it 

works) 

Refrigerant is clogged by 

dirt 

The system is clogged 

• Refrigerant is not circulated 

Replace the condenser 


51 

It is vacuum at low pressure 

side, and the pressure of 

high pressure side is very 

low. 

It is frosted or there is ice on 

the pipeline of front and rear 

side of condenser/dryer or 

expansion valve. 

The flow of refrigerant is 

blocked by vapor or dirt. 

The flow of refrigerant is 

blocked by the leak of 


Refrigerant can not 

circulate. 

1. Check expansion valve. 

2. Clear away the dirt inside 

of expansion valve by 

compressed air. 

3. Replace condenser. 

4. Make it vacuum and 

supplement some 

refrigerant. 

5. Replace the expansion 

valve if it is leaking.


51-33 


is insufficient 

• Refrigerant is excessive or the heat elimination of 

condenser is bad 




pressure side are high. 

Excessive refrigerant 

causes insufficient 

refrigeration. 

Heat elimination of 

condenser is bad 

Refrigerant is excessive. 

Condenser is dirty. 

Fan of condenser is broken. 

1. Clean the condenser 

2. Check the fan of 

condenser. 

3. Check the quantity of 

refrigerant and fill some 

refrigerant if condenser 

and fan work properly. 

• There is air inside of refrigeration system 

Condition: 

refrigeration 

does not work 

system 

Note: the readings displayed on the 

meters are when refrigeration 

system is started and the refrigerant 

is replaced but it is not in vacuum 





Low pressure pipe is too 

hot. 

There is air inside of 


There is air inside of 


Degree of vacuum is not 

enough. 

1. Check if the 

refrigeration oil is dirty 

or insufficient. 

2. Make it vacuum and 

refill the refrigerant. 

51

51-34 


• Malfunction of expansion valve 


is insufficient 





There is frost or large 

quantity of dew on the 

pipeline of low pressure 

side. 

There is problem on 


There is excessive 

refrigerant in low pressure 

pipe. 

The opening of expansion 

valve is too big. 

• Malfunction of compressor 

Check and replace 


Condition: it is not 

refrigerated 



pressure side is too high 

The pressure of high 

pressure side is too low. 

Inside of compressor is 

leaking. 

Malfunction of compressor. 

It is leaking on the position 

of damaged valve or moving 

part. 

Repair or replace the 

compressor 

51

Reading of pressure meter (reference value) 


51-35 

Pressure of low pressure side 

High speed area of fan 

Low speed area of fan 

Pressure of high 

pressure side 

2. Leak detection by soap lye 

For the bigger leak on the connection position of refrigerant pipe, it can be checked by spraying 

soap lye by sprayer to observe if there is air bubble generated on its surface. This method is simple 

and convenient but it can not find the tiny leak. 

3. Leak detection by non-specific detector 

This kind of detector can check all kinds of liquid or gas leak and take no account of the chemical 

element of the detected object. It has the advantages of convenient, stable and low cost. But it can 

not be used for area detection. 

4. Leak detection by halogen leak detector 

It is equipped with special sensor so it can detect the trace compound of fluorine, chlorine, bromine 

and iodine in the air but without disturbance. Its biggest advantage is high sensitivity which can 

decrease the misinformation efficiently. The lowest detection limit is lower than 5g/year for area 

detection; and lower than 1.5g/year for spot detection (the leakage of one leak point every year is 

1.5g). 

5. Leak detection by special electronic leak detector 

This kind of detector is complicated and expensive, and it can detect some special compound 

sensitively without disturbance by other objects. For example: R-134a special leak detector which is 

with high sensitivity and high selectivity, it can find the leak point accurately and it can recognize if 

the refrigerant is R-134a; pay attention to the contamination around during application because it is 

so sensitive, otherwise there may be misinformation reported. 

6. Leak detection by fluorescent dye 

Fluorescent dye can produce fluorescence under the irradiation of ultraviolet rays; put this kind of 

dye into refrigerant oil or refrigerant, and the leak point will be found clearly under irradiation of 

ultraviolet lamp when there is leak inside of the system. 

51

51-36 

Replace 

1. Exhaust the refrigerant 

(a). 

(b). 

(c). 

Turn on the AC switch. 


Run the engine 5 to 6 minutes at 1000rmp to make the refrigerant flow; and collect the 

refrigerant oil in every part to compressor as possible. 

Stop the engine. 

(d) 

Hint: 

Reclaim the refrigerant. 

Do not exhaust the refrigerant into air because it will 

pollute the environment. 

51 

3. Air tightness inspection 

(a). 

2. Evacuate to vacuum 

(a). Connect dual manifold pressure meter, 

refrigerant filling pipe and vacuum pump together 

and evacuate to vacuum. 

(b). 

(c). 

First open the high pressure and low pressure 

valves of the pressure meter, then open the valve 

of vacuum pump (if there is) when the evacuation 

begins. 

Turn the switch of vacuum pump to ON position 

and evacuate more than 20m; turn off high/low 

pressure valves of the pressure meter and the 

switch of vacuum to stop vacuum pump when the 

pressure displayed on the meter reaches to or 

near to -760mmHg. 

Notes the reading of pressure meter and check the pressure inside of the circuit 5 minutes 

after vacuum pump is stopped; continue the next step when it is confirmed that the reading is 

not changed. Repair the leak and then evacuate if the pressure increases (the speed of 

increase is related with the scale of leak).

4. Fill refrigerant 


51-37 

Start the vacuum pumping; 

More than 20m 

Stop the vacuum pumping 

Place it 5m 

Air tightness inspection 

Pressure 

displayed on 

the meter is 

proper 

Fill in refrigerant 

Inspection of air leak 

Fill in refrigerant 

Pressure 

displayed on 

the meter is 

abnormal 

Fill in refrigerant until 0.1Mpa. All 

of above should be at gas state. 

inspection and correction of 

connection part 

(a). 

(b). 

Connect the yellow charging pipe in the middle of pressure meter with gas service tank of 

refrigerant after making sure there is no air leak. 

Make sure the nut on air charging valve of service tank is tight. Discharge the air and make 

refrigerant flow into circuit. Press the air port on the side of pressure meter by screwdrivingr 

for 1-2 seconds to discharge refrigerant and exhaust the air from charging pipe and pressure 

meter. 

(c). 

(d). 

(e). 

Open the high pressure valve of pressure meter 

and fill in refrigerant from high pressure side 

circuit. Now Notes the finger movement of 

pressure meter and make sure the fingers of 

high/low pressure meter increases stably. Check 

if the connection parts of rubber tubes are loose 

or if the sealing port is damage, and repair them 

if there are. 

Close high pressure valve and start the engine 

when pressure meter stops increasing. 

Turn AC switch to ON position; turn switch of 

temperature control to the coldest and wind 

volume of air sending port to the biggest. Open 

all doors and windows, and switch the 

inside/outside circulation to inside circulation. 

51

51-38 


51 

(f). 

(g). 

Service tank (or compressed air container) 

should be placed vertically (because the 

refrigerant will be charged by gas state); 

open the low pressure valve of pressure 

meter to fill in refrigerant continuously. High 

pressure valve is absolutely not allowed to 

be opened when the compressor runs, 

otherwise the refrigerant will be charged 

reversely, and the service tank will be 

damaged easily. 

Fill in refrigerant according to the specified 

quantity of AC system. Observe the high/low 

pressure value of pressure meter and the 

flowing state of refrigerant (transparent, with 

bubble or turbid), if there is no specified filling 

quantity, to estimate the time to stop filling. 

Standard value: 500±50g 

You should set the basic conditions if the filling 

quantity needs to be estimated by yourself: 

(h). 

· Water temperature of radiator: keeping 

at a stable state 

· AC switch: ON 

· Thermostat: regulate the temperature of 

intake air of inside circulation to 25-30℃ 

· Fan switch: HI position 

· Switch of inside/outside circulation: 

inside circulation 

· Door: all opened 

· Window: all opened 

· Estimated filling quantity of refrigerant 

Turn the AC switch to OFF when the above 

mentioned filling process is finished; and turn 

AC switch to ON position and make 

judgment when it comes back to balance 

pressure state. 

The state with bubbles: there will be bubbles 

generated when it is gaseous and liquid refrigerant 

mixed. 

Transparent state: it will be transparent state when 

the refrigerant is only liquid. 

Turbid state: it will be displayed a thin layer of milk 

white when oil is separated from refrigerant. 

Turbid state with bubbles: it will be displayed a thin 

layer of milk white with bubbles when gaseous 

refrigerant is mixed with separated oil.

Filling quantity of refrigerant 


State of windows (about 1 minute 

after AC is turned on) 

51-39 

Pressure on high pressure side 

Appropriate 

1.8 ~ 2.5 MPa 

Excessive 

> 2.5 MPa 

Insufficient 

1.2 MPa 

(i). 

(j). 

(k). 

The states of above windows are general conditions seen by naked eyes; sometime it is 

difficult to judge the state of window because of the environmental conditions, so the 

pressure changes of high pressure side should be checked at the same time (that is 

excessive filling will cause the pressure increases sharply). 

Notes the state changes of refrigerant inside of window and the pressure value changes on 

the pressure meter of high pressure side during refrigerant filling. 

Close the low pressure valve first when refrigerant filling is finished, then turn off the switch 

on fast connector (if there is), and take off the fast connector of filling pipe quickly from filling 

port; at the same time close the cover of charging valve in order to prevent air leaking. 

5. Run engine to normal working temperature 

6. Check if the refrigerant is leaking (refer to “Chapter 51 Heater and AC-Refrigerant, 

Inspection”) 

51

51-40 

Refrigerant oil 

Inspection 


1. Antitheses: take standard refrigerant oil and put it into test tube as standard oil, then 

take the refrigerant oil to be checked and put it into test tube with same size for 

comparison; if the color of checked oil is buff or orange, which means the oil is ok; if 

the color changed to henna cloudy liquid, which means it can not be used any more. 

2. Paper dripping method: take one drop from the refrigerant oil to be checked and drip it 

onto a piece of clean and white paper; after a while, observe its color, if the color is 

shallow and the oil is distributed evenly it means it can be used; if there are black 

specks in the middle of oil drop, it means the oil had degenerated and it can not be 

used. 

51

Replacement 


51-41 

1. Discharge the refrigerant (refer to “Chapter 51 Heater and AC-Refrigerant, 

Replacement”) 

2. Discharge the refrigerant oil 

(a). 

(b). 

Disassemble the compressor (refer to “Chapter 51 Heater and AC-compressor, 


Pour out refrigerant oil from compressor. 

3. Fill in refrigerant oil 

(a). 

(b). 

Install compressor (refer to “Chapter 51 Heater and AC-compressor, Replacement”). 

Fill in refrigerant oil according to specified quantity. 

Standard value: 180ml 

• Normally for new AC system, it does not need to fill extra refrigerant oil, because 

inside of new compressor there is stored all necessary refrigerant oil required by the 

complete system (14%-18% of the refrigerant inside of AC system). It will need filling 

refrigerant oil if the AC system is repaired more than two times or there is refrigerant 

oil deficient caused by other reasons. Supplement some refrigerant oil after the 

replacement of system. 

Name of replaced part 

Compressor 

Evaporator 

Liquid reservoir 

Refrigerant oil quantity to be supplemented 

It does not need filling in grease because there are 180ml grease brought by 

compressor 

40 ~ 60 ml 

10 ~ 30 ml 

Condenser 

No oil leak mark 

There is oil leak mark 

0 ~ 30 ml 

40 ~ 60 ml 

Hose 

Air leak of the system 

No oil leak mark - 


40 ~ 60 ml 

No oil leak mark - 


80ml 

Replace the pipe of complete system 

40 ~ 60 ml 

4. Fill in refrigerant (refer to “Chapter 51 Heater and AC-Refrigerant, Replacement”) 




51

51-42 

AC pipe 

Part diagram 

Heater and AC-AC Pipe 

1 Condenser assembly 

12 Cooler 

2 Steam pipe assy 

3 Steam pressure pipe assy 

4 Reservoir assy 

51 

5 Fixed bracket of liquid reservoir 

6 Cold storage pipe assy 

8 Steam pipe assy 

9 Pressure plate 

10 Condenser support 1 

11 Condenser support 2

Inspection 


51-43 

1. Full the pipeline with dry nitrogen; high pressure pipe uses 3.5MPa pressure and low 

pressure pipe uses 1.67MPa pressure; immerse the pipe into water 5 minutes and 

observe if there is air bubble on its surface. 

51

51-44 

Replacement 

Notess: 


There should be cover on the end face of AC pipe before connection for protection; 

especially the liquid reservoir is with high moisture absorption ability so that it should be 

assembled at last. Coat compressor oil on the top of connection pipe where O ring sits to 

avoid O ring from damage. Inlet and outlet of evaporator, and the AC pipe of high pressure 

side should be wrapped by heat insulation material to avoid the heat influence from 

environment. 

1. Discharge refrigerant (refer to “Chapter 51 Heater and AC-Refrigerant, Replacement”) 

2. Disassemble compressor-condenser pipeline assembly. 

(a). 

Loose compressor pipe clamp, AC pipe clamp and condenser pipeline to disassemble 

compressor-condenser pipeline assembly. 

51


3. Disassemble condenser- reservoir pipeline assembly 

(a). 

51-45 

Loose AC pipe clamp and pipeline connector to disassemble condenser- reservoir pipeline 

assembly. 

4. Disassemble reservoir-evaporator pipeline assembly 

(a). 

Loose reservoir pipeline, AC pipe clamp and evaporator pipeline connector to disassemble 

reservoir-evaporator pipeline assembly. 

51


51-47 

5. Disassemble evaporator-compressor pipeline assembly 

(a). Loose AC pipe clamp, evaporator pipeline connector and compressor pipe clamp to 

disassemble evaporator-compressor pipeline assembly. 

6. Assemble compressor-condenser pipeline assembly 

(a). Make O ring wet by refrigerant oil; fasten compressor pipe clamp, AC pipe clamp and the 

condenser pipeline connector to assemble compressor-condenser pipeline assembly. 

Torque: 15 ± 5 N•m (Φ9 aluminum pipe) 


Torque: :30 N•m (Φ16 aluminum pipe) 

51

51-48 


7. Assemble condenser- reservoir pipeline assembly 

(a). 

Make O ring wet by refrigerant oil; fasten condenser- reservoir pipeline connector and fasten 

AC pipe clamp 



Torque: 30 N•m (Φ16 aluminum pipe) 

51


8. Assemble reservoir-evaporator pipeline assembly 

(a). 

51-49 

Make O ring wet by refrigerant oil; fasten reservoir pipeline connector, AC pipe clamp and 

evaporator pipeline connector to assemble reservoir-evaporator pipeline assembly. 



Torque:30 N•m (Φ16 aluminum pipe) 

51

51-50 


9. Assemble evaporator-compressor pipeline assembly 

(a). 

Make O ring wet by refrigerant oil; fasten AC pipe clamp and evaporator pipeline connector 

and compressor pipe clamp to assemble evaporator-compressor pipeline assembly. 



Torque:30 N•m (Φ16 aluminum pipe) 





51

Evaporator 

Parts diagram 

Heater and AC-Evaporator 

51-51 

51

51-52 

Overhaul 

Notess: 


The evaporator is assembled under the instrument panel where a lot of parts of locate (there 

is control wire circuit, control box and meters etc.), so please be careful during assembly not 

to damage those parts. Think about the insert angle of drainpipe and make the condensation 

water discharged to outside of vehicle smoothly. For the installation of expansion valve 

temperature sensing part, please pay more attention to that during assembly because it will 

influence the opening degree and sensitivity of the expansion valve: the temperature 

sensing part of expansion valve and outlet pipe of evaporator should be fixed by clamp. 

Wrap expansion valve temperature sensing part by heat insulation material in order to avoid 

it from contact with outside air. Different models of thermistor will generate different reaction 

temperatures which will cause bad effects like frost or cut off earlier etc.; so the thermistor 

matching with amplifier should be used. 


2. Disassemble front cover assembly (refer to “Chapter 77 Inner/outer trimming 

parts-Front cover assembly, Replacement”) 

3. Disconnect the connection of AC pipe 

(a). 

(b). 

Screw off the bolt from AC pipe clamp 

Loose connection nut of AC pipe. 

4. Disassemble the instrument panel (refer to “Chapter 73 Instrument panel/combined 

meters/cigar liter-Instrument panel, Replacement) 

5. Disassemble instrument panel installation cross member welding assembly (refer to 

“Chapter 51 Heater and AC-Heater, Replacement”) 

6. Disassemble evaporator assembly 

(a). 

Loose 2 bolts and disasemble fuse box. 

51 

(b). Disconnect inserts and loose 5 bolts to 

disassemble evaporator assembly.


51-53 

7. Disassemble thermostat switch 

(a). 

Loose the clamp of thermostat switch and take 

off thermostat switch. 

8. Disassemble evaporator 

(a). 

Loose 4 bolts and 4 clamps; open the shell of evaporator and take out evaporator. 

9. Disassemble evaporator pipeline assembly 

(a) 

Loose bolt and disassemble evaporator pipeline 

assembly. 

51

51-54 


10. Disassemble expansion valve 

(a). 

Loose 2 hexagon socket bolt and disassemble 


11. Assemble expansion valve 

(a). 

(b) 

Lubricate new O ring by grease and install it 

onto evaporator. 

Fasten 2 hexagon socket bolt and assemble 


12. Assemble evaporator pipeline assembly 

(a). 

(b). 

Lubricate O ring by grease and install it onto 

evaporator pipeline. 

Fasten bolt and assemble the evaporator 

pipeline. 

51


13. Assemble evaporator 

(a). Put evaporator into its housing, put on 4 clamps and fasten 4 bolts. 

51-55 

14. Assemble thermostat switch 

(a). 

Hint: 

Lock the clamp of thermostat switch. 

Distance between thermostat switch and surface of 

core is 8-10mm. 

15. Assemble evaporator assembly 

(a). 

Fasten 5 bolts, connect the inserts and 

assemble evaporator assembly. 


51

51-56 


(b). 

Fasten 3 bolts and assemble fuse box. 

16. Assemble instrument panel installation cross member welding assembly (refer to 

“Chapter 51 Heater and AC-Heater, Replacement”). 

17. Assemble instrument panel (refer to “Chapter 73 Instrument panel/combined 

meters/cigar liter-Instrument panel, Replacement). 

18. Connect AC pipe 

(a) 

(b). 

Fasten connection nut of AC pipe to connect AC 

pipe. 



Torque: :30 N•m (Φ16 aluminum pipe) 

Fasten bolt and install the AC pipe clamp. 

19. Assemble front cover assembly (refer to “Chapter 77 Inner/outer trimming parts-Front 

cover assembly, Replacement”) 

20. Fill in refrigerant (refer to “Chapter 51 Heater and AC-Refrigerant, Replacement) 




51

AC compressor 

Parts diagram 

Heater and AC- AC compressor 

51-57 

51

51-58 

Overhaul 

Heater and AC-AC compressor 


2. Disassemble compressor 

(a). Loose tension wheel and disassemble compressor belt (refer to “Service Manual of ISF 

Series Cummins Engine”). 

(b). Loose bolt and disassemble compressor pipeline 

and O ring. 

(c). 

Disconnect inserts and loose 3 bolts to 

disassemble compressor. 

3. Disassemble electromagnetic clutch of compressor 

(a) Place electromagnetic clutch onto bench vice. 

(b). Fix electromagnetic clutch by bench vice. 

(c). Disassemble bolt and disassemble the pressure 

plate. 

51 

(d). 

Disassemble clamp by clamp pliers and take off 

belt pulley.


51-59 

(e). 

Disassemble clamp by clamp pliers and take off 

electromagnet. 

4. Assemble electromagnetic clutch of 

compressor 

(a). 

Hint: 

Assemble electromagnet. 

Align with the installation mark. 

(b). 

Use a new clamp. 

(c). 

Notes: 

Assemble belt pulley and use a new clamp. 

Do not change the combination state before 

disassembly of the electromagnetic clutch. 

51 

(d). 

(e). 

Install compressor onto bench vice. 

Fix the electromagnetic clutch by bench vice 

and fasten the bolt.

51-60 

Heater and AC-AC compressor 

6. Inspect refrigerant oil 

(a). 

Notes: 

5. Check the clearance of electromagnetic 

clutch 

(a). 

Electrify the electromagnetic clutch. Measure the 

clearance by turning on and turning off 

electromagnetic clutch. 

Standard value: 0.35-0.60mm 

Disassemble the pressure plate and adjust the belt 

pulley if the measured value is out of standard range. 

Notes : 

The adjustment should be less than 3 times. 

For the replaced new compressor, first discharge gaseous refrigerant gradually and then 

pour out refrigerant oil inside of new compressor before installation according to the following 

standard. 


Refrigerant oil quantity of new compressor- residual refrigerant oil quantity inside of 

old compressor = oil quantity needs to be poured out from new compressor. 

· Pay attention to the disassembly and assembly notices during oil quantity inspection. 

· There is residual refrigerant oil inside of vehicle pipeline, so if one new compressor is 

assembled without pouring out partial refrigerant oil, the oil inside of system will be 

excessive; this will influence the heat exchange rate of refrigeration circuit and cause 

malfunction. 

· Check if the refrigerant oil is leaking if the residual oil quantity is little inside of 

disassembled compressor. 

· Make sure it is the correct refrigerant oil. 

7. Assemble compressor 

(a). 

Fasten 3 bolts to install the compressor. 


51 

(b). 

(c). 

Make O ring wet by refrigerant oil and install it 

onto pipeline. 

Fasten the bolt and assemble compressor 

pipeline. 


(d). 

Fasten the bolt and assemble compressor belt


51-61 

8. Fill in refrigerant (refer to “Chapter 51, Heater and AC-Refrigerant, Replacement”). 




51

51-62 

Air Blower 

Replacement 

Heater and AC- Blower 

1. Disassemble instrument panel (refer to “Chapter 73 Instrument panel/combined 

meters/cigar liter-Instrument panel, Replacement) 

2. Disassemble washer (refer to “Chapter 55 Wiper and Washer-Washer, Replacement”) 

3. Disassemble blower assembly 

(a). 

Loose 4 clips to disassemble the blower 

assembly. 

4. Disassemble the blower motor 

(a). 

Loose 3 bolts to disassemble the blower motor. 

5. Assemble the blower motor 

(a). 

Fasten 3 bolts and assemble the blower motor. 

51 

6. Assemble of blower assembly 

(a). 

Clamp 4 clips and assemble blower assembly. 

7. Assemble washer (refer to “Chapter 55 Wiper and Washer-Washer, Replacement”). 

8. Assemble instrument panel (refer to “Chapter 73 Instrument panel/combined 

meters/cigar liter-Instrument panel, Replacement).

Condenser 

Parts diagram 

Heater and AC- Condenser 

51-63 

51

51-64 



1. Check condenser assembly 

(a). Clean the condenser fin by water if it is dirty, and dry it by compressed air. 

Notes: 

Do not damage the condenser fin. 

(b). Fix the condenser fin if it is deformed by fin comb. 

2. Check if there is refrigerant leaking of the condenser assembly 

(a). Check if there is gas leaking on the pipeline connector by leak detector. 

(b). Check the torque value of the connector if there is gas leaking of the connector. 

51

Overhaul 

Notes: 


51-65 

Condenser is a kind of heat exchanger, so there are lots of fragile parts on structural and 

material aspects (especially for the heat radiator parts); so do not make them collide or fall 

them down during assembly and disassembly. 

1. Disassemble condenser fan 

(a). 

(b). 

Disconnect 1 insert part. 

Loose 4 bolts to disassemble condenser fan. 

2. Disassemble condenser 

(a). 

(b). 

(c). 

Discharge refrigerant (refer to “Chapter 51 Heater and AC-Refrigerant, Replacement”) 

Disconnect the connection of compressor-condenser pipeline (refer to “Chapter 51 Heater 

and AC pipe, Replacement”). 

Disconnect the connection of condenser-liquid reservoir pipeline (refer to “Chapter 51 Heater 

and AC pipe, Replacement”). 

(d). 

Loosen 4 bolts and disassemble the condenser. 

3. Assemble the condenser 

(a). 

Notes: 

Fasten 4 bolts and assemble the condenser. 

Take care of the pipeline and bracket about the 

installation position. First adjust the position of 

front/rear, up/down and left/right, but do not fasten 

them until the pipeline of entry is assembled. 

(b). 

(c). 

Connect the pipeline of condenser- reservoir 

(refer to “Chapter 51 Heater and AC-AC pipe, 


Connect the pipeline of compressor-condenser 

(refer to “Chapter 51 Heater and AC-AC pipe, 


51

51-66 


4. Assemble the condenser fan 

(a). Fasten 4 bolts and assemble condenser fan. 


(b) Connect 1 insert part. 





51

Liquid reservoir 

Replacement 

Heater and AC- Liquid Reservoir 

51-67 


2. Disassemble pressure switch 

(a). 

Disconnect insert parts and take off pressure 

switch. 

3. Disassemble liquid reservoir 

(a). 

(b). 

Disconnect condenser- reservoir pipeline (refer to “Chapter 51 Heater and AC-AC pipe, 


Disconnect reservoir-evaporator pipeline (refer to “Chapter 51 Heater and AC-AC pipe, 


(c). 

Loose the bolt of fixation clamp to disassemble 

the liquid reservoir. 

4. Assemble liquid reservoir 

(a). 

Fasten the bolt of fixation clamp to assemble the 

liquid reservoir. 

51 

(b). 

(c). 

Connect reservoir-evaporator pipeline (refer to “Chapter 51 Heater and AC-AC pipe, 


Connect condenser-reservoir pipeline (refer to “Chapter 51 Heater and AC-AC pipe, 

Replacement”).

51-68 

Heater and AC- Liquid Reservoir 

5. Assemble pressure switch 

(a). 

Fasten pressure switch and connect the insert 

parts. 

Torque:10.8 N·m 




Inspection”). 

51

Heater and AC- Control Mechanism Assembly 

Control mechanism assembly 

Parts diagram 

51-69 

51

51 

51-70 

Replacement 

Heater and AC- Control Mechanism Assembly 

1. Disassemble control mechanism assembly 

(a). 

Screw off the bolt and take out control mechanism assembly (refer to “Chapter 73 Instrument 

panel/combined meters/cigar liter-Instrument panel, Replacement). 

(b). 

Notes: 

Open the clip and disassemble the control cable 

of defroster. 

Be careful and do not bend the cable. The control to 

control mechanism will become difficult if the cable 

is bent. 

(c). 

Notes: 

Open the clip by screwdrive to disassemble the 

mixed throttle control cable. 



is bent. 

2. Assemble the control mechanism assembly 

(a). 

Notes: 

Assemble mixed throttle control cable onto 

throttle control rod and clip. 



is bent. 

Hint: 

Operate the control rod of mixed throttle, and move the 

mixed throttle to the coldest and the hottest positions; 

check if they are at correct positions and not rebounded. 

Check if there is movement when cable is pulled. 

(b). 

Notes: 

Assemble control cable of defroster onto control 

rod and clip. 



is bent. 

Hint: 

Operate the control rod of defroster, and check if they 

are at correct positions and not rebounded when it is 

moved to specified position. 

Check if there is movement when cable is pulled. 

(c). 

Connect the insert part to assemble control 

mechanism assembly (refer to “Chapter 73 

Instrument panel/combined meters/cigar 

liter-Instrument panel, Replacement).

51-2 

- Memorandum - 

VOLUME 2 : BJ1099 

52

Safety Belts 

Safety belt of driver’s seat ................................. 52-1 

Notes .............................................................. 52-1 

Parts diagram ................................................. 52-2 

Replacement .................................................. 52-3 

Safety belts of middle and co-driver's seat......52-7 

Parts diagram ................................................. 52-7 

Replacement .................................................. 52-8 

Buckles of driver’s seat and middle seat ......... 52-9 

Parts diagram ................................................. 52-9 

Replacement ................................................ 52-10 

52

Safety belt-Safety belt of driver’s seat 

Safety belt of driver’s seat 

Notes 

52-1 

1. Performance requirement of WOVEN TAPE: the surface should be clean, smooth and with 

good hand feeling; WOVEN TAPE should be even, no stain, no crack, no burrs or defects. 

2. Performance requirement of the retractor: it should furl the belt freely and automatic 

restoration on installation angle. 

3. Performance requirement of the adjustment part: it should be adjusted conveniently; the 

belt can not be released automatically; it should be safety and reliable. 

4. Performance requirement of the buckle: the process of buckle tongue inserting into 

buckle and opening the buckle should be felt in position obviously; the buckle can not be 

unlocked automatically and the assembly should be in effect. 

52

52-2 

Parts diagram 


1 Safety belt of driver’s seat assembly 

52

Replacement 


52-3 

1. Disassemble WOVEN TAPE retractor 

assembly 

(a). 

Disassemble trimming cover of the bolt. 

(b). 

Loose the safety belt bolt on the middle pillar. 

(c). 

(d). 

Turn back the cushion of rear seat. 

Take out inner trimming plate by pulling it 

outwards. 

Hint: Take out the inner trimming plate directly if there is 

only one row of seat. 

(e). 

Loose the bolt of WOVEN TAPE belt retractor. 

52


52-5 

(f). 

Loose the fixation bolt the end of the floor , and 

take off safety belt assembly for replacement. 

2. Assemble woven tape belt retractor assembly 

(a). Fasten the fixation bolt the end of floor . 


(b). 

Fasten the bolt of WOVEN TAPE belt retractor 

assembly. 


Hint: align the limit hole with limit pin during the 

installation of WOVEN TAPE belt retractor 

assembly. 

(c). 

Knock the inner trimming plate slightly and make 

it to its position. 

52

52-6 


(d). 

Install the bolt of safety belt on middle pillar. 


(e). 

Assemble the trimming plate of bolt. 

3. Disassemble the safety belt of co-driver’s seat 

Hint: 

The steps to disassemble safety belt of co-driver’s seat are same to that of safety belt of driver’s 

seat. 

52

Safety belt-Safety belt of middle seat and safety belt buckle of co-driver’s seat 

52-7 

Safety belts of middle and co-driver’s seats 

Part diagram 

1 Safety belt of middle seat and safety belt buckle of co-driver’s seat 

52

52-8 

Replacement 

Safety belt-Safety belt of middle seat and safety belt buckle of co-driver’s seat 

1. Disassemble the cushion of co-driver’s seat (refer to “Chapter 74- Cushion of 

co-driver’s seat, Replacement). 

2. Disassemble the safety belt of middle seat 

(a). 

Loose the fixation nut, and take off safety belt of 

middle seat and safety belt buckle of co-driver’s 

seat. 

3. Assemble the safety belt of middle seat 

(a). 

Fasten the fixation nut, and assemble safety belt 

of middle seat and safety belt buckle of 

co-driver’s seat. 


4. Assemble the cushion of co-driver’s seat (refer to “Chapter 74- Cushion of co-driver’s 

seat, Replacement). 

52

Safety belt- Buckles of driver’s seat and middle seat 

Buckles of driver’s seat and middle seat 

Part diagram 

52-9 

1 

Buckles of driver’s seat and middle 

seat 

52

52-10 

Replacement 

Safety belt- Buckles of driver’s seat and middle seat 

1. Move the seat 

(a). Move seat to the front end of the guide rail. 

2. Disassemble buckle of driver’s seat 

(a). 

Loose the bolt to take off both buckles of driver’s 

seat and middle seat. 

3. Assemble buckle of driver’s seat 

(a). 

Fasten the bolt to assemble buckles of driver’s 

seat and middle seat. 


52 

4. Move the seat 

(a). 

Sleek seat to the original position.

Battery 

Battery.................................................................... 53-1 

Definition ........................................................ 53-1 

Structure ......................................................... 53-2 

Working principle ........................................... 53-5 

Application and maintenance ......................... 53-7 

Basic inspection ............................................ 53-11 

Analysis of common malfunction 

phenomenon and troubleshooting ............... 53-13 

Part diagram ................................................. 53-16 

Replacement ................................................ 53-17 

Electrolyte............................................................ 53-19 

Preparation ................................................... 53-19 

Fill ................................................................. 53-23 

53

53

Battery 

Definition 

Battery-Battery 

53-1 

Lead-acid battery is kind of acid battery which takes thin sulfuric acid as electrolyte, lead dioxide as 

positive pole and spongy lead as negative pole. 

53

53-2 

Structure 


Lead-acid battery is mainly composed of positive/negative plate, separator, sulfuric acid electrolyte, 

and battery case. 

1 Blow-off coch 

2 Negative pole 

3 Battery cover 

4 Cell-to-cell connector 

5 Bus bar 

6 Integral groove 

7 Negative plate 

8 Separator 

9 Positive plate 

1. Positive/negative plates are composed of plate grill and active material. 

53 

1 Pole plate 

2 Active material 

3 Grid 

4 Grid


53-3 

(a). 

(b). 

Function of plate grill: support the active material; conduct the current and make the current 

distributed evenly. 

There are two kinds of plate grill structures: straight line type and radiation type; modern 

vehicle adopts radiation type separator in order to decrease the inside resistance of battery 

and improve the starting performance. 

(c). 

Normal the material of plate grill is lead-stibium alloy; stibium can increase the mechanical 

strength and casting performance. But stibium will speed up the precipitation of hydrogen 

and speedup the consumption of electrolyte, and also, it can cause battery to discharge 

automatically and separator corrosion; thus the service life of battery will be shortened. 

Nowadays, lead- low stibium alloy grill or lead-calcium- tin alloy grill are used more and for 

the maintenance free battery, normally it uses lead-calcium alloy. 

2. Separator 

(a). Battery separator is composed of micro-hole rubber, plastic glass fiber etc.. Its function is: 

(b). 

• Prevent positive/negative plate from short-circuit. 

• Make the cation and anion inside of electrolyte pass smoothly. 

• Make the falling off of active material on positive/negative plate slow; prevent the 

positive/negative plate from damage causing by vibration. 

The separator used by battery must have the following characteristics: high hole rate, small 

hole diameter, anti-acid, no harmful impurity produced, with certain strength, small 

resistance inside of electrolyte and with stable chemical performance. 

3. Electrolyte 

(a). Main function of electrolyte is conducting the current and attending the electrochemical 

reaction. 

(b). 

(c). 

Electrolyte is made of concentrated sulfuric acid and purified water; purity and density of the 

electrolyte has important influence to the capacity and service life of the battery. 

Density of electrolyte inside of vehicle battery is 1.280 ± 0.005 g / cm3 (25 ℃)thin sulfuric acid. 

53

53-4 


4. Battery case and cover 

The case and cover of battery is the container to store positive/negative palate and 

electrolyte; it is mainly made of plastic and rubber material. 

5. Blow-off cock 

(a). 

Blow-off cock is made of plastic material and it seals the battery; it prevent air coming in and 

keep the pole plates from oxidation. 

(b). 

Penetrate the blind hole on vent cap by iron nail before using to guarantee the air venting. 

6. Others 

There are plate bridge, terminal, pole and level indicator etc. on the battery except for the 

above main parts. 

53


53-5 

Working principle 

For the lead-acid battery, the active material of positive pole is lead dioxide and the active material 

of negative pole is sponge like metal lead, and the conductive medium is thin sulfuric acid 

(electrolyte). Positive and negative will arise the following reaction during battering charging and 

discharging process, which will change electric energy into chemical energy which is stored inside 

of battery, or change chemical energy into electric energy which supply to outside. 

Negative pole reaction 

discharg 

charge e 

Positive pole reaction 

discharg 

charge e 

discharge 

charge 

Discharge: concentration of H 2 SO 4 is decreased and the PbSO 4 on positive/negative poles is 

increase; inside resistance is increased and the concentration of electrolyte is decrease; 

electromotive force of battery is decreased. 

53

53-6 


Charge: concentration of electrolyte increases; inside resistance decrease; electromotive force of 

battery increases, and there will be large quantity of air bubble generated because of the 

electrolysis of water at the later period of charging. 

General reaction of the battery 

Active material on 

positive pole 

Electrolyte 

Active material on 

negative pole 

Generated by 

positive pole 

Generated by 

electrolyte 

Generated by 

negative pole 

discharge 

charge 

Lead 

dioxide 

Thin sulfuric acid 

Lead 

Lead sulfate 

Water 

Lead sulfate 

Active materials on both positive and negative poles will be converted to lead sulfate after battery is 

discharged; this theory explained flow reaction of lead-acid battery is called as “dual Sulfation” 

theory. 

53


Application and maintenance 

1. Charging device 

Notes: 

53-7 

It is a must to use DC to charge the battery; the AC supplied by power plant should be transformed 

to DC. 

(a). 

(b). 

Rectifier 

Solid rectifier (copper oxide rectifier, selenium rectifier and silicon rectifier)in common, 

charging pipe rectifier (tungsten lamp rectifier and mercury rectifier are the commonly used 

rectifier. The input AC voltage normally is 110V or 220V, and then output nominal voltage is 

6V, 12V and 24V. Solid rectifier is used normally because it is easy to be used and needs 

not care during charging. 

Controllable silicon voltage-regulated battery charger 

During charging, it will need change the voltage to control the charging current because the 

quantity of series connected batteries are different; the DC with adjustable voltage is 

necessary. Silicon rectifier is light, small and easy to be moved, but there is still requirement 

to heavier voltage-regulated transformer. The controllable silicon voltage-regulated battery 

charger can overcome the above defect. There is a kind of 8KW controllable silicon 

voltage-regulated battery charger in the market, which converts 220V AC through 

controllable silicon rectifier. And the output DC is 0-220V and the output current is 0-4A. 

2. Notices during charging 

(a). 

(b). 

(c). 

(d). 

Charge the battery in a dry and ventilated room, and the temperature should be between 

5-40℃. 

Do not pile the batteries and do not put it on the ground directly; put it on the wooden rack. 

Do not put it together with alkaline battery or other chemical stuff. 

No fire in the charging place and the battery should be far away from heat resource. 

Temperature of electrolyte can not exceed 45 ℃, otherwise take suitable measures to 

decrease the temperature (make the charging current smaller, stop charging or put the 

battery into water for cooling). 

3. Charge criterion 

Notes: 

Make electrolyte by chemical pure sulfuric acid and distilled water, and it is not allowed to use 

industrial sulfuric acid and common water, because the impurity may cause battery discharge 

automatically or the pole plate may be damaged. 

Battery 

type 

Preliminary charging 

Supplementary charging 

the first stage the second stage the first stage the second stage 

Current(A) Time(h) Current(A) Time(h) Current(A) Time(h) Current(A) Time(h) 

6-Q-60 4 2 6 3 

6-Q-75 5 3 7.5 4 

6-Q-90 6 25 ~ 30 3 20 ~ 30 9 10 ~ 11 4 

6-Q-105 7 4 10.5 5 

6-Q-120 8 4 12 6 

3 ~ 5 

53

53-8 


4. Preparation before charging 

(a). Check if the electrolyte or pure water is accord to the specification. 

(b). 

(c). 

Open the blow off cock on the battery. 

Fill electrolyte or water to the highest mark. 

5. Connection for charging. 

(a). 

The positive pole of battery charger is connected with the positive pole of battery, and 

negative pole is connected with the negative pole of battery. Do not connect them mixed. 

(b). 

For most of the batteries, it can be decided by the power of battery charger, but the 

connection must firm. 

6. Charge mode 

(a). 

There are three charging modes: constant current charge, constant voltage charge and 

quick charge. 

Constant current charge 

53 

(b). 

(c). 

For constant current charge, it includes initial charging, supplementary charging, general 

charging and equilibrium charging. 

 

 

 

 

 

Initial charging is the first time charging for charged drained battery before using. After 

charged drained battery is filled with electrolyte and placed stillness for 1-6 hours, and 

start to charge when the temperature decreases to below 35℃. 

The charging current normally is 0.07C20A (that is 0.07 × 20 = 1.4 ampere current)for 

initial charging, and decrease the current to its half and continue the charging when the 

cell voltage reaches to 2.4V. 

Supplementary charging is for the dry charged battery with poor dry charging 

performance and stored for a long time, or for the battery not used for about one month 

after it is charged after filling acid. Current of supplementary charging is 0.1C20A, and 

charging time is about 5 hours or it is decided by the time of storage. 

General charging means the charges after initial charging. The first stage of general charging 

adopts 0.1C20A and charges 8-12 hours, and then decreases the current to its half and 

charge about 10 hours when the cell voltage reaches to 2.4V. Charged electrical quantity 

normally is 1.5 times of discharged electrical quantity, or 1.3-1.5 times of rated capacity. 

Equilibrium charging means charge the battery using general charging method to full and 

then charge it again by 0.035C20A current. Stop charging for 1 hour when temperature 

increase and air bubbles emit evenly; repeat this process 3-5 times. Finish the charging 

when one battery generates a great deal of bubbles, and voltage and density of 

electrolyte does not change. 

Constant voltage charge 

Constant voltage charge means charge the battery at constant voltage. At the beginning the 

current is bigger and then it decreases gradually; voltage is normally around 2.3-2.4V for constant 

voltage charge; for this kind of charging, the bubbles generated is less and water consumed is 

less, so constant voltage charge is normally used for maintenance free seal lead-acid battery. 

Quick charge 

Quick charge adopts big current and impulse charging with short time discharge intermittent 

charging method. Normally for quick charge, it uses 1-2 times of C20A big current for charge. 

Quick charge adopts special made quick battery charger. 

7. Indication to judge if the battery is charged fully 

(a). 

(b). 

There is great deal of air bubbles generated inside of battery cell. 

The voltage of battery cell is around 2.6-2.8V, and it does not change more than 2 hours.

(c). 


53-9 

Specific gravity of electrolyte reaches to 1.280 ± 0.01 g / cm3 (25 ℃),and it does not change 

more than 2 hours. 

8. Measure it by instrument after charging, and confirm if the battery resume to standard 

value by specific gravity method, voltage method or capacity method. 

(a) 

Specific gravity method 

Specific gravity value Judgment Treatment 

Above 1.300 

Concentration of electrolyte is 

overhigh or the wrong liquid is filled 

Adjust the specific gravity by 

deionized water (refer to “Chapter 53 

Battery-Electrolyte-Preparation”) 

1.250 ~ 1.280 Good Continue to use 

1.220 ~ 1.250 Undercharge 

Under 1.100 ~ 1.220 

Specific gravity difference of 

every cell is above 0.04 

(b). 

Voltage method 

Over discharged; concentration is 

too low 

The cell may be have malfunction 

Charge (refer to “Chapter 53 

Battery-Battery, Application and 

maintenance”) 

Initial charge and then inspect (refer 

to “Chapter 53 Battery-Battery, 

Application and maintenance”) 




Voltage Judgment Treatment 

Above 12.5 V Good Continue to use 

(c). 

11.5 ~ 12.5 V Undercharge 

Under 11.5 V 

Capacity method 

Indication of the capacity 

meter 

Over discharged or inside 

malfunction 

Judgment 




Initial charge and then inspect (refer to 

“Chapter 53 Battery-Battery, Application 

and maintenance”) 

Treatment 

53 

White area Sufficient Continue to use 

Green area Good Continue to use 

Yellow area 

Read area 

Undercharge 

Over discharged 





“Chapter 53 Battery-Battery, Application 

and maintenance”)

53-10 


9. Application and maintenance of the battery in winter 

(a). 

(b). 

Often keep the battery at sufficient state to prevent the electrolyte from icing caused by 

decreased specific gravity; electrolyte icing will cause malfunctions like container broken, 

pole plate bent and active material broken etc.. 

Fill in the electrolyte with 1.40 specific gravity into battery for adjustment in the winter 

according to the specification of the following table. 

Measured electrolyte temperature +45 +30 +15 0 -15 -30 -45 

Corrected value of hydrometer reading +0.02 +0.01 0 -0.01 -0.02 -0.03 -0.04 

(c). 

(d). 

In winter, water only can be filled when the engine runs and alternator charges engine to 

prevent the electrolyte icing caused uneven mixture of water and electrolyte. 

Preheat the engine before cold start because the battery capacity decreases in the winter; 

every connection time to starter can not exceed 15 seconds, and the interval of two starts 

should be 2-3 minutes; find out the trouble of engine if it can not be started in 3 times; clear 

away the trouble and then start. 

10. Application of new replaced batter 

(a). For dry charged battery, fill in specified electrolyte into battery (refer to “Chapter 53 

Battery-Electrolyte, Fill) and it can be used half an hour later; it needs not initial charging, but 

it is better to charge it 3-4 hours which is good to battery. 

(b). For charged drained battery, it only can be used after initial charging (refer to “Chapter 53 

Battery-Battery, Application and maintenance”). 

53

Basic inspection 

1. Appearance inspection 

(a). 

(b). 

(c). 

(d). 


53-11 

First check if the appearance of the battery is good; if the connection of fixed tie-rod and lead 

wire is firm. 

Observe the level of electrolyte: it is specified that the level should be 10-15 mm above the 

pole plate; fill in distilled water if it is lower than the specified level. 

Observe if there are cracks on the battery case and central separator; knock the battery case 

and central separator by crabstick, and listen to if there is broken sound, especially the 

border of central separator and housing wall. 

If sight glasses is available, green means the electricity is sufficient; red and white means 

electricity is insufficient and no power. It will need carrying out the following capacity, specific 

gravity and voltage inspection. 

2. Capacity inspection 

(a). 

(b). 

(c). 

High efficient discharge gage is also called as 

discharge tongs, and it is composed of one DC 

voltmeter and one load resistance. 

Put two fork tips onto the positive and negative 

plates tightly for 5 seconds during measurement; 

observe the kept voltage of battery under large 

load discharging, and by this the discharge 

degree and start ability of the battery can be 

judged accurately. 

For different high efficient discharge gage with 

different brands, it should be checked according 

to the value specified in the manual. For the 

normal battery with good technical conditions, 

the cell voltage should be above 1.5V and it can 

keep 5 seconds stably. It means there is problem 

of the battery if the voltage decreases rapidly 

within 5s or the voltage of one cell is above 0.1V 

lower than the other cells. 

The following is a comparison table measured by high efficient discharge gage. 

53 

Indicated area Judgment Treatment 

White area Sufficient Continue to use 

Green area Good Continue to use 

Yellow area 

Red area 

Undercharge 

No power 

Charge (refer to “Chapter 53 Battery-Battery, 



“Chapter 53 Battery-Battery, Application and 

maintenance”)

53-12 

3. Specific gravity inspection 

Hint: 


The application of hydrometer please refers to “Chapter 53 Battery-Electrolyte, Preparation). 

The following is a comparison table measured by hydrometer 

Specific gravity value Judgment Treatment 

Above 1.300 

Wrong liquid is filled 

Adjust the specific gravity by 

deionized water (refer to “Chapter 53 

Battery-Electrolyte- Preparation”) 

1.250 ~ 1.280 Good Continue to use 

1.220 ~ 1.250 Undercharge 




Under 1.100 ~ 1.220 

Specific gravity difference of 

every cell is above 0.04 

Over discharged or there is 

malfunction 

The cell may be have malfunction 







4. Voltage inspection 

The following is a comparison table measured by digital multimeter 

Voltage Judgment Treatment 

Above 12.5 V Good Continue to use 

53 

11.5 ~ 12.5 V Undercharge 

Under 11.5 V 

Over discharged or inside 

malfunction 






Application and maintenance”)


53-13 

Analysis of common malfunction phenomenon and 

troubleshooting 

1. The battery is stored for a long time so the electricity is insufficient 

(a). 

(b). 

The fully charged battery will lose electricity gradually if it is not used for a long time, and we 

call this phenomenon as “self discharge”. The key reason for self discharge is the material is 

not pure. For example, there are impurities inside of pole plate or electrolyte, and there is 

potential difference generated between impurity and pole plate, impurity and impurity; this 

form closed “partial current” and make the battery discharge. 

The material of battery can not absolutely pure, and the positive plate and metal of frame 

(lead-stibium alloy) form battery also. So slight self discharging is unavoidable. Improper use will 

speed up the discharging. The battery will be discharged completely in 24 hours if the electrolyte is 

not pure and content of iron reaches to 1%; electrolyte or other conductive material on battery 

cover will connect positive and negative plates and cause self discharge; sulfuric acid will go down 

to the bottom if the battery is not used for a long time, so the specific gravity of bottom is bigger 

than that of up, which will generate potential difference and cause self discharging. 

2. Sulfuration of battery plates 

(a). 

(b). 

(c). 

(d). 

Sulfuration of battery plates means there is a layer of white coarse crystal grain lead sulfate. 

Lead sulfate will clog the holes on plate seriously, and it is very difficult for the electrolyte 

penetrate the plates, so the battery capacity will be decreased; the conductive performance 

of lead sulfate is bad, so the inside resistance of battery is increased greatly; it can not 

provide big starting current, so the vehicle can not be started. This kind of coarse crystal 

grain lead sulfate is difficult to be dissolved in the electrolyte, so it will not disappear in the 

normal charge time. The battery will be scrap when it is vulcanized heavily. 

For the phenomenon of sulfuration, cell voltage decreases sharply when it is checked by high 

efficient discharge gage; the battery is boiled too early during charging; the specific gravity of 

electrolyte increases too slow (even there is no obvious changes); and the temperature of 

electrolyte increases rapidly. 

The main reason of pole plates sulfuration is the battery is undercharged for a long time or it is not 

charged for a long time after it is discharged, and lead sulfate is recrystallized because of the 

temperature changes; the liquid level is too low, so the upper part of pole plate contacts with air 

and is oxidized (mainly for the negative plate); the electrolyte waves and contact with the oxidized 

part of pole plate during vehicle running, it will also generate coarse crystal grain lead sulfate and 

vulcanize he upper part of pole plate; specific gravity of electrolyte is too high, electrolyte is not 

pure and outside temperature changes sharply will also speed up the sulfuration. 

Prevention of plates sulfuration 

 

 

 

Do not store the half discharged battery for a long time; make the battery at full charged state. 

Electrolyte level can not be too low, and make it 10-15mm higher than pole plates; fill in 

distilled water as necessary. 

Do not over discharge the battery. 

Repair the vulcanized battery 

 

 

 

For slight sulfuration, charge the battery with small current for a long time. That is to 

overcharge the battery with the current at the second stage of initial charge continuously 

until there are lots of air bubbles generated in the electrolyte and the specific gravity 

reaches to around 1.280 g / cm 3 . 

For heavier sulfuration, it can be repaired by “water method”. It should be ok when the 

discharge capacity reaches to the 80% of rating capacity. Repeat the above charge and 

discharge method when the discharge capacity is still very small until the battery is repaired. 

For the very serious sulfuration, replace the battery. 

3. Inside short circuit of the battery 

(a). 

Possible reasons of inside short circuit: 

53

53 

53-14 

 

 

 


The quality of separator is poor or is damaged, which will let the active material go through 

and make positive plate and negative plate contact directly forming short circuit. 

Fallen active material is accumulated too much and make the lower rim of pole plate 

contact with sediment forming short circuit. 

Charge current or discharge current is too big, make the pole plate bend, or some 

conductive material falls into the battery causing short circuit. Open the battery for 

inspection when there is short circuit inside of battery. It will need to replace to a new 

separator if it is damaged or penetrated. Clear away the sediment if the fallen active 

material is too much. Make the pole plate flat if it is bent. 

(b). Main character of pole plate short circuit is low open circuit voltage and small capacity. Terminal 

voltage of cell decreases to 0 rapidly when it is checked by high efficient discharge gage. During 

charging, the terminal voltage increases very slow, and the specific gravity of electrolyte increases 

very slow too; there is less or no air bubble in the later period of charge. 

4. Battery pole plates are bent 

(a). 

(b). 

(c). 

The positive plate of battery is easy to be bent but the negative plate is not bent easily; even 

there is negative plate bent, it is because the positive plate is bent too much. The main 

reasons of pole plate bent are: 

Poor quality. Diachylon is not coated evenly during manufacturing, and this will make the 

active material distribute unevenly. So electrochemistry actions caused by pole plate during 

charging and discharging are different, this will make the expansion and constriction of pole 

plates different, which will make plate bend even break. 

Big current discharge frequently, so the current densities of pole plate surface are different 

and the expansions of active material are different, which will make the plate bend. 

There is sulfuric acid generated inside of deep layer of pole plate because of frequent over 

discharge, and it can not be resumed during charging; so it will cause inside expansion and 

make the plate bend. 

5. A great deal of active material falls down from pole plate 

(a). 

(b). 

(c). 

(d). 

(e). 

The phenomenon of active material falls down normally happened on positive plate. It can 

not be avoided for the active material falling down because the volume of active material 

changes during battery charging and discharging. It will speed up the falling down of active 

material if the battery is not used correctly. 

The main reasons of active material falling down: 

Charge current is too big, and this will make the temperature of electrolyte is too high; the 

active material is expanded and soften to fall down. 

The battery is over charged frequently. There is a great deal of air venting from the hole of pole 

plates which will form pressure inside of plate holes and make the active material fall down. 

Discharge current is too big and the time connecting to starter is too long will bend the plate 

and speed up the fall down of active material. 

It is not charged in time after discharge in winter, so the electrolyte is iced when its specific 

gravity is too low. 

Battery is vibrated heavily during vehicle running. 

6. Polarity of one cell is reversed 

(a). 

(b). 

The reason is that there is malfunction of this cell or by other reason the capacity is 

decreased. The cell with low capacity will be first discharged to 0 during battery discharging. 

The current discharged by other cells will charge it if the battery is discharged continuously 

and its polarity will be reversed. In three cells, if the polarity of one cell is reversed, the 

terminal voltage is 2 V but not 6V when the battery is checked by voltmeter. 

In order to prevent this phenomenon happening, the cell with low capacity should be 

charged/discharged independently or replace the pole plates; it can be used when its


capacity is same or similar with the capacities of other cells. 

53-15 

7. Battery explosion 

(a). 

(b). 

(c). 

(d). 

The main reason of battery explosion is that when the battery is over charged, there is a 

great deal of air bubbles generated because the water inside electrolyte is decomposed into 

hydrogen and oxygen; inside short circuit of battery and sulfuration malfunction; temperature 

of electrolyte increases sharply during charging make the water evaporate a lot; now if the 

ventilation hole of filling cap is clogged or the gas is too much that can not vent, the battery 

will explode when the inside pressure reaches to a certain limit (or meet fire). The method to 

prevent battery explosion are: 

Keep the ventilation hole of fill cap free. 

Wire connection on the pole should be firm to prevent fire generating. 

Open the ventilation hole of fill cap when it is checked by High efficient discharge gage. 

Control the charge and do not over charge to decrease the gas quantity. No fire inside of 

battery charging room and keep the room ventilated. 

8. Liquid level decreases rapidly 

The main reason of liquid level decreases rapidly is that the charge current is too big, and 

the charge system should be adjusted. It may because the housing or seal glue is broken of 

that cell and cause the electrolyte leak if the liquid level of one cell decreases rapidly. Maybe 

there is sulfuration or short circuit in that cell if the housing and seal glue are intact. Fill in 

distilled water when the liquid level is decreased. Repair the crack or replace the battery 

housing if they are broken. 

9. There is yellow or white stuff on the battery 

Yellow or white stuff on battery cover or around plates is because there is sulfuric acid 

solution on the battery cover and this make the pole, wire clip and fixation bracket corrode; 

white stuff is lead sulfate and yellow stuff is iron sulfate. Those two kinds of stuff have big 

resistance, and they will form very big contact resistance and cause bad conductive if they 

are at the wire connection place. Wipe electrolyte from battery cove and housing by a rag 

invaded with 10% carbonated water. And then wash it by water, dry it with clean rag. The 

stuff on wire head and poles should be wiped away by rag with carbonated water. Take the 

oxidation stuff away by knife. Coat a layer of Vaseline or grease on the surface of pole and 

wire clip after they are fixed. 

10. Battery is iced 

(a). 

(b). 

The common reason of battery icing is that the specific gravity of electrolyte is lower at 

exworks, and the electrolyte reaches to its freezing point when it is used at cold area; 

specific gravity of electrolyte decreases too much when the battery is used and it is not 

charged in time; the liquid level of electrolyte is low, and the engine is not run for a certain 

period after distilled water is filled, so the specific gravity of electrolyte is disaccord. 

Move the iced battery to warm room and let it melt slowly, and then charge it with small 

current; observe the voltage of every cell and the temperature of electrolyte, and the specific 

gravity of electrolyte should reach to specified value after charge (refer to “Chapter 53 

Battery-Battery, Basic inspection”). Replace to new pole plate or replace to new battery for 

the serious iced battery. 

53

53-16 

Parts diagram 


53 

1 Battery protective cover 

2 Pressure plate 

3 Tie rod 

4 Battery 

5 Battery support assembly

Replacement 

1. Turn off all electric devices 

2. Ignition key: OFF 


3. Disassemble battery protective cover 

(a). 

53-17 

Disassemble 2 bolts and take off tie rod and 

pressure plate. 

4. Disassemble the battery protective cover. 

(a). 

Take off battery protective cover directly. 

53 

5. Disassemble the connection wire of battery 

poles 

(a). 

Notes: 

Disassemble the connection wire of battery 

poles 

First disassemble the connection wire of negative 

pole and then disassemble the connection 

wire of positive pole. 

6. Take out battery

53-18 

7. Assemble the battery 


(a). 

Place the battery in the installation position 

correctly. 

8. Assemble the battery pressure plate and tie rod 

9. Assemble the battery connection wire of pole 

(a). 

Notes: 

 

 

Assemble battery connection wire of pole first as 

shown in the figure 2. 

Installation principle is to assemble positive 

connection wire and then assemble negative 

connection wire. 

The connection wire must be firm; take proper 

measures and treat it if there is corrosion, rust or 

other bad connection on the joint position of 

negative connection wire and frame. Make sure 

the return circuit of electric device free. 

53 

10. Assemble the battery protective cover

Electrolyte 

Preparation 

1. Notice 

(a). 

(b). 

(c). 

(d). 

(e). 


53-19 

The operator must wear safety goggles, rubber gloves, plastic apron, high rubber shoes 

during electrolyte make to prevent burn. Wet the clothes with 10% carbonated water solution 

immediately if sulfuric acid is plashed onto clothes and then wash it by clean water. 

The container to make electrolyte must be acid-proof and temperature-proof ceramics, glass 

jar, plastic groove or wooden groove with lead lining. 

Clean the container and then wash it by clean water before make. 

Put pour water into container in first ,and then pour concentrated sulfuric acid into pour water 

slowly, and churn it continuously; it is strictly not allowed to pour water into concentrated 

sulfuric acid for fear that the liquid splashes out cause hurt. 

Electrolyte of dead-acid battery is made by pure water and concentrated sulfuric acid; 

electrolyte density of vehicle used battery is 1.280 ±0.005 g / cm 3 (25 ℃) 

53

53-20 


2. Measure the specific gravity of electrolyte 

(a). Measure the specific gravity of electrolyte by hydrometer as the following figure. 

53 

1 Thermometer 

2 Hydrometer 

3 Battery 

4 Electrolyte 

5 

Visually observe the mark where the 

floater of hydrometer is aligned with 

the liquid level


(b). Conversion formula of electrolyte density: d 25 = dt + 0.007 (t - 25) 

53-21 

Items 

Explanation 

d 25 Electrolyte density at 25 ℃ 

dt Electrolyte density at t℃ 

0.007 Temperature coefficient 

t 

Measured electrolyte temperature 

(c). 

Measure the temperature of electrolyte at the same time of measuring the specific gravity, 

and then convert the measured value into specific gravity at 15 ℃. The specific gravity of 

electrolyte will decrease 0.007 g / cm 3 when the temperature increases one degree, and in 

China we take 15 ℃ as standard. Correct the value according to temperature after 

measurement. Add the corrected value if it exceeds 15 ℃, and deduct the corrected value if 

it lower than 15 ℃. The corrected value should be accord to the following table. 

Measured electrolyte temperature +45 +30 +15 0 -15 -30 -45 

Corrected value of hydrometer reading +0.02 +0.01 0 -0.01 -0.02 -0.03 -0.04 

3. Selection of specific gravity of electrolyte 

Specific gravity of electrolyte increases and the freezing point of electrolyte will decrease, 

which will decrease the dangerous of frost and increase the battery capacity. The viscous of 

electrolyte will increase if the specific gravity is too big which will make the penetration 

difficult; instead the battery capacity will be decreased; this will speed up the carbonization of 

wooden separator, and the pole plate will be vulcanize easily; the service life to battery will 

be shorten. So select different specific gravity according to different application conditions. 

The selection of specific gravity in different areas and different climates can refer to the 

following table. 

Climates 

Area with temperature lower than 

-40 ℃ in winter 

Area with temperature above 







0 ℃ in winter 

Electrolyte specific gravity at 15℃ for a fully charged battery 

Winter 

Summer 

1.31 1.27 

1.29 1.25 

1.28 1.25 

1.27 1.24 

1.24 1.24 

53

53-22 


4. Adjustment of electrolyte specific gravity 

Full charge the battery and then measure the specific gravity when the electrolyte specific 

gravity needs to be adjusted according to seasons changing. Suck out some electrolyte by 

sucker if the specific gravity is not suitable; fill in distilled water if the specific gravity is higher 

than required specific gravity; and fill in 1.40 g / cm 3 electrolyte if it is lower than required 

specific gravity; charge the battery a while again and mix them evenly; check the specific 

gravity again until it is correct. The specific gravity adjustment in winter for battery should be 

accord with the following table. 

Discharge 

degree 

Fully charged 25 % 50 % 75 % 100 % 

Specific 

gravity 

Freezing 

point 

Specific 

gravity 

Freezing 

point 

Specific 

gravity 

Freezing 

point 

Specific 

gravity 

Freezing 

point 

Specific 

gravity 

Freezing 

point 

15 ℃ 0 ℃ 15 ℃ 0 ℃ 15 ℃ 0 ℃ 15 ℃ 0 ℃ 15 ℃ 0 ℃ 

Specific 

gravity 

and 

freezing 

point of 

electrolyte 

1.310 -76 1.270 -58 1.230 -36 1.190 -22 1.150 -14 

1.290 -70 1.250 -50 1.210 -28 1.170 -18 1.130 -10 

1.280 -69 1.240 -42 1.200 -25 1.160 -16 1.120 -9 

1.270 -58 1.230 -36 1.190 -22 1.150 -14 1.110 -8 

1.250 -50 1.210 -28 1.170 -18 1.130 -10 1.090 -6 

1.240 -42 1.200 -25 1.160 -16 1.120 -9 1.080 -5 

53

Fill 

Notes: 


53-23 

The protective appliance must be worn before filling the electrolyte. Wet the clothes with 

10% carbonated water solution immediately if sulfuric acid is plashed onto clothes and then 

wash it by clean water. 

1. Fill in acid 

(a). 

Take off vent cap; the ventilation hole on the cap must be penetrated, and take away the seal 

gasket and seal paper under the vent cap after filling. 

(b). The electrolyte can be filled into battery only when its temperature reaches to below 30 ℃. 

(c). 

(d). 

Hint: 

Fill the electrolyte into every cell, and make the level of electrolyte align with the “max” mark 

on housing; in the rubber groove, the level of electrolyte should be 10-15mm higher than 

separator. 

Fasten the vent cap and prevent acid leaking. 

For the discharged drained battery, it is a must to be initial charged after filling the acid (refer to 

“Chapter 53 Battery-Battery, Application and maintenance”). For the dry charged battery, it can be 

used half an hour later after filling the acid and needs not to be initial charged; but it is better charge 

it 3-4 hours which is better for battery performance. 

53

Lighting 

Lighting system ........................................ 54-1 

Notice ..................................................... 54-1 

Inspection on vehicle .............................. 54-2 

Inspection ............................................... 54-4 

Front combined lamp ............................... 54-7 

Parts diagram ......................................... 54-7 

Replacement .......................................... 54-8 

Adjustment ............................................ 54-10 

Bulb of front combined lamp ................. 54-11 

Replacement ........................................ 54-11 

Fog lamp ................................................. 54-15 

Replacement ........................................ 54-15 

Adjustment ............................................ 54-17 

Bulb of fog lamp ..................................... 54-18 

Replacement ........................................ 54-18 

Rear combined lamp .............................. 54-20 

Parts diagram ....................................... 54-20 

Replacement ........................................ 54-21 

Bulb of rear combined lamp .................. 54-23 

Replacement ........................................ 54-23 

License plate lamp ................................. 54-25 

Replacement ........................................ 54-25 

Bulb of license plate lamp ..................... 54-26 

Replacement ........................................ 54-26 

Side turning lamp ................................... 54-27 

Replacement ........................................ 54-27 

Bulb of side turning lamp ...................... 54-28 

Replacement ........................................ 54-28 

Side marker lamp ................................... 54-30 

Replacement ........................................ 54-30 

Bulb of side marker lamp ....................... 54-31 

Replacement ........................................ 54-31 

Front ceiling lamp .................................. 54-33 

Replacement ........................................ 54-33 

Bulb of front ceiling lamp ...................... 54-34 

Replacement ........................................ 54-34 

Switch of door lamp ............................... 54-35 

Replacement ......................................... 54-35 

54

54


Notices 

1. Expression of ignition switch 

Lighting- Lighting system 

54-1 


LOCK 

ACC 

ON 

START 

Expression of ignition switch 


Ignition switch ACC 



2. Turn off the power supply 

(a). 

Hint: 

First disconnect the cable of battery negative pole before the disassembly/assembly of any 

electric device and at the time of tools or devices may contact with the bare electric pin; this 

will prevent personnel or vehicle from hurt. 

Do not leave key inside of vehicle before the disconnection of negative pole cable to prevent the 

door locking. 

(b). 

The ignition switch must be turned off if there is no special explanation. 

3. The disconnection of negative pole cable will reset daily odometer and clock. 

Hint: 

Total odometer will not be reset. 

4. The disconnection of negative pole cable will make the audio system lose stored 

setting. 

Hint: 

The audio system needs to be reset after negative pole cable is reconnected . (refer to “Chinese 

and English Application Manual of Audio System”). 

5. Notes during bulb replacement 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

(g). 

The service life of bulb will be shortened if there is oil dirt left on the surface of halogen bulb 

because the bulb will be burnt by overheating. 

Be careful during the treatment of halogen bulb. There is high voltage inside of bulb, and it 

may cause the bulb explosion if the bulb is falling down, knocked or damaged. 

The safety goggles must be worn during the replacement of halogen bulb. 

Only the bulb seat can be hold and do not contact the glass when you hold the bulb. 

Make one spare bulb ready anytime. During replacement the reflector may suck dust and 

water if the disassembly time is too long. 

New bulb should have the same power as the replaced one. 

Fix the bulb seat after the bulb is replaced. The reflector will be hazy if there is water entering 

into the bulb seat. 

54

54-2 



1. Check the three in one controller circuit 

(a). 

Disconnect the connector of three in one 

controller, and check the connection terminal of 

the wire according to the following table. 


Connection pin of multimeter Conditions Standard value 

9-grounding Ignition switch OFF→ON 20-28V 

6-grounding Switch of small lamp OFF→ON 0V→above 18V 

7-grounding Switch of front fog lamp OFF→ON 0V→above 18V 

(b). 

Connect the connector of three in one controller, and check the back of connection terminal 

according to the following table. 


Connection pin of multimeter Conditions Standard value 

1- grounding Not change 20-28V 

2- grounding Switch of rear fog lamp OFF→ON 0V→>18V 

3- grounding Switch of rear fog lamp OFF→ON 0V→> 18V 

54 

5- grounding Switch of rear fog lamp OFF→ON 0V→> 18V 

6- grounding Switch of small lamp OFF→ON 0V→> 18V 

7- grounding Switch of front fog lamp OFF→ON 0V→> 18V 

8- grounding Switch of headlamp OFF→ON 0V→> 18V 

9- grounding Ignition switch OFF→ON 20-28V→20-28V 

12- grounding Switch of dangerous warning 

OFF→ON 

Switch of turning lamp OFF→ON 

0V→0->18V (60 to 120 times per 

minute) 

2. Inspect the function of getting on lighting system 

(a. The getting on lighting system controls the inside lamp assembly. 

(b. Check if the door lamp is lit when any door is opened. Check if the door lamp is extinct at any 

of the following situations: 

 

 

 

15 seconds after all doors are closed. 

Ignition switch is at ON position and all doors are closed. 

All doors are closed and locked.


54-3 

(c). Check if the bulb can be lit at least 15s as described in (b) before it goes out when any door is 

opened. And then check if the bulb will go out within15s after all door opened. 

(d). 

Check if the bulb is lit after any door is opened and if it will go out immediately after all doors 

are closed and locked or the ignition switch is turned to ACC or ON 

3. Check the function of energy saving. 

(a). 

(b). 

(c). 

(d). 

(e). 

Take out ignition key and close all the doors. 

Open any door and turn on vehicle inside lamp, and keep the door open. Check if the lamp 

will go out automatically after 20 minutes. 

Close the door when the inside lamp of the vehicle goes out. 

Open any door and turn one vehicle inside lamp, and then open another door. Check if the 

lamp will go out automatically 20 minutes after the door opened. 

Close all the doors. Insert ignition key, open any door and turn on vehicle inside lamp, then 

take out the ignition key. Check if the lamp will go out automatically after 20 minutes. 

54

54-4 


Inspection 

1. Combined switches assembly 

(a). 

Check the on-off of lighting control switch. 

• Measure the resistance value according to the 



Connection pin 

of multimeter 


Standard 

value 

14-9-12 Overtake lamp ≤2Ω 

8-12-3 Low beam ≤2Ω 

9-12 High beam ≤2Ω 

(b). 

Check the on-off of turning lamp switch. 




of multimeter 



8-1 Turn right ≤2Ω 

8-1 

5-1 

Middle 

>1MΩ 

5-1 Turn left ≤2Ω 

54 

(c). 

Check the on-off of fog lamp switch. 




of multimeter 



7-2 Fog lamp ≤2Ω 

7-2 Not fog lamp >1MΩ 

(d). 

Check the on-off of small lamp switch. 




of multimeter 



11-2 Small lamp ≤2Ω 

11-2 Not small lamp >1MΩ 

2. Reverse lamp switch assembly 

(a). 

Measure the resistance value according to the following table.


54-5 



OFF 

ON 


>1MΩ 

≤2Ω 

3. Brake lamp switch assembly 

(a). Measure the resistance value according to the following table. 



OFF 

ON 


>1MΩ 

≤2Ω 

4. Dangerous warning lamp switch assembly 

(a). 

Measure the resistance value according to the 




of multimeter 



7-10 OFF ≤2Ω 

7-8 

5-9-6 

ON 

≤2Ω 

5. Inside lamp switch assembly 

(a). 

Connect positive pole of battery to pin No. 1, and 

negative pole to pin No. 2; check if the lamp is lit. 

54 

6. Headlamp relay 

(a). 





of multimeter 



86-85 Normal Breakover 

30-87 


voltage between pin 

No. 86 and No. 85 

Breakover

54-6 


7. Fog lamp relay 

(a). 





of multimeter 




30-87 



No. 86 and No. 85 

Breakover 

8. Front/rear combined lamp relay 

(a). 





of multimeter 




30-87 Input power supply 


No. 86 and No. 85 

Breakover 

54 

9. Door lamp switch assembly 

(a). Measure the resistance value according to the following table. 



Compressed position 

Released position 


>1MΩ 

≤2Ω

Lighting- Front combined lamp 

54-7 

Front combined lamp 

Parts diagram 

1 Bulb of turning lamp 

2 Bulbs of high beam and low beam 

3 Bulb of front position lamp 

4 Bulb of turning lamp 

5 Housing of front combined lamp 

54

54-8 

Replacement 


1. Disassemble left front combined lamp assembly 

(a. 

Disassemble the trimming parts from left front headlamp (refer to “Chapter 77 Inner/outer 

trimming part-Front face cover assembly, Replacement”). 

(b). 

Disassemble 3 bolts, and pull out the left front 

combined lamp assembly. 

(c). 

Disconnect (high/low beam lamp, turning lamp 

and front position lamp) insert parts, and take off 

left front combined lamp assembly. 

54 

2. Disassemble the right front combined lamp assembly 

Hint: 

The steps to disassemble right front combined lamp are same as that of left front combined lamp. 

3. Assemble left front combined lamp assembly 

(a). Connect (high/low beam lamp, turning lamp 

and front position lamp) insert parts, and take off 

left front combined lamp assembly. 

(b). 

Insert left front combined lamp assembly, and 

fasten 3 bolts. 

Torque:9-11 N•m


54-9 

4. Assemble right front combined lamp 

Hint: 

The steps to assemble right front combined lamp are same as that of left front combined lamp. 

5. Set the vehicle state (refer to “Chapter 54 Lighting-Combined front lamp, 

Adjustment”) 

6. Adjust the light range of front headlamp (refer to “Chapter 54 Lighting-Combined front 

lamp, Adjustment”) 

54

54 

54-10 

Adjustment 


1. Adjust the irradiation range of front headlamp 

(a). 

(b). 

(c). 

Hint: 

Adjust vehicle to the following conditions. 

· There should be no deformation around the front combined lamp. 

· Park the vehicle on a flat ground. 

· Tyre pressure should be at standard value (refer to “Chapter 23 Wheel and tyre-Wheel and 

tyre assembly, Inspection on vehicle). 

· Driver sits inside of vehicle and make the vehicle ready to be started at any time (with fuel 

tank fuelled). 

· Vehicle is shaken may times. 

Check the irradiation range of headlamp 

· Prepare a piece of thick white paper. 

· Place the paper perpendicular to the ground at the position of 3m away from front 

combined lamp. 

· Make sure the angel between the central line of vehicle and paper is 90°. 

· Draw a horizontal line on the paper and point out the position where headlamp should 

irradiate to. 

· Draw a vertical line on the paper and point out the position where the central line of vehicle 

locates. 

· Draw two pieces of vertical lines and point out the position where two headlamps should 

irradiate to ( right headlamp vertical line and left headlamp vertical line). 

· Draw a horizontal line (mark to connect the centers of two low beams), and point out the 

position where headlamp should irradiate to (horizontal lines of right front combined lamp 

and left front combined lamp). 

· Take proper measurement method so as not to influence the other lamps. 

· Adjust the horizontal position of headlamp to “0”, then adjust the shaft angle of front 

combined lamp. 

Hint: 

Horizontal lines of right headlamp and left headlamp should be 0.4° lower than horizontal line. 

· Start the engine. 

· Turn on front combined lamp 

· Check if the irradiation range of headlamp is accord with the figure. 

· Adjust the headlamp along perpendicular direction if it is not accord with the figure. 

Adjust the irradiation rang of headlamp along perpendicular direction: fasten/loose the bolt 

and adjust the irradiation rang of headlamp to standard range. 

Rotate the screwdriver clockwise, the irradiation range will move forward. Rotate the screwdriver 

counterclockwise, the irradiation range will move downward.

Lighting- Bulb of front combined lamp 

Bulb of front combined lamp 

Replacement 

54-11 

1. Disassemble left front combined lamp assembly (refer to “Chapter 54 Lighting-Front 

combined lamp, Replacement) 

2. Disassemble bulb of left high/low beam 

(a). 

Disassemble the cover and disconnect the insert 

part. 

(b). 

Loose the fixation steel wire to disassemble the 

bulb. 

3. Disassemble bulb of left front turning lamp 

54 

(a). 

Screw off the seat of turning lamp. 

(b). 

Disassemble the bulb.

54-12 


4. Disassemble the bulb of left front position 

lamp 

(a). 

Screw off the seat of front position lamp. 

(b). 

Disassemble the bulb of front position lamp 

5. Disassemble right front combined lamp assembly 

Hint: 

The steps to disassemble right front combined lamp assembly are same with that of left front 


54 

6. Disassemble bulb of right high/low beam 

Hint: 

The steps to disassemble the bulb of right high/low beam bulb are same with that of left right 

high/low beam. 

7. Disassemble the bulb of right turning lamp 

Hint: 

The steps to disassemble the bulb of right turning lamp are same with that of left turning lamp. 

8. Disassemble the bulb of right front position lamp 

Hint: 

The steps to disassemble the blub of right front position lamp are same with that of left front position 

lamp. 

9. Assemble the bulb of high/low beam 

(a). 

Assemble the bulb of high/low beam and fix it by 

fixation steel wire.


54-13 

(b) 

Assemble the cover 

10. Assemble the bulb of left front turning lamp 

(a). 

Assemble the bulb of turning lamp. 

(b) 

Screw on turning lamp seat. 

11. Assemble the bulb of left front position lamp 

54 

(a). 

Assemble the bulb of front position lamp 

(b). 

Screw on front position lamp seat.

54-14 


12. Assemble left front combined lamp assembly (refer to “Chapter 51 Lighting 

system-Front combined lamp, Replacement) 

13. Assemble the bulb of right high/low beam 

Hint: 

The steps to assemble the bulb of right high/low beam are same with that of left high/low beam. 

14. Assemble the bulb of right front turning lamp 

Hint: 

The steps to assemble the bulb of right front turning lamp are same with that of left front 

turning lamp. 

15. Assemble the bulb of right front position lamp 

Hint: 

The steps to assemble the bulb of right front position lamp are same with that of left front 

position lamp. 

16. Assemble right front combined lamp assembly 

Hint: 

The steps to assemble the right front combined lamp assembly are same with that of left 

front combined lamp assembly. 

54 

17. Adjustment of front combined lamp assembly(refer to “Chapter 51 Lighting 

system-Front combined lamp, Adjustment)

Fog lamp 

Replacement 

Lighting-Fog lamp 

54-15 

1. Disassemble left front fog lamp assembly 

(a). 

Disconnect the insert part. 

(b) 

Loose 3 nuts and disassemble the left front fog 

lamp assembly. 

2. Disassemble right front fog lamp assembly 

Hint: 

The steps to disassemble right front fog lamp assembly are same with that of left front fog lamp 

assembly. 

3. Assemble left front fog lamp assembly 

(a). 

Connect the insert part. 

54 

(b). 

Fasten 3 nuts and assemble the fog lamp 

assembly. 


54-16 


4. Assemble right front fog lamp assembly 

Hint: 

The steps to assemble right front fog lamp are same with that of left front fog lamp. 

5. Set the vehicle state 

(refer to “Chapter 54 Lighting - Combined front lamp, Adjustment”) 

6. Adjust the light range of front headlamp 

(refer to “Chapter 54 Lighting - Combined front lamp, Adjustment”) 

54


54-17 

Adjustment 

1. Adjust vehicle to the following conditions. 

(a). 

(b). 

Tyre pressure should be at standard value (refer to “Chapter 23 Wheel and tyre-Wheel and 

tyre assembly, Inspection on vehicle). 


2. Adjust the irradiation range of fog lamp 

(a). 

The irradiation range of fog lamp can be adjusted by adjustable bolt on vertical direction. 

Hint: 

Rotate the screwdriver clockwise, the irradiation range will move forward. Rotate the 

screwdriver counterclockwise, the irradiation range will move downward. 

3. Check the irradiation range of front fog lamp 

54

54-18 

Bulb of fog lamp 

Replacement 

Lighting-Bulb of fog lamp 

1. Disassemble the bulb of left front fog lamp 

(a). Disconnect the insert part and open the cover. 

(b). 

Disconnect the insert plate and loose fixation 

steel wire. 

(c). 

Take out the bulb of fog lamp. 

54 

2. Disassemble the bulb of right front fog lamp 

Hint: 

The steps to disassemble the bulb of right front fog lamp are same as that of left front fog lamp. 

3. Assemble the bulb of left front fog lamp 

(a). 

Assemble the bulb of left front fog lamp

Lighting-Bulb of fog lamp 

54-19 

(b). 

Clamp the fixation steel wire and connect the 

insert part. 

(c). 

Close the cover and connect the insert part. 

4. Assemble the bulb of right front fog lamp 

Hint: 

The steps to assemble the bulb of right front fog lamp are same as that of left front fog lamp. 

5. Set the vehicle state 

(refer to “Chapter 54: Lighting - Combined front lamp, Adjustment”) 

6. Adjust the light range of front head lamp 

(refer to “Chapter 54: Lighting - Combined front lamp, Adjustment”) 

54

54-20 

Rear combined lamp 

Parts diagram 

Lighting-Rear combined lamp 

54 

1 Bulb of rear position/brake lamp 

2 Bulb of rear turning lamp 

3 Bulb of reverse lamp 

4 Bulb of rear fog lamp 

5 Lid of rear combined lamp 

6 Housing of rear combined lamp

Lighting- Rear combined lamp 

54-21 

Replacement 

1. Disassemble left rear combined lamp 

assembly 

(a). 

Disassemble the lid of rear combined lamp. 

(b). 

Disconnect the insert part and loose 3 nuts to 

disassemble rear combined lamp assembly 

2. Disassemble right rear combined lamp assembly 

Hint: 

The steps to disassemble right rear combined lamp assembly are same with that of left rear 


3. Assemble left rear combined lamp assembly 

54 

(a). 

Fasten 3 nuts and connect the insert part to 

assemble rear combined lamp assembly. 

(b). 

Assemble the lid.

54-22 

Lighting-Rear combined lamp 

4. Assemble right rear combined lamp assembly 

Hint: 

The steps to assemble right rear combined lamp assembly are same with that of left rear 


54

Lighting- Bulb of rear combined lamp 

Bulb of rear combined lamp 

Replacement 

54-23 

1. Disassemble the bulb of left rear combined 

lamp 

(a). 

Disassemble the lid of rear combined lamp. 

(b). 

Screw off the bulb seat of rear combined lamp 

and disassemble the bulb of rear combined lamp. 

2. Disassemble the bulb of right rear combined lamp 

Hint: 

The steps to disassemble the bulb of right rear combined lamp assembly are same with that of left 

rear combined lamp assembly. 

3. Assemble the bulb of left rear combined lamp 

(a). 

Assemble the bulb of rear combined lamp, and 

screw it up to the bulb seat of rear combined 

lamp. 

54 

(b). 

Assemble the lid of rear combined lamp.

54-24 

Lighting- Bulb of rear combined lamp 

4. Assemble bulb of right rear combined lamp 

Hint: 

The steps to assemble the bulb of right rear combined lamp assembly are same with that of left rear 


54

License plate lamp 

Replacement 

Lighting-License plate lamp 

54-25 

1. Disassemble the license plate lamp 

(a). 

(b). 

Loose the bolt and disassemble the lampshade 

of license plate lamp. 

Disconnect the insert part to disassemble the 

license plate lamp assembly. 

2. Assemble the license plate 

(a). Connect the insert part 

(b). Fasten the bolt on lampshade of license plate. 

54

54-26 

Lighting-Bulb of license plate lamp 

Bulb of license plate lamp 

Replacement 

1. Disassemble the bulb of license plate lamp 

(a). 

(b). 

Loose 2 bolts to disassemble the lampshade of 

license plate 

Take off the bulb. 

2. Assemble the bulb of license plate lamp 

(a). 

(b). 

Insert the bulb of license plate lamp. 

Fasten 2 bolts and assemble the lampshade of 

license palte. 

54

Side turning lamp 

Replacement 

Lighting-Side turning lamp 

54-27 

1. Disassemble the left side turning lamp 

assembly 

(a). 

Disconnect the insert part and loose 2 bolt; pull 

out the side turning lamp assembly inwards 

2. Disassemble the right side turning lamp assembly 

Hint: 

The steps to disassemble the right side turning lamp assembly are same with that of left side turning 


3. Assemble the left side turning lamp assembly 

(a). 

Fasten 2 bolt and connect insert part to 

assemble the side turning lamp assembly. 

4. Assemble the left side turning lamp assembly 

Hint: 

The steps to assemble the right side turning lamp assembly are same with that of left side turning 


54

54-28 

Lighting-Bulb of license plate lamp 

Bulb of side turning lamp 

Replacement 

1. Disassemble the bulb of left side turning 

lamp 

(a). 

Screw off the lamp seat. 

(b). 

Disassemble the bulb of turning lamp. 

54 

2. Disassemble the bulb of right side turning lamp 

Hint: 

The steps to disassemble the bulb right side turning lamp assembly are same with that of left side 

turning lamp assembly. 

3. Assemble the bulb of left side turning lamp 

(a). 

Install the bulb of turning lamp. 

(b). 

Screw up the lamp seat.

Lighting-Side turning lamp 

54-29 

4. Assemble the bulb of right side turning lamp 

Hint: 

The steps to assemble the bulb right side turning lamp assembly are same with that of left side 

turning lamp assembly. 

54

54-30 

Side marker lamp 

Replacement 

Lighting-Side marker lamp 

1. Disassemble left side marker lamp assembly 

(a). 

Disconnect the insert part and loose bolt to 

disassemble the side marker lamp assembly. 

2. Disassemble right side marker lamp assembly 

Hint: 

The steps to disassemble the right side marker lamp assembly are same with that of left side 

marker lamp assembly. 

3. Assemble left side marker lamp assembly 

(a). 

Connect the insert part and fasten the bolt to 

assemble side marker lamp assembly. 

54 

4. Assemble right side marker lamp assembly 

Hint: 

The steps to assemble the right side marker lamp assembly are same with that of left side marker 

lamp assembly.

Lighting- Bulb of side marker lamp 

Bulb of side marker lamp 

Replacement 

54-31 

1. Disassemble the bulb of left side marker 

lamp 

(a). 

Screw off bulb seat. 

(b). 

Disassemble the bulb of turning lamp 

1. Disassemble the bulb of right side marker lamp 

Hint: 

The steps to disassemble the bulb of right side marker lamp are same with that of left side marker 

lamp. 

3. Assemble the bulb of left side marker lamp 

(a). 

Assemble the bulb of turning lamp 

54 

(b). 

Screw of the bulb seat.

54-32 


4. Assemble the bulb of right side marker lamp 

Hint: 

The steps to assemble the bulb of right side marker lamp are same with that of left side marker 

lamp. 

54


54-33 

Front ceiling lamp 

Replacement 

1. Disassemble the trimming plate of rearview mirror (refer to “Chapter 72 Windscreen 

glass/Window glass/Rearview mirror-Outside rearview mirror, Replacement”) 

2. Disassemble front ceiling lamp assembly 

(a). 

Loose the bolt. 

(b). 

Disconnect the insert part and disassemble the 

front ceiling lamp assembly. 

3. Assemble the front ceiling lamp assembly 

(a). 


54 

(b). 

Fasten the bolt and assemble the front ceiling 

lamp assembly.

54-34 

Lighting-Bulb of clearance lamp 

Bulb of front ceiling lamp 

Replacement 

1. Prize up the lampshade of front ceiling lamp 

2. Disassemble the bulb of front ceiling lamp 

(a). 

Take off the bulb from bulb seat. 

3. Assemble the bulb of front ceiling lamp 

(a). 

Assemble bulb onto its seat. 

4. Assemble lampshade of front ceiling lamp 

54

Door lamp switch 

Replacement 

Lighting-Front ceiling lamp 

54-35 

1. Disassemble the switch of left door lamp 

(a). 

(b). 

Withstand the switch of door lamp by hand and 

loose the bolt. 

Disconnect the insert part to disassemble the 

switch of door lamp. 

2. Disassemble the switch of right door lamp 

Hint: 

The steps to disassemble the switch of right door lamp are same with that of left door lamp. 

3. Assemble the switch of left door lamp 

(a). 

(b). 


Withstand the switch of door lamp to fasten the 

bolt. 

4. Assemble the switch of right door lamp 

Hint: 

The steps to assemble the switch of right door lamp are same with that of left door lamp. 

54

54-36 

Lighting-Bulb of front ceiling lamp 

54


Wiper and washer assembly ..................... 55-1 

Table of malfunction phenomenon. ........ 55-1 

Inspection on vehicle ............................. 55-3 

Inspection .............................................. 55-4 

Wiper arm assembly .................................. 55-5 

Replacement. ........................................ 55-5 

Blade of wiper arm..................................... 55-7 

Replacement ......................................... 55-7 

Wiper motor assembly .............................. 55-9 

Replacement ......................................... 55-9 

Connection rod ........................................ 55-10 

Replacement ....................................... 55-10 

Washer ..................................................... 55-11 

Replacement ....................................... 55-11 

Injection nozzle ...................................... 55-12 

Replacement ....................................... 55-12 

Adjustment ......................................... 55-14 

55

Wiper and washer-Wiper and washer assembly 

Wiper and washer assembly 

Table of malfunction phenomenon 

55-1 

The following table will help you to find out the reason of malfunction. Series number means the 

order of possible reasons. Check every part according to this order and replace according to the 

requirement. 

Malfunction phenomenon Doubtful part Refer to 

Wiper does not work when the 

switch is turned on 

The wiper arm does not move 

when motor runs 

Wiper moves slowly 


2. Combined switch (damaged) 


4. Wire (open circuit or short 

circuit to ground) 

1. Wiper arm (loose) 

2. Wormgear (loose) 

3. Connection rod (loose) 

1. Battery (voltage is too low) 

2. Wire (bad contact) 

3. Motor bearing and reducer 

gear (bad lubricated) 


1. Glass (with oil dirt or wax) 

2. Blade of wiper arm (wrong 

type) 

- 


mechanism-Combined switch, 

Replacement 

Chapter 55 Wiper and washer- 

Wiper and washer assembly, 

Replacement 

- 

- 

- 

Chapter 55 Wiper and 

washer-Connection rod, 

Replacement 

- 

- 

- 



Replacement 

- 

Chapter 55 Wiper and washer-Blade 

of wiper arm, Replacement 

55 

Bad wiping effect 

3. Blade of wiper arm (rubber 

damaged) 

4. Wiper arm (damaged) 

Chapter 55 Wiper and washer-Blade 

of wiper arm, Replacement 

Chapter 55 Wiper and washer-Wiper 

arm assembly, Replacement 

Chapter 55 Wiper and washer-Wiper 

arm assembly, Replacement 

Strange noise 

Wiper can not be stopped 

5. Wiper arm (elasticity of spring 

is decreased) 

1. Wormgear rod (not 

lubricated) 

2. Connection rod mechanism 

(distorted) 

3. Connection rod head (worn) 

- 



Replacement 



Replacement 

1. Combined switch (damaged) Chapter 41 Steering 


Replacement

55-2 


Malfunction phenomenon Doubtful part Refer to 

Wiper does not work in the 

interval shift 


2. Wire (open circuit or short circuit 

to ground) 

3. Three in one controller 

(damaged) 



Replacement 

- 

- 

Wiper does not work at low 

speed 



to ground) 



Replacement 

- 

3. Three in one controller (damaged) 

- 

Wiper does not work at high 

speed 



to ground) 

3. Three in one controller 

(damaged) 



Replacement 

- 

- 

Wiper can not return to its 

original position when the 

switch is turned off 


to ground) 

2. Switch connection point of 

camshaft (bad contact) 

- 

- 

1. Washing liquid (deficient) 

- 

55 

Washer does not work but 

wiper works properly 

2. Injection nozzle (clogged) 

3. Tube (damaged) 



washer-Injection nozzle, 

Replacement 

- 



Replacement 



washer-Wiper motor assembly, 

Replacement 

6. Wire 

- 

1. Injection nozzle (clogged) 


washer-Injection nozzle, 

Replacement 

The washing liquid can not be 

injected 

2. Tube (damaged) 



- 


washer-Washer, Replacement 



Replacement 

5. Wire (open circuit or short circuit to 

ground 

-



55-3 

1. Washer motor 

(a). 

Function inspection 

• Pour water into the washing pot with washer 

motor inside. 

• Connect the positive pole(+)of battery with the 

No. 2 pin of washer motor; negative pole (-) 

with No. 1 pin of washer motor. Check if the 

water can flow out from washing pot. 

55

55-4 


Inspection 

1. Combined switch 

(a). 

Check the breakover 

· Check on/off among every pin of insert part. 




of multi meter 


OFF 4-7 ≤2Ω 

Interval 

4-7 

12-16 

≤2Ω 

Slow speed 7-18 ≤2Ω 

High speed 13-18 ≤2Ω 

(b). Check the interval working 

• Turn wiper switch to INT position. 

• Connect multimeter with No.12 and No. 16 pins 

of the combined switch. 

2. Wiper motor assembly 

(a). 

Check the function of low speed 




motor is running at low speed. 

(b). 

Check the function of high speed 

55 




motor is running at high speed. 

• Check the function of automatic stop 

Connect the positive pole(+)of battery with the No. 2 pin 

of washer motor; negative pole (-) with No. 3 pin of 

washer motor; disconnect the connection of No. 2 when 

the motor runs at low speed at any position except for 

automatic stop. 

• Connect the No.2 and No.5 pins of the motor; 

connect the positive pole(+)of battery with the 

No. 6 pin to restart the motor and make it run at 

low speed. 

• Check if the automatic stop position is correct.

Wiper arm assembly 

Replacement 

Wiper and washer- Wiper arm assembly 

1. Disassemble the left wiper arm 

(a). Run the wiper arm to automatic stop position. 

(b). Take out the nut cover. 

55-5 

(c). 

Turn over the left wiper arm, loose the nut and 

take off the wiper arm. 

2. Disassemble the right wiper arm 

Hint: 

The steps to disassemble right wiper arm are same with that of left wiper arm. 

3. Assemble left wiper arm 

(a). Clean the spline. 

55

55-6 

Wiper and washer-Wiper arm assembly 

(b). 

Put on left wiper arm and fasten the nut. 

(c). 

Turn over the left wiper arm and put on the nut 

cover. 

4. Assemble the right wiper arm 

Hint: 

The steps to disassemble right wiper arm are same with that of left wiper arm. 

55

Blade of wiper arm 

Replacement 

Wiper and washer- Connection rod mechanism 

55-7 

1. Disassemble the blade of left wiper arm 

(a). 

Turn over left wiper arm. 

(b). Disconnect the connection place and 

disassemble the blade of left wiper arm. 

2. Disassemble the blade of right wiper arm 

Hint: 

The steps to disassemble the blade of right wiper arm are same with that of left wiper arm. 

55

55-8 

Wiper and washer-Wiper arm assembly 

3. Assemble the blade of left wiper arm 

(a). 

Connect the connection position to assemble the 

blade of left wiper arm. 

(b). 

Turn over left wiper arm. 

2. Assemble the blade of right wiper arm 

Hint: 

The steps to assemble the blade of right wiper arm are same with that of left wiper arm. 

55

Wiper motor assembly 

Replacement 

Wiper and washer- Wiper motor assembly 

55-9 

1. Disassemble the blower assembly (refer to “Chapter 51 Heat and AC-Blower, 


2. Disassemble wiper motor assembly 

(a). 

Disconnect the insert part. 

(b). 

Loose 3 nuts to disassemble the wiper motor 

assembly. 

3. Assemble wiper motor assembly 

(a). 

Fasten those 3 nuts to assemble wiper motor 

assembly. 

55 

(b). 


4. Assemble the blower assembly (refer to “Chapter 51 Heat and AC-Blower, 

Replacement”)

55-10 

Wiper and washer- Connection rod mechanism 

Connection rod mechanism 

Replacement 

1. Disassemble the wiper arm (refer to “Chapter 55 Wiper and washer- Wiper arm, 


2. Disassemble blower assembly (refer to “Chapter 51 Heat and AC-Blower, 


3. Disassemble wiper motor assembly (refer to “Chapter 55 Wiper and washer- Wiper 

motor assembly, Replacement”) 

4. Disassemble the connection rod mechanism 

(a). 

Loose 4 fixation nuts to disassemble the connection rod mechanism. 

55 

5. Assemble the connection rod mechanism 

(a). 

Fasten 4 fixation nuts to assemble the connection rod mechanism. 

6. Assemble wiper motor assembly (refer to “Chapter 55 Wiper and washer- Wiper 

motor assembly, Replacement”) 

7. Assemble the wiper arm (refer to “Chapter 55 Wiper and washer- Wiper arm, 


8. Assemble blower assembly (refer to “Chapter 51 Heat and AC-Blower, Replacement”)

Washer 

Replacement 

Wiper and washer- Wiper motor assembly 

55-11 

1. Disassemble instrument panel (refer to “Chapter 73 Instrument panel/Combined 

meter/Cigar lighter-Instrument panel, Replacement”) 

2. Disassemble the washer 

(a). 

(b). 

Take off the tube and disconnect the insert part. 

Loose 3 bolts to disassemble the washer. 

3. Assemble the washer. 

(a). Fasten 3 bolts to assemble the washer. 

(b). Connect the tube and insert part. 

4. Assemble the instrument panel (refer to “Chapter 73 Instrument panel/Combined 

meter/Cigar lighter-Instrument panel, Replacement”) 

55

55-12 

Injection nozzle 

Replacement 

Wiper and washer-Injection nozzle 

1. Disassemble left injection nozzle 

(a). 

Screw off the fixation ring. 

(b). 

Screw out left injection nozzle and disconnect the 

tube. 

55 

2. Disassemble the right injection nozzle 

Hint: 

The steps to disassemble the right injection nozzle are same with that of left injection nozzle. 

3. Assemble left injection nozzle 

(a). 

Connect the tube and screw on left injection 

nozzle. 

(b). 

Fasten the fixation ring.

4. Assemble right injection nozzle 

Hint: 

Wiper and washer- Injection nozzle 

The steps to assemble the right injection nozzle are same with that of left injection nozzle. 

55-13 

5. Adjust the injection nozzle (refer to “Chapter 55 Wiper and washer-Injection nozzle, 


55

55-14 

Adjustment 

1. Check the injection nozzle 

Wiper and washer-Injection nozzle 

Start the engine and check the position where the washing liquid can be injected. 

2. Adjust the injection nozzle 

(a). 

Adjust the injection nozzle by small needle until the washing liquid is injected to specified 

position. 

Standard value: normally the injection angle is 15° to up/down and left/right. 

55

Audio System 

Audio system ..................................... 56-1 

Notes .............................................. 56-1 

Parts diagram .................................. 56-2 

Stereo unit .......................................... 56-3 

Replacement .............................. .....56-3 

Speaker ............................................... 56-8 

Replacement ................................... 56-8 

Antenna .............................................. 56-9 

Replacement. .................................. 56-9 

56

56

Audio system 

Notess 

1. Expression of ignition switch 

Audio system- Audio system 

56-1 


LOCK 

ACC 

ON 

START 

Expression of ignition switch 


Ignition switch ACC 



2. Cut off the power supply 

(a). 

Hint: 

It is a must to disconnect the negative cable of the battery first before assembly/disassembly 

any electric device and the bare terminals may be contacted by tools or devices; this will 

prevent personnel or vehicle from hurt. 

Do not leave key inside of vehicle before the disconnection of negative pole cable to prevent the 

door looking. 

(b). 


3. The disconnection of negative pole cable will reset daily odometer and clock. 

Hint: 


4. The disconnection of negative pole cable will make the audio system lose stored 

setting. 

Hint: 

The audio system needs to be reset after negative pole cable is connected. (refer to “Chinese and 

English Application Manual of Audio System”). 

56

56-2 

Parts diagram 


56 

1 Middle bracket assembly 

2 Stereo unit 

3 Cover of left central control panel screw 

4 

Cover of right central control panel 

screw 

5 Central control panel 

6 Speaker 

7 Antenna

Stereo unit 

Replacement 

Notes: 

Audio system- stereo unit 

It will lose the setting stored by stereo unit if it is disassemble, as radio station etc.. 

1. Turn off the audio system 

2. Ignition switch: OFF 

3. Disconnect the negative cable of battery 

Hint: 

56-3 

Please turn off the ignition switch and lighting switch 

first when the battery cable is connected and 

disconnected, and then loose the cable nut completely. 

Do not prize up the cable during above operations. 

4. Disassemble central control panel assembly 

(a). 

Disassemble the cover of left/right central control 

panel screws. 

56

56-4 


(b). 

(c). 

Note: 

Disassemble 2 fixation screws from central 

control panel. 

Pull out the central control panel backwards. 

Do not break the insert part on central control 

panel. 

(d). 

(e). 

(f). 

(g). 

(h). 

Disconnect the insert part of dangerous warning 

switch. 

Disconnect the insert part of ECU diagnosis 

switch. 

Disconnect the insert part of rear fog lamp switch. 

Disconnect the insert part of rearview mirror 

heating switch (if it is equipped). 

Disconnect the insert part of ABS diagnosis 

switch (if it is equipped). 

5. Disassemble the stereo unit 

(a). 

Disassemble 4 fixation bolts from the fixation 

bracket of stereo unit. 

56 

(b). Take out the antenna of stereo . 

Hint: 

The force to insert and pull out the antenna is 39.2 ± 

19.6 N


56-5 

(c). Disconnect the insert part of stereo unit. 

Note: 

Do not make stereo unit fall down. 

(d). 

(e). 

Disassemble 4 fixation screws from stereo unit. 

Take off stereo unit. 

56 

6. Assemble the stereo unit 

(a). Assemble 4 fixation screws of stereo unit. 

(b). Connect the insert part of stereo unit. 

(c). 

Connect the antenna of stereo.

56-6 


(d). 

Assemble 4 fixation bolts of stereo unit. 

56


7. Assemble the central control panel assembly 

(a). Connect the insert part of ABS diagnosis switch (if it is equipped). 

(b). Connect the insert part of rearview mirror heating switch (if it is equipped). 

(c). Connect the insert part of rear fog lamp switch. 

(d). Connect the insert part of ECU diagnosis switch. 

(e). Connect the insert part of dangerous warning switch. 

(f). Assemble 2 fixation screws from central control panel. 

56-7 

(g). 

Assemble the covers of left/right central control 

panel. 

8. Connect the negative cable of battery. 

9. Ignition switch: ON 

10. Reset stereo unit 

56

56-8 

Speaker 

Replacement 

Hint: 

Audio system-Speaker 

The steps to replace left and right speaker are same because they are symmetrical. 



3. Disassemble (right) inner trimming plate 

assembly of front door (refer to “Chapter 77 

Inner/outer trimming parts-Replacement”) 

56 

4. Disassemble (right) speaker 

(a). Disconnect the insert part of (right) speaker. 

(b). Disassemble 4 screws of (right) speaker. 

Note: 

Do not make the speaker fall down. 

5. Assemble the (right) speaker 

(a). 

(b). 

Assemble 4 screws of (right) speaker. 

Assemble the insert part of (right) speaker. 

6. Assemble (right) inner trimming plate assembly of front door (refer to “Chapter 77 

Inner/outer trimming parts-Replacement”)

Antenna 

Replacement 



56-9 

Audio system- Antenna 

3. Disassemble the antenna 

(a). Disassemble 2 fixation screws from antenna. 

4. Disassemble central control panel assembly 

(a). 

Disassemble the covers of screws on left/right 

central control panel. 

56

56-10 

Audio system- antenna 

(b). 

(c). 

Note: 

Disassemble 2 fixation screws from central 

control panel. 

Pull out the central control panel backwards. 

Do not break the insert part on central control 

panel. 

(d). 

(e). 

(f). 

(g). 

(h). 

Disconnect plug-in unit of dangerous warning 

switch. 

Disconnect the insert part of ECU diagnosis 

switch. 

Disconnect the insert part of rear fog lamp 

switch. 

Disconnect the insert part of rearview mirror 

heating switch (if it is equipped). 

Disconnect the insert part of ABS diagnosis 


5. Disassemble the stereo unit plug-in unit of 

antenna; 

(a). 

Disassemble 4 fixation bolts from the fixation 

bracket of stereo unit. 

56 

(b). 

Hint: 

Take out the antenna of stereo plug 

The force to insert and pull out the antenna plug is 39.2 

± 19.6 N 

Note: 

Do not make stereo unit fall down. 

(c). 

Take out antenna assembly.

Audio system- Antenna 

6. Assemble the antenna plug of stereo unit 

(a). Connect the antenna plug of stereo unit. 

Hint: 

The force to insert and pull out the antenna is 39.2 ± 19.6 N 

(b). Assemble 4 fixation bolts of stereo unit. 

56-11 

7. Assemble the central control panel assembly 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

Connect the insert part of ABS diagnosis switch 

(if it is equipped). 

Connect the insert part of rearview mirror heating 


Connect the insert part of rear fog lamp switch. 

Connect the insert part of ECU diagnosis switch. 

Connect the insert part of dangerous warning 

switch. 

Assemble 2 fixation screws from central control 

panel. 

56


56-12 

Audio system- antenna 

(g). 

Assemble the covers of screws on left/right 

central control panel 

8. Assemble the antenna 

(a). 

Assemble 2 fixation screws of antenna. 

56

Circuitry 

Guide to the circuit ....................................61-1 

Guide to the circuit .............................. 61-1 

Sample of the system circuit diagram ..61-2 

Sample power supply circuit diagram..61-3 

Sample of insert part information.........61-7 

Symbol of electric element ..................61-8 

Fuse and relay ..................................61-11 

System circuit diagram ..........................61-17 

Power supply system ....................... 61-17 

Start system......................................61-19 

Charge system................................. 61-21 

ABS(anti-lock brake) system .............61-23 

AC system ........................................ 61-27 

Combined meters ............................ 61-32 

Headlamp ......................................... 61-39 

Fog lamp .......................................... 61-42 

Turn warning lamp and dangerous 

warning lamp. ................................... 61-44 

Inside small lamp .............................. 61-46 

Outside clearance lamp ................... 61-49 

Ceiling lamp ...................................... 61-52 

Brake lamp ....................................... 61-54 

Reverse lamp .................................. .61-56 

License plate lamp ............................ 61-58 

Exhaust brake................................... 61-60 

Cigar lighter ...................................... 61-62 

Horn ................................................. .61-64 

Audio system ................................... .61-66 

Power window control system .......... 61-68 

Central control locking system ......... 61-71 

Wiper system .................................... 61-74 

Exhaust post-treatment control 

system .............................................. 61-76 

Wire inserts information ....................... 61-80 

Wire harness A (ABS ) ......................61-80 

Wire harness B (Body) ..................... 61-83 

Wire harness C (Chassis) ................61-99 

Wire harness D (Right door)........... 61-113 

Wire harness E (Left door) ............. 61-115 

Wire harness F (Ceiling wire).......... 61-117 

Wire harness G 

(Rear clearance lamp).................... .61-118 

Wire harness H (Right floor) ............ 61-119 

Wire harness I (Rear chassis) ......... 61-120 

Wire harness J (Left floor) ............... 61-122 

Layout of wire harness and parts ....... 61-123 

ABS wire harness ............................ 61-123 

Body wire harness 1.........................61-124 

Body wire harness 2 ........................ 61-125 

Body wire harness 3 ........................ 61-126 

Chassis wire harness 1 ................... 61-127 

Chassis wire harness 2 ................... 61-128 

Chassis wire harness 3 

(rear chassis and clearance lamp)...61-129 

Right door wire harness ................ 61-130 

Left door wire harness ................... 61-131 

Ceiling, Left floor and Right floor 

wire harness.....................................61-132 

61

61

Guide to the circuit 

Guide to the circuit 

Circuit- Guide to the circuit 

61-1 

This manual provides the circuit data of related vehicle, and the circuit is divided into different 

systems circuit according to functions. It is described the power supply, fuse, relay, control part, and 

the relationship between electricity consuming device and grounding (earth) of every system circuit 

(in all circuit diagram, ignition switch is at OFF state). 

It is required to know the working principle of the system circuit first (refer to system circuit part), 

then know the power supply (refer to power supply part), and at last know the operation process of 

the circuit (refer to system summarization) when there is any failure in the system circuit. You can 

analyze and solve the problem according to the phenomenon of the failure (according to the relay, 

control part, electricity consuming device, insert parts between wire harness, sensor, actuator, 

switch, grounding point of the circuit, the position of electric device insert and the layout of wire 

harness) after you know the working conditions of the circuit. 

61

61-2 

Circuit-Guide to circuit 

Sample of the system circuit diagram 

Turning lamp 

Battery 

White- Blue 

ON/SART 

i 

Fuse box of chassis1 

White 

- Blue 

Red - 

White 

Black-white 

White 

- Blue 

White 

61 

IG power 

relay 

Fuse box of body 

Green 

-Orange 

Red - White 

Green -White 

Whit -Blacke 

Terminal 

Switch 

(position) 

OFF 

ON 

Warning 

switch 

Blue 

-White 

Green 

-White 

Green 

-White 

Green 

-White 

Terminal 

Switch 

(position) 

Left 

Green -Yellow 

Combined switch 

Headlamp 

Right 

Green - 

Yellow 

Controller 

Green - 

Blacke 

Green 

-Blacke 

Green 

-Blacke 

Green - 

Yellow 

Green - 

Yellow 

Green - 

Yellow 

Green - 

Blacke 

Turn light Turn light 

Instrument Turn light Turn light 

Whit -Blacke 

Whit -Blacke 

Whit -Blacke Whit -Blacke Whit -Blacke 

Whit -Blacke 

Whit -Blacke 

* It is just an example and it is different from actual system circuit diagram.

Note: 


61-3 

S/N Name Description 

1 System name 

2 Lead color 

It is an integral name with specific function and is composed 

of some electric elements. 

It is used to separate the lead for inquiry 

The color of lead is basically one color or double color. 

For example: 

Red 

(red) 

Blue-Black (blue and black) 

3 Name of electric element It is name by the function of electric element. 

4 SN of electric element 

5 

Pin of electric element 

insert 

It is a king of SN according to the wire harness where the 

insert part of electric element locates; one insert is 

corresponding to one SN for searching. 

The arrangement order made to the insert pin of electric 

element is used to search and maintain. 

Normal order: (except for special conditions) 

Socket 

61 

Insert of wire harness 

6 

7 

8 

Grounding (earth) 

position 

Indication mark of 

related system 

Connection part No. of 

wire harness 

The connection point of return circuit of electric element and 

metal body of vehicle. 

It is defined with different No. according to the different 

grounding (earth) position. 

It is used to indicate the lead function has relationship with 

other system; the detailed situation should refer the 

indicated system. 

The No. of the insert that is used to the connection between 

wires. 

One group of insert part between wire harness is two piece: 

male insert and female insert 

9 

Insert part of wire 

harness 

Male insert 

Metric Plug 

Metric System 

symbols 

Female insert 

Master System plug 

Mother System symbols

61-4 


61 

System summarization- 

· Battery provides current, and current is supplied to the controller of central control lock through fuse 

F/L 0 inside of chassis fuse box, fuse F/L 2 and fuse F13 inside of body fuse box, controlling the door 

opening and locking. 

· Left door lock will be locked when the driver presses down the button of left door lock. Pin No. 6 of 

central control lock controller to pin No. 1 of left front door lock, and ground through pin No. 2 of left 

front door lock passing the switch of left door to produce the grounding signal. The grounding signal 

input to central control lock controller will be used to confirm the left door is under locked. Current goes 

to pin No. 1 of right front door lock through pin No. 4 of central control lock controller, then goes to 

motor, pin No. 2 of right front door lock, to pin No. 2 of central control lock controller; the motor gets 

electrified and runs to forward direction, and the right front door is locked. 

· Left door lock will be opened when the driver lifts the left door lock button. The pin No. 6 of central 

control lock controller can not form a return circuit, so there will be no grounding signal generated. 

There is no grounding signal input into central control lock controller, so it is confirmed that the left door 

is open. Current goes to pin No. 2 of right front door lock through pin No. 2 of central control lock 

controller, then goes to motor, pin No. 1 of right front door lock, to pin No. 4 of central control lock 

controller; the motor gets electrified and runs to reverse direction, and the right front door is opened. 

Service hint- 

· B035 controller of central control lock 

3- grounding: voltage is about 24V. 

4- grounding: moment voltage is about 24V when the button of left door lock is pressed. 

2- grounding: moment voltage is about 24V when the button of left door lock is lifted. 

· D005 right front door lock 

1- grounding: moment voltage is about 24V when the button of left door lock is pressed. 

2- grounding: moment voltage is about 24V when the button of left door lock is lifted. 

· E005 left front door lock 

1-2: resistance is about 0 when the button of left door lock is pressed down and the contact point is 

closed. 

Resistance is about∞when the button of left door lock is lifted and the contact point is opened. 

part position- 

S/N 

Reference wire 

harness 

S/N 


harness 

S/N 


harness 

B035 Body wire C051 Chassis wire E005 Left door wire 

B050 Body wire D005 Right door wire 

: nsert parts among wire harnesses- 

S/N S/N Reference wire harness (position of the insert parts) 

B103 C101 Body wire and chassis wire (middle of the first cross member of frame) 

D101 

B101 

Right door wire and body wire (right of washing pot right under the instrument 

panel) 

E101 B111 Left door wire and body wire(clutch pedal left under the instrument panel) 

: grounding- 

S/N 

B206 

B207 

Grounding position 

Grounding on the right side of instrument panel 

Grounding on the right side of front panel 

* It is just an example and it is different from actual system circuit description.

Note: 


61-5 


10 

System 

summarization 

11 Service guide 

12 Part position 

13 

14 

Insert part of 

wire harness 

Grounding 

(earth) 

Summary to describe the system or the working principle of the system. 

It is used to describe the numeral value or working state of electric element; for 

reference during troubleshooting. 

It is used to indicate the page of wire harness needs to be referred (the position 

of the electric element on vehicle and the direction of the wire harness) 

It is used to indicate the reference wire page of the wire to which insert part 

connecting to each other belong (the wire with female connector is in the front 

and the wire with male connector is in the rear). 

It is a reference page to indicate the connection point of return circuit of electric 

element and metal body of vehicle. 

61

61-6 


Sample of the power supply circuit diagram 

The power supply circuit diagram describes the current transportation way of the electric system of 

complete vehicle (fuse cutout, fuse and relay). Inside of power supply circuit diagram, the electricity 

supplying conditions of every system are explained. All the system circuit diagrams start from power 

supply, so we must know the power supply system completely. 

Condenser blower 

Main relay R18 

Alternator 

AC system 

61 

White 

-Blue 

White 

-Blue 

AC system 

Combined instrument 

Audio system 

ABS system 

Inside lamp 

Fog lamp 

Relay of power 

window R12 

Control system of 

power window 

Control system 

of exhaust post-treatment 

Battery 

* It is just an example and it is different from actual system circuit diagram.


Sample of insert part information 

61-7 

Condenser blower 

main relay 

Generator 

White-b 

lue 

Air conditioner 

system 

White-b 

lue 

Air conditioner 

system 

Combination 

instrument 

Audio system 

ABS brake 

anti-lock systme 

Residential lamp 

Fog lamp 

Power window 

relay 

Power window 

control system 

61 

Processing control system after 

exhaust 

Battery 

* It is just an example and it is different from actual insert part information. 

Note: 


1 Shape of insert part It is described the outline of insert part and the order of inside pins. 

2 

3 

4 

Name of electric 

element 

SN of electric 

element 

Information of insert 

part 

It is name by the function of electric element. 

One electric element is corresponding to one name and the name inside of 

circuit diagram. 

It is a king of SN according to the wire harness where the insert part of 

electric element locates; one insert is corresponding to one SN for 

searching. 

The shape of insert part 

It is used to make the arrangement order of the pin of insert part of electric 

element. 

It is defined the color and function of pin wire.

61-8 

Symbol of electric element 

Battery 


It is used to store chemical energy which is converted into electric 

energy required by vehicle electric device. 

Fuse cutout 

Fuse 

Grounding (earth) 

Negative wire (or housing) of electricity consuming device connects 

with the metal part like frame, and take it as public passage; this kind 

of connection method is called as grounding (earth). 

Fuse cutout(fuse) 

In big power circuit (or circuit of one electricity consuming device) 

when the passed current exceeds rate load, it will burnt automatically 

to disconnect the current and protect the circuit. 

61 

Electromagnetic induction coil 

Coil in closed circuit moves to cut the magnetic line of force in 

magnetic field; the changes of magnetic flux will produce electromotive 

force. 

Solenoid valve 

Electrified electromagnetic coil controls the valve and control the 

direction of current by valve. 

Lighting buld,single filament 

Lighting lamp 

It is a kind of device providing light for vehicle running. 

Normally it is divided into single filament and double filaments. 

Single speed motor 

Lighting buld,dual filament 

Dual speed motor 

Motor 

It converts electric energy into mechanical energy. 

It is according to electromagnetic induction principle: stator coil is 

electrified and then generate magnetic field; rotor cuts the magnetic 

field and produce inductive electric potential which will flow through 

rotor and reciprocate with rotated magnetic field; rotor will rotate 

pushing by the electromagnetic torque. 

Insert part 

It is used to insert to each other of wire harness.


61-9 

Crystal diode 

It is a kind of semiconductor, and its function is to permit the current flow as 

fixed direction. 

Light emitting diode 

It is a kind of Crystal diode, and its function is to convert electric energy into 

light energy. 

Horn 

It is a kind of electroacoustic element, and its function is to convert 

electrical signal into sound. 

Resistance 

Resistance 

It is a kind of electronic element, and its function is to partial pressure and 

limit the current. 

Speed adjusting resistor 

61 

Sensor (temperature) 

It is a kind of resistor with its resistance changes with the changes of 

temperature; its function is to convert temperature changing into electrical 

signal. 

Cigar lighter 

It is a kind of resistor, and it can light the cigar by generated heat when the 

current passed the resistor for a while. 

Touch switch 

It is a kind of switch and its function is to connect and disconnect the circuit 

by touching two points at the same plane. 

Rotate type switch 

It is a kind of switch and it changes shift by rotation to connect and 

disconnect he circuit. 

Warning switch 

It is a kind of automatic switch and its function is to convert physical 

variable into electric signal by sliding resistor and switch.

61-10 


Big relay 

12 relay 

Relay 

It is a kind of automatic switch to control bigger 

current by smaller current; its function is self 

adjustment, safety protection and changes the circuit 

etc.. 

12V small relay 

61

Fuse and Relay 

Position of fuse box 

Circuit- Guide to circuit 

61-11 

Body fuse box 


61 

Chassis fuse box 2

61-12 

Body fuse box 


Electromagnetic 

clutch relay 

IG power 

supply relay 

Blower 

relay 

Power 

window relay 

Light changing 

relay 

light relay 

61 

Main relay 

of AC 

AC turn 

off relay 

Horn 

relay 

Front fog 

lamp 

relay 

Right 

Small highbeam 

lamp relay relay 

left 

highbeam 

relay 

Fuse 

S/N 

Rated 

current 

F1 15A Fuse, preheat 

F2 15A Fuse, starting 

Name 

F3 20A Fuse, rear power window 

F4 20A Fuse, power window 

F5 7.5A Fuse , rear fog lamp 

F6 15A Fuse, cigar lighter 

F7 15A Fuse, right highbeam 

F8 15A Fuse, left highbeam 

F9 15A Fuse, right lowbeam 

F10 15A Fuse, left lowbeam 

S/N 

Rated 

current 

Name 

F11 15A Fuse, danger waning lamp 

F12 10A Fuse, small lamp 

F13 15A Fuse, central control lock 

F14 7.5A Fuse, brake lamp 

F15 10A Fuse, ceiling lamp 

F16 25A Fuse, heater 

F17 7.5A Fuse, instrument 

F18 15A Fuse, A/C switch 

F19 15A Fuse, turning lamp 

F20 15A Fuse, wiper


61-13 

S/N 

Rated 

current 

Name 

S/N 

Rated 

current 

Name 

F21 5A Fuse, ABS control unit 

F22 10A Fuse, AC 

F23 

15A 

Fuse, Power of ABS control 

unit 

F24 15A Fuse, front fog lamp 

F25 15A Fuse, ignition switch 

24V relay 

S/N 

Name 

S/N 

Name 

61 

R10 

Relay, light 

R13 

Relay, blower 

R11 

Relay, light changing 

R14 

Relay, IG power 

R12 

Relay, power window 

R15 

Relay, electromagnetic crutch 


S/N 

Name 

S/N 

Name 

R30 

Relay, left highbeam 

R34 

Relay, horn 

R31 

Relay, right highbeam 

R35 

Relay, AC switching off 

R32 

Relay, small lamp 

R36 

Main relay, AC 

R33 

Relay, front fog lamp

61-14 



Relay, 

exhaust 

brake 

Relay, diesel filter Relay, diesel filter Relay, speed adjustment 

of condenser 

61 

Main relay, 

condenser 

blowe 

Relay, starting; 

Fuse cutout 

S/N 

Rated current 

S/N 

Rated current 

F/L0 

80A 

F/L3 

60A 

F/L1 

50A 

F/L4 

40A 

F/L2 

50A

Fuse 


61-15 

S/N 

Rated 

current 

Name 

S/N 

Rated 

current 

Name 

F26 5A Fuse, ECM ignition 

F27 15A Fuse, diesel filter 

F28 20A Fuse, blower of condenser 

F29 30A Fuse, ECM power supply 

F30 

15A 

Fuse, lighting inside of van 

truck 

Big relay 

61 

S/N 

R1 

Relay, starting 

Name 

24V relay 

S/N 

Name 

S/N 

Name 

R30 

Relay, condenser 

R18 

Main relay, blower of condenser 

R31 

Relay, speed regulation of 

condenser 


S/N 

Name 

S/N 

Name 

R37 

Relay, exhaust brake 

R38 

Relay, diesel filter

61-16 



Relay, sensor of 

nitrogen oxide; 

Relay, heating of 

post-treatment 

61 

Fuse 

S/N 

Rated 

current 

Name 

S/N 

Rated 

current 

Name 

F31 5A Fuse, post-treatment unit 

F32 

24V relay 

20A 

Fuse, heating of 


F33 

F34 

30A 

20A 

Fuse, power supply of 

post-treatment control unit 

Fuse, sensor of nitrogen 

oxide 

S/N 

Name 

S/N 

Name 

R19 

Relay, sensor of nitrogen oxide 

R20 

Relay, heating of post-treatment

System circuit diagram 

Circuit- System circuit diagram 

61-17 

Power supply system 

Cigar lighter 


Audio system 

AC system 

Alternator 

starting relay 

starter 

61 

blower of 

condenser 

Main relay 

AC system 

AC system 

AC system 

Combined meters 

Audio system 

ABS anti-lock braking 

system 

ABS anti-lock 

braking system 

Turn warning lamp 

and dangerous 

warning lamp 

Horn 

Inside lamp 


Inside small lamp 

Outside clearance 

lamp 

Fog lamp 

Door lock control 

system 

Fog lamp 

power window relay 

power window 

control system 

starter 

Battery 

Control system of exhaust post-treatment

61-18 


Inside 

lamp 

Combined meters 

ABS anti-lock braking system 

Exhaust brake 

Turn warning lamp and 

danger warning lamp 

Reverse lamp 

Wiper system 

Brake lamp 

61 

AC system 

left highbeam 

relay 

light changing 

relay 

Right 

highbeam 

relay 

Headlamp 

light 

relay

Starting system 

Starting system 


61-19 

battery 


Starting 

relay 

61 

Black-red 

white-red 

red white White-black Black-red white 

Body 

fuse box 

Black-white 

White-blue 

Starter 

Terminal 

Switch 

(position) 


Self-grounding

61-20 


Service hint 

· B026 Ignition switch 

1-3: it is connected when the ignition switch is at ON or ST. 

1-2: it is connected when the ignition switch is at ST. 

· R1 starting relay 

1`-4 When ignition switch locate ST position, contactor is closed 

: part position 

1-4: the contacts will be closed when the ignition switch is at ST. 



S/N 

S/N 

harness 

harness 

S/N 


harness 

B026 Body wire C008 Body wire C051 Chassis wire 

B050 Body wire C009 Body wire 

61 

: insert parts among wire harnesses 




: grounding 

S/N 

B237 

B238 


The chassis wire is grounded 

The chassis wire is grounded

Charging system 

Charging system 


61-21 

battery 



Black-white 

61 

White-red 

White 

IG power 

relay 

Body fuse box 

White 

blue 

Combined 

meter 

White-red 

White-black 

White-red 

Alternator 

Self grounding

61-22 


System summarization 

· The current goes through IG power supply relay when ignition switch is turned on, and R14 

electromagnetic coil is grounded; electromagnetic coil will generate magnetic field, and contacts of 

relay R14 will be closed; current of battery goes to fuse F/L4 through main fuse F/L0, goes to the pin 

No. 10 of combined meter through the contact of relay R14, goes to pin No. 6 of combined meter and 

excitation bind posting of alternator through charging indicator, goes to the excitation of alternator 

excitation winding. 

· The alternator begins to supply electricity through 2 circuits after it is run. 

One circuit: internal supply to voltage regulator and to alternator excitation winding through the voltage 

regulator to control the electricity capacity generated by alternator. 

The second circuit: goes to battery through F/L0 to charge the battery with constant voltage and supply 

electricity to power consuming devices. Now, the voltage on pins No.10 and No. 6 of combined meters 

are supplied by alternator, so they are at the same potential and charging indicator will be off. 

: part position-12 

61 

S/N 

Reference 

wire harness 

S/N 

Reference 

wire harness 

S/N 

Reference 

wire harness 

B033 Body wire C004 Chassis wire C051 Chassis wire 

B050 Body wire C005 Chassis wire 

: insert parts among wire harnesses-13 



D106 B104 Chassis wire and body wire (middle of the first cross member of frame)



61-23 


Battery 


Chassis fuse 

box 1 

C051 

White- 

Blue 

White- 

-Red 

Black 

-White 

White- 

Blue 

White 

61 

IG 

power 

supply 

R14 

Body fuse box 

B050 

ABS 

inspectio 

n 

interface 

B023 

Red 

Yellow 

White- 

Black 

White- 

Blue 

White 

White- 

Black 

White- 

Black 

White- 

Black 

Yellow 

Malfunction 

indicator of 

ABS 

ABS control unit B013、B014 

White- 

Black 

White- 

Black 

Brown 

Black 

Brown 

Blue 

Brown 

Black 

Brown 

Blue 

Yellow 

-Red 

White- 

Black 

Brown 

Black 

Brown 

Blue 

Brown 

Black 

Brown 

Blue 

Left front 

wheel speed 

sensor 

A005 

Green- 

Yellow 

Left front 

wheel 

Electroma 

gnetic 

valve 

A004 

Right front 

wheel speed 

sensor 

A002 

Green- 

Yellow 



valve 

A003 

Green- 

Yellow

61-24 


ABS control unit B013,B014 

Oran 

ge 

brow 

n 

black 

brow 

n 

Blue 

brow 

n 

black 

brow 

n 

Blue 

61 

ABS 

flasher 

indicator 

Inside 

small lamp 

Gree 

n 

Oran 

ge 

brow 

n 

black 

brow 

n 

Blue 

brow 

n 

black 

brow 

n 

Blue 

ABS 

diagnos 

is 

switch 

B046 

Wheel 

speed 

sensor of 

left rear 

wheel 

A006 

Left rear 

solenoid 

valves 

A007 

Wheel 

speed 

sensor of 

right rear 

wheel 

Right 

rear 

solenoid 

valves 

A009 

White 

- 

Black 

White 

- 

Black 

Greenyellow 

Greenyellow 

Greenyellow


Circuit-System circuit diagram 

61-25 

· ABS (anti-lock braking system) is a kind of electronic control system to monitor and control the vehicle 

speed during brake. ABS works through normal brake system and enhance the active safety 

performance of the vehicle. Its task is to prevent the wheel from locking because of over high brake 

force (especially on the slippery road), and this will guarantee the horizontal traction force even under 

complete brake; guarantee the best effect of the driving stability, steering controllability and brake 

compatibility of the vehicle. At the same time to realize the optimization of brake friction force between 

tyre and road surface, speed reduction and brake distance. 

Input signal 

· ABS control unit detects the wheel speed signal by the wheel speed sensors on left front wheel, right 

front wheel, left rear wheel and right rear wheel. 

System operation 

· the operation of ABS system: gear ring matches with sensor to generate inductive voltage signal and 

the signal is transported to ABS control unit; ABS control unit receives and treats the electric signal 

from sensor, and it will send the signal to solenoid valve; solenoid valve regulates the brake pressure 

inside of brake chamber according to the order given by ABS control unit. ABS indicator is used to 

remind the driver whether ABS system works properly or not. 

Service hint: 

· A002 wheel speed sensor of left front wheel; A005 wheel speed sensor of left front wheel; A006 

wheel speed sensor of left rear wheel; A008 wheel speed sensor of right rear wheel. 

1-2: sensor resistance is between 110-1250Ω . 

· A003 solenoid valve of right front wheel; A004 solenoid valve of left front wheel; A007 solenoid 

valve of left rear wheel; A009 solenoid valve of right rear wheel. 

2-grounding: 14-15.5Ω 

3-grounding: 14-15.5Ω 

61 

: part position 

S/N 

Reference 

wire 

harness 

S/N 

Reference 

wire 

harness 

S/N 

Reference 

wire 

harness 

A002 ABS wire A007 ABS wire B023 Body wire 



A005 ABS wire A013 Body wire C051 Chassis wire 

A006 ABS wire A014 Body wire 

: insert parts among wire harnesses-13 



D101 B108 ABS wire and body wire (middle of the first cross member of frame)

61-26 


: grounding 

S/N 

A201 

B203 

B206 

B207 

B208 

B209 


ABS wire is grounded 

Left side of instrument panel is grounded 

Right side of instrument panel is grounded 

Right side of front panel is grounded 



61

AC system 

AC system 


61-27 


Battery 

Main relay 

of 

condenser 

blower 

Relay of 

condenser 

Relay of 

condenser 

regulator 

Chassis 

fuse box 1 

Black-White 

White -red 

White-blue 

White 

-blue 

Red-black 

Green 

61 

The 

conde 

nser 

fan 

C003 

Blue-white 

Electromagneti 

c clutch of 

compressor 

White-Black 

Blue 

-white 

White 

Green-red 

White-Black 


Reboot 

your 

system 

IG power 

supply 

Air 

conditionin 

g cut 

relays 

R35 

Warm air 

relays 

Body fuse 

B050 

Blue-white 

Yellow-red 

White-Black 

Yellow-red

61-28 


61 

Green 

Green 

Green 

Air 

condition 

ing main 

relays 

R36 

Electromag 

netic clutch 

Relay 

R15 

Body 

fuse box 

B50 

Black 

-Red 

Black 

-Red 

Brown 

-Red 

Brown 

-Red 

Yellow 

-Red 

Red- 

Blue 

Blue 

- Red 

Red 

Red 

White- 

Black 

White- 

Black 

White- 

Black 

Black 

-White 

Blue- 

White 

Blue- 

White 

Blue- 

White 

Blue- 

White 

Blue- 

Black 

Blue- 

Black 

Blue- 

Orange 

Blue- 

Yellow 

AC milan 

switch 

B043 

White- 

Black 

White- 

Green 

White- 

Orange White- 

Orange 

White- 

Orange 

Engine 

control 

unit 

C033 

High 

voltage 

switch 

Low-vol 

tage 

switch 

Medium 

voltage 

switch 

Air 

pressure 

switch 

C002 

AC amplifier 

Signal 

amplifier 

B001 

Blue- 

Black 

Blowers 

B007 

Speed resistance 

B005 

Fan 

switch 

B042 

Yellow 

-Orange 

White- 

Green 

Thermistors 

B008 

Yellow 

-Red


61-29 


· The current of battery is divided into two circuits after it passes main fuse F/L0: one circuit passes fuse 

F/L1 to the R18 contact of main relay of condenser blower, and it is prepared for the work of condenser 

fan; the second circuit passes F/L4 to R14 contact of IG power supply relay and to R13 contact of heater 

relay through fuse F16 to provide power supply to blower separately. Current passes IG power supply 

relay when the ignition switch is turned on, and R14 electromagnetic coil is grounded; electromagnetic 

coil will generate magnetic field, and contacts of relay R14 will be closed; current of battery goes to fuse 

F/L4 through main fuse F/L0; through the contact of relay R14 and fuse F18, it will be divided into 3 

circuits: one circuit to the electromagnetic coil of AC main relay R36; the second circuit goes to the 

electromagnetic coil of main relay R18 of condenser blower and the electromagnetic coil of condenser 

relay R16; the third coil pass the contact of AC cut off relay R35 to the No. 4 pin of AC switch, to 

electromagnetic coil of heater relay R13, to fuse F22, to the contact of AC main relay R36, to No. 4 pin of 

signal amplifier, to the contact of electromagnetic clutch relay R15, to the No. 2 pin of AC pressure 

switch, and through the high voltage switch and low voltage switch inside of AC pressure switch to the 

No. 4pni of AC pressure switch; and then to the No. 3 pin of signal amplifier and the electromagnetic coil 

of electromagnetic clutch relay R15, prepare to run the AC. 

Idle state of the AC 

· Idle state of the condenser fan 

IG power supply relay will be electrified when the ignition switch is turned on; the current passes fuse F18 

and is divided into 2 circuits, one circuit goes the electromagnetic coil of condenser relay R16 and to the 

No. 1 pin of AC pressure switch; to the No.3 pin of AC pressure switch to ground through middle voltage 

switch; electromagnetic coil will produce magnetic field and contacts of relay R16 will be closed (30 and 

87 is connected); another circuit goes to the electromagnetic coil of main relay R18 of condenser fan; 

electromagnetic coil will produce magnetic field and contacts of relay R18 will be closed; then current 

goes through the contacts to fuse F28, to No.3 pin of condenser fan, to No. 4 pin of condenser fan and 

contact of condenser relay R16 through fan motor; to the contact of condenser regulation relay R17 

through the contacts of relay R16 (30 and 87); prepare to run the condenser at low speed. 

61

61-30 


AC runs state 

61 

AC starts to run when AC switch is at closed position and the blower switch is at LO position 

· Running state of blower 

Current goes through electromagnetic coil of heater relay R13 to the pin No. 12 of blower switch; to the 

pin No. 9 of blower switch to ground through blower switch; electromagnetic coil generates magnetic field 

and contact of relay R13 closes; current goes through the contact of heater relay R13 to the pin No. 1 of 

blower; to pin No. 2 of blower and pin No. 9 of speed regulating resistor through blower motor; to pin No. 

4 of speed regulating resistor and pin No. 12 of blower switch through speed regulating resistor; to pin 

No. 9 of blower to ground through blower switch, and the blower starts to run at low speed. 

Current goes through blower motor to pin No. 2 of blower and pin No. 1 of speed regulating resistor when 

blower switch is at M1 position; to pin No. 2 of speed regulating resistor and pin No. 1 of blower switch 

through speed regulating resistor; to pin No. 9 of blower to ground through blower switch. 

Current goes through blower motor to the pin No. 2 of blower and pin No. 1 of speed regulating resistor 

when blower switch is at M2 position; to pin No. 3 of speed regulating resistor and pin No. 8 of blower 

switch through speed regulating resistor; to pin No. 9 of blower to ground through blower switch. 

Current goes through blower motor to pin No. 2 of blower and pin No. 11 of blower switch when blower 

switch is at HI position; to pin No. 9 of blower to ground through blower switch. 

· Compressor runs state 

From pin No. 11 of signal amplifier to pin No. 5 of AC switch; through AC switch to pin No. 6 of AC switch 

and pin No. 12 of blower switch; to pin No. 9 of blower through blower switch; signal amplifier confirms 

the running signal of AC and controls the electromagnetic coil of the electromagnetic clutch relay R15 to 

ground through pin No. 7 of signal amplifier; electromagnetic coil generates magnetic field and contacts 

of relay R15 is closed; current goes through the contacts of electromagnetic clutch relay R15 to the pin 

No. 27 of engine control unit; and engine control unit will control the electromagnetic coil of AC main relay 

R36 after it receives the signal; engine control unit is grounding and electromagnetic coil generates 

magnetic field; contacts of relay R36 close and current goes through the contact of AC main relay R36 to 

the pin No. 1 of compressor electromagnetic clutch; to the external housing to ground through the 

electromagnetic coil of clutch; compressor starts to run. 

AC pressure switch will be at disconnection state when there is abnormal of high voltage or low voltage 

inside of AC system; electromagnetic clutch relay R15 will be failed and compressor stops running. 

· Condenser fan runs state 

Current goes through the contacts of AC main relay R36 to electromagnetic oil of speed regulating relay 

R17 of condenser to ground when compressor is at working state; electromagnetic coil is electrified to 

produce magnetic field; contacts of speed regulating relay R17 of condenser close and current goes 

through the contacts of speed regulating relay R17 of condenser to pin No. 1 of condenser fan; to pin No. 

2 of condenser fan to ground through inside resistor; condenser fan starts to ran at low speed. 

Electromagnetic oil of condenser relay R16 will fail when middle voltage switch is turned on; contacts of 

condenser relay R16 will return (30 and 87a is connected); pin No. 4 of condenser fan is grounded 

through the contact of condenser relay R16; condenser fan starts to ran at high speed. 

:Part position 

S/N 


harness 

S/N 


harness 

S/N 


harness 

B001 Body wire B042 Body wire C003 Chassis wire 




: position of the insert part 




C103 B107 Body wire and chassis wire (middle of the first cross member of frame)


61-31 

: Grounding 

S/N 

B206 

B207 

B208 

B209 

C237 

C238 






Chassis wire harness is grounded 


61

61-32 

Combined meter 



Battery 


ON/START 

Chassis fuse 

box 1 

Black-White 

White-Blue 

White-Red 

61 

White-Blue 

White 

IG power 

relay 

Vehicle body fuse box 

White-Black 

Yellow 

Blue 

Black- 

Red 

Black- 

Red 

Black- 

Red 

Urea 

meter 

Water 

temper 

ature 

meter 

Tacho 

meter 

Indicator 

of 

engine 

preheat 

SVS 

warning 

lamp 

Warning 

lamp of 

engine 

stop 

Urea 

indicator 

Engine 

malfunction 

indicator 

Combined 

meter 

Yellow-Black Blue-Black White- White- 

Blue Black 

Red-Blue 

Blue- 

Yellow 

Red 

Yellow- 

Red 

White- 

Red 

Yellow-Black Blue-Black White- White- 

Blue Black 

Red-Blue 

Blue- 

Yellow 

Red 

Yellow- 

Red 

White- 

Red 

Post-treat 

ment 

control unit 

Water 

temper 

ature 

sensor 

Engine 

control unit 

Self grounding


61-33 

Speedometer 

/odometer 

Fuel meter 

Fuel 

warning 

Warning 

indicator of 

air filter is 

clogged 

Charging 

indicator 

ABS/ASR 

flasher 

indictor 

Combined 

meter 

ABS 

system 

Yellow-Black Yellow-Red 

Green- 

Yellow 

Green- 

White 

Blue-Red 

White-Red 

61 

Yellow-Black 

Yellow-Red 

Blue- 

Yellow 

Blue-Red 

Red- 

Yellow 

White-Red 

Orange 

Sensor of 

speedomete 

r/odometer 

Fuel 

sensor 

Alternator 

Switch of warning indicator 

of air filter is clogged 

ABS diagnosis switch 

White-Black 

White-Black 

White-Black 

White-Black

61-34 


Turn left 

Turn right 

Low pressure 

warning 

indicator 

Buzzer 

warning 

ABS 

malfunction 

lamp 

Brake 

liquid level 

warning 

lamp 

Combined 

meter 

Red-Black 

Red-Black 

Yellow 

Blue-White 

61 

Green-Black Green-Yellow White- 

Black 

Red-Black 

Terminal 

Switch 

(position) 

Off 

Lighting 

Danger 

warning 

switch 

Over low 

pressure 

annunciat 

or 1 

Over low 

pressure 

annunciat 

or 2 

Warning switch of 

brake liquid level 

ON 

ABS 

control unit 

White- 

Black 

Self 

grounding 

Self 

grounding


61-35 

Indicator 

of front fog 

lamp 

Indicator 

of rear fog 

lamp 

Reverse 

indicator 

Indicator of 

exhaust brake 

Highbeam 

indicator 

Combined 

meter 

White- 

Black 

Blue-Red Red-Yellow Green-Red Green-Yellow 

Blue- 

White 

61 

Fog lamp 

system 

Fog lamp 

system 

Headlamp 

system 

Green-Red 

White-Black 

Reverse 

lamp switch 

Combine switch 

Reverse lamp 

system

61-36 


Warning of 

coolant level 

Warning of oil 

pressure 

Parking brake 

indicator 

Combined 

meter 

61 

Red-Black 

White-Red 

Red-Yellow 

Red-Black 

White-Red 

Red-Yellow 

Water level 

warning 

switch 

Oil pressure 

warning 

switch 

Parking brake 

indicator switch 

White-Black 


Self grounding


61-37 

Service hint: 

• C001 warning lamp switch of clogged air filter 

1-2: the switch will be closed when the vacuum degree is 6 ± 0.5 KPa; the indicator on meter will be lit 

and starts warning. 

• B022 brake fluid warning switch 

1-2: the switch will be closed with the descending of the brake fluid; the indicator on meter will be lit and 

starts warning. 

• B032 combined meter 

9-grounding: ignition switch is at ON position and the voltage is about 24V. 


2-grounding: the voltage is about 24V. 

10, 11-grounding: ignition is at ON position and the voltage is about 24V. 


3- grounding: ignition switch is at ON position and the voltage is about 24V. 

• C027 over low pressure annunciator 1 

1-grounding: the switch will be closed when the air pressure is lower than 0.4 ± 0.025 MPa; the indicator 

on meter will be lit and starts warning. 

• C032 reverse lamp switch 

2-1: the switch will be closed when the gear shift lever is at reverse position; the indicator on meter will be 

lit. 

• C037 over low pressure annunciator 2 

1- grounding: the switch will be closed when the air pressure is lower than 0.4 ± 0.025 MPa; the indicator 

on meter will be lit and starts warning. 

• C039 water level warning switch 

1-2: series resistor inside of switch is 6.2 KΩ. The switch will be closed when the antifreeze inside of 

expansion tank is lower than 3L; and the indicator on meter will be lit and starts warning. 

• C040 oil pressure warning switch 

1-grounding: oil pressure range is 0-1MPa, and the switch will be closed when the oil pressure is lower 

than 0.05 ± 0.01 MPa; and the indicator on meter will be lit and starts warning. 

• L002 parking brake indicator switch 

1- grounding: vehicle stops running and the parking brake handle is engaged; the switch will be closed 

and the indicator on meter will be lit. 

61

61-38 


: Part position 

S/N 


harness 

S/N 


harness 

S/N 


harness 







B037 Body wire C032 Chassis wire L002 Left floor wire 


61 

: Insert parts between wire harnesses 



C103 B107 Body wire and chassis wire (middle of the first cross member of frame) 



L101 B110 Body wire and left floor wire (left and below of meter, at the position of clutch pedal) 

: Grounding 

S/N 

A204 

B205 

B206 

B207 

B208 

B209 

C211 

C238 








Negative pole of battery is grounded to frame 

Chassis wire is grounded

Headlamp 

Headlamp 


61-39 

Battery 


White-Blue 

White-Blue 

61 

Light 

relay 

Right 

highbe 

am 

relay 

Light 

changing 

relay 

Left 

highbeam 

relay 

Vehicle 

body 

fuse box 

Red- 

Yellow 

Blue-Black 

Blue-White 

Red- 

White 

Red- 

White 

Red- 

Green 

Red- 

Yellow 

Red- 

Blue 

Red-Black 

Terminal 

Switch 

(position 

) 

Headla 

mp 

Low 

beam 

High 

beam 

Combined 

switch 

High 

beam 

Right front 

Low 

combined lamp 

beam 

Low 

beam 

Left right 

High combined lamp 

beam 


??? 

White- 

Black 

White- 

Black 

White- 

Black 

White- 

Black 

White- 

Black 

White- 

Black

61-40 


61 


• Current of battery goes through main fuse F/L0 to fuse F/L2, to electromagnetic coil of light relay R10, to 

the pins No. 13 and No. 14 of combined switch. Current inside of the electromagnetic coil of light relay 

R10 is grounded through the pins No. 9 and No. 2 of combined switch when the combined switch is at the 

position of light working; electromagnetic coil produces magnetic field and contacts of light relay R10 are 

closed, and at the same time it will supply power to other relays. 

Lowbeam 

• Current goes through the electromagnetic coil of light relay R10 to pin No. 13 of combined switch when 

the combined switch is at the lowbeam position; it is grounded through pin No. 11, and the 

electromagnetic coil produces magnetic field; contacts of light relay R10 are closed; current goes through 

the contact of light relay R10 to electromagnetic coil of light changing relay R11, to pin No. 3 of combined 

switch and it is grounded through pin No. 9; electromagnetic coil produces magnetic field and contacts 

are closed; current of the battery goes through main fuse F/L0 to fuse F/L2, to the fuse F9 and F10 

through contact of light changing relay R11, to pin No. 1 of right front combined lamp and pin No. 1 of left 

front combined lamp; to pin No. 3 of right front combined lamp and pin No. 3 of left front combined lamp 

to ground; left and right lowbeam start to work. 

Highbeam 

• Current goes through the electromagnetic coil of light relay R10 to pin No. 13 of combined switch when 

the combined switch is at the highbeam position; it is grounded through pin No. 2, and the 

electromagnetic coil produces magnetic field; contacts of light relay R10 are closed; current goes through 

the contact of light relay R10 to electromagnetic coil of right highbeam relay R31 and the electromagnetic 

coil of left highbeam relay R30; to pin No. 12 of combined switch and it is grounded through pin No. 9; two 

electromagnetic coils are grounded at the same time, electromagnetic coil produces magnetic field and 

contacts of left and right highbeam relay are closed; current of the battery goes through main fuse F/L0 to 

fuse F/L2, to the fuse F7 and F8 through contacts of left and right highbeam relay, to pin No. 2of right 

front combined lamp and pin No. 2 of left front combined lamp; to pin No. 3 of right front combined lamp 

and pin No. 3 of left front combined lamp to ground; left and right highbeams start to work. 

• Right highbeam relay starts to work when combined switch is at highbeam lamp position; and through the 

contact of relay to pin No. 12 of combined meter, to pin No. 13 of combined meter to ground through 

highbeam indicator; highbeam starts to work. 

Overtaking lamp (highbeam) 

• Current goes through the electromagnetic coil of light relay R10 to pin No. 14 of combined switch when the 

combined switch is at the overtaking lamp position; it is grounded through pin No. 9, and the electromagnetic 

coil produces magnetic field; contacts of light relay R10 are closed; current goes through the contact of light 

relay R10 to electromagnetic coil of right highbeam relay R31 and the electromagnetic coil of left highbeam 

relay R30; to pin No. 12 of combined switch and it is grounded through pin No. 9; two electromagnetic coils 

are grounded at the same time, electromagnetic coil produces magnetic field and contacts of left and right 

highbeam relay are closed; current of the battery goes through main fuse F/L0 to fuse F/L2, to the fuse F7 and 

F8 through contacts of left and right highbeam relay, to pin No. 2of right front combined lamp and pin No. 2 of 

left front combined lamp; to pin No. 3 of right front combined lamp and pin No. 3 of left front combined lamp to 

ground; left and right overtaking lamps (highbeams) start to work. 

• Right highbeam relay starts to work when combined switch is at overtaking lamps (highbeams) position; 

and through the contact of relay to pin No. 12 of combined meter, to pin No. 13 of combined meter to 

ground through highbeam indicator; highbeam starts to work. 

Service hint 

• R10 light relay 

30-87: contacts are closed when the combined switch is at lowbeam, highbeam and overtaking position. 

• R11 light changing relay 

30-87: contacts are closed when the combined switch is at lowbeam position. 

• R30 left highbeam relay 

3-5: contacts are closed when the combined switch is at highbeam position. 

• R31 right highbeam relay 

3-5: contacts are closed when the combined switch is at highbeam position.


61-41 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B012 Body wire B025 Body wire B050 Body wire 





: Grounding 

S/N 

A204 

B205 

B208 

B209 






61

61-42 

Fog lamp 


Fog lamp 

Battery 

Chassis fuse box 

White-Blue 

White-Blue 

61 

Front fog 

lamp 

relay 

Small 

light 

relay 

Vehicle body 

fuse box 

Blue-Red 

Green 

Red-Black 

Green-Red 

Green-Blue 

Three in one controller 

Three in one 

controller 

Terminal 

Switch 

(position 

Small ) lamp 

Fog lamp 


Red- 

Yellow 

Red-Blue 

Red-Green 

Switch of rear fog lamp 

Blue-Red 

White-Black 

Red- 

Yellow 

Red-Yellow 

White-Black 

Red-Yellow 

Red-Yellow 

Blue-Red Blue-Red Blue-Red 

Red-Yellow 

Red-Yellow 

Red-Yellow 

Left front 

fog lamp 

Right front 

fog lamp 

Combined 

meter 

Left rear 

combined lamp 

Right rear 

combined lamp 

White-Black 

White-Black 

White-Black 

White-Black 

White-Black


61-43 

Service hint 

• R33 front fog lamp relay 

3-5:contacts are closed when combined switch is at fog lamp position. 


S/N 


harness 

S/N 


harness 

S/N 


harness 


B010 Body wire B034 Body wire J002 


B025 Body wire B050 Body wire 

Chassis rear 

wire 

Chassis rear 

wire 

61 





C102 J101 Chassis wire and chassis rear wire (rear side of frame right side member) 

: Grounding 

S/N 

A204 

B205 

B206 

B207 

C237 

C238 






Chassis wire is grounded 


61-44 


Turn warning lamp and danger warning lamp 

Turn warning lamp and danger warning lamp 

Battery 


ON/START 


1 

White-Blue 

White-Red 

Black-White 

White-Blue 

White 

61 

IG power 

supply relay 

Vehicle body 

fuse box 

Green- 

Orange 

Red-White 

White-Black 

Terminal 

Switch 

(position) 

Close 

Open 

Switch of danger 

warning lamp 

Green 

-Black Green 

bule 

Green-White 

Green-White 

Green-Yellow 

Three in one 

controller 

Three in one 

controller 

B003 

Terminal 

Switch 

(position) 

Left 

Right 

Green- 

Black 


Green-Yellow 

Green- 

Yellow 

Green- 

Black 

Green- 

Black 

Green- 

Black 

Green- 

Yellow 

Green- 

Yellow 

Green- 

Black 

Green- 

Black 

Green- 

Black 

Green- 

Black 

Green- 

Yellow 

Green- 

Yellow 

Green- 

Yellow 

Green- 

Yellow 

Green- 

Yellow 

Green-Black 

Green- 

Black 

Left front 

combine 

lamp (left 

front turn 

lamp) 

Left 

rear 

combin 

ed 

lamp 

Left door side 

turn lamp 

Left front 

combined 

lamp (left 

side turn 

lamp) 

Combined 

meter 

Right front 

combined 

lamp (right 

side turn 

lamp) 

Right 

door side 

turn lamp 

Right rear 

combined 

lamp 

Right front 

combined 

lamp (right 

front turn 

lamp) 

White-Black White-Black White-Black White-Black White-Black White-Black White-Black White-Black White-Black 

White-Black 

White-Black 

White-Black 

White-Black


61-45 

Service hint: 

• Boo3 three in one controller 

Turning signal: flashing frequency is 85 ± 10 times/minute 

Warning signal: flashing frequency is 85 ± 10 times/minute 


S/N 


harness 

S/N 


harness 

S/N 


harness 


B006 Body wire B032 Body wire D006 

Wire of right 

door side 

B011 Body wire B033 Body wire E006 Left wire 



Wire of rear 

chassis 

Wire of rear 

chassis 

61 






: Grounding 

S/N 

A204 

B205 

C237 

C238 






61-46 




Battery 


White-Blue 

61 

White-Blue 

Small 

lamp relay 


Green 

Green-Blue 

Green 

Terminal 

Switch 

(position) 

Small lamp 

Combined 

switch 

Background 

indicator 

Combined 

meter 

Big lamp 

White-Black 

White-Black


61-47 

Green Green Green Green Green Green Green Green 

61 

Lighting for 

ignition 

switch 

Radio and 

tape 

recorder 

Rear fog 

lamp switch 

Cigar lighter 

Danger 

warning 

switch 

A/C switch 

Blower switch 

ABS 

diagnosis 

switch 

Green 

White-Black White-Black White-Black White-Black White-Black White-Black White-Black White-Black

61-48 


Service hint 

• R32 small lamp relay, 

3-5: contacts will be closed when combined switch is at small lamp position. 


S/N 


harness 

S/N 


harness 

S/N 


harness 






61 




: Grounding 

S/N 

A204 

B205 

C208 

C209 





Right side of instrument panel is grounded

External clearance lamp 

External clearance lamp 


61-49 

Battery 


White-Blue 

White-Blue 

61 


Small 

relay 

lamp 

Green 

Green-Blue Green Green 

Green 

Terminal 

Switch 

(position) 

Combined 

switch 

Left front 

combined 

lamp 

Right front 

combined 

lamp 

Green 

Left 

clearance 

lamp 

Green 

Right 

clearance 

lamp 

Small lamp 

White-Black 

White-Black 

Big lamp 

White-Black White-Black White-Black White-Black 

White-Black

61-50 


Green 

Green 

61 

Green 

Green 

Green Green Green Green Green 

Green 

Green 

Left rear 

clearance 

lamp 

Green 

Right rear 

clearance 

lamp 

Left front 

marker 

Right front 

marker 

Left rear 

marker 

Right rear 

marker 

Green 

Left rear 

combined lamp 

Green 

Right rear 

combined 

lamp 

White-Black 

White-Black 

White-Black 

White-Black 

White-Black 

White-Black White-Black White-Black White-Black White-Black White-Black


61-51 

Service hint: 

• R32 , small lamp relay 

3-5: contacts will be closed when combined switch is at small lamp position. 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B011 Body wire C024 Chassis wire F003 Ceiling wire 

B017 Body wire C025 Chassis wire F004 Ceiling wire 

B025 Body wire C030 Chassis wire J002 

B050 Body wire C036 Chassis wire J005 


Chassis rear 

wire 

Chassis rear 

wire 

61 




F101 B112 Ceiling wire and body wire (left side of instrument panel) 


: Grounding 

S/N 

A204 

B205 

C208 

C209 

C237 

C238 







Chassis wire harness is grounded

61-52 

Ceiling lamp 


Ceiling lamp 

Battery 


White-Blue 

61 

White-Blue 


Yellow 

Red-Yellow 

Door 

control 

Close 

Close 


Open Open 

Red-White 

Green 

Green 

Green 

Green 

Green 

Switch of left 

door lamp 

Switch of right 

door lamp 


Self grounding


61-53 

Service hint 

• L001 Switch of left door lamp; H001 Switch of right door lamp. 

1-grounding: the switch will be closed when the door is opened. 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B050 Body wire F002 Ceiling wire L001 Wire of left door 

C051 Chassis wire H001 

Wire of right 

door 




F101 B112 Ceiling wire and body wire (left side of instrument panel) 

H101 B102 Wire of right floor and body wire (right side of washing pot under right side of meter) 

L101 B110 Wire of left floor and body wire (at the position of clutch pedal under left side of meter) 

61

61-54 

Brake lamp 



BATTERY 

ON/START 


White-Red 

Black-White 

61 

White 

IG power 

supply relay 


Blue-Yellow 

Switch of brake lamp 

Yellow-Green 

Yellow-Green 

White-Black 

Yellow-Green 

Yellow-Green 

Yellow-Green 

Left rear combined lamp 

Right rear combined lamp 

White-Black 

White-Black 

White-Black 

White-Black


61-55 

Service hint 

• B015 Switch of brake lamp 

1-2: the switch will be closed when the vehicle is at brake state. 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B015 Body wire C003 Chassis wire J002 Chassis rear wire 







61 

: Grounding 

S/N 

A206 

B207 

C237 

C238 






61-56 

Reverse lamp 


Reverse lamp 

Battery 


ON/START 


White-Red 

Black-White 

61 

White 

IG power 

supply relay 

Vehicle body 

fuse box 

Red-Yellow 

White-Black 

Green-Yellow 

Reverse 

switch 

lamp 

Green-Red 

Green-Red 

Green-Red 

Green-Red 

Green-Red 

Left rear 

combined lamp 

Green-Red 

Right rear 

combined lamp 

Combined 

meter 

White-Black 

White-Black 

White-Black 

White-Black 

White-Black


61-57 

Service hint 

• C032 Reverse lamp switch 

1-2: the switch will be closed when gear shifting lever is at reverse position. 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B032 Body wire B050 Body wire J002 Chassis rear wire 







61 

: Grounding 

S/N 

B204 

B205 

A206 

B207 

C237 

C238 








61-58 




Battery 


White-Blue 

61 

White-Blue 

Small lamp 

relay 


Green 

Green-Blue 

Termina 

Switch l 

(position) 

Combined 

switch 

Green 

Small lamp 

Big lamp 

Green 

Rear license plate 

White-Black 

White-Black 

White-Black


61-59 

Service hint 

• B025 combined switch 

11-2: it is connected when the combined switch is at small lamp position. 

• R32 small lamp relay 

3-5: the contact will be closed when the combined switch is at the small lamp position. 


S/N 

Reference 

wire harness 

S/N 


harness 

B025 Body wire C051 Body wire 

B050 Body wire J003 Chassis rear wire 

S/N 


harness 


61 




J102 C102 Chassis wire and chassis rear wire (rear side of frame right side member) 

: Grounding 

S/N 

A208 

B209 

C237 

C238 






61-60 

Exhaust brake 


Exhaust brake 


ON/START 

Battery 

Exhaust 

brake relay 


Black-white White-Red Green-Yellow 

61 

White 

Red-Yellow 

Yellow- Blue 

IG power 

supply relay 

Vehicle 

fuse box 

body 

Black-Red 

Solenoid valve of 

exhaust brake 

White-Black 

Indicator 

of 

exhaust 

brake 

Combined 

meter 

Green-Red 

Green 

Green-Yellow 

Green-Yellow 

Exhaust 

brake switch 

Combined 

switch 

Black-Blue 

Yellow-Green 

Green-Yellow 

Black-Blue 

Yellow-Green 

Engine 

control unit


61-61 

Service hint 

• C044 solenoid valve of exhaust brake 

1-grounding: turn on the ignition switch and the voltage is about 24V when combined switch is at exhaust 

brake position. 

2-grounding: it is always connected. 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B029 Body wire B050 Body wire C033 Chassis rear wire 

B034 Body wire C051 Chassis wire C044 Chassis rear wire 


61 





: Grounding 

S/N 

B204 

B205 

A206 

B207 

C237 

C238 








61-62 


Cigar lighter 

Cigar lighter 

Battery 


ACC/ON 


White-Blue 

Blue-Red 

61 

White-Blue 


Small lamp relay 

Green-Blue Green Gray 

Terminal 

Switch 

(position) 

Combined 

switch 

Cigar lighter 

lighting 

Cigar lighter 

Small lamp 

Big lamp 

White-Black White-Black White-Black


61-63 

Service hint 

• B025 combined switch 

11-2: it is connected when the combined switch is at small lamp position. 

• R32 small lamp relay 

3-5: the contact will be closed when the combined switch is at the small lamp position. 

• B039 lighting, cigar lighter 

1-grounding: the voltage is about 24 V when the combined switch is at small lamp position. 

2-grounding: it is connected always. 

• B040 Cigar lighter 

1-grounding: the voltage is about 24V when the ignition switch is at ACC or ON position. 

2-grounding: it is connected always. 


61 

S/N 


harness 

S/N 


harness 

S/N 


harness 

B025 Body wire B040 Chassis wire C051 Chassis wire 

B039 Body wire B050 Chassis wire 




: Grounding 

S/N 

B208 

B209 




61-64 


Horn 

Battery 


White-Blue 

61 

White-Blue 


Horn relay 

Green 

Blue-White 

Blue-White 


(horn switch) 

Blue-White 

Blue-White 

Horn 1 Horn 2 

White-Black 

White-Black 

White-Black 

Self 

grounding


61-65 

Service hint 

• R34 Horn relay 

3-5: the contacts will be closed when the combined switch is at horn position. 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B025 Body wire C046 Chassis wire C051 Wire of right door 

B050 Body wire C047 Wire of left door 




C105 C105 Body wire and chassis wire (middle of the first cross member of frame) 

61 

:Grounding 

S/N 

B208 

B208 

C237 





61-66 

Audio system 


Audio system 

Battery 


ACC/ON 


White-Blue 

Blue-Red 

61 

White-Blue 


Yellow 

Gray 

Antenna 

of radio 

Green 


Radio/cassette 

player 

Radio/cassette 

player 

Green- 

Black 

Green 

Blue- 

Black 

Blue 

White- 

Black 

Green- 

Black 

Green 

Blue- 

Black 

Blue 

Left front 

speaker 

Right front 

speaker


61-67 

Service hint 

• B045 Radio/cassette player. 

4-grounding: it is always about 24V. 

3-grounding: it is about 24V when the ignition switch is at ACC/ON position. 

7-grounding: it is always connected 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B045 Body wire C051 Chassis wire E002 Wire of right door 

B050 Body wire D002 Wire of left door 


61 



D101 B101 Right door wire and body wire (right side of washing pot at right under of the meter) 

E101 B111 Left door wire and body wire (at the position of clutch pedal left under of the meter) 

: Grounding 

S/N 

B208 

B209 




61-68 


Power window control system 

Power window control system 

Battery 


ON/START 


Black-White 

White-Blue 

White-Red 

White-Blue 

White 

61 

Power 

window 

relay 

IG 

power 

supply 

relay 


White-Black 

Blue- 

Red 

White-Black 

Blue 

-Red 

Blue- 

Red 

Green-Yellow 

Green-Black 

Green-Yellow 

Green-Black 

Blue- 

Red 

Green- 

Black 

Green- 

Yellow 

Blue-Red 

Terminal 

Switch 

(position) 

Rise 

Left 

Close 

front 

door Desce 

nding 

Rise 

Left front 

door control 

switch 

Terminal 

Switch 

(position) 

Rise 

Right 

front 

door 

Close 

Desce 

nding 

Right front door 

power window 

switch 

Right Close 

front 

Desce 

door nding 

Lock 

White-Black 

Blue- 

Yellow 

Blue- 

Black 

Blue- 

Yellow 

Blue- 

Black 

Rise Desce 

nding 

Left front 

door glass 

regulator 

White-Black 

Rise Desce 

nding 

Right front 

door glass 

regulator


61-69 


• Current is grounded through the electromagnetic coil of IG power relay R14 when the ignition switch is 

turned on; electromagnetic coil produces magnetic field and the contacts of relay R14 will be closed; 

current of battery goes through main fuse F/L0 to fuse F/L4; to ground through the electromagnetic coil 

of power window relay R12 through the contact of relay R14; electromagnetic coil produces magnetic 

field and the contacts of relay R12 will be closed; current of battery goes through main fuse F/L0 to fuse 

F/L2; supply power to pin No. 3 of left front door control switch and pin No. 5 of right front door power 

window switch through the contacts of relay R12. 

Manual operation (left front door) 

• Left front door control switch (left window) is at rise position when ignition switch is turned on, and 

current goes through pin No. 3 of left front door control switch to pin No. 10 of left front door control 

switch and pin No. 1 of left front window regulator; through regulator motor and pin No. 2 of left front 

window regulator, to pin No. 9 of left front door control switch; it is grounded by the pin No. 6 of left front 

door control switch. 

• Left front door control switch (left window) is at descending position when ignition switch is turned on, 

and current goes through pin No. 3 of left front door control switch to pin No. 9 of left front door control 

switch and pin No. 2 of left front window regulator; through regulator motor and pin No. 1 of left front 

window regulator, to pin No. 10 of left front door control switch; it is grounded by the pin No. 6 of left front 


• Left front door control switch (right window) is at rise position when ignition switch is turned on, and 

current goes through pin No. 3 of left front door control switch to pin No. 4 of left front door control switch 

and pin No. 2 of right front window regulator; to pin No. 3 of right front power window switch, to pin No. 1 

of right front window regulator; through regulator motor and pin No. 2 of right front window regulator, to 

pin No. 1 of right front door power window switch and pin No. 4 of right front door power window switch; 

to pin No. 2 of left front door control switch; it is grounded by the pin No. 6 of left front door control switch. 

• Left front door control switch (right window) is at descending position when ignition switch is turned on, 

and current goes through pin No. 3 of left front door control switch to pin No. 2 of left front door control 

switch and pin No. 4 of right front window regulator; to pin No. 1 of right front power window switch, to pin 

No. 2 of right front window regulator; through regulator motor and pin No. 1 of right front window 

regulator, to pin No. 3 of right front door power window switch and pin No. 2 of right front door power 

window switch; to pin No. 4 of left front door control switch; it is grounded by the pin No. 6 of left front 


• Switch of right front door power window can manipulate the right front door window regulator when the 

lock door/window lock of left front door is locked. 

• Switch of right front door power window can not manipulate the right front door window regulator when 

the lock door/window lock of left front door is unlocked. 

61 

Manual operation (right front door) 

• Right front door control switch is at rise position when ignition switch is turned on, and current goes 

through pin No. 5 of right front power window switch to pin No. 3 of right front door power window switch 

and pin No. 1 of right front glass regulator; through regulator motor and pin No. 2 of right front window 

regulator, to pin No.1 of right front power window and pin No. 2 of right front power window, to pin No. 4 

of left front door control switch; through door/window lock it is grounded by the pin No. 6 of left front door 

control switch. 

• Right front door control switch is at descending position when ignition switch is turned on, and current 

goes through pin No. 5 of right front power window switch to pin No. 1 of right front door power window 

switch and pin No. 2 of right front glass regulator; through regulator motor and pin No. 1 of right front 

window regulator, to pin No.3 of right front power window and pin No. 4of right front power window, to pin 

No. 2 of left front door control switch; through door/window lock it is grounded by the pin No. 6 of left front 

door control switch.

61-70 


61 

Service hint 

• E003 control switch of left front door 

3-grounding: the voltage is about 24V when the ignition switch is ON position. 

10-grounding: the voltage is about 24V when the ignition switch is ON position and the control switch 

of left front door (left window) is at rise position. 

9--grounding: the voltage is about 24V when the ignition switch is ON position and the control switch of 

left front door (left window) is at descending position. 

4- grounding: the voltage is about 24V when the ignition switch is ON position and the control switch of 

left front door (right window) is at rise position. 


left front door (right window) is at descending position. 

• D003 right front door power window switch 

5- grounding: the voltage is about 24V when the ignition switch is ON position. 


right front door is at rise position. 

1- grounding: the voltage is about 24V when the ignition switch is ON position and the control switches of 

right/left front doors are at descending position. 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B050 Body wire D003 Wire of right door E003 Wire of left door 

C051 Chassis wire D004 Wire of right door E004 Wire of left door 





E101 B111 Left door wire and body wire (at the position of clutch pedal left under of the meter) 

: Grounding 

S/N 

B206 

B207 

B208 

B209 







Central control locking system 


61-71 

Battery 


White-Blue 

White-Blue 

Body fuse box 

61 

Purple 


Purple 

Blue-Black 

Blue-Yellow 

Purple 

Switch of 

left door 

lock 

Left front door lock 

White-Black 

White-Black 

Blue-Black 

Blue-Yellow 

White-Black 

Locked Un 

locked 

Right front door lock

61-72 



• Current is provided by battery, and it goes the F/L 0 fuse inside of chassis fuse box, fuse F/L2, and fuse 

F13 inside of body fuse box to the controller of central control lock, so as to lock and unlock the door 

lock. 

61 

Operation of door lock 

• The switch of left door lock will be closed when the left door lock button is pressed down by the driver. 

Pin No. 6 of controller of central control lock to pin No. 1 of left front door lock; to pin No. 2 of left front 

door lock to ground through left door lock switch and generates a grounding signal. There is grounding 

signal input to controller of central control lock, so it can confirm the left door is at locked state. The 

current goes through pin No. 4 of controller of central control lock to pin No. 1 of right front door lock; 

through the motor to pin No. 2 of right front door lock and pin No. 2 of controller of central control lock; 

the motor is electrified and runs forward and right front door is locked. 

• The switch of left door lock will be open when the left door lock button is lifted up by the driver. Pin No. 6 

of controller of central control lock can not form a return circuit so there will be no grounding signal 

produced. There is no grounding signal input to controller of central control lock, so it can confirm the left 

door is at open position. The current goes through pin No. 2 of controller of central control lock to pin No. 

2 of right front door lock; through the motor to pin No. 1of right front door lock and pin No. 4 of controller 

of central control lock; the motor is electrified and runs reversal and right front door is opened. 

Service hint 

• B035 Controller of central control lock 

3-grounding: the voltage is about 24V. 

4-grounding: the moment voltage is about 24V when the left door lock button is pressed down. 

2-grounding: the moment voltage is about 24V when the left door lock button is lifted up. 

• D005 Right front door lock 

1-grounding: the moment voltage is about 24V when the left door lock button is pressed down. 

2-grounding: the moment voltage is about 24V when the left door lock button is lifted up. 

• E005 Left front door lock 

1-2: Contacts will be closed when the left door lock button is pressed down and the resistance is about 

0 Ω. 

Contacts will be disconnected when the left door lock button is lifted up and the resistance is about ∞ Ω. 


S/N 


harness 

S/N 


harness 

S/N 


harness 

B035 Body wire C051 Chassis wire E005 Wire of left door 

B050 Body wire D005 Wire of right door 





E101 B111 Left door wire and body wire (at the position of clutch pedal left under of the meter)


61-73 

: Grounding 

S/N 

B206 

B207 

B208 

B209 






61

61-74 

Wiper system 

Wiper system 



ON/START 

Battery 


Black-White 

White-Red 

White 

61 

IG power 

supply 

relay 


Blue 

Blue 

Washer motor 

Blue 

Blue- White 

Blue 

White-Black 

Blue 

Blue 

Terminal 

Switch 

(position) 

Interval 

Low speed 

Combined 

switch 

High speed 

Cyan-Black 

Three in one 

controller 

Three in one 

controller 

Blue 

Blue-Yellow 

Blue-Red 

White- 

Black 

Blue- 

Black Blue-Orange 

Wiper motor 

White-Black


61-75 


• Contacts of IG power supply relay will be closed when the ignition switch is turned on, and the current will 

flow to main fuse F/L0 from battery, to fuse F/L4, to fuse F20, to pin No. 18 of combined switch; and make 

the wiper and washer work through combined switch. 

Low speed of wiper 

• Turn on the ignition switch when combined switch is at low speed, contacts of IG power supply relay will 

be closed, and current will flow to main fuse F/L0 from battery, to fuse F/L4, to fuse F20, to pin No. 18 of 

combined switch; from pin No. 7 of combined switch to pin No. 2 of wiper motor, and ground through pin 

No. 3 of wiper motor. 

High speed of wiper 

• Turn on the ignition switch when combined switch is at high speed, contacts of IG power supply relay will 

be closed, and current will flow to main fuse F/L0 from battery, to fuse F/L4, to fuse F20, to pin No. 18 of 

combined switch; from pin No. 13 of combined switch to pin No. 2 of wiper motor, and ground through pin 

No. 3 of wiper motor. 

Water injection shift of the wiper 

• Turn on the ignition switch when combined switch is at water injection shift, contacts of IG power supply 

relay will be closed, and current will flow to main fuse F/L0 from battery, to fuse F/L4, to fuse F20, to pin 

No. 1 of washer motor; from pin No. 2 of washer motor to pin No. 8 of combined switch, and ground 

through pin No. 12 of combined switch. 

61 

Service hint 

• B003, B004 three in one controller 

Interval time of wiper: 4s ± 1s. 


S/N 


harness 

S/N 


harness 

S/N 


harness 







: Grounding 

S/N 

B206 

B207 

B208 

B209 






61-76 


Exhaust post-treatment control system 

Exhaust post-treatment control system 

Battery 


ON/START 

White-Red 

White 


IG power 

supply 

relay 


Green- 

Yellow 

White-Black 

61 

White 

Green 

-Yellow 

Posttreatment 

heating 

relay 

Oxynitride 

sensor relay 

Chassis 

fuse box 2 

White-Black 

Whit 

e 

Blue-Yellow 

White 

-Black 

Red Red 

Red Red 

White 

-Blue 

White 

Electronic control unit of posttreatment 

(urea system control unit) 

White Blue-Black White Yellow-Black White 

Red-Black 

Urea injection, 

pipeline heater 

Urea return, 

pipeline heater 

Urea suction, 

pipeline heater


61-77 

Engine control unit 

Urea canister, 

heating 

solenoid valve 

Urea injection 

nozzle, 


Green 

Green-Red 

White 

Oxynitride 

sensor 

White-Black 

Green-Red 

Green 

Yellow 

-Red 

White-Red 

Black Red 

61 

Electronic control unit of post-treatment 

(control unit of urea system) 

Red Yellow-Red Black Red Yellow-Red White 

-Black 

Red Blue Red-Black Yellow-Black 

Feeding unit of post-treatment (control unit of urea pump)

61-78 


Sensor of urea canister 

Blue White-Black Yellow 

-Black 

White-Black 

61 

Electronic control unit of post-treatment 

(control unit of urea system) 

White-Black White-Black White-Black White-Black White-Black


61-79 


S/N 


harness 

S/N 


harness 

S/N 


harness 


C013 Body wire C018 Chassis wire C051 Chassis wire 

C014 Chassis wire C019 Chassis wire C052 Chassis wire 

C015 Chassis wire C020 Chassis wire 

C016 Chassis wire C033 Chassis wire 





61 

: Grounding 

S/N 

C216 

C237 

C238 





61-80 

Wire Inserts Information 

A wire (ABS wire) 


61 

Terminal 

No. 

A002 right front wheel speed sensor 

1 Brown 

2 Black 

Color Function Remarks 

Right front 

wheel 

speed 

sensor 

Right front 

wheel 

speed 

sensor 

Terminal 

No. 

A004 left front wheel solenoid valve 

1 G-Y 

2 Brown 

3 Blue 



solenoid valve is 

grounded 





4 - - Plug 

Terminal 

No. 

A003 right front wheel solenoid valve 

1 G-Y 

2 Brown 

3 Blue 


Right front 

wheel 

solenoid 

valve is 

grounded 

Right front 

wheel 

solenoid 

valve 

Right front 

wheel 

solenoid 

valve 

4 - - Plug

Circuit-Information of wire insert parts 

61-81 

Terminal 

No. 

A005 left front wheel speed sensor 

1 Brown 

2 Black 


Left front 

wheel 

speed 

sensor 

Left front 

wheel 

speed 

sensor 

Terminal 

No. 

A007 left rear wheel solenoid valve 

1 G-Y 

2 Brown 

3 Blue 


Left rear 

wheel 


(-) 

Left rear 

wheel 


Left rear 

wheel 


4 - - Plug 

61 

Terminal 

No. 

A006 left rear wheel speed sensor 

1 Brown 

2 Black 


Left rear 

wheel 

speed 

sensor 

Left rear 

wheel 

speed 

sensor

61-82 


61 

Terminal 

No. 

A008 right rear wheel speed sensor 

1 Brown 

2 Black 

Terminal 

No. 


Right rear 

wheel speed 

sensor 

Right rear 

wheel speed 

sensor 

A009 right rear wheel solenoid valve 

1 G-Y 

2 Brown 

3 Blue 


Right rear 

wheel solenoid 

valve (-) 

Right rear 


valve 

Right rear 


valve 

4 - - Plug 

Terminal 

No. 

A101 wire connected with body 

1 Black 

2 Brown 

3 Blue 

4 Brown 

5 Brown 

6 Black 

7 Brown 

8 Brown 

9 Blue 

10 Brown 

11 Black 

12 Black 

13 Brown 

14 Blue 

15 Blue 

16 Brown 


Right front 

wheel speed 

sensor 

Right front 

wheel speed 

sensor 

Right front 


valve 

Right front 


valve 

Right rear 

wheel sensor 


sensor 


speed sensor 

Right rear 


valve 





Right rear 

wheel speed 

sensor 


speed sensor 


speed sensor 

Right rear 


valve 




solenoid valve

B wire (body wire) 


61-83 

Terminal 

No. 

1 W-O 

2 W-O 

3 Red 

4 Y-R 

B001 signal amplifier 


Front 

thermistor 

Front 

thermistor 

Signal 

amplifier 

Signal 

amplifier 

5 - - Null 

6 - - Null 

7 R-B 

Relay, 

solenoid 

valve 

8 - - Null 

9 - - Null 

10 - - Null 

11 Y-O A/C switch 

12 W-B 

13 W-G 

Signal 

amplifier (-) 

Front 

thermistor 

14 - - Null 

15 W-B 

Signal 

amplifier (-) 

16 - - Null 

17 - - Null 

Terminal 

No. 

1 Blue 

2 B-W 

Terminal 

No. 

B002 washer motor 


Front 

washer 

motor (+) 

Front 

washer 

motor (-) 

B003 three in one controller 

9 Cyan 

10 Blue 

11 W-B 

12 B-W 

13 B-Y 


Three in one 

controller 

(B+) 

Three in one 

controller 

(B+) 

Three in one 

controller 

Three in one 

controller 

Combined 

switch 

14 B-R Wiper motor 

61

61-84 


61 

Terminal 

No. 

B004 three in one controller 

1 R-B 

2 R-Y 

3 R-B 

4 C-B 

5 R-G 


Three in one 

controller 

Three in one 

controller 

Three in one 

controller 

Combined 

switch 

Combined 

switch 

Terminal 

No. 

B006 right front turn lamp 

1 G-Y 

2 W-B 


Right front 

turn lamp 

(+) 

Right front 

turn lamp 

(-) 

6 Green 

7 B-R 

8 R-W 

Three in one 

controller 

Three in one 

controller 

Three in one 

controller 

Terminal 

No. 

B007 blower 


1 B-B Blower (+) 

2 B-W Blower (-) 

Terminal 

No. 

B005 speed regulating resistor 

1 B-B 

2 B-Y 

3 B-O 

4 B-W 


Speed 

regulating 

resistor 

Speed 

regulating 

resistor M1 

Speed 

regulating 

resistor M2 

Speed 

regulating 

resistor LO 

Terminal 

No. 

1 W-O 

2 W-G 

B008 front thermistor 


Front 

thermistor (-) 

Front 

thermistor 

(+)


61-85 

Terminal 

No. 

1 B-O 

2 B-B 

3 W-B 

B009 Wiper motor 


Wiper motor 

(H) 

Wiper motor 

(L) 

Wiper motor 

grounding 

4 - - null 

5 B-R 

Interval of 

wiper motor 

B011 right front combined lamp 

(right front position lamp and side turn lamp) 

Terminal 

No. 

1 Green 

2 W-B 

3 G-Y 


Right front 

small lamp 

Right front 

small lamp 

(-) 

Right side 

turn lamp 

(+) 

61 

6 Blue 

Reset of 

wiper motor 

Terminal 

No. 

B010 right front fog lamp 

1 B-R 

2 W-B 


Right front 

fog lamp 

(+) 

Right front 

fog lamp (-) 

Terminal 

No. 

B012 right front combined lamp 

(right headlamp) 

1 R-B 

2 R-B 

3 W-B 


Right 

lowbeam 

(+) 

Right inside 

highbeam 

(+) 

Ground of 

right 

headlamp 

4 - (-) Plug

61-86 


61 

Terminal 

No. 

B013 ABS control unit 


1 - - Null 

2 - - Null 

3 - - Null 

4 W-B Ground 

5 - - Null 

6 - - Null 

7 Yellow ABS fuse 

8 Red ABS fuse 

9 W-B Ground 

10 W ECU k line 

11 - - Null 

12 - - Null 

13 Orange 

ABS 

(ASR) 

flasher 

indicator 

14 - - Null 

15 Yellow 

ABS 

failure 

indicator 

Terminal 

No. 

3 Brown 

4 Blue 

5 Blue 

6 Blue 





Right front 


valve 





7 - - Null 

8 Brown 

9 Blue 

10 Brown 

11 Brown 

12 Brown 

13 Black 

14 Black 

15 Black 





Right front 

wheel speed 

sensor 


speed sensor 


speed sensor 

Right front 

wheel speed 

sensor 


speed sensor 


speed sensor 

16 - - Null 

17 Brown 

18 Black 


speed sensor 


speed sensor 

Terminal 

No. 


1 Brown 

2 Brown 


Right front 

wheel 

solenoid 

valve 

Left rear 

wheel 

solenoid 

valve 

Terminal 

No. 

1 B-Y 

B015 Brake lamp switch 


Brake switch (vice 

switch B+) 

2 Y-G Brake switch


61-87 

Terminal 

No. 

3 B-B 

B015 Brake lamp switch 


Brake switch 

(main switch 

B+) 

4 G-R Brake switch 

B017 left front combined lamp 

(left front position lamp and side turn lamp) 

Terminal 

No. 

1 Green 

2 W-B 

3 G-B 


Left front 

small lamp 

Left front 

small lamp 

(-) 

Left side 

turn lamp 

(+) 

Terminal 

No. 

B019 Left front combined lamp 

(left front turn lamp) 

1 G-B 

2 W-B 

Terminal 

No. 

1 B-W 

2 W-B 


Left front turn 

lamp (+) 

Left turn lamp 

(-) 

B021 Left front fog lamp 


Left front fog 

lamp (+) 

Left front fog 

lamp (-) 

61 

Terminal 

No. 

B018 Left front combined lamp 

(left headlamp) 

1 R-Y 

2 B-B 

3 W-B 


Left low 

beam (+) 

Left low 

beam (-) 

Left 

headlamp 

(+) 

4 - - Plug 

B022 warning switch of brake liquid level 

Terminal 

No. 

1 B-W 

2 W-B 


Warning 

switch of 

brake fluid 

level 

Warning 

switch of 

brake fluid 

level (-)

61-88 


61 

Terminal 

No. 

B023 ABS inspection interface 


1 - - Null 

2 - - Null 

3 - - Null 

4 W-B Ground 

5 W-B Ground 

6 Green 

7 White 

Diagnosis 

signal 

CAN (+) 

ABS 

inspection 

interface 

8 - - Null 

9 - - Null 

10 - - Null 

11 - - Null 

12 - - Null 

13 - - Null 

14 G-R 

Diagnosis 

signal 

CAN (-) 

15 Null 

16 W-B 

ABS 

inspection 

interface 

(+) 

Terminal 

No. 

B025 combined switch 


1 G-W Turn lamp 

2 W-B Light switch (-) 

3 R-Y 


low beam 

4 - - Null 

5 G-B 

6 W-B 

7 G-R 

8 G-Y 

9 W-B 

10 B 

11 G-B 

12 R-G 

13 R-W 

14 R-W 

Combined switch, 

turn left 


ground 


front fog lamp 


turn right 

Light changing 

switch (-) 


horn 


small lamp 


high beam 


high beam 


overtaking


61-89 

Terminal 

No. 

B026 Ignition switch 


1 W-B Ignition switch 

2 W-B 

3 B-W 


(ST) 


(IG) 

4 - - Null 

5 - - Null 

6 - - Null 

7 B-R 

Terminal 

No. 


(ACC) 

B027 lighting of ignition switch 


1 - - Null 

2 Green 

Lighting of 


(+) 

3 - (-) Null 

4 W-B 

Lighting of 


Ground 

Terminal 

No. 

1 B-B 

2 Y-B 

Terminal 

No. 

1 B-Y 

B028 Clutch switch 


Clutch switch 

(-) 

Clutch switch 

(+) 

B029 Combined switch 


Exhaust 

brake 

switch 

2 - - Null 

3 - - Null 

4 B-Y 

Three in 

one 

controller 

5 - - Null 

6 - - Null 

7 B-B Wiper motor 

8 B-W 

Washer 

motor 

9 - - Null 

10 G-Y 

Exhaust 

brake 

switch 

11 Null 

12 W-B 

Wiper 

switch (-) 

13 B-O Wiper motor 

14 - - Null 

15 - - Null 

61

61-90 


Terminal 

No. 

16 C-B 

B029 combined switch 


Three in one 

controller 

17 - - Null 

18 Blue 

Wiper switch 

(B+) 

19 - - Null 

20 - - Null 

Terminal 

No. 

B032 combined meter 


15 - - Null 

16 B-W 

17 Red 

18 R-B 

Warning 

lamp of 

brake fluid 

level 

Engine 

brake lamp 

Low 

pressure 

warning 

lamp 

61 

Terminal 

No. 

B032 Combined meter 


1 - - Null 

2 G-Y 

3 B-B 

4 R-B 

5 Y-R 

Fuel meter 

(level 

indicator) 

Water temp. 

sensor 

Low 

pressure 

buzzer 

warning 

Urea liquid 

warning 

lamp 

6 - - NULL 

7 - - NULL 

8 Y-B 

9 B-R 

Urea liquid 

level 

indication 

MIL lamp 

(IG) 

10 W-R MTII lamp 

11 G-Y 

12 W-B 

Right turn 

indication on 

meter 

Ground of 

meter (fog 

lamp) 

13 - - Null 

14 Yellow 

ABS failure 

indicator 

Terminal 

No. 

1 G-B 

2 Yellow 

3 W-B 

4 W-B 

5 W-B 

6 W-R 

B033 Combined meter 


Left turn 

indication on 

the meter 

Meter power 

supply (+) 

Ground of 

meter (turn) 

Meter sensor 

(-) 

Meter sensor 

(-) 

Charging 

indication 

7 O ASR indicator 

8 W-B 

9 G-W 

10 Blue 

11 B-R 

12 R-B 

Tyre pressure 

warning 

indicator 

Fuel meter 

(warning) 

Meter power 

supply (IG) 

Preheat 

indicator (IG) 

Preheat 

indicator 

13 Y-R Speedometer


61-91 

Terminal 

No. 

14 Y-R 



Vacuum 

warning lamp 

15 W-B Tachometer 

16 - - Null 

17 - - Null 

18 - - Null 

19 B-R 

20 B-Y 

Terminal 

No. 

Air filter 

warning 

SVS warning 

lamp 



1 - - Null 

2 - - Null 

3 B-R 

4 G-Y 

5 B-R 

6 R-Y 

Exhaust brake 

indicator 

Exhaust brake 

indication on 

meter 

Front fog lamp 

indication on 

meter 

Rear fog lamp 

indicator 

7 - - Dull 

8 G-R Reverse indicator 

9 R-B 

10 W-R 

11 R-Y 

12 B-W 

13 W-B 

Water level 

warning of meter 

Oil pressure 

warning lamp 

Hand brake 

indication on 

meter 

High beam 

indication on 

meter 

Ground of meter 

(high beam) 

Terminal 

No. 



14 Y-B Speedometer 

15 G Meter lighting 

16 - - Null 

17 - - Null 

18 - - Null 

19 - - Null 

20 - - Null 

B035 controller of central control lock 

Terminal 

No. 

1 W-B 

2 B-Y 

3 Purple 

4 B-B 


Ground, 

controller of 

central 

control lock 

Left front 

door lock is 

opened 

Controller of 

central 

control lock 

(B+) 

Right front 

door lock 

5 Null 

6 Purple 


front door 

lock is 

opened 

7 - - Null 

8 - - Null 

9 - - Null 

10 - - Null 

61

61-92 


61 

Terminal 

No. 

B037 danger warning switch 


1 - - Null 

2 Green 

3 W-B 

Lighting, 

Danger 

warning 

switch 

Danger 

warning 

switch (-) 

4 - - Null 

5 G-B 

6 G-Y 

7 Cyan 

8 G-O 

9 G-W 

10 R-W 

Terminal 

No. 

Danger 

warning 

switch (left 

turn lamp) 

Danger 

warning 

switch (right 

turn lamp) 

Three in one 

controller 

Danger 

warning 

switch (power 

supply) 

Three in one 

controller 

Three in one 

controller 

(power 

supply) 

B039 lighting of cigar lighter 

1 Green 

2 


Lighting of 

cigar lighter 

Lighting of 

cigar lighter (-) 

Terminal 

No. 

1 Gray 

B040 cigar lighter 


Cigar lighter 

(+) 

2 W-B Cigar lighter (-) 

Terminal 

No. 

B041 Rear fog lamp switch 


1 - - Null 

2 Green 

3 R-Y 

Lighting, 

rear fog 

lamp switch 

Lighting, 

rear fog 

lamp switch 

4 - - Null 

5 - - Null 

6 R-G 

7 W-B 

Rear fog 

lamp switch 

Rear fog 

lamp switch 

(-) 

8 - - Null 

9 R-B 

Rear fog 

lamp switch 

10 Null


61-93 

Terminal 

No. 

1 B-Y 

B042 blower switch 


Speed regulating 

resistor M1 

2 - - Dull 

3 - - Dull 

4 - - Dull 

5 - - Dull 

6 W-B Blower switch (-) 

7 G 

8 B-O 

Lighting, blower 

switch 


resistor M2 

9 W-B Blower switch (-) 

10 - - Null 

11 B-B Blower motor 

12 B-W 

Terminal 

No. 


resistor (Lo) 

B043 A/C switch 


1 W-B A/C switch (-) 

2 - - Null 

3 G 

Lighting, A/C 

switch 

Terminal 

No. 

4 Y-R 

5 Y-O 

B043 A/C switch 


Cutoff relay, 

AC 

Signal 

amplifier 

6 B-W Blower switch 

Terminal 

No. 

B045 Radio and cassette player 

1 B-B 

2 G-B 

3 Gray 

4 Yellow 

5 Blue 

6 Green 

7 W-B 


Radio and 

cassette player 

(FR+) 

Radio and 


(FL+) 

Radio and 


(ACC) 

Radio and 


(power supply) 

Radio and 


(FR-) 

Radio and 


(FL-) 

Radio and 

cassette player (-) 

8 Null 

9 Null 

10 Green 

Lighting, Radio 

and cassette 

player 

61

61-94 


61 

Terminal 

No. 

B046 ABS diagnosis switch 

1 Orange 

2 W-B 

3 W-B 


ABS 

triggering 

signal 

Ground, ABS 

diagnosis 

switch 

lighting 

ABS 

diagnosis 

switch (-) 

4 - - Null 

5 - - Null 

6 Green 

Lighting, ABS 

diagnosis 

switch 

Terminal 

No. 

B101 wire connect to right door 

8 G-Y 


Turn lamp, 

right door 

9 - - Null 

10 B 

Terminal 

No. 

Right front 

speaker (-) 

B102 connect to right floor wire 


1 - - Null 

2 Green 

Right door 

lamp switch 

3 - - Null 

4 - - Null 

5 - - Null 

6 - - Null 

Terminal 

No. 

B101 connect to right door wire 

1 G-B 

2 B-B 

3 B-R 

4 B-B 

5 G-Y 

6 B-Y 

7 W-B 


Power window 

rise, right front 

door 


lock is open 

Right power 

window switch B 

Right front 

speaker (+) 

Power window 

descending of 



is locked 

Ground, right 

door side turn 

lamp 

Terminal 

No. 

B103 connect to chassis wire 


1 W-B Battery (+) 

2 W Master fuse F/L4


61-95 

Terminal 

No. 


1 R-Y 


Reverse lamp 

switch (+) 

2 G-Y Right rear turn 

3 G-B Left rear turn 

4 Y-G Brake lamp (+) 

5 B-R 

Parking brake 

switch 

6 R-B Expansion tank 

7 R-B ECM 35 pin 

8 G-R 

9 W-B 

10 B-R 

Reverse lamp 

(+) 

Connect to the 

negative pole of 

battery 

Air filter warning 

switch 

11 Red ECM 49 pin 

12 B-Y ECM 36 pin 

13 G-Y ECM 13 pin 

14 G-Y Fuel sensor 

15 G-W Fuse sensor 

16 W-R Alternator (IG) 

Terminal 

No. 



1 R-Y Rear fog lamp 

2 B-W Horn 

3 Green Small lamp 

4 Y-B ECM 39 pin 

5 - - Plug 

6 W-B ECM 09 pin 

7 B-B ECM 29 pin 

8 B-R Start relay 

9 Y-R 

10 W-R 

11 B-B 

Speed sensor; 

signal 

Oil pressure 

warning switch 

Water tem. 

Sensor 

12 G-R Condenser relay 

13 R-B 

14 RED 

15 Y-R 

16 Y-B 

Air pressure 


Dual pressure 

switch (-S) 

Dual pressure 

switch (+S) 

Speed sensor; 

power supply 

61

61-96 


61 

Terminal 

No. 



1 G-R ECU 52 pin 

2 W-B ECU 26 pin 

3 G-R ECU 37 pin 

4 Y-G ECM 24 pin 

5 B 

6 W-G 

7 W-B 

ECM (electronic 

accelerator) pin 

No. 57 



No. 44 



No. 56 

8 R-B ECU 10 pin 

9 B-Y 

10 B-B 

11 W-G 



No. 42 



No. 43 



No. 55 

12 Green ECM 14 pin 

13 - - Plug 

14 G-Y 

DCU IG power 

supply 

15 B-W DCU IG signal 

16 G-R ECM 15 pin 

Terminal 

No. 



1 - - Plug 

2 B-R AC main relay 

3 B-R AC request 

4 Green 


clutch of 

compressor 

5 - - Plug 

6 Y-B Urea level (signal) 

7 W-R ECM 22 pin 

8 Y-R ECM 23 pin 

9 B-W 

10 R-G 

Tire pressure 

warning signal 

Right reverse 

radar+ 

11 W-B Left reverse radar- 

12 R-Y 

Left reverse 

radar+


61-97 

Terminal 

No. 


1 Black 

2 Brown 

3 Blue 

4 Brown 

5 Brown 

6 Black 

7 Brown 

8 Brown 

9 Blue 

10 Brown 

11 Black 

12 Black 

13 Brown 

14 Blue 

15 Blue 

16 Brown 



speed sensor 


speed sensor 

Exhaust coil of 

right front wheel 



right front wheel 


speed sensor 


speed sensor 


speed sensor 


right rear wheel 


left rear wheel 


left rear wheel 


speed sensor 


speed sensor 


speed sensor 


right rear wheel 


left front wheel 


left front wheel 

Terminal 

No. 

B110 connect to left floor wire 

1 Green 


Left door lamp 

switch 

2 - - Null 

3 - - Null 

4 - - Null 

5 R-Y 

Hand brake 

switch 

6 - - Null 

7 - - Null 

8 - - Null 

61

61-98 


61 

Terminal 

No. 

B111 connect to left door wire 

1 B-B 

2 Purple 

3 B-R 

4 G-B 

5 B-Y 

6 W-B 

7 G-B 

8 G-B 

9 G-Y 

10 Green 



lock is opened 


lock is opened 

Left power 

window switch 

Left front 

speaker (+) 


is locked 

Left door wire is 

grounded 

Left door side 

turn lamp (+) 


front power 

window; right 

door rise 


front power 

window; right 

door 

descending 

Left front 

speaker 

Terminal 

No. 

B112 connect to ceiling wire 

1 Green 

2 Yellow 

3 W-B 

4 Green 


Left clearance 

lamp 

Front ceiling 

lamp (+) 


lamp (-) 

Front ceiling 

lamp

C wire (chassis wire) 


61-99 

Terminal 

No. 

C002 AC pressure switch 

1 B-R 

2 G-R 

3 W-B 

4 RED 


Middle 

pressure 

switch 

Dual 

pressure 

switch 

Middle 

pressure 

switch 

Dual 

pressure 

switch 

Terminal 

No. 

C004 alternator 


1 W-R Alternator (IG) 

Terminal 

No. 

C005 alternator 


1 White Alternator 

61 

Terminal 

No. 

1 R-B 

2 W-B 

3 W-B 

4 B-W 

C003 condenser fan 


Speed 

regulating 

resistor of 

condenser 

Grounding, 

speed 

regulating 

resistor of 

condenser 

Condenser 

blower (+) 

Condenser 

blower (-) 

C006 electromagnetic clutch of compressor 

Terminal 

No. 

1 Green 



clutch of 

compressor

61-100 


61 

Terminal 

No. 

C007 water temperature sensor 

1 B-B 


Water 

temperature 

sensor 

C011 warning switch of clogged air filter 

Terminal 

No. 

1 R-Y 

2 W-B 


Warning 

switch of 

clogged air 

filter (+) 

Warning 

switch of 

clogged air 

filter (-) 

Terminal 

No. 

C008 starter 


1 White Starter (A) 

C013 solenoid of urea injection nozzle 

Terminal 

No. 


Terminal 

No. 

C009 starter 


1 Red Battery (+) 

1 Red 

2 Black 


nozzle (+) 


nozzle (-) 

Terminal 

No. 

C0010 starter 


1 B-W Starter (+) 

Terminal 

No. 

C014 post-treatment control unit 


1 W-B Grounding 



4 W-B Grounding


61-101 

Terminal 

No. 




6 Red 

7 Red 

8 Red 

9 Red 

Post-treatment 

control unit (B+) 







10 - - Plug 

11 - - Plug 

12 - - Plug 

13 - - Plug 

14 Green 

15 G-R 

Engine control 

unit 

Engine control 

unit 

16 - - Plug 

17 - - Plug 

18 - - Plug 

19 - - Plug 

20 - - Plug 

21 - - Plug 

22 - - Plug 

23 - - Plug 

24 - - Plug 

25 - - Plug 

26 - - Plug 

27 - - Plug 

28 - - Plug 

29 - - Plug 

30 B-Y 

Heating relay, 


Terminal 

No. 



31 - - Plug 

32 - - Plug 

33 - - Plug 

34 - - Plug 

35 - - Plug 

36 - - Plug 

37 - - Plug 

38 - - Plug 

39 - - Plug 

40 - - Plug 

41 W-B 

Heating relay, 


42 - - Plug 

43 - - Plug 

44 - - Plug 

45 - - Plug 

46 - - Plug 

47 - - Plug 

48 - - Plug 

49 - - Plug 

50 - - Plug 

51 - - Plug 

52 W-B 


control unit (IG) 

53 - - Plug 

61

61-102 


61 

Terminal 

No. 


1 B-B 

2 Y-B 

3 Y-R 


Heating pipe, 

urea injection 

pipeline 

Heater, urea 

return pipeline 

Feeding unit of 


unit 

4 - - Plug 

5 Red 



unit 

6 - - Plug 

7 - - Plug 

8 Y-R 

Heating 


of urea tank 

9 - - Plug 

10 - - Plug 

11 - - Plug 

12 Black 


of urea injection 

nozzle 

13 - - Plug 

14 - - Plug 

15 - - Plug 

16 - - Plug 

17 Y-R 

18 Black 

19 red 







Terminal 

No. 



20 - - Plug 

21 - - Plug 

22 - - Plug 

23 - - Plug 

24 Blue 



25 - - Plug 

26 W-B 



27 - - Plug 

28 - - Plug 

29 - - Plug 

30 - - Plug 

31 - - Plug 

32 Red 


of urea injection 

nozzle 

33 - - Plug 

34 - - Plug 

35 - - Plug 

36 - - Plug 

37 - - Plug 

38 - - Plug 

39 - - Plug 

40 - - Plug 

41 - - Plug 

42 - - Plug 

43 - - Plug 

44 - - Plug 

45 - - Plug 

46 Red 



47 - - Plug


61-103 

Terminal 

No. 


48 R-B 


Heater of urea 

suction pipeline 

49 - - Plug 

50 - - Plug 

51 - - Plug 

52 - - Plug 

53 - - Plug 

54 - - Plug 

55 - - Plug 

56 - - Plug 

57 - - Plug 

58 W-B 

59 Y-B 

Sensor of urea 

pipe 


pipe 

60 - - Plug 

61 - - Plug 

62 - - Plug 

63 - - Plug 

64 - - Plug 

65 Y-B 



66 - - Plug 

67 - - Plug 

68 - - Plug 

69 - - Plug 

70 - - Plug 

71 - - Plug 

72 - - Plug 

73 - - Plug 

74 - - Plug 

75 - - Plug 

76 - - Plug 

77 - - Plug 

Terminal 

No. 


78 W-B 

79 Blue 



pipe 


pipe 

80 - - Plug 

81 - - Plug 

82 - - Plug 

83 - - Plug 

84 - - Plug 

85 W-R 

86 R-B 

Terminal 

No. 

Heating solenoid 

valve of urea tank 



C016 feeding unit of post-treatment 


1 - - Plug 

2 Red 

3 Y-R 

4 Black 

5 Red 

6 Y-R 


electronic 

control unit 


electronic 

control unit 


electronic 

control unit 


electronic 

control unit 


electronic 

control unit 

7 - - Plug 

8 W-B 

9 Red 


electronic 

control unit 


electronic 

control unit 

61

61-104 


Terminal 

No. 

C016 feeding unit of post-treatment 

10 Blue 

11 R-B 

12 Y-B 



electronic 

control unit 


electronic 

control unit 


electronic 

control unit 

Terminal 

No. 

C019 heater of urea suction pipeline 

1 White 


Urea pipe 3 

(+) 

2 R-B Urea pipe 3 (-) 

61 

C017 heating solenoid valve of urea tank 

Terminal 

No. 

1 Y-R 

2 W-R 


Heating valve 

of urea tank (+) 

Heating valve 

of urea tank (-) 

Terminal 

No. 

C020 heater of urea return pipeline 


1 White Urea pipe 2 (+) 

2 Y-B Urea pipe 2 (-) 

Terminal 

No. 

C018 heater of urea injection pipeline 


1 White Urea pipe 1 (+) 

2 B-B Urea pipe 1 (-) 

Terminal 

No. 

1 Green 

2 W-B 

C021 right front marker 


Relay, small 

lamp 

Right front 

marker (-)


61-105 

Terminal 

No. 

1 Green 

2 W-B 

C024 right rear marker 


Relay, small 

lamp 

Right rear 

marker (-) 

C027 over low pressure warning switch 1 

Terminal 

No. 

1 R-B 


Over low 

pressure 


61 

Terminal 

No. 

1 Green 

2 W-B 

C025 left rear marker 


Relay, small 

lamp 

Left rear 

marker (-) 

Terminal 

No. 

C028 nitrogen oxide sensor 

1 Green 

2 G-R 

3 W-B 

4 White 


Nitrogen oxide 

sensor (CAN+) 


sensor 

(CAN-) 


sensor (-) 


sensor (+) 

Terminal 

No. 

1 B-R 

2 W-B 

C026 brake lamp switch 


Parking brake 

switch 

Brake lamp 

switch (-)

61-106 


61 

Terminal 

No. 

C032 reverse lamp switch 

1 G-RY 

2 G-R 

Terminal 

No. 

1 Red 

2 W-B 

3 Red 

4 W-B 

5 Red 

6 W-B 

7 Y-B 

8 G-B 

9 W-B 

10 R-B 


Reverse lamp 

switch (+) 

Reverse lamp 

switch (-) 

C033 engine control unit 


ECM 

power 

supply 1 

ECM 

ground 2 

ECM 

power 

supply 3 

ECM 

ground 4 

ECM 

power 

supply 5 

ECM 

ground 6 

ECM 07 

pin 

ECM 08 

pin 

ECM 09 

pin 

ECM 10 

pin 

11 - - Plug 

12 - - Plug 

Terminal 

No. 



13 Y-G ECM 13pin 



16 - Plug 

17 White ECM 17 pin 


19 - - Plug 

20 - - Plug 


22 W-R ECM 22 pin 


24 Y-G ECM 24 pin 

25 - - Plug 


27 B-R A/C request 


29 B-B ECM 29 pin 

30 Black ECM 30 pin 

31 - - Plug 

32 - - Plug 

33 - - Plug 


35 R-B ECM 35 pin 



38 - - Plug 


40 - - Plug 

41 W-R ECM 41 pin


61-107 

Terminal 

No. 

42 B-Y 

43 B-B 

44 W-G 



ECM 

(electronic 

accelerator) 

pin No. 42 

ECM 

(electronic 

accelerator) 

pin No. 43 

ECM 

(electronic 

accelerator) 

pin No. 44 

45 - Plug 

46 Blue 

ECM 

(electronic 

accelerator) 

pin No. 46 

47 Plug 


49 Red ECM 49 pin 

50 Plug 

51 Plug 


53 Plug 

54 Plug 

55 W-G 

56 W-B 

57 Blue 

ECM 

(electronic 

accelerator) 

pin No. 55 

ECM 

(electronic 

accelerator) 

pin No.56 

ECM 

(electronic 

accelerator) 

pin No. 57 

58 Plug 

Terminal 

No. 

1 R-W 

2 Blue 

Terminal 

No. 

1 Green 

2 W-B 

C034 oil separator 


Oil separator 

(+) 

Oil separator 

(-) 

C036 left front marker 


Relay, small 

lamp 

Left front 

marker (-) 

C037 over low air pressuring warning switch 2 

Terminal 

No. 

1 R-B 


Switch, air 

pressure 

warning 

61

61-108 


61 

Terminal 

No. 

C038 fuel sensor 


1 B-R Fuel sensor 

2 W-B 

Grounding 

of fuel 

sensor 

3 B-B Fuel sensor 

C043 control unit (interface of oil separator) 

Terminal 

No. 

1 R-W 

2 Blue 


Interface of oil 

separator (+) 

Interface of oil 

separator (-) 

Terminal 

No. 

C039 water level warning switch 

1 R-B 

2 W-B 


Water level 

warning 

switch 

Water level 

warning 

switch (-) 

Terminal 

No. 

C044 exhaust brake solenoid valve 

1 R-B 

2 W-B 


Water level 


Water level 


(-) 

Terminal 

No. 

C040 oil pressure warning switch 

1 W-R 


Oil pressure 

warning 

switch 

Terminal 

No. 

C046 horn 1 


1 B-W Horn (+) 

2 W-B Horn (-)


61-109 

Terminal 

No. 

C047 horn 2 


1 B-W Horn (+) 

2 W-B Horn (-) 

Terminal 

No. 

C048 speedometer sensor 

1 Y-B 

2 W-B 

3 Y-R 


Speedometer 

sensor (+) 

Speedometer 

sensor (-) 

Speedometer 

sensor 

(signal) 

Terminal 

No. 

1 Y-B 

2 W-B 

3 Blue 

4 W-B 

C049 urea tank sensor 



electronic 

control unit 


electronic 

control unit 


electronic 

control unit 


electronic 

control unit 

C101 connect to the wire of instrument panel 

Terminal 

No. 


1 W-B Light fuse 

2 W-R 

IG power 

supply fuse 

61

61-110 


61 

Terminal 

No. 

C102 connect to rear wire 

1 Green 

2 W-R 

3 Y-G 

4 R-Y 


Small 

lamp (+) 

Lighting 

fuse 

inside of 

van 

vehicle 

Brake 

lamp 

Rear fog 

lamp (+) 

5 Plug 

6 R-G 

7 R-Y 

8 G-R 

9 G-B 

10 G-B 

11 G-Y 

12 W-B 

Right 

reverse 

radar (+) 

Left 

reverse 

radar (-) 

Left 

reverse 

radar (+) 

Reverse 

lamp 

Left rear 

turn 

Right rear 

turn 

Ground of 

rear tail 

wire 

Terminal 

No. 

C103 connect to body wire 


1 - - Plug 


3 B-R AC request 

4 Green 


clutch of 

compressor 

5 - - Plug 

6 Y-B 

Urea level 

indicator 

7 W-R MILL lamp 

8 Y-R 

Urea level 

indicator 

9 - - Plug 

10 R-G 

11 R-W 

12 R-Y 

Reverse radar 

controller 

Reverse radar 

controller 

Reverse radar 

controller


61-111 


Terminal 

No. 

1 G-R 


Brake switch 

(vice switch +) 

2 W-B Cruise switch 

3 G-R Cruise 

4 Y-G Cruise 

5 Blue 

6 W-G 

7 W-B 

8 R-B 

9 B-Y 

10 B-B 

11 W-G 

12 Green 

Electronic 

accelerator 

sensor (a-VCC) 

Electronic 

accelerator 

sensor 

(a-signal) 

Electronic 

accelerator 

sensor 

(a-grounding) 

Diagnosis 

switch L 

Electronic 

accelerator 

sensor (b-VCC) 

Electronic 

accelerator 

sensor 

(b-signal) 

Electronic 

accelerator 

sensor 

(b-grounding) 

Diagnosis 

signal CAN (+) 

13 - - Plug 

14 G-Y 

15 B-W 

16 G-R 

DCU IG power 

supply 

DCU IG power 

supply 

Diagnosis 

signal (CAN) 


Terminal 

No. 

1 R-Y 


Three in one 

controller 

2 B-W Horn relay 

3 Green 

Small lamp 

relay 

4 Y-B Clutch switch 

5 - - Plug 

6 W-B 

7 B-B 

Connect to 

meter speed 

signal 

Clutch switch 

(B+) 

8 B-R Fuse, starting 

9 Y-R Speedometer 

10 W-R 

11 B-B 

Oil pressure 

warning lamp 

Water 

temperature 

meter 

12 G-R AC switch fuse 

13 R-B 

Air pressure 

warning 

14 Red A/C amplifier 

15 G-R Relay, AC cutoff 

16 Y-B Speedometer 

61

61-112 


61 


Terminal 

No. 


1 G-Y Fuse, turn 

2 G-Y Right turn switch 

3 G-B Left turn switch 

4 Y-G Brake lap switch 

5 B-R 

6 R-B 

Hand brake 

indication 

Water level 

warning on the 

meter 

7 R-B Preheat indicator 

8 G-R 

9 W-B 

Reverse lamp 

indication 

Grounding, 

meter 

10 R-Y Air filter warning 

11 Red 

12 B-Y 

13 Y-G 

Engine stop 

lamp 

Engine failure 

lamp 

Exhaust brake 

switch 

14 B-Y Fuel indication 

15 B-R Fuel warning 

16 W-R 

Charging 

indicator 

C107 connect to rear clearance lamp 

Terminal 

No. 

1 W-B 

2 Green 


Rear 

clearance 

lamp (-) 

Relay, 

small lamp

D wire (right door wire) 


61-113 

Terminal 

No. 

D002 right front speaker 

1 B-B 

2 Blue 


Right front 

speaker (+) 

Right front 

speaker (-) 

D004 glass regulator, right front door 

Terminal 

No. 

1 B-B 

2 B-Y 


Rise of power 

window, right 

front door 

Descending 

of power 

window, right 

front door 

61 

D003 switch of right front door power glass 

Terminal 

No. 

1 B-Y 

2 G-B 

3 B-B 

4 G-Y 

5 B-R 


Left descend, 

right front 

power window 

switch 

Rise, right 

front power 

window switch 

Left rises, 

right front 

power window 

switch 

descend, right 

front power 

window switch 


front power 

window (B+) 

Terminal 

No. 

D005 right front door lock 

1 B-B 

2 B-Y 


Right front 

door is 

unlocked 

Right front 

door is locked 

3 - - Plug 

4 - - Plug

61-114 


61 

D006 turn lamp on the side of right door 

Terminal 

No. 

1 W-B 

2 G-Y 


Right side 

turn lamp 

(-) 

Right side 

turn lamp 

(+) 

Terminal 

No. 

D101 connect to body wire 

1 G-B 

2 B-B 

3 B-R 

4 B-B 

5 G-Y 

6 B-Y 

7 W-B 


Rise, left front 

power window 

switch 

Lock controller 

is started 

Fuse, power 

window 

Radio and 


(FR+) 

Descend, right 

front power 

window switch 

Lock controller 

is locked 

Grounding, 

body wire 

8 G-Y Right turn lamp Null 

9 - - 

10 Blue 

Radio and 


(FR-)

E wire (left door wire) 


61-115 

Terminal 

No. 

E002 left front door speaker 

1 B-B 

2 Green 


Left front 

speaker (+) 

Left front 

speaker (-) 

Terminal 

No. 

E004 glass regulator, left front door 

1 B-B 

2 B-B 



power window 

switch 

Descending, 

left front power 

window switch 

61 

Terminal 

No. 

E003 left front door control switch 


1 - - Null 

2 G-Y 

3 B-R 

4 G-B 

Left door 

descends, left 

front power 

window switch 

Switch, left 

front power 

window (B+) 

Left door rises, 

left front power 

window switch 

5 - - Null 

6 W-B 

Grounding, 

power window 

7 - - Null 

8 - - Null 

9 B-Y 

10 B-B 

Descend, left 

front power 

window switch 


power window 

switch 

Terminal 

No. 

E005 left front door lock 

1 Purple 

2 W-B 


Left door lock 

switch (B+) 

Grounding, 

left door lock 

actuator 

3 - - Plug 

4 - - Plug

61-116 


61 

E006 turn lamp on the side of left door 

Terminal 

No. 

1 W-B 

2 G-B 


Left side turn 

lamp (-) 

Left side turn 

lamp 

Terminal 

No. 

E101 connect to body wire 


1 - - Null 

2 Purple 

3 B-R 

4 G-B 

Door lock 

controller 

Fuse, power 

window 

Radio and 

cassette 

player (FL+) 

5 - - Null 

6 W-B 

Grounding, 

body wire 

7 G-B Left turn lamp 

8 G-B 

9 G-Y 

10 Green 

Rise, right 

front door 

power window 

Descending, 

right front 

door power 

window 

Radio and 

cassette 

player (FL-)

F wire (roof wire) 


61-117 

Terminal 

No. 

1 R-Y 

2 R-W 

F002 front ceiling lamp 


Front ceiling 

lamp (+) 

Front ceiling 

lamp (-) 

Terminal 

No. 

F004 right clearance lamp 

1 Green 

2 W-B 


Right 

clearance 

lamp (+) 

Right 

clearance 

lamp (-) 

61 

Terminal 

No. 

1 Green 

2 W-B 

F003 left clearance lamp 



lamp (+) 


lamp (-) 

Terminal 

No. 

F101 connect to body wire 

1 Green 

2 R-Y 


Relay, small 

lamp 

Fuse L, front 

ceiling lamp 

3 W-B 

4 R-W 

Grounding, 

body wire 

Switch, door 

lamp

61-118 


G wire (wire of rear clearance lamp) 

61 

Terminal 

No. 

G002 left rear clearance lamp 

1 Green 

2 W-B 



lamp (+) 


lamp (-) 

Terminal 

No. 

G101 connect to chassis wire 

1 Green 

2 W-B 


Connect to 

chassis wire 

Connect to 

chassis wire 

Terminal 

No. 

G003 right rear clearance lamp 

1 Green 

2 W-B 


Right 

clearance 

lamp (+) 

Right 

clearance 

lamp (-)

H wire (right floor wire) 


61-119 

Terminal 

No. 

H001 switch of right door lamp 

1 Green 



door lamp 

Terminal 

No. 

H101 connect to body wire 


1 - - Null 

2 Green 

Front ceiling 

lamp 

3 - - Null 

4 - - Null 

5 - - Null 

6 - - Null 

61

61-120 


J wire (wire of rear chassis) 

61 

Terminal 

No. 

J002 left rear combined lamp 


1 G-B Left rear turn 

2 Y-G Brake lamp 

3 Green 

4 W-B 

Relay, small 

lamp 

Left rear 

combined 

lamp (-) 

5 G-R Reverse lamp 

6 R-Y 

Left rear fog 

lamp 

Terminal 

No. 

J003 rear license plate lamp 

1 Green 

2 W-B 


Rear license 

plate lamp 

Rear license 

plate lamp (-)


61-121 

Terminal 

No. 

J005 right rear combined lamp 


1 G-Y Right rear turn 

2 Y-G 

3 Green 

4 W-B 

Right rear 

brake lamp 

Relay, small 

lamp 

Right rear 

combined 

lamp (-) 

5 G-R Reverse lamp 

6 R-Y 

Rear fog lamp 

(+) 

Terminal 

No. 

1 Green 

2 W-R 

3 Y-G 

4 R-Y 

J101 chassis wire 


Relay, small 

lamp 

Lighting fuse 

inside of van 

vehicle 

Brake lamp 

switch (-) 

Three in one 

controller 

5 - - plug 

6 R-G 

7 W-R 

8 R-Y 

9 G-R 

10 G-Y 

Reverse radar 

controller 

Reverse radar 

controller 

Reverse radar 

controller 

Reverse lamp 

switch (-) 

Right turn 

switch 

11 G-B Left turn switch 

12 W-B Body 

61

61-122 

L wire (left floor wire) 


61 

Terminal 

No. 

L001 left door lamp switch 

1 Green 


Left door lamp 

switch 

L002 switch of parking brake indicator 

Terminal 

No. 


Terminal 

No. 

L101 connect to body wire 

1 Green 


Front ceiling 

lamp 

2 - - Null 

3 - - Null 

4 - - Null 

5 R-Y 

Hand brake 

indication on 

meter 

6 - - Null 

7 - - Null 

1 R-Y 

Switch of 

parking brake 

indicator 

8 - - Null

Layout of wire and parts 

ABS wire 

Audio system- Layout of wire and parts 

61-123 

61 

A002 

Right front wheel speed sensor 

A007 

Left rear wheel solenoid valve 

A003 

Right front wheel solenoid valve 

A008 

Right rear wheel speed sensor 

A004 

Left front wheel solenoid valve 

A009 

Right rear wheel solenoid valve 

A005 

A006 

Left front wheel speed sensor 

Left rear wheel speed sensor 

A101 

A201 

Wire insert parts (connect to chassis 

wire) 

Grounding, ABS frame left front side 

member

61-124 

Body wire 1 


61 

B002 

Washer motor 

B029 


B005 

Speed regulating resistor 

B030 

Cruise switch 

B007 

Blower 

B031 

Cruise switch(+/-) 

B008 

Front thermistor 

B032 


B009 

Wiper motor 

B033 


B015 

Brake lamp switch 

B034 


B016 

Electronic accelerator 

B037 

Danger warning switch 

B022 

Warning switch, brake fluid level 

B038 

ECM diagnosis switch 

B023 

ABS detection interface 

B039 

Lighting of cigar lighter 

B024 

ECM detection interface 

B040 

Cigar lighter 

B025 


B041 

Rear fog lamp switch 

B026 


B042 

Blower switch 

B027 

Ignition switch lighting 

B043 

A/C switch 

B028 

Clutch switch 

B046 

ABS diagnosis switch

Body wire 2 


61-125 

61 

B001 

B003 

B004 

B013 

B014 

B035 

B045 

B050 

Signal amplifier 





Controller of central control lock 

Radio and cassette player 

Body fuse box 

B102 

B110 

B111 

B112 

B204 

Wire insert parts(connect to right 

floor wire) 

Wire insert parts(connect to left floor 

wire) 

Wire insert parts(connect to left door 

wire) 

Wire insert parts (connect to roof 

wire) 

Grounding, left side of instrument 

panel 

B101 

Wire insert parts (connect to the right 

door wire) 

B206 

Grounding, right side of instrument 

panel 

B208 

Grounding, left side of instrument 

panel 

B209 

Grounding, right side of instrument 

panel

61-126 

Body wire 3 


61 

B006 

Right front combined lamp ( right front 

turn lamp) 

B103 

Wire insert parts(connect to chassis 

wire) 

B010 

B011 

B012 

B017 

B018 

B019 

B021 

Right front fog lamp 

Right front combined lamp 

(right front position lamp, side turn lamp) 

Right front combined lamp (right 

headlamp) 

Left front combined lamp 

(left front position lamp, side turn lamp) 

Left front combined lamp(left headlamp) 

Left front combined lamp(left front turn 

lamp) 

Left front fog lamp 

B104 

B105 

B106 

B107 

B108 

B203 

B205 


wire) 


wire) 


wire) 


wire) 


wire) 

Grounding, the first cross meter of frame 

Grounding, right side of front panel 

B207 

Grounding, right side of front panel

Chassis wire 1 


61-127 

61 

C002 

C003 

C013 

C014 

C015 

C016 

C017 

C018 

C019 

C020 

C021 

C028 

C036 

AC pressure switch 

Condenser fan 

Urea injection nozzle 

Post-treatment control unit 



Urea tank heating solenoid vale 

Heater of urea injection pipe 

Heater of urea suction pipe 

Heater of urea return pipe 

Right front marker 

Nitrogen oxide sensor 

Left front marker 

C037 Over low pressure warning switch 2 

C038 Fuel sensor 

C039 Water level warning switch 

C046 Horn 1 

C047 Horn 2 

C049 Urea tank sensor 

C101 Wire insert parts(connect to body wire) 





C211 Grounding, right middle of the frame

61-128 

Chassis wire 2 


61 

C004 

C005 

C006 

C007 

C008 

C009 

C010 

C011 

Alternator(D+) 

Alternator(B+) 

Compressor solenoid valve 

Water temperature sensor 

Starter 

Starter 

Starter 

Warning switch of clogged air filter 

C032 Reverse lamp switch 

C033 Engine control unit 

C040 Oil pressure warning switch 

C044 Exhaust brake solenoid valve 

C048 Speedometer sensor 

C051 Chassis fuse box 1 

C052 Chassis fuse box 2


61-129 

Chassis wire 3 (wire of chassis rear, wire of rear 

clearance lamp) 

61 

C024 

C025 

C026 

Right rear marker 

Left rear marker 

Brake lamp switch 

C027 Over low air pressure warning switch 1 

C102 

C107 

G002 

Wire insert part (connect to rear wire of 

chassis) 

Wire insert part(connect to rear 

clearance lamp) 

Left rear clearance lamp 

G003 

G101 

J002 

J003 

J005 

J101 

Right rear clearance lamp 

Wire insert part (connect to chassis 

wire) 

Left rear combined lamp 

Rear license plate 

Right rear combined lamp 

Wire insert part (connect to chassis 

wire)

61-130 

Right door wire 


61 

D002 

Right front speaker 

D005 

Right front door lock 

D003 

Power window switch, right front door 

D006 

Turn lamp on the right door side 

D004 

Glass regulator, right front door 

D101 

Wire insert parts (connect to body 

wire)

Left door wire 


61-131 

61 

E002 

Left front speaker 

E005 

Lock, left front door 

E003 

Control switch, left front door 

E006 

Turn lamp, left door 

E004 

Glass regulator, left front door 

E101 

Wire insert part (connect to body wire)


61-132 


Ceiling wire, left floor wire, and right floor wire 

61 

F002 

F003 

F004 

F101 

H001 


Left clearance lamp 

Right clearance lamp 

Wire insert part (connect to body 

wire) 

Right door lamp switch 

H101 

L001 

L002 

L101 


wire) 

Left door lamp switch 

Switch, parking brake indicator 


wire)

Communication System 

Communication System .................................... 71-1 


Inspection ...................................................... 71-2 

Horn ..................................................................... 71-3 

Replacement ................................................. 71-3 

71

71

Communication system - Communication system 

71-1 

Communication System 



Horn does not ring. 

1. Horn (damage) 

2. Combination switch (damage) 

3. Horn button (damage) 

4. Harness (damage) 

Chapter 71: 

Chapter 41: 

Chapter 41: 

Communication system 

– Horn, replacement 


– Switch, replacement 


– Steering, overhaul - 

71 

Horn keeps ringing. 

1. Combination switch (damage) 

2. Horn button (damage) 

3. Harness (damage) 

Chapter 41: 

Chapter 41: 


– Switch, replacement 


– Steering, overhaul -

71-2 

Inspection 


1. Horn assy 

(a). 

Measure resistance value of interterminals 

according to the below table. 

Multimeter connecting 

pin 


1 – 2 4 Ω 

71 

If the resistance value does not meet the standard, 

replace horn assy. 

2. Horn button 

(a). 

(b). 

Press down horn button and check whether the horn sound can be heard. 

Loosen horn button and check whether the button returns to its position and the horn sound 

stops. 

In case of failing to meet the standard, repair horn button or replace steering assy.


71-3 

Horn 

Replacement 

1. Remove horn button (Refer to “Chapter 41 Steering mechanism- steering, overhaul”) 

2. Remove left horn assy 

(a). Disconnect insert part. 

71 

(b). 

Loosen bolts and remove horn. 

3. Remove right horn assy 

Hints: 

The steps for removing right horn assy are the same with those for the right one. 

4. Install horn button (refer to “Chapter 41 Steering Mechanism-Steering, Overhaul”) 

5. Install left horn assy. 

(a). 

Screw the bolt tightly and connect insert parts.

71-4 


(b). 


71 

6. Install right horn assy 

Hints: 

The steps for installing right horn assy are the same with those for the right one.

Windscreens/Mirrors/Glass 

Front windscreen ............................................... 72-1 

Parts diagram ................................................ 72-1 

Replacement ................................................. 72-2 

Rear window glass ........................................... 72-12 

Parts diagram .............................................. 72-12 

Replacement ............................................... 72-13 

Side window glass ........................................... 72-17 

Parts diagram .............................................. 72-17 

Replacement ............................................... 72-18 

Door glass regulator ........................................ 72-25 

Inspection .................................................... 72-25 

Replacement ............................................... 72-26 

Door glass ........................................................ 72-29 

Replacement ............................................... 72-29 

72 

Inside rearview mirror ...................................... 72-30 

Parts diagram .............................................. 72-30 

Replacement ............................................... 72-31 

Outside rearview mirror ................................. 72-32 

Parts diagram .............................................. 72-32 

Replacement ............................................... 72-33

Front Windscreen 

Parts diagram 

Windscreen/Window glass/Rearview mirror-Front Windscreen 

72-1 

72 

1 Positioning clip, glass 

2 Trimming strip, front windscreen 

3 Inside weather strip, front windscreen 

4 Front windscreen

72 

72-2 

Replacement 



2. Disassemble left/right wiper arm blade assemblies (refer to “Chapter 55 Wiper and 

washer-Wiper arm assembly, Replacement”) 

3. Disassemble the lower trimming cover of left/right wiper arm blade 

4. Disassemble the fixation trimming cover of wiper injection nozzle (refer to “Chapter 55 

Wiper and washer-Injection nozzle, Replacement”) 

5. Disassemble the upper trimming plate of front panel 

6. Disassemble left/right sun visor (refer to “Chapter 77 Inner/Outer trimming part-Sun 

visor, Replacement”) 

7. Disassemble inside rearview mirror (refer to “Chapter 72 Windscreen/Window 

glass/Rearview mirror-Inside rearview mirror, Replacement”) 

8. Disassemble front ceiling lamp assembly (refer to “Chapter 54 Lighting-Front ceiling 

lamp, Replacement”) 

9. Disassemble inside roof and the roof assembly is not necessary to be disassembled. 

Make the front part of roof assembly lower (refer to “Chapter 77 Inner/Outer trimming 

part-Trimming part of ceiling, Replacement”) 

10. Disassemble the get on handle and right side ceiling handle (refer to “Chapter 77 

Inner/Outer trimming part-Cover plate of front pillar/get on handle, Replacement) 

11. Disassemble the cover plate of left and right front pillar (refer to “Chapter 77 

Inner/Outer trimming part-Cover plate of front pillar/get on handle, Replacement) 

12. Disassemble the inside weather strip of front 

windscreen

13. Disassemble front windscreen 

Notes: 


72-3 

· As shown in the figure, there are two positioning clips under the windscreen. Do not damage 

the windscreen when the binder is moved away. 

· Make sure the windscreen is caught up by sucker during this operation and prevent the 

windscreen falling down. 

72 

(a). 

Hint: 

Stick protective tape on the position where front 

windscreen is assembled on the body. 

Stick the protective tape on the installation surface to 

prevent scratch.

72-4 


(b). 

Hint: 

Make the matching mark on the position shown 

on the figure on windscreen and body. 

It needs not to make the matching marker if the 

windscreen will not be used again. 

72 

(c). 

(d). 

(e). 

Notes: 

Thread a fine steel wire through the clearance 

between body and windscreen. 

Tie both ends of the steel wire to wooden block 

or similar thing. 

Pull the steel wire around the windscreen to 

delete the binder. 

· Do not damage the paint or inside/outside 

trimming parts when the windscreen is 

separated. 

· Put one plastic pad between steel wire and 

safety mat to prevent the safety mat from 

scratch before the windscreen is 

disassembled. 

(f). Disassemble the windscreen assembly by 

sucker. 

Notes: 

· Be careful and do not drop the windscreen. 

· Keep more binder on the body as possible 

when the windscreen is disassembled. 

14. Disassemble the outside trimming strip of front windscreen 

Hint: 

The outside trimming strip should be replaced.


15. Disassemble the positioning clip 

Hint: 

Replace the positioning clip in time if it is damaged. 

72-5 

72 

16. Clean front windscreen 

(a). 

Notes: 

Take off the adhesive tape and binder from 

windscreen by scraper. 

Do not damage the windscreen. 

(b). 

Notes: 

Around clean the windscreen by dissoluble 

detergent. 

· Do not touch the surface of the windscreen 

glass after cleaning. 

· Clean the windscreen by dissoluble detergent 

it is a brand new one.

72-6 


72 

17. Clean the vehicle body 

(a). 

Clean and refit the contact face of the body. 

· Take off coarse glass sealant from the contact 

surface of body by knife. 

· Clean the contact face of body by a piece of cloth 

soaked by detergent. 

Notes: 

18. Clean inside trimming strip of the windscreen 

Hint: 

· Be careful and do not damage the body. 

· Clean the body even if all glass sealant are 

removed. 

Replace the inside trimming strip of the windscreen if it is damaged or deformed. 

(a). 

Notes: 

Take off the adhesive tape and binder from inside trimming strip of the windscreen by 

scraper. 

It is strictly not allowed to clean the outside around of the inside trimming strip of the 

windscreen by dissoluble detergent. 

19. Assemble the glass positioning clips 

(a). 

Hint: 

Assemble 2 glass positioning clips as shown in the figure. 

Replace the glass positioning clip if it is not tight any more.


20. Assemble the outside trimming strip of front windscreen 

(a). Assemble the outside trimming strip of front windscreen as shown in the figure. 

Hint: 

· Please take off insulation paper of double sided tape. 

· Make sure the double sided tape and front windscreen glass are stuck tightly. 

· The WS marker on connection position should be downwards during installation. 

72-7 

72 

1 1 × 4mm double sided tape 

2 WS marker on connection position 

3 Glass positioning clips 

4 Outside trimming strip of front windscreen

72-8 


21. Assemble inside weather strip of the front windscreen 

(a). 

Hint: 

Assemble inside weather strip of the front windscreen as shown in the figure. 

· The double sided tape should be toward to outside of the body during assembly. 

· Please take off insulation paper of double sided tape when the front windscreen is 

assembled. 

72 

1 4 × 2mm double sided tape 

2 Inside weather strip of front windscreen 

3 Body


72-9 

22. Assemble front windscreen assembly 

(a). 

Put the front windscreen assembly 

· As shown in the figure, place front windscreen 

assembly to correct position by sucker. 

· Check and make sure the complete contact 

surface of the glass rim is smooth. 

· Align the alignment marker on front windscreen 

assembly and body. 

Notes: check and make sure the glass clips are 

assembled on the body correctly. 

· Take off the front windscreen assembly 

(b). 

Notes: 

Coat the reactive PU black primer on the 

installation surface of the body by brush. 

· Do not coat it with too much primer. 

· Dry the primer layer 5 minutes or longer. 

· Do not keep the unsealed primer for future 

use. 

Hint: 

Clean the primer away by clean rags before it is dry if 

the primer is painted on the unspecified area. 

72 

(c). 

Sealing 

· Coat the specified area with PU black glass 

sealant by sealing gun as shown in the figure. 

Notes: 

· Do not coat the position with too much glass 

glue. 

· Clean the glass sealant away by clean rags 

before it is dry if the glass sealant is painted 

on the unspecified area.

72-10 


72 

1 Front windscreen 

2 

Outside trimming strip of front 

windscreen 

3 Upper trimming plate of front panel 

4 Glass positioning clip 

5 

Glass sealant (along with the perimeter of 

glass)


72-11 

(d). 

23. Check if it is leaking, and repair it if it is leaking 

Assemble front windscreen assembly 

· Take off the insulation paper of the double sided 

tape on inside weather strip of front windscreen 

before the installation. 

· Place the windscreen to its position by sucker 

and align the matching markers; and press it 

down along its rim slightly. 

· Press the front surface of the windscreen slightly 

to make sure it is assembled onto body tightly. 

· Refit the horizontal level or position of the glass 

sealant by scraper as necessary. 

· Fix the windscreen by adhesive tape until the 

glass sealant is hardened. 

Hint: 

The adhesive tape should be taken away at least after 4 

hours. 

Notes: 

· Check and make sure the windscreen stopper 

is assembled on the body correctly. 

· Check the clearance between body and 

windscreen. 

72 

(a). 

(b). 

(c). 

Spray water from the outside of windscreen after the glass sealant is hardened. Check and 

make sure there is no leaking. 

Paint glass sealant after the water is dried if it is leaking. 

Take off the adhesive tape. 

24. Assemble cover plate of front left/right pillar (refer to “Chapter 77 Inner/Outer 

trimming part-Cover plate of front pillar/get on handle, Replacement”) 

25. Assemble the get on handle and right side ceiling handle (refer to “Chapter 77 

Inner/Outer trimming part-Cover plate of front pillar/get on handle, Replacement”) 

26. Assemble vehicle roof, and the roof assembly is not necessary to be disassembled. 

Make the front part of roof assembly lower (refer to “Chapter 77 Inner/Outer trimming 

part-Trimming part of ceiling, Replacement”) 

27. Assemble front ceiling lamp assembly (refer to “Chapter 54 Lighting-Front ceiling 

lamp, Replacement”) 

28. Assemble inside rearview mirror (refer to “Chapter 72 Windscreen/Window 

glass/Rearview mirror-Inside rearview mirror, Replacement”) 

29. Assemble left/right sun visor (refer to “Chapter 77 Inner/Outer trimming part-Sun visor, 


30. Assemble the upper trimming plate of front panel 

31. Assemble the fixation trimming cover of wiper injection nozzle (refer to “Chapter 55 

Wiper and washer-Injection nozzle, Replacement”) 

32. Assemble the lower trimming cover of left/right wiper arm blade 

33. Assemble left/right wiper arm blade assemblies (refer to “Chapter 55 Wiper and 

washer-Wiper arm assembly, Replacement”)

72-12 

Rear window glass 

Parts diagram 

Windscreen/Window glass/Rearview mirror-Rear window glass 

72 

1 Weather strip of rear window glass 

2 Rear window glass 

3 Trimming plate assembly of rear penal 

4 Big clip

Replacement 


72-13 

1. Disassemble rear window glass 

(a). 

Notes: 

Push the rear window glass assembly from any 

one of four points as shown in the figure, and 

make it out. 

· It will need two persons to carry out this 

operation at the same time. 

· Stick the glass by sucker from rear outside of 

the glass to prevent the glass damage. 

(b). 

Check the weather strip of the rear window glass 

· Replace the damaged or deformed weather strip 

during disassembly. 

72

72-14 


2. Assemble weather strip of the rear window glass 

(a). Assemble weather strip of the rear window glass as shown in the figure. 

Hint: 

Make the scupper towards downward of glass during assembly. 


2 Rear window glass 

3 Scupper 

72 

3. Assemble the rear window glass assembly 

(a). Assemble the nylon rope as shown in the figure. 

· Select a suitable nylon rope and put it into the weather strip of rear window glass. 

· Keep a longer section of the nylon rope outside.

(b). 


72-15 

Take off the insulation paper of the double sided taper from weather strip of rear window 

glass. 

72 

1 Body 


3 10*0.2 double sided tape 

4 Rear window glass

72-16 


72 

(c). 

Hint: 

As shown in the figure, one person pull out the 

nylon rope and assemble the rear window into 

rear panel of the body. 

The scupper should be downwards. 

Notes: 

· It will need two persons to carry out this 

operation at the same time. 

· Support the glass by hand or sucker from 

rear outside of the glass. 

(d). 

Check if the weather strip is fallen into body 

completely after the nylon rope is pulled out. 

· Get out the weather strip by flat screwdriver if it is 

not stuck by the body completely. 

Notes: 

4. Check if it is leaking, and repairs it if there is leaking 

(a). 

(b). 

(c). 

Do not damage the weather strip of rear window 

glass 

Spray water from the outside of windscreen. Check and make sure there is no leaking. 


Reassemble the rear window glass if it is still leaked.

Side window glass 

Parts diagram 

Windscreen/Window glass/Rearview mirror-Side window glass 

72-17 

72 

1 Inside weather strip of side window glass 

2 Sealant of side glass 

3 Side glass

72-18 

Replacement 

Hint: 


The replacement steps are same for left and right side glass because they are symmetrical. 

1. Disassemble the inside weather strip of left 

side window glass 

2. Disassemble left side window glass assembly 

(a). 

Stick protective tape on the position where the 

side window glass assemble will be assembled. 

72 

(b). 

Hint: 

Make matching marker on side glass and body 

as shown in the figure. 

It needs not to make the matching marker if the 

windscreen will not be used again.


72-19 

(c). 

(d). 

(e). 

Notes: 

Thread a fine steel wire through the clearance 

between body and glass. 

Tie both ends of the steel wire to wooden block 

or similar thing. 

Pull the steel wire around the glass to delete 

glass sealant and glass binder. 

· Do not damage the paint or inside/outside 

trimming parts when the glass is separated. 

· Put one plastic pad between steel wire and 

safety mat to prevent the safety mat from 

scratch before the glass is disassembled. 

(f). 

Notes: 

Disassemble the glass assembly by sucker. 

· Be careful and do not drop the side glass. 

· Keep more binder on the body as possible 

when the side glass is disassembled 

(a). 

Notes: 

3. Clean left side window glass 

Take off the adhesive tape and sealant from 

side window glass by scraper. 

Do not damage the side window glass. 

(b). 

Notes: 

Around clean the glass by dissoluble detergent. 

· Do not touch the surface of the glass after 

cleaning. 

· Clean the glass by dissoluble detergent it is 

a brand new one. 

4. Clean inside trimming strip of the left side 

window glass 

(a). 

Notes: 

Take off the adhesive tape and binder from 

inside trimming strip of the glass by scraper. 

· Be careful and do not damage inside 

trimming strip of the side window glass 

· It is strictly not allowed to clean the outside 

around of the inside trimming strip of the 

glass by dissoluble detergent. 

Hint: 

Replace the inside trimming strip of the glass if it is 

damaged or deformed. 

72

72-20 


72 

5. Clean the vehicle body 

(a). 

Clean and refit the contact face of the body. 

· Take off coarse glass sealant from the contact 

surface of body by knife. 

· Clean the contact face of body by a piece of cloth 

soaked by detergent. 

Notes: 

· Be careful and do not damage the body. 

· Clean the body even if all glass sealant are 

removed. 

6. Assemble left side glass sealant 

Hint: 

Use new side glass sealant. 

(a). 

Notes: 

As shown in the figure, coat the installation area 

of side window glass with 0.3 mm PU glue. 

· Do not put too much PU glue. 

· Clean the PU glue away by clean rags before 

it is dry if the PU glue is painted on the 

unspecified area. 

(b). 

Assemble the side glass sealant as shown in the 

figure.


72-21 

7. Assemble inside weather strip of left side window glass 

(a). 

Hint: 

Assemble inside weather strip of left side window glass as shown in the figure. 

· Make double sided tape toward outside of the body during assembly. 

· Please take off the insulation paper of the double sided tape during the installation of side 

window glass. 

72 

1 3*2mm double sided tape 


3 Body

72-22 


72 

8. Assemble side window glass assembly 

(a). 

Place the side window glass assembly 

· As shown in the figure, place side window glass 

assembly to correct position by sucker. 

· Check and make sure the complete contact 

surface of the glass rim is smooth. 

· Align the alignment markers on side window 

glass assembly and body. 

· Take off the side window glass assembly 

(b) 

Notes: 

Coat the reactive PU black primer on the 

installation surface of the body by brush. 

· Do not coat it with too much primer. 

· Dry the primer layer 5 minutes or longer. 

· Do not keep the unsealed primer for future 

use. 

Hint: 

Clean the primer away by clean rags before it is dry if 

the primer is painted on the unspecified area. 

(c). 

Sealing 

· Coat the specified area with PU black glass 

sealant by sealing gun as shown in the figure. 

Notes: 

· Do not coat the position with too much glass 

glue. 

· Clean the glass sealant away by clean rags 

before it is dry if the glass sealant is painted 

on the unspecified area.


72-23 

1 Body 

2 Side glass sealant 

3 15*7 glass sealant 


5 Side window glass 

72

72-24 


72 

(d). 

Assemble side window glass assembly 

· Take off the insulation paper of the double sided 

tape on inside weather strip of side window glass 

before the installation. 

· Place the side window glass to its position by 

sucker and align the matching markers; and 

press it down along its rim slightly. 

· Press the front surface of the side window glass 

slightly to make sure it is assembled onto body 

tightly. 

· Refit the horizontal level or position of the glass 

sealant by scraper as necessary. 

· Fix the side window glass by adhesive tape until 

the glass sealant is hardened. 

Hint: 

The adhesive tape should be taken away at least after 4 

hours. 

Notes: 

Check the clearance between body and side glass. 

9. Check if it is leaking, and repair it if it is leaking 

(a). 

(b). 

(c). 

Spray water from the outside of side glass after the glass sealant is hardened. Check and 

make sure there is no leaking. 


Take off the adhesive tape.

Windscreen/Window glass/Rearview mirror- Door glass regulator 

Door glass regulator 

Inspection 

Hint: 

72-25 

The inspection steps are same for left and right door glass regulator because they are symmetrical. 

1. Check if door glass regulator is deformed 

(a). 

Replace it by a new one if it is deformed. 

2. Check the movement of idler wheel 

(a). 

(b). 

As shown in the figure, check every idler wheel if 

they are worn or deformed. 

Replace the door glass regulator by a new one if 

idler wheel is worn or deformed. 

72 

3. Check the ratchet of rocker arm 

(a). 

Replace the door glass regulator by a new one if 

the meshing clearance of rocker arm ratchet and 

window rocker arm is too big or they are 

dislocated. 

4. Check the shaft of rocker arm 

As shown in the figure, rotate the shaft of rocker arm, 

and it should be smooth without “kada” sound; if it is not 

smooth and with “kada” sound, replace the door glass 

regulator

72-26 

Replacement 

Hint: 


The replacement steps are same for left and right door glass regulator because they are 

symmetrical. 


2. Disassemble the inner trimming plate 

assembly of left door (refer to “Chapter 77 

Inner/Outer trimming part- Inner trimming 

plate of the door, Replacement”) 

3. Disassemble the inside trimming strip of left 

door 

Hint: 

The side with glass fuzz should be toward to the door 

glass. 

72 

4. Disassemble the left rain-proof curtain 

Notes: 

Be careful and do not damage the rain-proof curtain. 

5. Disassemble left door glass 

(a). 

(b). 

(c). 

(d). 

Ignition switch: ON. (Carry out this operation if 

the vehicle is equipped with power glass 

regulator.) 

Move the window glass to the position shown in 

the figure. 

Ignition switch: OFF. (Carry out this operation if 

the vehicle is equipped with power glass 

regulator.) 

Disassemble 2 door glass fixation bolts.


72-27 

(e). 

Notes: 

Make the door glass incline 45° and take it out as 

shown in the figure. 

Do not drop down the glass. 

6. Disassemble left door glass regulator 

(a). 

(b). 

(c). 

Disconnect the insert part of door glass regulator 

motor. (Carry out this operation if the vehicle is 

equipped with power glass regulator.) 

Disassemble 6 door glass regulator fixation bolts. 

Take out door glass regulator. 

72 

7. Assemble left door glass regulator 

(a). 

(b). 

Assemble 6 door glass regulator fixation bolts. 

Connect the insert part of door glass regulator motor. (Carry out this operation if the vehicle 

is equipped with power glass regulator.) 

8. Assemble left door glass 

(a) 

Notes: 

As shown in the figure, make and glass incline 

45° and assemble it. 

Be careful and do not drop down the glass.

72-28 


(b). 

(c). 

Place door glass to the figure shown position, 

and align the bolt installation hole of glass clip to 

the installation hole of door glass regulator. 

Assemble 2 door window glass fixation bolts. 

9. Assemble left rain-proof curtain. 

72 

10. Assemble the inner trimming strip of left side 

door. 

Hint: 

The side with glass fuzz should be toward to the door 

glass. 

11. Assemble the inner trimming plate assembly 

of left door (refer to “Chapter 77 Inner/Outer 

trimming part- Inner trimming plate of the 

door, Replacement”)

Door glass 

Replacement 

Hint: 

Windscreen/Window glass/Rearview mirror- Door glass 

The replacement steps are same for left and right side glass because they are symmetrical. 

72-29 

1. Disassemble left door glass (refer to “Chapter 72 Windscreen/Window glass/Rearview 

mirror-Door glass regulator, Replacement”) 

2. Disassemble the glass clip of left door glass 

Hint: 

The flat face of door glass clip should face to outside 

direction of the vehicle body during assembly. 

72 

out 

3. ssemble glass clip of left door 

Note: 

The glass clip of left door should be fixed firmly.

72-30 

Windscreen/Window glass/Rearview mirror-Inside rearview mirror 

Inside rearview mirror 

Parts diagram 

72

Replacement 

Windscreen/Window glass/Rearview mirror-Inside rearview mirror 

72-31 

1. Disassemble the trimming cover of inside 

rearview mirror 

2. Disassemble inside rearview mirror 

(a). 

(b). 

Notes: 

As shown in figure, disassemble 2 fixation bolts 

of inside rearview mirror. 

Take off the inside rearview mirror. 

Be careful and do not drop the inside rearview 

mirror. 

72 

3. Assemble inside rearview mirror 

4. Assemble the trimming cover of inside rearview mirror.

72-32 

Windscreen/Window glass/Rearview mirror-Outside rearview mirror (small) 

Outside rearview mirror 

Parts diagram 

72

Replacement 

Hint: 

Windscreen/Window glass/Rearview mirror-Outside rearview mirror (small) 

72-33 

The replacement steps are same for left and right side outside rearview mirror (small) because they 

are symmetrical. 

1. Disassemble the cover plate of left rearview 

mirror 

(a). 

As shown in the figure, disassemble 2 fixation 

screws of left rearview mirror. 

2. Disassemble left rearview mirror assembly 

(a). 

Notes: 

As shown in the figure, disassemble 4 fixation 

bolts of left rearview mirror. 

Be careful and do not drop down the left rearview 

mirror. 

72 

3. Assemble left rearview mirror assembly 

(a). Assemble 4 fixation bolts of left rearview mirror. 

4. Assemble the cover plate of left rearview mirror 

(a). Assemble 2 fixation screws of left rearview mirror.

72-34 

Windscreen/Window glass/Rearview mirror-Outside rearview mirror (big) 

72

Instrument Panel 

Instrument panel .............................................. 73-1 

Notices ........................................................ 73-1 

Parts diagram .............................................. 73-2 

Replacement ............................................... 73-3 

Combined meter ............................................. 73-12 

Notices ...................................................... 73-12 

Parts diagram ............................................ 73-13 

Replacement ............................................. 73-14 

Cigar lighter .................................................... 73-18 

Parts diagram ............................................ 73-18 

Replacement ............................................. 73-19 

73

73

Instrument panel 

Notices 

Instrument panel/Combined meter/Cigar lighter-Instrument panel 

73-1 

1. Please release the air pressure inside of brake system before the instrument panel is 

disassembled. 

(a). 

(b). 

(c). 

(d). 

(e). 

Align wheel to right ahead. 

Fix 4 wheels by wedge block. 



Step down brake pedal repeated until the reading on pressure meter decreases to below 

0.4MPa. 

2. The disassembly of instrument panel will reset daily odometer and clock. 

Hint: 


3. The disassembly of instrument panel will make the audio system lose stored setting. 

Hint: 

The audio system needs to be reset after negative pole cable is connected. (refer to “Chinese and 

English Application Manual of Audio System”). 

4. Cutoff the power supply 

(a). 

(b). 


electric device and at the time of tools or devices may contact with the bare electric terminals; 

this will prevent personnel or vehicle from hurt. 


73

73-2 

Parts diagram 


73 

1 

Welding assembly of instrument panel 

installation cross member 

8 Middle bracket assembly 

2 Filling port and cap of brake fluid 9 Ash tray assembly 

3 Instrument panel assembly 10 Audio unit 

4 Cover of throttle cable port 11 Central control panel assembly 

5 Combined meter assembly 12 Screw cover 

6 Cigar lighter assembly 13 Glove box assembly 

7 Meter cover assembly 14 Right lower cover plate

Replacement 

1. Align the wheel to right ahead. 



3. Disconnect the negative pole of battery 

Hint: 

73-3 

Please turn off ignition switch and lighting switch, and 

loose terminal nut completely when the battery cable is 

connected and disconnected. Do not prize up the 

terminal during the operation. 

4. Disassemble the upper and lower covers of 

adjustable combined switch. 

(a). 

(b). 

(c). 

Rotate adjustment arm of steering wheel to the 

position as shown in the figure. 

Adjust the steering wheel to the lowest point. 

Disassemble 5 fixation screws of upper and 

lower covers of adjustable combined switch. 

73 

5. Disassemble 4 fixation bolts of steering 

column. 

Notes: 

Fix the steering column by rope or ribbon after the 

steering column bolts are disassembled, to prevent it 

from rotation.

73-4 


6. Disassemble the filling port and cap of brake 

fluid 

73 

7. Disassemble cruise switch +\- (refer to “Chapter 82 Cruise control- Cruise switch +\-, 


8. Disassemble the cruise switch (refer to “Chapter 82 Cruise control- Cruise switch +\-, 


9. Disassemble the combined meter assembly (refer to “Chapter 73, Instrument 

panel/Combined meter/Cigar lighter-Combined meter, Replacement”). 

10. Disassemble the central control panel assembly (refer to “Chapter 56 Audio 

system-Audio unit, Replacement”) 

11. Disassemble audio unit (refer to “Chapter 56 Audio system-Audio unit, 


12. Disconnect the insert part of cigar lighter. 

13. Disassemble AC control mechanism 

(a). 

Hint: 

Pull out 4 rod covers of the AC control 

mechanism. 

Press the AC control mechanism at the same time of 

pulling out rod covers.


73-5 

(b). 

Note: 

Disassemble 6 fixation clips from the trimming 

plate of AC control mechanism. 

It is strictly not allowed to pull out the trimming 

plate of AC control mechanism after 6 fixation clips 

are opened. 

(c). 

(d). 

Disassemble the insert part of AC switch. 

Take off the trimming plate of AC control 

mechanism. 

73 

(e). 

(f). 

Disassemble 3 fixation screws of the AC control 

mechanism. 

Loose AC control mechanism.

73-6 


14. Disassemble glove box assembly 

(a). 

(b). 

Disassemble 4 fixation screws of glove box 

assembly. 

Take off the glove box assembly. 

73 

15. Disassemble right lower cover plate 

(a). 

(b). 

Disassemble 5 fixation screws from right lower 

cover plate. 

Take off right lower cover plate. 

16. Disassemble the right side screw of 

instrument panel assembly 

17. Disassemble the left side screw of instrument 

panel assembly


73-7 

18. Disassemble instrument panel assembly 

(a). 

(b). 

As shown in the figure, disassemble 9 fixation bolts of instrument panel assembly. 

Disassemble the instrument panel assembly. 

73 

Notes: 

· Do not damage the surface of instrument panel. 

· Cover the disassembled instrument panel with protective cover if it is not assemble for a 

while. 

· Place the instrument panel at a dry and ventilated room and far away from heat resource and 

chemicals. 

· It is strictly not allowed to place articles on the instrument panel. 

· Place the disassembled bolts in order. 

19. Assemble the instrument panel assembly 

(a). Assemble 9 fixation bolts of instrument panel assembly. 


Notes: 

· Be careful and do not damage the surface of instrument panel. 

· Be careful and do not squeeze or distort the wire and connection air pipe. 

20. Assemble the left side screw of 

instrument panel assembly

73-8 


21. Assemble the right side screw of instrument 

panel assembly 

22. Assemble right lower cover plate 

(a). 

Assemble 5 fixation screws from right lower 

cover plate. 

73 

23. Assemble glove box assembly 

(a). 

Assemble 4 fixation screws of glove box 

assembly. 

24. Assemble the AC control mechanism 

(a). 

Assemble 3 fixation screws of the AC control 

mechanism.


73-9 

(b). Assemble trimming plate of AC control 

mechanism. 

Hint: 

4 clips should be assembled to its position when it is 

assembled and there should be “kada” sound to be 

heard. 

(c). Connect the AC switch insert part. 

Notes: 

The contact of AC switch insert part should be firm. 

73 

(d). Assemble 4 rod covers of AC control 

mechanism. 

25. Connect the insert part of cigar lighter.

73-10 


26. Assemble audio unit (refer to “Chapter 56 Audio system-Audio unit, Replacement”). 

27. Assemble the central control panel assembly (refer to “Chapter 56 Audio 

system-Audio unit, Replacement”) 

28. Assemble the combined meter assembly (refer to “Chapter 73, Instrument 

panel/Combined meter/Cigar lighter-Combined meter, Replacement”). 

29. Assemble the cruise switch (refer to “Chapter 82 Cruise control- Cruise switch +\-, 


30. Assemble cruise switch +\- (refer to “Chapter 82 Cruise control- Cruise switch +\-, 


31. Assemble the filling port and cap of brake 

fluid 

73 

32. Assemble 4 fixation bolts of steering column. 


33. Assemble the upper and lower cover of 

adjustable combined switch 

(a). 

Assemble 5 fixation screws of the upper and 

lower cover of adjustable combined switch


73-11 

(b). 

Adjust the steering wheel and make it to its 

original height, and lock the adjustment arm of 


34. Connect the negative pole cable of battery. 

73

73 

73-12 


Notices 

Instrument panel/Combined meter/Cigar lighter- Combined meter 

1. Please release the air pressure inside of brake system before the instrument panel is 

disassembled. 

(a). 

(b). 

(c). 

(d). 

(e). 

Align wheel to right ahead. 

Fix 4 wheels by wedge block. 



Step down brake pedal repeated until the reading on pressure meter decreases to below 

0.4MPa. 

2. The disassembly of instrument panel will reset daily odometer and clock. 

Hint: 


3. Cutoff the power supply 

(a). 

(b). 


electric device and at the time of tools or devices may contact with the bare electric terminals; 

this will prevent personnel or vehicle from hurt. 

The ignition switch must be turned off if there is no special explanation.

Parts diagram 


73-13 

73 

1 Meter cover assembly 2 Combined meter assembly

73-14 

Replacement 



2. Disconnect the negative pole of battery 

Hint: 

Please turn off ignition switch and lighting switch, and 

loose terminal nut completely when the battery cable is 

connected and disconnected. Do not prize up the 

terminal during the operation. 

3. Adjust the steering wheel to the lowest point. 

(a). 

(b). 

Rotate adjustment arm of steering wheel to the 

position as shown in the figure. 

Adjust the steering wheel to the lowest point. 

73 

4. Disassemble the meter cover assembly 

(a). 

Pull out the meter cover assembly backwards.


73-15 

5. Disassemble combined meter assembly 

(a). 

Disassemble 4 fixation screws of combined 

meter assembly 

6. Disassemble insert parts of combined meter 

assembly 

(a). 

Hint: 

Disassemble 3 insert parts of combined meter 

assembly. 

Take off the insert parts after the positioning clip of insert 

part is pressed down. 

Notes: 

• Grasp the insert part but not the wire when the insert 

part is pulled out. 

• Be careful and do not damage the housing of combined 

meter. 

73 

7. Disassemble the connection pipe of air 

pressure meter 

(a). 

Hint: 

Disassemble 2 connection pipes of air pressure 

meter 

Paint installation mark on connection pipe before 

disassembly using marker paint. 

Notes: 

• Do not disassemble the connection pipe 

immediately after it is loosed; loose the nut slowly 

and stop the operation when there is air vented. 

Disassemble the connection pipe to meter 

completely until there is no more air vented. 

• Use 2 wrenches at the same time during 

disassembly. 

• Be careful and do not damage the housing of 

combined meter.

73-16 


9. Plug up the interface of connection pipe to 

pressure meter 

Notes: 

Seal the interface of pressure meter connection pipe 

by sealing film when the connection pipe is 

disassemble, to prevent the foreign body or liquid 

entering. 

73 

10. Assemble the connection pipe of pressure 

meter 

(a). Assemble 2 connection pipes of pressure meter 


Hint: 

Take off the sealing film from connection pipes of 

pressure meter. 

Assemble the connection pipe according to the 

installation marks made on the pipe before disassembly. 

Notes: 

• Use 2 wrenches at the same time during 

disassembly. 

• Be careful and do not damage the housing of 

combined meter. 

11. Assemble the insert part of combined meter 

assembly 

(a). Assemble 3 insert parts of combined meter 

assembly. 

Notes: 

The clear sound “kada” should be heard and then it 

can be confirmed that the insert part is assembled to 

position.


73-17 

12. Assemble the combined meter assembly 

(a). 

Notes: 

Assemble 4 fixation screws of the combined 

meter assembly. 

Be careful and do not squeeze or distort the wire 

and connection pipe. 

13. Assemble meter cover assembly 

(a). 

Assemble meter cover assembly in the direction 


73 

14. Reposition the steering wheel 

(a). 

(b). 

Adjust the steering wheel to a suitable position. 

As shown in the figure, adjust the adjustment 

arm of steering wheel to figure shown position 

and lock it. 

15. Connect negative pole cable of battery.

73-18 

Cigar lighter 

Parts diagram 

Instrument panel/Combined meter/Cigar lighter- Cigar lighter 

73

Replacement 


2. Pull out the head of cigar lighter 


73-19 

3. Push out the inner ring of cigar lighter seat 

(a). 

Notes: 

Rotate about 60° from the rear side of the inner 

ring of cigar lighter seat, ant then push it out. 

Do not damage the wire when the inner ring of cigar 

lighter seat is pushed out. 

73 

4. Disassemble the outer ring of cigar lighter 

seat 

(a). 

Notes: 

As shown in the figure, pick out 2 clips from the 

cigar lighter seat. 

Be careful and do not damage the clips. 

(b). 

Push out the outer ring of cigar lighter seat from 

rear side.

73-20 


5. Disassemble the cigar lighter seat 

(a). Disconnect the insert part of cigar lighter. 

(b). Take off cigar lighter seat. 

6. Connect the insert part of cigar lighter seat 

73 

7. Assemble the outer ring of cigar lighter seat 

(a). 

As shown in the figure, align the protrusion point 

of outer ring of cigar lighter seat to the gap on the 

trimming ring of cigar lighter seat during 

installation and make it upwards.


73-21 

(b). 

Hint: 

Push in the outer ring of cigar lighter seat 

Check and make sure the positioning clip of outer ring 

of cigar lighter seat is locked into instrument panel after 

the outer ring of cigar lighter seat is pushed into 

instrument panel. 

8. Assemble the inner ring of cigar lighter seat 

(a). 

Hint: 

Insert the inner ring of cigar lighter seat. 

• Make sure the inner ring of cigar lighter seat can 

not be pulled out after it is inserted into position; 

rotate the inner ring of cigar lighter seat a certain 

degree and try to pull again if it can be pulled out. 

• The rotated degree should be smaller than 90° to 

avoid twisting the wire. 

73 

9. Insert the head of cigar lighter

73 

-Memorandum -

Seats 

Driver’s seat ..................................................... 74-1 

Parts diagram .............................................. 74-1 

Replacement ............................................... 74-2 

Cushion of driver’s seat .................................. 74-4 

Replacement ............................................... 74-4 

Cushion of co-driver’s seat ............................. 74-5 

Parts diagram .............................................. 74-5 

Replacement ............................................... 74-6 

Berth ................................................................. 74-8 

Parts diagram .............................................. 74-8 

Replacement ............................................... 74-9 

Backrest of driver’s seat................................ 74-10 

Replacement ............................................. 74-10 

Backrest of co-driver’s seat .......................... 74-11 

Parts diagram ............................................ 74-11 

Replacement ............................................. 74-12 

Backrest of middle seat ................................. 74-13 

Parts diagram ............................................ 74-13 

Replacement ............................................. 74-14 

Angle regulator of driver’s seat .................... 74-15 

Replacement ............................................. 74-15 

Angle regulator of co-driver’s seat ............... 74-17 

Replacement ............................................. 74-17 

74

74

Driver’s seat 

Parts diagram 

Seat- Driver’s seat 

74-1 

74 

1 Driver’s seat assembly 2 Hexagon bolt

74-2 

Replacement 


1. Disassemble driver’s seat 

(a). 

Move the driver’s seat to the rear end of sliding 

rail. 

(b). 

(d) . 

Disassemble the plastic housing of sliding rail 

bracket of driver’s seat. 

Loose 2 bolts on the front end of driver’s seat. 

74 

(d). 

Move driver’s seat to the front end of sliding rail. 

(e). 

Hint: 

Loose 2 bolts on the rear side of driver’s seat to 

disassemble the seat. 

Do not move the sliding rail when the seat is 

disassembled, otherwise, it may cause wrong 

installation.


74-3 

2. Assemble driver’s seat 

(a). 

(b) 

Put the driver’s seat into its installation position 

inside of cab. 

Fasten 2 bolts on the rear side of driver’s seat. 

Toque: 50 N•m 

(c). 

Move the driver’s seat to the rear side of sliding 

rail. 

74 

(d). 

(e). 

Hint: 

Fasten 2 bolts on the front side of driver’s seat. 


Assemble the plastic housing of sliding rail 

bracket of driver’s seat. 

Adjust the seat to a suitable position and shake it to 

make sure it is assembled firmly.

74-4 

Cushion of driver’s seat 

Replacement 

Seat- Cushion of driver’s seat 

1. Turn up the cushion of driver’s seat and 

replace it . 

74

Seat- Cushion of co-driver’s seat 

Cushion of co-driver’s seat 

Parts diagram 

74-5 

74 

1 Cushion of co-driver’s seat 

2 Backrest of co-driver’s seat 

3 Backrest of middle seat 


5 Flat washer 

6 1 type hexagon nut

74-6 

Replacement 


1. Disassemble the cushion of co-driver’s seat 

(a). 

Loose 2 bolts on the rear side of co-driver’s seat 

cushion. 

74 

(b). 

Tilt up the cab and loose the fixation bolt and nut 

on the front side of co-driver’s side. Then the 

cushion of co-driver’s seat can be disassembled. 

2. Assemble the cushion of co-driver’s seat 

(a). 

Insert safety belt buckle of co-driver and safety 

belt of middle seat into the cushion of co-driver’s 

seat.


74-7 

(b). 

Assemble 2 fixation bolts on the rear side of 

co-driver’s seat cushion. 


(c). 

Tilt up the cab and fasten 2 fixation bolts and 

nuts on the front end of co-driver side. 


74

74-8 

Berth 

Parts diagram 

Seat-Berth 

74 

1 Berth mattress assembly

Replacement 

Seat-Berth 

74-9 

1. Turn up the berth mattress to disassemble 

and replace it. 

74

74-10 

Seat- Backrest of driver’s seat 

Backrest of driver’s seat 

Replacement 

1. Disassemble the driver’s seat (refer to “Chapter 74 Seat-Driver’s seat, Replacement”) 

2. Disassemble the backrest of driver’s seat. 

(b). Loose right side bolt. 

74 

(b). 

Disassemble the angle regulator of driver’s seat. 

(refer to “Chapter 74 Seat-Angle regulator of 

driver’s seat, Replacement”) 

3. Assemble the backrest of driver’s seat 

(a). Fasten 4 fixation bolts of angle regulator. 


(b). 

Fasten right side bolt. 


4. Assemble driver’s seat (refer to “Chapter 74 Seat-Driver’s seat, Replacement”)

Seat-Backrest of co-driver’s seat 

Backrest of co-driver’s seat 

Parts diagram 

74-11 

74 





5 Flat washer 

6 1 type hexagon bolt

74-12 

Replacement 

Seat-Backrest of co-driver’s seat 

1. Disassemble backrest of co-driver’s seat 

(a). 

Turn over the backrest of co-driver’s seat, and 

loose 2 fixation bolt of co-driver’s seat backrest. 

(b). 

(c). 

Pull out the movable pin of backrest of co-driver’s 

seat. 

Disassemble the backrest of co-driver’s seat. 

74 

2. Assemble the backrest of co-driver’s seat 

(a). 

Insert the movable pin of backrest of co-driver’s 

seat. 

(b). 

Fasten 2 fixation bolt of co-driver’s seat backrest 

and turn up the backrest of co-driver’s seat. 

Torque: 50 N•m

Backrest of middle seat 

Parts diagram 

Seat- Backrest of middle seat 

74-13 

74 





5 Flat washer 

6 1 type hexagon bolt

74-14 

Replacement 

Seat-Backrest of middle seat 

1. Disassemble the backrest of middle seat 

(a). 

Turnover the backrest of middle seat and loose 

4 fixation bolts on both ends of it, to 

disassemble the backrest of middle seat. 

74 

2. Assemble the backrest of middle seat 

(a). 

Fasten 4 fixation bolts on both ends of the 

backrest and turn up the backrest. 

Torque: 50 N•m

Seat-Angle regulator of driver’s seat 

Angle regulator of driver’s seat 

Replacement 

74-15 

1. Disassemble the driver’s seat (refer to “Chapter 74 Seat-Driver’s seat, Replacement”) 

2. Disassemble regulator of driver’s seat 

(a). Disassemble the plastic handle of regulator 

(b). 

(c). 

Loose the fixation screw of angle regulator 

housing. 

Disassemble the plastic housing of angle 

regulator. 

74 

(d). 

Loose 4 fixation bolts of the angle regulator to 

disassemble it. 

3. Assemble the angle regulator of driver’s 

seat 

(a). 

Fasten 4 fixation bolts of the angle regulator 

Torque: 50 N•m

74-16 

Seat-Angle regulator of driver’s seat 

(b). 

(c). 

Assemble the plastic housing of angle regulator. 

Fasten the fixation screw of angle regulator 

housing. 

(d). 

Assemble the plastic handle of angle regulator. 

74 

4. Assemble the driver’s seat (refer to “Chapter 74 Seat-Driver’s seat, Replacement”)

Seat-Angle regulator of co-driver’s seat 

Angle regulator of co-driver’s seat 

Replacement 

74-17 

1. Disassemble the backrest of co-driver’s seat (refer to “Chapter 74 Seat-Backrest of 

co-driver’s seat, Replacement”) 

2. Disassemble the angle regulator of 

co-driver’s seat 

(a). 

Loose 2 fixation bolts of angle regulator. 

74 

(b). 

Disassemble the angle regulator.

74-18 

Seat-Angle regulator of co-driver’s seat 

3. Assemble the angle regulator of co-driver’s 

seat 

(a). 

Fasten 2 fixation bolts of the angle regulator. 


74 

4. Assemble the backrest of the co-driver’s seat (refer to “Chapter 74 Seat-Backrest of 

co-driver’s seat, Replacement”)

Door Locks 

Door lock ............................................................ 75-1 

Parts diagram ................................................ 75-1 

Replacement ................................................. 75-2 

75

75

Door lock 

Parts diagram 

Door lock-Door lock 

75-1 

75 

1 

Tie rod of outside handle of left front door 

lock 

2 Inside handle assembly of left door lock 

3 Lock cylinder assembly 

4 

Outside handle installation assembly of 

left front door 

5 Locker assembly of left front door 

6 

Locker installation bracket of left front door 

locker 

7 Cross tie rod of left front door lock 

8 

Cylinder block assembly of left front door 

lock 

9 Latch hook installation assembly of door lock 

10 Plastic clip 

11 Button of door lock 

12 Vertical tie rod of left front door lock 

13 Plastic guiding clip

75 

75-2 

Replacement 

Hint: 


The replacement steps for left and right door lock are same because they are symmetric. 

1. Ignition switch: ON (carry out this operation if the vehicle is equipped with power 

glass regulator) 

2. Regulate the (left) front window glass to its highest position. 


4. Disconnect the negative pole cable of battery 

Hint: 

• Please turn off ignition switch and lighting switch, 

and loose terminal nut completely when the battery 

cable is connected and disconnected. Do not prize 

up the cable during the operation. 

• Do not keep the key inside of vehicle if the vehicle 

is equipped with central control lock before the 

negative pole cable is disconnected, so as not to 

lock the door. 

5. Disassemble the outside trimming plate assembly of (left) door (refer to “Chapter 77 

Inner/Outer trimming part-Replacement”) 

6. Disassemble the rain-proof curtain of (left) door. 

7. Disassemble the outside handle of (left) front 

door lock 

(a). 

Take away the tie rod outside handle of (left) 

front door lock from the side of outside handle of 

(left) front door lock as shown in the Figure.


75-3 

(b) Take away the tie rod of lock cylinder of (left) front 

door 

Notice: 

· As shown in the figure, take away the plastic 

clip lock cylinder tie rod from (left) front door. 

Be careful and do not damage the plastic clip. 

75 

(c). 

Pull out the tie rod of lock cylinder from (left) 

front door to the direction as shown in the 

figure.

75-4 


(d). 

(e). 

Notice 

Disassemble the outside handle of (left) front 

door lock from the service hole. 

· Disassemble 2 fixation bolts of outside handle 

of (left) front door lock as the sequence shown 

in the figure. 

Take out the outside handle of (left) front door 

lock. 

Be careful and do not damage the plastic clip of tie 

rod of lock cylinder on (left) front door. 

75 

8. Disassemble the lock cylinder assembly of 

(left) front door 

(a). 

Disassemble the snap spring of lock cylinder of 

(left) front door to the direction as shown in the 

figure.


75-5 

(b). 

Pull out the lock cylinder of (left) front door to the 

direction as shown in the figure. 

9. Disassemble the vertical tie rod of (left) front 

door lock 

(a). 

Notice: 

Take away the plastic clip of vertical tie rod on (left) 

front door lock to the direction as shown in the 

figure. 

Be careful and do not damage the plastic clip of 

vertical tie rod on (left) front door lock. 

75 

(b). 

(c). 

Take away the vertical tie rod of (left) front door 

lock. 

Take out the vertical tie rod of (left) front door lock 

to upwards.

75-6 


10. Disassemble the cross tie rod of (left) front 

door lock 

(a). 

Notice: 

Take away the plastic guide clip from the cross 

tie rod of (left) front door lock. 

Be careful and do not damage the plastic guide clip 

from the cross tie rod of (left) front door lock. 

75 

(b). 

Notice: 

Disassemble the inside handle assembly of the 

(left) door lock. 

· Take away the plastic clip of inside handle on 

(left) door lock to the direction as shown in the 

figure. 


inside handle on (left) door lock. 

(c). 

Take off the inside handle of (left) door lock


75-7 

(d). 

Notice: 

Take away the plastic clip of cross tie rod on (left) 

front door lock from the side of (left) front door 

lock assembly. 


cross tie rod on (left) front door lock. 

(e). 

Take out the cross tie rod of (left) front door lock 

to the direction as shown in the figure. 

75 

11. Disassemble the (left) front door lock body 

assembly 

(a). 

Disconnect the insert part of (left) front door 

locker. (Carry out this operation if the vehicle is 

equipped with central control lock.)

75-8 


(b). 

(c). 

Disassemble 3 fixation screws of (left) front door 

lock body. 

Take out the (left) front door lock body assembly. 

75 

12. Disassemble the locker assembly of (left) front 

door (Carry out this operation if the vehicle is 

equipped with central control lock.) 

(a). 

(b). 

Disassemble 3 fixation screws of (left) front door 

locker. 

Take off the locker assembly of (left) front door. 

13. Check (left) front door locker assembly (Carry 

out this operation if the vehicle is equipped with 

central control lock.) 

(a). 

(b). 

(c). 

Measure the resistance of (left) front door locker 

assembly by multimeter. 

Pull the vertical tie rod of (left) front door lock up. 

· Resistance: ≤ 2 Ω 

Press down vertical tie rod of (left) front door lock 

· Resistance: > 1 MΩ


75-9 

14. Assemble locker assembly of (left) front door 

(Carry out this operation if the vehicle is 


(a). 

Assemble 3 fixation screws of (left) front door 

locker assembly. 

75 

15. Assemble the lock body assembly of (left) 

front door 

(a). 

(b). 

As shown in the figure, assemble the lock body 

assembly of (left) front door. 

Assemble 3 fixation screws of (left) front door 

lock body.

75-10 


(c). 

Connect the insert part of (left) front door locker. 

(Carry out this operation if the vehicle is 


75 

16. Assemble the cross tie rod of (left) front door 

lock 

(a). 

Assemble the cross tie rod of (left) front door lock 

to the direction as shown in the figure. 

(b). 

Put the plastic clip of the cross tie rod on (left) 

front door lock from the side of (left) front door 

lock body assembly.


75-11 

17. Assemble the inside handle assembly of (left) 

door lock 

(a). 

Put the plastic clip of inside handle on (left) front 

door lock to the direction as shown in the figure. 

75 

18. Assemble the plastic guide clip of cross tie 

rod on (left) front door lock

75-12 


19. Assemble the vertical tie rod of (left) front 

door lock 

(a) Assemble the vertical tie rod of (left) front door lock 


75 

(b). 

As shown in the figure, assemble the plastic clip 

of vertical tie rod on (left) front door lock. 

20. Assemble the lock cylinder assembly of (left) 

front door 

(a). 

Assemble the lock cylinder assembly of (left) 

front door as shown in the figure.


75-13 

(b). 

Hint: 

Assemble the snap spring of lock cylinder on 

(left) front door to the direction as shown in the 

figure. 

The lock cylinder of (left) front door should be not 

rotated when the snap spring is assembled; 

otherwise, please reassemble the lock cylinder of 

(left) front door. 

75 

21. Assemble outside handle of (left) front door 

lock 

(a). 

(b). 

Assemble outside handle of (left) front door 

lock. 

Assemble the 2 fixation bolts of outside handle 

of (left) front door lock as the sequence shown 

in the figure.

75-14 


22. Assemble the tie rod of lock cylinder of (left) 

front door 

(a). 

As shown in the figure, put the plastic clip of 

lock cylinder of (left) front door. 

75 

23. Assemble the tie rod of outside handle on 

(left) front door. 

(a). 

Assemble the tie rod of outside handle on (left) 

front door from the side of outside handle of 

(left) front door lock to the direction as shown in 

the figure.


75-15 

24. Assemble the rain-proof curtain of (left) front door 

25. Assemble the outside trimming plate assembly of the (left) front door (refer to 

“Chapter 77 Inner/outer trimming parts-Replacement”) 

26. Connect the negative pole cable of the battery 

27. Reset the audio unit 

28. Check the function of lock and unlock of (left) front door lock by key. 

Hint: 

· Do not keep the key inside of vehicle if the vehicle is equipped with central control lock 

before the negative pole cable is disconnected, so as not to lock the door. 

· The right front door should be locked and unlocked at the same time to check the function of 

lock and unlock of the left front door by the key if the vehicle is equipped with central control 

lock. 

75

75 

- Memo-

Body Tilt/Doors/Cargo Box 

Lock mechanism of the cab ............................ 76-1 

Operation .................................................... 76-1 

Parts diagram .............................................. 76-4 

Replacement ............................................... 76-6 

Turnover mechanism of the cab ..................... 76-9 

Parts diagram .............................................. 76-9 

Replacement ............................................. 76-10 

Door ................................................................ 76-13 

Adjustment ................................................ 76-13 

Replacement ............................................. 76-14 

76 

Cargo box ....................................................... 76-18 

Parts diagram ............................................ 76-18

76

Body turnover / Door / Cargo box - Lock mechanism of the cab 

Lock mechanism of the cab 

76-1 

Operation 

Notice: 

· Make sure the vehicle is parked on a flat road and there is enough operative room. 

· Engage the parking brake lever and make shift lever at neutral position; close the door and 

there should be no slippery article. 

· It is strictly to protrude your head or hands under the cab when the cab is tilted up. 

Tilt up the cab 

1. Unlock 

(a). 

Open the safety hook “A” to unlock the cab. 

76 

(b). 

Rotate the operation handle “C” to the direction 


2. Unlock the safety hook 

(a). 

Hold the tilting handle of the cab and unlock the 

safety hook “B”.

76-2 


3. Tilt up the cab 

(a). 

Tilt up the cab to its maximum position and lock 

the bracket. 

76 

Lock the cab 

1. Release the insurance 

(a). 

Hold the tilting handle of the cab to release the 

supporting status of the bracket.


76-3 

2. Lock the safety hook 

(a). 

Pull the cab down until the safety hook “B” is 

engaged. 

76 

(b). 

Rotate operative handle “C” to the direction as 

shown in the figure until it is engaged with safety 

hook “A”.

76-4 

Parts diagram 


76


76-5 



3 Flat washer 

4 Handle assembly 

5 Right lock body assembly 

6 Bracket assembly 

7 Cushion assembly 


9 Flat washer 


11 1 type hexagon nut 

12 Wave like spring spacer 

13 Cotter pin 

14 Long tie rod assembly 

15 Connection plate 


17 Left lock body assembly 

18 Short tie rod assembly 

19 Operative mechanism assembly 

20 Bracket assembly 

21 Slot nut 




25 

26 

Fixation bracket assembly of left 

body 

Fixation bracket assembly of right 

body 

27 Nut plate of tilting bracket 

28 Washer 

29 Flat washer 

76

76 

76-6 

Replacement 

Notice: 


· Make sure the vehicle is parked on a flat road and there is enough operative room around and 

up side of the cab. 

· Engage the parking brake lever and use blocks on the wheels as necessary. 

· Make shift lever at neutral position; 

· There should be no slippery article. 

· Close all doors tightly. 

1. Tilt up the cab 

2. Disassemble the long tie rod assembly 

(a). 

(b). 

Hint: 

As shown in the figure, disassemble the left side 

cotter pin of the long tie rod. 

Disassemble the right side cotter pin of the long 

tie rod. 

The steps to disassemble right side cotter pin are same 

with that of left side cotter pin. 

3. Disassemble the operational mechanism 

assembly 

(a). 

Loose 3 fixation bolts of the operational 

mechanism. 

4. Disassemble the left lock body assembly 

(a). 

Disassemble 4 fixation bolts of left lock body. 

5. Disassemble right lock body assembly 

(a). Disassemble 4 fixation bolts of right lock body. 

Hint: 

The steps to disassemble right lock body are same with that of left lock body.


76-7 

6. Disassemble the left bracket assembly 

(a). 

Disassemble 4 fixation bolts of left bracket and 

take off the left bracket assembly. 

7. Disassemble the right bracket assembly 

(a). 

Hint: 

Disassemble 4 fixation bolts of right bracket 

The steps to disassemble right bracket are same with that of left bracket. 

8. Assemble left bracket assembly 

(a). Assemble left bracket assembly and fasten 4 

fixation bolts. 


76 

9. Assemble right bracket assembly 

(a). 

Hint: 

Assemble right bracket assembly and fasten 4 fixation bolts. 


The steps to assemble right bracket are same with that of left bracket. 

10. Assemble left lock body assembly 

(a). 

Assemble left lock body and fasten 4 fixation 

bolts. 


11. Assemble right lock body assembly 

(a). Assemble right lock body and fasten 4 fixation bolts. 


Hint: 

The steps to assemble right lock body are same with that of left lock body.

76-8 


12. Assemble the operational mechanism 

assembly 

(a). 

Assemble the operational mechanism and fasten 

3 fixation bolts. 


76 

13. Assemble the long tie rod assembly 

(a). 

(b). 

Hint: 

Assemble the long tie rod, and lock the left cotter 

pin. 

Lock right side cotter pin. 

The steps to assemble right cotter pin are same with 

that of left cotter pin.

Body turnover / Door / Cargo box - Tilting mechanism of the cab 

Tilting mechanism of the cab 

Parts diagram 

76-9 

76 

1 Left swing arm 



4 Left front bracket assembly 

5 Upper shim of twist bar sleeve 

6 Lower shim of twist bar sleeve 

7 Hexagon flange blot 

8 Hexagon stud 

9 Plastic sheath 

10 Sleeve 

11 Left front upper bracket arm 

12 Cushion spacer of front bracket seat 


14 Nut 

15 Cotter pin 

16 Left twist bar 

17 Right twist bar 

18 Right front bracket assembly 

19 Right front upper bracket arm 

20 Right swing arm

76-10 

Replacement 


1. Disassemble front bumper (refer to “Chapter 77 Inner/outer trimming parts-Front bumper, 


2. Disassemble front cover (refer to “Chapter 77 Inner/outer trimming parts-Front cover, 


3. Disconnect the cable and pipeline 

(a). Disconnect all the wire and pipeline 

connection between cab and chassis, and 

between steering column and chassis. 

76 

4. Disassemble the tilting mechanism 

(a). 

Take off the cotter pin and disassemble the 

nut. 

5. Hoist the cab assembly 

Notice: 

· Make sure there is enough operative space. 

· Hoist the cab by traveling crane or other kind 

of lifting machine, and support the cab by 

fasten bar. 

6. Disassemble left front bracket seat 

assembly 

(a). 

Disassemble 4 fixation bolts of left front 

bracket seat.


76-11 

7. Disassemble the right front bracket seat 

assembly 

(a). 

Disassemble 4 fixation bolts of right front bracket 

seat. 

8. Check the cab turnover mechanism 

(a). 

(b). 

Check if there are obvious cracks or damages on left front bracket seat and right front 

bracket seat; and replace it as necessary. 

Check if there are obvious distortion, cracks or twist etc. on twist rod; and replace it as 

necessary. 

9. Assemble right front bracket seat assembly 

(a). Assemble right front bracket seat and fasten 4 



76 

10. Assemble left front bracket seat assembly 

(a). Assemble left front bracket seat and fasten 4 



11. Hoist and assemble cab assembly 

Notice: 

· Hoist the cab by traveling crane or other kind of 

lifting machine, and support the cab by fasten 

bar. 

· It is a must to fasten the connection bolt between 

cab and frame firmly after the operation, and 

make sure the connection should be reliable 

during running.

76-12 


12. Assemble the tilting mechanism of the cab 

(a). 

Fasten the nut and lock the cotter pin. 

76 

13. Assemble the cable and pipeline 

(a). 

Connect all the cable and pipeline between cab 

and chassis, and between the steering column 

and chassis. 

14. Assemble front cover (refer to “Chapter 77 Inner/outer trimming parts-Front bumper, 


15. Assemble front cover (refer to “Chapter 77 Inner/outer trimming parts-Front cover, 

Replacement”)

Door 

Adjustment 

Body turnover / Door / Cargo box - Door 

1. Loose the buckle of left front door 

(a). 

76-13 

Loose the buckle of left front door until the buckle 

can be moved. 

2. Loose the hinge of front left door 

(a). 

Loose 4 fixation blots of left front door hinge 

slowly and make the door can be moved slightly. 

76 

3. Adjust left front door 

(a). 

Hint: 

Adjust the clearance of left front door as the 

method shown in the figure until the clearance 

between door and cab is suitable. 

The adjustment method of right front door is same of 

that left front door.

76-14 

Replacement 


1. Disconnect the insert part of left front door 

cable 

76 

2. Disassemble the stopper of left front door 

(a). 

Disassemble 2 fixation bolts from the stopper of 

left front door.


76-15 

3. Disassemble the hinge of left front door 

(a). 

(b). 

Disassemble 4 fixation bolts from the hinge of 

left front door. 

Disassemble left front door assembly. 

76 

4. Disassemble the weather strip of left front 

door 

(a). 

Notice: 

Disassemble the clip of left front door weather 

strip, and take off the weather strip assembly. 

The disassembled clip can not be used again. 

5. Assemble the weather strip of left front door 

(a). 

Notice: 

Assemble the weather strip of left front door and 

fix the clip of weather strip. 

The clip only can be used one time, so replace to 

new clip during installation.

76-16 


6. Assemble the hinge of left front door 

(a). 

Assemble left front door, and fasten 4 fixation 

bolts after the correct clearance of left front door 

is adjusted to. 


76 

7. Assemble the stopper of left front door 

(a). Assemble the left front door stopper and fasten 2 




76-17 

8. Connect the insert part of left front door. 

76 

9. Adjust left front door (refer to “Chapter 76 Body turnover/Door/Cargo box-Door, 

Adjustment”)

76-18 

Cargo box 

Parts diagram 

Body turnover / Door / Cargo box - Cargo box 

76 

1 Cargo box assembly 

2 Front U bolt 

3 Pressing plate of U bolt 

4 Spacer 

5 Rear U bolt 

6 Pressing plate of U bolt 


8 Chock 




12 Rear protective guard assembly 

13 Left side protective guard assembly 


15 Connection pull plate 



18 1 type hexagon nut

Interior & Exterior Trim 

Interior trim panel of door ....................... 77-1 

Components ....................................... 77-1 

Replacement ...................................... 77-3 

Sun visor .................................................. 77-8 

Components ....................................... 77-8 

Replacement ...................................... 77-9 

Front dome light/inside mirror ............. 77-11 

Components ..................................... 77-11 

Replacement .................................... 77-12 

Front column shield/grab handle ......... 77-15 

Components ..................................... 77-15 

Replacement .................................... 77-16 

Top-roof trim panel ............................... 77-20 

Components ..................................... 77-20 

Replacement .................................... 77-21 

Carpet ..................................................... 77-23 

Components ..................................... 77-23 

Replacement .................................... 77-24 

Transmission control shield ................. 77-28 

Components ..................................... 77-28 

Replacement .................................... 77-29 

Front bumper ......................................... 77-31 

Components ..................................... 77-31 

Replacement .................................... 77-32 

Front mask ............................................. 77-36 

Components ..................................... 77-36 

Replacement .................................... 77-37 

Front fender ........................................... 77-40 

Components ..................................... 77-40 

Replacement .................................... 77-41 

Wheel brow ............................................ 77-46 

Replacement .................................... 77-46 

Foot plate ............................................... 77-48 

Components ..................................... 77-48 

Replacement .................................... 77-49 

Container fence ..................................... 77-51 

Components ..................................... 77-51 

Replacement .................................... 77-52 

Rear fender ............................................ 77-53 

Components ..................................... 77-53 

Replacement .................................... 77-54 

Rear protective guard ........................... 77-58 

Components ..................................... 77-58 

Replacement .................................... 77-59 

77

77

Internal/external trimming parts- Interior trim panel of door 

Interior trim panel of door 

77-1 

Notices: 

1. Use screwdriver with shield. 

2. Prevent the inner trim side from being polluted by oil stains 

3. Try to use disposable clip. 

4. Dismantle finishing components skillfully. 

77

77-2 

Components 

internal/external trimming parts- Interior trim panel of door 

77 

1 Cross Recessed Pan Head Screw 

2 Washer 

3 Plastic Nut 

4 Lower Trimming part of Left Door 

5 Flat Washer 

6 Cross Recessed Pan Head Tapping Screw 

7 Plug 

8 Interior Trim Strip of Left Front Door 

9 Rain Cover 

10 Left Front Door Stopper Limit Assy 

11 Left Front Support Arm Installation Assy 

12 

Cross Recessed Pan Head Screw, Spring 

Washer and Flat Washer Assembly Part 

13 Plastic Fastener Assy 

14 

Left Front Door Interior Trim Panel Assy 

(Electric) 

15 Plastic Nut-Guide Rail

Replacement 



77-3 

2. Remove the regulating handle of glass for left 

front vehicle window (Manual) 

(a). 

HINT: 

Remove the regulating handle of glass for left 

front vehicle window. 

The steps for the removal of the regulating handle of 

glass for right front vehicle window are the same with 

those for the left one. 

3. Remove the switch for the electric glass of 

the left front door (Electric) 

(a). 

Pry off the switch cover for the electric glass of 

the left front door with a screwdriver wrapped 

with protective belt as shown in the illustration. 

77 

Protective belt 

(b). 

HINT: 

Disconnect the switch connector from the electric 

glass for the left front door. 

The steps for the removal of the electric glass switch for 

the right front door are the same with those for the left 

one. 

4. Remove the left front support arm 

(a). 

(b). 

HINT: 

Pry off the rubber plug of the support arm with a 

screwdriver. 

Remove the 4 cross bolts of the left front support 

arm as shown in the illustration. 

The steps for the removal of the right front support arm 

are the same with those for the left one.

77-4 


5. Remove the interior handle of the left front 

door 

(a). 

HINT: 

Remove the cross bolt of the interior handle of 

the left front door and take out the interior handle 

of the left front door. 

The steps for the removal of the right front door interior 

handle are the same with those for the left one. 

77 

6. Remove the interior handle of the left front 

door 

(a). 

Remove the cross bolt of the interior handle of 

the left front door. 

(b). 

HINT: 

Take down the interior handle assy. 


handle are the same with those for the left one. 

7. Remove the interior trim strip of the left front 

door 

(a). 

NOTICE: 

Remove the interior trim strip assy of the left front 

door. 

Don’t distort or bend the interior trim strip during 

the removal. 

HINT: 


trim strip are the same with those for the left one.


77-5 

8. Remove the interior trim panel assy of the left 

front door 

(a). Remove the tapping screw for the trim panel of the 

left front door. 

(b). Disconnect the connection buckle between the left 

front door interior trim panel and the door. 

NOTICE: 

The buckle removed can’t be used again. 

(c). Take down the interior trim panel assy of the left 

front door according to the direction shown in the 

illustration. 

HINT: 


trim panel are the same with those for the left one. 

77 

9. Install the interior trim panel assy of the left 

front door 

(a). Install the interior trim panel assy of the left front 

door according to the direction shown in the 

illustration. 

(b). Connect the fixing buckle of the interior trim panel 

and install the interior trim panel of the door to the 

correct position. 

NOTICE: 

The interior trim panel buckle of the door is a 

disposable part; a new one shall be replaced with 


(c). Screw down the tapping screw of the left front door 

interior trim panel. 

HINT: 

The steps for the installation of the right front door interior 

trim panel are the same with those for the left one.

77-6 


77 

10. Install the interior trim strip of the left front 

door 

(a). 

NOTICE: 

Install the interior trim strip of the left front door to 

the correct position. 

Don’t turn around the trim strip by force while 

installing the interior trim strip of the door; install it 

according to appropriate angle. 

HINT: 

The steps for the installation of the right front door 

interior trim strip are the same with those for the left 

one. 

11. Install the interior handle of the left front door 

(a). 

Install the interior handle of the left front door to 


(b). 

HINT: 

Screw down the cross bolt as shown in the 

illustration. 


interior handle are the same with those for the left one. 

12. Install the interior handle of the left front door 

(a). 

HINT: 

Install the interior handle of the left front door and 

screw down the cross bolt. 


interior handle are the same with those for the left one.


77-7 

13. Install the left front support arm 

(a). 

(b). 

HINT: 

Install the left front support arm as shown in the 

illustration and screw down the 4 cross bolts. 

Install the rubber plug. 

The steps for the installation of the right front support 

arm are the same with those for the left one. 

14. Install the electric glass switch of the left 

front door 

(a). 

(b). 

HINT: 

Connect the electric glass switch connector to 

the left front door. 

Install the electric glass switch cover of the left 

front door. 

The steps for the installation of the right front door glass 

switch are the same with those for the left one. 

77 


16. Inspect whether the glass can go up and down normally and whether each connection 

is firm.

77-8 

Sun visor 

Components 

internal/external trimming parts- Sun visor 

77 

1 Left Sun Visor Assy 3 Right Sun Visor Assy 

2 Fixing Buckle Seat

Replacement 

Internal/external trimming parts- Sun visor 

77-9 

1. Remove the left sun visor assy 

(a). 

Disconnect the left sun visor from the fixing 

buckle seat. 

(b). 

(c). 

HINT: 

Loosen the 2 cross bolts of the left sun visor seat 


Take down the left sun visor assy. 

The steps for the removal of the right sun visor are the 

same with those for the left one. 

77 

2. Remove the fixing buckle seat of the left sun 

visor 

(a). 

HINT: 

Pry off the fixing buckle seat of he left sun visor 

with a screwdriver. 

The steps for the removal of the right sun visor are the 


3. Install the fixing buckle seat of the left sun 

visor 

(a). 

HINT: 

Install the fixing buckle seat of the left sun visor 

to the correct position to ensure the firm 

installation. 

The steps for the installation of the fixing buckle seat of 

the right sun visor are the same with those for the left 

one.

77-10 

internal/external trimming parts- Sun visor 

4. Install the left sun visor assy 

(a). Install the left sun visor and screw down the 2 

cross bolts of the left sun visor seat. 

(b). 

Connect the left sun visor to the fixing buckle 

seat. 

77 

(c). 

Hint: 

Inspect whether the installation is firm after 

completing the installation of the sun visor. The 

operation shall be flexible and stable without 

noises and the sun visor shall stop at any 

position reliably. . 

The steps for the installation of the right sun visor assy 

are the same with those for the left one.

Internal/external trimming parts- Front dome light/inside mirror 

Front dome light/inside mirror 

Parts diagram 

77-11 

77 

1 Inside Mirror Trim Cover 


3 Front Dome Light Assembly 

4 Inside Mirror Assembly 

5 Flat Washer 


7 Cross Recessed Pan Head Nut

77-12 

Replacement 

internal/external trimming parts- Front dome light/inside mirror 


2. Remove the front dome light assembly 

(a). Remove the front dome light trim cover. 

77 

(b). 

Remove the 2 cross nuts of the front dome light 


(c). 

Take down the front dome light assembly. 

(d). 

Disconnect the connector of the front dome light.

Internal/external trimming parts- Front dome light/inside mirror 

77-13 

3. Remove the inside mirror assembly of the 

driving cab 

(a). 

(b). 

Loosen the 2 fixing nuts of the inside mirror 

bracket of the driving cab. 

Take down the inside mirror assembly. 

4. Install the inside mirror assembly of the 

driving cab. 

(a). 

Install the inside mirror of the driving cab and 

screw down the 2 fixing nuts of the inside mirror 

bracket. 


77 

(b). Inspect whether the support part of the inside 

mirror is firm and whether the mirror can be 

adjusted to any direction flexibly and be kept in 

any positions in the permitted scope after installing 

the inside mirror, it can’t change the direction itself 

for the vibration of vehicle. 

HINT: 

Inspect whether the reflecting surface of the mirror glass 

has bubbles, glass reams, scratches and cracks before 

installing the inside mirror, opaqueness and double 

images are not permitted. 

5. Install the front dome light assembly 

(a). 

Connect the front dome light connector. 

(b). 

Install the front dome light assembly and screw 

down the 2 fixing nuts of the front dome light.

77-14 

internal/external trimming parts- Front dome light/inside mirror 

(c). 

Install the front dome light trim cover. 

77 


7. Inspect whether the front dome light works normally and whether the inside mirror is 

installed firmly.

Internal/external trimming parts- Front column shield/grab handle 

Front column shield/grab handle 

Parts diagram 

77-15 

77 

1 Left Front Column Shield 

2 Left Grab Handle 

3 Cross Recessed Pan Head Nut 

4 Right Grab Handle 

5 Right Front Column Shield

77-16 

Replacement 

internal/external trimming parts- Front column shield/grab handle 

1. Remove the left grab handle 

(a). 

HINT: 

Remove the 2 fixing nuts of the left grab handle. 

The steps for the removal of right grab handle are the 


77 

2. Remove the sealing strip of the left door 

(a). 

Loosen the fixing screws of the sealing strip trim 

strip of the left door and take down the sealing 

strip trim strip. 

(b). 

HINT: 

Remove the sealing strip of the left door. 

The steps for the removal of sealing strip of the right 

door are the same with those for the left one.


77-17 

Protective belt 

3. Remove the left front column shield 

(a). 

(b). 

Notice: 

Pry off the left front column shield with a 

screwdriver wrapped with protective belt as 


Disconnect the connection buckle of the left front 

column shield. 

The buckle removed can’t be used again. 

77 

(c). 

HINT: 

Take down the left front column shield assembly. 

The steps for the removal of the right front column 

shield are the same with those for the left one.

77-18 

internal/external trimming parts- Front column shield/grab handle 

77 

4. Install the left front column shield 

(a). 

(b). 

Notice: 

Connect the fixing buckle of the left front column 

shield. 

Install the left front column shield to the correct 

position as shown in the illustration. 

The buckle of the front column shield is a 

disposable part and a new one shall be replaced 

with during the installation. 

Hint: 

The steps for the installation of the right front column 

shield are the same with those for the left one. 

5. Install the sealing strip of the left front door 

(a). 

Install the sealing strip of the left front door as 


(b). 

Hint: 

Install the sealing strip trim strip of the left door 

and screw down the 4 fixing screws of the 

sealing strip trim strip. 


sealing strip are the same with those for the left one.


77-19 

6. Install the left grab handle 

(a). Install the left grab handle and screw down the 2 

fixing nuts. 

Hint: 

The steps for the installation of the right grab handle are 

the same with those for the left one. 

7. Inspect whether the front column shield/grab handle is installed firmly. 

77

77-20 

Top-roof trim panel 

Parts diagram 

internal/external trimming parts- Top-roof trim panel 

77 

1 Top-roof Trim Panel Assembly 

2 Plastic Expansion Screw 

3 Buckle

Replacement 

Internal/external trimming parts- Top-roof trim panel 

77-21 

1. Remove the sun visor (Refer to “Chapter 77 Internal/External Trimming Parts-Sun 

Visor, Replacement”) 

2. Remove the front dome light/inside mirror (Refer to “Chapter 77 Internal/External 

Trimming Parts-Front Dome Light/Inside Mirror, Replacement) 

3. Remove the front column shield/grab handle (Refer to “Chapter 77 Internal/External 

Trimming Parts-Front Column Shield/Grab Handle, Replacement) 

4. Remove the right roof handle 

(a). 

Remove the 2 cross nuts of the right roof handle. 

77 

5. Remove the reinforcement plate of top-roof 

trim panel (Half vehicle) 

(a). 

Remove the 4 fixing nuts of the reinforcement 

plate of top-roof trim panel. 

6. Remove the top-roof trim panel assembly 

(a). 

NOTICE: 

Remove the expansion screws of the top-roof trim panel. 

The expansion screws removed can’t be used again. 

(b). 

Remove the 4 fixing buckles of the top-roof trim 

panel as shown in the illustration.

77-22 

internal/external trimming parts- Top-roof trim panel 

7. Install the top-roof trim panel assembly 

(a). 

(b). 

NOTICE: 

Install the 4 fixing buckles of the top-roof trim 

panel as shown in the illustration. 

Install the expansion screws of the top-roof trim 

panel. 

The expansion screw is a disposable part and a new 

one shall be replaced with during the installation. 

77 

8. Install the reinforcement plate of top-roof trim 

panel (Half vehicle) 

(a). 

Install the 4 fixing nuts of the reinforcement plate 

of top-roof trim panel. 

9. Install the right roof handle 

(a). Install the right roof handle and screw down the 2 

cross nuts. 

10. Install the front column shield/grab handle (Refer to “Chapter 77 Internal/External 

Trimming Parts-Front Column Shield/Grab Handle, Replacement”) 

11. Install the front dome light/inside mirror (Refer to “Chapter 77 Internal/External 

Trimming Parts-Front Dome Light/Inside Mirror, Replacement) 

12. Install the sun visor (Refer to “Chapter 77 Internal/External Trimming Parts-Sun Visor, 

Replacement) 

13. Inspect whether each connection is firm.

Carpet 

Parts diagram 

Internal/external trimming parts- Carpet 

77-23 

77 

1 Steering Cover Assembly 


3 Front Part of Front Carpet 


5 Flat Washer 

6 Right Carpet Trim Strip 

7 Left Carpet Trim Strip 

8 Rear Part of Front Carpet

77 

77-24 

Replacement 

internal/external trimming parts- Carpet 

1. Remove the driver seat (Refer to “Chapter 74 Seat-Driver Seat, Replacement”) 

2. Remove the co-driver seat (Refer to “Chapter 74 Seat-Co-driver Seat, Replacement”) 

3. Remove the sleeper device (Refer to “Chapter 74 Seat-Sleeper Device, Replacement”) 

4. Remove the parking brake handle (Refer to “Chapter 27 Parking Brake-Parking Brake 

Handle, Replacement”) 

5. Remove the parking hand brake valve (Refer to “Chapter 27 Parking Brake-Handle 

Brake Valve, Replacement”) 

6. Remove the transmission control shield (Refer to “Chapter 77 Internal/External 

Trimming Parts-Transmission Control Shield, Replacement”) 

7. Remove the steering column assembly (Refer to “Chapter 41 Steering 

Mechanism-Steering Column Assembly, Overhaul”) 

8. Remove the steering support (Refer to “Chapter 41 Steering Mechanism-Steering 

Support, Replacement”) 

9. Remove the pedal suspension 

(a). 

Remove the 2 fixing nuts of the pedal suspension 

and the driving cab. 

10. Remove the sealing strip of the left door 

(a). 

Remove the 4 fixing screws of the sealing strip 

trim strip of the left door.


77-25 

b). 

Remove the sealing strip of the left door as 


77 

11. Remove the sealing strip of the right door. 

HINT: 

The steps for the removal of the sealing strip of the right door are the same with those for the left 

one. 

12. Remove the carpet assembly 

(a). 

Remove the carpet assembly of driving cab. 

13. Install the carpet assembly 

(a). 

Install the carpet assembly as shown in the 

illustration.

77-26 

internal/external trimming parts- Carpet 

14. Install the sealing strip of the left door 

(a). 

Install the sealing strip of the left door as shown 


77 

(b). 

Install the sealing strip trim strip of the left door 

and screw down the 4 fixing screws. 

15. Install the sealing strip trim strip of the right door 

HINT: 

The steps for the installation of the sealing strip of the right door are the same with those for the left 

one. 

16. Install the pedal suspension 

(a). 

Install the 2 fixing nuts of the pedal suspension 

and the driving cab.


77-27 

17. Remove the steering column assembly (Refer to “Chapter 41 Steering 

Mechanism-Steering Column Assembly, Overhaul) 

18. Remove the steering support (Refer to “Chapter 41 Steering Mechanism-Steering 

Support, Replacement”) 

19. Remove the transmission control shield (Refer to “Chapter 77 Internal/External 

Trimming Parts-Transmission Control Shield, Replacement”) 

20. Remove the parking brake handle (Refer to “Chapter 27 Parking Brake-Handle Brake 

Valve, Replacement”) 

21. Remove the parking hand brake valve (Refer to “Chapter 27 Parking Brake-Handle 

Brake Valve, Replacement”) 

22. Remove the sleeper device (Refer to “Chapter 74 Seat-Sleeper Device, Replacement”) 

23. Remove the co-driver seat (Refer to “Chapter 74 Seat-Co-driver Seat, Replacement”) 

24. Remove the driver seat (Refer to “Chapter 74 Seat-Driver Seat, Replacement”) 

25. Inspect whether each connection is firm. 

77

77-28 

internal/external trimming parts- Transmission control shield 

Transmission control shield 

Parts diagram 

77 

1 Handle Ball Head 

2 Control Rod Shield Sleeve 

3 Sleeve Retainer Ring 

4 Control Protective Shell 

5 Plastic Staple Nut Assembly 

6 Front Transmission Control Mechanism 

7 All-metal Flange Lock Nut 

8 Hexagon Flange Nut 


10 Hexagon Nut-style 1 

11 Hexagon Flange Nut 

12 Flexible Axle Seal Ring Pressing Plate 

13 Flexible Axle Seal Ring

Replacement 

Internal/external trimming parts- Transmission control shield 

77-29 




2. Remove the control rod shield sleeve of the 

transmission 

(a). 

Remove the control rod shield sleeve as shown 


77 

3. Remove the transmission control protective 

shell 

(a). 

Remove the 5 staple nuts of the control 

protective shell 

4. Install the transmission control protective 

shell 

(a). 

Install the 5 staple nuts of the control protective 

shell.

77-30 

internal/external trimming parts- Transmission control shield 

5. Install the control rod shield sleeve of 

transmission 

(a). Install the control rod shield sleeve of 

transmission as shown in the illustration. 

77 

6. Install the control handle ball head 

(a). 

HINT: 

Screw down the control handle ball head 

clockwise. 

Apply appropriate amount of anaerobic adhesive 

during the assembly of control handle ball head and 

control rod.

Front bumper 

Parts diagram 

Internal/external trimming parts- Front bumper 

77-31 

77 

1 Hexagon Head Nut 2 Front Bumper Assembly

77-32 

Replacement 


internal/external trimming parts- Front bumper 

2. Disconnect the connector of left front fog 

light 

77 

3. Disconnect the connector of right front fog light 

HINT: 

The steps for the disconnection of the connector of right front fog light are the same with those for 

the left one. 

4. Remove the front bumper assembly 

(a). 

Attach guard band on the surface of the bumper 

to avoid damaging the surface of the bumper 

during the removal, transportation and 

installation. 

Guard band 

(b). 

(c). 

Remove the 4 fixing nuts of the front bumper bar. 

Take down the front bumper assembly and place 

it at the safe place.


77-33 

5. Disassemble the front bumper assembly 

(a). 

(b). 

Remove the 21 connecting nuts of the front 

bumper body and the front bumper bar frame. 

Disconnect the bumper body and the front 

bumper frame. 

77 

(c). 

Remove the 3 fixing nuts of the left front fog light 

assembly. 

(d). 

HINT: 

Remove the 3 fixing nuts of the right front fog light assembly. 

The steps for the removal of the right front fog light assembly are the same with those for the left 

one. 

6. Assemble the front bumper assembly 

(a). 

Install the left front fog light assembly and screw 

down the 3 fixing nuts.

77-34 

(b). 

HINT: 

internal/external trimming parts- Front bumper 

Install the right front fog light assembly and screw down the 3 fixing nuts. 

The steps for the installation of the right front fog light assembly are the same with those for the left one. 

(c). 

HINT: 

Connect the front bumper body and the front 

bumper frame and screw down the 21 fixing nuts. 


Since there are too many nuts, screw on all the nuts first 

and then screw down all of them after adjusting the front 

bumper body and the frame to the correct position. 

77 

7. Install the front bumper assembly 

(a). 

Install the front bumper assembly and screw 

down the 4 fixing nuts. 


(b). 

Take down the guard band of the front bumper 

bar. 

Guard band 

8. Connect the connector of the left front fog 

light.


9. Connect the connector of the right front fog light. 

HINT: 

77-35 

The steps for the connection of the connector of right front fog light are the same with those for the 

left one. 


11. Inspect whether the front bumper assembly is installed firmly and all the parts can’t 

be loose. 

77

77-36 

Front mask 

Parts diagram 

internal/external trimming parts- Front mask 

77 

1 Hexagon Head Nut 2 Front Mask Assembly

Replacement 

Internal/external trimming parts- Front mask 

77-37 

1. Remove the trimming parts of the left 

headlight 

(a). 

Remove the trimming parts of the left headlight 


2. Remove the trimming parts of the right headlight 

(a). 

Hint: 

Remove the trimming parts of the right headlight. 

The steps for the removal of the right headlight trimming parts are the same with those for the left one. 

3. Remove the cover plate of the left rearview 

mirror 

(a). 

(b). 

Remove the 2 fixing nuts of the left rearview 

mirror cover plate. 

Take down the cover plate assembly of the left 

rearview mirror. 

77 

4. Remove the cover plate of the right rearview mirror 

(a). 

(b). 

Hint: 

Remove the 2 fixing nuts of the right rearview mirror cover plate. 

Take down the right rearview mirror cover plate assembly. 

The steps for the removal of the right rearview mirror cover plate are the same with those for the left 

one. 

5. Remove the front mask assembly 

(a). 

(b). 

Hint: 

Remove the 2 fixing nuts at the left side of the 

front mask as shown in the illustration. 

Remove the 2 fixing nuts at the right side of the 

front mask. 

The steps for the removal of the fixing nuts at the right 

side of the front mask are the same with those for the 

left one.

77-38 

internal/external trimming parts- Front mask 

(c). 

(d). 

Remove the 2 fixing nuts in the middle of the 

front mask assembly. 

Disconnect the connection buckle of the front 

mask. 

77 

6. Install the front mask assembly 

(a). 

(b). 

Notice: 

Connect the buckle of the front mask and install 

the front mask assembly to the correct position. 

Screw on the 2 fixing nuts in the middle of the 

front mask as shown in the illustration and screw 

down all of them after installing all the nuts. 

The buckle of the front mask is a disposable part 

and a new one shall be replaced with during the 

installation. 

(c). 

(d). 

Hint: 

Install the 2 fixing nuts at the left side of the front 

mask. 

Install the 2 fixing nuts at the right side of the 

front mask. 

The steps for the installation of the fixing nuts at the 

right side of the front mask are the same with those for 

the left one. 

7. Install the cover plate of the left rearview 

mirror 

(a). 

Install the cover plate of the left rearview mirror 

and screw down the 2 fixing nuts.

Internal/external trimming parts- Front mask 

8. Install the cover plate of the right rearview mirror 

(a). 

Hint: 

Install the cover plate of the right rearview mirror and screw down the 2 fixing nuts. 

77-39 

The steps for the installation of the cover plate of the right rearview mirror are the same with those 

for the left one. 

9. Install the trimming parts of the left headlight 

(a). 

Install the trimming parts of the left headlight to 


77 

10. Install the trimming parts of the right headlight 

(a). 

HINT: 

Install the trimming parts of the right headlight to the correct position. 

The steps for the installation of the trimming parts of the right headlight are the same with those for 

the left one. 

11. Inspect whether the front mask is installed firmly and all the parts can’t be loose.

77-40 

Front fender 

Parts diagram 

internal/external trimming parts- Front fender 

77 

1 Left Down Fender of the Engine 

2 Rear Fender of the Left Front Wheel 

3 Hexagon Head Nut, Spring Washer and 

Flat Washer Assembly Part 

4 Rear Fender Reinforcement Plate of the 

Left Front Wheel 

5 Splash Shield of the Left Front Wheel 

6 Front Lower Mudguard of the Left Front 

Wheel 

7 Upward Extended Plate of the Left Front 

Wheel Fender 

8 Front Fender of the Left Front Wheel

Replacement 

Internal/external trimming parts- Front fender 

77-41 

1. Remove the left down fender of the engine 

(a). 

Single vehicle: 

Remove the 2 fixing nuts of the left down fender of the 

engine. 

(b). 

Half vehicle: 

Remove the 3 fixing nuts of the left down fender of the 

engine. 

77 

(c). 

HINT: 

Remove the 3 fixing nuts of the left down fender 

of the engine. 

The steps for the removal of the right down fender of the 

engine are the same with those for the left one. 

2. Remove the rear fender assembly of the left 

front wheel 

(a). 

Remove the 3 fixing nuts of the left down fender 

of the engine.

77-42 


(b). 

Hint: 

Remove the 3 fixing nuts of the rear fender 

reinforcement plate of the left front wheel. 

The steps for the removal of the rear fender assembly of 

the right front wheel are the same with those for the left 

one. 

77 

3. Disassemble the rear fender of the left front 

wheel 

(a). 

Remove the 3 connecting nuts of the rear fender 

and reinforcement plate of the left front wheel.


77-43 

(b). 

Hint: 


and splash shield of the left front wheel and take 

down the pressing plate of the splash shield. 

The steps for the disassembly of the rear fender of the 

right front wheel are the same with those for the left one. 

77 

4. Assemble the rear fender assembly of the left 

front wheel. 

(a). 

Connect the rear fender and splash shield of the 

left front wheel and screw down the 4 nuts.

77-44 


(b). 

Hint: 

Connect the rear fender and reinforcement plate 

of the left front wheel and screw down the 3 fixing 

nuts. 


The steps for the assembly of the rear fender of the right 

front wheel are the same with those for the left one. 

77 

5. Install the rear fender assembly of the left 

front wheel 

(a). 

Install the rear fender reinforcement plate of the 

left front wheel and screw down the 3 fixing nuts. 


(b). 

Hint: 

Install the left down fender of the engine and 

screw down the 3 fixing nuts. 


The steps for the installation of the rear fender of the 

right front wheel are the same with those for the left one.


77-45 

6. Install the left down fender of the engine 

(a). 

Single vehicle: 




(b). 

Half vehicle: 


screw down the 3 nuts. 


77 

(c). 

Hint: 

Screw down the 3 fixing nuts as shown in the 

illustration. 


The steps for the installation of the right down fender of 

the engine are the same with those for the left one. 

7. Inspect whether the front fender assembly is installed firmly and all the parts can’t be 

loose.

77-46 

Wheel brow 

internal/external trimming parts- Wheel brow 

Replacement 


2. Disconnect the connector of the left steering 

light 

Hint: 

The steps for the disconnection of the connector of the 

right steering light are the same with those for the left 

one. 

77 

3. Remove the left front wheel brow 

(a). 

Remove the 2 fixing nuts of the lower trim panel 

of the left front door and take down the lower trim 

panel of the left front door. 

(b). 

Hint: 

Remove the 5 cross recessed pan head tapping 

screws of the left front wheel brow. 

The steps for the removal of right front wheel brow are 


4. Install the left wheel brow 

(a). 

Install the left front wheel brow and screw down 

the 5 cross recessed pan head tapping screws

Internal/external trimming parts- Wheel brow 

77-47 

(b). 

Hint: 

Install the lower trim panel of the left front door 

and screw down the 2 fixing nuts. 

The steps for the installation of right front wheel brow 

are the same with those for the left one. 

5. Connect the connector of the left steering 

light. 

Hint: 

The steps for the connection of right steering light are 


77 


7. Inspect whether the left steering light can work normally 

8. Inspect whether the wheel brow is installed firmly and all the parts can’t be loose.

77-48 

Foot plate 

Parts diagram 

internal/external trimming parts- Foot plate 

77 

1 

Hexagon Head Nut, Spring Washer and 

Flat Washer Assembly Part 

2 Left Front Foot Plate Body 

3 Left Front Foot Plate Skirt 

4 Flat Washer 


6 Cross Recessed Pan Head Screw

Replacement 

Internal/external trimming parts- Foot plate 

77-49 

1. Remove the left front foot plate assembly 

(a). 

Remove the 2 fixing nuts of the left front door 

stopper limit. 

(b). 

(c). 

Hint: 

Remove the 6 fixing nuts of the left front foot 

plate. 

Take down the left front foot plate assembly. 

The steps for the removal of right front foot plate are the 


77 

2. Disassemble the left front foot plate 

assembly 

(a). 

Remove the 2 screws of the reinforcement plate 

of left front foot plate. 

(b). 

Hint: 

Remove the 5 connecting screws of the body and 

skirt of left front foot plate. 

The steps for the removal of right front foot plate are the 

same with those for the left one.

77-50 

internal/external trimming parts- Foot plate 

3. Assemble the left front foot plate assembly 

(a). 

Connect the body and skirt of left front foot plate 

and screw down the 5 screws. 

77 

(b). 

Hint: 

Screw down the 2 screws of the reinforcement 

plate of left front foot plate. 

The steps for the installation of right front foot plate are 


4. Install the left front foot plate assembly 

(a). 

Install the left front foot plate and screw down the 

6 fixing nuts. 


(b). 

Hint: 

Install the left front door stopper limit and screw 

down the 2 fixing nuts. 


The steps for the installation of right front foot plate are 

the same with those for the left one.

Container fence 

Parts diagram 

Internal/external trimming parts- Container fence 

77-51 

77 

1 Container Assembly 

2 Left Fence Assembly 



5 Flat Washer 



8 Flat Washer 


10 Hexagon lobular socket pan head screw

77-52 

Replacement 

internal/external trimming parts- Container fence 

1. Remove the left fence of the container 

(a). 

Hint: 

Remove the left fence and connecting nuts of the 

container. 

The steps for the removal of the right fence of the 

container are the same with those for the left one. 

77 

2. Install the left fence of the container 

(a). 

Hint: 

Install the left fence and connecting nuts of the 

container. 


The steps for the installation of the right fence of the 

container are the same with those for the left one.

Rear fender 

Parts diagram 

Internal/external trimming parts- Rear fender 

77-53 

77 


2 Fender Support 



5 Flat Washer 

6 Front Fender of Left Rear Wheel 




10 Rear Fender of Left Rear Wheel 



13 

14 

Splash Shield of the Rear Fender of Left 

Rear Wheel 

Pressing Plate of the Splash Shield of Left 

Rear Wheel

77-54 

Replacement 

internal/external trimming parts- Rear fender 

1. Remove the rear fender assembly of the left 

rear wheel 

(a). 

Remove the 2 fixing nuts of the rear fender 

bracket of the left rear wheel. 

77 

(b). 

(c). 

Remove the 4 fixing nuts of the rear fender of the 

left rear wheel. 

Take down the rear fender of the left rear wheel. 

2. Disassemble the rear fender of the left rear 

wheel 

(a). 


and splash shield of the left rear wheel.


77-55 

3. Assemble the rear fender of the left rear 

wheel 

(a). 

Install the rear fender and splash shield of the 

left rear wheel and screw down the 3 fixing nuts. 

77 

4. Install the rear fender assembly of the left 

rear wheel 

(a). 

Install the rear fender of the left rear wheel and 



(b). 

Install the rear fender bracket of the left rear 

wheel and screw down the 2 fixing nuts. 

Torque: 21~25 N•m

77-56 

internal/external trimming parts- Rear fender 

5. Remove the front fender assembly of the left 

rear wheel 

(a). 

Remove the 2 nuts of the front fender bracket of 

the left rear wheel. 

77 

(b). 

Remove the 4 fixing nuts of the front fender of the 

left rear wheel. 

6. Install the front fender assembly of the left 

rear wheel 

(a). 

Install the front fender of the left rear wheel and 


Torque: 21~25 N•m


77-57 

(b). 

Install the front fender bracket of the left rear 

wheel and screw down the 2 fixing nuts 


77

77-58 

internal/external trimming parts- Rear protective guard 

Rear protective guard 

Parts diagram 

77 


2 Rear Protective Guard Assembly 



5 Flat Washer 

6 Hexagon Nut-style 1

Replacement 

Internal/external trimming parts- Rear protective guard 

77-59 

1. Remove the rear protective guard assembly 

(a). Remove the rear protective guard and the 2 

connecting nuts at the left side of the frame. 

77 

(b). Remove the rear protective guard and the 2 

connecting nuts at the right side of the frame. 

(c). 

Take down the rear protective guard assembly. 

2. Install the rear protective guard assembly 

(a). 

Install the rear protective guard and screw down 

the 2 nuts at the right side of the frame. 

Torque: 70~75 N•m

77-60 

internal/external trimming parts- Rear protective guard 

(b). 

Install the rear protective guard and screw down 

the 2 nuts at the left side of the frame. 


77

Vehicle Control System 

Ignition switch assy ........................................... 81-1 

Inspection ...................................................... 81-1 

Replacement ................................................. 81-2 

81

81

Vehicle control system- ignition switch assy 

Ignition switch assembly 

Inspection 

81-1 

1. Inspect the ignition switch assy 

(a). 

Measure the resistance between the pins and 

carry out the switching inspection. 

81 

Standard: 

Switch position Pin Resistance 

LOCK 1-2-3-4-5-6-7 > 1MΩ 

ACC 1-7 < 2Ω 

ON 1-3-7 < 2Ω 

START 1-2-3 < 2Ω 

If the resistance doesn’t conform to the standard, replace with a new ignition switch assy.

81-2 

Replacement 

vehicle control system- ignition switch assy 

1. Remove the combination switch assy (Refer to “Chapter 41 Steering 

Mechanism-Combination Switch Assy, Overhaul”) 

2. Remove the ignition switch assy 

(a). 

Disconnect the connector of the ignition switch. 

81 

(b). 

NOTICE: 

Remove the retainer ring with circlip pliers and 


The retainer ring removed can’t be used again. 

(c). 

Loosen the 3 bolts. 

(d). 

Pull out the ignition switch from the steering 

column.

Vehicle control system- ignition switch assy 

81-3 

3. Install the ignition switch assy 

(a). 

Set the ignition switch on the steering column. 

(b). 

Screw down the 3 bolts. 

81 

(c). 

NOTICE: 

Install the retainer ring with circlip pliers and 


A new retainer ring must be replaced with, and 

ensure to install it into the groove. 

(d). 

Connect the connector of ignition switch. 

4. Install the combination switch assy (Refer to “Chapter 41 Steering 

Mechanism-Combination Switch Assy, Overhaul”)

81 

-MEMO-

Cruise Control 

Cruise switch ...................................................... 82-1 

Replacement ................................................. 82-1 

Cruise switch +/- .............................................. 82-2 

Replacement ................................................. 82-2 

82

82

Cruise Switch 

Replacement 

Cruise control-cruise switch 


82-1 

2. Disconnect the connector of the cruise 

switch 

82 

3. Push out the switch from the rear part 

HINT: 

A reverse block is at the rear part of the 

switch, therefore the switch can only be 

pushed out through pressing down by hand. 

4. Push in cruise switch from mounting hole 

HINT: 

A clear “click” shall be heard while pushing 

in the cruise switch, please install it again if 

this sound can’t be heard. 

5. Connect the connector of the cruise switch 

HINT: 

A clear “click” shall be heard while connecting the connector of the cruise switch, please install 

it again if this sound can’t be heard.

82-2 

Cruise control-cruise switch 

Cruise Switch + / - 

Replacement 


2. Disconnect the connector of the cruise 

switch 

82 

3. Push out the switch from the rear part 

HINT: 

A reverse block is at the rear part of the 

switch, therefore the switch can only be 

pushed out through pressing down by hand. 

4. Push in cruise switch from mounting hole 

HINT: 

A clear “click” shall be heard while pushing 

in the cruise switch, please install it again if 

this sound can’t be heard. 

5. Connect the connector of the cruise switch +/- 

HINT: 

A clear “click” shall be heard while connecting the connector of the cruise switch, please install 

it again if this sound can’t be heard.

Reverse Radar 

Reverse Radar .................................................... 83-1 

Working principle ........................................... 83-1 

Part diagram .................................................. 83-1 

Test ............................................................... 83-2 

Reverse radar display ........................................ 83-3 

Overhaul ....................................................... 83-3 

83 

Reverse radar controller .................................... 83-4 

Overhaul ....................................................... 83-4 

Reverse radar probe .......................................... 83-5 

Overhaul ....................................................... 83-5

83 

d

Reverse Radar 

Working principle 

Reverse radar- reverse radar 

83-1 

Reverse radar, a safe-assistant device for vehicle parking and reserving, is composed of ultrasonic 

sensor (named as probe), controller, display and so on. Displaying visually the situation of 

the surrounding obstacles for drivers, it can remove the troubles that drivers have to view all 

around while parking, reserving and starting vehicles and help driver to get rid of the flaw of view 

dead and sight flaw, which ensures the safety of the driver. 

83 

Part diagram 

1 Reverse radar dispaly 3 Reverse radar probe 

2 Reverse radar controller

83-2 

Test 


1. Distance test 

(a) 

Put the obstacle with the height of approx 1m in the position of 1.5m right behind the probe. 

83 

d 

(b) 

(c) 

(d) 

Slowly reverse vehicle from far to near. 

Measure the actual distance respectively from the obstacle and vehicle tail respectively at 

the far and near ends. 

Compare the measured distance with obstacle distance displayed from reverse radar in the car. 

Distance range detected by reverse radar: 0.4~1.5m2. Test about obstacle location 

display 

(a) 

Three pieces of 1m length obstacle are put respectively at the left, middle and right of car. 

(b) 

(c) 

Slowly reverse vehicle from far to near. 

Test the obstacle location accurate displayed from reverse radar detect.


83-3 

Reverse Radar Display 

Overhaul 

1. Disconnect reverse radar display lead plug 

2. Measure the reverse radar display with the 

digital multimeter. 

(a) 

Measure the reverse radar display terminal with 

the digital multimeter. 

83 

NOTICE: 

Check the lead connector fastening before detecting 

3. Replace reverse radar display 

(a) 

(b) 

(c) 

Remove reverse radar display screw. 

Remove reverse radar display, replace the new display 

Install reverse radar display screw, plug the lead end.

83-4 


Reverse Radar Controller 

Overhaul 

1. Disconnect reverse radar display lead plug 

2. Measure the reverse radar display with the 

digital multimeter. 

83 

d 

(a) 

Measure the reverse radar display terminal with 

the digital multimeter for the conducting status of: 

× Terminals: No.1 and No.9 

× 

× 

× 

Terminals: 

Terminals: 

Terminals: 

No.2 and No.9 

No.5 and No.13 

No.7 and No.15 

NOTICE: 

Check the lead connector fastening before detecting 

3. Reverse radar controller 

(a) 

(b) 

(c) 

Remove reverse radar display screw. 

Remove reverse radar controller, replace the new controller. 

Install reverse radar display screw, plug the lead end.


Reverse Radar Probe 

83-5 

Overhaul 

1. Check the probe is clear. 

(a) 

Check the probe surface is clear. If it is not clear, 

First clean the probe surface, and then check 

again. 

83 

2. Disconnect probe lead plug 

(a) 

Disconnect probe lead plug 

NOTICE: 

When disconnecting the lead plug, firstly check the 

lead is fasten. 

3. Detect the probe 

(a) 

Measure terminal connecting the probe with the 

digital multimeter. Detect the conducting status 

between the terminals, if it is not conducted, 

please replace it. 

4. Remove probe assembly 

(a) Remove probe fixing locking piece. 

(b) Take off the probe assembly.

83-6 


5. Install the probe assembly. 

(a) Fix the probe at the location. 

(b) Install probe fixing locking piece. 

83 

d 

6. Connect probe lead plug 

(a) 

Connect probe lead plug. 

NOTICE: 

When the plug is inserted, the sound of Kaca shall 

be heard to ensure the right installation of connector.

Foton Workshop Manual - Aumark (BJ1099)

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