Foton Workshop Manual - View (CS2)

POWERED BY 

WCRKSHCP manuaL

VOLUME 1 

FOTON WORKSHOP MANUAL - VIEW (CS2 / C2) 

Table of Contents 

Edition: January 2013 01 INTRODUCTION 07 

Printed: February 2013 02 PREPARATION 43 

Publication: FWSM-201301 03 SERVICE SPECIFICATIONS 83 

Location: China 04 DIAGNOSTICS 123 

© 2013 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 prIor written permission of Foton. 

VOLUME 2 689 

04 DIAGNOSTICS (RHD) 691 

Pg. 

05 VEHICLE MAINTENANCE 1203 

11A ENGINE CONTROL SYSTEM 1263 

12A FUEL SYSTEM 1327 

13A EMISSION CONTROL 1355 

14A INTAKE AIR 1365 

15A ENGINE MECHANICAL 1383 

16A EXHAUST SYSTEM 1465 

17A COOLING SYSTEM 1477 

18A LUBRICATION SYSTEM 1503 

19A IGNITION SYSTEM 1525 

20A STARTING AND CHARGING 1533 

VOLUME 3 1567 

11B ENGINE CONTROL SYSTEM 1569 

12B FUEL SYSTEM 1617 

13B EMISSION CONTROL 1669 

14B INTAKE AIR 1681 

15B ENGINE MECHANICAL 1703 

16B EXHAUST SYSTEM 2019 

17B COOLING SYSTEM 2035 

18B LUBRICATION SYSTEM 2065 


20B STARTING AND CHARGING 2103 

21 SUPERCHARGER 2139 

VOLUME 4 2157 

11C ENGINE CONTROL SYSTEM 2159 

12C FUEL SYSTEM 2171 

13C EMISSION CONTROL 2193 

14C INTAKE AIR 2199 

15C ENGINE MECHANICAL PART 2207 

16C EXHAUST SYSTEM 2233 

17C COOLING SYSTEM 2241 

18C LUBRICATION SYSTEM 2261 

20C STARTING AND CHARGING 2271 

VOLUME 5 2299 

31-32 SUSPENSION SYSTEM 2301 

33 TYRE AND WHEEL 2339 

34 AXLE AND PROPELLER SHAFT 2351 

35-36 BRAKING SYSTEMS 2405 

41 TRANSMISSION 2465 

42 CLUTCH 2543 

51 STEERING COLUMN 2565 

52 POWER STEERING 2589 

61 HEATER AND AIR CONDITIONING 2625 

62 SUPPLEMENTAL RESTRAINT SYSTEM 2713 

63 SEAT BELT 2733 

64 LIGHTING 2757 

65 WIPER AND WASHER 2787 

66 AUDIO SYSTEM 2809 

71 WIRING 2825 

81 COMMUNICATION SYSTEM 3219 

82 WINDSHIELDS, MIRRORS & GLASS 3235 

83 INSTRUMENT PANEL 3259 

84 SEATS 3277 

85 DOOR LOCKS 3303 

86 SLIDING ROOF 3325 

87 DOORS AND ENGINE HOOD 3335 

88 EXTERIOR AND INTERIOR TRIM 3357 

91 VEHICLE CONTROL SYSTEM 3395

WORKSHOP MANUAL - VIEW CS2 / C2 

V O L U M E 1 

01 INTRODUCTION 07 

02 PREPARATION 43 

03 SERVICE SPECIFICATIONS 83 

04 DIAGNOSTICS 123

INTRODUCTION 

HOW TO USE THIS MANUAL........................................................... 01-1 

GENERAL INFORMATION.......................................................... 01-1 

IDENTIFICATION INFORMATION..................................................... 01-6 

VEHICLE IDENTIFICATION NUMBER (VIN) .............................. 01-6 

SERIAL NUMBER (SN) ............................................................... 01-7 

REPAIR INSTRUCTION..................................................................... 01-8 

PRECAUTION.............................................................................. 01-8 

VEHICLE LIFT AND SUPPORT LOCATIONS........................... 01-16 

HOW TO TROUBLESHOOT............................................................ 01-18 

GENERAL INFORMATION........................................................ 01-18 

HOW TO PROCEED WITH TROUBLESHOOTING .................. 01-20 

ELECTRONIC CIRCUIT INSPECTION PROCEDURE ............. 01-29 

TERMS ............................................................................................. 01-33 

ABBREVIATIONS USED IN THIS MANUAL ............................. 01-33 

01 

01 

Page 7

Page 8

HOW TO USE THIS MANUAL 

INTRODUCTION 

GENERAL INFORMATION 

INTRODUCTION - HOW TO USE THIS MANUAL 

01-1 

1. GENERAL DESCRIPTION. 

(a) Carrying out operations described in this manual in the correct sequence may help you improve the 

quality and efficiency during servicing. 

(b) Generally, service operations can be separated in the following 3 main processes: 

• Diagnosis 

• Removal / Installation, Replacement, Disassembly / Assembly, (On-vehicle) Inspection and Adjustment 

• Final Inspection 

(c) This manual includes the 1st process of “Diagnosis” (Refer to “Chapter 04 diagnostics”) and the 2nd 

process of “Removal / Installation, Replacement, Disassembly / Reassembly, (On-vehicle) Inspection 

and Adjustment”, but the 3rd process of “Final Inspection” is not included. 

(d) The following essential operations are not written in this manual. However, these operations must be 

performed in actual situations. 

• Clean a removed part when necessary 

• Visual check 

2. INDEX. 

(a) An alphabetical INDEX section is provided at the end of this chapter as a reference to help you to 

understand these abbreviation meaning. 

3. PREPARATION. 

(a) Special service tools (SST) and special service materials (SSM) may be required depending on the servicing 

situation. Be sure to use SST and SSM when they are required and follow the correct operation 

sequence. A list of SST and SSM is in the “Chapter 02 preparation”. 

4. SERVICING PROCEDURES. 

(a) According to chapter content, the components’ illustration is added into chapters. 

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01-2 

(b) 


The components’ illustration shows the all parts relationship in the same assy. A table following the 

illustration lists the name of each part. 

Example: 

Page 10


01-3 

(c) If installation is performed in the reverse order of removal, only important points will be described. 

(d) In this manual, only items with important points are described in the procedure and the illustration 

shows what and where we can do. In the explanations, details of the operational method, standard 

value and notices are listed. 

(e) Some illustrations in this manual for similar vehicle models may be the same. In this case, some details 

in illustration may be different from the actual vehicle. 

(f) The procedures are presented in a step-by-step format: 

• The illustration shows what to do and where to do it. 

• The task title tells us what to do. 

• The explanation text tells us how to perform the task and includes other information such as 

specifications, service notice and warnings. 

Example: 

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01-4 


5. SERVICE SPECIFICATIONS. 

(a) Specifications are presented in bold type throughout the manual. You never have to leave the servicing 

to look for the specifications. The specifications can also be found in the “Chapter 03 service 

specifications” for quick reference. 

6. TERM DEFINITIONS. 

WARNING 

CAUTION 

NOTE 

Indicates the possibility of injury to you or other persons. 

Indicates the possibility of damage to the components being 

repaired and the equipments being operated. 

Provides additional information to help you perform the servicing 

efficiently. 

7. INTERNATIONAL SYSTEM OF UNITS. 

(a) The units used in this manual comply with the International System of Units (SI UNIT) standard. 

Example: 

Torque: 30 N•m 

Page 12


01-5 

8. APPLICABLE VEHICLES. 

Series 

Steering 

Wheel 

Engine Transmission Model Examples 

BJ6549B1PDA-AA 6549B1PDA-AAZA09 

6549BDPDA-AAZA01 

F2.8 038J2 BJ6549BDPDA-AA 

6549BDPDA-AAZ001 

01 

01 

01 

BJ6549B1PDA-3 

6549B1PDA-03ZA01 

01 

widebody 

longshaft 

LHD 

4JB1T ZM001AJD 

BJ6549B1PDA-1 6549B1PDA-01ZA05 

BJ6549B1PDA-2 6549B1PDA-02ZA02 

6549B1PXA-EEZA03 

BJ6549B1PXA-EE 

4G69 

ZM001AD 

549B1PXA-EEZA08 

BJ6549BDPXA-EE 6549BDPXA-EEZA01 

ZM011D BJ6549B1PXA-2 6549B1PXA-02ZA02 

F2.8 038J2 

BJ6549B1PDA-RA 6549B1PDA-RAZA01 

BJ6549B1PDA-R2 6549B1PXA-R2ZA03 

01 

01 

01 

01 

01 

01 

RHD 

ZM001AJD BJ6549B1PXA-RE 6549B1PXA-REZA02 

4G69 

ZM011D BJ6549B1PXA-R2 6549B1PXA-R2ZA01 

4JB1T ZM001AJD BJ6549B1PDA-R1 6549B1PDA-R1ZA01 

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01-6 

INTRODUCTION - IDENTIFICATION INFORMATION 

IDENTIFICATION INFORMATION 

VEHICLE IDENTIFICATION NUMBER (VIN) 

1. VEHICLE IDENTIFICATION NUMBER (VIN). 

(a) The Vehicle Identification Number (VIN) is stamped on the vehicle identification number label and 

vehicle certification plate as shown in the illustration. 

• Vehicle identification number label: Can be found through the windshield at front left corner of the 

instrument panel. 

• Vehicle certification plate: Can be found after turning over the front vehicel hood. 

Page 14

INTRODUCTION - IDENTIFICATION INFORMATION 

01-7 

SERIAL NUMBER (SN) 

1. FINAL DRIVE SERIAL NUMBER. 

(a) The final drive serial number is stamped on the rear axle 

welding housing. 

01 

01 

01 

01 

2. PROPELLER SHAFT SERIAL NUMBER. 

(a) The propeller shaft serial number is stamped on the propeller 

shaft tube. 

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01-8 

INTRODUCTION - REPAIR INSTRUCTION 

REPAIR INSTRUCTION 

PRECAUTION 

1. BASIC REPAIR NOTE. 

(a) Notes on operation. 

1 Protection 

2 Safe operation 

• Be sure to wear a clean uniform. 

• Be sure to wear hat and safety shoes. 

• Perform safty inspection each other, when 2 or more persons servicing 

togehter. 

• When working with the engine running, pay attention to the ventilation 

of the workshop. 

• In case of operating on high temperature parts, rotating, moving and 

vibrating parts, protective clothing is necessary and pay attention not 

to burn or injury yourself. 

• When jacking up the vehicle, be sure to support the vehicle at correct 

position and use safe jack. 

• When lifting up the vehicle, use a safe and standard equipment. 

3 

Preparation of tools and 

measuring gauge 

• Before starting the servicing, prepare a tool stand, SST, gauge, oil, 

shop rag and new parts for replacement. 

Page 16


01-9 

4 

Removal and installstion, 

disassembly and assembly 

operations 

5 Removed parts 

• Diagnose problems with a thorough understanding of the trouble 

phenomenon and perform effective operations. 

• Before removing the parts, check the assembly for general condition: 

deformation and damage. 

• When the part structure is complicated, take a note or make match 

marks so as not to make mistakes that affect the function of the parts. 

• Clean and wash the removed parts if necessary, and assemble them 

after a thorough inspection. 

• Place the removed parts in the correct order to avoid mixing up or 

making them dirty. 

• As for non-reusable parts such as gasket, O-rings, and self lock nut, 

replace them with new one following the instruction of manual. 

• Put the old parts into a box and show them to the customer. 

01 

01 

01 

01 

01 

(b) Jacking up and supporting vehicle. 

• Be carefully when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the 

proper locations. (Refer to “Chapter 01 introduction - repair instruction, vehicle lift and support 

locations”) 

(c) Precoated part. 

• Precoat removed parts like bolts, nuts, etc. that are coated with sealant at the factory. 

• If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the 

sealant. 

• When reusing precoated parts, clean the old sealant and dry the part with compressed air. Then apply 

the specified sealant to the bolts, nut or threads. 

• Sometimes, it is necessary to leave the installed precoated parts for a specified time until the sealant 

hardens. 

(d) Gasket. 

• If necessary, use a sealer or new gasket to prevent leakage. 

(e) Bolts, nuts and screws. 

• Always tighten the bolts, nuts and screws at the specified torque with a torque wrench. 

WARNING 

Perform the torque check with the lower limit value of the torque tolerance. 

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01-10 


(f) Fuse. 

• When replacing a fuse, make sure the amperage rating of new fuse is correct. The amperage rating of 

new fuse should be the same as old fuse, neither more nor less. 

Illustration Symbol Part Name 

Fuse 

Circuit Breaker 

Page 18


01-11 

(g) Clips. 

• The removal and installation methods of typical clips used in body parts are shown in the below table. 

NOTE 

If the clip is damaged during the servicing, replace with a new one. 

01 

Shape (Example) 

Removal / Installation 

01 

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01 

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01-12 


Shape (Example) 

Removal / Installation 

(h) Removal and installation of vacuum hoses. 

• To disconnect the vacuum hoses, pull the hoses by 

holding at the end, not at the middle of hose. 

• When disconnecting vacuum hoses, use tags to identify 

where they should be reconnected. 

• After performing the servicing, check carefully whether 

the hoses are connected properly. 

• When using a vacuum gauge, never force the hose onto 

a connector . Always use a adapter to connect hose. The 

stretched hose may cause leakage. 

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01-13 

(i) Torque when using a torque wrench with extension tool. 

• In case of tightening with a torque wrench which has an 

extended length by combining the torque wrench with 

SST or extension tool, if you tighten until the reading of 

the torque wrench reaches the specified torque value, 

the actual value becomes excessive. 

• In this manual, only the specified torque is described. In 

case of using SST or an extension tool, calculate the 

reading of the torque wrench by the following formula. 

• Formula: T’ = T × L2 / (L1 + L2) 

T’ Reading of torque wrench (N·m) 

T 

Torque (N•m) 

01 

01 

01 

01 

01 

01 

L1 

L2 

Length of SST or extension tool (mm) 

Length of torque wrench (mm) 

01 

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01 

2. ELECTRONIC CONTROL. 

(a) Disconnection and connection of battery terminal. 

• Before performing electrical operations, disconnect the 

battery negative terminal cable firstly so as to prevent 

burnt-out damage by short. 

01 

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01 

• Disconnect the battery terminal completely without twist 

after turning off all switches. 

• When the negative (-) terminal cable is disconnected from 

the battery, the memory of the clock and audio system will 

be cleared. So before servicing, record the necessary data 

of the clock and audio system. After servicing, reset the 

clock and audio system. 

(b) Handling of electronic parts. 

• Do not open the cover or case of the module. If the IC 

terminals are touched, the IC may be destroyed by static 

electricity. 

• To disconntect electronic connectors, pull the connector, 

not the wire harness. 

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Page 21

01-14 


• Do not drop electronic components, such as sensors or 

relays. If they are dropped on a hard floor, they should be 

replaced. 

• When cleaning the engine with steam, protect the 

electronic components, air filter and emission-related 

components from water. 

• Never use an impact wrench to remove or install 

temperature switches or temperature sensors. 

• When checking the wire harness connector, insert the 

tester probe carefully to prevent terminals from bending. 

• After replacing electronic components, always perform 

function check. 

3. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS. 

(a) Place for removing and installing of fuel system parts. 

• Work in a place with good air ventilation and without anything flammable such as welder, grinder, drill, 

electric motor or stove in the surroundings. 

• Never work in a place such as a pit or nearby a pit, as there is a place that vaporized fuel is filled in. 

(b) Removing and installing of fuel system parts. 

• Prepare a fire extinguisher before starting the servicing. 

• For prevention of static electricity, connect the fuel changer, vehicle and fuel tank to ground and keep 

floor dry to prevent slipping. 

• Never use any electric equipment like an electric motor or a working light, as they may cause sparks or 

high temperature. 

• Never use an iron hammer, as it may cause sparks. 

• Dispose the shop rag without any fuel deposit. 

4. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS. 

CAUTION 

If any metal chips are into the inlet pass, this may get a bad effect to the engine and turbocharger. 

(a) 

When removing and installing the inlet system parts, 

wrap the opening of engine intake system with clean rag 

or tape. 

(b) 

When installing the inlet system parts, check that there is 

no mixing of metal chips. 

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01-15 

5. HANDLING OF HOSE CLAMPS. 

(a) Before removing the hose, record the depth of the inserting 

portion and the old clamp position in order to reinstall it 

correctly. 

(b) If deformation or dent is found, replace it with a new one. 

(c) In case of reusing the hose, install the clamp on the hose 

where it has a clamp track. 

(d) For a spring type clamp, adjust it by applying force to the 

arrow mark direction after the installation. 

6. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER. 

CAUTION 

If large amount of unburned fuel flows into the converter, it may cause overheating and a fire hazard. 

To prevent this, observe the following precautions. 

(a) Use only unleaded gasoline (gasoline vehicles). 

(b) Avoid running the engine at idle speed for more than 20 minutes. 

(c) Avoid a spark jump test. 

• Perform a spark jump test only when absolutely necessary. Perform this test as quickly as possible. 

• While testing, never race the engine. 

(d) Avoid a prolonged engine compression measurement. This operation must be performed as quickly as 

possible. 

(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and 

damage the catalytic converter. 

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01-16 


VEHICLE LIFT AND SUPPORT LOCATIONS 

1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP. 

(a) According to rules, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle 

with things of heavy weight loading. 

(b) When removing any parts of heavy weight like the engine and transmission, the center of gravity of the 

vehicle will be changed. Place a balance weight in vehicle so as to keep it from rolling, or support the 

vehicle with jack at the position of specification. 

2. NOTICE FOR USING JACK AND 4 POSE LIFT. 

(a) Follow the instruction in this manual for a safety operation. 

(b) Do not damage tires or wheels with a pry bar. 

(c) Park the vehicle on a flat road with applying parking brake. 

(d) Shift in the reverse position. 

(e) Using a wheel stopper, fix the vehicle. 

(f) Jack up the vehicle using a jack with rubber attachment. 

WARNING 

Be sure to jack up the vehicle at the correct support location. 

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01-17 

(g) Lift the vehicle up by using a 4 pose lift with rubber attachment. 

WARNING 

Be sure to lift up the vehicle at the correct support location. 

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01-18 

INTRODUCTION - HOW TO TROUBLESHOOT 

HOW TO TROUBLESHOOT 

GENERAL INFORMATION 

There are many electronic controlled systems in the vehicle. In general, electronic controlled system is considered 

to be very complex and require a high level of technical knowledge and expert skill to troubleshoot. 

However, the fact is that if you check the circuits one by one, troubleshooting of these systems is not complex. 

If you have adequate understanding of the system and basic knowledge of electricity, the problem can be 

accurately found out and comfirmed. 

This manual is designed based on the above principle to help service technicians perform accurate and 

effective troubleshooting. 

The troubleshooting procedures are described on the following chapter. 

System 

Engine Control System 

Anti-lock Brake System 

Audio System 

Supplemental Restraint System 

Heater And Air Conditioning System 

Lighting System 

Wiper And Washer 

Multimedia System 

Auxiliary Power 

Horn System 

Reverse Radar System 

Power Windows 

Outside Mirror 

Defrost System 

Instrument Cluster 

Power Door Locks 

Sliding Roof 

Reference 

Chapter 04 diagnostics - engine control system-4G69 

Chapter 04 diagnostics - engine control system-ISF2.8 

Chapter 04 diagnostics - engine control system-4JB1T 

Chapter 04 diagnostics - anti-lock brake system 

Chapter 04 diagnostics - audio system 

Chapter 04 diagnostics - supplemental restraint system 

Chapter 04 diagnostics - heater and air condition system 

Chapter 04 diagnostics - light system 

Chapter 04 diagnostics - wiper and washer 

Chapter 04 diagnostics - multimedia system 

Chapter 04 diagnostics - auxiliary power 

Chapter 04 diagnostics - horn system 

Chapter 04 diagnostics - reverse radar system 

Chapter 04 diagnostics - power windows 

Chapter 04 diagnostics - outside mirrors 

Chapter 04 diagnostics - defrost system 

Chapter 04 diagnostics - instrument cluster 

Chapter 04 diagnostics - power door locks 

Chapter 04 diagnostics - Sliding Roof 

Page 26


01-19 

FOR USING HAND-HELD TESTER 

NOTE 

• Before using the tester, be sure to read thoroughly the tester operating manual. 

• Connect the tester to the diagnosis wire harness connector and turn the ignition switch to “ON” 

position. If the tester can not communicate with the module, there is a problem on the vehicle 

side or tester side. 

• If the communication is normal when the tester is connected to another vehicle, inspect the 

diagnosis data link or module power circuit of the vehicle. 

• If the communication is still impossible when the tester is connected to another vehicle, the 

problem is probably in the tester itself, so perform the self test procedures described in the 

“Tester Operating Manual”. 

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01-20 


HOW TO PROCEED WITH TROUBLESHOOTING 

NOTE 

• Here, only the basic procedures are shown. 

• Carry out troubleshooting in accordance with the procedures on the following pages. 

• Details are provided in Chapter 04 diagnostics, showing the most effective methods for each 

circuit. 

• Confirm the troubleshooting procedures firstly for the relevant circuit before servicing. 

1. VEHICLE VISITED TO WORKSHOP 

2. CUSTOMER PROBLEM ANALYSIS 

(a) 

Ask the customer about the conditions and environment that the problem occurred. 

3. SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK 

(a) 

(b) 

(c) 

(d) 

Check the battery positive voltage. 

Voltage: 11 ~ 14 V (Engine stopped) 

Visually check the wire harness, connectors and fuses for open and short, etc. 

Warm up the engine to the operating temperature. 

Confirm the problem symptoms and conditions and check for DTCs according to the related chart. 

Does the DTC display? 

YES > Go to next step. 

NO > Go to step 5. 

4. DTC CHART 

(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part 

which should be checked with the DTC chart. 

Go to step 6 directly. 

5. PROBLEM SYMPTOMS TABLE 

(a) 

Check the results obtained in step 3, then confirm the inspection procedures for the system or the part 

which should be checked with the problem symptoms table. 

6. CIRCUIT INSPECTION OR PARTS INSPECTION 

(a) Inspect the circuit or parts according to results obtained in step 4 and 5. 

(b) Confirm the circuil or parts which should be repaired. 

7. REPAIR 

(a) Perform adjustment, repair or replacement according to the results obtained in step 6. 

8. CONFIRMATION TEST 

(a) 

(b) 

After servicing, confirm that the problem has been solved. 

If the problem does not recur, perform a confirmation test under the same conditions and enviroment 

that vehicle fault occurred at the first time. 

9. END 

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01-21 

CUSTOMER PROBLEM ANALYSIS 

NOTE 

• In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all 

preconceptions must be set aside in order to make an accurate judgement. 

• Before comfirmation the problem symptoms, it is very important to ask the the customer about 

some detail information of problems. 

• The following 5 items are important points in the problem analysis. 

01 

01 

01 

What? 

When? 

Where? 

Under what conditions? 

How did it happen? 

Vehicle model, system name 

Date, time, occurrence frequency 

Road conditions 

Running conditions, driving conditions, weather conditions 

Problem symptoms 

01 

01 

01 

01 

• Past problems and the repair history which are thought to be unrelated may be useful in some 

cases. Therefore, as much information as possible should be gathered and its relationship with 

the problem symptoms should be correctly ascertained for use as reference in troubleshooting. 

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01-22 


SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK 

NOTE 

The diagnosis system in vehicle has various functions. 

• The first function is the Diagnostic Trouble Code (DTC) checking. We could check out stored 

fault in the module memory. 

• Another function is the Input Signal Check, which checks whether the signals from various 

switches are sent to the module correctly. 

By using these check functions, it is possible to quickly find potential problem areas and 

troubleshooting can be performed effectively. 

System System Description DTC Signal Check Data Stream Symptom 

Engine Control System ○ ○ ○ ○ ○ 

Anti-lock Brake System ○ ○ - - ○ 

Supplemental Restraint 

System 

○ ○ - - ○ 

Heater And Air Conditioning - - - - ○ 

Lighting System - - - - ○ 

Wiper And Washer - - - - ○ 

Multimedia System - - - - ○ 

Auxiliary Power - - - - ○ 

Horn System - - - - ○ 

Reverse Radar System ○ - - - ○ 

Power Windows - - - - ○ 

Outside Mirror - - - - ○ 

Defrost System ○ - - - ○ 

Instrument Cluster - - - - ○ 

Power Door Locks - - - - ○ 

Sliding Roof ○ - - - ○ 

Page 30


01-23 

(a) 

(b) 

In the DTC checking, it is very important to determine whether the problem indicated by the DTC is current 

fault or stored fault. In addition, during the problem symptom confirmation, a step must be taken 

whether the malfunction indicated by the DTC is directly related to the problem symptom or not. For this 

reason, the DTC should be checked before problem confirmation. If missing this step, it may result in 

unnecessary troubleshooting for systems which are operating normally. It will cause more difficult to 

detect the problem area or repair irrelevant areas. Therefore, always follow the procedures in the 

correct order and perform the DTC check. 

A flow chart showing how to proceed with troubleshooting with the DTC checking is shown below. This 

flow chart shows how to use the DTC checking effectively. Throughout this chart flow, we can know 

how to process the DTC troubleshooting and the troubleshooting of problem symptoms table. 

1. DTC CHECK 

2. RECORD AND CLEAR THE DTC 

NOTE 

If a fault code is displayed in the initial DTC checking, it indicates that a trouble may have occurred in 

a wire harness or connectors in the past. Therefore, check the wire harness and connectors. (Refer to 

“Chapter 01 introduction - how to troubleshoot, electronic circuit inspection procedure”) 

3. SYMPTOM CONFIRMATION 

Do the problem symptoms still exist? 



4. SIMULATION TEST WITH THE METHODS OF SYMPTOM SIMULATION (Refer to “Chapter 01 

introduction - how to troubleshoot, how to proceed with troubleshooting”) 

5. DTC CHECK AGAIN 

Does DTC display? 

YES > Proceed with DTC chart. 

NO > Go to next step. 

6. SYMPTOM CONFIRMATION 

Does any symptom exist? 


NO > The system is normal. 

7. PROCEED WITH PROBLEM SYMPTOMS TABLE 

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01 

01 

01 

01 

01 

(a) 

The problem beyond the DTC system ability. The fault code displayed in the DTC is either a past 

problem or a secondary problem. 

8. END 

Page 31

01-24 


SYMPTOM SIMULATION 

NOTE 

• The most difficult case in troubleshooting is when no symptoms occurs. In such cases, be sure 

to carry out a thorough customer problem analysis. Then simulate the same or similar 

conditions and enviroment in which the customer’s vehicle was and when the problem 

occurred. No matter how much experience and skill a technician has. If he troubleshoot the 

problem without the direction, he will tend to miss some important things during servicing and 

make some mistakes, which will lead to a standstill. 

• For example, for a problem which only occurs when the engine is cold, or for a problem which 

occurs due to vibration caused by the road during driving, etc., the problem can never be found 

out when the engine is hot or when the vehicle is stopped. Since enviroment problem like 

vibration, heat or moisture which is difficult to reproduce, the symptom simulation tests 

introduced here are effective measures that the external causes are applied to the vehicle in a 

stationary condition. 

1. IMPORTANT POINTS IN THE SYMPTOM SIMULATION TEST: 

(a) In the symptom simulation test, the problem symptoms should be confirmed and the problem area or 

parts must also be found. So, before starting simulation test, connect hand-held tester into the vehivle 

firstly in order to reduce the range of testing. 

(b) After the step aboved, carry out the symptom simulation test, judging whether the circuit being tested is 

defective or normal and also confirming the problem symptoms at the same time. Refer to the problem 

symptoms table of each system, find out the possible causes of the problem. 

2. VIBRATION METHOD: When vibration seems to be 

the major cause. 

(a) Part and sensor. 

• Apply slight vibration with your finger to the part or the 

sensor and check whether the malfunction occurs. 

CAUTION 

Apply strong vibration to relays may result in open. 

(b) Connectors. 

• Lightly shake the connector vertically and horizontally. 

(c) Wire harness. 

• Lightly shake the wire harness vertically and horizontally. 

The connector joint is the major area that should be checked 

thoroughly. 

Page 32


01-25 

3. HEAT METHOD: If the problem seems to occur when 

the temperature is higher. 

(a) Heat the component that is possible cause of the malfunction 

with a hair dryer or similar object. Check it if the malfunction 

occurs. 

CAUTION 

• Never heat the components to more than 60 ℃ to 

prevent from being damaged. 

• Never apply heat directly to the module. 

4. WATER SPRINKLING METHOD: When the malfunction 

seems to occur on a rainy day or in high-humidity. 

(a) Sprinkle water on the vehicle and check whether the 

malfunction occurs. 

CAUTION 

• Never spray water directly on the engine hood. Spray a 

mist of water on the radiator front surface to change the 

temperature and humidity. 

• Never spray water directly on the electronic components. 

• If a vehicle is subject to water leakage, the leaking water 

may damage the module. When testing a vehicle for 

water leakage problem, this factor must be considered. 

5. HIGH ELECTRICAL LOAD METHODS: If the malfunction seems to occur when electrical load is 

excessive. 

(a) Turn on all the electrical equipment including the heater blower, headlights, rear windows defrost, etc. 

and check whether the malfunction occurs. 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

Page 33

01-26 


DTC CHART 

Take the engine control system as an example, inspection procedures are shown in the illustration below. 

The chart indicates the DTCs of the engine control system and lists the corresponding troubleshooting 

procedures. It will be more effective and accurate to proceed with troubleshooting in accordance with the 

inspection procedures listed in the chart. 

Page 34


01-27 

PROBLEM SYMPTOMS TABLE 

The problem symptoms table indicates the suspect circuits or parts for each problem symptom, as shown in 

the illustration below. Using this table to troubleshoot the problem when the problem is occuring but no DTC 

displayed. The number in the table indicates the procedures of troubleshooting. 

NOTE 

When the problem is not detected by the diagnostic system even though the problem symptoms is 

present, it may be that the problem is occuring beyond the detection range of the dignostic system. 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

Page 35

01-28 


CIRCUIT INSPECTION 

How to read and use each page is shown below. 

Page 36


01-29 

ELECTRONIC CIRCUIT INSPECTION PROCEDURE 

1. BASIC INSPECTION. 

(a) Resistance measuring condition. 

• Unless special instruction, all resistance is measured at an ambient temperature of 20 ℃ . 

• The resistance may be out of the specifications when measured at high temperature (such as the 

engine is hot). So measurements should be performed when the engine is cooled down. 

(b) Handling of connectors. 

• When disconnecting the connector, press the connector 

in the direction of engagement and remove the lock by 

lightly pressing the lock claw. 

• When removing the connector, do not pull the wire harness 

but pull the connector. 

• Make sure there is no deformation, damage or missing 

terninals before connecting the connector. 

• The connector with a lock should be inspected until hearing 

a “click”. 

• When checking the connector with a mutimeter, be sure 

to check it from the backside (wire harness side) of the 

connector by using a mini test lead. 

NOTE 

• As a water proof connector can not be checked from 

the backside, check it by a connecting the adapter. 

• Do not damage the terminals when moving the inserted 

tester needle. 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

(c) Connector checking points. 

Check when the connector is connected: 

• Hold the connector and check the inserting condition and 

locking efficiency (engaged condition). 

Check when the connector is disconnected: 

• Pull the wire harness lightly and check the connector for 

missing terminal, terminal crimping condition and core 

wire break. 

• Check visually for any rust, metal chips, water and bent 

terminals. 

01 

01 

01 

01 

01 

01 

01 

Page 37

01-30 


Check the contact pressure of the terminal: 

• Prepare a spare male terminal and insert it into a female 

terminal. Check the engaged condition and sliding. 

CAUTION 

Always use a gold-plated male terminal to test a gold-plated 

female terminal. 

(d) Repair method of connector terminal. 

• If there is dirty on the contact point, clean the contact 

point by using an air gun or shop rag. However, never 

polish the contact point using sand paper as the plating 

may come off. 

• In case of abnormal contact pressure, replace the female 

terminal. However, if a male terminal is gold-plated (gold 

colour), use a gold-plated female termina. If it is silverplated 

(silver colour), use a silver-plated female terminal. 

(e) Handling of wire harness. 

• When removing the wire harness, check the position of 

the wire harness and clamps before servicing, reinstall it 

correctly. 

• Never twist, pull or loosen the wire harness. 

• Never allow the wire harness to cross a area of high-temperature, 

rotating, moving, vibrating or sharp (edge of the 

panel, tip of the screw, etc.) part. 

• When installing parts, never let the wire harness be interfered. 

• Never cut or break the cover of the wire harness. If it is 

cut or broken, replace it or repair it with electrical tape. 

2. CHECK OPEN CIRCUIT. 

(a) For the open circuit shown in the illustration, perform a 

resistance check in step (b) or voltage check in step (c) 

to comfirm fault. 

Page 38


01-31 

(b) Check the resistance. 

• Disconnect connector A & C and measure the resistance 

between them. 

Resistance: < 2 Ω 

NOTE 

Measure the resistance while lightly shaking the wire harness 

vertically and horizontally. 

For this circuit: 

The resistance between terminal 1 of connector A and terminal 

1 of connector C: ≥ 1 MΩ 

The resistance between terminal 2 of connecor A and terminal 2 

of connector B: < 2 Ω 

Therefore, the cause is an open circuit between terminal 1 of 

connector A and terminal 1 of connector C. 

• Disconnect connector B and measure the resistance 

between the connectors. 


The resistance between terminal 1 of connector A and terminal 

1 of connector B1: < 2 Ω 

The resistance between terminal 1 of connector B2 and terminal 

1 of connector C: ≥ 1 MΩ 

Therefore, the cause is an open circuit between terminal 1 of 

connector B2 and terminal 1 of connector C. 

(c) Check the voltage. 

• An open circuit which voltage is applied can be checked by 

conducting a voltage check. 

• For the open circuit which each connector is still connected 

shown in the illustration, measure the voltage orderly 

between ground and terminal 1 of connector A at the ECU 5 

V output terminal, terminal 1 of connector B and terminal 1 of 

connector C. 


The voltage between terminal 1 of connector A and ground: 5 V 

The voltage between terminal 1 of connector B and ground: 5 V 

The voltage between terminal 1 of connector C and ground: 0 V 

Therefore, the cause is an open circuit in the wire harness 

between terminal 1 of connector B and terminal 1 of connector 

C. 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

01 

Page 39

01-32 


3. CHECK SHORT CIRCUIT. 

(a) For the short circuit shown in the illustration, perform a 

resistance check in step (b) to locate the section. 

(b) Check the resistance. 

• Disconnect connector A & C and measure the resistance 

between terminal 1 and 2 of connector A and ground. 

Resistance: ≥ 1 MΩ 

NOTE 

Measure the resistance while lightly shaking the wire 

harness vertically and horizontally. 


The resistance between terminal 1 of connector A and ground: < 2 

Ω 

The resistance between terminal 2 of connector A and ground: ≥ 1 

MΩ 

Therefore, the cause is an short circuit between terminal 1 of 

connector A and terminal 1 of connector C. 

• Disconnect connector B and measure the resistance between 

terminal 1 of connector A and B2 and ground. 


The resistance between terminal 1 of connector A and ground: ≥ 1 MΩ 

The resistance between terminal 1 of connector B2 and ground: < 2 Ω 

Therefore, the cause is a short circuit between terminal 1 of 

connector B2 and terminal 1 of connector C. 

Page 40

INTRODUCTION - TERMS 

01-33 

TERMS 

ABBREVIATIONS USED IN THIS MANUAL 

A/C 

Abbreviations 

Air Conditioning 

Meaning 

01 

01 

A/F 

ABS 

ACC 

ASSY 

BAT 

B-joint 

BTDC 

CKP 

Air-fuel Ratio 

Anti-lock Brake System 

Accessory 

Assembly 

Battery 

Ball Joint 

Before Top Dead Center 

Crankshaft Position 

01 

01 

01 

01 

01 

01 

CMP 

Camshaft Position 

DLC3 Data Link Connector 3 

DTC 

Diagnostic Trouble Code 

ECM 

Engine Control Module 

01 

01 

01 

ECT 

ECU 

EFI 

EGR 

EVAP 

GEN 

GND 

HO2S 

HVAC 

IAT 

ISC 

KS 

LSP 

MAF 

MIL 

MWP 

No. 

O2S 

Engine Coolant Temperature 

Engine Control Unit 

Engine Fuel Injection 

Exhaust Gas Recirculation 

Evaporative Emission 

Generator 

Ground 

Heated Oxygen Sensor 

Heater And Air Conditioning 

Intake Air Temperature 

Idle Speed Control 

Knock Sensor 

Load Sensing Proportioning 

Mass Air Flow 

Malfunction Indicator Lamp 

Max Working Pressure 

Number 

Oxygen Sensor 

01 

01 

01 

01 

01 

01 

01 

01 

01 

Page 41

01-34 

INTRODUCTION - TERMS 

Abbreviations 

Meaning 

OBD 

PCV 

RCM 

RPM 

SFI 

SRS 

SSM 

SST 

TC 

TPS 

U-joint 

On-Board Diagnostic 

Positive Crankcase Ventilation 

Restraint Control Module 

Revolutions Per Minute 

Sequential Multiport Fuel Injection 

Supplemental Restraint System 

Special Service Materials 

Special Service Tools 

Turbocharger 

Throttle Position Sensor 

Universal Joint 

Page 42

PREPARATION 

DIAGNOSTICS................................................................................... 02-1 

PREPARATION ........................................................................... 02-1 

ENGINE CONTROL SYSTEM............................................................ 02-3 

PREPARATION ........................................................................... 02-3 

FUEL .................................................................................................. 02-4 

PREPARATION ........................................................................... 02-4 

EMISSION CONTROL........................................................................ 02-5 

PREPARATION ........................................................................... 02-5 

INTAKE AIR ....................................................................................... 02-6 

PREPARATION ........................................................................... 02-6 

ENGINE MECHANICAL..................................................................... 02-7 

PREPARATION ........................................................................... 02-7 

EXHAUST......................................................................................... 02-10 

PREPARATION ......................................................................... 02-10 

COOLING ......................................................................................... 02-11 

PREPARATION ......................................................................... 02-11 

LUBRICATION ................................................................................. 02-12 

PREPARATION ......................................................................... 02-12 

STARTING AND CHARGING .......................................................... 02-14 

PREPARATION ......................................................................... 02-14 

FRONT SUSPENSION..................................................................... 02-15 

PREPARATION ......................................................................... 02-15 

REAR SUSPENSION ....................................................................... 02-16 

PREPARATION ......................................................................... 02-16 

TIRE AND WHEEL........................................................................... 02-17 

PREPARATION ......................................................................... 02-17 

AXLE AND PROPELLER SHAFT.................................................... 02-18 

PREPARATION ......................................................................... 02-18 

BRAKE ............................................................................................. 02-21 

PREPARATION ......................................................................... 02-21 

PARKING BRAKE............................................................................ 02-22 

PREPARATION ......................................................................... 02-22 

TRANSMISSION .............................................................................. 02-23 

PREPARATION ......................................................................... 02-23 

CLUTCH ........................................................................................... 02-25 

PREPARATION ......................................................................... 02-25 

STEERING COLUMN....................................................................... 02-26 

PREPARATION ......................................................................... 02-26 

POWER STEERING......................................................................... 02-27 

PREPARATION ......................................................................... 02-27 

HEATER AND AIR CONDITIONING................................................ 02-28 

PREPARATION ......................................................................... 02-28 

SEAT BELT...................................................................................... 02-30 

PREPARATION ......................................................................... 02-30 

WIPER AND WASHER .................................................................... 02-31 

PREPARATION ......................................................................... 02-31 

WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR....... 02-32 

PREPARATION ......................................................................... 02-32 

INSTRUMENT PANEL/INSTRUMENT............................................. 02-33 

PREPARATION ......................................................................... 02-33 

02 

02 

02 

Page 43

SEAT ................................................................................................ 02-34 

PREPARATION ......................................................................... 02-34 

DOOR LOCKS.................................................................................. 02-35 

PREPARATION ......................................................................... 02-35 

DOORS............................................................................................. 02-36 

PREPARATION ......................................................................... 02-36 

VEHICLE CONTROL SYSTEM........................................................ 02-37 

PREPARATION ......................................................................... 02-37 

Page 44

PREPARATION - DIAGNOSTICS 

02-1 

DIAGNOSTICS 

PREPARATION 

PREPARATION 

RECOMMENDED TOOLS 

02 

02 

Collective Intellegence Scan Tool 

ENGINE CONTROL SYSTEM 

Digital Multimeter 

Test Lead Set 


ANTI-LOCK BRAKE SYSTEM 

SUPPLEMENTAL RESTRAINT 

SYSTEM 

HEATER AND AIR 

CONDITIONING SYSTEM 

LIGHTING SYSTEM 

WIPER AND WASHER 

MULTIMEDIA SYSTEM 

AUXILIARY POWER 

HORN SYSTEM 

REVERSE RADAR SYSTEM 

POWER WINDOWS 

OUTSIDE MIRROR 

DEFROST SYSTEM 

INSTRUMENT CLUSTER 

POWER DOOR LOCKS 

SLIDING ROOF 



SUPPLEMENTAL RESTRAINT 

SYSTEM 

HEATER AND AIR 

CONDITIONING SYSTEM 





HORN SYSTEM 


POWER WINDOWS 


DEFROST SYSTEM 



SLIDING ROOF 

19A 

Torque Wrench - 

EQUIPMENT 

Oscilloscope - 

Page 45

02-2 

PREPARATION - DIAGNOSTICS 

SSM 

Item Capacity Specification 

Thread sealant - 3M No.4171 or equivalent 

Page 46


PREPARATION 


PREPARATION - ENGINE CONTROL SYSTEM 

Collective Intellegence Scan Tool 

FUEL INJECTION SYSTEM 

IGNITION SYSTEM 

SENSOR 

ACTUATOR 

ECM 

02-3 

02 

02 


SENSOR 

ACTUATOR 

ECM 

Test Lead Set 

SENSOR 

ACTUATOR 

ECM 


EQUIPMENT 

Oscilloscope - 

SSM 

19A 


Thread sealant - 3M No.4171 or equivalent 

Page 47

02-4 

PREPARATION - FUEL 

FUEL 

PREPARATION 


Needle Nose Plier 

FUEL PRESSURE REGULATOR 

Hydraulic Jack 

FUEL TANK ASSY 

Torque Wrench 

FUEL FITER ASSY 

FUEL PUMP REMOVER 

FUEL PUMP 


FUEL PUMP 

EQUIPMENT 

Fuel injector leakage tester - 

SSM 


Grease - - 

Page 48

EMISSION CONTROL 

PREPARATION 


PREPARATION - EMISSION CONTROL 

Air Blow Gun 

02-5 

VAPER CANISTER 

CANISTER CONTROL SOLENOID 

VALVE 

PCV 

02 

02 


CANISTER CONTROL SOLENOID 

VALVE 

19A 

Page 49

02-6 

INTAKE AIR 

PREPARATION 


PREPARATION - INTAKE AIR 


SSM 


Sealant - Foton sealant 

Page 50

PREPARATION - ENGINE MECHANICAL 

02-7 

ENGINE MECHANICAL 

PREPARATION 

SST 

02 

02 

Camshaft Pulley Spanner Wrench 

CAMSHAFT TIMING PULLEY 

Cylinder Cover Bolt Spanner 

CYLINDER COVER BOLT 

Crankshaft Front Oil Seal Guide 

CRANKSHAFT FRONT OIL SEAL 

Crankshaft Front Oil Seal Installer 


Hydraulic Tappet Adjuster Leakage 

Tester 

HYDRAULIC TAPPET ADJUSTER 

Hydraulic Tappet Adjuster Keeper 


19A 

Hydraulic Tappet Adjuster Wiring 


Hydraulic Tappet Adjuster Keeper 


Camshaft Oil Seal Installer 

CAMSHAFT OIL SEAL 

Pin For Belt Gear 

CAMSHAFT TIMING PULLEY 

Oil Pan Remover 

OIL PAN 

Page 51

02-8 


Valve Spring Compressor 

VALVE AND INTERRELATED 

PARTS 

Valve Oil Seal Installer 

VALVE OIL SEAL 

Crankshaft Rear Oil Seal Installer 

CRANKSHAFT REAR OIL SEAL 

Crankshaft Pulley Puller 

CRANKSHAFT TIMING PULLEY 

Piston Disassembling and 

Assembling Tool 

PISTON 

Flywheel Holder 

FLYWHEEL 


Snap Ring Plier - 


ENGINE ASSY 

Feeler Gauge - 


CLAMP 


Page 52


02-9 

EQUIPMENT 

V-block - 

SSM 


02 

02 


Coolant 10 L Foton long life coolant 

Engine oil 

gasoline 

diesel 

4 L 

5 ~ 5.5 L 

Temperature -25 ~ 30 ℃ 





SL 10W-30 

SL 15W-40 

SL 5W-30 

CF-4 or above, 15W-40 


19A 

Page 53

02-10 

PREPARATION - EXHAUST 

EXHAUST 

PREPARATION 


Feeler Gauge 

EXHAUST MANIFOLD 


SSM 


Exhaust pipe sealant - Foton sealant 

Page 54

PREPARATION - COOLING 

02-11 

COOLING 

PREPARATION 


02 

02 

Radiator Cap Tester 

COOLANT RESERVOIR 

Air Blow Gun 


Thermometer 

THERMOSTAT 

Torque Wrench 


THERMOSTAT 

EQUIPMENT 

Steam cleaner - 

SSM 

19A 




Page 55

02-12 

PREPARATION - LUBRICATION 

LUBRICATION 

PREPARATION 

SST 

Oil Filter Wrench 

OIL FILTER 

Oil Pan Remover 

OIL PAN 

Engine Oil Pressure Switch 

Remover 

ENGINE OIL PRESSURE SWITCH 

Crankshaft Front Oil Seal Installer 



Rubber Hammer 

OIL PAN 


Feeler Gauge - 

Planometer - 

Page 56

PREPARATION - LUBRICATION 

02-13 

SSM 




Engine oil 

gasoline 

diesel 

4 L 

5 ~ 5.5 L 






SL 10W-30 

SL 15W-40 

SL 5W-30 



02 

02 

19A 

Page 57

02-14 

STARTING AND CHARGING 

PREPARATION 


PREPARATION - STARTING AND CHARGING 


GENERATOR 

STARTER 

Dial Indicator 

GENERATOR 

STARTER 

Vernier Caliper 

STARTER 

Puller 

STARTER 

Soldering Gun 

GENERATOR 

Snap Ring Plier 

STARTER 


Belt Tension Gauge - 

EQUIPMENT 

Battery Charger - 

Discharge Tongs - 

Page 58

PREPARATION - FRONT SUSPENSION 

02-15 

FRONT SUSPENSION 

PREPARATION 


02 

02 


EQUIPMENT 

Wheel alignment instrument - 

Tire changer - 

Tire dynamic balancer - 

SSM 


Grease - - 

19A 

Page 59

02-16 

PREPARATION - REAR SUSPENSION 

REAR SUSPENSION 

PREPARATION 



Spring Scale - 

EQUIPMENT 



Tire dynamic balancer - 

SSM 


Grease - - 

Page 60

PREPARATION - TIRE AND WHEEL 

02-17 

TIRE AND WHEEL 

PREPARATION 


02 

02 

Tire Pressure Gauge 



EQUIPMENT 



Tire inflater - 

SSM 


Balance block - - 

19A 

Page 61

02-18 

PREPARATION - AXLE AND PROPELLER SHAFT 

AXLE AND PROPELLER SHAFT 

PREPARATION 


Tire Pressure Gauge 

TIRE 

Feeler Gauge 

PROPELLER SHAFT SPLINE 

DRIVE AXLE SIDE GEAR 

Hammer 

Brass Bar 

PROPELLER SHAFT U-JOINT 

CENTER SUPPORT BEARING 

FRONT AXLE HUB GREASE CAP 

REAR AXLE HUB BEARING 

STEERING KNUCKLE 

DIFFERENTIAL PINION SHAFT 



FRONT AXLE HUB GREASE CAP 



DIFFERENTIAL PINION SHAFT 

Micrometer Calipers 


CROSS SPIDER 




FRONT AXLE HUB BEARING 


DRIVE PINION 

CROWN GEAR 

DRIVE AXLE SIDE GEAR 

DIFFERENTIAL PINION 

PINION FLANGE 



OUTPUT FLANGE 

Puller 

PROPELLER SHAFT END YOKE 

AXLE SHAFT BEARING 

DRIVING GEAR BEARING 

Grease Gun 

FRONT AXLE HUB BEARING 



Page 62


02-19 

Spring Scale 


FRONT AXLE HUB STARTING 

TORQUE 

REAR AXLE HUB STARTING 

TORQUE 

COTTER PIN 

CENTER SUPPORT BEARING OIL 

SEAL 

OUTPUT FLANGE OIL SEAL 

DRIVE PINON OIL SEAL 

02 

02 

Tapeline 

REAR AXLE BACK LASH 

Allen Wrenchs (Key) - 


FINAL DRIVE ASSY 


DRIVE AXLE SIDE GEAR THRUST 

WASHER 

DIFFERENTIAL PINION THRUST 

WASHER 

DRIVE PINION ADJUSTING SHIM 

Torque Wrench 

DRIVE PINION STARTING 

TORQUE 

19A 

EQUIPMENT 

V-block - 

Propeller dynamic balancer - 

Vice - 

Press machine - 

Page 63

02-20 


SSM 


Balance block - - 

Red lead - - 

Grease 

propeller shaft U-joint 

center support bearing 

U-joint 

front axle hub 

front axle hub 

axle shaft 

output flange oil seal 

drive pinion oil seal 

- 

- 

- 

- 

- 

- 

- 

- 

Lithium base grease No.2 

Lithium base grease No.2 

Final drive oil 2.5 L GL-5 80W/90 

Sealant 

ouput flange 

crown gear 

differential bearing 

- 

- 

- 

LOCTITE 204 

LOCTITE 204 

LOCTITE 204 

Page 64

PREPARATION - BRAKE 

02-21 

BRAKE 

PREPARATION 



FRONT BRAKE DISK 

02 

02 


FRONT BRAKE DISK 


REAR BRAKE DRUM 

REAR BRAKE SHOE 

Nipper Plier 


WHEEL BRAKE CYLINDER 

Tapeline 

BRAKE PAD 


BRAKE MASTER CYLINDER 

19A 

Grease Gun 

FRONT AXLE HUB 

REAR AXLE HUB 

Puller 

FRONT AXLE HUB 

REAR AXLE HUB 

FRONT AXLE HUB OIL SEAL 

REAR AXLE HUB OIL SEAL 

AXLE SHAFT 


SSM 


Brake fluid - V3/V4 

Page 65

02-22 

PREPARATION - PARKING BRAKE 

PARKING BRAKE 

PREPARATION 



REAR BRAKE DRUM 



FRONT PARKING BRAKE PULL 

CABLE ASSY 

REAR PARKING BRAKE PULL 

CABLE ASSY LH 

REAR PARKING BRAKE PULL 

CABLE ASSY RH 

EQUIPMENT 

Vice - 

Page 66

PREPARATION - TRANSMISSION 

02-23 

TRANSMISSION 

PREPARATION 


02 

Feeler Gauge 

SYNCHRONIZER ASSY 

COUNTER SHAFT WASHER 

02 


RETURN SPRING 

Brass Bar 

REVERSE IDLER GEAR SHAFT 

Hammer 

REVERSE IDLER GEAR SHAFT 


OUTPUT SHAFT 


INPUT SHAFT WASHER 

OUTPUT SHAFT 

19A 


INPUT SHAFT ASSY 

OUTPUT SHAFT ASSY 

SHIFT MECHANISM 


GEARSHIFT FORK 

SYNCHRONIZER ASSY 

Puller 

OUTPUT FRONT BEARING 

OUTPUT MIDDLE BEARING 

OUTPUT REAR BEARING 


Page 67

02-24 

PREPARATION - TRANSMISSION 

EQUIPMENT 

V-block - 

Vice - 

SSM 


Transmission fluid 2 L GL-4 75W/90 

Grease - Mitsubishi No.0101011 

Sealant - 

Mitsubishi No.997740 

3M No.4170 

Page 68

PREPARATION - CLUTCH 

02-25 

CLUTCH 

PREPARATION 



FLYWHEEL 

CLUTCH DISK 

02 

02 


CLUTCH DISK 

CLUTCH COVER 


CLUTCH MASTER CYLINER ASSY 


EQUIPMENT 

Vice - 

SSM 


19A 

Brake fluid - V3/V4 

Grease - Mitsubishi No.0101011 

Page 69

02-26 

STEERING COLUMN 

PREPARATION 


PREPARATION - STEERING COLUMN 

Tapeline 

OFF TRACK 

Allen Wrenchs (Key) 

HORN SWITCH ASSY 

Spring Scale 

STEERING WHEEL TURNING 

FORCE 


STEERING PROPELLER SHAFT 

U-JOINT 


EQUIPMENT 

V-block - 

Page 70

POWER STEERING 

PREPARATION 


PREPARATION - POWER STEERING 

02-27 

02 

02 

Tapeline 

OFF TRACK 


SSM 


Steering fluid 1.2 L ATF - Ⅲ 

Grease power steering box - QL-5 80W/90 

Sealant low-pressure hose - - 

19A 

Page 71

02-28 

PREPARATION - HEATER AND AIR CONDITIONING 

HEATER AND AIR CONDITIONING 

PREPARATION 


Manifold Gauge 

REFRIGERANT 

COMPRESSOR 

Service Hoses 

REFRIGERANT 

COMPRESSOR 

Service Coupler 

REFRIGERANT 

COMPRESSOR 

3-way Joint 

REFRIGERANT 

COMPRESSOR 

Service Tank 

REFRIGERANT 

COMPRESSOR 

Vacuum Pump Connector 

REFRIGERANT 

COMPRESSOR 

Refrigerant Leakage Tester 

REFRIGERANT 

Eyes Protecter - 

Thermometer 

ENVIRONMENT TEMPERATURE 

Thermistance Type Thermometer 

OUTLET TEMPERATURE 

Belt Tension Gauge 

PULLEY 

Page 72

PREPARATION - HEATER AND AIR CONDITIONING 

02-29 

Refrigerant Recovery / Recycling 

Station 

(With this device, vacuum pump is 

not required.) 

Vacuum Pump 

REFRIGERANT 

COMPRESSOR 

REFRIGERANT 

COMPRESSOR 

02 

02 

SSM 


Refrigerant 

front and rear A/C 

only front A/C 

850 ± 25 g 

700 ± 25 g 

R-134a 

R-134a 

Compressor oil 180 ml - 

19A 

Page 73

02-30 

SEAT BELT 

PREPARATION 


PREPARATION - SEAT BELT 


Page 74


PREPARATION 


PREPARATION - WIPER AND WASHER 


02-31 

02 

02 

19A 

Page 75

02-32 

PREPARATION - WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR 

WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR 

PREPARATION 


Scraper 

WINDSHIELD 

SIDE WINDOW 

REAR WINDOW 

Suction Cup 

WINDSHIELD 

SIDE WINDOW 

REAR WINDOW 

Knife 

WINDSHIELD 

SIDE WINDOW 

REAR WINDOW 

Sealer Gun 

WINDSHIELD 

SIDE WINDOW 

REAR WINDOW 

Rubber Hammer 

WINDSHIELD 

SIDE WINDOW 

REAR WINDOW 

SSM 


Protective Tape - - 

Block - - 

Plastic Paper - - 

Steel Wire - - 

Nylon Cord - - 

Adhesive Tape - - 

Primer - Reactive polyester primer, black 

Sealant - Polyurethane sealant, black 

Page 76

PREPARATION - INSTRUMENT PANEL/INSTRUMENT 

INSTRUMENT PANEL/INSTRUMENT 

PREPARATION 



02-33 

02 

02 

Allen Wrenchs (key) - 

Pry - 

19A 

Page 77

02-34 

PREPARATION - SEAT 

SEAT 

PREPARATION 


Allen Wrenchs (Key) - 

Needle Nose Plier - 


Page 78

DOOR LOCKS 

PREPARATION 


PREPARATION - DOOR LOCKS 

02-35 

02 

02 


DOOR LOCK CORE 

SSM 


Grease - Lithium base grease No.2 

19A 

Page 79

02-36 

PREPARATION - DOORS 

DOORS 

PREPARATION 


Grease Gun 

DOOR 


SSM 


Grease - Lithium base grease No.2 

Page 80

VEHICLE CONTROL SYSTEM 

PREPARATION 


PREPARATION - VEHICLE CONTROL SYSTEM 

02-37 

02 

02 


IGNITION SWITCH ASSY 


19A 

Page 81

MEMO 

Page 82

SERVICE SPECIFICATIONS 

SPECIFIED TORQUE FOR SPECIFICATION BOLTS...................... 03-1 


SERVICE DATA........................................................................... 03-2 

TORQUE SPECIFICATION ......................................................... 03-3 

FUEL .................................................................................................. 03-4 

SERVICE DATA........................................................................... 03-4 


EMISSION CONTROL........................................................................ 03-5 


ENGINE MECHANICAL..................................................................... 03-6 

SERVICE DATA........................................................................... 03-6 


INTAKE AIR ..................................................................................... 03-10 

SERVICE DATA......................................................................... 03-10 

TORQUE SPECIFICATION ....................................................... 03-10 

EXHAUST......................................................................................... 03-11 

SERVICE DATA......................................................................... 03-11 


COOLING ......................................................................................... 03-12 

SERVICE DATA......................................................................... 03-12 


LUBRICATION ................................................................................. 03-13 


IGNITION.......................................................................................... 03-14 

SERVICE DATA......................................................................... 03-14 


STARTING AND CHARGING .......................................................... 03-15 

SERVICE DATA......................................................................... 03-15 


FRONT SUSPENSION..................................................................... 03-17 

SERVICE DATA......................................................................... 03-17 


REAR SUSPENSION ....................................................................... 03-18 


TIRE AND WHEEL........................................................................... 03-19 

SERVICE DATA......................................................................... 03-19 


AXLE AND PROPELLER SHAFT.................................................... 03-20 

SERVICE DATA......................................................................... 03-20 


BRAKE ............................................................................................. 03-23 

SERVICE DATA......................................................................... 03-23 


PARKING BRAKE............................................................................ 03-24 


TRANSMISSION .............................................................................. 03-25 

SERVICE DATA ........................................ 03-25 

TORQUE SPECIFICATION .............................. 03-26 

CLUTCH ........................................................................................... 03-27 

SERVICE DATA......................................................................... 03-27 

03 

03 

03 

Page 83


STEERING COLUMN....................................................................... 03-28 

SERVICE DATA......................................................................... 03-28 


POWER STEERING ......................................................................... 03-29 

SERVICE DATA......................................................................... 03-29 


HEATER AND AIR CONDITIONING................................................ 03-31 

SERVICE DATA......................................................................... 03-31 


SEAT BELT ...................................................................................... 03-32 


LIGHTING......................................................................................... 03-33 


WIPER AND WASHER .................................................................... 03-34 


SEAT ................................................................................................ 03-35 


DOORS............................................................................................. 03-36 

SERVICE DATA......................................................................... 03-36 


EXTERIOR AND INTERIOR TRIM................................................... 03-37 


VEHICLE CONTROL SYSTEM........................................................ 03-38 


Page 84

SERVICE SPECIFICATIONS - SPECIFIED TORQUE FOR SPECIFICATION BOLTS 

03-1 

SPECIFIED TORQUE FOR SPECIFICATION BOLTS 

SERVICE SPECIFICATIONS 

NOTE 

The range of the tightening torques listed in the following table have already contained the error of the 

used tools. 

03 

Thread Standard 

Torque (N·m) 

Grade 8.8 Grade 10.9 

03 

M5 9 ~ 11 12 ~ 14 

M8 

M8 × 1 

M10 

M10 × 1.25 

M10 × 1 

M12 

M12 × 1.5 

M12 × 1.25 

M14 

M14 × 1.5 

M16 

M16 × 1.5 

M18 

M18 × 1.5 

M20 

M20 × 1.5 

21 ~ 25 

22 ~ 27 

41 ~ 51 

45 ~ 55 

46 ~ 56 

73 ~ 89 

75 ~ 92 

78 ~ 96 

122 ~ 149 

126 ~ 154 

182 ~ 222 

199 ~ 243 

243 ~ 285 

287 ~ 336 

389 ~ 456 

396 ~ 465 

29 ~ 35 

32 ~ 39 

58 ~ 71 

63 ~ 77 

65 ~ 79 

105 ~ 128 

106 ~ 130 

113 ~ 138 

160 ~ 195 

178 ~ 218 

247 ~ 290 

265 ~ 311 

380 ~ 437 

397 ~ 457 

486 ~ 548 

540 ~ 596 

Page 85

03-2 

SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM 


SERVICE DATA 

GASOLINE ENGINE (4G69) 

ECT sensor resistance 0 ℃ 

20 ℃ 

40 ℃ 

80 ℃ 

5.1 ~ 6.5 KΩ 

2.1 ~ 2.7 KΩ 

0.9 ~ 1.3 KΩ 

0.26 ~ 0.36 KΩ 

Engine idle speed Standard 750 ± 50 RPM 

Idle air control motor coil resistance 

Standard 28 ~ 33 Ω ( 20 ℃) 

TPS resistance Standard 3.5 ~ 6.5 Ω ( 20 ℃) 

IAT resistance 0 ℃ 

20 ℃ 

40 ℃ 

80 ℃ 

5.3 ~ 6.7 KΩ 

2.3 ~ 3.0 KΩ 

1.0 ~ 1.5 KΩ 

0.30 ~ 0.42 KΩ 

CKP resistance Standard 560 Ω ± 10% ( 20 ℃) 

Upstream HO2S resistance 

Downstream HO2S resistance 

Terminal 3 and 4 2.5 ~ 4.5 Ω ( 20 ℃) 

Terminal 3 and 4 2.5 ~ 4.5 Ω ( 20 ℃) 

Canister solenoid valve Standard 19 ~ 22 Ω ( 20 ℃) 

DIESEL ENGINE (ISF2.8) 

Coolant temperature sensor (ECT) resistance - 10 ℃ 

0 ℃ 

20 ℃ 

40 ℃ 

80 ℃ 

100 ℃ 

9.397 Ω 

5.986 Ω 

2.500 Ω 

1.175 Ω 

0.323 Ω 

0.186 Ω 

TPS(APPS1) 

TPS(APPS2) 

Fully opened 

Fully closed 

Fully opened 

Fully closed 

0.72 ~ 0.74 V 

3.95 V 

0.36 ~ 0.37 V 

1.97 V 

CKP resistance Standard 860 Ω ± 86 Ω ( 20 ℃) 

Page 86

SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM 

03-3 

TORQUE SPECIFICATION 


Part Tightened 

N•m 

03 

ECM × Body 19.6 

ECT sensor × Engine cylinder block 20 ~ 25 

Idle air control valve × Throttle body 20 ~ 25 

03 

TPS × Throttle body 1.7 ~ 2.6 

MAP sensor / IAT sensor × Intake manifold - 

CKP sensor × flying wheel housing - 

Upstream HO2S × Exhaust pipe 40 ~ 60 

Downstream HO2S × Exhaust pipe 40 ~ 60 

Ignition control module - 

Canister solenoid valve x engine bracket - 

Odometer sensor × Transmission - 



N•m 

ECM × Body 19.6 

EGR temperature sensor × Engine cylinder block - 

Preheat plug - 

EGR vacuum regulator - 

Odometer sensor × Transmission - 

EGR cooling tube - 

Inlet solenoid valve - 

Page 87

03-4 

SERVICE SPECIFICATIONS - FUEL 

FUEL 

SERVICE DATA 

FUEL 

Gasoline engine fuel pressure 

Ignition switch ON 

Engine idling 

Ignition switch OFF 

- 

- 

- 

Diesel engine fuel pressure - 

Injector electric power parameter 

Peak current 

Holding current 

resistance 

- 

- 

- 

Fuel pump filling quantity Standard - 



N•m 

Rear Fuel tank bracket × Fuel tank 41 ~ 51 

Fuel hose board retaining bolt × Body 41 ~ 51 

Fuel level sensor & bracket assy × Fuel tank 60 ~ 70 

Fuel pump × Fuel tank 60 ~ 70 

Gasoline engine fuel filter belt bolt 21 ~ 25 

Gasoline fuel fliter - 

Diesel filter hand pump bolt - 

High-pressure tube - 

High-pressure tube × Injector - 

Injector plate retaining bolt 

1st step 

2nd step 

- 

- 

Lower-pressure filter bracket bolt - 

Page 88



SERVICE SPECIFICATIONS - EMISSION CONTROL 


Diesel engine EGR valve × EGR cooling pipe - 

Diesel engine EGR valve × Exhaust pipe - 

N•m 

Vacuum regulator bolt Diesel 9 ~ 11 

03-5 

03 

03 

Page 89

03-6 


SERVICE DATA 

GASOLINE ENGINE(4G69) 

ENGINE ASSY 4G69 

SERVICE SPECIFICATIONS - ENGINE MECHANICAL 

Type 

Four cylinder in-line, water cooling, four stroke, EFI 

Cylinder 4 

Combustion chamber 

Displacement 

Bore 

Stroking 

Maximum torque 

Rated power 

Pent-roof combustion chamber 

2.378 L 

87 mm 

100 mm 

200 N·m 

96 KW (5250 r / min) 

Compression ratio 10:1 

Lubrication system 

Fuel pump type 

Water pump type 

Pressure, splash compound 

Gear type 

Centrifugal vane wheel type 

TIMING BELT 

Tensioner ejector pin herniation amount Standard 12 mm 

Tensioner ejector pin displacement ( force 98 ~ 196N) 

Standard 

≤ 1 mm 

ROCKER ARM/ROCKER SHAFT 

Rocker arm inner diameter - 

Rocker shaft diameter - 

Clearance 

HYDRAULIC ADJUSTER/VALVE PUSH ROD 

Standard 

Limit 

- 

- 

Run-out of push rod Limit - 

Hydraulic adjuster external diameter Standard - 

Hydraulic adjuster hole diameter Standard - 

Fit clearance 

CAMSHAFT 

Standard 

Limit 

- 

- 

Cam height Intake Standard 

Limit 

Exhaust 

Standard 

Limit 

37.39 mm 

36.89 mm 

36.83 mm 

36.33 mm 

Page 90


03-7 

1st camshaft journal Standard - 

2nd camshaft journal Standard - 

3rd camshaft journal Standard - 

03 

4th canshaft journa Standard - 

5th camshaft journal Standard - 

1st canshaft bearing bore Standard - 

03 

2nd canshaft bearing bore Standard - 

3rd canshaft bearing bore Standard - 

4th canshaft bearing bore Standard - 

5th canshaft bearing bore Standard - 

axial clearance between thrust plate and 1st camshaft 

journal thrust surface 

Standard 

Limit 

- 

- 

Camshaft run-out Limit - 

CYLINDER HEAD 

Cylinder head gasket surface flatness Limit 0.2 mm 

VALVE 

Edge thickness Intake Standard 

Limit 

Exhaust 

Standard 

Limit 

1.0 mm 

0.5 mm 

1.2 mm 

0.7 mm 

Valve rod diameter 

Standard 

Limit 

6.0 mm 

- 

Crest clearance between valve rod and guide 

Intake 

Exhaust 

Standard 

Limit 

Standard 

Limit 

0.02 mm ~ 0.05 mm 

0.1 mm 

0.03 mm ~ 0.07 mm 

0.15 mm 

Inclination valve Standard 45° ~ 45.5° 

Valve rod length Intake Standard 

Exhaust 

Standard 

112.30 ~ 111.80 mm 

114.11 ~ 113.61 mm 

Valve stem guide hole 

Oversize 0.05 mm 



11.05 mm ~ 11.068 mm 

11.25 mm ~ 11.268 mm 

11.50 mm ~ 11.518 mm 

Valve height Intake Standard 

Limit 

Exhaust 

Standard 

Limit 

112.30 mm 

111.8 mm 

114.11 mm 

113.61 mm 

VALVE SPRING 

Page 91

03-8 


Free height 

Pre-loading force/operation height km/mm 

Center line 

Standard 

Limit 

Standard 

Limit 

Standard 

Limit 

51.0 mm 

50.0 mm 

27.2 Kg/44.2 mm 

- 

≤ 2° 

4° 

Valve spring elastic Standard - 

PISTON 

Clearance between piston ring and groove side 

Standard 

Limit 

Clearance No.1 ring Standard 

Limit 

No.2 ring 

Standard 

Limit 

Oil ring 

Standard 

Limit 

0.02 ~ 0.06 mm 

0.1 mm 

0.25 ~ 0.35 mm 

0.8 mm 

0.40 ~ 0.55 mm 

0.8 mm 

0.1 ~ 0.4 mm 

1.0 mm 

Piston pin bore diameter Standard 22.0 mm 

Piston pin outer diameter Standard - 

Piston pin bore and piston pin clearance Standard - 

piston pin wear limit - 

Connecting rod and piston pin clearance Standard - 

Depressing force 

Depressing temperature 

Axial clearance of connecting rods 

CRANKSHAFT 

Axial clearance of crankshaft 

Standard 

Limit 

Standard 

Limit 

7500 ~ 17500 N 

Room temperature 

0.1 ~ 0.25 mm 

0.4 mm 

0.05 ~ 0.18 mm 

0.25 mm 

Clearacne between main journal and main bearing 

Standard 

Limit 

0.20 ~ 0.040 mm 

0.1 mm 

Main journal diameter Standard 56.982 ~ 57.000 mm 

CYLINDER BLOCK 

Upper surface flatness 

Upper surface grinding limit 

Standard 

Limit 

Standard 

Limit 

0.05 mm 

0.1 mm 

- 

0.2 mm 

Page 92


03-9 

Cylinder hole diameter 

Standard 

Limit 

87 mm 

- 

Clearance between piston and cylinder Standard 0.020 ~ 0.04 mm 




N•m 

03 

03 

Timing belt cover 

Down cover 

Middle cover 

Upper cover 

11 

11 

18 ~ 26 

Crankshaft pulley (timing) 165 

Crankshaft pulley (damping) 25 

Rockshaft retaining bolt 31 

Valve - chamber cover bolt 4 

Camshaft thrust plate 19 

Oil pump driving shaft 55 

Camshaft pulley 90 

Cylinder head assy Step 1 

Step 2 

Step 3 

Connecting rod cap Step 1 

Step 2 

Step 3 

78 

20 

180° 

20 

90° ~ 100° 

90° ~ 100° 

Rear engine block cover 11 

Flywheel bolt 135 

Crankshaft bearing cap 25 

Page 93

03-10 

SERVICE SPECIFICATIONS - INTAKE AIR 

INTAKE AIR 

SERVICE DATA 

Compressor blade and compressor case clearance 

Minimum - 

Turbocharger rotor axial clearance 



Standard 

Limit 

- 

- 


N•m 

Engine cover - 

Intake air pipe retaining bolt - 

Intake air filter cover bolt - 

Intake air filter assy 21 ~ 25 

Air straining box bolt - 

Air grille bolt - 

Intake air manifold bolt - 

Throttle body bolt 15 ~ 25 



N•m 

Engine cover - 

Intake air filter cover bolt - 

Intake air filter assy - 

Air straining box bolt - 

Air grille bolt - 

Intake air manifold bolt - 

Exhaust manifold × Turbocharge - 

Exhaust pipe × Turbocharge - 

Turbocharge oil outlet pipe - 

Turbocharge oil inlet pipe - 

Intake air connect pipe × Intake manifold - 

Intake pipe × EGR - 

Page 94

SERVICE SPECIFICATIONS - EXHAUST 

03-11 

EXHAUST 

SERVICE DATA 

Exhaust manifold and cylinder block cover flatnes 

Standard 

Limit 



- 

- 

03 

03 


N•m 

Front exhaust pipe × Exhaust manifold 41 ~ 51 

Front exhaust pipe × Catalytic converter 41 ~ 51 

Middle exhaust pipe bolt 41 ~ 51 

Muffer × Rear exhaust pipe 41 ~ 51 

Exhaust manifold bolt 41 ~ 51 

Heat shield 10 ~ 14 



N•m 

Exhaust pipe retaining belt bolt - 

Catalytic converter × Exhaust manifold 41 ~ 51 

Front exhaust pipe × Exhaust manifold 41 ~ 51 

Middle exhaust pipe bolt 41 ~ 51 

Muffer × Rear exhaust pipe 41 ~ 51 

Exhaust manifold bolt - 

Exhaust pipe × EGR - 

Heat shield - 

Page 95

03-12 

SERVICE SPECIFICATIONS - COOLING 

COOLING 

SERVICE DATA 

Cooling system outlet temperature - 

Thermostat valve opening temperature 80 ~ 84 ℃ 

Thermostat valve lift 8 mm ( At 95 ℃ ) 



N•m 

Coolant drain plug - 

Coolant filling pipe bolt - 

Fan cover upper support bolt 9 ~ 11 

Fan cover lower support bolt 9 ~ 11 

Coolant reservior bolt 21 ~ 25 

Thermostat housing bolt 21 ~ 25 

Cooling fan(electrical) bolt 9 ~ 11 

Water pump pulley bolt 

Gasoline 

Diesel 

14 

- 

Water pump bolt 14 

Page 96

SERVICE SPECIFICATIONS - LUBRICATION 

03-13 

LUBRICATION 



03 


N•m 

Drain plug 34 ~ 45 

Oil pan 6 ~ 7 

03 

Oil strainer bolt 19 

Oil filter 13 ~ 15 

Oil pump driving shaft 55 



N•m 

Drain plug 35 ~ 45 

Oil pan - 

Oil filter bracket bolt - 

Oil pump - 

Oil filter 25 ~ 30 

Cooler pipe x Oil filter bracket - 

Page 97

03-14 

SERVICE SPECIFICATIONS - IGNITION 

IGNITION 

SERVICE DATA 

Spark plug gap 

1.1 mm 



N•m 

Spark plug 25 

Ignition coil 24 

Page 98

SERVICE SPECIFICATIONS - STARTING AND CHARGING 


SERVICE DATA 

GENERATOR 

03-15 

03 

Nominal voltage 

12 V 

Rated current - 

Rotation revolution - 

03 

Power - 

Rotation mode 

Polarity 

Work mode 

Generator rotor coil resistance 

Generator rotor diameter 

Standard 

Limit 

clockwise 

Negative ground 

continuous rated type 

3 ± 0.5 Ω 

14.2 mm ~ 14.4 mm 

12.8 mm 

Pinion-to-stopper clearance Standard 0.5 mm ~ 2.0 mm 

Starter commutator run-out 

Starter commutator diameter 

Standard 

Limit 

Standard 

Limit 

≤ 0.05 mm 

0.10 mm 

29.4 mm 

28.4 mm 

Brush attrition value Limit 7.0 mm 

REGULATOR 

Type - 

Regulation voltage - 

STARTER 

Voltage - 

Output power - 

Direction of rotation - 

Battery rated voltage - 

Page 99

03-16 

SERVICE SPECIFICATIONS - STARTING AND CHARGING 



N•m 

Regulator - 

Generator bracket bolt 20 ~ 24 

Generator retaining bolt 20 ~ 24 

Generator cable nut - 

Generator lock bolt 20 ~ 24 

Starter pulley bolt - 

Starter shell bolt 8 ~ 10 

Magnetic switch bolt 8 ~ 10 

Magnetic coil nut 14 ~ 16 

Starter × Battery cable 18 ~ 20 

Starter retaining bolt 68 ~ 72 

Battery plate × Body 16 ~ 18 

Battery hold down - 

Battery cable - 

Page 100


SERVICE DATA 

FRONT WHEEL ALIGNMENT 

SERVICE SPECIFICATIONS - FRONT SUSPENSION 

Front toe-in 2±2 mm (8′±8′) 

03-17 

03 

Front wheel camber -0°20′±45′ (Difference between left and right ≤ 30′) 

03 

Kingpin inclination 13°05′±45′ (Difference between left and right ≤ 30′) 

Kingpin caster 2°35′±45′ (Difference between left and right ≤ 30′) 



N•m 

Front shock absorber × Body 30 

Front shock absorber × Lower control arm assy 80 ~ 90 

Torsion bar × Frame 

Rating nut 

Locking nut 

75 ~ 85 

120 ~ 130 

Upper control arm assy × Frame 170 ~ 200 

Upper control arm ball joint × Upper control arm assy 110 ~ 115 

Upper control arm assy × Torsion bar 100 ~ 110 

Lower control arm assy × Frame 180 ~ 220 

Lower control arm ball joint × Lower control arm assy 110 ~ 120 

Stabilizer bar link × Stabilizer bar 40 ~ 60 

Stabilizer bar bracket × Frame 110 ~ 130 

Strut rod × Lower control arm assy 110 ~ 120 

Strut rod × Frame 105 ~ 125 

Page 101

03-18 



SERVICE SPECIFICATIONS - REAR SUSPENSION 


N•m 

Rear shock absorber × Anchor plate 60 ~ 80 

Rear shock absorber × Frame 55 ~ 65 

Shackle pin upper bolt 110 ~ 115 

Shackle pin lower bolt 125 ~ 130 

Leaf spring pin nut 110 ~ 120 

U-bolt nut 85 ~ 105 

Page 102


SERVICE DATA 

TIRE PRESSURE 

SERVICE SPECIFICATIONS - TIRE AND WHEEL 

03-19 

03 

195R15C-104S 

Front tire 

Rear tire 

Spare tire 

350 KPa 

400 KPa 

420 KPa 

03 



N•m 

Wheel nut 90 ~ 120 

Page 103

03-20 

SERVICE SPECIFICATIONS - AXLE AND PROPELLER SHAFT 


SERVICE DATA 

PROPELLER ASSY 

Propeller tube outer diameter × Thickness 

φ 63.5 ×2.5 mm 

Operating torque Maximum 1600 N·m 

Angle without interference Maximum - 

Dynamic unbalance Maximum 20 g.cm (3200 r/min) 

Propeller radial run-out 

Standard 

Limit 

- 

0.3 mm 

Clearance between tube yoke and transmission output 

shaft spline 

Standard 

Limit 

- 

- 

U-JOINT 

Cross spider journal 

Clearance between needle bearing and yoke 

Standard 

Limit 

- 

- 

0 mm (Interferencefit) 

Clearance between cross spider and needle bearing - 

Axial clearance of cross spider - 

AXLE HUB 

Back lash 

Deviation 

Primal rotating force 

REAR AXLE 

Rear wheel track 

FINAL DRIVE ASSY 

Front 

Rear 

Front 

Rear 

Front 

Rear 

- 

- 

- 

- 

- 

- 

1650 mm 

Back lash - 

Number of drive pinion teeth 10 

Number of crown gear teeth 39 

Final ratio 3.9 

DIFFERENTIAL ASSY 

Crown gear deviation - 

Crown gear back lash - 

Page 104


03-21 

Contact area between drive pinion and crown gear 

Length 

Width 

Center of the tooth surface. The distance away from 

small end ≥ 2 mm 

≥ 60% tooth length 

≥ 60% tooth width 

03 

Drive axle side gear and pinion back lash - 

Drive axle side gear clearance - 

Radial clearance between differential pinion and pinion 

shaft 

- 

03 

Radial clearance between drive axle side gear and differential 

case 

Thickness of drive axle side gear thrust washer 

Standard 

Limit 

- 

- 

- 

Thickness of differential pinion thrust washer 

DRIVE PINION 

Standard 

Limit 

- 

- 

Pinion flange back lash - 

Pinion flange deviation - 

Drive pinion primal rotating force - 



N•m 

Final drive pinion flange × Propeller shaft 70 ~ 79 

Center support bearing bracket × Frame 60 ~ 70 

End yoke retaining bolt - 

Front axle hub × Front brake disc 50 ~ 60 

Rear wheel brake cylinder × brake tube 21 ~ 24 

Steering knuckle × Upper control arm joint 110 ~ 115 

Steering knuckle × Lower control arm assy 110 ~ 115 

Lower control arm joint × Lower control arm 110 ~ 120 

Tie rod × Steering knuckle arm 84 ~ 100 

Final drive drain plug - 

Final drive filler cap - 

Final drive vent plug - 

Main retard assy × Final drive assy - 

Crown gear × Differential case - 

Page 105

03-22 



N•m 

Differential bearing cap × Differential case - 

Pinion nut 

Minimum 

Increment 

Maximum 

- 

13 

- 

Page 106

SERVICE SPECIFICATIONS - BRAKE 

03-23 

BRAKE 

SERVICE DATA 

BRAKE PEDAL 

Height Standard 148 mm 

Free play Standard 5 ~ 10 mm 

FRONT BRAKE 

Thickness of front brake pad 

Thickness of front brake disk 

Front brake disk run-out 

REAR BRAKE 

Thickness of rear brake shoe 

Brake drum inside diameter 


Standard 

Limit 

Standard 

Limit 

Standard 

Limit 

Standard 

Limit 

Clearance between rear brake drum and brake shoe 

Standard 

16 ~ 16.1 mm 

8 mm 

28 ± 0.1 mm 

- 

- 

0.03 mm 

5 mm 

1.5 mm 

254 ~ 254.2 mm 

0.5 mm 

03 

03 


N•m 

Front disk brake caliper bleeding plug 8 ~ 13 

Rear wheel brake cylinder bleeding plug 9 ~ 11 

Brake master cylinder bolt 20 ~ 26 

Brake master cylinder tube connector 21 ~ 24 

Front brake disk x front wheel hub 50 ~ 70 

Front wheel hub x knuckle 85 ~ 120 

Front disk brake caliper mounting bolt 30 ~ 35 

Front disk brake caliper bolt 90 ~ 110 

Front disk brake caliper fluid tube connector 21 ~ 24 

Rear wheel cylinder brake fluid tube connector 21 ~ 24 

Rear wheel brake cylinder assy 8 ~ 13 

Speed sensor - 

ABS pipe connector 21 ~ 24 

Page 107

03-24 

PARKING BRAKE 


SERVICE SPECIFICATIONS - PARKING BRAKE 


N•m 

Parking brake front part assy - 

Parking brake swinging arm bracket - 

Page 108

TRANSMISSION 

SERVICE DATA 

Transmission fluid 

SERVICE SPECIFICATIONS - TRANSMISSION 

Zomax 

Aisin 

2.0 L 

2.4 L 

03-25 

03 

1st gear ratio 

2nd gear ratio 

Zomax 

Aisin 

Zomax 

Aisin 

4.452 

3.83 

2.398 

2.33 

03 

3rd gear ratio 

Zomax 

Aisin 

1.414 

1.436 

4th gear ratio 1.000 

5th gear ratio 

Reverse gear ratio 

Zomax 

Aisin 

Zomax 

Aisin 

0.802 

0.789 

4.473 

4.22 

Odometer gear ratio (Driven gear / driving gear) Zomax 

Aisin 

19/6 

32/10 

Input shaft gear bearing axial clearance 

Output shaft radial run-out 

Output shaft journal 

Standard 

Limit 

Standard 

Limit 

A 

B 

C 

D 

- 

- 

- 

- 

- 

- 

- 

- 

Axial clearance between od-r synchronizer ring and 

gear 

Standard 

Limit 

Axial clearance between 4th synchronizer ring and 

gear 

Standard 

Limit 

Axial clearance between 3rd synchronizer ring and 

gear 

Standard 

Limit 

Axial clearance between 2nd synchronizer ring and 

gear 

Standard 

Limit 

Axial clearance between 1st synchronizer ring and 

gear 

Standard 

Limit 

Radial clearance between 1st synchronizer ring and 

gear 

Standard 

Limit 

1.0 ~ 1.6 mm 

0.8 mm 

1.0 ~ 1.6 mm 

0.8 mm 

1.0 ~ 1.6 mm 

0.8 mm 

1.0 ~ 1.6 mm 

0.8 mm 

1.0 ~ 1.6 mm 

0.8 mm 

1.0 ~ 2.0 mm 

0.8 mm 

Page 109

03-26 

SERVICE SPECIFICATIONS - TRANSMISSION 

Clearance between od-r synchronizer sleeve and 

gearshift fork 

Standard 

Limit 

Clearance between 3rd-4th synchronizer sleeve and 


Standard 

Limit 

Clearance between 1st-2nd synchronizer sleeve and 


Standard 

Limit 

- 

- 

- 

- 

- 

- 



N•m 

Drain plug 

Zomax 

Aisin 

35 ~ 45 

29.8 ~ 44.6 

Transmission operation mechanism × Body - 

Transmission lifting lug × Transmission 41 ~ 51 

Transmission assy × Engine 

Zomax 

Aisin 

Aisin 

42.2 ~ 53.9 

78 ~ 96 (M6 × 1.25) 

45 ~ 55 (M6 × 1.25) 

Odometer sensor × Transmission assy - 

Backup lamp switch × Transmission assy - 

Gear shift connecting rod × Transmission assy 22 ~ 28 

Gear select connecting rod × Transmission assy 22 ~ 28 

Filler cap 

Front bearing retainer × Transmission assy 

Zomax 

Aisin 

Zomax 

Aisin 

35 ~ 45 

29.8 ~ 44.6 

17 ~ 22 

- 

Output shaft rear bearing baffle × Transmission assy 

Zomax 

Aisin 

Reverse idler gear shaft plate × Transmission assy 

Zomax 

Aisin 

15 ~ 20 

- 

15 ~ 20 

- 

Lever housing assy × Transmission assy 14 ~ 26 

Extension housing sub-assy × Transmission assy 26 ~ 48 

Clutch housing × Transmission assy 16 ~ 21 

Page 110

SERVICE SPECIFICATIONS - CLUTCH 

03-27 

CLUTCH 

SERVICE DATA 

CLUTCH PEDAL 

03 

Height Standard 165 mm 

Free play Standard 5 ~ 10 mm 

03 

Push rod play Standard 26.4 mm 

CLUTCH 

Clutch disk thickness 

Width of diaphragm spring 

Height of diaphragm spring 

Clutch disk run-out 

Standard 

Limit 

Standard 

Limit 

Standard 

Limit 

Standard 

Limit 

- 

- 

- 

- 

- 

- 

- 

- 

Flywheel run-out 

Standard 

Limit - 



N•m 

Bleeding plug - 

Clutch pedal lock nut 17 ~ 21 

Clutch pedal pin nut - 

Clutch master cylinder nut 20 ~ 26 

Clutch master cylinder fluid tube connector 21 ~ 24 

Clutch slave cylinder fluid tube connector 21 ~ 24 

Clutch slave cylinder bolt - 

Clutch cover bolt 25 

Page 111

03-28 


SERVICE DATA 

VEHICLE 

SERVICE SPECIFICATIONS - STEERING COLUMN 

Steering radius Minimum 5.75 m 

Off track (30 m,40 Km/h) 

STEERING WHEEL 

Left 

Right 

< 2 m 

< 1 m 

Diameter - 

Free play ± 15° 

Turning force 

STEERING PROPELLER SHAFT 

Engine stopped 

Engine idling 

< 200 N 

< 45 N 

Clearance between cross spider and bearing 

≤ 0.15 mm 



N•m 

Steering wheel nut 40 ~ 50 

Steering column assy 29 ~ 35 

Main retard assy 29 ~ 35 

Steering propeller shaft assy × Steering column assy 29 ~ 35 

Steering propeller shaft assy × Steering box 29 ~ 35 

Steering box 108 ~ 125 

Page 112


SERVICE DATA 

VEHICLE 

SERVICE SPECIFICATIONS - POWER STEERING 

Steering radius Minimum 5.75 m 

03-29 

03 

Off track (30 m,40 Km/h) 

Left 

Right 

< 2 m 

< 1 m 

03 

STEERING WHEEL 

Diameter - 

Free play ± 15° 

Turning force 

STEERING PUMP BELT 

Engine stopped 

Engine idling 

< 200 N 

< 45 N 

Deflection 5.5 ~ 8.5 mm (98 N) 

STEERING FLUID 

Operating temperature - 40 ~ 120 ℃ 

Pressure 

Engine idling, valve closed 

Engine idling, valve open, steering wheel at lock position 

10±0.5 MPa 

≤ 10.5 Mpa 

Pressure difference 

Vavle open, engine running at 1000 and 3000 r/min - 

STEERING BOX 

Weight - 

Number of rack teeth - 

Number of pinion teeth - 

Module - 

Gear ratio - 

Rotating angle of rack shaft - 

Gross rotating turn of pinion - 

Pitch circle of pinion - 

Radial run-out of rack - 

Page 113

03-30 

SERVICE SPECIFICATIONS - POWER STEERING 



N•m 

Power steering line connector - 

Steering wheel nut 40 ~ 50 

Steering box 108 ~ 128 

Steering box × Steering propeller shaft assy 29 ~ 35 

Steering tie rod × Steering knuckle arm 84 ~ 100 

Page 114

SERVICE SPECIFICATIONS - HEATER AND AIR CONDITIONING 


SERVICE DATA 

AMOUNT OF COMPRESSOR OIL 

03-31 

03 

Replace compressor 

Replace all pipes 

Replace evaporator 

Compressor has 180 ml oil, no need added 

40 ~ 60 ml 

10 ml 

03 

Replace condenser 

Replace pipes 

Gas leakage 

Pressure of low side 

Pressure of high side 


No leakage 

Leakage 

No leakage 

Leakage 

No leakage 

Leakage 

ON 

OFF 

ON 

OFF 

5 ml 

10 ml 

No need added 

5 ml 

No need added 

80 ml 

0.15 ~ 0.25 MPa 

- 

1.37 ~ 2.37 MPa 

- 


N•m 

Φ9 aluminium tube, M16×1.5 thread 12 ~ 15 



Front evaporator and heater assy bolt - 

Page 115

03-32 

SEAT BELT 


SERVICE SPECIFICATIONS - SEAT BELT 


N•m 

Driver / assistant driver seat retractor × Body 50 ~ 55 

Driver / assistant driver seat belt lower anchor × Body 50 ~ 55 

Page 116

SERVICE SPECIFICATIONS - LIGHTING 

03-33 

LIGHTING 



N•m 

03 

Front combination lamp × Frame 2 ~ 3 

Rear combination lamp × Frame 2 ~ 3 

03 

Page 117

03-34 



SERVICE SPECIFICATIONS - WIPER AND WASHER 


N•m 

Front wiper assy nut - 

Rear wiper assy nut - 

Front wiper motor with link assy bolt 6 ~ 8 

Rear wiper motor with link assy bolt 6 ~ 8 

Page 118

SERVICE SPECIFICATIONS - SEAT 

03-35 

SEAT 



N•m 

03 

Driver seat assy bolt 45 ~ 55 

Assistant driver seat assy bolt 45 ~ 55 

03 

Passenger seat assy bolt 45 ~ 55 

Page 119

03-36 

SERVICE SPECIFICATIONS - DOORS 

DOORS 

SERVICE DATA 

FRONT DOOR 

Clearance 

Flatness 

SLIDING DOOR 

Clearance 

Flatness 

REAR HATCH 

Clearance 

Front 

Up 

Rear 

From up to down of A pillar 

Other 

Front 

Rear 

Up 

Down 

Left 

Right 

Down 

5.5 mm 

5 mm 

5 mm 

-2 ~ 0 mm 

0 mm 

5 mm 

5 mm 

5 mm 

6 mm 

0 mm 

5 mm 

5 mm 

10 mm 

Flatness - 



N•m 

Front door hinge bolt 28 ~ 32 

Front door lock catch screw 28 ~ 32 

Sliding door hinge bolt 28 ~ 32 

Sliding door concave limiting device bolt 28 ~ 32 

Rear hatch bolt 28 ~ 32 

Rear hatch concave limiting device bolt 28 ~ 32 

Page 120

SERVICE SPECIFICATIONS - EXTERIOR AND INTERIOR TRIM 

EXTERIOR AND INTERIOR TRIM 



N•m 

Sunvisor hook bolt 6 ~ 8 

Floor trim strip screw 6 ~ 8 

Front bumper assy bolt 6 ~ 8 

Rear bumper assy bolt 6 ~ 8 

Front wiper bolt 6 ~ 8 

03-37 

03 

03 

Page 121

03-38 

SERVICE SPECIFICATIONS - VEHICLE CONTROL SYSTEM 




N•m 

Ignition switch assy bolt - 

Page 122

DIAGNOSTICS 


PRECAUTION.............................................................................. 04-1 

LOCATION................................................................................... 04-4 

HOW TO DIAGNOSTICS ANALYSE........................................... 04-6 

DIAGNOSTIC HELP - INTERMITTENT FAULT .......................... 04-9 

BASIC SERVICE PROCEDURE................................................ 04-11 

TERMINALS OF ECM................................................................ 04-12 

DIAGNOSTIC SYSTEM............................................................. 04-17 

READING AND ERASING DIAGNOSTIC 

TROUBLE CODE (DTC)........................................................... 04-19 

CAPTURING DATA ................................................................... 04-21 

FAIL - SAFE CHART.................................................................. 04-22 

DATA STREAM LIST/ACTIVE TEST......................................... 04-24 

DIAGNOSTIC TROUBLE CODE CHART.................................. 04-28 

DTC DIAGNOSTIC .................................................................... 04-33 

PROBLEM SYMPTOMS TABLE................................................ 04-60 

ENGINE SYMPTOM DIAGNOSTIC........................................... 04-61 

ANTI - LOCK BRAKE SYSTEM....................................................... 04-98 

PRECAUTION............................................................................ 04-98 

LOCATION............................................................................... 04-100 

ABS MODULE CONNECTOR ................................................. 04-101 

DIAGNOSTIC TROUBLE CODE CHART................................ 04-102 

PROBLEM SYMPTOMS TABLE.............................................. 04-104 

PRE - CHECK.......................................................................... 04-105 

POWER SUPPY VOLTAGE HIGH OR LOW........................... 04-107 

SOLENOID VALVES AND VALVES RELAY FAILURE........... 04-108 

PUMP MOTOR FAILURE ........................................................ 04-112 

WHEEL SPEED SENSOR SIGNAL FAULT ............................ 04-118 

ABS CONTROL IS UNREASONABLE .................................... 04-122 

ABS SYSTEM IS INOPERATIVE............................................. 04-125 

SUPPLEMENTAL RESTRAINT SYSTEM ..................................... 04-129 

PRECAUTION.......................................................................... 04-129 

LOCATION............................................................................... 04-130 

RESTRAINT CONTROL MODULE (RCM) 

CONNECTOR PIN................................................................... 04-131 



8102 - POWER SUPPLY VOLTAGE LOW.............................. 04-135 

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE ......... 04-139 

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE.......... 04-139 

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND...... 04-141 

8211 - CO - PILOT SIDE AIRBAG FAULT - HIGH 

RESISTANCE .......................................................................... 04-145 

8212 - CO - PILOT SIDE AIRBAG FAULT - LOW 

RESISTANCE ......................................................................... 04-145 

8213 - CO - PILOT SIDE AIRBAG CIRCUIT 

SHORT TO GROUND.............................................................. 04-148 

8214 - CO - PILOT SIDE AIRBAG CIRCUIT 

SHORT TO BATTERY............................................................. 04-150 

SRS WARNING LIGHT IS INOPERATIVE .............................. 04-154 

04 

04 

04 

04 

Page 123

HEATER AND AIR CONDITIONING SYSTEM.............................. 04-156 

PRECAUTION.......................................................................... 04-156 

BASIC INSPECTION ............................................................... 04-157 

LOCATION............................................................................... 04-158 


A/C SYSTEM IS INOPERATIVE.............................................. 04-162 

FRONT BLOWER MOTOR IS INOPERATIVE ........................ 04-166 

REAR EVAPORATOR MOTORS ARE INOPERATIVE........... 04-172 

FRONT AIR FLOW IS INSUFFICIENT .................................... 04-178 

REAR AIR FLOW IS INSUFFICIENT....................................... 04-182 

NO COOLING FROM FRONT A/C SYSTEM .......................... 04-184 

NO COOLING FROM REAR A/C SYSTEM............................. 04-191 

REAR HEATER IS INOPERATIVE OR 

INSUFFICIENT HEATING ....................................................... 04-195 

LIGHTING SYSTEM ....................................................................... 04-202 

PRECAUTION.......................................................................... 04-202 


LOCATION............................................................................... 04-204 


LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ........ 04-212 

HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ......... 04-218 

HI - BEAM HEADLAMPS ARE INOPERATIVE 

(BOTH SIDES) ........................................................................ 04-220 

LO - BEAM AND HI - BEAM HEADLAMPS ARE 

INOPERATIVE (ONE SIDE) .................................................... 04-224 

ALL HEADLAMPS ARE INOPERATIVE .................................. 04-227 

FRONT FOG LAMPS ARE INOPERATIVE ............................. 04-233 

FRONT FOG LAMPS ARE ALWAYS ON ................................ 04-238 

REAR FOG LAMPS ARE INOPERATIVE................................ 04-241 

REAR FOG LAMPS ARE ALWAYS ON .................................. 04-246 

ALL FOG LAMPS ARE INOPERATIVE ................................... 04-249 

HAZARD WARNING LAMPS ARE INOPERATIVE (TURN SIGNAL 

LAMPS ARE NORMAL) ........................................................... 04-256 

TURN SIGNAL LAMPS ARE INOPERATIVE (HAZARD WARNING 


HAZARD WARNING AND TURN SIGNAL LAMPS ARE INOPERA- 

TIVE ......................................................................................... 04-264 

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)...... 04-272 

HAZARD WARNING LAMPS ARE ALWAYS ON .................... 04-275 

ALL STOP LAMPS ARE INOPERATIVE ................................. 04-277 

STOP LAMP IS INOPERATIVE (ONE SIDE) .......................... 04-282 

HIGH - MOUNTED STOP LAMP IS INOPERATIVE................ 04-284 

BACK - UP LAMP IS INOPERATIVE(ONE SIDE) ................... 04-286 

BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES) ....... 04-288 

IGNITION SWITCH ILLUMINATION IS INOPERATIVE .......... 04-293 

CENTRAL DOME LIGHT IS INOPERATIVE ........................... 04-296 

AIR PURIFIER LAMP IS INOPERATIVE ................................. 04-301 

STEP LAMP ARE INOPERATIVE ........................................... 04-304 

TRUNK LAMP IS INOPERATIVE ............................................ 04-307 

FRONT DOME LIGHT IS INOPERATIVE................................ 04-310 

ALL INTERIOR ILLUMINATION LAMPS ARE 

INOPERATIVE ........................................................................ 04-314 

INSTRUMENT CLUSTER ILLUMINATION IS 

NOT INOPERATIVE ................................................................ 04-319 

DIAGNOSIS SWITCH ILLUMINATION IS 

Page 124


CIGARETTE LIGHTER ILLUMINATION IS 

NOT INOPERATIVE ............................................................... 04-324 

A/C CONTROL PANEL ILLUMINATION IS 


RADIO ILLUMINATION IS NOT INOPERATIVE ..................... 04-328 

REAR BLOWER FORWARD SWITCH ILLUMINATION IS 


DOME LIGHT SWITCH ILLUMINATION IS 


OUTSIDE MIRROR DEFROSTER SWITCH ILLUMINATION IS 


HEADLAMP DIMMER SWITCH ILLUMINATION IS 


REAR WINDOW DEFROSTER SWITCH ILLUMINATION IS 


INSTRUMENT DIMMER SWITCH ILLUMINATION IS 


HAZARD WARNING SWITCH ILLUMINATION IS 


WIDTH LAMPS IS NOT INOPERATIVE.................................. 04-344 

TAIL LAMPS ARE INOPERATIVE........................................... 04-347 

LICENSE LAMP IS INOPERATIVE ......................................... 04-350 

WIDTH LAMPS TAIL LAMPS AND LICENSE 

LAMP ARE INOPERATIVE..................................................... 04-352 

WIPER AND WASHER .................................................................. 04-356 

PRECAUTION.......................................................................... 04-356 

LOCATION............................................................................... 04-357 



WIPERS ARE INOPERATIVE - WINDSHIELD........................ 04-361 

WIPERS ARE INOPERATIVE AT 

LOW SPEED - WINDSHIELD.................................................. 04-367 

WIPERS ARE INOPERATIVE AT 

HIGH SPEED - WINDSHIELD ................................................ 04-369 

WIPERS ARE INOPERATIVE IN INTERMITTENT MODE - WIND- 

SHIELD .................................................................................... 04-371 

WASHER PUMP IS INOPERATIVE - WINDSHIELD............... 04-374 

WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE DOES 

NOT RETRACT........................................................................ 04-378 

WIPER IS INOPERATIVE - REAR WINDOW.......................... 04-381 

WASHER PUMP IS INOPERATIVE - REAR WINDOW .......... 04-387 

AUDIO SYSTEM............................................................................. 04-392 

PRECAUTION.......................................................................... 04-392 

LOCATION............................................................................... 04-393 



RADIO DOES NOT WORK...................................................... 04-396 

RADIO RECEPTION IS POOR................................................ 04-400 

POOR SOUND QUALITY....................................................... 04-401 

SPEAKER DOES NOT WORK ................................................ 04-402 

AUXILIARY POWER...................................................................... 04-406 

LOCATION............................................................................... 04-406 


CIGARETTE LIGHTER IS INOPERATIVE .............................. 04-408 

04 

04 

04 

04 

Page 125

INSPECTION PROCEDURE ................................................... 04-409 

12V POWER SUPPLY OUTPUT SOCKET IS 

INOPERATIVE ......................................................................... 04-411 

HORN SYSTEM.............................................................................. 04-415 

LOCATION............................................................................... 04-415 


HORN IS INOPERATIVE ......................................................... 04-417 

INSPECTION PROCEDURE ................................................... 04-418 

HORN IS ALWAYS ON............................................................ 04-422 

REVERSE RADAR SYSTEM ......................................................... 04-424 

PRECAUTION.......................................................................... 04-424 

LOCATION............................................................................... 04-425 

SYSTEM DESCRIPTION......................................................... 04-426 


REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL ........ 04-429 

REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE SHIFT LE- 

VER IS OUT OF REVERSE POSITION .................................. 04-434 

REVERSE RADAR SYSTEM IS INOPERATIVE WITHIN SPECIFIED 

DISTANCE (BACK - UP LAMP IS NORMAL) ......................... 04-436 

REVERSE RADAR SYSTEM IS OPERATIVE BUT THERE IS NO 

OBSTACLE BEHIND VEHICLE ............................................... 04-439 

BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY WITH- 

IN SPECIFIED DISTANCE (DISPLAYER IS NORMAL) .......... 04-442 

DISPLAYER IS INOPERATIVE WITHIN SPECIFIED DISTANCE 

(BUZZER IS NORMAL)............................................................ 04-445 

POWER WINDOWS ....................................................................... 04-448 

PRECAUTION.......................................................................... 04-448 

LOCATION............................................................................... 04-449 

DOOR CONTROL SWITCH PIN.............................................. 04-450 

WINDOW CONTROL SWITCH RH PIN .................................. 04-451 

CENTRAL LOCKING CONTROLLER ASSY A PIN................. 04-452 

BASIC INSPECTION ............................................................. 04-453 


ALL POWER WINDOWS ARE INOPERATIVE ....................... 04-456 

FRONT POWER WINDOW LH IS INOPERATIVE .................. 04-461 

FRONT POWER WINDOW LH DOES NOT OPEN................. 04-464 

FRONT POWER WINDOW LH DOES NOT CLOSE............... 04-466 

FRONT POWER WINDOW RH IS INOPERATIVE (USE DOOR CON- 

TROL SWITCH) ....................................................................... 04-468 

FRONT POWER WINDOW RH IS INOPERATIVE (USE WINDOW 

CONTROL SWITCH RH) ......................................................... 04-470 

OUTSIDE MIRROR ........................................................................ 04-473 

LOCATION............................................................................... 04-473 

TERMINALS OF OUTSIDE MIRROR SWITCH....................... 04-474 



MIRRORS ARE INOPERATIVE (BOTH SIDES) ..................... 04-477 

A SINGLE MIRROR IS INOPERATIVE ................................... 04-480 

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE ......... 04-483 

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE...... 04-485 

DEFROSTER SYSTEM .................................................................. 04-487 

LOCATION............................................................................... 04-487 




Page 126

REAR WINDOW DEFROSTER IS INOPERATIVE................. 04-492 

OUTSIDE MIRROR DEFROSTER IS INOPERATIVE............ 04-497 

INSTRUMENT CLUSTER .............................................................. 04-502 

PRECAUTION.......................................................................... 04-502 

LOCATION............................................................................... 04-503 

INSTRUMENT CLUSTER INFORMATION.............................. 04-504 

TERMINALS OF INSTRUMENT CLUSTER ............................ 04-507 



MALFUNCTION IN SPEEDOMETER...................................... 04-513 

MALFUNCTION IN TACHOMETER ........................................ 04-515 

MALFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT 

NEVER OR ALWAYS ON........................................................ 04-517 

MALFUCTION IN ENGINE COOLANT 

TEMPERATURE GAUGE........................................................ 04-520 

ENGINE OIL PRESSURE WARNING LIGHT 

NEVER / ALWAYS ON ........................................................... 04-523 

SEAT BELT WARNING LIGHT 


PARKING BRAKE INDICATOR LIGHT 


POWER DOOR LOCKS................................................................. 04-533 

PRECAUTION.......................................................................... 04-533 

LOCATION............................................................................... 04-534 

CENTRAL LOCKING CONTROLLER ASSY A........................ 04-535 

CENTRAL LOCKING CONTROLLER ASSY B........................ 04-536 



THE FUNCTION OF POWER DOOR LOCKS IS 

INOPERATIVE (USING THE KEY).......................................... 04-539 

ONE DOOR IS INOPERATIVE (USING THE KEY)................. 04-543 

DOOR DOES NOT OPEN / CLOSE (USING 

THE REMOTE KEY) ................................................................ 04-545 

SLIDING ROOF SYSTEM .............................................................. 04-548 

LOCATION............................................................................... 04-548 


TERMINALS OF MAIN COMPONENTS.................................. 04-550 



SLIDING ROOF SYSTEM IS INOPERATIVE.......................... 04-553 

04 

04 

04 

04 

Page 127

Page 128


DIAGNOSTICS 

PRECAUTION 

1. POWER OFF. 

DIAGNOSTICS - ENGINE CONTROL SYSTEM 

04-1 

• The battery negative cable must be disconnected first before removing or installing any electric 

appliance and when tools or facilities will touch the exposed terminals. It should be connected 

eventually. This will prevent person injured and vehicle damaged. 

• The ignition switch must be OFF without any special descriptions. 

WARNING 

The ignition and illuminatioin switches must be OFF before disconnecting or connecting the battery 

negative cable (the semiconductor maybe damaged without doing that). 

CAUTION 

Do not leave the key in the vehicle in case the doores are locked before disconnecting the battery negative 

cable for the vehicle equipped with remote control central lock. 

2. RESET THE ODOMETER AND CLOCK IF DISCONNECTING THE COMBINATION INSTRUMENT 

BATTERY NEGATIVE CABLE. 

04 

04 

CAUTION 

The total course will not be reset. 

3. THE SAVING DATA SETTING WILL LOST IF DISCONNECTING THE BATTERY NEGATIVE CABLE. 

CAUTION 

After connecting the battery negative cable, the audio system shoud be reset. 

4. EXPRESSIONS OF IGNITION SWITCH 

Switch Type Ignition Switch (position) Ignition Switch (condition) 

Ignition switch off LOCK Off 

Expression 

Ignition switch on (IG) ON On (IG) 

Ignition switch on (ACC) ACC On (ACC) 

Engine start START Start 

5. PRECAUTIONS FOR OVERHAULING THE ENGINE CONTROL SYSTEM FAILURE. 

CAUTION 

(a) Do not disconnect power circuit while engine is running at high speed in case the instantaneous overvoltage 

damage the ECM and sensors. 

(b) The ECM should be disconnected when welding on the vehicle body. It is special attention that performing 

the repair work beside the ECM or sensors. 

(c) The system will resume its normal state temporarily or competely by removing and reinstalling the suspicious 

faulty components when the connector terminals or the installing state of the components go 

out of order. 

(d) The high impedance type multimeter should be used to the test except the especial description of the 

procedure in place of the traditional analogue types multimeter. 

(e) Don’t check any electric appliance connecting the ECM with a test light. 

(f) Never connect the negative and positive battery cables wrong. The battery negative cable must be 

grounded. 

Page 129

04-2 


(g) ECM and sensors must be kept from moisture. No permission damaging the seal device of ECM and 

sensors and washing them more. 

(h) Prevent human body static electricity from damaging ECM: The operator body must be grounded when 

operator checks ECM or replace chips. 

(i) In order to identifying the faulty position, we must check the vehicle condition while vehicle goes out of 

order. For example, we check the faults through the DTC. We record these faults states before 

disconnecting every connector or removing and installing components. 

(j) We must remove and install ECM, actuators and independent sensors when the ignition switch is OFF 

unless there is additional specification in the checking procedure. 

(k) If the removed and installed ECM, actuators and sensors are to be reinstalled, the system should be 

checked after completing installation. Using the special diagnosis tool to check DTC. 

(l) Check the ECM connector terminals with a multimeter. 

• Connect the small probing pin to the probe of a multimeter. 

• Check voltage value of terminals referring to the inspection sheet by back probing ECM connectors 

terminals. 

(m) When diagnosis, the ignition switch turns “ON” and the connectors are disconnected. DTC of the other 

system will be set. After diagnosis, confirm DTC in all systems.Turn the ignition switch “LOCK” when 

the connectors are connected and disconnected. 

(n) The test probe must not be probed in wire harness. This will reduce the waterproofness. And it also 

cause corrossion. Using the test wire, wire connector, measure wire harness and so on. 

(o) Check the common connectors when they are in connection status by probing terminals in the wire 

harness. If the connector is too small to check, do not force inserting. 

(p) If check the common connectors when they are not in connection status (check male connectors): 

• Do not short terminals circuit by using a probe. This will damage the interior circuit in ECM. 

• The system to be checked and other system will store DTC when they aren’t in connecting status. 

(q) If check the common connectors when they are not in connection status (check female connectors): 

• Use the special tools to check wire harness. 


(r) We shall have a short harness or connectors without taking cautions by wrong insertion. This will 

damage wire harness, sensor, ECM and other components So we must carefully handle when 

checking. 

(s) Do not check with the list order. 

• If the check results are different from the standard value, then check related sensors, actuators and 

wire harness. Repair or replace if necessary. 

• Check with the voltage meter again after repairing or replacing. Confirm if the faults have been 

eliminated. 

(t) Check resistance and continuity between terminals of ECM with multimeter. 

• Ignition switch: OFF 

• Disconnect ECM harness connector. 

(u) Ground inspection. 

• Ground connections are very important to the proper operation of electrical and electronic circuits. 

Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion 

(rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit 

works. 

• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can 

drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the 

circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. 

• When inspecting a ground connection follow these rules: 

Page 130


04-3 

04 

04 

1 Remove Bolt (Screw) 

2 

Inspect Mating Surface For Tarnish, 

Dirt, Rust, Etc. Clear As Required To 

Assure Good Contact. 

3 Reinstall Bolt (Screw) Securely 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

Remove the ground bolt or screw. 

Inspect all mating surfaces for tarnish, dirt, rust, etc. 

Clean as required to assure good contact. 

Reinstall bolt or screw securely. 

Inspect for “add - on” accessories which may be interfering with the ground circuit. 

If several wires are crimped into one ground eyelet terminal, check for improper crimps. Make 

sure all of the wires are clean, securely fastened and providing a good ground path. If multiple 

wires are cased in one eyelet, make sure no ground wires have excess wire insulation. 

Page 131

04-4 


LOCATION 

1 Injector 

2 Throttle Body 

3 Spark Plug 

4 Idle Air Control Motor 

5 

Engine Coolant Temperature (ECT) 

Sensor 

6 Knock Sensor 

7 Crankshaft Position (CKP) Sensor 

9 

Manifold Absolute Pressure/Intake Air 

Temperature (MAP/IAT) Sensor 

10 Ignition Control Module 

11 Fuel Pressure Regulator 

12 PCV Valve 

13 Inlet Fuel (From Fuel Pump) 

14 

Outlet Fuel (Return Back To Fuel 

Tank) 

8 Vehicle Speed Sensor 

Page 132


04-5 

04 

04 

1 Diagnosis Link Connector (DLC) 

2 Brake Lamp Switch 

3 Instrument Cluster 

4 Accelerator Pedal 

5 Muti - media 

Page 133

04-6 


HOW TO DIAGNOSTICS ANALYSE 

NOTE 

Use diagnostic scan tool to diagnose vehicle. 

1. VEHICLE INTO REPAIR SHOP 


2. COLLECT AND ANALYSE CUSTOMER’S SYMPTOM 


3. CONNECT THE DIAGNOSTIC SCANNER TO DLC3 


4. CHECK DTC AND DATA FREEZE - FRAME DATA 


5. ERASE DTC 


6. VISUAL CHECK 


7. CONFIRM FAULT SYMPTOM 

Check result (if engine can not start,check following first) 

Result 

Proceed To 

Fault present Step 9 

Normal Step 8 

8. SIMULATE FAULT SYMPTOM 


9. CHECK IF DTC PRESENT 

Check result 

Result 

DTC present 

Proceed To 

Next step 

10. REFER TO DTC TABLE 

YES > Go to step 13. 

Normal Step 11 

Page 134


04-7 

11. BASIC CHECK 

Check result 

Result 

Proceed To 

04 

Fault can not be confirmed 

Next step 

Fault can be confirmed Step 16 

12. REFER TO SYMPTOM TABLE 

Check result 

04 

Result 

Fault can be confirmed circuit 

Proceed To 

Next step 

Fault can be confirmed part Step 15 

13. CHECK ECM POWER SUPPLY CIRCUIT 


14. CHECK ELECTRIC CIRCUIT 

Check result 

Result 


Proceed To 

Next step 


15. CHECK INTERMITTENT FAULT 


16. CHECK PARTS 


17. CONFIRM FAULT 


18. ADJUST OR REPAIR 


19. PERFORM CONFIRMATION TEST 

YES > END. 

Page 135

04-8 


THE MAIN POINTS OF REPAIRING BURNED FUSE OUT 

CAUTION 

DTC cause by burned fuse. 

(a) Remove the burned fuse. Check the resistance between 

the load side and ground where the fuse burned. Turn off 

all the switch that connecting to the fuse. If the resistance 

is almost zero, the switch and the load components 

circuit must be shorted somewhere. If the resistance is 

not zero, there is no circuit for short. But the temporaly 

shorted circuit also will cause the fuse burning. 

(b) The shortage caused by following: 

• Clipped harness 

• Damaged harness 

• Water seep into connection 

• Operation 

1 Battery 

2 Fuse 

3 Load switch 

4 Burned fuse 

5 Short position 

Page 136


04-9 

DIAGNOSTIC HELP - INTERMITTENT FAULT 

If an intermittent fault exists, perform diagnosis as follow: 

CAUTION 

• Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or 

circuit function returns to normal without intervention). It is important to realize that the 

symptoms described in the customer's complaint often do not recur on (1st trip) DTC visits. 

Realize also that the most frequent cause of intermittent incidents occurrences is poor 

electrical connections. Because of this, the conditions under which the incident occurred may 

not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may 

not indicate the specific malfunctioning area. 

• In this case, the maintenance staff must find out the situation in detail from the customer, ask 

the car owner for the details of driving conditions, weather conditions, frequency of occurrence 

and symptom of failure, take analysis and simulate the same or similar conditions and 

environment, then, determine if the symptom of failure is caused by vibration, temperature or 

other factors. No matter how experienced the maintenance staff are, how skilled their technique 

is, if analyzing the failure without checking, they would certainly neglect some important factors 

during repairing which causes wrong speculation and the repair work will take an indirect route 

or can’t go forward. The following checking will help to find out this kind of failure. 

04 

04 

1. VIBRATION METHOD. 

(a) Connector: Shake the connector lightly in vertical or 

horizontal directions, check if the wiring harness 

connector connecting the connector and corresponding 

parts is loose, the terminal is dirty, rusty, worn or bended 

and if the connection is loose because of the terminal 

extension. 

(b) Harness: Shake the harness lightly in vertical or 

horizontal directions, thoroughly check the harness 

breakaway condition in the connector connecting 

vibration section and engine/cab instruments. 

(c) Relay, part and sensor: Pat the sensor, relay and part 

considered as the failure cause lightly with hands, check 

them for failure, don't hit the relay with force, otherwise 

the relay may be open. 

Page 137

04-10 


2. HEATING METHOD. 

(a) If one doubtful region is considered to cause a failure, heat the part which is the most possible cause of 

failure with an electric blower or the like to check if the failure occurs. 

CAUTION 

Don’t heat to over 60℃ (the heating temperature should be in the limit of touching the part with hands); 

don’t heat the control module. 

3. SPRAYING METHOD. 

(a) If the failure is considered to occur in rainy day or wet weather, spray water to the vehicle to check if the 

failure occurs. 

CAUTION 

• Don’t spray water to the engine directly to cool the engine, sprinkle water on the front face of 

radiator to change the temperature and humidity indirectly. 

• Don’t spray water on electronic parts directly. 

• Please take extra care to sprinkle water on vehicle leaking water. 

4. ELECTRIC APPLIANCE CONNECTED FULLY METHOD. 

(a) If the failure is possible to be caused by electric overload, connect all electrical loads, including the 

heater blower, the headlamps and the rear - window defroster, to check if the failure occurs. The trouble 

location or failure part must be found out while the symptom is confirmed during the failure symptom 

simulation test. To do this, narrow the range of circuit which is possible to failure based on the symptom 

of failure before starting the test and the pre - connection of connectors, then carry out the symptom 

simulation test and judge if the circuit tested is normal. When a puzzling failure occurs, make full use of 

troubleshooting and diagnostic code list for fault analysis and diagnosis to narrow the failure range and 

find out the trouble location quickly. This method is very practical and effective. 

5. DATA FLOW CAPTURE WITH DIAGNOSTIC SCANNER. 

(a) Use the function of data flow capture on the diagnostic scanner. When seeing the data flow on the 

diagnostic scanner, make the rated data status to simulate the fault conditions based on the freeze - 

frame on the diagnostic scanner. 

6. OSCILLOSCOPE METHOD. 

(a) Using the oscilloscope, capture waveform can be more helpful to find intermittent malfunction. 

7. OTHER METHODS. 

(a) Before replacing ECM of other electronic control modules in part replacing method, take full diagnosis 

for other external causes; ECM or other electronic control modules are expensive products with high 

reliability. 

CAUTION 

When replacing and testing possible damaged ECM or control modules, install the possible damaged 

ECM or control modules on a failure - free vehicle for testing; Don’t install new control modules on a 

failed vehicle for testing to avoid damaging the control modules. 

Page 138


04-11 

BASIC SERVICE PROCEDURE 

1. CHECK BATTERY VOLTAGE 

CAUTION 

Check when engine stops or ignition switch is OFF. 

Check result 

04 

Result 

More than 11V 

Less than 11V 

Proceed To 

Next step 

Charge or change battery 

04 

2. CHECK IF THE ENGINE STARTS 

Is the check result normal? 


NO > Go to fault symptom chart. 

3. CHECK FILTER 



NO > Replace or clean filter. 

4. CHECK IDLE SPEED 




5. CHECK FUEL PRESSURE 



NO > Eliminate fuel pressure fault, and go to next step. 

6. CHECK IGNITION 


YES > Go to fault symptom chart. 

NO > Eliminate ignition system fault. 

Page 139

04-12 


TERMINALS OF ECM 

ECM TERMINAL DEFINITION 

Terminal No. Terminal Description Color Terminal No. Terminal Description Color 

1 Ignition control L 43 - - 

2 Ground B 44 Main relay control G - W 

3 Ground B 45 - - 

4 Ignition control G 46 - - 

5 - - 47 

6 Injector 1 L - W 48 

Upstream oxygen 

signal + 

Downstream oxygen 

signal + 

7 Injector 3 L - P 49 ECT sensor + W - B 

8 Injector 2 L - V 50 - - 

9 Pump relay control G 51 Vehicle speed input W - G 

10 A/C low voltage output L 52 ECT sensor - W - R 

11 

Crankshaft position 

sensor - 

P 53 - - 

12 SVS R - B 54 Air pressure MAP L - Y 

13 - - 55 - - 

14 - - 56 - - 

15 - - 57 - - 

16 - - 58 Knock sensor power O - V 

17 High fan control W - B 59 Accelerator sensor + 

18 Vehicle speed R - W 60 - - 

W 

O 

Page 140


04-13 


19 MIL G - B 61 - - 

20 Idle control high A G - Br 62 - - 

21 Idle control low A G - Y 63 - - 

22 - - 64 EVAP control W - Y 

23 

24 

Heated downstream 

oxygen sensor - 

Heated upstream 


Y - H 65 Low fan control Y 

L - R 66 

Air temperature/ 

pressure power 

25 Injector 4 L - O 67 ECU continued power W - L 

26 A/C MP IN R - W 68 ECU IG power B - G 

27 Throttle position signal V - G 69 - - 

28 - - 70 Sensor power SB 

29 - - 71 Air temperature L - W 

30 


sensor + 

31 - - 73 

O 72 - - 

Upstream/downstream 

oxygen sensor signal - 

32 - - 74 Sensor ground Br - R 

33 - - 75 ECU K signal R - L 

34 - - 76 


pressure signal - 

35 - - 77 - - 

36 - - 78 - - 

SB 

Br - R 

37 Knock signal W - B 79 A/C request Y - B 

38 - - 80 - - 

39 - - 81 - - 

40 - - 

41 Idle control high B Y - P 

42 Idle control low B Br - Y 

04 

04 

13. 

Page 141

04-14 


CHECK ECM TERMINAL WITH MULTIMETER 

CAUTION 

The normal standard voltage of per terminal as follow “normal condition”. The table also points out the 

check condition 

Terminal No. Terminal Description Detection Condition Specified Condition 

6 No.1 Injector 




20 Idle air control motor loop A 

41 Idle air control motor loop B 

Idle: depress accelerator suddenly 

Engine: warm condition, start 

engine 

Voltage: 11 ~ 14 V 


9 Pump relay 

64 EVAP solenoid 

Ignition switch: ON 

Engine: idle 


Engine: warm condition, 3000 RPM 

Battery voltage 

0 ~ 3 V 


0 ~ 3 V 

1 Ignition control: (1 - 4) Engine: 3000 RPM 0.3 ~ 3.0 V 


68 Continuity power supply 

Ignition switch: 

OFF 


79 A/C request signal Engine running, depress A/C switch - 

26 A/C feed back signal Engine running, depress A/C switch - 

19 MIL Ignition switch: OFF → ON 0 ~ 3 V 

44 Main relay 

Ignition switch: OFF 



0 ~ 3 V 

24 

Heated upstream oxygen 

sensor 

Engine: warm condition, idle 

Engine: 5000 RPM 

0 ~ 3 V 


23 

Heated downstream oxyge 

sensor 



0 ~ 3 V 


IAT: 0 ℃ 

3.2 ~ 3.8 V 

66 IAT sensor Ignition switch: ON 

IAT: 20 ℃ 

IAT: 40 ℃ 

IAT: 80 ℃ 

2.3 ~ 2.9 V 

1.5 ~ 2.1 V 

0.4 ~ 1.0 V 

Page 142


04-15 


47 Upstream oxygen sensor Engine: warm condition, 2000 RPM 0.1 ~ 0.9 V 

48 Downstream oxygen sensor Engine: warm condition, 2000 RPM About 100 mV 

04 

49 ECT sensor Ignition switch: ON 

ECT: 20 ℃ 

ECT: 40 ℃ 

2.3 ~ 2.9 V 

1.3 ~ 1.9 V 

70 TPS Ignition switch: ON 

ECT: 80 ℃ 0.3 ~ 0.9 V 

TPS: idle 0.3 ~ 1.0 V (0 %) 

Open widely 4.5 ~ 5.5 V (100 %) 

04 

51 VSS 

30 CKP sensor 


Move forward slowly 

Start motor 

Idle 

0 ~ 5 V (repeat) 

0.4 ~ 4.0 V 

1.5 ~ 2.5 V 

3 Ground - 0 V 

Page 143

04-16 


CHECK ECM HARNESS - SIDE TERMINAL WITH A MULTIMETER 

Standard normal resistance and continuity as follow: 

No. Item Normal Condition (20 ℃ ) 

1 No.1 injector 



13 ~ 16 Ω 


5 Idle air control motor loop A, B terminal 

6 Idle air control motor loop C, D terminal 

28 ~ 33 Ω 

7 EGR solenoid valve 36 ~ 44 Ω 

8 EVAP solenoid valve 36 ~ 44 Ω 

9 ECM ground Continuity 

10 Heated oxygen sensor About 12 Ω 

5.3 ~ 6.7 Ω 

11 IAT sensor 

2.3 ~ 3.0 Ω 

1.0 ~ 1.5 Ω 

0.30 ~ 0.42 Ω 

5.1 ~ 6.5 Ω 

12 ECT sensor 

2.1 ~ 2.7 Ω 

0.9 ~ 1.3 Ω 

0.26 ~ 0.36 Ω 

Page 144


04-17 

DIAGNOSTIC SYSTEM 

1. The failure of engine electric control system is 

divided into 2 classes: 

(a) 

(b) 

(c) 

First is lighting MIL lamp (1); When the instrument MIL 

lamp lights, based on relevant requirements of national 

rules, it needs to be treated immediately, otherwise the 

system will limit the speed of the engine so as to affect 

the normal operating of vehicle. 

The other is lighting SVS lamp (2), indicating that the 

system fails and needs to be repaired in time. 

The failures of both classes should be checked with 

diagnostic scanner or special equipment with corresponding 

functions. 

04 

04 

NOTE 

The following matters should be noted during the engine running and service processes. 

2. The lighting of SVS lamp and MIL lamp is controlled by ECM; The special lighting of SVS lamp 

and MIL lamp after and before starting are described below: 

(a) For system without failure, the ignition switch is turned ON, the MIL lamp lights on, SVS lamp lights and 

then goes out (system self - checking). The SVS lamp and MIL lamp are off after engine starting and 

stalling. 

(b) For system with failure, the ignition switch is turned ON, the MIL lamp lights on, the SVS lamp is off and 

then lights on after self - checked; After engine starting, if the SVS lamp in failure class is defined as 

lighting on mode, the SVS lamp will light on after the requirements for SVS lamp lighting are met; if the 

MIL lamp in failure class is defined as lighting on mode, the SVS lamp will light on after the 

requirements for MIL lamp lighting are met; After engine stalling, the ignition switch is turned OFF and 

goes out after process (90s for the longest). 

3. If an engine failure that may involve the fuel injection system - electronic controlled is to be 

diagnosed and cleared, first determine if the failure is related with the fuel injection system - 

electronic controlled. If the engine fails but the malfunction indicator lamp doesn't light, the failure 

is unrelated to the electronic control system generally. 

(a) 

The diagnostic trouble codes record and data related 

with sensors and actuators in ECM can be read by 

KT600 diagnostic scanner. Additional, the actuator can 

be positive driven by the scan tool under specified 

conditions. 

Page 145

04-18 


(b) 

(c) 

(d) 

DLC - data link connector. 

ECM communicate with DLC. 

Terminals in DLC arrange according to standard. 

Terminal No. Name Check Result 

4 Ground Less than 1 Ω 


6 Diagnostic signal 

Pulse signal (When 

commnicate) 

7 

Diagnostic 

communication K 


commnicate) 

16 Battery positive 9 ~ 14 V 

ENGINE CONTROL SYSTEM SELF - DIAGNOTIC ITEM 

NOTE 

• Connect the diagnostic scanner cable to DLC. Turn 

the ignition switch ON. Try to open it. If displayed 

error communication on screen, then the diagnostic 

scanner faults . 

• If the diagnostic scanner communicates with other 

vehicle normally, then check the DLC on the original 

vehicle. 

No. 

Check Item 

1 Injector 

2 Main Relay 

3 Fuel Pump 

4 Ignition Coil 

5 Oxygen Sensor 

6 EVAP Solenoid 



9 Poor Accelerator Sensor 

10 CKP Sensor 

11 Throttle Position Sensor 

12 ECT Sensor 

13 MAP/IAT Sensor 

Page 146


04-19 

READING AND ERASING DIAGNOSTIC TROUBLE CODE (DTC) 

NOTE 

The troubles are tested and determined by the engine control system and stored in the Engine Control 

Module (ECM); the system troubles can be current or history. 

(a) 

Current troubles: Exist in ECM currently. For example: The circuit of Engine Coolant Temperature 

(ECT) sensor is open. The current troubles must be repaired. Otherwise, they can’t be erased from 

memory. 

(b) History troubles: Have two storage types. 

• The trouble has been repaired and actual trouble has disappeared, but the memory hasn’t been erased 

from ECM. 

• The trouble occurred once and didn’t exist, but it is possible to occur again. For example: Poor contact 

of conducting wire. As the stored troubles are not current ones, it’s unnecessary to repair them before 

erased from the memory, or it can be processed referring to the trouble - shooting methods for 

intermittent malfunction. 

CAUTION 

• If the battery voltage is too low and the trouble code can’t be output normally from ECM, the 

battery voltage must be tested before checking and the voltage should not be less than 11 V. 

• When the battery or ECM connectors are disconnected, the trouble code stored in ECM will be 

erased. 

• Before connecting or disconnecting KT600 scan tool, be sure to confirm the ignition switch is in 

OFF (LOCK) position. 

CAUTION 

• Using the KT600 collective intelligence scan tool, read DTC. 

• Using the KT600 scan tool, perform the reading DTC procedure below: 

04 

04 

(a) Check and confirm the following conditions: 

• The throttle is closed. 

• Turn A/C switch OFF. 

• Shift transmission in neutral. 

(b) Turn the ignition switch OFF. 

(c) Connect the KT600 scan tool to the Data Link Connector 

(DLC) - use the most current software available. 

(d) Turn the ignition switch ON. 

(e) Select the item, read dtc. 

(f) Check DTC and data stream. After recording, delete it (If 

DTC cannot be deleted, then perform the diagnosis 

procedure refering to “Diagnostics trouble code check”. 

Repair faults ). 

(g) Start engine and warm it to normal operating temperature. 

(h) Under one of the condition, run engine to MIL ON: 

• Simulate DTC setting condition. 

• Simulate the customer’s description. 

• Simulate the scan tool freeze data. 

(i) Use the scan tool to read the DTC in ECM. 

Page 147

04-20 


(j) 

If there are DTCs, but the data stream is normal or the 

function is good, then refer to the diagnostics help. If there 

are DTCs, but the stream is abnormal or the function is not 

good, then perform diagnosis procedure refering to 

“Diagnostics trouble code chart”. 

NOTE 

• Use the scan tool to delete DTCs. As soon as DTC is detected, ECM will record the vehicle and 

driving conditions as the type of freeze stream. When eliminating faults, the catching function 

will help to confirm the condition of the fault, such as warm condition, stop condition and lean 

or rich A/F ration and other data. 

• DTC setting condition: 

(a) Engine speed 

(b) VSS 

(c) ECT sensor 

(d) MAP sensor 

(e) Barometric sensor 

(f) IAT sensor 

(g) TPS 

(h) EVAP 

(i) Fuel pressure adjustment 

(j) A/C switch 

THE WAY OF CLEAR DTC 

1. Using the scan tool, clear DTC: 

(a) Turn the ignition switch OFF. 

(b) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software 

available. 

(c) Turn the ignition switch ON. 

(d) Select the item, clear DTC. 

Page 148


04-21 

CAPTURING DATA 

CAUTION 

Once DTC is captured and stored, ECM records the vehicle and driving conditions information as a 

form of rated data. During troubleshooting, the rated data can help determine if the vehicle was 

running or parked, and data of other sensors and actuators has been recorded when the trouble 

occurred. 

CAUTION 

If the DTC is detected but the trouble can’t reappear, confirm the freeze - frame rated data. ECM records 

the engine condition in form of freeze - frame data at regular intervals. The diagnostic scanner can be 

used to read several sets of freeze - frame data respectively. KT600 diagnostic scanner provides 

powerful random data flow help function. Select read data flow function menu in engine system, enter 

the data flow testing result display interface, click “?Help” button to eject the following windows: 

• Driving Record Playback 

• Calculator 

• Data Range Reference 

• Data Capture 

• Data Comparisons 

• Data Flow Settings 

• Data/Waveform Display 

• Driving Recorder Menu 

04 

04 

CAUTION 

The data can be used to simulate the vehicle conditions as the failure occurs. It also can help 

determine the cause of trouble and judge if it’s temporary fault. When the engine is running with 

trouble, select the menu items, read data flow (Click “?Help”)\Data Capture\Click Record\(Click 

“?Help”)\Data Comparisons. 

Page 149

04-22 


FAIL - SAFE CHART 

NOTE 

When the DTC listed below is detected, the ECM enters fail - safe mode and the MIL lights up. 

Number Item Control Contents Period Of Fault 

1 Injector 

2 Relay 

3 Fuel pump 

4 Ignition coil 

5 Oxygen sensor 

6 EVAP solenoid valve 

7 KS 

8 VSS 

9 IAT sensor 

• The MIL light will turn on. 

• Unstable idle. 

• Lack of engine power. 

• Poor acceleration. 

• Engine will not start. 

• Plugged injector. 


• System is out of work. 

• Can not start engine. 


• Noisy fuel pump operation. 






• Poor fuel economy. 

• Excessive exhaust emissions. 

• Weak spark. 




• Sluggish acceleration. 

• Poor driving capability. 


• The engine base fuel closed - loop control self - learning will be shut 

off. 

• The engine idle air control self - learning will be shut off. 

• Unstable idle or high idle. 


• The engine produces an engine knock. 

• Overheated engine. 




• Internal engine damage. 


• The engine RPM will be limited. 

• No VSS diaplay. 



• The IAT is equal to ECT. 

Page 150


04-23 


10 Poor accelerator sensor 

11 CKP sensor 

12 TPS 

13 ECT sensor 

14 MAP/IAT sensor 


• Misfire. 


• Rough engine operation. 


• Engine is hard to start. 

• The engine RPM will be limited after the engine starts. 

• The highest RPM is less than 3800 RPM. 


• No ignition signal to the ECM. 

• The tachometer does not work. 





• Engine hard to start when cold. 

• Engine hard to start when hot. 


• If the sensor circuit is shorted to power, the engine will run under the 

default values. 

• The temperature gauge indicates too high. 

• The temperature gauge indicates too low. 

• The cooling fan operates continuously on high speed. 

• The high temperature warning lamp will flash when the instrument 

panel indicates low temperature. 





04 

04 

Page 151

04-24 


DATA STREAM LIST/ACTIVE TEST 

1. DATA STREAM LIST. 

NOTE 

• Through reading the data stream displayed on scan tool sreen, we can check the sensor, 

actuator and switch data value but not removing any components. As the first step, this way is 

the best way to short diagnosis period . 

• The following arranged the data stream under the normal condition. It only offers to reference. 

Don’t judge a component normal or not only depend on these value. 

READ DATA STREAM PROCEDURE 

(a) 

(b) 

(c) 

Start the engine and warm it to normal operating temperature. 

Turn the ignition switch OFF. 

Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software 

available. 

Turn the ignition switch ON. 

Select the item, read data sream. 

The table below lists the data found in inspection items at different states by the KT600 in “DATA LIST” 

items. 

• If no concrete specification of idle condition, the shift selector lever is in neutral position. The A/C and 

accessories switch are in the OFF position. 

(d) 

(e) 

(f) 

• Injector driving time means time is taken by crankshaft at speed of less than 250 RPM and power 

supply voltage of 11 V. 

• For new vehicle (within operation distance of 500 km), sometimes injector driving time is 10% more 

than standard time. 

• For new vehicle (within operation distance of 500 km), sometimes step length of stepper motor is more 

30 steps than standard step length. 

Page 152


04-25 

Displayed Item Check Item Specified Condition 

Oxygen sensor 

• Engine: Warm 

• A/F: Mixture is made 

leaner when decelerating 


richer when accelerating 

Engine suddenly decelerate 

from 4000 RPM 

Engine suddenly accelerate 

≤ 0.2 V 

0.6 ~ 1 V 

04 


• Check A/F with oxygen 

sensor 

Engine: Idle 

≤ 0.4 V 

2500 RPM 0.6 ~ 1 V 

04 

MAP sensor 

IAT sensor 

• ECT: 80 ~ 95 ℃ 

• Lamp and all other 

accessorie: OFF 

• Transmission: Neutral 

• Ignition switch: ON 

• Or engine is running 

Engine: Idle - 

2500 RPM - 


IAT: - 20 ℃ - 20 ℃ 

IAT: 0 ℃ 0 ℃ 

IAT: 20 ℃ 20 ℃ 

IAT: 40 ℃ 40 ℃ 

IAT: 80 ℃ 80 ℃ 

Engine: Idle 0.3 ~ 1 V (0%) 

TPS 


TP open slowly 

Increase proportionally 

Wide open 

4.5 ~ 5.5 V 

Power supply Ignition switch: ON System voltage 

Ignition switch 


Engine: Stop 

Engine: Start 

OFF 

ON 

ECT sensor 


ECT: - 20 ℃ - 20 ℃ 

ECT: 0 ℃ 0 ℃ 

ECT: 20 ℃ 20 ℃ 

ECT: 40 ℃ 40 ℃ 

ECT: 80 ℃ 80 ℃ 

Altitude: 0 m 

101 kPa 

Barometric sensor 


Altitude: 600 m 


95 kPa 

88 kPa 


81 kPa 

A/C switch 

Engine: Idle 

(Turn A/C switch ON, A/C 

compressor works) 

A/C switch: OFF 

A/C switch: ON 

OFF 

ON 

Page 153

04-26 



ECT: 0 ℃ 

60 ~ 90 ms 

Injector 

Engine: Running 

ECT: 20 ℃ 

30 ~ 5 ms 

ECT: 80 ℃ 

6.7 ~ 10.1 ms 

Injector 

• ECT: 80 ~ 95 ℃ 

• Accessorie: OFF 


Engine: Idle 

2.2 ~ 3.4 ms 

2500 RPM 1.9 ~ 3.1 ms 

Engine runs at high speed 

suddenly 

Increase 

Ignition coil • Engine: Warm 

Engine: Idle 

2 ~ 18 BTDC 

2500 RPM 27 ~ 47 BTDC 

Idle air control 

motor 

• ECT: 80 ~ 95 ℃ 



• Engine: Idle 

• A/C works 


A/C switch: OFF → ON 

2 ~ 25 steps 


A/C relay 

Engine: Warm and idle 



Not activate (Compressor 

clutch does not work) 

Activate (Compressor 

clutch works) 

• Engine: Running 

• Tachometer: Connection 

Compare the values read 

from tachometer and KT600 

respectively 

The same 

ECT: - 20 ℃ 

1275 ~ 1475 RPM 

CKP sensor 

ECT: 0 ℃ 

1225 ~ 1425 RPM 

Engine: Idle 

ECT: 20 ℃ 

1100 ~ 1300 RPM 

ECT: 40 ℃ 

950 ~ 1150 RPM 

ECT: 80 ℃ 

650 ~ 850 RPM 

2. ACTIVE TEST. 

CAUTION 

The active test function for us to check the sensor, actuator and switch data value but not removing 

any components. We can use the scan tool to perform the test. As the first step, this way is the best 

way to short diagnosis period. 

The displayed data stream when performing the active test. 



available. 


(d) Select the item, actice test. 

(e) Refer to the following chart, perform the active test. The following chart is the item which in the 

“ACTIVE TEST” of the KT600 scan tool. 

(f) When performing the function of the “ACTIVE TEST”, if there is fault phenomenon, check and repair. 

Page 154


04-27 

(g) 

(h) 

(i) 

(j) 

After repairing, using the KT600 to perform again. 

Clear DTC. 

Disconnect KT600 scan tool. 

Restart engine to perform test. Confirm the faults has been eliminated. 

Displayed Item Test Component Control Area Diagnosis Remark 

MIL Control MIL ON/OFF - 

EVAP EVAP solenoid valve ON/OFF - 

Fuel pump relay Fuel pump relay ON/OFF - 

Low fan Control low fan ON/OFF - 

High fan Control high fan ON/OFF - 

A/C relay Shut off A/C relay ON/OFF - 

Idle air control motor Control idle motor steps - - 

Idle air control motor Control idle motor speed - - 

Idle control motor reset Control Idle motor reset - - 

Ignition advance angle Ignition advance angle - - 

Gear signal learn 58X learn - - 

Injector (A/B/C/D) Shut off fuel injection ON/OFF - 

BLM learn - - - 

BLM reset - - - 

Fuel open control Open control - - 

Inspect catalysator at idle Check catalysator at idle - - 

Oxygen sensor response Oxygen sensor response - - 

04 

04 

Page 155

04-28 


DIAGNOSTIC TROUBLE CODE CHART 

Note 

If a malfunction code is displayed during the DTC check in the check mode, check the harness or connectors 

for the codes listed in the table below. For details of each code, refer to the DTC chart 

DTC No. DTC Definition Trouble Area 

P0106 

P0107 

P0108 

P0112 

P0113 

P0117 

P0118 

P0122 

P0123 

P0131 

MAP / TPS Rationality 

MAP Circuit Low Voltage or Open 

MAP Circuit High Voltage 

IAT Circuit Low Voltage or Open 

IAT Circuit High Voltage 

Coolant Circuit Low Voltage 

Coolant Circuit High Voltage 

Throttle Position Low Voltage 

Throttle Position High Voltage 

Front Oxygen Sensor Short Low 

• MAP sensor 

• Open or short in MAP sensor harness or 

connectors 

• ECM 


• Short in MAP sensor harness or connectors 

• ECM 



connectors 

• ECM 

• IAT sensor 

• Short in IAT sensor harness or connectors 

• ECM 


• Open or short in IAT sensor harness or 

connectors 

• ECM 

• ECT sensor 

• Short in ECT sensor harness or connectors 

• ECM 


• Open or short in ECT sensor harness or 

connectors 

• ECM 

• Throttle position sensor 

• Open or short in throttle position sensor 

harness or connectors 

• ECM 


• Short in throttle position sensor harness or 

connectors 

• ECM 

• Upstream oxygen sensor 

• Short in upstream oxygen sensor harness or 

connectors 

• ECM 

Page 156


04-29 


P0132 

Front Oxygen Sensor Short High 



connectors 

• ECM 

04 

P0133 

Front Oxygen Sensor slow response 

• Open or short in upstream oxygen sensor 



• Upstream oxygen sensor heater 

• Relay 

• Air induction system 

• Fuel pressure 

• Injector 

• ECM 

04 

P0134 

Front Oxygen Sensor Inadequate 

Activeness Or Open 


• Open in upstream oxygensensor harness or 

connectors 

• ECM 

P0135 

Front Oxygen Heater Fault 

• Upstream oxygen heater 

• Open or short in upstream oxygen heater 


• ECM 

P0137 

Rear Oxygen Sensor Short Low 


• Open or short in downstream oxygen sensor 


• ECM 

P0138 

Rear Oxygen Sensor Short High 

• Downstream oxygen sensor 



• ECM 

P0140 

Rear Oxygen Sensor Inadequate 



• Open in downstream oxygen sensor harness 

or connectors 

• ECM 

P0141 

Rear Oxygen Heater Fault 

• Downstream oxygen heater 

• Open or short in downstream oxygen heater 


• ECM 

Page 157

04-30 



P0171 

P0172 

P0201 

P0202 

P0203 

P0204 

P0230 

P0300 

Fuel Trim BLM Learn Too Lean 

Fuel Trim BLM Learn Too Rich 

Injector 1 Circuit Diagnostic 




Fuel Pump Relay Fault 

The Engine Misfire Fault 


• Injector blockage 



• Open or short in oxygen sensor circuit 

• Oxygen sensor 

• ECM 

• Injector leak or blockage 


• Engine coolant temperature sensor 


• Gas leakage in exhaust system 

• Open or short in oxygen sensor harness or 

connectors 


• ECM 

• Injector 1 

• Injector A harness or connectors 

• ECM 



• ECM 



• ECM 



• ECM 

• Pump relay 

• Pump relay harness or connectors 

• ECM 

• Open or short in engine wire 

• Ignition system 

• Injector 



• Compression pressure 

• Valve timing 

• PCV hose connection 

• PCV hose 

• ECM 

Page 158


04-31 


P0324 

Knock System Fault 

• Knock sensor 

• Knock sensor harness or connectors 

• ECM 

04 

P0325 

P0335 

Knock Sensor Fault 

CKP Sensor Circuit No Signal 



• ECM 

• Open or short in CKP sensor harness or 

connectors 

• ECM 

04 

P0336 

CKP Sensor Circuit Noisy Signal 

• CKP sensor 

• Open or short in CKP sensorharness or 

connectors 

• ECM 

P0351 EST Output #1 


• Ignition coil 1 harness or connectors 

• Ignition coil 1 



P0420 

P0443 

P0480 

P0481 

P0502 

P0506 

P0507 

Catalyst failure 

Purge Solenoid Diagnostic 

Fan 1 Fault 

Fan 2 Fault 

Vehicle Speed Sensor No Signal 

Idle Speed Control - Low RPM 

Idle Speed Control - High RPM 

• Catalyst harness or connectors 

• Catalyst 

• Purge solenoid diagnostic harness or 

connectors open or short 

• Purge solenoid diagnostic 

• ECM 

• Fan1 

• Fan 1 harness or connectors 

• ECM 

• Fan 2 


• ECM 

• Vehicle speed sensor 

• Vehicle speed sensor harness or connectors 

• Idle motor 

• Idle control vale 

• Idle motor harness or connectors 

• ECM 




• ECM 

Page 159

04-32 



P0562 

P0563 

P0645 

P0650 

P0685 

P1167 

P1171 

P1336 

P1391 

P1392 

P1393 

P1659 

Voltage Low Diagnostics 

Voltage High Diagnostics 

A/C clutch output circuit fault 

Malfunction Indicator Lamp Fault 

Main Power Relay Fault 

Front Oxygen Sensor Signal Rich in 

fuel 

Front Oxygen Sensor Signal Lean In fuel 

TEC Not Learned 

G Sensor Rationality 

G sensor short low 

G Sensor Short High 

SVS Light Fault 

• Battery 

• Generator 

• Power supply harness or connectors 

• Generator 

• ECM 

• A/C clutch 

• A/C clutch harness or connectors 

• Malfunction indicator lamp 

• Malfunction indicator lamp harness or 

connectors 

• ECM 

• Main Power Relay 

• Main Power Relay harness or connectors 

• ECM 




• Engine hood main relay 

• Upstream oxygen heater and main relay 


• ECM 







• ECM 

• CKP sensor is not installed 

• ECM 

• Accelarator 

• ECM 


• Short in accelarator harness or connectors 

• ECM 



• ECM 

• SVS Light harness or connector 

• Instrument Panel 

Page 160


04-33 

DTC DIAGNOSTIC 

P0107 - MAP CIRCUIT LOW VOLTAGE OR OPEN 

P0108 - MAP CIRCUIT HIGH VOLTAGE 

P0112 - IAT CIRCUIT LOW VOLTAGE OR OPEN 

P0113 - IAT CIRCUIT HIGH VOLTAGE 

DESCRIPTION 

MT20U2 adopted speed - density air measurement method to check the air intake volume into the engine so 

as to control the fuel injection pulse width for the precise control of engine power output. Meanwhile, this 

system adopted intake pressure cylinder determination technology and the intake air sensor is installed near 

the inlet opening of cylinder 4 intake manifold. At the moment when the throttle is opened, there will be one 

instantaneous pressure drop at the sensor, of which the value is about 1 kPa. When the ECM detected and 

received this instantaneous pressure drop, the ECM will determine the compression upper dead center signal 

after software diagnosis treatment (its functions is similar with the camshaft position sensor of traditional 

electric injection system, also referred as phase sensor). 

WIRING DIAGRAM 

04 

04 

Page 161

04-34 


DTC No. DTC Definition DTC Detection Condition Trouble Area 

P0107 

MAP sensor circuit low 

voltage or open 


• No TPS faults 

• ECM detects that the MAP 

input signal is less than 

acceptable value 


• MAP sensor loose connector 

• Open or short in MAP sensor 

signal circuit 

• Short circuit in MAP sensor 


• Open circuit in MAP sensor 

5V circuit 

• Open in MAP sensor ground 

circuit 

• ECM 

P0108 

MAP sensor circuit high 

voltage 




input signal is higher than 



• Short in MAP sensor signal 

circuit 

• Short in MAP sensor 5V 

power circuit 

• ECM 

P0112 

IAT sensor circuit low 


• Ignition switch: ON. 

• 60 seconds since the ignition 

switch is turned “ON”, or after 

engine starts. 

• Sensor output voltage has 

continued to be 0.2 V or lower 

(corresponding to an intake air 

temperature of 125 ℃ or 

lower) for 4 seconds. 


• Short in IAT sensor 5 V 

reference circuit 

• ECM 

P0113 

IAT sensor circuit high 

voltage 






continued to be 4.6 V or 

higher (corresponding to an 

intake air temperature of - 45 

℃ or lower) for 4 seconds. 


• Open in IAT sensor 5 V 


• ECM 

NOTE 

• While performing electrical diagnosis & testing, assure the ECM ground good contact. 

• While performing electrical diagnosis & testing, always refer to the electrical schematics for 

specific circuitand component information. 

• While performing electrical diagnosis & testing, look for broken, bent, pushed out or corroded 

terminals. 

• If any DTC is detected, using the scan tool, select the item, read data stream. 

Page 162


04-35 

INSPECTION PROCEDURE 

1. READ VALUE AND DTC OF SCAN TOOL 

(a) 

(b) 

(c) 

(d) 


With the KT600 scan tool, perform the DTC confirming procedure. 

Perform the reading data stream procedure. 

Read IAT value displayed on the KT600 scan tool. 

Displayed DTC And Pressure Proceed To Malfunction 

• P0108 

• About 45 kPa (or 4 V) 

Next step Short to voltage 

04 

04 

• P0107 


• P0107 or P0108 

• Pressure normal 

Next step 

Diagnostic help 

Open or short to ground 

Check for intermittent problems 


YES > Go to diagnostic help for checking intermittent problems. 

NO > If there an open or short circuit, go to next step. 

2. CHECK HARNESS AND CONNECTOR (INTAKE AIR TEMPERATURE PRESSURE SENSOR - 

GROUND) 

(a) 

(b) 

(c) 


Disconnect the E006 intake air temperature pressure sensor. 


(d) Measure the voltage according to the value in the table 

below. 

Standard voltage 

Tester Connection 

E006 (2) - Ground 

Specified Condition 

5.0 ± 0.25 V 



NO > Repair or replace harness or connector. 

Page 163

04-36 



ECM) 

(a) 

(b) 

(c) 



Disconnect the E001 ECM connector. 

(d) Measure the resistance according to the value in the 

table below. 

Standard resistance (check for open) 


E001 (76) - E006 (4) 

E001 (71) - E006 (3) 


< 2 Ω 




4. CHECK MAP SIGNAL 


(b) Disconnect the E006 intake air temperature pressure sensor. 

(c) Start engine. 


below. 




E006(2) - Ground • Idle: 5.0 ± 0.25 V 

E006(4) - Ground 

• Idle: 1.3 V 

• No load condition, opening 

throttle slowly: 1.3 V 

• Open quickly: 4 V, then return 

back to 1.5 V 




Page 164


04-37 


GROUND) 

(a) 

(b) 

(c) 

(d) 





(e) Measure the voltage according to the value in the table 

below. 


04 

04 


E006 (4) - Ground 


0 V 


YES > Replace the ECM. 


Page 165

04-38 


P0117 - COOLANT CIRCUIT LOW VOLTAGE 

P0118 - COOLANT CIRCUIT HIGH VOLTAGE 

1 Electric Appliance Connector 

2 Cabinet 

3 NTC Resistance 

DESCRIPTION 

This sensor is one Negative Temperature Coefficient (NTC) thermistance, of which the resistance will reduce 

following the increasing of the temperature in non - linear relation. When the coolant temperature is low, the 

resistance in the thermistor increases. When the temperature is high, theresistance drops. The variations in 

resistance are reflected in the voltage output from the sensor. 

The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. 



P0117 

Engine cooling 

temperature sensor circuit 

low voltage 


• 60 seconds since the ignition switch is 

turned “ON” or after engine starts 

• Sensor output voltage has continued to be 

0.2 V or lower (corresponding to an intake 

airtemperature of 145 ℃ or higher) for 4 

seconds 


• Short in ECT 

sensor circuit 

• ECM 

P0118 



high voltage 





4.6 V or higher (corresponding to an 

intakeair temperature of - 45 ℃ or lower) 

for 4 seconds 


• Open or short in 

ECT sensor 

circuit 

• ECM 

Page 166


04-39 

NOTE 





terminals. 

• If the ECM detects the DTC P0117 or P0118, it operates the fail–safe function in which the engine 

coolant temperature is assumed to be a default value. At the same time, with the ignition switch 

ON, the cooling fans will operate at high speed. The fail–safe function will not untill the ECM 

detects the acceptance condition. 

• If any DTC is detected, using the scan tool, select the item, read the data stream. 

04 

04 

Displayed Temperature 

Malfunction 

- 40 °C Open circuit 

140 °C Short circuit 



(a) 

(b) 

(c) 

(d) 



Read sensor value displayed on the KT600 scan tool. 

Read sensor value displayed on the KT600 scan tool. 

Display DTC And Temperature Proceed To Malfunction 

• P0118 

• - 40 °C 

• P0117 

• 140 °C or more 

• P0117 or P0118 

• 80°C - 100°C 

Next step 

Step 5 


Open or short to power 

Short to ground 




NO > If there is an open circuit, go to next step. 

If there is a short circuit, go to step 5. 

2. READ VALUE OF KT600 SCAN TOOL 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 


Disconnect the E010 ECT sensor connector 

Connect terminals 1 and 2 of the engine coolant temperature sensor connector E010 on the wire 

harness side. 


Select the item, read data stream. 

Read ECT value displayed on the KT600 scan tool. 

Temperature value: ≥ 140 °C 

Page 167

04-40 



YES > Replace engine coolant temperature sensor, clear the DTC. 


3. CHECK HARNESS AND CONNECTOR (COOLANT TEMPERATURE SENSOR - GROUND) 

(a) 

(b) 

(c) 


Disconnect the E010 coolant temperature sensor. 



below. 



E010 (1) - Ground 


4.5 ~ 5.0 V 




4. CHECK HARNESS AND CONNECTOR (COOLANT TEMPERATURE SENSOR - ECM) 

(a) 

(b) 

(c) 



Disconnect the E001 ECM. 


table below. 



E010 (2) - E001 (52) 


< 2 Ω 


YES > Replace the coolant temperature sensor. 


Page 168


04-41 

P0122 - THROTTLE POSITION LOW VOLTAGE 

P0123 - THROTTLE POSITION HIGH VOLTAGE 

DESCRIPTION 

MT20U2 Throttle Position Sensor (TPS) is used to provide throttle angle, angle speed and engine idle position 

information to the ECM, based on which the ECM can obtain the engine load information, operating mode 

(such as start, idle, reverse towing, partial load, full load) and acceleration & deceleration information. This 

sensor is of three - line type and the ECM will check the throttle open extent by monitoring the voltage 

variation. 


04 

04 


P0122 

Throttle position low 

voltage 


• 60 seconds since the ignition switch 

is turned “ON”, or after engine starts 

• Sensor output voltage has continued 

to be 0.2V or lower for 4 seconds 

• TPS failed or maladjusted 

• Open or short in TPS circuit 

• ECM 

P0123 

Throttle position 

high voltage 




• Setting the closed throttle position 

switch ON, the sensor output 

voltage has continued to be 2 V or 

higher for 4 seconds 


• Short in TPS circuit 

• ECM 

NOTE 





terminals. 


Page 169

04-42 




(a) 

(b) 

(c) 

(d) 


Using the KT600 scan tool, perform the DTC confirming procedure. 

Read TPS value displayed on the KT600 scan tool. 

Read TPS signal data displayed on the KT600 scan tool 

Displayed DTC And Voltage Proceed To Malfunction 

• P0122 ( < 0.2 V) Step 4 Short to voltage 

• P0123 ( > 2 V) Next step Open or short to ground 

• P0122 or P0123 

• TPS signal is normal 





NO > If there is an open or short circuit, go to next step. 

2. CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - GROUND) 

(a) 

(b) 

(c) 


Disconnect the E009 throttle position sensor. 


(d) 

Measure the voltage according to the value in the table 

below. 



E009 (1) - Ground 


4.5 ~ 5.0 V 




Page 170


04-43 

3. CHECK THROTTLE POSITION SENSOR SIGNAL 

(a) Turn the ignition switch ON. 

(b) Jump wire at terminals 2 and 3 of the E009 TPS connector. 

(c) Perform reading sensor data stream procedure with scan tool. 

Voltage value: 4 V 




4. CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - ECM) 

04 

04 

(a) 

(b) 

(c) 




(d) 

Measure the resistance according to the value in the 

table below. 



E009 (2) - E001 (74) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 





(e) 


below. 



E009 (3) - Ground 


0 V 


YES > Replace the throttle position sensor. 


Page 171

04-44 


P1167 - FRONT OXYGEN SENSOR SIGNAL RICH IN FUEL 

P1171 - FRONT OXYGEN SENSOR SIGNAL LEAN IN FUEL 

P0131 - FRONT OXYGEN SENSOR SHORT LOW 

P0132 - FRONT OXYGEN SENSOR SHORT HIGH 

P0133 - FRONT OXYGEN SENSOR RESPONSE 

P0134 - FRONT OXYGEN SENSOR OPEN 

P0135 - FRONT OXYGEN SENSOR HEATER FAULT 

1 Air 

2 Case 

3 Solid electrolyte 

4 Platinum electrode 

5 Heater 

6 Lining 

7 Exhaust gas 

8 Rich 

9 Air/fuel ratio 

10 Lean 

Page 172


04-45 

DESCRIPTION 

The Engine Control Module (ECM) supplies a voltage of about 450 mV between the ECM terminals 62 and 6. 

The oxygen sensor varies the voltage within a range of about 1V if the exhaust is rich, down to about 0.1 V if 

the exhaust is lean. The oxygen sensor is like an open circuit and produces no voltage when it is below 360 ℃ 

. An open oxygen sensor circuit or a cold oxygen sensor causes open - loop operation. 

04 


P0131 

Front oxygen sensor 

short low 

• The engine controls system 

is in closed loop 

• The engine speed is below 

6000 RPM 


feedback voltage has 


lower at least 40 seconds 

• Upstream oxygen 

sensor 

• Short in upstream 

oxygen sensor 

circuit 

• ECM 

04 

P0132 


short high 




higher for at least 0.2 

seconds 


sensor 


oxygen sensor 

circuit 

• ECM 

P0134 


open 



continued to be between 

0.42 ~ 0.48 V 


sensor 

• Open in upstream 

oxygen sensor 

circuit 

• ECM 

P0133 


response 





• DTC P0135、 P01167 are 

not set 


sensor 


oxygen sensor 

circuit 

• ECM 

P0135 


heater fault 





• P1171DTC P0133、P01167 

are not set 


sensor 


oxygen sensor 

circuit 

• ECM 

Page 173

04-46 



P1167 


signal rich in fuel 





• DTC P01171、 P0133 are 

not set 


sensor 

• ECM 

P1171 


signal lean in fuel 





• DTC P0135、 P01167 are 

not set 


sensor 

• ECM 

NOTE 





terminals. 


DIAGNOSIC HELP 

• Normal scan tool voltage varies between 0.1 to 1.0 V while in closed - loop. 

• Check oxygen sensor harness, maybe the oxygen sensor is not well installed. It touch the exhaust pipe. 

• Check if there is intermittent ground existent between ECM and oxygen sensor. 

• Perform an injector balance test. Check if the lean mixture was caused by injector blocking. 

• The vacuum leaking of crankcase cause lean mixture. 

• The out air enter into exhaust pipe and through the oxygen sensor by the leaking of exhaust manifold 

wsaher. 

Page 174


04-47 



(a) 

(b) 

(c) 

(d) 



Read oxygen sensor value displayed on the KT600 scan tool. 

Engine runs at idle. 

Result 


04 

04 

P0131 ( < 0.21 V) Step 6 Short to ground 

P0132 ( > 4.8 V) Step 7 Short to power 

P0134 (0.42 V ~ 0.48 V ) Next step Open 

2. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - ECM) 

(a) 

(b) 

(c) 


Disconnect the E007 front oxygen sensor. 


(d) 


below. 



E007 (1) - E007 (2) 


0.45 V 


YES > Replace the front oxygen sensor. 


3. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - GROUND) 

(a) 

(b) 

(c) 




(d) 


below. 



E007 (2) - Ground 


0.45 V 

Page 175

04-48 






(a) 

(b) 

(c) 




(d) 


table below. 



E007 (2) - E001 (47) 

E007 (1) - E001 (73) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 





(e) 


table below. 

Standard resistance (check for short) 


E007 (2) - Ground 

E007 (1) - Ground 


≥ 1MΩ 




Page 176


04-49 


(a) 

(b) 

(c) 




(d) 


below. 


04 


E007 (4) - Ground 



04 





(a) 

(b) 

(c) 




(d) 


table below. 

Standard resistance(check for open) 


E007 (3) - E001 (24) 


< 2 Ω 




Page 177

04-50 



(a) 

(b) 

(c) 




(d) 


table below. 



E007 (3) - Ground 


≥ 1MΩ 




Page 178


04-51 

P0335 - CRANKSHAFT POSITION SENSOR CIRCUIT NO SIGNAL 

P0336 - CRANKSHAFT POSITION SENSOR CIRCUIT NOISY SIGNAL 

1 Shielded cable 

04 

2 Permanent magnet 

3 Sensor case 

4 Mounting bracket 

5 Soft magnet iron core 

04 

6 Coil 

7 Air clearance 

DESCRIPTION 

The 58X reference signal is produced by the Crankshaft Position (CKP) sensor. The Engine Control Module 

(ECM) uses the 58X reference signal to calculate engine RPM and CKP. The ECM constantly monitors the 

number of pulses on the 58X reference circuit and compares them to the number of MAP signal being 

received. If the ECM receives and incorrect number of pulses on the 58X reference circuit, DTC P0336 will be 

set. 

Page 179

04-52 




P0336 

CKP sensor circuit 

noisy signal 


• ECM received no or 

error signal 


• CKP loose connector 

• Open or short in CKP sensor 

circuit 

• ECM 

P0335 

CKP sensor circuit no 

signal 

• ECM received no signal 




circuit 

• ECM 

NOTE 





terminals. 


Page 180


04-53 


1. READ VALUE AND DTC USING SCAN TOOL 

(a) 

(b) 

(c) 

(d) 

(e) 



Read CKP sensor value displayed on the KT600 scan tool. 


Using scan tool, perform the CKP sensor waveform confirming procedure. 




04 

04 

2. CHECK CKP SIGNAL USING THE OSCILLOSCOPE 

(f) 

Using the oscilloscope, check the CKP sensor waveform. 




3. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM) 

(a) 

(b) 

(c) 


Disconnect the E008 crankshaft position sensor. 



table below. 



E008 (1) - E001 (30) 

E008 (2) - E001 (11) 


< 2 Ω 




Page 181

04-54 


4. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - GROUND) 

(a) 

(b) 



(c) Measure the resistance according to the value in the 

table below. 



E008 (3) - Ground 


< 2 Ω 




5. CHECK CRANKSHAFT POSITION SENSOR 

(a) 

Replace the CKP sensor with a known good one. 

(b) Using the oscilloscope, check the CKP sensor waveform. 


YES > Replace the crankshaft position sensor. 



(a) 

(b) 

(c) 





table below. 

• Standard resistance (check for short) 


E008 (3) - Ground 

E008 (1) - Ground 


≥ 1MΩ 

Page 182


04-55 





04 

(a) 

(b) 

(c) 





below. 


04 


E008 (1) - Ground 


0 V 




8. CHECK CKP SENSOR SIGNAL PLATE 

(a) 


(b) 

(c) 

Check for a problem such as scrap, dirt, foreign body 

and loose with the 58X CKP signal plate and signal 

tooth. 

Check the mounting clearance of the CKP sensor. 

Clearance: 0.3 ~ 1.5 mm 

9. Is the check result normal? 


NO > Remove any foreign obstacles, clean 58X signal tooth. If there is fault present, replace 58X signal 

plate. 

Page 183

04-56 


P0324 - KNOCK SYSTEM FAULT 

P0325 - KNOCK SENSOR FAULT 

No. 

Item 

1 1 ms\DIV 

DESCRIPTION 

The Knock Sensor (KS) system is used to detect engine detonation, allowing the Engine Control Module 

(ECM) to retard ignition control spark timing based on the KS signal being received. The KS produces an AC 

signal. The KS signal’s amplitude and frequency depend upon the amount of knock being experienced. The 

ECM contains a non - replaceable knock filter module called a Signal - to - noise Enhancement Filter (SNEF) 

module. This filter module in the ECM determines whether knock is occurring by comparing the signal level on 

the KS circuit with the voltage level on the noise channel. The noise channel allows the ECM to reject any false 

knock signal by knowing the amount of normal engine mechanical noise present. Normal engine noise varies 

depending on engine speed and load. When the ECM determines that an abnormally low noise channel 

voltage level is being experienced, DTC P0324 & P0325 will be set. 

Page 184


04-57 


04 

04 


P0324 

Knock system fault 

• ECT is higher than 80 ℃ 

• Engine RPM is higher than 

2,500 RPM 

• ECM detect that the KS 

signal is out of the range 


• KS loose connector 

• Open or short in KS circuit 

• ECM 

P0325 

Knock sensor fault 



2,500 RPM 

• The knock sensor voltage is 

below 0.2 V 



• Short in KS circuit 

• ECM 

NOTE 





terminals. 


Page 185

04-58 




(a) 

(b) 

(c) 



Driving vehicle, read knock sensor value displayed on the KT600 scan tool. 

Result: Feed back value change 

YES > Check intermittent problems. 


2. CHECK HARNESS AND CONNECTOR (KNOCK SENSOR - ECM) 

(a) 

(b) 

(c) 



Disconnect the E001 knock sensor connector. 

(d) 


table below. 



E011 (1) - E001 (58) 

E011 (2) - E001 (37) 


< 2 Ω 




3. CHECK HARNESS AND CONNECTOR (KNOCK SENSOR - GROUND) 

(a) 

(b) 

(c) 





table below. 



E011 (1) - Ground 

E011 (2) - Ground 


≥ 1 MΩ 




Page 186


04-59 


(a) 

(b) 

(c) 

(d) 






below. 



E011 (2) - Ground 


0 V 

04 

04 

(f) 

(g) 

(h) 

Connect the E001 ECM connector. 



below. 



E011 (2) - Ground 


5 V 


YES > Replace the knock sensor. 


Page 187

04-60 



Use the table below to help you find the cause of the problem. The numbers indicate thepriority of the likely 

cause of the problem. Check each part in order. If necessary, replace these parts. 

ENGINE CONTROL SYSTEM SYMPTOM 

Symptom 

Check Order 

Communication with KT600 is impossible KT600 failed to communicate with ECM. 1 

Starting 

Idling stability (Improper idling) 

Idling stability (Engine stalls) 

Driving 

Engine cranks, but will not start. 2 

When engine is cold, it starts difficultly, body shock. 3 

Unstable idle (Rough idle, hunting). 4 

Idle speed is high (Improper idle speed). 5 

When the engine is cold, it stalls (At idle). 6 

The engine stalls when accelerating. 7 

Accelerated reaction is slow, acceleraton 

disturbance. 

Poor acceleration capability. 9 

8 

ENGINE CONTROL SYSTEM SYMPTOM DESCRIPTION 

Item 

Symptom 

Starting 

Idling stability 

(Improper idling) 


(Engine stalls) 

Driving 

Failed to start 

Hard starting 

Hunting 

Incorrect idle speed 

Engine will stall when it is cold (Idle) 

Engine stalls when moving 

Accelerated reaction is slow, 

acceleraton disturbance 

Poor acceleration capability 

The starter is used to crank the engine, but there is 

no combustion within the cylinders, and the engine 

does not start. 

Engine starts after cranking a while. 

Engine speed does not remain constant. 

The engine does not idle at the usual correct speed. 

Engine stall easily when ECT is low after it start for 

a while. 

The engine stalls when the accelerator pedal is 

depressed. 

Hesitation is the delay in response of the vehicle 

speed that occurs when the accelerator is 

depressed in order to accelerate from the speed at 

which the vehicle is now traveling or a temporary 

drop in vehicle speed during such acceleration. 

Serious hesitation is called “sag”. 

Poor acceleration is the inability to obtain an 

acceleration corresponding to the degree of throttle 

opening (Even though acceleration is smooth) or 

the inability to reach maximum speed. 

Page 188


04-61 

ENGINE SYMPTOM DIAGNOSTIC 

CAUTION 

• Some symptom diagnostics require visual and outer inspection. Perform these inspections 

first. These inspection can select a problem that needn’t check deeply. And it can save the 

expensive time. 

• Inquiry customer about the fault after taking over vehicle: 

(a) The first time when the faults appear. 

(b) The engine temperature when the faults appear. 

(c) The vehicle roadhaul. 

(d) The road which the customer usually drives. 

(e) The vehicle maintenace log. 

(f) The vehicle maintenace record. 

(g) Is there any aftermarket retrofit device on vehicle? After the inspection, the checking time will be 

shorted. 

• Perform the primary inspection. 

(a) Confirm the engine MIL is normal. If it is not good, repair it first. 

(b) Confirm that no DTC exists in the ECM. If DTC exists, refer to the DTC chart to eliminate it. 

(c) With the scan tool to inspect the engine control system hot data stream. And confirm them in the normal 

range. 

(d) Confirm the fault and the reason. 

(e) When repairing the vehicle, confirm the repair record. 

• Visual inspection. 

(a) Check the fuel system for any fuel leakage. 

(b) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses. 

(c) Check the intake air pipe for being jammed, leaking, or damaged. 

(d) Check the ignition system for any broken or aging spark plug wires and verify the engine firing order is 

correct. 

(e) Check the engine ground cable and verify a clean and tight connection. 

(f) Check the sensors and actuators electrical connectors and verify good contact and tight connection. 

CAUTION 

• The carbon deposits in the back of the valve will cause the poor engine acceration, unsteady 

idling, starting difficulty in cold temperature, ect. 

• Valve, carbon deposits in the combustion chamber. 

Determined by the ECI (Electronic Controlled Injection) engine control features, the cylinder carries out 

the fuel injection first and then the ignition at each running. The ignition is cut off immediately the engine 

is shut off, but the petrol injected in this running cycle can’t be recovered and is attached on the intake 

valve and the combustion chamber wall. The petrol is volatile, but the waxes and colloids in the petrol 

remain. In the long term, the waxes and colloids become thick and hard after repeatedly heated, so the 

carbon deposits are formed. If the engine burns oil or the filled petrol quality is poor and with many 

impurities, the valve carbon deposits are more severe and the formation rate is faster. As the carbon 

deposit structure is similar to the sponge, after the valve carbon deposits are formed, part of fuel 

injected into the cylinder every time will be attached, making the air - fuel mixture strength actually into 

the cylinder thin, which causes poor engine running, difficult starting, rough idling, poor accelerating, 

backfire during emergency fueling, exhaust exceeding the standards, consumption increasing and 

other abnormal symptoms. If the carbon deposits are more severe, they may lead to improperly sealed 

valve, and the cylinder can't work without cylinder pressure, or even the valve is adhered and can’t 

return. Now the motion interference occurs between the valve and the piston which would damage the 

engine finally. 

04 

04 

Page 189

04-62 


• Carbon deposits in the intake manifold. 

As the running of each piston in the whole engine is not synchronous, when the engine is shut off, 

some intake valves in some cylinders can’t be fully closed, the unburned fuel evaporates and is 

oxidized continuously thus to form some softer black carbon deposits in the intake pipe, especially at 

the rear of the throttle valve. On the one hand, the carbon deposits make the intake pipe wall coarse; 

the air forms a spiral vortex at the coarse section, affecting the air intake effect and the quality of air - 

fuel mixture. On the other hand, the carbon deposits block the idling aisle, making the idling speed 

control device clamped or exceeding its regulation range, leading to low idling speed and rough idling. 

• If the carbon deposit in the cylinder is too much, usually it will cause the high pressure. But the 

vehicle has more mileage, there is much more carbon deposit in the cylinder. Because of the 

wear, the cylinder pressure will decline. So it is not the good way to judge if there is the carbon 

deposit in the cylinder . The good way is: 

(a) With the electronic endoscopy. 

(b) Inspect the feedback voltage. 

(c) Disassembly way. 

• It’s a gradual process from the carbon deposit formation to aggregation and to affecting engine 

normal running. When the engine cold starting is hard and the idling is rough, it shows that the 

carbon deposits are quite serious, if further it will cause misfire and cylinder fuel cut, until the 

engine unable to start. When the cold starting is hard, check the engine at once, clean the valve 

carbon deposits in time after removing other factors to avoid damage caused by removing the 

cylinder cover. 

• Should pay attention to the following for the danger of the carbon deposit: 

(a) Fill with the high quality gasoline. 

(b) Don’t idle long. 

(c) Run at high speed usually. 

Page 190


04-63 

COMMUNICATION WITH KT600 IS IMPOSSIBLE 

Symptom Diagnosic Logic Suspect Area 

Communication with KT600 is 

impossible 


1. READ VALUE OF SCAN TOOL 

• No power supply 

• Open in the harness of ECMand 

scan tool KT600 

• ECM 

• ECM power supply 

• Open in the harness of ECM and 


• ECM 

04 

04 


(b) Connect the KT600 scan tool to the Diagnostic Link Connector (DLC) - use the most current software 

available, press the POWER key to start the KT600. 


(d) Using scan tool, select the item, read data stream. 

(e) Using the KT600 scan tool, read data stream displayed on the screen. 

Whether the ECM data stream can be read? 



2. CHECK DLC COMMUNICATION K 


(b) Disconnect the E001ECM connector. 

(c) Check the continuity between the data link connector M002 terminal 7 - ECM connector terminal 75. 

Resistance:< 2 Ω 

(d) Using the multimeter, check the continuity between the data link connector M002 terminal 7 and 

ground. 

Resistance:≥ 1 MΩ 

(e) Turn the ignition switch ON, using the multimeter, check the voltage between data link connector M002 

terminal 7 and ground. 

Voltage: 0 V 




Page 191

04-64 


ENGINE CRANKS, BUT WILL NOT START 

Symptom Condition Diagnosic Logic Suspect Area 

Engine cranks, but will not 

start 

• Engine run normally 

• Battery is normal 

• MIL is normal 

• No phenomenon of 

burning when cranking 

the engine 

• Spark plugs are fouled 

defective 

• No supply of fuel to the 

combustion chamber 

is defective 

• Cylinder pressure is 

not normal 

• Malfunction of the 

ignition system 

• Malfunction of the fuel 

pump system 


injector 

• Leakage or 

malfunction of intake 

air system 

• ECM 

NOTE 

If the engine can’t be started with starting symptom, it shows the ignition system, fuel system and 

control system don’t fully lose the functions even though work normally. The cause of this starting 

failure is nothing but may be that the high tension sparks are too weak, the ignition is improper, the air/ 

fuel mixture is too thin or thick, or the cylinder pressure is too low. In general, first check the ignition 

system, then the air intake system, the fuel system, the control system, the engine cylinder pressure at 

last. 


1. INSPECTION MIL AND DTC 

(a) Using the KT600 scan tool, perform the reading DTC procedure. 

Is the DTC present? 



2. VISUAL INSPECTION 

(a) Perform the visual inspection. 

Is the inspection result normal? 


NO > Eliminate the exterior problems. 

3. CHECK THE SECONDARY IGNITION SYSTEM 

(a) Perform the following to test the secondary ignition system: 

• Disconnect the injector fuse. 

• Remove any of the 4 spark plugs. 

• Connect the spark plug to spark plug wire. 

• Ground the spark plug on the cylinder block. 

• Crank the engine to test the secondary ignition system with the spark plugs removed. 

Normal result: A strong blue spark visible is at each spark plug while cranking the engine 




Page 192


04-65 


(a) Check ignitioin coil resistance, and clear connector terminals. 

(b) Check whether there is carbon deposit in plug, carbon tracking, residual current in insulating ceramics 

cause of crack, clearance, burned in the positive and negative. And clear the plug. 



NO > Clear, replace the faulty components. 

5. CHECK IGNITION SPARK PLUG WIRE 

04 

04 

(a) Using multimeter, check resistance of the ignition spark wire. 

Resistance: ≥ 4 kΩ 



NO > Replace the ignition spark wire. 

6. CHECK CKP SENSOR 

(a) Using scan tool, select the item, read data stream. 

(b) Read the displayed CKP sensor value. It should be within the specified value. 



NO > Check whether the sensor installion is correct. 

7. CHECK THE THROTTLE BODY 

(a) Depress the accelerator slightly. 

(b) Check whether the engine can start. 

Can the engine start? 

YES > Check throttle body and idle air path. Clear the carbon deposit. Disconnect the idle air control motor 

connector, Check whether there is 12 V. And the resistance value is 28 ~ 33Ω when the temperature is 

20 ℃ . Check whether the idle air control motor is clip. If necesasary, repair or replace it. 

CAUTION 

The carbon and grease beside the throttle and air path change the cross section of the idle air path. It 

makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The 

borning will not be normal. And the usual reasons of unnormal borning are: carbon and grease, grease 

beside the throttle air path, carbon and grease with the idle air control motor. 


8. CHECK ECT SENSOR AND MAP/IAT SENSOR 

(a) Check whether the installation of the MAP/IAT is normal. 

(b) Check whether the MAP/IAT sensor is dirty. 

(c) Using scan tool, select the item, read data stream. 


(e) Read the displayed ECT and MAP/IAT sensor value. It should reach the specified value. 



NO > Repair or replace the harness or connector. 

Page 193

04-66 


9. CHECK THE FUEL SYSTEM CIRCUIT 

(a) 


(b) Check whether the pump relay and pump operate normally. 




10. CHECK THE FUEL SYSTEM PRESSURE 

(a) Release the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”) 

(b) Check the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”) 



NO > Repair or replace the fuel system parts and harness: 

• If the pressure is higher than 350 kPa, check the return pipe: 

(1) If the return pipe is bent or twisted, repair or replace it. 

(2) If the return pipe is normal, replace the pressure regulator. 

• If the pressure is less than 350 kPa, turn the ignition switch ON, make the pump operate, check 

the pressure again: 

(1) If the pressure can be established, go to step 12. 

(2) If the pressure cannot be established, go to step 13. 

11. CHECK INJECTOR 

(a) Disconnect the injector connector. 

(b) Remove the injector and fuel rail assy. 

(c) Apply 12 V battery voltage to the injector directly. 

(d) Check whether every injector can spray even and standard quantity gasline. 

CAUTION 

If the spraying condition is not normal just as the “cylindrical growth”, or the spraying quantity is not 

equal much more under the same condition (more than 5 ml), then replace the injector. 

WARNING 

When check the fuel system: 

• Place a “Caution - No inflammable” symbol inside the operation area. 

• Never smoke while servicing the vehicle. 

• Service vehicles in well - ventilated areas and avoid ignition sources. 

• Release fuel system pressure before servicing fuel system components. 


YES > Go to step14. 

NO > Clear the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault is 

not present. If not OK, go to next step. 

Page 194


04-67 

12. CHECK FUEL SYSTEM RETURN 

(a) Using the fuel return blocker, clamping the return pipe, make the system fuel can not return. 

(b) Check whether the system pressure can establish again quickly. 

YES > Replace the fuel pressure regulation. 

NO > Repair or replace the fuel supply pipe, pump or injector. 

04 

13. CHEKC FUEL SYSTEM SUPPLY 

(a) 

Check whether the input pipe leakage or block. 

CAUTION 

Running the engine, Check connectors for fuel leaks as following: 

(b) Turn the ignition switch ON (Do not start the engine). Apply pressure on the fuel pipe. Check whether 

fuel leaks at fuel pipe connection. 


YES > Repair or replace the inlet fuel pipe. 

NO > Replace fuel pump. 

04 

14. CHECK CYLINDER PRESSURE 

(a) Perform the cylinder compression pressure test. The standard as following: 

• Per cylinder pressure: 1270 kPa 

• Per cylinder limit: 880 kPa 

• Per cylinder difference limit: less than 25% 




15. CHECK ENGINE VALVE - TIMING 

(a) Check whether the engine valve - timing gear mark is aligned, damaged. And the belt is loose. Whether 

the jumping over teeth exists. 



NO > Perform the valve timing align operation. 

16. CHECK ENGINE MECHANISM 

(a) Perform the engine mechanism inspection: 

• Check the cylinder with the endoscopy. 

• Inspect the feedback voltage. 

• Disassembly the engine inner faults. 



NO > Repair the engine inner mechanism faults. 

Page 195

04-68 


ENGINE STARTS DIFFICULTILY WHEN IT IS COLD 


Engine starts difficultily 

when it is cold (idle) 

• Engine runs normally 


• It needs several times 

for engine starts 

successfully when it is 

cold 

1. A/F is not correct 

2. Carbon deposit at 

valve 

3. Operation condition is 

not equal between 

every cylinder 

4. ECT sensor is fault 

5. Others: 

• MAP/IAT sensor 

• Idle step motor 

• Fuel quality 


• Supply fuel system 

• Injector 

• Leakage of the inlet 

system 

• Cylinder compression 

pressure 

• Engine management 

system 

• Battery 

• ECM 

NOTE 

Hard engine starting refers to that the starter is able to drive the engine to run in normal speed with 

clear starting symptom, but the engine only run after continuous starting or the starter driving for a 

long time. For the failure of hard starting, determine whether the occurrence is in cold starting or hot 

starting, or both of them. The cause of this failure is from the fuel injection system generally. Check it 

in the following method. 


1. CHECK ENGINE MIL AND DTC 



YES > Refer to DTC chart. Perform the diagnostic procedure. 


2. CHECK THE VISUAL INSPECTION 


(b) Check following after opening the engine hood: 

• Air filter. 

• Leakage of the intake manifold. 




3. CHECK BATTERY 

(a) Check the battery voltage when cranking the engine. 

Battery voltage: ≥ 9.6 V 



NO > Charge or replace battery. 

Page 196


04-69 

4. CHECK STARTER 

(a) Check whether the starter or the starter circuit exist fault. 




04 



(b) Read the displayed CKP sensor value. 




04 

6. CHECK ECT SENSOR 


(b) With the multimeter to check the ECT sensor or feedback voltage. (or with a 1.5 kΩ resistance, replace 

the ECT sensor. Start engine. If OK, it means that the ECT sensor isnot normal). 



NO > Replace the ECT sensor. 

7. CHECK MAP SENSOR 

(a) Check MAP sensor after starting engine successfully. 

Pressure value: 35 ~ 55 kPa 



NO > Eliminate the leakage of intake system. 

8. CHECK THROTTLE BODY 

(a) Depress the accelerator slightly. Start egnine. 





CAUTION 


makes the ECM control the idle air impossilly. And it will cause the A\F too lean or too rich. The borning 

will not be normal. And the usual reasons are: carbon and grease, grease beside the throttle air 

path, carbon and grease with the idle air controlmotor. 

9. CHECK IDLE AIR CONTROL MOTOR 

(a) Disconnect the idle air control motor connector. Check whether there is 12 V. And the resistance value 

is 28 ~ 33 Ω when the temperature is 20 ℃ . 

(b) Remove the idle air control motor to test: 

• Check expansion of the idle air control motor when turning the ignition switch ON. 

• Check whether the idle air control motor can move when turning the ignition switch OFF. 

Page 197

04-70 




NO > Repair or replace the idle control motor. 





(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT sensor value. 



NO > Replace the MAP/IAT sensor. 


(a) Release the fuel system pressure. 

(b) Check the fuel system pressure. 












(a) Remove the injector connector. 




CAUTION 

If the spraying condition isnot normal just as the “cylindrical growth”, or the spraying quantity is not 


WARNING 








NO > Clean the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault 

isnot present. If not OK, go to next step. 

Page 198


04-71 


(a) 

(b) 

Using the fuel return blocker, and clamping the return pipe, make the system fuel not return. 

Check whether the system pressure can establish again quickly. 




(a) 

Check whether the input pipe leaks or block. 

CAUTION 


(b) Turn the ignition switch ON (not crank the engine). Apply pressure on the fuel pipe. Check whether fuel 

leakage at fuel pipe connection. 





04 

04 













(b) Check whether there is carbon deposit in plug, carbon tracking,residual current in insulating ceramics 






(a) With multimeter, check resistance of the ignition spark wire. 

Resistance:≥ 4 kΩ 




Page 199

04-72 











(a) Check whether the engine valve - timing gear mark is aligned, damaged and the belt is loose. 



NO > Perform the valve timing align operation or replace the timing belt. 





• Disassembly the engine. 

• Clear the carbon deposit or remove and check the engine cylinder head. 

• Check valves, carbon deposit of manifold. For example: the clearance between the cylinder and the 

piston ring. The leakage of the cylinder gasket, and loose of the valve guides, carbon deposit of the 

valve. 




Page 200


04-73 

UNSTABLE IDLE 


Unstable idle (Rough idle, 

hunting) 

The engine cannot keep 

stability 

• The ignition system, 

air - fuel. 

• Air ratio 

• IAC motor 


is too low 



• Malfunction of air - fuel 

ratio control system 

• Malfunction of the IAC 

system 

• Poor compression 

• Drawing air into intake 

air system 

• ECM 

04 

04 

NOTE 

The unstable idle is the usually faulty. It has many kinds of types. It includes unstable, misfire, etc. 

When performing the diagnosis and elimination, should analyse according to the specific symptom. 





YES > Refer to DTC chart. Perform the diagnosis procedure. 




(b) Check after opening the engine hood: 

(c) Inspect the engine operating condition. 

(d) Inspect the tachometer if the pointer deviates the idle target value. 

(e) Inspect if the idle trembles is normal or load reasons, such as: A/C, lighting, push the lever into gear, 

turn the steering wheel, etc. 

(f) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses. 

(g) Check whether the exhaust pipe emit black smoke. 

(h) Check whether there is unburned petrol fumes. 

(i) Check whether the throttle cable is adjusted to be appropriate. 




3. CHECK THE THROTTLE AND IDLE CONTROL MOTOR 

(a) Check throttle body and idle air path. Clear the carbon deposit and greasy dirt. 

(b) Start engine and runs at idle. 

(c) Using scan tool, select the item, active test. 

(d) Perform the idle air control motor test. 

• When the scan tool control the rotation of expansion of the idle air control motor, the engine RPM 

changes from high to low in synchronism (touching the idle air control motor, can feel vibration). 

Page 201

04-74 


(e) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is 

28 ~ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary, 

repair or replace it. 

(f) Remove the idle air control motor . Connect the connector: 

• Check whether the idle air control motor can extend - retract when turning the switch off. 

• Check whether the idle air control motor can move when turning the ignition switch on. 



NO > Repair or replace idle control motor. 

4. CHECK ENGINE IGNITION SYSTEM 

(a) Engine runs at idle speed. 

(b) Brennschluss one by one. 

(c) Inspect if the idle speed changes. 

CAUTION 

It is better that use the active test function of the scan tool to perform the brennschluss test. If without 

the scan tool or the scan tool wirhout the function, the brennschluss period shoul not be too long, if 

not, the Three Way Catalytic Converter (TWC) will be damaged. 

(d) When brennschluss every cylinder, the same RPM should decline obviously or the same vibration. 








• Connect the spark plug to spark plug wire. Ground the spark plug on the cylinder block. 

• Start the engine to test the secondary ignition system with the spark plugs removed. 

normal result: A strong blue spark visible is at each spark plug while cranking the engine 





(a) Check secondary ignition wire resistance. And clear the connector terminals. 





NO > Replace the faulty components. 

Page 202


04-75 


(a) 

With multimeter, check resistance of the ignition spark wire. 





8. CHECK THE INJECTOR 

(a) Using scan tool, select the item, active test. 

(b) Perform the injector active test. 

(c) Check whether the same engine RPM decline obviously and shortly in synchronism (touching the injector, 

can feel vibration, or with the voice - tool, touch the injector, the action voice should be hearded). 



NO > Repair, clear or replace harness or connectors. Every injector can spray even and standard quantity 

gasoline. If not OK, replace it. 

CAUTION 

If the spraying condition isnot normal just as the “cylindrical growth”, or the 4 injectors spraying quantity 

is not equal much more under the same condition (more than 5 ml), then replace the injector. 

WARNING 






04 

04 














Page 203

04-76 



(a) 

Using the fuel return blocker and clamping the return pipe, make the system fuel not return. 






(a) 


CAUTION 

Check connectors for fuel leakage as following: 

(b) Turn the ignition switch ON (Do not start the engine). 

(c) Apply pressure on the fuel pipe. 

(d) Check whether fuel leaks at fuel pipe connection. 




12. CHECK INTAKE AND EXHAUST SYSTEM 




(d) Check the sensors and actuators electrical connectors and verify good contact and tight connection. 

(e) Check the PCV valve. 

(f) Check whether the EVAP system leakage. 

(g) Checkif the fuel pressure regulator vacuum pipe broken, kinked or crack. 

(h) Check whether the Three - Way Catalytic Converter (TWC) is blocked. 

(i) Check whether the throttle body gasket leakage. 

(j) Check whether the intake manifold gasket leakage. 



NO > Repair or replace the faulty components. 

13. CHECK MAP/IAT SENSOR 

(a) Check whether the installation of the MAP/IAT is normal? 

(b) Remove the MAP/IAT sensor. 

(c) Check whether the MAP/IAT sensor is dirty. 


(e) Read the scan tool displaied MAP/IAT sensor data stream value. 

(f) With the 3 kinds of the basic types: idle tets, accerlerate suddenlly test and blocked test in exhaust 

system. Test the vaccum rate in the intake manifold. 



NO > Clear and reinstall or repair. If not OK, go to step 15. 

Page 204


04-77 

14. CHECK OXYGEN SENSOR 

(a) Engine idle. 

(b) Inspect the displayed scan tool data stream. 

(c) When the temperature is normal after the engine enter into the closed - loop control, inspect if the 

oxygen sensor operate normally. 

Oxygen Sensor Normal Value: 0 ~ 1 V. Change 5 ~ 8 times in 10 seconds periodically. 



NO > Replace xoygen sensor harness or connector. 

04 

04 



• Per cylinder pressure: 1270 kPa. 

• Per cylinder limit: 880 kPa. 

• Per cylinder difference limit: less than 25%. 











(b) Check the cylinder with the endoscopy. 

(c) Inspect the feedback voltage. 

(d) Disassembly the engine inner faults. 

(e) Clear the carbon deposit or remove and check the engine cylinder head. 

(f) Check valves, carbon deposit of manifold. For example: the clearance between the cylinder and the 


valve. 




Page 205

04-78 


IDLE IS TOO HIGH 


Idle is too high (The 

engine does not idle at the 

usual correct speed) 

Engine idle speed too 

high 

The cause is probably that the 

intake air volume during idle 

is too great 

• Malfunction of the Idle 

air control motor 


throttle body 

• ECM 










• Inspect the engine operating condition. 

• Inspect the tachometer if the pointer deviates the idle target value. 

• Inspect if the idle trembles is normal or load reasons, such as: A/C, lighting, push the lever into gear, 


• Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses. 

• Check whether the exhaust pipe emit black smoke. 

• Check whether there is unburned petrol fumes. 

• Check whether the throttle cable is adjusted to be appropriate. 




3. CHECK THE ACCELERATOR PEDAL 

(a) Check whether the accelerator pedal cable blocked. 



NO > Adjust or replace the accelerator cable. 

4. CHECK RELATED ACCESSORIES 

(a) Check EVAP. 

(b) Check the fuel pressure vacuum regualtor. 

(c) Check whether the PCV vacuum pipe installation is reliable. 

(d) Check whether the braking system vacuum booster pipe installation is reliable. 



NO > Adjust or replace. 

Page 206


04-79 

5. CHECK IDLE 


(b) Gear in N position. 

(c) Depress brake pedal. 

(d) Inspect if the idle speed is too high. 




6. CHECK THE VACUUM BOOSTER 

04 

04 

(a) Blocking the vacuum pipe, inspect if the idle become normal. 



NO > Repair or replace the vacuum booster. 

7. CHECK PCV VALVE 

(a) Clipping the PCV vacuum pipe, inspect if the idle become normal. 

(b) Check whether the PCV valve clip. If the opening degree is normal. 



NO > Replace PCV valve. 


(a) Start engine and runs at idle. 

(b) Using scan tool, select the item, active test. 

(c) Perform the idle air control motor test: 



• Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is 

28 - 33 Ω when the temperature is 20 ℃ . 

(d) Remove the idle air control motor to test: 





NO > Replace the idle control motor. 

9. CHECK THE INTAKE SYSTEM 

(a) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses. 

(b) Check the intake air pipe for being jammed, leaking, or damaged. 



NO > Repair or replace vacuum pipes. 

Page 207

04-80 



(a) Check whether the installation of the MAP/IAT sensor is normal? 



(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT value. It should be within the specified 

value. 









NO > Repair or replace related components of fuel system. 






CAUTION 



WARNING 







YES > Replace the injector washer. 

NO > Clean or replace the injectpor. 

Page 208


04-81 

WHEN THE ENGINE IS COLD, IT STALLS 


When the engine is cold, 

it stalls (At idle) 

The cause is probably 

that the air/fuel mixture is 

inappropriate when the 

engine is cold, or that the 

intake air 

volume is insufficient. 


that the intake air volume 

during idle is too great 


motor 


throttle body 


injector 



• ECM 

04 

04 















• Check whether the exhaust pipe emit black smoke. Check whether there is unburned petrol fumes. 





3. CHECK THE THROTTLE AND IDLE AIR CONTROL MOTOR 


CAUTION 


makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The borning 



(b) Start engine and run at idle. 


(d) Perform the idle air control motor test: 

(e) When the scan tool control the rotation of expansion of the idle air control motor, the engine RPM 


Page 209

04-82 


(f) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is 

28 - 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary, 




NO > Clean, repair or replace idle control motor. 

4. CHECK THE ECT SENSOR 

(a) Check the resistance accord with the standard: 

20 ℃ : 2.1 ~ 2.7 kΩ 

80 ℃ : 0.26 ~ 0.36 kΩ 

(b) Using scan tool, select the item, read the data stream. 




5. CHECK THE IAT SENSOR 


20 ℃ : 2.3 ~ 3.0 kΩ 

80 ℃ : 0.3 ~ 0.42 kΩ 




NO > Replace the IAT sensor. 









gasline. If not OK, replace it. 

CAUTION 



WARNING 






Page 210


04-83 


(a) 

Release the fuel system pressure. 












04 

04 


(a) Using the fuel return blocker and clamping the return pipe, make the system fuel not return. 






(a) 


CAUTION 

Check connectors for fuel leaks as following: 





YES > Repair or replace the intake fuel pipe. 

NO > Replace the fuel pump. 









Page 211

04-84 






NO > Perform the valve timing align operation or replace timing belt. 









valve. 



NO > Repair the engine mechanism faults. 

Page 212


04-85 

THE ENGINE STALLS WHEN ACCELERATING 


The engine stalls when 

accelerating 


the accelerator pedal is 

depressed 

• Poor power when starting 

• Malfunction of the Idle air 

control motor 

• Malfunction of the throttle 

body 

• Malfunction of the injector 

• Malfunction of the ignition 

system 



• ECM 

04 

04 

NOTE 

Start in idling mode: Put into gear without pressing the accelerator pedal, disengage the clutch and 

start the engine. This moment, as the throttle valve is closed and the idling electric shock is closed, 

ECM considers it as the idling mode. The control of idling mode is a cruise control without any load 

signal, namely a steady speed control that the engine is controlled in target speed range. Speed - 

raising control is done if with load signal. During starting, the load signal is input into ECM, the later 

raises the engine speed, enhances the dynamic property and keeps the idling from the effect of load. 

This moment the starting is smoothly and hard to be shut off generally. If the starting is wobbled and 

easy to be shut off and the speed falls in idling mode, find the causes from the idling control. 

Page 213

04-86 





























(e) Disconnect the idle air control motor connector, Check whether there 12 V exists. And the resistance value 

is 28 - 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary, 


(f) Remove the idle air control motor. Connect the connector: 

• Check whether the idle air control motor can extend - retract when turning the switch off. 




NO > Clear, repair or replace idle control motor. 

Page 214


04-87 

4. CHECK THROTTLE POSITION 

(a) 

With the scan tool, check whether the throttle is normal. 

(b) Check whether the throttle open degree is normal when depressing the accelerator pedal. 



NO > Adjust the throttle position. 

5. CHECK THE LOAD SIGNAL 

(a) Check whether the gear signal is sent to ECM. 

(b) Check whether the A/C signal is sent to ECM. 

(c) Check whether the load signal is sent to ECM. 




04 

04 

6. CHECK THE IGNITION SYSTEM 


(b) Cut off spark plug wire one by one. 


CAUTION 

It is better that use the active test function of the scan tool to perform the cutoff test. If without the 

scan tool or the scan tool wirhout the function, the brennschluss period shoul not be too long, if not, 

the TWC will be damaged. 
















Page 215

04-88 



(a) 

Check secondary ignition wire resistance. And clean the connector terminals. 



















NO > Repair or replace injector 

CAUTION 

If the spraying condition is not normal just as the “cylindrical growth”, or the 4 injectors spraying 

quantity is not equal much more under the same condition (more than 5 ml), then replace the injector. 

WARNING 



















Page 216


04-89 


(a) 

Using the fuel return blocker and clamping the return pipe, make the system fuel not return. 




NO > Repair or replace the fuel supply pipe, pump, injector. 


(a) 


CAUTION 



leaks at fuel pipe connection. 




04 

04 



















• Clear the carbon deposit or remove and check the engine cylinder head. Check valves, carbon deposit 

of manifold. For example: the clearance between the cylinder and the piston ring. The leakage of the 

cylinder gasket, and loose of the valve guides, carbon deposit of the valve. 




Page 217

04-90 


ACCELERATED REACTION IS SLOW, ACCELERATON DISTURBANCE 


Accelerated reaction is 

slow, acceleraton 

disturbance 

When the accelerator is 

depressed in order to 

accelerate from the 

speed, the vehicle is now 

traveling or a temporary 

drop in vehicle speed 

during such acceleration. 


that ignition system, air - 

fuel mixture or 

compression pressure is 

defective 




throttle body 





• Malfunction of fuel 

supply system 


• ECM 





















3. CHECK THE AIR FILTER 

(a) Check whether the air filter dirty, grease and blocked. 



NO > Clean or replace the air filter. 

4. CHECK IDLE 

(a) 

(b) 

Start engine and runs at idle. 

Check whether the idle speed is normal. 

Page 218


04-91 



NO > Refer to the symptom chart, eliminate the problems. 






(e) Read the scan tool displayed MAP/IAT sensor data stream value. 




04 

04 

6. CHECK TPS 


(b) With the analogue mulitimeter to check TPS resistance (resistance should be continuity). 

(c) Refer to engine DTC chart. 



NO > Repair or replace the throttle position sensor. 

7. CHECK FUEL SYSTEM PRESSURE 


















CAUTION 



Page 219

04-92 


WARNING 








NO > Repair or replace the injector. 





NO > Repair or replace the fuel supply pipe, pump and injector. 


(a) 


CAUTION 


(b) Turn the ignition switch ON (not crank the engine). 


(d) Check whether fuel leakage at fuel pipe connection. 




11. CHECK EXHAUST SYSTEM 

(a) Check the exhaust system and Three - Way Catalytic Converter (TWC). 

(b) Check whether the exhaust pipe blocked with the exhaust pressure meter. 



NO > Replace or clean the exhaust system. 









Page 220


04-93 


(a) Check whether the engine valve - timing gear mark is aligned, damaged. And the belt is loose. 




04 





• Disassembly the engine faults. 





YES > Repalce the ECM. 


04 

Page 221

04-94 


POOR ACCELERATION 


Poor Acceleration 

Poor acceleration is the 

inability to obtain an 

acceleration corresponding 

to the degree of throttle 

opening (even though 

acceleration is smooth) or 

the inability to reach 

maximum speed 

Defective ignition system, 

abnormal air - fuel ratio, poor 

compression, etc are 

suspected. 






supply system 

• Poor acceleration 

• Clogged exhaust 

system 

• ECM 



(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04 engine control 

system - read and clear DTC”) 




2. CHECK VISUAL INSPECTION 














3. CHECK THROTTLR POSITION SENSOR 


(b) With the analogue mulitimeter to check throttle position sensor resistance (resistance should be 

continuity). 




Page 222


04-95 










04 

04 



















CAUTION 



WARNING 








NO > Clean or replace the injector. 

Page 223

04-96 



(a) Using the fuel return blocker and clamping the return pipe, make the system fuel not return. Check 

whether the system pressure can establish again quickly. 





(a) 


CAUTION 


























Page 224


04-97 


(a) 














04 

04 

















Page 225

04-98 

DIAGNOSTICS - ANTI - LOCK BRAKE SYSTEM 

ANTI - LOCK BRAKE SYSTEM 

PRECAUTION 


(a). Before removing or installing any electrical device, please disconnect the negative cable to 

prevent damage to the device or personal injury. 

(b). 

Make sure ignition switch is OFF if no specific instructions. 

NOTE 

If equipped with central locking, do not leave ignition switch in the car before disconnecting the 

battery negative cable. 

2. REMOVE INSTRUMENT CLUSTER OR DISCONNECT THE NEGATIVE CABLE WILL RESULT IN 

LOSS OF DATA. 

NOTE 

Total odometer will not be cleared. 

3. WHEN THE BATTERY TERMINAL IS REMOVED, ALL THE MEMORIES OF THE CLOCK, RADIO, 

DTCS, ETC. WILL BE ERASED. SO BEFORE REMOVING IT, CHECK THEM AND NOTE THEM 

DOWN. 

NOTE 

When service is finished, reset the clock and audio systems. 

4. EXPRESSIONS OF IGNITION SWITCH. 



Expression 




5. NOTES ABOUT ANTI - LOCK BRAKE SYSTEM. 

(a) The system will resumes its normal state temporarily or competely by removing and reinstalling the 

suspicious faulty components when the connector terminals or the installing state of the components go 

out of order. 

(b) In order to identify the faulty position, we must check the vehicle condition while vehicle goes out of 

order. For example, we check the faults through the DTC. And we record these fault states before 


(c) The sensor and ABS module can be removed or installed with the ignition switch in OFF position. 

(d) After repairing the anti - lock brake system is completed, check the ABS warning light. 

(e). Never use the multimeter to measure the terminal of ABS module. 

(f). The ABS system must be repaired by technicians trained and mastered maintenance 

skills, and only use original parts for replacement. 

(g). Before repairing the ABS system, if there are some failures with mechanical braking 

system, must be excluded. Such as: 

• Brake system noise. 

• Brake pedal is excellent. 

• Brake pedal or vehicle vibration when pressing pedal. 

Page 226


04-99 

• Vehicle deviation. 

• Parking brake system failure. 

(h). ABS control module (refer to the ABS electronic control unit and hydraulic control unit, not 

including brake lines, sensors ,etc.) can only be replaced as assembly, can not be 

overhauled or part replacement / swap. 

(i). The following two cases show that ABS system failure is detected: 

• Turn the ignition switch On, the system self - test is completed, but the warning light 

is on. 

• The warning light is always on when driving the vehicle. 

The driver can stop the vehicle conventionally, but it should be as far as possible to reduce the 

braking force to prevent the wheels from locking. Warning lamp lights need to be careful driving 

and immediately to the authorized service station overhaul to prevent more failures occurred, 

resulting in a traffic accident. 

(j). Pay attention to the following points when connect the ABS system connector: 

• Turn the igintion OFF before disconnecting ABS wiring harness and connector. 

• Ensure that the connector dry and clean, to avoid any foreign objects to enter. 

• ABS harness connector is installed in place, must be in the horizontal direction and 

a vertical direction to avoid damage to the connectors. 

(k). Ensure proper connection when connectiong the ABS system pipes. ABS control module 

can not detect that the brake lines are connected properly or not. The error connection 

may lead to a serious accident. Connecting the brake lines, must be in compliance with 

the ABS assembly on the mark: 

• MC1: Brake line 1 connected to the brake master cylinder. 


• FL: Brake line connected the wheel cylinders FL. 

• FR: Brake line connected the wheel cylinders FR. 

• RL: Brake line connected the wheel cylinders RL. 

• RR: Brake line connected the wheel cylinders RR. 

(l). There are noise with ABS system in the following cases: 

• Vehicle power or start the engine, it will produce a short sound of "Om", this is a 

normal phenomenon with the sound of the ABS self - check.. 

• There will be sound when ABS system work properly, mainly reflected in the 

following: 

1) Sound made by ABS hydraulic unit motor, solenoid valve and the reflux pump. 

2) Sound caused by brake pedal rebounding. 

3) Emergency brake caused the crash of the suspension and the body. 

04 

04 

Page 227

04-100 


LOCATION 

1 Front Brake Pipe RH 

2 ABS Control Module 

3 Front Brake Pipe LH 

4 Rear Brake Pipe LH 

5 Rear Brake Pipe RH 

Page 228


04-101 

ABS MODULE CONNECTOR 

04 

04 

No. Wiring Color Difinition 

1 R ABS motor power input 

2 - - 

3 Y - R EBD warning ligh output 

4 L Front sensor signal RH 

5 - - 

6 R - L Dinostic connector K 

7 - - 

8 W Front sensor signal LH 

9 - - 

10 - - 

11 - - 

12 - - 

13 W - B ABS motor ground 

14 - - 

15 - - 

16 G 

17 P 

Front sensor power 

suppy RH 

Rear sensor power 

suppy RH 

18 L - G Rear sensor signal LH 

19 B 

Front sensor power 

suppy LH 


20 - - 

21 - - 

22 - - 

23 - - 

24 - - 

25 R - W 

ABS solenoid valve 

power suppy input 

26 - - 

27 Y - G ABS warning ligh output 

28 R - W ABS - IG input 

29 LG Rear sensor signal RH 

30 G - W Brake signal 

31 Y - W 

Rear sensor power 

suppy LH 

32 - - 

33 - - 

34 - - 

35 - - 

36 - - 

37 - - 

38 W - B ECU ground 

Page 229

04-102 



NOTE 

If a malfunction code is displayed during the DTC checking, check the circuit listed below. For details 

of each code, turn to the relevant troubleshooting page in the DTC chart. 

DTC No. 

C190004 

C190104 

C100004 

C101008 

C006B06 

C003108 

C003200 

C00A000 

C00A100 

C00A900 

C003408 

C003500 

C00A200 

C00A300 

C00AA00 

C003708 

C003800 

C00A400 

C00A500 

C00AB00 

C003A08 

C003B00 

C00A600 

C00A700 

C00AC00 

ECU Power Suppy High 

ECU Power Suppy Low 

Detection Item (DTC Definition) 

ECU Malfunction (Hardware, Central Controller Error) 

ECU Malfunction (Software Error) 

Abs Control Is Unreasonable (Controling Time Too Long) 

Front Wheel Speed Sensor LH Output Signal Malfunction: Beyond The Scope Of Loss, 

Noise, Intermittent Interruption 

Front Wheel Speed Sensor LH Wiring Malfunction: Open 

Front Wheel Speed Sensor LH Wiring Malfunction: Short For Ground 

Front Wheel Speed Sensor LH Wiring Malfunction: Short For Power Suppy 

Front Wheel Speed Sensor LH Malfunction: Unknow 

Front Wheel Speed Sensor RH Output Signal Malfunction: Beyond The Scope Of Loss, 


Front Wheel Speed Sensor RH Wiring Malfunction: Open 

Front Wheel Speed Sensor RH Wiring Malfunction: Short For Ground 

Front Wheel Speed Sensor RH Wiring Malfunction: Short For Power Suppy 

Front Wheel Speed Sensor RH Malfunction: Unknow 

Rear Wheel Speed Sensor LH Output Signal Malfunction: Beyond The Scope Of Loss, 


Rear Wheel Speed Sensor LH Wiring Malfunction: Open 

Rear Wheel Speed Sensor LH Wiring Malfunction: Short For Ground 

Rear Wheel Speed Sensor LH Wiring Malfunction: Short For Power Suppy 

Rear Wheel Speed Sensor LH Malfunction: Unknow 

Rear Wheel Speed Sensor RH Output Signal Malfunction: Beyond The Scope Of Loss, 


Rear Wheel Speed Sensor RH Wiring Malfunction: Open 

Rear Wheel Speed Sensor RH Wiring Malfunction: Short For Ground 

Rear Wheel Speed Sensor RH Wiring Malfunction: Short For Power Suppy 

Rear Wheel Speed Sensor RH Malfunction: Unknow 

Page 230


04-103 

DTC No. 

C109904 

C001004 

C001104 

C001404 

C001504 

C001804 

C001904 

C001C04 

C001D04 

C109504 

C002004 

C007208 

Wheel Speed Sensor Group Malfunction (Wheel Speed Sensor Interchangeable, Each 

Of The Wheel Speed Difference Is Too Large, Wheel Speed Sensors Fault) 

Front Inlet Hydraulic Valve LH Failure 

Front Outlet Hydraulic Valve LH Failure 

Front Inlet Hydraulic Valve RH Failure 

Front Outlet Hydraulic Valve RH Failure 

Rear Inlet Hydraulic Valve LH Failure 

Rear Outlet Hydraulic Valve LH Failure 

Rear Inlet Hydraulic Valve RH Failure 

Rear Outlet Hydraulic Valve RH Failure 

Valve Relay Failure 

Reflux Pump Motor Failure 


Valve Group Failure (Overheating Protection Signal Is Invalid, Hardw Is Damaged) 

04 

04 

Page 231

04-104 



Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely 


Symptom Suspect Area Reference 

1. Brake pipe leakage, 

breakage, etc. 

- 

2. Lack of brake fluid - 

3. Differential fault 

Chapter 34 axle and propeller shaft - differential 

assy, check and adjustment 

4. Front brake fault Chapter 35 brake - front brake, overhaul 

5. Rear brake fault Chapter 35 brake - rear brake, overhaul 

ABS is inoperative. 

6. Hydraulic regulator assembly 

fault 

7. Parking light switch fault 

8. Brake fluid level sensor fault 

9. Brake switch fault 

10. Speed sensor fault 

11. Stop valve fault 

12. Pressure relief valve fault 

13. ABS module power supply 

fault 

14. ABS module ground fault 

Chapter 04 diagnostics - instrument cluster, 

ABS warning light is inoperative/always on 





Chapter 04 diagnostics - anti - lock brake system, 

ABS system is inoperative 









- 

15. ABS module fault - 

Page 232


04-105 

PRE - CHECK 

Before diagnosis of the ABS system, check the ABS system failure and easily accessible 

components first, visual inspection can quickly determine fault, and thus do not need to do further 

diagnosis. 

1. CHECK TIRE. 

(a). Make sure that the vehicle only install the 

recommended size tires and wheels. coaxial style 

of tire tread depth must be the same. Specific tire 

models, refer to the vehicle owner's manual for 

details. 

04 

04 

2. CHECK THE ABS HYDRAULIC MODULATOR, BRAKE PIPES AND CONNECTIONS 

FOR LEAKING. 

3. CHECK ABS SYSTEM FUSES TO ENSURE THAT THE FUSES ARE NOT BURNED, 

AND THE MODEL IS CORRECT. ABS SYSTEM HAS THREE FUSES: 

• Pump motor fuse (40A) 

• Solenoid valve fuse (25A) 

• Electronic control unit Fuse (5A) 

4. CHECK THE BATTERY VOLTAGE, DETECT WHETHER THE BATTERY TERMINAL 

CORROSION OR LOOSE. ABS SYSTEM NORMAL OPERATING VOLTAGE RANGE IS 

9.3V - 16.8V. 

5. CHECK ABS GROUND. 

(a). Check ABS grounding point is loose. The 

location is changed or not. 

(b). 

ABS ground has good sealing, in order to avoid 

water and moisture in capillary (siphon) effect 

through wiring harness of channel infiltration ABS 

control module, which cause function failure. 

Page 233

04-106 


6. VISUAL INSPECTION OF THE FOLLOWING 

ELECTRICAL COMPONENTS: 

(a). 

(b). 

NOTE 

ABS system harness and connectors of the 

related components are properly connected, to be 

pinched or cut or not. 

Harness routing is too close to high - voltage or 

high - current devices, such as high - voltage or 

parts, generators, motors or stereo amplifier. 

The high voltage or high current device may cause 

the circuit to generate the induced noise, and 

thereby interfere with the normal working of the 

circuit. 

(c). ABS parts are sensitive to electromagnetic 

interference (EMI). Suspected intermittent fault, 

check the aftermarket installation of anti - theft 

device, lights, or whether the mobile phone is not 

installed correctly. 

7. IF THE ABS NOISE IS TOO LARGE, IT MAY BE CAUSED BY THE FOLLOWING 

REASONS: 

(a). Loosening of ABS assembly with bracket. 

(b). Loosening of ABS bracket and body. 

(c). ABS plastic bracket washer missing or damaged. 

Page 234


04-107 

POWER SUPPY VOLTAGE HIGH OR LOW 

DIAGNOSTIC TROUBLE CODE: 

C190004; C190104 

CONDITIONS OF FAULT SETTING 

It will be caused failure by one of the following conditions are met when the supply voltage of the 

ECU: 

(1) Voltage is lower than 4.5V when starting engine. 

(2) Voltage is lower than 7.7V or higher than 16.8V when ignition switch is ON. 

(3) Voltage is between 7.7V to 9.2V when vehicle speed is higher than 6km/h. 

04 

04 


1. PERFORM PRE - CHECK STEPS 



NO > Repair or replace related components. 

2. INSPECT BATTERY 

(a). Turn the ignition switch ON. 

(b). Measure the battery voltage. 



NO > Repair or replace battery. 

3. ABS CONTROL MODULE CROSS - VALIDATION 

(a). Turn the ignition switch OFF. 

(b). Remove the ABS actuator. (Refer to “Chapter 35 brake - abs actuator, replacement”) 

(c). Install the removed ABS to another known vehicle with the same model. (Ensure that ABS 

connectors are securely installed without connecting pipes when vehicle was driven. ) 

(d). Start the engine and to ensure that the vehicle speed is not lower than 20km/h, so that the 

ABS dynamic self - check. 


YES > Replace ABS module. 

NO > Replace the ABS actuator. 

Page 235

04-108 


SOLENOID VALVES AND VALVES RELAY FAILURE 


C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04; C109504; 

C007208 



ECU: 

(1) Valves power supply failure. (Power supply short for ground or ground open.) 

(2) Solenoid valve temperature is too high. (Overheating protection) 

(3) Solenoid valve is shorted. (Fuse) 

(4) Actuating the corresponding solenoid valve, but no feedback. 

(5) Solenoid valve failure. 

(6) Valves relay failure. 

POSSIBLE CAUSE 

(1) Solenoid valve short for power supply or ground, circuit open. 

(2) Fuses failure. 

(3) Overheating protection (Solenoid valve long working hours, common in vacuum filling and 

offline detection) 

(4) ABS damaged 


1. DETECT THE OCCASIONAL FAULT OF SYSTEM 


(b). Disconnect the battery negative cable. 

(c). Vehicle was allowed to stand for 5 minutes. 

(d). Connect the negative battery cable. 


YES > System is normal . 






Page 236


04-109 

3. READ DTC AND DATA ON THE DIAGNOSTIC TOOL 

(a). 

(b). 

NOTE 

Selecte diagnostic mode in the disgnostic tool and read data stream. 

Detect vehicle speed displayed on the instrument panel and diagnostic tool when vehicle 

is running, and compare whether they are consistent. 

If speedmeter display shows the speed value and the diagnostic value of error within ± 10%, it belongs 

to the normal range. 


04 

04 

YES > Clear the DTC(s). 


4. INSPECT FUSE 

(a). 

Disconnect the battery negative cable. 

(b). Inspect the ABS valve fuse in battery 

compartment junction box (A001): 25 A. 

(c). Inspect the ABS IG fuse in battery compartment 

junction box (A001): 5 A. 



NO > Replace the fuse. 





connectors are securely installed without connecting pipes when vehicle was driven.) 


ABS dynamic self - check 




Page 237

04-110 


6. CHECK HARNESS AND CONNECTOR (ABS VALVE FUSE - GROUND) 

(a). 


(b). 

Measure the voltage according to the value(s) in 

the table below. 



ABS valve fuse - Ground 






7. CHECK HARNESS AND CONNECTOR (ABS IG FUSE - ABS MODULE) 

(a). 

(b). 

Remove the ABS IG fuse (5A) in the battery compartment junction box. 

Disconnect the A009 ABS module connector. 

(c). 

Measure the resistance according to the value(s) 

in the table below 



ABS IG fuse - A009 (28) 


< 2 Ω 




Page 238


04-111 

8. CHECK HARNESS AND CONNECTOR (ABS VALVE FUSE - ABS MODULE) 

(a). 

(b). 

Remove ABS valve fuse (25A) in the battery compartment junction box. 


04 

(c). 






04 

ABS valve fuse - A009 (25) 

< 2 Ω 


YES > Replace ABS MODULE. 


Page 239

04-112 


PUMP MOTOR FAILURE 


C002004 



ECU: 

(1) Pump motor is overloaded with work, the temperature is too high. (Overheat protection) 

(2) Reflux pump motor relay work over 60ms, reflux pump monitoring is still not detected voltage 

signal. 

(3) Reflux pump motor relay did not work, reflow pump monitoring detected voltage exceeds 

2.5s. 

(4) Reflux pump motor relay stops working and the reflux pump monitoring detected voltage 

does not drop. 


(1) Pump motor is poorly grounded. 

(2) System overheating protection. 

(3) Pump motor power supply is not normal(Fuse, battery terminal) 

(4) Pump motor relay failure. 

(5) Pump motor failure. 




(b). Disconnect the battery negative cable. 

(c). Vehicle was allowed to stand for 5 minutes. 

(d). Connect the negative battery cable. 


YES > System is normal 






Page 240


04-113 


(a). 

(b). 

NOTE 




If speedmeter display shows the speed value and the diagnostic value of error within ± 

10%, it belongs to the normal range. 


04 

04 




(a). 


(b). 

(c). 

Inspect the ABS pump fusible link in battery 


Inspect the ABS IG fuse in battery compartment 















Page 241

04-114 


6. CHECK HARNESS AND CONNECTOR (ABS PUMP FUSIBLE LINK - GROUND) 

(a). 


(b). 





ABS pump fusible link - 

Ground 







(a). 

(a). 



(b). 





ABS IG fuse - A009 (28) 


< 2 Ω 




Page 242


04-115 

8. CHECK HARNESS AND CONNECTOR (ABS PUMP FUSIBLE LINK - ABS MODULE) 

(a). 

(a). 



04 

(b). 






04 

ABS valve fuse - A009 (1) 

< 2 Ω 




Page 243

04-116 


WHEEL SPEED SENSOR CIRCUIT FAULT 


C003200; C00A000; C00A100; C00A900; C003500; C00A200; C00A300; C00AA00; C003800; 

C00A400;C00A500; C00AB00; C003B00; C00A600; C00A700; C00AC00; C109904 


(1) ECU detects wheel speed sensor signal wire is shorted to ground. 

(2) Wheel speed sensor circuit open. 


(1) Wheel speed sensor circuit is disconnected, patch loosening, fracture. 

(2) Wheel speed sensor signal circuit and the power suppy circuit is connected in reverse. 

(3) Signal circuit is shorted to ground. 

(4) Damage to the sensor head or connector pins. 







(a). 

(b). 




NOTE 







(a). 

(b). 

(c). 

(d). 


Remove the ABS actuator. (Refer to “Chapter 35 brake - abs actuator, replacement”) 

Install the removed ABS to another known vehicle with the same model. (Ensure that ABS 


Start the engine and to ensure that the vehicle speed is not lower than 20km/h, so that the 


Page 244


04-117 




4. CHECK HARNESS AND CONNECTOR (WHEEL SPEED SENSOR - GROUND) 

04 

(a). 

(b). 

(c). 


Disconnect the A010 front wheel speed sensor connector. 


(d). Measure the resistance according to the value(s) 



04 


A010 (1) - Ground 

A010 (2) - Ground 


≥ 1 MΩ 




5. CHECK HARNESS AND CONNECTOR (WHEEL SPEED SENSOR - ABS MODULE) 

(a). 

(b). 

(c). 








A010 (1) - A009 (8) 

A010 (2) - A009 (19) 


< 2 Ω 




Page 245

04-118 


WHEEL SPEED SENSOR SIGNAL FAULT 


C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08; C00AC00; C109904 


1. ECU detects wheel speed sensor signal circuit is shorted to power supply. 

2. ECU detects wheel speed sensor power supply circuit is shorted to ground. 

3. Wheel speed sensor signal is not normal. 


1. Wheel speed sensor circuit is disconnected, patch loosening, fracture. 

2. Wheel speed sensor signal circuit is shorted to power supply. 

3. Wheel speed sensor power supply is shorted to ground. 

4. The ring gear is not installed, missing teeth, dirty dust and installed incorrectly. 

5. The gap between the sensor and the ring is too large. 

6. The wheel speed sensor is subjected to the external magnetic field interference. (Wheel or 

axle is not demagnetization) 

7. The wheel speed sensor fault. 

8. The number of teeth of the ring gear error. 

9. Tire size does not meet specifications 

10. ECU is damaged. 






2. INSPECT WHEEL SPEED SENSOR 

(a). 

(b). 


Raise the vehicle. 

Page 246


04-119 

(c). Inspect whether the ABS speed sensor 

installation is correct or not. 

(d). 

(e). 

(f). 

Inspect whether the ABS speed sensor connector 

is loose or not. 

Inspect whether the ABS speed sensor tightening 

bolt is loose or not. 

Remove ABS speed sensor to inspect whether 

the speed sensor is damaged or the surface is 

dirty. 

04 

04 



NO > Replace wheel speed sensor. 


(a). 

(b). 




NOTE 






4. INSPECT WHEEL SPEED SENSOR INSTALLATION 

(a). Position the front wheel speed sensor RH 

properly. 

NOTE 

Installation bolts are tightened properly, the sensor 

installation position should be flat. 




Page 247

04-120 


5. INSPECT WHEEL SPEED SENSOR TIP 

(a). 

Remove the front wheel speed sensor. 

(b). Check wheel speed sensor tip. 

NOTE 

No scratches or foreign objects on the sensor tip. 




6. INSPECT WHEEL SPEED SENSOR ROTOR 

(a). 

Check the sensor serrations. 

NOTE 

No scratches, missing teeth or foreign objects. 

If foreign object is attached, please remove it. After 

reassembling, check the output voltage. 



NO > Replace the wheel speed sensor rotor. 


(a). 

(b). 

(c). 








A010 (1) - Ground 


≥ 1 MΩ 

Page 248


04-121 





04 

(a). 

(b). 

(c). 







04 


A010 (1) - A009 (8) 


< 2 Ω 




Page 249

04-122 


ABS CONTROL IS UNREASONABLE 


C006B06 


ABS received continuous working instruction (more than 1 minute). 


(1) Continued brake on ice. 

(2) Wheel speed difference is too large. 







(a). 

(b). 




NOTE 







(a). 

(b). 



Page 250


04-123 

(c). 

(d). 

(e). 

(f). 

Inspect whether ABS speed sensor installation is 

correct or not. 

Inspect whether the ABS speed sensor connector 

is loose or not. 

Inspect whether the ABS speed sensor tightening 

bolt is loose or not. 

Remove ABS speed sensor to inspect whether 

the speed sensor is damaged or the surface is 

dirty. 

04 

04 

(a). 

NOTE 

Position front wheel speed sensor RH properly. 







(a). 


(b). Check wheel speed sensor tip. 

NOTE 





Page 251

04-124 



(a). 

NOTE 



If foreign object is attached, please remove it. After 

reassembling, check the output voltage. 










ABS dynamic self - check. 




7. CHECK HARNESS AND CONNECTOR (ABS MODULE - GROUND) 

(a). 

(b). 



(c). 





A009 (13) - Ground 

A009 (38) - Ground 


< 2 Ω 




Page 252


04-125 

ABS SYSTEM IS INOPERATIVE 

WIRING DIAGRAM ( 

04 

04 

Page 253

04-126 




(a). 


(b). 

(c). 

(d). 

(e). 

Inspect ABS valve fuse in battery compartment 


Inspect the ABS pump fusible link in battery 


Inspect the ABS IG fuse in battery compartment 


Inspect the stop lamp switch fuse in engine room 





2. INSPECT BACK - UP LAMP SWITCH 

(a). 

Disconnect the A025 stop lamp switch connector. 

(b). 

Inspect the stop lamp switch according to the 

value(s) in the table below. 

Condition 

Release stop 

lamp switch 

Press stop lamp 

switch 


Specified 

Condition 

1 - 2 ≥ 1 MΩ 

1 - 2 < 2 Ω 



NO > Replace stop lamp switch. 

3. CHECK HARNESS AND CONNECTOR (ABS MODULE - GROUND) 

(a). 

(b). 



Page 254


04-127 

(c). 






04 

A009 (13) - Ground 

A009 (38) - Ground 

< 2 Ω 




04 

4. CHECK ABS MODULE POWER SUPPLY 

(a). 


(b). 






ABS IG fuse - Ground 



ABS pump fusible link - Ground 




5. CHECK HARNESS AND CONNECTOR (STOP LAMP FUSE - STOP LAMP SWITCH) 

(a). 

(b). 



Page 255

04-128 


(c). 


in the table below. 



Stop lamp fuse - A025 (2) 


< 2 Ω 




6. CHECK HARNESS AND CONNECTOR (ABS MODULE - STOP LAMP SWITCH) 

(a). 


(b). 

(c). 

(d). 







A009 (30) - A025 (1) 


< 2 Ω 




Page 256

DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 

04-129 

SUPPLEMENTAL RESTRAINT SYSTEM 

PRECAUTION 

WARNING 

• Fail to carry out the service operations in the correct sequence could cause the supplemental 

restraint system to unexpectedly deploy during servicing. It may lead to a serious accident. 

Furthermore, if a mistake is made in servicing the supplemental restraint system, it is possible 

that the SRS will fail to operate when requiring. Before servicing (including removal or 

installation of parts, inspection or replacement), be sure to read the following items carefully. 

Then follow the correct procedure described in this manual. 

• Work must be started after 90 seconds from the time that the ignition switch is turned to the 

”LOCK” position and the negative (–) terminal cable is removed from the battery. (The 

supplemental restraint system is equipped with a back–up power source, so if work is started 

within 90 seconds after disconnecting the negative (–) terminal cable from the battery, the SRS 

may deploy. 

• Do not directly expose the horn switch assy to hot air or flames. 

04 

04 

NOTE 

• Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the 

diagnostic trouble codes (DTC) become the most important source of information when 

troubleshooting. When repair the supplemental restraint system, always check the diagnostic 

trouble codes (DTC) before disconnecting the battery. 

• After completion of maintenance work,be sure to erase diagnostic trouble code (s) (DTC);If 

diagnostic trouble code (s) (DTC) can’t be erased,replace the restraint control module.Check for 

diagnostic trouble code (s) (DTC) again. 

• Even in case of a minor collision where the SRS does not deploy, the horn switch assy and 

restraint control module should be inspected. 

• Before repairing, remove the driver airbag and restraint control module if shocks are likely to be 

applied to the airbag and module during repairing. 

• Never use SRS related parts from another vehicle. If necessary, replace with new parts. 

• Never disassemble and repair the horn switch assy. 

• If the horn switch assy has been dropped, or if there are cracks, dents or other defects in the 

case, bracket or connector, replace them with new ones. 

• Use the multimeter with high impedance (10 kW/V minimum) for troubleshooting of an electrical 

circuit. 

• Information labels are attached to the SRS components. Follow the instructions on the notices. 

• After working on the supplemental restraint system is completed, check the SRS warning light. 

• When the negative (–) terminal cable is disconnected from the battery, memory of the clock and 

audio systems will lost. So, before starting work, make a record of the memorized contents in 

each memory system. Then, when work is finished, reset the clock and audio systems as 

before. To avoid erasing the memory in each memory system, never use a back–up power 

supply from another battery. 

Page 257

04-130 


LOCATION 

1 Restraint Control Module (RCM) 


3 Driver Airbag 

4 Clock Spring 

5 Passenger Airbag 

6 Driver Side Fuse Box 

7 Co - pilot Side Junction Box 

8 Ignition Switch 

Page 258


04-131 

RESTRAINT CONTROL MODULE (RCM) CONNECTOR PIN 

04 

04 

Terminal No. Wiring Color Definition 

1 - - 

2 - - 

3 - - 

4 - - 

5 B - O Power Supply 

6 W - B Ground 

7 B - Y SRS Warning Light 

8 - - 

9 R - L Diagnosis K 

10 Y Airbag + 

11 Y - B Airbag - 

12 - - 

13 G - B Airbag + 

14 G - R Airbag - 

15 - - 

16 - - 

17 - - 

18 - - 

19 - - 

20 - - 

21 - - 

22 - - 

23 - - 

24 - - 

25 - - 

Page 259

04-132 



26 - - 

27 - - 

28 - - 

29 - - 

30 Y Collision Output Interface 

Page 260


04-133 


NOTE 

If a malfunction code is displayed during the DTC check, check the circuit listed. For details of each 

code, turn to the relevant troubleshooting page in the DTC chart. 

04 

DTC No. Detection Item (DTC Definition) Trouble Area 

8101 Power supply voltage high 

8102 Power supply voltage low 

8201 Driver airbag fault - high resistance 

8202 Driver airbag fault - low resistance 

8203 Driver airbag circuit short to ground 

8204 Driver airbag circuit short to battery 

• Battery 

• Charging system 

• Power source circuit 

• Wire harness 

• Fuse 


• Ignition switch 

• Driver airbag circuit 

• Driver airbag 

• Clock spring 

• Restraint control module 













04 

8211 

8212 

8213 

8214 

Co - pilot side airbag fault - High 

resistance 

Co - pilot side airbag fault - Low 

resistance 

Co - pilot side airbag circuit short to 

ground 


battery 

• Passenger airbag circuit 

• Passenger airbag 











8610 ACU internal error • Restraint control module 

Page 261

04-134 



NOTE 

• If there is no DTC,but supplemental restraint system isn’t normal ,use the table below to check 

the circuit. 

• Before replacement of restraint control module (RCM) and instrument cluster,turn the ignition 

switch OFF,and disconnect the battery negative cable. 

• Use the table below to help you find the cause of the problem. The numbers indicate the priority 

of the likely cause of the problem. Check each part in order. If necessary, replace these parts. 


1. SRS warning light circuit - 

SRS warning light is 

always on 

2. Instrument Cluster 

3. Restraint control module 

Chapter 83 instrument panel - instrument cluster 

, replacement 

Chapter 62 supplemental restraint system - 

RCM , replacement 



inoperative 




, replacement 



Page 262


04-135 

8102 - POWER SUPPLY VOLTAGE LOW 

CIRCUIT DESCRIPTION 

DTC No. DTC Detecting Condition Trouble Area 

04 

8102 


With vehicle speed at 3 km/h or more, ignition 

switch terminal voltage is 10V or below for 10 

sec or longer. 


• Fuse 



04 

Page 263

04-136 



1. CHECK RESTRAINT CONTROL MODULE 

(a) 

(b) 

(c) 

(d) 

Disconnect the negative cable from the battery, and wait at least for 90 seconds. 

Disconnect the A027 restraint control module connector. 

Connect the battery negative cable. 


(e) Measure the voltage according to the value (s) in the 

table below. 



A027 (5) - Ground 




YES > Replace restraint control module. 


2. INSPECT FUSE (Co - pilot Side Junction Box) 

(a) 


(b) 

Measure the voltage according to the value (s) in the 

table below. 



Airbag fuse (10A) - Ground 







Page 264


04-137 

3. CHECK HARNESS AND CONNECTOR (AIRBAG FUSE - RESTRAINT CONTROL MODULE) 

(a) 

(b) 



04 

(c) 

Measure the resistance according to the value (s) in the 

table below. 



Airbag fuse (10A) - A027 (5) 


< 2 Ω 

04 

(d) 


table below. 



A027 (5) - Ground 


≥ 1 MΩ 




Page 265

04-138 


4. CHECK HARNESS AND CONNECTOR (IGNITION SWITCH - AIRBAG FUSE) 

(a) 

(b) 


Disconnect the I009 ignition switch connector. 

(c) 


table below. 



I009 (2) - Airbag fuse (10A) 


< 2 Ω 

(d) 


table below. 



I009 (2) - Ground 


≥ 1 MΩ 


YES > Replace ignition switch assy. 


Page 266


04-139 

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE 

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE 


04 


8201 

8202 

• Short circuit between airbag plus wire harness and 

airbag negative wire harness. 

• Open circuit between airbag plus wire harness and 


• Driver airbag malfunction 

• Clock spring malfunction 

• Restraint control module malfunction 





04 


Page 267

04-140 



1. INSPECT CLOCK SPRING AND DRIVER AIRBAG 

(a) 

(b) 

(c) 

(d) 


Disconnect the I014 clock spring connector. 

Relace clock spring and driver airbag. 

Connect the battery negative cable.Turn the ignition switch ON. 

Dose the systerm work correctly? 

YES > Relace clock spring and driver airbag. 


2. CHECK HARNESS AND CONNECTOR (CLOCK SPRING - RESTRAINT CONTROL MODULE) 

(a) 

(b) 

(c) 




(d) 


table below. 



A027 (10) - I014 (3) 

A027 (11) - I014 (4) 


< 2 Ω 

(e) 


table below. 



I014 (3) - Ground 

I014 (4) - Ground 


≥ 1 MΩ 




Page 268


04-141 

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND 



04 

8203 

• Short circuit in airbag wire harness (to 

ground) 








04 


Page 269

04-142 




(a) 

(b) 

(c) 

(d) 

(e) 










(a) 

(b) 



(c) 


table below. 



A027 (10) - Ground 

A027 (11) - Ground 


≥ 1 MΩ 




Page 270


04-143 

8204 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY 



04 

8204 


battery) 








04 


Page 271

04-144 



1. CHECK HARNESS AND CONNECTOR (RESTRAINT CONTROL MODULE - CLOCK SPRING) 

(a) 

(b) 

(c) 

(d) 

(e) 






(f) 


table below. 



A027 (10) - Ground 

A027 (11) - Ground 


0 V 





(a) 

(b) 

(c) 

(d) 

(e) 






Does the system work correctly? 


NO > Replace restraint control module. 

Page 272


04-145 

8211 - CO - PILOT SIDE AIRBAG FAULT - HIGH RESISTANCE 

8212 - CO - PILOT SIDE AIRBAG FAULT - LOW RESISTANCE 


04 


8211 

8212 


airbag negative wire harness 



• Passenger airbag malfunction 





04 


Page 273

04-146 



1. INSPECT PASSENGER AIRBAG 

(a) 

(b) 

(c) 

(d) 

(e) 


Disconnet the I035 passenger airbag connector. 

Replace passenger airbag. 




YES > Replace passenger airbag. 


2. CHECK HARNESS AND CONNECTOR (PASSENGER AIRBAG - RESTRAINT CONTROL 

MODULE) 

(a) 

(b) 

(c) 




(d) 


table below. 



A027 (13) - I035 (1) 

A027 (14) - I035 (2) 


< 2 Ω 

Page 274


04-147 

(e) 


table below. 




04 

I035 (1) - Ground 

I035 (2) - Ground 

≥ 1 MΩ 

04 




Page 275

04-148 


8213 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO GROUND 



8213 


ground) 







Page 276


04-149 



(a) 

(b) 

(c) 

(d) 

(e) 









04 

04 

2. CHECK HARNESS AND CONNECTOR (PASSENGER AIRBAG - RESTRAINT CONTROL MODULE) 

(a) 

(b) 



(c) 


table below. 



A027 (13) - Ground 

A027 (14) - Ground 


≥ 1 MΩ 




Page 277

04-150 


8214 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO BATTERY 



8214 


battery) 







Page 278


04-151 



(a) 

(b) 

(c) 

(d) 

(e) 









04 

04 

2. CHECK HARNESS AND CONNECTOR (RESTRAINT CONTROL MODULE - PASSENGER 

AIRBAG) 

(a) 

(b) 

(c) 

(d) 

(e) 






(f) 


table below. 



A027 (13) - Ground 

A027 (14) - Ground 


0 V 




Page 279

04-152 


SRS WARNING LIGHT IS ALWAYS ON 


Page 280


04-153 


1. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - RESTRAINT CONTROL 

MODULE) 

(a) 

(b) 

(c) 


Disconnect the I003 instrument B connector. 


04 

(d) 


table below. 


04 


A027 (7) - Ground 


≥ 1 MΩ 




2. INSPECT INSTRUMENT CLUSTER 

(a) 

(b) 

(c) 

(d) 

(e) 


Disconnect the I002 instrument A connector. 


Replace instrument cluster. 


Does the instrument cluster work correctly? 

YES > Replace instrument cluster. 


Page 281

04-154 


SRS WARNING LIGHT IS INOPERATIVE 


Page 282


04-155 



MODULE) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 


04 


I003 (B27) - A027 (7) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 

(e) 


Replace instrument cluster,and keep the I003 instrument connector disconnecting. 

Connect Pin B27 of the I003 instrument B connector to ground. 






DIAGNOSTICS 

Page 283

04-156 

DIAGNOSTICS - HEATER AND AIR CONDITIONING SYSTEM 

HEATER AND AIR CONDITIONING SYSTEM 

PRECAUTION 

1. DO NOT DEPOSIT REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME. 

2. ALWAYS WEAR SAFETY GOGGLES. 

3. AVOID CONTACTING WITH LIQUID REFRIGERANT R - 134A. 

If liquid refrigerant is in your eyes or on your skin: 

(f) Wash the area with lots of cold water. 

(g) Apply clean petroleum jelly to the skin. 

(h) Immediately go to a hospital or see a physician for professional treatment. 

4. DO NOT HEAT CONTAINER OR EXPOSE THE CONTAINER TO OPEN FLAME. 

5. DO NOT DROP DOWN CONTAINER OR APPLY PHYSICAL SHOCKS TO IT. 

6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT 

SYSTEM. 

(a) If there is not enough refrigerant in A/C system, oil lubrication will be insufficient and the compressor 

may be damaged. 

7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING. 

(a) Open and close only the low pressure valve. 

If the high pressure valve is opened, refrigerant flowing in the reverse direction will cause the charging 

cylinder to rupture. 

8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT. 

(a) If refrigerant is overcharged, it will cause problems such as insufficient cooling, poor fuel economy, 

engine overheating, etc. 

9. DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT. 




Expression 




Page 284


04-157 

BASIC INSPECTION 

Step Condition Action 

1 

Check the refrigerant. 

• Open the cap of release valve. 

• Press the release valve. 


Yes 

No 

Go to next step 

Charge the refrigerant system 

04 

2 

Check the A/C switch. 

• Start the engine. 

• Press the A/C switch. 

• Check the A/C switch. 


Yes 

No 


Go to problem symptoms table 

04 

3 

Check the A/C clutch field coil. 

• check the A/C clutch field coil. 


Yes 

No 



4 

Check compressor belt. 

• Check compressor belt. 


Yes 

No 



5 

Check the compressor. 

• Check the compressor cluth for noisy. 


Yes 

No 



6 

Check the condenser. 

• Check the dirt between the condenser 

and radiator. 


Yes 

No 


Clear the dirt or repalce the condenser 

7 

Check pressure A/C liquid line. 

• Check the line for inhibition or leakage. 


Yes 

No 


Replace or reroute the pressure A/C liquid 

line 

Page 285

04-158 


LOCATION 

1 Rear Blower Forward Switch 

2 A/C Switch 

3 Blower Control Knob 

4 Temperature Control Knob 

Page 286


04-159 





04 

1. Fuse - 

A/C system is inoperative 

2. Relay - 

3. Wire harness - 

1. Fuse - 

04 

2. Relay - 

Front blower motor is inoperative 

3. A/C control panel 

4. Front blower control module 

5. Front blower motor 

Chapter 61 heater and air 

conditioning - multi - media and A/C 

controller assy, replacement 


conditioning - front blower control 

module, replacement 


conditioning - front A/C blower, 

replacement 


1. Fuse - 

2. Relay - 

Top evaporator blower motors are 

inoperative 

3. Top evaporator blower switch 

4. Top evaporator blower resistor 

5. Rear blower forward switch 



conditioning - top evaporator blower 

switch, replacement 



resistor, replacement 

Chapter 83 instrument panel - 

dashboard assy, replacement 





Page 287

04-160 



Front air flow is insufficient 




4. Front A/C vent duct 









replacement 


conditioning - front A/C vent duct , 

replacement 


Rear air flow is insufficient 

1. Rear A/C blower switch 

2. Top evaporator blower resistor 


conditioning - rear A/C blower 




resistor, replacement 


1. Fuse - 

2. Relay - 

No cooling from front A/C system 

3. A/C compressor 


5. Refrigerant 

6. Triple pressure switch 

7. Front evaporator thermistor 


conditioning - compressor, overhaul 





conditioning - refrigerant 

replacement 


conditioning - A/C pressure switch, 

replacement 


conditioning - front evaporator 

thermistor, replacement 


Page 288


04-161 


1. Top evaporator temperature 

sensor 


conditioning - top evaporator 

temperature sensor, replacement 

04 

No cooling from rear A/C system 

2. Rear A/C solenoid valve 


conditioning - rear A/C shut off 

solenoid valve, replacement 

3. Relay - 





04 

1. Fuse - 

2. Relay - 

Rear heater is inoperative or insufficient 

heating 

3. Rear heater blower switch 

4. Rear heater solenoid valve 

5. Rear heater motor 


conditioning - rear heater blower 



conditioning - rear heater solenoid 

valve, replacement 


conditioning - rear heater blower, 

overhaul 

Page 289

04-162 


A/C SYSTEM IS INOPERATIVE 


Page 290


04-163 

04 

04 

Page 291

04-164 




(a) 


(b) 

Inspect the A/C fuse (15A) in driver side junction box 

(I001). 




2. CHECK HARNESS AND CONNECTOR ( A/C CUT OFF RELAY - GROUND) 

(a) 

(b) 

(c) 


Remove A/C cut off relay. 


(d) 

Measure the voltage according to the value(s) in the 

table below. 



A/C cut off relay (30) - Ground 

Specified 

Condition 





Page 292


04-165 


(a) 

(b) 

(c) 




04 

(d) 


table below. 

Standard voltage (check for a short to battery) 


Specified 

Condition 

04 


0 V 




Page 293

04-166 


FRONT BLOWER MOTOR IS INOPERATIVE 


Page 294


04-167 



(a) 


04 

(b) 

(c) 

Inspect the front blower fusible link (30A) in Co-pilot 

Junction Box (A003). 

Inspect the A/C controller fuse (7.5A) in Driver Side 

Junction Box (I001). 

04 




2. INSPECT FRONT BLOWER RELAY 

(a) 

(b) 


Remove the front blower relay. 

(c) 

Inspect the front blower relay according to the value(s) in 


Standard resistance: 

Condition Tester Connection Specified Condition 

Constant 85 - 86 Continuity 

Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the front blower relay. 

3. INSPECT FRONT BLOWER CONTROL MODULE 

(a) 

(b) 

(c) 


Disconnect the I025 front blower control module connector. 

Replace the front blower control module with a new one. 

Page 295

04-168 



YES > Replace the front blower motor resistor. 


4. INSPECT FRONT BLOWER MOTOR 

(a) Disconnect the battery negative cable. 

(b) Disconnect the A028 front blower motor connector. 

(c) Replace a new front blower motor. 


YES > Replace the front blower motor. 


5. CHECK HARNESS AND CONNECTOR (FRONT BLOWER RELAY - FRONT BLOWER ) 

(a) 

(b) 

(c) 


Disconnect the A028 front blower motor connector. 


(d) 

Measure the resistance according to the value(s) in the 

table below. 



Front blower relay (30) - A028 (1) 

Specified 

Condition 

< 2 Ω 




6. CHECK HARNESS AND CONNECTOR (FRONT BLOWER - FRONT BLOWER CONTROL 

MODULE) 

(a) 

(b) 

(c) 


Disconnect the A027 front blower connector. 


Page 296


04-169 

(d) 


table below. 




04 

A028 (2) - I025 (4) 

< 2 Ω 

04 




7. CHECK HARNESS AND CONNECTOR (FRONT BLOWER CONTROL MODULE - GROUND) 

(a) 

(b) 


Disconnect the I025 blower control module connector. 

(c) 


table below. 



I025 (8) - Ground 


< 2 Ω 




8. CHECK HARNESS AND CONNECTOR (FRONT BLOWER CONTROL MODULE - A/C CONTROL 

PANEL) 

(a) 

(b) 

(c) 



Disconnect the I021 A/C control panel connector. 

Page 297

04-170 


(d) 


table below. 



I025 (2) - I021 (35) 

I025 (3) - I021 (28) 


< 2 Ω 




9. CHECK HARNESS AND CONNECTOR (FRONT BLOWER RELAY - A/C CONTROL PANEL) 

(a) 

(b) 

(c) 


Remove front blower relay. 


(d) 


table below. 



Front blower relay (86) - I020 (8) 

Specified 

Condition 

< 2 Ω 




10. CHECK HARNESS AND CONNECTOR ( A/C CONTROL PANEL - GROUND) 

(a) 

(b) 

(c) 




Page 298


04-171 

(d) 


table below. 




04 

I020 (10) - Ground 

I020 (19) - Ground 


04 





(a) 

(b) 



(c) 


table below. 



I020 (18) - Ground 

I020 (20) - Ground 


< 2 Ω 


YES > Replace A/C control panel ( Multi - media and A/C controller assy). 


Page 299

04-172 


REAR EVAPORATOR MOTORS ARE INOPERATIVE 


Page 300


04-173 


(a) 


(b) 

Inspect the rear A/C fusible link (30A) in Co - pilot 


04 

04 




2. INSPECT REAR A/C RELAY 

(a) 

(b) 


Remove the rear A/C relay. 

(c) 






Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the rear A/C relay. 

Page 301

04-174 


3. INSPECT REAR BLOWER FORWARD SWITCH 

(a) 

(b) 


Disconnect the I023 rear blower forward switch connector. 

(c) 

Inspect the rear blower forward switch according to the 


Position Tester Connection Specified Condition 

Release 2 - 5 ≥ 1 ΜΩ 

Press 2 - 5 < 2 Ω 



NO > Replace the rear blower forward switch. 

4. INSPECT TOP EVAPORATOR BLOWER SWITCH 

(a) 

(b) 


Disconnect the L005 top evaporator blower switch connector. 

(c) 

Inspect the top evaporator blower switch according to the 



I 

II 

III 

1 - 2 

3 - 4 

1 - 2 

3 - 5 

1 - 2 

3 - 6 

< 2 Ω 



NO > Replace the top evaporator blower switch. 

5. INSPECT TOP EVAPORATOR BLOWER RESISTOR 

(a) 

(b) 

(c) 


Disconnect the L003 top evaporator blower resistor connector. 

Replace a new top evaporator blower resistor. 


YES > Replace the top evaporator blower resistor . 


Page 302


04-175 

6. CHECK HARNESS AND CONNECTOR (REAR A/C RELAY - GROUND) 

(a) 

(b) 

(c) 


Remove the rear A/C relay. 

Turn the ignition switch ON and press the I023 rear blower forward switch. 

04 

(d) 


table below. 



Specified 

Condition 

04 

Rear A/C relay (30) - Ground 





7. CHECK HARNESS AND CONNECTOR (REAR A/C RELAY - TOP EVAPORATOR BLOWER 

SWITCH) 

(a) 

(b) 

(c) 


Remove rear A/C relay. 


(d) 


table below. 



Rear A/C relay (86) - L005 (2) 

Specified 

Condition 

< 2 Ω 




Page 303

04-176 


8. CHECK HARNESS AND CONNECTOR (TOP EVAPORATOR BLOWER SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



L005 (1) - Ground 

L005 (3) - Ground 


< 2 Ω 




9. CHECK HARNESS AND CONNECTOR (TOP EVAPORATOR BLOWER RESISTOR - TOP 

EVAPORATOR BLOWER SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 




L003 (1) - L005 (6) 

L003 (2) - L005 (5) 

< 2 Ω 

L003 (3) - L005 (4) 




10. CHECK HARNESS AND CONNECTOR ( REAR A/C RELAY - LEFT/RIGHT BLOWER) 

(a) 

(b) 

(c) 

(d) 



Disconnect the L001 left blower connector. 

Disconnect the L002 right blower connector. 

Page 304


04-177 

(e) 


table below. 



Specified 

Condition 

04 

Rear A/C relay (87) - L001 (1) 

Rear A/C relay (87) - L001 (1) 

< 2 Ω 

04 




11. CHECK HARNESS AND CONNECTOR ( LEFT/RIGHT BLOWER - TOP EVAPORATOR BLOWER 

RESISTOR) 

(a) 

(b) 

(c) 

(d) 


Remove the L003 top evaporator blower resistor connector. 

Disconnect the L001 left blower connector. 

Disconnect the L002 right blower connector. 

(e) 


table below. 



L001 (2) - L003 (1) 

L002 (2) - L003 (1) 


< 2 Ω 


YES > Replace left or right blower. 


Page 305

04-178 


FRONT AIR FLOW IS INSUFFICIENT 


Page 306


04-179 


1. INSPECT FRONT BLOWER MOTOR RESISTOR 

(a) 

(b) 

(c) 



Replace the front blower control moduler with a new one. 


YES > Replace the front blower control module. 


04 

04 

2. CHECK THE HARNESS AND CONNECTOR (FRONT BLOWER - FRONT BLOWER CONTROL 

MODULE) 

(a) 

(b) 

(c) 


Disconnect the A028 front blower connector. 


(d) 


table below. 



A028 (2) - I025 (4) 


< 2 Ω 





(a) 

(b) 


Disconnect the I025 blower control module connector. 

(c) 


table below. 



I025 (1) - Ground 


< 2 Ω 




Page 307

04-180 



PANEL) 

(a) 

(b) 

(c) 




(d) 


table below. 



I025 (2) - I021 (35) 

I025 (3) - I021 (28) 


< 2 Ω 





(a) 

(b) 

(c) 




(d) 


table below. 



I020 (10) - Ground 

I020 (19) - Ground 






Page 308


04-181 


(a) 

(b) 



04 

(c) 


table below. 



I020 (18) - Ground 

I020 (20) - Ground 


< 2 Ω 

04 




Page 309

04-182 


REAR AIR FLOW IS INSUFFICIENT 


Page 310


04-183 


1. INSPECT TOP EVAPORATOR BLOWER SWITCH 

(a) 

(b) 



04 

(c) 




1 - 2 

I 

3 - 4 

04 

II 

III 

1 - 2 

3 - 5 

1 - 2 

3 - 6 

< 2 Ω 



NO > Replace the rear evaporator blower switch. 

2. CHECK HARNESS AND CONNECTOR (TOP EVAPORATOR BLOWER RESISTOR - TOP 

EVAPORATOR BLOWER SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 




L003 (1) - L005 (6) 

L003 (2) - L005 (5) 

< 2 Ω 

L003 (3) - L005 (4) 


YES > Replace top evaporator blower resistor. 


Page 311

04-184 


NO COOLING FROM FRONT A/C SYSTEM 


Page 312


04-185 

04 

04 

Page 313

04-186 



1. INSPECT COMPRESSOR RELAY 

(a) 

(b) 


Remove the compressor relay. 

(c) 






Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the compressor relay 

2. CHECK HARNESS AND CONNECTOR (COMPRESSOR RELAY - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



Compressor relay (30) - Ground 







Page 314


04-187 

3. CHECK HARNESS AND CONNECTOR (COMPRESSOR - GROUND) 

(a) 

(b) 

(c) 


Disconnect the E013 compressor connector. 

Start the engine, turn A/C switch on. 

04 

(d) 


table below. 




04 

E013 (1) - Ground 



YES > Replace the compressor. 


4. CHECK HARNESS AND CONNECTOR (COMPRESSOR RELAY - ENGINE ELECTRONIC CON- 

TROL MODULE(4G69) / ENGINE ECM(ISF2.8) ) 

(a) 

(b) 

(c) 



Disconnect the C016 blower switch connector. 

(d) 


table below. 



Compressor relay (86) - A036 (48) 

Compressor relay (86) - E001 (10) 

Specified 

Condition 

< 2 Ω 




5. INSPECT TRIPLE PRESSURE SWITCH 

(a) 

(b) 


Disconnect the V017 triple pressure switch connector. 

Page 315

04-188 


(c) 

Inspect the triple pressure switch according to the 



V017 (1) - V017 (4) 

V017 (2) - V017 (3) 


< 2 Ω 



NO > Replace the triple pressure switch. 

6. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - ENGINE ELECTRONIC 

CONTROL MODULE(4G69) / ENGINE ECM(ISF2.8) ) 

(a) 

(b) 



(c) 


table below. 




V017 (4) - E001 (79) 

V017 (3) - E001 (26) 

V017 (4) - A036 (27) 

< 2 Ω 

V017 (3) - A036 (11) 




7. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - A/C CONTROL PANEL) 

(a) 

(b) 

(c) 




Page 316


04-189 

(d) 


table below. 




04 

V017 (2) - I020 (9) 

< 2 Ω 

04 


YES > Go to next step for 4G69, go to step 9 for ISF2.8. 


8. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - GROUND)(4G69) 

(a) 

(b) 



(c) 


table below. 



V017 (2) - Ground 


< 2 Ω 




9. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - ENGINE ECM)(ISF2.8) 

(a) 

(b) 

(c) 



Disconnect the A036 engine ECM connector. 

(d) 


table below. 



V017 (2) - A036 (29) 


< 2 Ω 

Page 317

04-190 





10. INSPECT FRONT EVAPORATOR THERMISTOR 

(a) 

(b) 


Disconnect the I026 front evaporator thermistor connector. 

(c) 

Inspect the front evaporator thermistor according to the 



Check Condition 

Specified Condition (KΩ) 

2 ℃ 14.5 ~ 15.2 

5 ℃ 12.5 ~ 13.0 

10 ℃ 9.7 ~ 10.3 

15 ℃ 7.6 ~ 8.1 

20 ℃ 6.1 ~ 6.4 

25 ℃ 4.8 ~ 5.1 



NO > Replace the front evaporator thermistor. 

11. CHECK HARNESS AND CONNECTOR (FRONT EVAPORATOR THERMISTOR - A/C CONTROL 

PANEL) 

(a) 

(b) 

(c) 


Disconnect the I026 front evaporator thermistor connector. 


(d) 

Inspect the resistance according to the value(s) in the 

table below. 


I026 (1) - I021 (29) 

I026 (2) - I021 (33) 


< 2 Ω 




Page 318


04-191 

NO COOLING FROM REAR A/C SYSTEM 


04 

04 

Page 319

04-192 



1. INSPECT TOP EVAPORATOR TEMPERATURE SENSOR 

(a) 

(b) 


Disconnect the L004 top evaporator temperature sensor connector. 

(c) 

Inspect the top evaporator temperature sensor according 

to the value(s) in the table below. 




2 ℃ 14.5 ~ 15.2 

5 ℃ 12.5 ~ 13.0 

10 ℃ 9.7 ~ 10.3 

15 ℃ 7.6 ~ 8.1 

20 ℃ 6.1 ~ 6.4 

25 ℃ 4.8 ~ 5.1 



NO > Replace the top evaporator temperature sensor. 

2. CHECK HARNESS AND CONNECTOR (REAR A/C RELAY - REAR A/C SOLENOID VALVE) 

(a) 

(b) 

(c) 


Disconnect the N003 rear A/C solenoid valve connector. 

When ignition switch turns ON, press the top evaporator blower switch. 

(d) 


table below. 



N003 (1) - Ground 






Page 320


04-193 

3. CHECK HARNESS AND CONNECTOR (REAR A/C SOLENOID VALVE - A/C CONTROL PANEL) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

N003 (2) - I021 (36) 

< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (REAR A/C SOLENOID VALVE - GROUND) 

(a) 

(b) 

(c) 



When ignition switch turns ON, press the top evaporator blower switch. 

(d) 


table below. 

Standard resistance 


N003 (2) - Ground 


< 2 Ω 


YES > Replace rear A/C solenoid valve. 


Page 321

04-194 


5. CHECK HARNESS AND CONNECTOR (REAR A/C RELAY - A/C CONTROL PANEL) 

(a) 

(b) 

(c) 




(d) 


table below. 



Rear A/C relay (86) - I020 (1) 


< 2 Ω 




Page 322


04-195 

REAR HEATER IS INOPERATIVE OR INSUFFICIENT HEATING 


04 

04 

Page 323

04-196 




(a) 


(b) 

Inspect the rear heater fuse (15A) in Co - pilot Junction 

Box (A003). 




2. INSPECT REAR HEATER RELAY 

(a) 

(b) 


Remove the rear heater relay. 

(c) 

Inspect the rear heater relay according to the value(s) in 





Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the rear heater relay. 

Page 324


04-197 

3. INSPECT WATER VALVE RELAY 

(a) 

(b) 


Remove the water valve relay. 

04 

(c) 

Inspect the water valve relay according to the value(s) in 





04 

Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the water valve relay. 

4. INSPECT REAR HEATER BLOWER SWITCH 

(a) 

(b) 


Disconnect the A007 rear heater blower switch connector. 

(c) 




L 

M 

H 

1 - 2 

3 - 4 

1 - 2 

3 - 5 

1 - 2 

3 - 6 

< 2 Ω 



NO > Replace the rear heater blower switch. 

Page 325

04-198 


5. CHECK HARNESS AND CONNECTOR (REAR HEATER RELAY / WATER VALVE RELAY - 

GROUND ) 

(a) 

(b) 

(c) 


Remove the rear blower relay and water valve relay. 

When ignition switch turns ON, press the rear blower forward switch. 

(d) 


table below. 



Rear heater relay (85) - Ground 

Water valve relay (85) - Ground 

Specified 

Condition 





6. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER SWITCH - REAR BLOWER 

RELAY/WATER VALVE REALY) 

(a) 

(b) 

(c) 

(d) 


Remove the rear blower relay. 



(e) 


table below. 



A007 (2) - Rear heater relay (86) 

A007 (2) - Water valve relay (86) 

Specified 

Condition 

< 2 Ω 

Page 326


04-199 




7. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER SWITCH - GROUND) 

04 

(a) 

(b) 



(c) 


table below. 


04 


A007 (3) - Ground 

A007 (1) - Ground 


< 2 Ω 




8. CHECK HARNESS AND CONNECTOR (REAR HEATER SOLENOID VALVE - GROUND) 

(a) 

(b) 

(c) 


Disconnect the P001 rear heater solenoid valve connector. 

When ignition switch turns ON, press the rear heater blower switch. 

(d) 


table below. 



P001 (1) - Ground 






Page 327

04-200 



(a) 

(b) 



(c) 


table below. 



P001 (2) - Ground 

Specified 

Condition 

< 2 Ω 


YES > Replace rear heater solenoid valve. 


10. CHECK HARNESS AND CONNECTOR ( REAR HEATER RELAY - REAR HEATER MOTOR ) 

(a) 

(b) 

(c) 


Disconnect the P002 rear heater motor connector. 

When ignition switch turns ON, press the rear heater forward switch and rear heater blower switch. 

(d) 


table below. 



P002 (2) - Ground 






Page 328


04-201 

11. CHECK HARNESS AND CONNECTOR ( REAR HEATER MOTOR - REAR HEATER BLOWER 

SWITCH) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 



P002 (4) - A007 (4) 


04 

P002 (1) - A007 (5) 

< 2 Ω 

P002 (3) - A007 (6) 


YES > Replace rear heater motor. 


Page 329

04-202 


PRECAUTION 

DIAGNOSTICS - LIGHTING SYSTEM 

1. PRECAUTION FOR USING BATTERY DURING INSPECTION. 

(a) While using the battery during inspection, do not bring the positive and negative tester probes too close 

to each other as a short circuit may occur. 

2. PRECAUTION FOR HEADLIGHT BULB REPLACEMENT. 

(a) If even a thin film of oil is left on the surface of the halogen light, the bulb may be damaged because the 

light will burn at a higher temperature. 

(b) Handle any halogen light with great care. Dropping, hitting or damaging the bulb, in any way, may result 

in exploding and shattering because the internal pressure is high. 

(c) Always prepare a new bulb for immediate replacement. While replacing the bulb, the lens may attract 

dust and moisture if removed from the vehicle for too long. 

(d) Always use a bulb of the same wattage for replacement. 

(e) Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may 

fill with water through the gaps around the socket. 




Expression 




Page 330


04-203 



1 

Check the battery voltage. 

• The voltage should not be below 12 V. 


Yes 

No 


Charge or replace battery. Refer to “Chapter 

20A/20B starting and charging - battery, 

replacement” 

04 

2 

Check the LO - beam lamps. 

• Turn the ignition switch ON. 

• Check the LO - beam lamps. 


Yes 

No 



04 

3 

Check the HI - beam lamps. 



Yes 

No 



4 

Check the turn signal lamps. 



Yes 

No 



5 

Check the hazard lamps. 



Yes 

No 



6 

Check the Indoor Lamps. 



Yes 

No 

Check harness and connector 


Page 331

04-204 


LOCATION 

Page 332


04-205 

1 Front Combination Lamp Assy LH 

2 Front Fog Lamp Assy LH 

3 Front Combination Lamp Assy RH 

4 Front Fog Lamp Assy RH 

5 Rear Combination Lamp Assy LH 

6 High - mounted Stop Lamp Assy 

7 License Lamp Assy 

8 Rear Combination Lamp Assy RH 

04 

04 

Page 333

04-206 






LO - beam headlamp is 

inoperative (One side) 

1. Fuse - 


1. Fuse - 

LO - beam headlamps are 

inoperative (Both sides) 

HI - beam headlamp is 


2. Relay - 


4. Combination switch 

1. Fuse - 


Chapter 64 lighting - combination switch, 

replacement 

1. Fuse - 

HI - beam headlamps are 


2. Relay - 



replacement 


LO - beam and HI - beam 

headlamps are inoperative 

(One side) 

1. Bulb(s) 


Chapter 64 lighting - front combination Lamp 

assy, replacement 

1. Fuse 

2. Relay - 



(Both sides) 


4. Bulb(s) 


replacement 




1. Fuse - 

Front fog lamps are 

inoperative 


3. Bulb(s) 


replacement 

Chapter 64 lighting - front fog lamp assy, 

replacement 

4. Relay - 


Page 334


04-207 


Front fog lamps are always 

on 


2. Front fog lamp relay - 

1. Fuse - 


replacement 

04 

Rear fog lamps are 

inoperative 


3. Bulb(s) 


replacement 

Chapter 64 lighting - rear combination Lamp 


04 

4. Relay - 


Rear fog lamps are always 

on 


2. Rear fog lamp relay - 


replacement 

1. Fuse - 

2. Relay - 

All fog lamps are 

inoperative 

3. Bulb(s) 



replacement 




replacement 


Hazard warning lamps are 

inoperative (Turn signal 

lamps are normal) 

1. Fuse - 

2. Hazard warning switch - 


1. Fuse - 

urn signal lamps are 

inoperative (Hazard 

warning lamps are normal) 




replacement 


Hazard warning and turn 

signal lamps are 

inoperative 

1. Fuse - 


3. Flasher - 

Page 335

04-208 





inoperative 

4. Bulb(s) 







replacement 


Turn signal lamps are 



2. Bulb(s) 


replacement 







always on 


2. Flasher - 

1. Fuse - 

All stop lamps are 

inoperative 

2. Stop lamp switch 

3. Bulb(s) 

Chapter 35 brake - brake pedal, 

replacement 



Chapter 64 lighting - high - mounted stop 

lamp assy, replacement 


Stop lamp is inoperative 

(One side) 

High - mounted stop lamp 

is inoperative 

Back - up lamps are 

inoperative(Both sides) 

1. Bulb(s) 


1. Bulb(s) 


1. Bulb(s) 








1. Fuse - 

Back - up lamp is 


2. Back - up lamp switch 

Chapter 41 transmission - transmission 

(yanchengzhongma ZM001), replacement 


(tangshanaixin), replacement 

Page 336


04-209 




Ignition switch illumination 


Central dome light is 

inoperative 

Air purifier lamp is 

inoperative 

3. Bulb(s) 


1. Bulb(s) - 

2. Central locking controller 

assy 


1. Bulb(s) 


1. Bulb(s) - 


Chapter 64 lighting - rear combination lamp, 

replacement 

Chapter 85 door locks - alarm controller, 

replacement 

Chapter 64 lighting - middle dome light assy, 

replacement 

04 

04 

1. Bulb(s) 

Chapter 64 lighting - step lamp assy, 

replacement 

Step lamp are inoperative 


3. Middle door lamp switch 

RH 

1. Bulb(s) - 

Trunk lamp is inoperative 

Front dome light is 

inoperative 


3. Rear hatch lock assy - 

switch 

1. Bulb(s) 


Chapter 64 lighting - front dome light assy, 

replacement 

1. Fuse - 

All interior illumination 

lamps are inoperative 

2. Relay - 



replacement 


Instrument cluster 

illumination is not 

inoperative 

1. Fuse - 

2. Instrument cluster 


Chapter 83 instrument - instrument cluster, 

replacement 

Page 337

04-210 



Diagnosis switch 


inoperative 

wiring diagram 

1. Diagnosis switch - 

2. Wire harness 

- 

Cigarette lighter 


inoperative 

1. Cigarette Lighter 


Chapter 66 audio system - electric device 

accessories, replacement 

A/C control panel 


inoperative 

Rear blower forward switch 


inoperative 

Radio illumination is not 

inoperative 

Dome light switch 


inoperative 

Outside mirror defroster 

switch illumination is not 

inoperative 

Headlamp dimmer switch 


inoperative 

Rear window defroster 


inoperative 

Instrument dimmer switch 


inoperative 

Hazard warning switch 


inoperative 

WIdth lamps is not 

inoperative 

Tail lamps are inoperative 



1. Rear blower forward switch - 


1. Radio 


1. Dome light switch - 


1. Outside mirror defroster 

switch 


1. Headlamp dimmer switch - 


1. Rear window defroster 

switch 


1. Instrument dimmer switch - 




1. Bulb(s) 


1. Bulb(s) 


Chapter 61 heater and air conditioning -multi - 

media And Air - condition Controler Assy, 

replacement 

Chapter 66 audio system - multi - media And 

air - condition controler Assy, replacement 

- 

- 

Chapter 64 lighting - front combination lamp 

LH, replacement 

Chapter 64 lighting - rear combination lamp 


Page 338


04-211 


License lamp is inoperative 

Width lamps tail lamps and 

license lamp are 

inoperative 

1. Bulb(s) 


1. Fuse - 

2. Relay - 



Chapter 64 lighting - licence lamp assy, 

replacement 


replacement 

04 

04 

Page 339

04-212 


LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) 


Page 340


04-213 


• This inspection procedure is an example of lo - beam headlamp LH, lo - beam headlamp RH inspection 

procedure is similar. 

1. INSPECT BULB 

(a) 

(b) 

(c) 

(d) 


Disconnect the V003 headlamp LH connector. 

Replace the headlamp LH bulb. 


Does the lo - beam headlamp LH work correctly? 

YES > Replace the headlamp LH bulb. 


04 

04 

2. CHECK HARNESS AND CONNECTOR (LO - BEAM LH FUSE - HEADLAMP LH) 

(a) 

(b) 



(c) 


table below. 



Lo - beam LH fuse (7.5A) - V003 (3) 


< 2 Ω 

(d) 


table below. 



V003 (3) - Ground 


≥ 1 MΩ 


YES > Replace Lo - beam LH fuse (7.5A) in driver side junction box (I001). 


Page 341

04-214 


LO - BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES) 


Page 342


04-215 


1. INSPECT HEADLAMP BULBS BOTH LH AND RH 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 




Disconnect the V006 headlamp RH connector. 

Replace headlamp bulb RH. 


Do both lo - beam headlamps work correctly? 

YES > Replace headlamp Bulbs both LH and RH. 


04 

04 

2. INSPECT LO - BEAM RELAY 

(a) 

(b) 


Remove lo - beam relay in driver side junction box (I001). 

(c) 

Inspect lo - beamheadlamp relay according to the 


Condition 


Specified 

Condition 

Normal 

Apply battery voltage to 

terminals 85 and 86 

85 - 86 breakover 

≥ 1 MΩ 

30 - 87 

< 2 Ω 



NO > Replace lo - beamheadlamp relay. 

Page 343

04-216 


3. INSPECT COMBINATION SWITCH (LIGHT) 

(a) 

(b) 


Disconnect the I012 combination switch (light) connector. 

(c) 

Inspect the combination switch according to the value(s) 


Condition 

Set the lo - beam headlamp 

switch to OFF 


switch to ON 


8 - 11 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 



NO > Replace the combination switch. 

4. CHECK HARNESS AND CONNECTOR (LO - BEAM RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 




(d) 


table below. 



Lo - beam Relay (86) - I012 (8) 


< 2 Ω 




Page 344


04-217 

5. CHECK HARNESS AND CONNECTOR (LO - BEAM FUSES BOTH LH AND RH, LO - BEAM 

HEADLAMPS BOTH LH AND RH) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 


Lo - beam fuse RH (7.5A) - V006 (3) 

< 2 Ω 

(e) 


table below. 



V003 (3) - Ground 

V006 (3) - Ground 


≥ 1 MΩ 


YES > Replace lo - beam headlamp fuse (7.5A) both LH and RH in driver side fuse box (I001). 


Page 345

04-218 


HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) 


Page 346


04-219 


• This inspection procedure is an example of hi - beam headlamp LH, hi - beam headlamp RH inspection 



(a) 

(b) 

(c) 

(d) 





Does hi - beam headlamp LH work correctly? 



04 

04 

2. CHECK HARNESS AND CONNECTOR (HI - BEAM LH FUSE - HEADLAMP LH) 

(a) 

(b) 



(c) 


table below. 



Hi - beam LH fuse (10A) - V003(2) 


< 2 Ω 

(d) 


table below. 



V003 (2) - Ground 


≥ 1 MΩ 


YES > Replace Hi - beam LH Fuse(10A) in driver side junction box (I001). 


Page 347

04-220 


HI - BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES) 


Page 348


04-221 



(a) 

(b) 

(c) 

(d) 

(e) 

(f) 





Replace headlamp Bulb RH. 


Do both hi - beam headlamps work correctly? 



04 

04 

2. INSPECT HI - BEAM RELAY 

(a) 

(b) 


Remove hi - beam relay in driver side junction box (I001). 

(c) 

Inspect hi - beamheadlamp relay according to the 

value(s) in the table below 

Condition 

Tester 

Connection 

Specified 

Condition 

Namal 



85 - 86 Breakover 

≥ 1 MΩ 

30 - 87 

< 2 Ω 



NO > Replace hi - beam relay. 


(a) 

(b) 


Disconnect the i012 combination switch (light) connector. 

Page 349

04-222 


(c) 



Condition 

Set the hi - beam headlamp 

switch to OFF 


switch to ON 

Tester 

Connection 

9 - 11 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (HI - BEAM RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 




(d) 


table below. 



hi - beam relay (86) - I012 (9) 


< 2 Ω 




Page 350


04-223 

5. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSES BOTH LH AND RH, HI - BEAM 

HEADLAMPS BOTH LH AND RH ) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

Hi - beam LH fuse (10A) - V003 (2) 

Hi - beam RH fuse (10A) - V006 (2) 

< 2 Ω 

(e) 


table below. 



V003 (2) - Ground 

V006 (2) - Ground 


≥ 1 MΩ 


YES > Replace hi - beam fuses both LH and RH in driver side box (I001). 


Page 351

04-224 


LO - BEAM AND HI - BEAM HEADLAMPS ARE INOPERATIVE (ONE 

SIDE) 


Page 352


04-225 


• This inspection procedure is an example of hi - beam headlamp and lo - beam headlamp LH, hi - beam 

headlamp and lo - beam headlamp RH inspection procedure is similar. 


(a) 

(b) 

(c) 

(d) 








04 

04 

2. CHECK HARNESS AND CONNECTOR (HEADLAMP LH - GROUND) 

(a) 

(b) 



(c) 


table below. 



V003 (1) - Ground 


< 2 Ω 




3. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSE AND LOW - BEAM FUSE LH - 

HEADLAMP LH) 

(a) 

(b) 



Page 353

04-226 


(c) 


table below. 



Hi - beam LH fuse (10 A) - V003 (2) 

Lo - beam LH fuse (7.5 A) - V003 (3) 


< 2 Ω 

(d) 


table below. 



V003 (2) - Ground 

V003 (3) - Ground 


≥ 1 MΩ 


YES > Replace hi - beam fuse and lo - beam fuse LH in driver side junction box (I001). 


Page 354


04-227 

ALL HEADLAMPS ARE INOPERATIVE 


04 

04 

Page 355

04-228 




(a) 


(b) 

Inspect the headlamp fuse (20A) in driver side junction 

box (I001). 




2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (LIGHT) - GROUND) 

(a) 

(b) 



(c) 


table below. 



I012 (11) - Ground 


< 2 Ω 





(a) 

(b) 



Page 356


04-229 

(c) 


in the table below.. 

Condition 

Tester 

Connection 

Specified 

Condition 

04 


switch to OFF 


switch to ON 


switch to OFF 


switch to ON 

9 - 11 

8 - 11 

≥ 1 MΩ 

< 2 Ω 

≥ 1 MΩ 

< 2 Ω 

04 





(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







Does both headlamp hulbs work correctly? 

YES > Replace headlamp bulbs both LH and RH. 


5. CHECK HARNESS AND CONNECTOR (HEADLAMP BOTH LH AND RH - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



V003 (1) - Ground 

V006 (1) - Ground 


< 2 Ω 

Page 357

04-230 





6. INSPECT HI - BEAM RELAY AND LO - BEAM RELAY 

(a) 

(b) 

(c) 




(d) 



Condition 

Tester 

Connection 

Specified 

Condition 

Namal 




30 - 87 ≥ 1 MΩ 

30 - 87 < 2 Ω 

(e) 



Condition 


Specified 

Condition 

Normal 




30 - 87 ≥ 1 MΩ 

30 - 87 < 2 Ω 



NO > Replace relays. 

7. CHECK HARNESS AND CONNECTOR (HI - BEAM RELAY AND LO - BEAM RELAY - 

COMBINATION SWITCH) 

(a) 

(b) 

(c) 

(d) 





Page 358


04-231 

(e) 


table below. 




04 

Hi - beam relay (86) - I012 (9) 

Lo - beam relay (86) - I012 (8) 

< 2 Ω 

04 




8. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSE AND LO - BEAM FUSE BOTH LH AND 

RH - HEADLAMP BOTH LH AND RH) 

(a) 

(b) 

(c) 




(d) 


table below. 






< 2 Ω 

Page 359

04-232 


(e) 


table below. 




Lo - beam RH fuse (7.5A) - V006 (3) 


< 2 Ω 

(f) 


table below. 



V003 (2) - Ground 

V003 (3) - Ground 


≥ 1 MΩ 

(g) 


table below. 



V006 (2) - Ground 

V006 (3) - Ground 


≥ 1 MΩ 


YES > Replace hi - beam fuse (10A) and lo - beam fuse (7.5A) both LH and RH in the driver side junction box 

(I001). 


Page 360


04-233 

FRONT FOG LAMPS ARE INOPERATIVE 


04 

04 

Page 361

04-234 




(a) 


(b) 

Inspect front fog lamp fuse (15 A) in driver side junction 

box (I001). 




2. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP) 

(a) 

(b) 

(c) 

(d) 

(e) 


Remove front fog relay in driver side junction box (I001). 

Disconnect the C001 front fog lamp LH connector. 

Disconnect the C002 front fog lamp RH connector. 

Disconnect the I002 instrument cluster A connector. 

(f) 


table below. 



C001 (1) - Ground 


≥ 1 MΩ 


YES > Replace the fuse. 

NO > Repair or replace harness or connector,and replace the fuse. 

Page 362


04-235 

3. INSPECT FRONT FOG LAMP BULBS 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 



relace front fog lamp bulb LH. 


relace front fog lamp bulb RH. 



YES > Replace front fog lamp bulb both LH and RH. 


04 

04 


(a) 

(b) 


Disconnect the I012 combination switch connector. 

(c) 



Condition 

Tester 

Connection 

Specified 

Condition 

Set the front fog lamp 

switch to ON 


switch to OFF 

2 - 4 < 2 Ω 

2 - 4 ≥ 1 MΩ 




5. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - COMBINATION SWITCH 

(LIGHT)) 

(a) 

(b) 

(c) 


Remove front fog lamp relay in driver side junction box (I001). 


Page 363

04-236 


(d) 


table below. 



Front fog lamp relay (86) - I012 (2) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



Front fog lamp relay (87) - C001 (1) 



< 2 Ω 




Page 364


04-237 

7. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP - GROUND) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

C001 (2) - Ground 

C002 (2) - Ground 

< 2 Ω 


YES > Replace front fog lamp relay. 


Page 365

04-238 


FRONT FOG LAMPS ARE ALWAYS ON 


Page 366


04-239 



(a) 

(b) 



04 

(c) 



Condition 

Tester 

Connection 

Specified 

Condition 

04 


switch to ON 


switch to OFF 

2 - 4 < 2 Ω 

2 - 4 ≥ 1 MΩ 




2. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - COMBINATION SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



I012 (2) - Ground 


≥ 1 MΩ 




Page 367

04-240 




(b) Remove front fog lamp relay in driver side junction box (I001). 

(c) Connect the battery negative cable, check the wire harness for short to power supply. 

NOTE 

The front fog lamps should not light. 




Page 368


04-241 

REAR FOG LAMPS ARE INOPERATIVE 


04 

04 

Page 369

04-242 




(a) 


(b) 

Inspect rear fog lamp fuse (10A) in driver side junction 

box (I001). 




2. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - REAR FOG LAMP) 

(a) 

(b) 

(c) 

(d) 

(e) 


Remove rear fog lamp relay in driver side junction box (I001). 

Disconnect the F006 rear combination lamp LH connector. 

Disconnect the G001 rear combination lamp RH connector. 

Disconnect the I003 instrument cluster B connector. 

(f) 


table below. 



F006 (5) - Ground 


≥ 1 MΩ 




Page 370


04-243 


(a) 

(b) 



(c) 



04 

Condition 

Set the rear foglamp 

switch to ON 


switch to OFF 

Tester 

Connection 

Specified 

Condition 

3 - 4 < 2 Ω 

3 - 4 ≥ 1 MΩ 

04 




4. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 




(d) 


table below. 



Rear fog lamp relay (86) - I012 (3) 


< 2 Ω 




Page 371

04-244 


5. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



F006 (2) - Ground 

G001 (2) - Ground 


< 2 Ω 




6. INSPECT REAR FOG LAMP BULBS 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 



Replace rear fog lamp bulb LH. 


Replace rear fog lamp bulb RH. 



YES > Replace rear fog lamp bulb both LH and RH. 


Page 372


04-245 

7. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - REAR FOG LAMP LH) 

(a) 

(b) 

(c) 

(d) 





04 

(e) 


table below. 




04 

Rear fog lamp relay (87) - F006 (5) 

Rear fog lamp relay (87) - G001 (5) 

< 2 Ω 


YES > Replace rear fog lamp relay. 


Page 373

04-246 


REAR FOG LAMPS ARE ALWAYS ON 


Page 374


04-247 



(a) 

(b) 



04 

(c) 



Condition 

Tester 

Connection 

Specified 

Condition 

04 


switch to ON 


switch to OFF 

3 - 4 < 2 Ω 

3 - 4 ≥ 1 MΩ 




2. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - COMBINATION SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



I012 (3) - Ground 


≥ 1 MΩ 




Page 375

04-248 




(b) Remove rear fog lamp relay in driver side junction box (I001). 


NOTE 

The rear fog lamps should not light. 




Page 376


04-249 

ALL FOG LAMPS ARE INOPERATIVE 


04 

04 

Page 377

04-250 




(a) 


(b) 

(c) 

Inspect the front fog lamp fuse (15 A) in driver side junction 

box (I001). 

Inspect the rear fog lamp fuse (10 A) in driver side junction 

box (I001). 



NO > If front fog lamp fuse (15 A) is damage,go to next step. 

If rear fog lamp fuse (10 A) is damage,go to step 3. 

If both front and rear fog lamp fuses are damage,go to step 2 and step 3. 


(a) 

(b) 

(c) 

(d) 

(e) 






(f) 


table below. 



C001 (1) - Ground 


≥ 1 MΩ 




Page 378


04-251 


(a) 

(b) 

(c) 

(d) 

(e) 





Disconnect the I003 instrument cluster B connector. 

04 

(f) 


table below. 


04 


F006 (5) - Ground 


≥ 1 MΩ 





(a) 

(b) 



(c) 


table below. 



I012 (4) - Ground 


< 2 Ω 




Page 379

04-252 



(a) 

(b) 



(c) 



Condition 

Set the front foglamp 

switch to ON 


switch to OFF 


switch to ON 


switch to OFF 

Tester 

Connection 

2 - 4 

3 - 4 

Specified 

Condition 

< 2 Ω 

≥ 1 MΩ 

< 2 Ω 

≥ 1 MΩ 




6. NSPECT BOTH FRONT AND REAR FOG LAMP RELAYS. 

(a) 

(b) 

(c) 



Remove rear fog relay in driver side junction box (I001). 

(d) 

Inspect relays according to the value(s) in the table 

below.. . 

Condition 

Tester 

Connection 

Specified 

Condition 

Namal 




30 - 87 ≥ 1 MΩ 

30 - 87 < 2 Ω 

NOTE 

• Front fog lamp relay and rear fog lamp relay have 

same pins. 

• Both relays shoud be measured. 




Page 380


04-253 

7. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY AND REAR FOG LAMP 

RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 

(d) 





04 

(e) 


table below. 


04 


Front fog lamp relay (86) - I012 (2) 

Rear fog lamp relay (86) - I012 (3) 


< 2 Ω 




8. CHECK HARNESS AND CONNECTOR (FRONT AND REAR FOG LAMP RELAY - FRONT FOG 

LAMP LH AND RE ,REAR FOG LAMP LH AND RH) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 








Page 381

04-254 


(h) 


table below. 






< 2 Ω 

(i) 


table below. 






< 2 Ω 




9. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP LH AND REAR FOG LAMP LH AND 

RH - GROUND) 

(a) 

(b) 

(c) 

(d) 

(e) 






Page 382


04-255 

(f) 


table below. 




04 

C001 (2) - Ground 

C002 (2) - Ground 

< 2 Ω 

04 

(g) 


table below. 



F006 (2) - Ground 

G001 (2) - Ground 


< 2 Ω 


YES > Replace all fog lamp bulbs. 


Page 383

04-256 



LAMPS ARE NORMAL) 


Page 384


04-257 



(a) 


04 

(b) 

Inspect the hazard warning fuse (15A) in driver side 

junction box (I001). 

04 




2. CHECK HARNESS AND CONNECTOR (HAZARD WARNING FUSE - HAZARD WARNING SWITCH) 

(a) 

(b) 


Disconnect the I006 hazard warning switch connector. 

(c) 


table below. 



I006 (8) - Ground 


≥ 1 MΩ 




3. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - FLASHER) 

(a) 

(b) 

(c) 


Disconnect the I034 flasher connector. 


Page 385

04-258 


(d) 


table below. 



I006 (6) - I034 (3) 


< 2 Ω 





(a) 

(b) 



(c) 


table below. 



Hazard warning fuse (15A) - I006 (8) 


< 2 Ω 




5. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - ALL TURN SIGNAL LAMPS) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 



Disconnect the V004 front turn signal lamp LH connector. 


Disconnect the V008 front turn signal lamp RH connector. 


Page 386


04-259 

(g) 


table below. 




04 

I006 (5) - V004 (2) 

I006 (5) - F006 (4) 

< 2 Ω 

04 

(h) 


table below. 



I006 (4) - V008 (2) 

I006 (4) - G001 (4) 


< 2 Ω 


YES > Replace hazard warning switch. 


Page 387

04-260 





Page 388


04-261 



(a) 


04 

(b) 

Inspect the turn signal fuse (10A) in driver side junction 

box (I001). 

04 




2. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - HAZARD WARNING SWITCH) 

(a) 

(b) 



(c) 


table below. 



I006 (10) - Ground 


≥ 1 MΩ 




3. INSPECT COMBINATION SWITCH (TURN SIGNAL SWITCH) 

(a) 

(b) 


Disconnect the I012 combination switch (turn signal switch) connector. 

Page 389

04-262 


(c) 

Inspect combination switch (turn signal switch) according 


Condition 

Turn the turn signal 

switch OFF 

Set turn signal switch to 

LEFT 


RIGHT 

Tester 

Connection 

6 - 5 

6 - 7 

6 - 5 

6 - 7 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 





(a) 

(b) 



(c) 


table below. 



Turn signal fuse (10A) - I006 (10) 


< 2 Ω 




5. CHECK HARNESS AND CONNECTOR (FLASHER - COMBINATION SWITCH (TURN SIGNAL SWITCH)) 

(a) 

(b) 

(c) 




Page 390


04-263 

(d) 


table below. 




04 

I034 (3) - I012 (6) 

< 2 Ω 

04 




6. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - ALL 

TURN SIGNAL LAMPS) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



I012 (5) - V004 (2) 

I012 (5) - F006 (4) 


< 2 Ω 

(h) 


table below. 



I012 (7) - V008 (2) 

I012 (7) - G001 (4) 


< 2 Ω 




Page 391

04-264 


HAZARD WARNING AND TURN SIGNAL LAMPS ARE INOPERATIVE 


Page 392


04-265 



(a) 


04 

(b) 

(c) 

Inspect the hazard warning fuse (15A) in driver side 


Inspect the turn signal fuse (10A) in driver side junction 

box (I001). 

04 



NO > If hazard warning fuse (15A) is damage, go to next step. 

If turn signal fuse (10A) is damage,go to step 3. 

If both hazard warning fuse (15A) and turn signal fuse (10A) are damge,go to step 2 and step 3. 


(a) 

(b) 



(c) 


table below. 



I006 (8) - Ground 


≥ 1 ΜΩ 





(a) 

(b) 



Page 393

04-266 


(c) 


table below. 



I006 (10) - Ground 


≥ 1 ΜΩ 





(a) 

(b) 



(c) 


table below. 



I034 (2) - Ground 


≥ 1 MΩ 




5. INSPECT HAZARD WARNING SWITCH 

(a) 

(b) 



(c) 

Inspect the hazard warning switch according to the 


Condition 

Set hazard warning 

switch OFF 


switch ON 

Tester 

Connection 

7 - 10 

7 - 8 

6 - 5 - 4 

Specified 

Condition 

< 2 Ω 

Page 394


04-267 



NO > Relace hazard warning switch. 

6. CHECK HARNESS AND CONNECTOR (FLASHER - GROUND) 

04 

(a) 

(b) 



(c) 


table below. 


04 


I034 (1) - Ground 


< 2 Ω 





(a) 

(b) 

(c) 




(d) 


table below. 



I006 (7) - I034 (2) 

I006 (6) - I034 (3) 


< 2 Ω 




8. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - HAZARD WARNING FUSE 

AND TURN SIGNAL FUSE) 

(a) 

(b) 



Page 395

04-268 


(c) 


table below. 



I006 (8) - Hazard warning fuse (15A) 


< 2 Ω 

(d) 


table below. 



I006 (10) - Turn signal fuse (10A) 


< 2 Ω 




9. INSPECT FLASHER 

(a) 

(b) 

(c) 

(d) 



Replace flasher. 



YES > Replace flasher. 


10. CHECK HARNESS AND CONNECTOR (FLASHER - COMBINATION SWITCH) 

(a) 

(b) 



Page 396


04-269 

(c) 


(d) 


table below. 


04 


I034 (3) - I012 (6) 


< 2 Ω 

04 




11. INSPECT COMBINATION SWITCH 

(a) 

(b) 



(c) 



Condition 


switch OFF 


LEFT 


RIGHT 

Tester 

Connection 

6 - 5 

6 - 7 

6 - 5 

6 - 7 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 




12. CHECK HARNESS AND CONNECTOR (TURN SIGNAL LAMP - GROUND) 

(a) 

(b) 

(c) 

(d) 

(e) 






Page 397

04-270 


(f) 


table below. 



V004 (1) - Ground 

F006 (2) - Ground 


< 2 Ω 

(g) 


table below. 



V008 (1) - Ground 

G001 (2) - Ground 


< 2 Ω 




13. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - ALL TURN SIGNAL LAMPS) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



I006 (5) - V004 (2) 

I006 (5) - F006 (4) 


< 2 Ω 

Page 398


04-271 

(h) 


table below. 




04 

I006 (4) - V008 (2) 

I006 (4) - G001 (4) 

< 2 Ω 

04 






(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



I012 (5) - V004 (2) 

I012 (5) - F006 (4) 


< 2 Ω 

(h) 


table below. 



I012 (7) - V008 (2) 

I012 (7) - G001 (4) 


< 2 Ω 


YES > Replace 4 turn signal lamp bulbs. 


Page 399

04-272 


TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE) 


Page 400


04-273 


• This inspection procedure is an example of turn signal lamp LH, turn signal lamp RH inspection 



NOTE 

If only one turn signal lamp is not bright,over this step. 

(a) 

(b) 


Disconnect the I012 combination switch(turn signal lamp) connector. 

04 

04 

(c) 



Condition 


switch OFF 


LEFT 


RIGHT 

Tester 

Connection 

6 - 5 

6 - 7 

6 - 5 

6 - 7 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 

NOTE 

• If only turn signal lamps LH is not bright,measure 6 - 

5. 

• If only turn signal lamps RH is not bright,measure 6 - 

7. 




2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - TURN 

SIGNAL LAMP) 

NOTE 

• If only front turn signal lamps LH is not bright,step d isn’t performed. 

• If only rear turn signal lamps LH is not bright,step c isn’t performed. 


(b) Disconnect the I012 combination switch(turn signal lamp) connector. 

(c) Disconnect the V004 front turn signal lamp LH connector. 

(d) Disconnect the F006 rear combination lamp LH connector. 

Page 401

04-274 


(e) 


table below. 



I012 (5) - V004 (2) 

I012 (5) - F006 (4) 


< 2 Ω 




NOTE 

• If only front turn signal lamps LH is not bright,measure 

I012 (5) - V004 (2) only. 

• If only rear turn signal lamps LH is not bright,measure 

I012 (5) - F006 (4) only. 


NOTE 

• If only front turn signal lamps LH is not bright,step c isn’t performed. 

• If only rear turn signal lamps LH is not bright,step b isn’t performed. 


(b) Disconnect the V004 front turn signal lamp LH connector. 

(c) Disconnect the F006 rear combination lamp LH connector. 

(d) 


table below. 



V004 (1) - Ground 

F006 (2) - Ground 


< 2 Ω 


YES > Replace turn signal lamp bulb(s). 


NOTE 


V004 (1) - Ground only. 


F006 (2) - Ground only. 

Page 402


04-275 

HAZARD WARNING LAMPS ARE ALWAYS ON 


04 

04 

Page 403

04-276 




(a) 

(b) 



(c) 



Condition 


switch OFF 

Tester 

Connection 

7 - 8 

6 - 5 - 4 

Specified 

Condition 

≥ 1 MΩ 



NO > Replace hazard warning switch. 

2. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - TURN SIGNAL LAMP) 

(a) 

(b) 

(c) 



Connect the battery negative cable,check the wire harness for shot to ground,hazard warning lamp is 

shoud not be bright. 




Page 404


04-277 

ALL STOP LAMPS ARE INOPERATIVE 


04 

04 

Page 405

04-278 




(a) 


(b) 

Inspect the stop lamp fuse (15A) in engine room junction 

box(A002). 




2. CHECK HARNESS AND CONNECTOR (BRAKE LAMP FUSE - STOP LAMP SWITCH) 

(a) 

(b) 



(c) 


table below. 



A025 (2) - Ground 


≥ 1 ΜΩ 




3. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - STOP LAMP) 

(a) 

(b) 

(c) 

(d) 




Disconnect the U002 high - mounted stop lamp connector. 

Page 406


04-279 

(e) 


table below. 




04 

F006 (3) - Ground 

≥ 1 ΜΩ 

04 




4. INSPECT STOP LAMP SWITCH 

(a) 

(b) 



(c) 

Inspect the stop lamp switch according to the value(s) in 


Condition 

Tester 

Connection 

Specified 

Condition 

Set stop lamp switch OFF 1 - 2 ≥ 1 MΩ 

Set stop lamp switch ON 1 - 2 < 2 Ω 




5. CHECK HARNESS AND CONNECTOR ( BRAKE LAMP FUSE - STOP LAMP SWITCH) 

(a) 

(b) 



Page 407

04-280 


(c) 


table below. 



Stop lamp fuse (15A) - A025 (2) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 

(e) 






(f) 


table below. 



A025(1) - F006 (3) 

A025(1) - G001(3) 


< 2 Ω 

(g) 


table below. 



A025(1) - U002 (2) 


< 2 Ω 

Page 408


04-281 




7. CHECK HARNESS AND CONNECTOR (STOP LAMP - GROUND) 

04 

(a) 

(b) 

(c) 

(d) 





(e) 


table below. 


04 


F006 (2) - Ground 

G001 (2) - Ground 


< 2 Ω 

(f) 


table below. 



U002 (1) - Ground 


< 2 Ω 


YES > Replace stop lamp bulbs. 


Page 409

04-282 


STOP LAMP IS INOPERATIVE (ONE SIDE) 


Page 410


04-283 


• This inspection procedure is an example of stop lamp LH, stop lamp RH inspection procedure is similar. 

1. CHECK HARNESS AND CONNECTOR (REAR COMBINATION LAMP - GROUND) 

04 

(a) 

(b) 



(c) 


table below. 


04 


F006 (2) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - REAR COMBINATION LAMP) 

(a) 

(b) 

(c) 




(d) 


table below. 



A025 (1) - F006 (3) 


< 2 Ω 


YES > Replace stop lamp bulb. 


Page 411

04-284 


HIGH - MOUNTED STOP LAMP IS INOPERATIVE 


Page 412


04-285 


1. CHECK HARNESS AND CONNECTOR (HIGH - MOUNTED STOP LAMP - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

U002 (1) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - HIGH - MOUNTED STOP LAMP) 

(a) 

(b) 

(c) 




(d) 


table below. 



A025 (1) - U002 (2) 


< 2 Ω 


YES > Replace high - mounted stop lamp bulb. 


Page 413

04-286 


BACK - UP LAMP IS INOPERATIVE(ONE SIDE) 


Page 414


04-287 


• This inspection procedure is an example of back - up lamp LH, back - up lamp RH inspection procedure 

is similar. 

(a) 

(b) 

(c) 

Check harness and connector (back - up lamp - ground) 



04 

(d) 


table below. 


04 


F006 (2) - Ground 


< 2 Ω 




3. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - BACK - UP LAMP) 

(a) 

(b) 

(c) 


Disconnect the A021 back - up lamp switch connector. 


(d) 


table below. 



A021 (2) - F006 (6) 


< 2 Ω 


YES > Replace back - up lamp bulb. 


Page 415

04-288 


BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES) 


Page 416


04-289 



(a) 


04 

(b) 

Inspect the back - up lamp fuse (10A) in driver side 


04 




2. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP FUSE - BACK - UP LAMP SWITCH) 

(a) 

(b) 



(c) 


table below. 



A021 (1) - Ground 


≥ 1 ΜΩ 




Page 417

04-290 



(a) 

(b) 

(c) 




(d) 


table below. 



F006 (6) - Ground 


≥ 1 ΜΩ 





(a) 

(b) 



(c) 

Inspect the back - up lamp switch according to the 


Condition 

Tester 

Connection 

Specified 

Condition 

Set back - up lamp 

switch OFF 


switch ON 

1 - 2 ≥ 1 MΩ 

1 - 2 < 2 Ω 



NO > Replace back - up lamp switch. 

Page 418


04-291 


(a) 

(b) 



(c) 


table below. 


04 


Back - up lamp (10A) - A021 

(1) 


< 2 Ω 

04 





(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



A021 (2) - F006 (6) 

A021 (2) - G001 (6) 


< 2 Ω 




Page 419

04-292 


7. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



F006 (2) - Ground 

G001 (2) - Ground 


< 2 Ω 


YES > Replace back - up lamp bulbs. 


Page 420


04-293 

IGNITION SWITCH ILLUMINATION IS INOPERATIVE 


04 

04 

Page 421

04-294 



1. INSPECT IGNITION SWITCH ILLUMINATION LAMP. 

(a) 

(b) 

(c) 

(d) 


Disconnect the I010 ignition switch illumination connector. 

Replace ignition switch illumination lamp. 



YES > Replace ignition switch illumination lamp. 


2. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - IGNITION SWITCH ILLUMINATION) 

(a) 

(b) 



(c) 


table below. 



Dome light fuse (10A) - I010 (1) 


< 2 Ω 




Page 422


04-295 

3. CHECK HARNESS AND CONNECTOR (IGNITION SWITCH ILLUMINATION - CENTRAL LOCKING 

CONTROLLER ASSY) 

(a) 

(b) 

(c) 



Disconnect the I008 central locking controller assy connector. 

04 

(d) 


table below. 




04 

I010 (2) - I008 (B1) 

< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY - GROUND) 

(a) 

(b) 



(c) 


table below. 



I008 (B10) - Ground 


< 2 Ω 


YES > Replace central locking controller asssy. 


Page 423

04-296 


CENTRAL DOME LIGHT IS INOPERATIVE 


Page 424


04-297 

04 

04 

Page 425

04-298 



1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - CENTRAL DOME LIGHT) 

(a) 

(b) 


Disconnect the F004 central dome light connector. 

(c) 


table below. 



Dome light fuse (10A) - F004 (1) 


< 2 Ω 

NOTE 

If central dome light can’t be contrled by door lamp switch,over 

this step. 

(d) 


table below. 





< 2 Ω 

NOTE 

If central dome light can be contrled by door lamp switch,over 

this step. 




2. CHECK HARNESS AND CONNECTOR (CENTRAL DOME LIGHT - DOME LIGHT SWITCH AND 

MIDDLE DOOR LAMP SWITCH RH) 

NOTE 

• If central dome light can be contrled by door lamp switch,perform this step. 

• If central dome light can’t be contrled by door lamp switch,over this step ,perform the next step. 


(b) Disconnect the F004 central dome light connector. 

(c) Disconnect the G003 middle door lamp switch RH connector. 

Page 426


04-299 

(d) 


table below. 




04 

F004 (3) - I018 (5) 

F004 (2) - G003 (1) 

< 2 Ω 

04 


YES > Replace central dome light assy. 


3. CHECK HARNESS AND CONNECTOR (CENTRAL DOME LIGHT - DOME LIGHT SWITCH) 

(a) 

(b) 

(c) 



Disconnect the I018 dome light switch connector. 

(d) 


table below. 



F004 (2) - I018 (5) 


< 2 Ω 




4. INSPECT DOME LIGHT SWITCH 

(a) 

NOTE 

Turn the dome light switch ON. 

If the dome light switch has no problem,it should be bright. 



NO > Replace dome light switch. 

Page 427

04-300 


5. CHECK HARNESS AND CONNECTOR (DOME LIGHT SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



I018 (2) - Ground 


< 2 Ω 




Page 428


04-301 

AIR PURIFIER LAMP IS INOPERATIVE 


04 

04 

Page 429

04-302 


Page 430


04-303 


1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - AIR PURIFIER LAMP) 

(a) 

(b) 


Disconnect the F007 air purifier connector. 

04 

(c) 


table below. 




04 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (AIR PURIFIER LAMP - DOME LIGHT SWITCH AND 


(a) 

(b) 

(c) 

(d) 




Disconnect the G003 middle door lamp switch RH connector. 

(e) 


table below. 



F007 (3) - I018 (5) 

F007 (2) - G003 (1) 


< 2 Ω 


YES > Replace air purifier. 


Page 431

04-304 


STEP LAMP ARE INOPERATIVE 


Page 432


04-305 


1. INSPECT STEP LAMP 

(a) 

(b) 

(c) 

(d) 


Disconnect the N002 step lamp connector. 

Replace step lamp bulb. 

Connect the battery negative cable,trun the middle door lamp switch RH ON. 


YES > Replace step lamp bulb. 


04 

04 

2. CHECK HARNESS AND CONNECTOR (dome light FUSE - STEP LAMP) 

(a) 

(b) 



(c) 


table below. 



dome light fuse (10A) - N002 (1) 


< 2 Ω 




Page 433

04-306 


3. CHECK HARNESS AND CONNECTOR (STEP LAMP - MIDDLE DOOR LAMP SWITCH RH) 

(a) 

(b) 

(c) 



Disconnect the G003 middle door lamp switch RH connector. 

(d) 


table below. 



N002 (2) - G003 (1) 


< 2 Ω 


YES > Replace middle door lamp switch RH. 


Page 434


04-307 

TRUNK LAMP IS INOPERATIVE 


04 

04 

Page 435

04-308 



1. INSPECT TRUNK LAMP 

(a) 

(b) 

(c) 

(d) 


Disconnect the J003 trunk lamp connector. 

Replace trunk lamp bulb. 

Connect the battery negative cable,turn rear hatch lock assy - switch ON. 


YES > Replace trunk lamp bulb. 


2. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - TRUNK LAMP) 

(a) 

(b) 



(c) 


table below. 



Dome light fuse (10A) - J003 (1) 


< 2 Ω 




3. CHECK HARNESS AND CONNECTOR (TRUNK LAMP - REAR HATCH LOCK ASSY - SWITCH) 

(a) 

(b) 

(c) 



Disconnect the J001 rear hatch lock assy - switch connector. 

Page 436


04-309 

(d) 


table below. 




04 

J003 (2) - J001 (1) 

< 2 Ω 

04 




4. CHECK HARNESS AND CONNECTOR (REAR HATCH LOCK ASSY - SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



J001 (2) - Ground 


< 2 Ω 


YES > Replace rear hatch lock assy - switch. 


Page 437

04-310 


FRONT DOME LIGHT IS INOPERATIVE 


Page 438


04-311 

04 

04 

Page 439

04-312 



1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - FRONT DOME LIGHT) 

(a) 

(b) 

Disconnect the battery negative cable.front dome light 

Disconnect the F001 front dome light connector. 

(c) 


table below. 






< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (FRONT DOME LIGHT - GROUND,FRONT DOOR LAMP 

DIODE LH,FRONT DOOR LAMP SWITCH RH,INSTRUMENT CLUSTER) 

(a) 

(b) 

(c) 

(d) 

(e) 



Disconnect the A029 front door lamp diode LH connector. 

Disconnect the A024 front door lamp switch rh connector. 


(f) 


table below. 



F001 (4) - A029 (1) 

F001 (4) - A024 (1) 


< 2 Ω 

Page 440


04-313 

(g) 


table below. 




04 

F001 (4) - I002 (A30) 

F001 (3) - Ground 

< 2 Ω 

04 


YES > Replace front dome light assy. 


Page 441

04-314 


ALL INTERIOR ILLUMINATION LAMPS ARE INOPERATIVE 


Page 442


04-315 

04 

04 

Page 443

04-316 



1. INSPECT LAMPLET RELAY 

(a) 

(b) 


Remove lamplet relay in driver side junction box (I001). 

(c) 

Inspect lamplet relay according to the value(s) in the 

table below 

Condition 

Tester 

Connection 

Specified 

Condition 

Normal 85 - 86 Breakover 



30 - 87 < 2 Ω 



NO > Replace lamplet relay. 

2. CHECK HARNESS AND CONNECTOR (LAMPLET RELAY - COMBINATION SWITCH) 

(a) 

(b) 

(c) 


remove lamplet relay in driver side junction box (I001). 


(d) 


table below. 



Lamplet relay (86) - I012 (13) 


< 2 Ω 




Page 444


04-317 


(a) 

(b) 



04 

(c) 


table below. 



I012 (10) - Ground 


< 2 Ω 

04 





(a) 


(b) 

(c) 

inspect lamplet fuse (7.5A) in driver side junction box 

(I001). 

inspect switch lighting fuse (7.5A) in driver side junction 

box (I001). 


YES > Replace the combination switch. 


Page 445

04-318 


5. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - INSTRUMENT CLUSTER) 

(a) 

(b) 



(c) 


table below. 



I002 (A6) - Ground 


≥ 1 ΜΩ 



NO > Repair or replace harness or connector,and go to next step. 

6. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - INTERIOR LAMPS) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

(j) 

(k) 

(l) 



Disconnect the I004 headlamp dimmer switch connector. 

Disconnect the I005 instrument dimmer switch connector. 

Disconnect the I016 rear window defroster switch connector. 

Disconnect the I017 outside mirror defroster switch connector. 



Disconnect the I033 cigarette lighter connector. 

Disconnect the I031 radio A connector. 

Disconnect the I021 A/C control panel B connector. 

Disconnect the I019 diagnosis switch connector. 

(m) 


table below. 



I006 (2) - Ground 


≥ 1 ΜΩ 




Page 446


04-319 

INSTRUMENT CLUSTER ILLUMINATION IS NOT INOPERATIVE 


04 

04 

Page 447

04-320 




(a) 


(b) 

Inspect lamplet fuse (7.5A) in driver side junction box 

(I001). 





(a) 

(b) 



(c) 


table below. 





≥ 1 MΩ 




Page 448


04-321 

3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 





< 2 Ω 

04 





(a) 

(b) 



(c) 


table below. 



Lamplet fuse (7.5A) - I002 (A6) 


< 2 Ω 


YES > Replace Instrument Cluster. 


Page 449

04-322 


DIAGNOSIS SWITCH ILLUMINATION IS NOT INOPERATIVE 


Page 450


04-323 


1. CHECK HARNESS AND CONNECTOR (DIAGNOSIS SWITCH - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

I019 (1) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - DIAGNOSIS SWITCH) 

(a) 

(b) 



(c) 


table below. 



Switch lighting fuse (7.5A) - I019 (3) 


< 2 Ω 


YES > Replace diagnosis switch. 


Page 451

04-324 


CIGARETTE LIGHTER ILLUMINATION IS NOT INOPERATIVE 


Page 452


04-325 


1. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

I033 (1) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - CIGARETTE LIGHTER) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace cigarette lighter. 


Page 453

04-326 


A/C CONTROL PANEL ILLUMINATION IS NOT INOPERATIVE 


Page 454


04-327 


1. CHECK HARNESS AND CONNECTOR (A/C CONTROL PANEL - GROUND) 

(a) 

(b) 


Disconnect the I020 A/C control panel A connector. 

04 

(c) 


table below. 




04 

I020 (20) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - A/C CONTROL PANEL) 

(a) 

(b) 


Disconnect the I021 A/C control panel B connector. 

(c) 


table below. 





< 2 Ω 


YES > Replace A/C control panel. 


Page 455

04-328 


RADIO ILLUMINATION IS NOT INOPERATIVE 


Page 456


04-329 


1. CHECK HARNESS AND CONNECTOR (RADIO - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - RADIO) 

(a) 

(b) 



(c) 


table below. 



Switch lighting fuse (7.5A) - I031 (A3) 


< 2 Ω 


YES > Raplace radio. 


Page 457

04-330 


REAR BLOWER FORWARD SWITCH ILLUMINATION IS NOT INOP- 

ERATIVE 


Page 458


04-331 


1. CHECK HARNESS AND CONNECTOR (REAR BLOWER FORWARD SWITCH - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

I023 (1) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - REAR BLOWER FORWARD 

SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace rear blower forward switch. 


Page 459

04-332 


DOME LIGHT SWITCH ILLUMINATION IS NOT INOPERATIVE 


Page 460


04-333 



(a) 

(b) 



04 

(c) 


table below. 




04 

I018 (1) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - DOME LIGHT SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace dome light switch. 


Page 461

04-334 


OUTSIDE MIRROR DEFROSTER SWITCH ILLUMINATION IS NOT 

INOPERATIVE 


Page 462


04-335 


1. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROSTER SWITCH - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

I017 (1) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - OUTSIDE MIRROR DEFROSTER 

SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace outside mirror defroster switch. 


Page 463

04-336 


HEADLAMP DIMMER SWITCH ILLUMINATION IS NOT INOPERA- 

TIVE 


Page 464


04-337 


1. CHECK HARNESS AND CONNECTOR (HEADLAMP DIMMER SWITCH - Ground) 

(a) 

(b) 



04 

(c) 


table below. 




04 

I004 (6) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - HEADLAMP DIMMER SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace headlamp dimmer switch. 


Page 465

04-338 


REAR WINDOW DEFROSTER SWITCH ILLUMINATION IS NOT 

INOPERATIVE 


Page 466


04-339 


1. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROSTER SWITCH - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

I016 (1) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - REAR WINDOW DEFROSTER 

SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace rear window defroster switch. 


Page 467

04-340 


INSTRUMENT DIMMER SWITCH ILLUMINATION IS NOT INOPERA- 

TIVE 


Page 468


04-341 


1. CHECK HARNESS AND CONNECTOR (INSTRUMENT DIMMER SWITCH - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

I005 (6) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - INSTRUMENT DIMMER SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace instrument dimmer switch. 


Page 469

04-342 


HAZARD WARNING SWITCH ILLUMINATION IS NOT INOPERATIVE 


Page 470


04-343 


1. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

I006 (3) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - HAZARD WARNING SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 




Page 471

04-344 


WIDTH LAMPS IS NOT INOPERATIVE 


Page 472


04-345 


1. CHECK HARNESS AND CONNECTOR (WIDTH LAMPS - GROUND) 

NOTE 

• If only width lamp LH is not bright,step c isn’t performed. 

• If only width lamp RH is not bright,step b isn’t performed. 


(b) Disconnect the V002 front position lamp LH connector. 

(c) Disconnect the V007 front position lamp RH connector. 

04 

04 

(d) 


table below. 



V002 (1) - Ground 

V007 (1) - Ground 


< 2 Ω 




NOTE 

• If only width lamp LH is not bright,measure V002 (1) - 

Ground onlyl. 

• If only width lamp RH is not bright,measure V007 (1) - 

Ground only. 

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - WIDTH LAMPS) 

NOTE 






Page 473

04-346 


(d) 


table below. 



Lamplet fuse (7.5A) - V002 (2) 



< 2 Ω 

NIOTE 

• If only width lamp LH is not bright,measure lamplet 

fuse (7.5A) - V002 (2) only. 

• If only width lamp RH is not bright,measure lamplet 

fuse (7.5A) - v007 (2) only. 


YES > Replace width lamp bulbs. 


Page 474


04-347 

TAIL LAMPS ARE INOPERATIVE 


04 

04 

Page 475

04-348 



1. CHECK HARNESS AND CONNECTOR (TAIL LAMPS - GROUND) 

NOTE 

• If only tail lamp LH is not bright,step c isn’t performed. 

• If only tail lamp RH is not bright,step b isn’t performed. 


(b) Disconnect the F006 rear combination lamp LH connector. 

(c) Disconnect the G001 rear combination lamp RH connector. 

(d) 


table below. 



F006 (2) - Ground 

G001 (2) - Ground 


< 2 Ω 




NOTE 

• If only tail lamp LH is not bright, measure F006 (2) - 

Ground only. 

• If only tail lamp RH is not bright,measure G001 (2) - 

Ground only. 

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - TAIL LAMPS) 

NOTE 






Page 476


04-349 

(d) 


table below. 




04 

Lamplet fuse (7.5A) - F006 (1) 

Lamplet fuse (7.5A) - G001 (1) 

< 2 Ω 

NOTE 

• If only tail lamp LH is not bright, measure Lamplet 

Fuse (7.5A) - F006 (1) only. 

• If only tail lamp RH is not bright,measure Lamplet 

Fuse (7.5A) - G001 (1) only. 

04 


YES > Replace tail lamp bulbs. 


Page 477

04-350 


LICENSE LAMP IS INOPERATIVE 


Page 478


04-351 


1. CHECK HARNESS AND CONNECTOR (LICENSE LAMP - GROUND) 

(a) 

(b) 


Disconnect the J004 license lamp connector. 

04 

(c) 


table below. 




04 

J004 (2) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - LICENSE LAMP) 

(a) 

(b) 



(c) 


table below. 



Lamplet fuse (7.5A) - J004 (1) 


< 2 Ω 


YES > Replace license lamp bulbs. 


Page 479

04-352 


WIDTH LAMPS TAIL LAMPS AND LICENSE LAMP ARE INOPERA- 

TIVE 


Page 480


04-353 



(a) 


04 

(b) 

Inspect the lamplet fuse (7.5A) in driver side junction box 

(I001). 

04 




2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - LAMPLET) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 


Disconnect the V002 front position lamp LH connector. 

Disconnect the V007 front position lamp RH connector. 




(g) 


table below. 



V002 (2) - Ground 


≥ 1 ΜΩ 




Page 481

04-354 



(a) 

(b) 


Remove lamplet relay in driver side junction box (I001). 

(c) 


table below 

Condition 

Tester 

Connection 

Specified 

Condition 




30 - 87 < 2 Ω 




4. CHECK HARNESS AND CONNECTOR (LAMPLET RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 


Remove the lamplet relay in driver side junction box (I001). 


(d) 


table below. 



lamplet relay (86) - I012 (13) 


< 2 Ω 




Page 482


04-355 


(a) 

(b) 



04 

(c) 


table below. 



I012 (10) - Ground 


< 2 Ω 

04 




Page 483

04-356 

DIAGNOSTICS - WIPER AND WASHER 


PRECAUTION 


Ignition Switch (position) 

LOCK 

ON 

ACC 

START 

Ignition Switch (condition) 

Ignition switch off 

Ignition switch on (IG) 

Ignition switch on (ACC) 

Engine start 

2. POWER OFF. 

(a) 

(b) 

Before removing or installing any electrical device, please disconnect the nagative battery cable to 


Make sure ignition switch is OFF if no specific instructions. 

Page 484


04-357 

LOCATION 

04 

04 

1 Front Wiper Arm Assy LH 2 Front Wiper Arm Assy RH 

1 Rear Wiper Arm Assy 2 Rear Wiper Blade Assy 

Page 485

04-358 




1 


• The voltage should be above 12 V. 


Yes 

No 





2 

Check the wiper motor in HIGH position. 

• Set the wiper and washer switch in HIGH 

position. 

Does the wiper motor operate in high mode? 

Yes 

No 



3 

Check the wiper motor in LOW position. 

• Set the wiper and washer switch in LOW 

position. 

Does the wiper motor operate in low mode? 

Yes 

No 



4 

Check the wiper motor in INT position. 

• Set the wiper and washer switch in INT 

position. 

Does the wiper motor operate in intermittent 

mode? 

Yes 

No 

Check wiper and washer switch 


Page 486


04-359 





04 

1. Fuse - 

Wipers are inoperative - windshield 

2. Wiper and washer switch 

3. Windshield wiper motor 

Chapter 51 steering column - 

combination switch, replacement 

Chapter 65 wiper and washer - 

wiper motor, replacement 

04 


Wipers are inoperative at low speed 

- windshield 








Wipers are inoperative at high 

speed - windshield 








Wipers are inoperative in 

intermittent mode - windshield 








Washer pump is inoperative - 

windshield 








When the wiper and washer switch 

is OFF, the wiper blade does not 

retract 








Wiper is inoperative - rear window 

1. Rear window wiper motor 







Page 487

04-360 



Wiper is inoperative in intermittent 

mode - rear window 








1. Washer pump - rear window - 

Washer pump is inoperative - rear 

window 





Page 488


04-361 

WIPERS ARE INOPERATIVE - WINDSHIELD 


04 

04 

Page 489

04-362 




(a) 


(b) 

Inspect the windshield wiper fuse in driver side junction 

box (I001): 15 A. 




2. CHECK HARNESS AND CONNECTOR ( FRONT WIPER FUSE - WINDSHIELD WIPER) 

(a) 

(b) 


Disconnect the V011 windshield wiper assy connector. 

(c) 


table below. 



Front wiper fuse - V011(2) 


Go to next step. 


Page 490


04-363 

3. CHECK HARNESS AND CONNECTOR (FRONT WIPER FUSE - COMBINATION SWITCH) 

(a) 

(b) 


Disconnect the I013 combination switch (wiper and washer control) connector. 

04 

(c) 


table below. 


Front wiper fuse - I013 (8) 


< 2 Ω 

04 




4. CHECK HARNESS AND CONNECTOR (FRONT WIPER FUSE - FRONT WASHING RESERVOIR 

MOTOR) 

(a) 

(b) 


Disconnect the V010 front washing reservoir motor connector. 

(c) 


table below. 



Front wiper fuse - V010 (2) 


< 2 Ω 




Page 491

04-364 


5. INSPECT RELAY IG2 

(a) 

(b) 


Pull out the relay IG2. 

(c) 

Inspect relay IG2. 

Condition 


Specified 

Condition 

Apply battery 

voltage to 

terminal 30 and 

87 

30 - 87 < 2 Ω 




NO > Replace relay IG2. 

6. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER - GROUND) 

(a) 

(b) 


Disconnect the V011 windshield wiper connector. 

(c) 


table below. 



Windshield wiper(V011) - 

Ground 


< 2 Ω 




Page 492


04-365 

7. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - WINDSHIELD WIPER) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 



I013(7) - V011(1) 


04 

I013(9) - V011(4) 

< 2 Ω 

I013(6) - V011(3) 




8. INSPECT WINDSHIELD WIPER 

(a) 

(b) 


Remove the windshield wiper assy. 

(c) 

Inspect the windshield wiper in high mode. 

Condition 

Apply battery 

voltage to 

terminal 4 and 5 


4 - 5 

Specified 

Condition 

Windshield wiper 

high - speed operation 

(d) 

Inspect windshield wiper in low mode 

Condition 

Apply battery 

voltage to 



1 - 5 

Specified 

Condition 

Windshield wiper 

low - speed operation 



NO > Repair or replace windshield wiper. 

Page 493

04-366 


9. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



I013(5) - Ground 


< 2 Ω 


YES > Replace combination switch. 


Page 494


04-367 

WIPERS ARE INOPERATIVE AT LOW SPEED - WINDSHIELD 


04 

04 

Page 495

04-368 




(a) 

(b) 



(c) 

Inspect combination switch (wiper and washer control) 

according to the value(s) in the table below. 

Condition 

Tester 

Connection 

Specified 

Condition 

Set the wiper and washer 

switch to OFF 


switch to LOW 

8 - 7 ≥ 1 MΩ 

8 - 7 < 2 Ω 





(a) 

(b) 

(c) 




(d) 


table below. 

Standard resisance 


I013(7) - V011(1) 


< 2 Ω 


YES > Replace windshield wiper. 


Page 496


04-369 

WIPERS ARE INOPERATIVE AT HIGH SPEED - WINDSHIELD 


04 

04 

Page 497

04-370 




(a) 

(b) 


Disconnect the V013 combination switch (wiper and washer control) connector. 

(c) 



Condition 

Tester 

Connection 

Specified 

Condition 


switch to OFF 


switch to HIGH 

8 - 9 ≥ 1 MΩ 

8 - 9 < 2 Ω 





(a) 

(b) 

(c) 




(d) 

Measure the resisitance according to the value(s) in the 

table below. 



I013 (9) - V011(4) 


< 2 Ω 




Page 498


04-371 


SHIELD 


04 

04 

Page 499

04-372 




(a) 

(b) 



(c) 

Inspect the windshield wiper in INT mode. 

Condition 

Apply battery 

voltage to terminal 

3 and 5 


Battery(+) - 3 

Battery( - ) - Ground 

Specified 

Condition 

Front washing 

reservoir motor 

operates at low 

speed 



NO > Replace the windshield wiper. 

2. CHECK HARNESS AND CONNECTOR ( COMBINATION SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 


I013 (5) - Ground 


< 2 Ω 

Is the inspecrtion result normal? 



Page 500


04-373 


(a) 

(b) 



(c) 


table below. 


04 


V011 (5) - Ground 


< 2 Ω 

04 




4. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER - COMBINATION SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



I013 (6) - V011 (3) 

I013 (7) - V011 (1) 


< 2 Ω 




Page 501

04-374 


WASHER PUMP IS INOPERATIVE - WINDSHIELD 


Page 502


04-375 



(a) 


04 

(b) 

Inspect the front wiper fuse in driver side junction box 

(I001): 15 A. 

04 





(a) 

(b) 



(c) 



Condition 


Specified 

Condition 


switch to OFF 


switch to WASH 

4 - 5 ≥ 1 MΩ 

4 - 5 < 2 Ω 




Page 503

04-376 


3. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - FRONT WASHER 

PUMP) 

(a) 

(b) 


Disconnect the V010 front washer pump connector. 

(c) 


table below. 



Driver side junction connector(87) 

- V010 (2) 


< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT WASHER PUMP) 

(a) 

(b) 

(c) 




(d) 


table below. 



V010 (1) - I013 (4) 


< 2 Ω 




Page 504


04-377 


(a) 

(b) 



04 

(c) 


table below. 



I013 (5) - Ground 


< 2 Ω 

04 


YES > Replace the front washer pump. 


Page 505

04-378 


WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE DOES NOT 

RETRACT 


Page 506


04-379 



(a) 

(b) 



04 

(c) 



Condition 


Specified 

Condition 

04 


switch to OFF 


switch to LOW 

5 - 7 < 2 Ω 

5 - 7 ≥ 1 MΩ 




2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - WINDSHIELD WIPER ) 

(a) 

(b) 

(c) 




(d) 


table below. 



I013 (7) - V011 (1) 


< 2 Ω 




Page 507

04-380 



(a) 

(b) 

(c) 




(d) 


table below. 



V011(3) - I013 (6) 


< 2 Ω 


YES > Repair or replace windshield wiper. 


Page 508


04-381 

WIPER IS INOPERATIVE - REAR WINDOW 


04 

04 

Page 509

04-382 




(a) 

(b) 



(c) 



Condition 


Specified 

Condition 


switch to OFF 

Set the rear wiper and 

washer switch to ON 

2 - 5 ≥ 1 MΩ 

2 - 5 < 2 Ω 





(a) 


(b) 

Inspect the rear wiper fuse in driver side junction box 

(I001): 10 A. 




Page 510


04-383 

3. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - COMBINATION 

SWITCH) 

(a) 

(b) 


Disconnect rear wiper relay connector. 

04 

(c) 


table below. 



Rear wiper relay(86) - I013 (2) 


< 2 Ω 

04 



NO > Replace fuse. 

4. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - REAR WIPER) 

(a) 

(b) 



(c) 


table below. 



Rear wiper relay(86) - U001 (2) 


< 2 Ω 




Page 511

04-384 


5. INSPECT REAR WIPER RELAY 

(a) 

(b) 


Disconnect rear wiper relay. 

(c) 


table below. 


Condition 


Specified 

Condition 

Constant 30 - 87a < 2 Ω 

Constant 85 - 86 < 2 Ω 





30 - 87a ≥ 1 MΩ 

30 - 87 Continuity 



NO > Repair or replace rear wiper relay. 

6. INSPECT RELAY 

(a) 

(b) 


Disconnect relay IG2. 

(c) 


table below. 


Condition 


Specified 

Condition 

Constant 85 - 86 < 2 Ω 






NO > Repair or replace relay. 

Page 512


04-385 

7. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - REAR WIPER) 

(a) 

(b) 



04 

(c) 


table below. 



Rear wiper relay (30) - U001 

(4) 


< 2 Ω 

04 





(a) 

(b) 



(c) 


table below. 




(1) 


< 2 Ω 




Page 513

04-386 


9. CHECK HARNESS AND CONNECTOR (REAR WIPER - GROUND) 

(a) 

(b) 


Disconnect the U001 rear wiper relay connector. 

(c) 


table below. 



U001(3) - Ground 


< 2 Ω 


YES > Replace the rear wiper. 


Page 514


04-387 

WASHER PUMP IS INOPERATIVE - REAR WINDOW 


04 

04 

Page 515

04-388 




(a) 

(b) 



(c) 



Condition 


Specified 

Condition 

Set rear wiper and 

washer switch to 

SART 



OFF 

5 - 2 < 2 Ω 

5 - 2 ≥ 1 MΩ 





(a) 


(b) 


(I001): 10 A. 




Page 516


04-389 

3. CHECK HARNESS AND CONNECTOR (REAR WIPER FUSE - REAR WASHING RESERVOIR 

MOTOR) 

(a) 

(b) 


Disconnect the V009 rear washing reservoir motor connector. 

04 

(c) 


table below. 




04 

Rear wiper fuse (87) - V009 (2) 

< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - COMBINATION SWITCH) 

(a) 

(b) 

(c) 


Disconnect the I001 rear wiper relay connector. 


(d) 


table below. 



Rear wiper relay (86) - I013 (2) 


< 2 Ω 




Page 517

04-390 


5. INSPECT RELAY 

(a) 

(b) 


Disconnect relay IG2. 

(c) 


table below. 


Condition 


Specified 

Condition 

Constant 85 - 86 < 2 Ω 






NO > Repair or replace relay. 

6. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - GROUND) 

(a) 

(b) 


Disconnect rear relay IG2. 

(c) 


table below. 



Junction connector - Ground 


< 2 Ω 




Page 518


04-391 


(a) 

(b) 



(c) 


table below. 


04 




< 2 Ω 

04 




8. CHECK HARNESS AND CONNECTOR ( REAR WASHING RESERVOIR MOTOR - COMBINATION 

SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



V009(1) - I013(3) 


< 2 Ω 


YES > Repair or replace rear washing reservoir motor. 


DIAGNOSTICS 

Page 519

04-392 

DIAGNOSTICS - AUDIO SYSTEM 

AUDIO SYSTEM 

PRECAUTION 

1. IT IS FORBIDDEN TO REFIT THE AUDIO SYSTEM. 

2. THE RADIO WAVE BANDS USED IN RADIO BROADCASTING ARE AS FOLLOWS. 

Radio wave AM FM 

Modulation method Amplitude modulation Frequency modulation 

Designation AM1 AM2 FM1 FM2 FM3 

Frequency 522 ~ 1620 KHz 87.5 ~ 108 MHz 

3. POWER OFF. 

(a) Before removing or installing any electrical device, please disconnect the negative battery cable to 

prevent the device damage or personal injury. 

(b) Ignition switch must be off if no specific instructions. 

Page 520


04-393 

LOCATION 

04 

04 

1 Rear Speaker Assy RH 

2 Rear Speaker Assy LH 

3 Radio Assy 

4 Front Speaker Assy RH 

3 Front Speaker Assy LH 

Page 521

04-394 




1 


• The voltage should be above 12V. 


Yes 

No 





2 

Check radio antenna. 

• Check whether the antenna is pulled out 

and pulled out to end. 

• Check whether the antenna is covered 

with obstacles. 

• Check whether the antenna is bended or 

deformation. 


Yes 

No 


Repair or replace the radio antenna assy. 

3 

Check radio. 

• Press the radio power button, check 

whether the radio work well. 


Yes 

No 



4 

Check speaker. 

• Set the radio volume level above 5 VOL, 

check whether the speaker sounds. 


Yes 

No 



5 

Check the radio broadcasting signal. 


Yes 

No 


Move the vehicle to the place where the 

signal is strong. 

Page 522


04-395 





04 

1. Fuse - 

Radio does not work 


3. Radio Chapter 66 audio system - radio system, replacement 

1. Setting impropriety Chapter 04 diagnositics - audio system, radio reception poor 

04 

Radio reception is poor 

2. Radio broadcasting 

signal 

Chapter 04 diagnositics - audio system, radio reception poor 

3. Antenna malfunction Chapter 04 diagnositics - audio system, radio reception poor 


1. Setting impropriety Chapter 04 diagnositics - audio system, sound quality poor 

Poor sound quality 


signal 

Chapter 04 diagnositics - audio system, sound quality poor 

3. Antenna malfunction Chapter 04 diagnositics - audio system, sound quality poor 

4. Speaker Chapter 04 diagnositics - front speaker assy, replacement 


1. Setting impropriety 

Chapter 04 diagnositics - audio system, speaker does not 

work 

Speaker does not work 




Page 523

04-396 


RADIO DOES NOT WORK 


Page 524


04-397 



(a) 


04 

(b) 

(c) 

Check Radio ACC fuse (7.5 A) in junction box (I001). 

Check Radio fuse (10 A) in junction box (I001). 

04 



NO > If the dome light fuse is blown, go to next step. 

If the radio & cigarette fuse is blown, go to step 3. 



(b) Disconnect the radio connector. 

NOTE 

Do not drop the radio. 

(c) 


table below. 



A7 - Ground 


≥ 1 ΜΩ 




Page 525

04-398 





NOTE 


(c) 


table below. 



A4 - Ground 


≥ 1 ΜΩ 




4. CHECK HARNESS AND CONNECTOR (RADIO FUSE - RADIO) 



NOTE 


(c) 


table below. 



Radio fuse (10 A) - A4 


< 2 Ω 




Page 526


04-399 

5. CHECK HARNESS AND CONNECTOR (RADIO ACC FUSE - RADIO) 

(a) 


(b) 


table below. 


04 


Radio ACC fuse(15 A) - A4 


< 2 Ω 

04 





(a) 


(b) 


table below. 



A8 - Ground 


< 2 Ω 


YES > Replace radio. 


Page 527

04-400 


RADIO RECEPTION IS POOR 


1. CHECK RADIO SETTING 

(a) 

(b) 

(c) 

(d) 


Press the radio power button. 

Adjust the volume level above 5 VOL. 

Turn the button and search the radio station. 

Check whether the radio setting is correct? 


NO > Reset the radio. 

2. CHECK THE RADIO BROADCASTING SIGNAL 

(a) 

(b) 

(c) 

(d) 

(e) 

Move the vehicle to the place where the signal is strong. 





Check whether the radio reception is good? 

YES > System is normal. 


NOTE 

• There is great difference in the size of the service area for AM, FM monaural, and FM stereo 

broadcasting. Thus it may happen that FM broadcast cannot be received even though AM comes in 

very clearly. Not only does FM stereo have the smallest service area, but also it picks up static and 

other types of interference most easilly. 

• AM broadcasts are susceptible to other types of interference, especially at night. This is because AM 

radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from 

the same transmitter that reach the vehicle’s antenna directly. 

• When a signal from broadcast transmitter antenna bounces off Mountains, tall buildings or other 

obstruction, it will interfere with the signal that is received directly. 

3. CHECK RADIO ANTENNA 

(a) 

(b) 

(c) 

(d) 

Check whether the antenna is pulled out to the end. 

Check whether the antenna is bended or deformation. 

Check whether the antenna is breakage. 

Check whether the antenna connnector is intalled correct. 

Adjust and check the radio antenna. Is the check result normal? 

YES > Repair or replace the radio antenna. 

NO > Replace the radio. 

Page 528


04-401 

POOR SOUND QUALITY 



(a) 

(b) 

(c) 

(d) 








04 

04 


(a) 

(b) 

(c) 

(d) 

(e) 










(a) 

(b) 

(c) 

(d) 








4. CHECK SPERKER 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 


Remove the speaker. (Refer to “Chapter 66 audio system - front speaker assy, replacement”) 

Check whether the speaker is around with obstacles. 

Check whether the speaker cone diaphragm accumulates dust. 

Check the speaker cone diaphragm for damage. 

Replace the old speaker with a troubleprool one and check the system. 

Check whether the radio sound quality is good? 

YES > Repair or replace the speaker. 


Page 529

04-402 


SPEAKER DOES NOT WORK 


Page 530


04-403 



(a) 

(b) 

(c) 

(d) 








04 

04 


(a) 


(b) 


table below. 



A8 - Ground 


< 2 Ω 




3. CHECK HARNESS AND CONNECTOR (RADIO - SPEAKER) 

(a) 

(b) 


Disconnect the speaker connector. 

(c) 


table below. 



B3 - H001 (1) 

H001 (2) - B4 


< 2 Ω 




Page 531

04-404 



(a) 


(b) 


(c) 


table below. 



B5 - D001 (1) 

D001 (2) - B6 


< 2 Ω 





(a) 


(b) 


(c) 


table below. 



B2 - G002 (2) 

G002 (1) - B1 


< 2 Ω 




Page 532


04-405 


(a) 

(b) 



(c) 


table below. 


04 


B7 - F0025(1) 

F005 (2) - B8 


< 2 Ω 

04 




7. CHECK SPEAKER 

(a) 

(b) 

(c) 



Check the speaker for damage. 


YES > Replace the speaker. 


Page 533

04-406 


LOCATION 

DIAGNOSTICS - AUXILIARY POWER 

1 Cigarette Ligter 2 12V Power supply output socket 

Page 534


04-407 





04 

Cigarette Ligter is 

inoperative 

12V Power supply 

output socket is 

inoperative 

8. Fuse - 

9. Relay - 

10.Wire harness - 

1. Relay - 

2. Fuse - 


04 

Page 535

04-408 


CIGARETTE LIGHTER IS INOPERATIVE 


Page 536


04-409 



(a) 


04 

(b) 

Inspect the cigarette lighter fuse in body junction box 

(I001):15 A. 

04 





(a) 

(b) 



(c) 


table below. 



I033 (2) - Ground 


≥ 1 ΜΩ 




Page 537

04-410 


3. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER FUSE - CIGARETTE LIGHTER) 

(a) 

(b) 



(c) 


table below. 



Cigarette lighter fuse - I033 (2) 


< 2 Ω 





(a) 

(b) 



(c) 


table below. 



I033 (1) - Ground 


< 2 Ω 


YES > Replace the cigarette lighter. 


Page 538


04-411 

12V POWER SUPPLY OUTPUT SOCKET IS INOPERATIVE 


04 

04 

Page 539

04-412 




(a) 


(b) Inspect the IG2 fuse in body junction box (I001):15 A . 

(c) Inspect the power fuse in body junction box (I001):40 A . 




2. INSPECT HORN RELAY 

(a) 

(b) 


Remove the IG2 relay. 

(c) 

Inspect IG2 relay. 




Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace horn relay. 

Page 540


04-413 

3. CHECK HARNESS AND CONNECTOR (INSTRUMENT FUSE - IG2 FUSE) 

(a) 

(b) 


Disconnect the IG2 relay. 

04 

(c) 


table below. 



IG2 (40A) - Instrument fuse(60A) 


< 2 Ω 

04 




4. CHECKHARNESS AND CONNECTOR (POWER FUSE - 12V POWER SUPPLY OUTPUT SOCKET 

FUSE) 

(a) 

(b) 


Disconnect I015 12V power supply output socket. 

(c) 


table below. 



Power fuse (15A) - I015(2) 


< 2 Ω 




Page 541

04-414 


5. CHECK HARNESS AND CONNECTOR (12V POWER SUPPLY OUTPUT SOCKET FUSE - GROUNUD) 

(a) 

(b) 


Disconnect I015 12V power supply output socket. 

(c) 


table below. 





< 2 Ω 


YES > Replace 12V power supply output socket. 


Page 542

HORN SYSTEM 

LOCATION 

DIAGNOSTICS - HORN SYSTEM 

04-415 

04 

04 

1 Horn Switch 

2 Alt Horn 

3 Bass Horn 

Page 543

04-416 






6. Horn fuse - 

7. Horn relay - 

Horn is inoperative 

8. Horn switch 

9. Clock spring 

10.Horn 

Chapter 51 steering column - steering wheel, 

replacement 

Chapter 81 communication system - horn, 

replacement 


replacement 



Horn is always on 




replacement 

4. Center Door Lock Controller - 

Page 544


04-417 

HORN IS INOPERATIVE 


04 

04 

Page 545

04-418 




(a) 


(b) Inspect the horn fuse in body junction box (I001):15 A. 



NO > Replace the horn fuse. 


(a) 

(b) 


Remove the horn relay. 

(c) 

Inspect horn relay. 




Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 




Page 546


04-419 

3. CHECK HARNESS AND CONNECTOR (HORN RELAY - CENTRAL LOCKING CONTROLLER B 

ASSY) 

(a) 

(b) 

(c) 



Disconnect the I008 central locking controller B connector. 

04 

(d) 


table below. 




04 

I008 (B4) - Horn relay(86) 

< 2 Ω 




4. INSPECT CENTRAL LOCKING CONTROLLER B ASSY 


(b) Disconnect the battery negative cable. 

(c) Replace the central locking controller B. (Refer to“Chapter 82 Windshiel window glass rearview mirror 

- power window, replacement”) 

(d) Connect the battery negative cable. 

(e) Turn the ignition switch ON. 

Does the horn sound? 

YES > Repair or replace central locking controller B. 


5. CHECK HARNESS AND CONNECTOR (HORN RELAY - CLOCK SPRING) 

(a) 

(b) 

(c) 

(d) 



Disconnect the horn relay connector. 

Disconnect the clock spring connector.(Refer to“Chapter 62 Supplemental Restraint System - clock 

spring, replacement”) 

Page 547

04-420 


(e) 


table below. 



Horn relay (86) - I014(2) 


< 2 Ω 




6. INSPECT CLOCK SPRING 

(a) 


(b) 

Replace the clock spring. (Refer to“Chapter 62 Supplemental 

Restraint System - clock spring, replacement”) 

(c) 



YES > Repair the clock spring. 


7. INSPECT HORN SWITCH 

(a) 

(b) 

(c) 

(d) 

Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 

Check the horn switch for corrosion or damaged pins. 

Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 

Press the horn switch. 


YES > Repair or replace the horn switch. 


Page 548


04-421 

8. CHECK HARNESS AND CONNECTOR (HORN RELAY - HORN) 

(a) 

(b) 

(c) 


Disconnect the V014 alt horn connector. 

Disconnect the V013 bass horn connector.. 

04 

(d) 


table below. 

Standard resistance (check for open). 



04 

Horn relay - V013(1) 


< 2 Ω 




9. CHECK HARNESS AND CONNECTOR (HORN - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



V014(2) - Ground 



< 2 Ω 


YES > Replace horn. 


Page 549

04-422 


HORN IS ALWAYS ON 


Page 550


04-423 




(b) Remove the horn relay. 

04 

(c) 




04 


Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 





(a) 


(b) 

Replace clock spring. (Refer to“Chapter 62 Supplemental 


(c) Connect the battery negative cable. 





(a) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 

(b) Check the horn switch for corrosion or damaged pins. 

(c) Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 

(d) Press horn switch. 


YES > Replace the horn. 

NO > Replace the horn switch. 

Page 551

04-424 


PRECAUTION 

DIAGNOSTICS - REVERSE RADAR SYSTEM 

1. UNDER THE FOLLOWING CONDITIONS, THE DETECTION FUNCTION MAY NOT FUNCTION 

PROPERLY: 

(e) The sensor is covered with foreign matter, such as mud or snow (detection function returns to normal 

when the sensor is cleaned). 

(f) The sensor is frozen (detection function returns to normal when the temperature of the sensor is going 

high). 

(g) The sensor is covered with a hand. 

(h) In very cold weather where a malfunction display appears, the sensor may not be able to detect 

obstacles. 

2. THE DETECTION RANGE MAY BE AFFECTED BY THE FOLLOWING CONDITIONS: 

(a) The sensor is covered with foreign matter, such as mud or snow. 

(b) The vehicle is in an excessively hot or cold area. 

3. UNDER THE FOLLOWING CONDITIONS, A DETECTION ERROR MAY OCCUR: 

(a) Driving on a bumpy road, an unpaved road, or in tall grass. 

(b) Ultrasonic waves from items such as another vehicle's horn, motorcycle engine sounds, a large 

vehicle's air brake sound, or another vehicle's sonar are transmitted near the vehicle. 

(c) It is raining heavily or the sensor comes into contact with water (sprayed). 

(d) The vehicle is tilted at a large angle. 

(e) The vehicle is equipped with a commercial fender pole or a wireless mechanism antenna. 

(f) The sensor is covered with foreign matter, such as mud or snow. 

(g) The vehicle is moving toward a high curb or the corner of a pointed object. 

4. THE SENSOR CANNOT DETECT SOME OBJECTS SUCH AS THE FOLLOWING: 

(a) Thin objects, such as wires and ropes. 

(b) Materials that absorb ultrasonic waves, such as cotton, snow, etc. 

(c) Objects with sharp edges. 

(d) Short objects. 

(e) Tall, overhanging objects. 

5. OTHER NOTICES: 

(a) The sensor cannot detect objects directly under the bumper. (The sensor may detect low objects and 

thin poles, and then lose track of the objects.) 

(b) The sensor may not be able to detect obstacles that are too close to the sensor. 

(c) The sensor may not be able to detect obstacles if it is dropped or subjected to a strong impact. 

Page 552


04-425 

LOCATION 

04 

04 

1 

Audio (Multi - media And Air - condition 

Controler Assy) 

2 Reverse Radar Control Unit 

3 Reverse Radar Sensor 

4 Camera 

Page 553

04-426 


SYSTEM DESCRIPTION 

1. GENERAL. 

This system uses ultrasonic sensors to send ultrasonic waves. The reverse radar sensors receive the 

echo. The reverse radar control unit then informs the driver of the distance between the sensors and 

the obstacles as well as their positions by indicating them on the combined display and by clearance 

warning buzzer. 

2. FUNCTION OF COMPONENTS. 

Components 

Reverse radar sensor 

Clearance warning buzzer 

Audio (multi - media and air 

- condition controler assy) 

Reverse radar control unit 

Camera 

Back - up lamp switch 

Function 

Detects the distance between the vehicle and an obstacle. 

Sounds from the buzzer to motify the driver for the distance between the vehicle 

and the obstacle. 

Displays the location of the obstacle and the approximate distance between the 

vehicle and the obstacle,and image in rear of vehicle. 

1. Judges the approximate distance between the vehicle and the obstacle based 

on the signals from the reverse radar sensor. 

2. Sounds the clearance warning buzzer. 

Shoot image information. 

Sends the back - up signal to the reverse radar control unit. 

3. DETECTION RANGE OF REVERSE RADAR SENSOR. 

(a) Detection range of reverse radar sensor (both sides). 

(b) 

Detection range of reverse radar sensor (middle). 

4. DISTANCE TO AN OBSTACLE, FREQUENCY AND MODE OF CLEARANCE WARNING BUZZER. 

NO. DISTANCE MODE FREQUENCY 

A 90 - 150 cm Long & Intermittent 1 Hz 

Page 554


04-427 


B 60 - 90 cm Short & Intermittent 2 Hz 

C 40 - 60 cm Rapid & Intermittent 4 Hz 

04 

D 40 ± 5 cm Continual Continual 

5. TERMINALS OF REVERSE RADAR CONTROL UNIT PIN. 

04 

Terminal No. Wiring Color Terminal Description 

1 B - R Power supply 

2 - - 

3 W - R Radar power supply 

4 R - W Reverse radar central sensor RH 

5 - - 

6 L - B Vehicle speed signal 

7 R - G Reverse radar sensor LH 

8 R - B Reverse radar central sensor LH 

9 Y Parking signal 

10 - - 

11 B Sensor ground 

12 - - 

13 - - 

14 - - 

15 R - L Reverse radar sensor RH 


Page 555

04-428 






1. Fuse - 

Reverse radar system is 

inoperative at all 

2. Reverse radar control unit 


Chapter 81 communication system - reverse 

radar, replacement 







operative when the shift 

lever is out of reverse 

position 

1. Reverse radar sensor 












everse radar system is 

inoperative within specified 

distance (Back - up lamp is 

normal) 









operative but there is no 

obstacle behind the vehicle 








Buzzer is inoperative or 

operative incorrectly within 

specified distance ( 

displayer is normal) 

Display is inoperative 

within specified distance 

(Back - up lamp is 

normal) 








1. Displayer Chapter 81 communication system - multi - 

media and air - condition controler 

assy,replacement 

2. Camera Chapter 81 communication system - astern 

image, replacement 


Page 556


04-429 

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL 


04 

04 

Page 557

04-430 




(a) 


(b) 

Inspect back - up lamp fuse (10A) in driver side junction 

box (I001). 





(a) 

(b) 

(c) 



Disconnect the I028 reverse radar control unit connector. 

(d) 


table below. 



A021 (1) - Ground 


≥ 1 ΜΩ 





(a) 

(b) 



Page 558


04-431 

(c) 


table below. 




04 

1 - Ground 

2 - Ground 

≥ 1 ΜΩ 

04 



NO > Replace back - up lamp switch and fuse. 

4. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - REVERSE RADAR 

CONTROL UNIT) 

(a) 

(b) 

(c) 




(d) 


table below. 



A021 (2) - Ground 


≥ 1 ΜΩ 




5. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROL UNIT - GROUND) 

(a) 

(b) 



(c) 


table below. 



I028 (16) - Ground 


< 2 Ω 

Page 559

04-432 






(a) 

(b) 



(c) 

Inspect back - up lamp switch according to the value(s) 


Condition 

Tester 

Connection 

Specified 

condition 

Set shift lever in reverse 

position 

Set shift lever out of 

reverse position 

1 - 2 < 2 Ω 

1 - 2 ≥ 1 ΜΩ 



NO > Replace back - up lamp. 


(a) 

(b) 



(c) 


table below. 



Back - up lamp fuse (10A) - A021 (1) 


< 2 Ω 




Page 560


04-433 


CONTROL UNIT) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

A021 (2) - I028 (1) 

< 2 Ω 


YES > Replace reverse radar control unit. 


Page 561

04-434 


REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE SHIFT 

LEVER IS OUT OF REVERSE POSITION 


Page 562


04-435 



(a) 

(b) 



04 

(c) 

Inspect back - up lamp switch according to the value(s) 


Condition 

Tester 

Connection 

Specified 

condition 

04 


position 



1 - 2 < 2 Ω 

1 - 2 ≥ 1 ΜΩ 





CONTROL UNIT) 

(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



I028 (1) - Ground 


0 V 




Page 563

04-436 



DISTANCE (BACK - UP LAMP IS NORMAL) 


Page 564


04-437 


1. INSPECT REVERSE RADAR SENSOR 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 


Disconnect the R001 Reverse Radar Sensor LH connector. 

Disconnect the R002 Reverse Radar Central Sensor LH connector. 

Disconnect the R003 Reverse Radar Central Sensor RH connector. 

Disconnect the R004 Reverse Radar Sensor RH connector. 

Replace reverse radar sensor. 


Set the shift lever in reverse position. 

Does reverse radar system work correctly? 

YES > Replace reverse radar sensor. 


04 

04 

2. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROL UNIT - REVERSE RADAR 

SENSOR) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



I028 (7) - R001 (1) 

I028 (11) - R001 (2) 


< 2 Ω 

(h) 


table below. 



I028 (8) - R002 (1) 

I028 (11) - R002 (2) 


< 2 Ω 

Page 565

04-438 


(i) 


table below. 



I028 (4) - R003 (1) 

I028 (11) - R003 (2) 


< 2 Ω 

(j) 


table below. 



I028 (15) - R004 (1) 

I028 (11) - R004 (2) 


< 2 Ω 




Page 566


04-439 


OBSTACLE BEHIND VEHICLE 


04 

04 

Page 567

04-440 




(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

Turn the ignition switch OFF.. 












SENSOR) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



I028 (7) - R001 (1) 

I028 (11) - R001 (2) 


< 2 Ω 

(h) 


table below. 



I028 (8) - R002 (1) 

I028 (11) - R002 (2) 


< 2 Ω 

Page 568


04-441 

(i) 


table below. 




04 

I028 (4) - R003 (1) 

I028 (11) - R003 (2) 

< 2 Ω 

04 

(j) 


table below. 



I028 (15) - R004 (1) 

I028 (11) - R004 (2) 


< 2 Ω 




Page 569

04-442 


BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY WITHIN 

SPECIFIED DISTANCE (DISPLAYER IS NORMAL) 


Page 570


04-443 



(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

Turn the ignition switch OFF.. 











04 

04 


SENSOR) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



I028 (7) - R001 (1) 

I028 (11) - R001 (2) 


< 2 Ω 

(h) 


table below. 



I028 (8) - R002 (1) 

I028 (11) - R002 (2) 


< 2 Ω 

Page 571

04-444 


(i) 


table below. 



I028 (4) - R003 (1) 

I028 (11) - R003 (2) 


< 2 Ω 

(j) 


table below. 



I028 (15) - R004 (1) 

I028 (11) - R004 (2) 


< 2 Ω 




Page 572


04-445 


(BUZZER IS NORMAL) 


04 

04 

Page 573

04-446 



1. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - CAMERA) 

(a) 

(b) 

(c) 



Disconnect the J005 camera connector. 

(d) 


table below. 



A021 (2) - J005 (2) 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (CAMERA - RADIO) 

(a) 

(b) 

(c) 



Disconnect the I029 radio connector. 

(d) 


table below. 



J005 (3) - I029 (1) 

J005 (4) - I029 (2) 


< 2 Ω 




Page 574


04-447 

3. CHECK HARNESS AND CONNECTOR (CAMERA - GROUND) 

(a) 

(b) 



(c) 


table below. 


04 


J005 (1) - Ground 


< 2 Ω 

04 




4. INSPECT CAMERA 

(a) 

(b) 

(c) 

(d) 

(e) 



Replace the camera. 



Does displayer work correctly? 

YES > Replace the camera. 


Page 575

04-448 

DIAGNOSTICS - POWER WINDOWS 

POWER WINDOWS 

PRECAUTION 




Expression 




2. POWER OFF. 

(a) Before removing or installing any electrical device, please disconnect the negative cable from battery to 


NOTE 

To prevent locking the key in the vehicle, do not leave the key in the vehicle when disconnecting the 

negative battery cable. 


3. DISCONNECTING THE NEGATIVE BATTERY CABLE WILL RESET BOTH THE TRIP ODOMETER 

AND THE CLOCK TO ‘0’. 

NOTE 

The total odometer can not be reset to ‘0’. 

4. THE AUDIO SYSTEM WILL LOSE STORED MEMORY DATA IF THE NEGATIVE BATTERY CABLE 

IS DISCONNECTED. 

NOTE 

After reconnecting the negative battery cable, the audio system will need to be reset. 

Page 576


04-449 

LOCATION 

04 

04 

1 Central Locking Controller 

2 Door Control Switch 

4 Window Control Switch RH 

5 Glass Lift Motor RH 

3 Glass Lift Motor LH 

Page 577

04-450 


DOOR CONTROL SWITCH PIN 

Terminal No. Wiring Color Description 

1 L - B Door control switch LH (date) 

2 L Door control switch LH (clock) 

3 L - Y Window control switch RH 

4 P - L Window control switch RH 

5 L - G Window control switch RH 

6 W - B Grond 

7 - - 

8 - - 

9 G - R Lamplet illumination 

10 - - 

11 - - 

12 - - 

Page 578


04-451 

WINDOW CONTROL SWITCH RH PIN 

04 

04 


1 L - G Door control switch 

2 - - 

3 P - L Door control switch 

4 L - Y Door control switch 

5 - - 

Page 579

04-452 


CENTRAL LOCKING CONTROLLER ASSY A PIN 



2 - - 

3 - - 

4 G Power window motor LH 

5 R Power window motor LH 

6 R - L Power window motor RH 

7 G - R Power window motor RH 

8 W - L Window control power input 

9 - - 

10 - - 

11 Y Collision signal 

12 - - 

13 - - 

14 R Door - status 



17 W - L Vehicle speed signal 

18 R - B Ignition switch 

Page 580


04-453 



1 


• The battery voltage should be over than 

12 V. 


Yes 

No 


Charge or replace the battery. Refer to 

“Chapter 20A starting and charging - 

battery”. 

04 

2 

Check the front power window motor LH. 


• Push or pull the front window switch LH to 

operate the fornt window LH open and 

close. 


Yes 

No 



04 

3 

Check power window auto open operation. 



operate the fornt window LH auto open. 


Yes 

No 



4 

Check power window motor RH. 


operate the fornt window RH open and 

close. 


Yes 

No 



5 


• ush or pull the front window switch RH to 


close. 


Yes 

No 

Replace power window motor. 


Page 581

04-454 



Use the table below to help you to find the cause of the problem. The numbers indicate the priority of the likely 



All power windows are 

inoperative. 

1. Power, ground circuits 

2. Door control switch 

3. Power window motor LH and 

RH 

Chapter 20A starting and charging - battery, 

replacement 

Chapter 20B starting and charging - battery, 

replacement 

Chapter 82 windshield/windowglass/rear view 

mirror - power window, replacement 




Front power window 

LH is inoperative. 



3. Central Locking Controller 

4. Power window motor LH 


replacement 


replacement 




replacement 





LH does not open. 






replacement 



LH does not close. 






replacement 



RH is inoperative (use 

door control switch). 



3. Window control switch RH 


replacement 


replacement 





Page 582


04-455 







window control switch 

RH). 

4. Power window motor RH 


1. Window control switch RH 









04 

04 

Page 583

04-456 


ALL POWER WINDOWS ARE INOPERATIVE 


Page 584


04-457 



(a) 


04 

(b) 

Inspect the power window fusible link (20 A) in driver 

side junction box (I001). 

04 




2. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - GROUND) 

(a) 

(b) 

(c) 


Disconnect the D005 door control switch connector. 

Disconnect the I007 central locking controller assy A connector. 

(d) 


table below. 



D005 (12) - Ground 


≥ 1 MΩ 




3. INSPECT DOOR CONTROL SWITCH 

(a) 

(b) 

(c) 



Replace door control switch. 

Page 585

04-458 


(d) 


Does power window work correctly? 

YES > Replace door control switch. 


4. CHECK HARNESS AND CONNECTOR (POWER WINDOW FUSIBLE LINK - DOOR CONTROL 

SWITCH) 

(a) 

(b) 



(c) 


table below. 



Power window fusible link (20A) - D005 (12) 

Specified 

Condition 

< 2 Ω 




5. CHECK HARNESS AND CONNECTOR (POWER WINDOW FUSIBLE LINK - CENTRAL LOCKING 

CONTROLLER ASSY A) 

(a) 

(b) 



(c) 


table below. 



Power window fusible link (20A) - I007 (A8) 

Specified 

Condition 

< 2 Ω 

Page 586


04-459 





04 

(a) 

(b) 



(c) 


table below. 


04 


D005 (6) - Ground 


< 2 Ω 




7. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - CENTRAL LOCKING CONTROLLER 

ASSY A) 

(a) 

(b) 

(c) 




(d) 


table below. 



D005 (1) - I007 (A15) 

D005 (2) - I007 (A16) 


< 2 Ω 




Page 587

04-460 


8. INSPECT POWER WINDOW MOTOR LH AND RH 

(a) 

(b) 

(c) 

(d) 

(e) 


Disconnect the D002 power window motor LH connector. 

Disconnect the H002 power window motor RH connector. 

Replace power window motor LH and RH. 



YES > Replace power window motor LH and RH. 


9. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY A - POWER 

WINDOW MOTOR LH AND RH) 

(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



I007 (A4) - D002 (2) 

I007 (A5) - D002 (1) 


< 2 Ω 

(f) 


table below. 



I007 (A6) - H002 (2) 

I007 (A7) - H002 (1) 


< 2 Ω 


YES > Replace central locking controller assy. 


Page 588


04-461 

FRONT POWER WINDOW LH IS INOPERATIVE 


04 

04 

Page 589

04-462 




(a) 

(b) 

(c) 

(d) 








2. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - CENTRAL LOCKING 


(a) 

(b) 

(c) 




(d) 


table below. 



D005 (1) - I007 (A15) 

D005 (2) - I007 (A16) 


< 2 Ω 




3. INSPECT POWER WINDOW MOTOR LH 

(a) 

(b) 

(c) 

(d) 



Replace power window motor LH. 





Page 590


04-463 


WINDOW MOTOR LH) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

I007 (A4) - D002 (2) 

I007 (A5) - D002 (1) 

< 2 Ω 




Page 591

04-464 


FRONT POWER WINDOW LH DOES NOT OPEN 


Page 592


04-465 



(a) 

(b) 

(c) 

(d) 








04 

04 


ASSY A) 

(a) 

(b) 

(c) 




(d) 


table below. 



D005 (1) - I007 (A15) 

D005 (2) - I007 (A16) 


< 2 Ω 




Page 593

04-466 


FRONT POWER WINDOW LH DOES NOT CLOSE 


Page 594


04-467 



(a) 

(b) 

(c) 

(d) 








04 

04 



(a) 

(b) 

(c) 




(d) 


table below. 



D005 (1) - I007 (A15) 

D005 (2) - I007 (A16) 


< 2 Ω 




Page 595

04-468 



TROL SWITCH) 


Page 596


04-469 



(a) 

(b) 

(c) 

(d) 





Does power window RH work correctly? 



04 

04 


WINDOW MOTOR RH) 

(a) 

(b) 

(c) 




(d) 


table below. 



I007 (A6) - H002 (2) 

I007 (A7) - H002 (1) 


< 2 Ω 




3. INSPECT POWER WINDOW MOTOR RH 

(a) 

(b) 

(c) 

(d) 



Replace power window motor RH. 


Does power windou RH work correctly? 

YES > Replace power window motor RH. 

NO > Replace central locking controller assy. 

Page 597

04-470 


FRONT POWER WINDOW RH IS INOPERATIVE (USE WINDOW 

CONTROL SWITCH RH) 


Page 598


04-471 


1. INSPECT WINDOW CONTROL SWITCH 

(a) 

(b) 

(c) 

(d) 


Disconnect the H004 window control switch RH connector. 

Replace window control switch RH. 



YES > Replace window control switch RH. 


04 

04 

2. CHECK HARNESS AND CONNECTOR (WINDOW CONTROL SWITCH RH - DOOR CONTROL SWITCH) 

(a) 

(b) 

(c) 


Disconnect the H004 window control switch RH connector. 


(d) 


table below. 



H004 (1) - D005 (5) 

H004 (3) - D005 (4) 


< 2 Ω 

(e) 


table below. 



H004 (4) - D005 (3) 


< 2 Ω 




Page 599

04-472 



(a) 

(b) 

(c) 

(d) 








4. INSPECT POWER WINDOW MOTOR RH 

(a) 

(b) 

(c) 

(d) 





Does power window RH work correctly? 

YES > Replace power window motor RH. 




(a) 

(b) 

(c) 




(d) 


table below. 



I007 (A6) - H002 (2) 

I007 (A7) - H002 (1) 


< 2 Ω 




Page 600


LOCATION 

DIAGNOSTICS - OUTSIDE MIRROR 

04-473 

04 

04 

1 Outside Mirror Assy LH 

3 Outside Mirror Remote Control Switch 

2 Outside Mirror Assy RH 

Page 601

04-474 


TERMINALS OF OUTSIDE MIRROR SWITCH 

OUTSIDE MIRROR SWITCH 


1 L - R 

Left Outside Mirror Left And Right 

Adjust Input 

2 - - 

3 L - Y 

Right Outside Mirror Left And Right 

Adjust Output 

4 G - R Outside Mirror Switch Power Input 

5 R - Y Outside Mirror - 


7 R 

8 R - L 

Left Outside Mirror Up And Down 

Adjust Input 

Right Outside Mirror Up And Down 

Adjust Output 

Page 602


04-475 



1 




Yes Go to step 2 

No 




04 

2 

Check the outside mirror. 


• Adjust the outside mirror LH and the outside 

mirror RH. 


Yes 

No 


Replace the outside mirror. Refer to “Chapter 

82 windshield - outside mirror, replacement” 

04 

Page 603

04-476 



Use the table below to help you find the cause of the problem. The numbers indicate the probability of the 



6. Fuse - 

Mirrors are inoperative (Both sides) 

7. Outside mirror defrost switch 

Chapter 85 door lock - front door 

lock - replacement 


A single mirror is inoperative 


2. Outside mirror 



Chapter 82 windshield - outside 

mirror, replacement 


Mirror adjustment UP/DOWN is 

inoperative 


2. Outside mirror motor 






Mirror adjustment LEFT/RIGHT is 

inoperative 








Page 604


04-477 

MIRRORS ARE INOPERATIVE (BOTH SIDES) 


04 

04 

Page 605

04-478 




(a) 


(b) 

Inspect the radio & ACC fuse (7.5 A) in body junction 

box(I001). 




2. CHECK HARNESS AND CONNECTOR (RADIO & ACC FUSE - OUTSIDE MIRROR REMOTE 

CONTROL SWITCH) 

(a) 

(b) 

(c) 


Remote the radio & ACC fuse. 

Disconnect the D004 outside mirror remote control switch connector. 

(d) 


table below. 



Radio & ACC fuse (7.5A) - 

D004 (4) 


< 2 Ω 




Page 606


04-479 

3. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR REMOTE CONTROL SWITCH - 

GROUND) 

(a) 

(b) 



04 

(c) 


table below. 



D004 (6) - Ground 


< 2 Ω 

04 


YES > Replace the outside mirror remote control switch. 


Page 607

04-480 


A SINGLE MIRROR IS INOPERATIVE 


Page 608


04-481 


• This inspection procedure is an example of outside mirror assy LH, outside mirror assy RH inspection 

procedure are similar. 

1. INSPECT OUTSIDE MIRROR REMOTE CONTROL SWITCH 

04 

(a) 

(b) 



(c) 

Inspect outside mirror remote control switch according to 

the value(s) in the table below. 

04 

Item 

Condition 

Tester 

Connection 

Specified 

Condition 

Left 

4 - 5 

1 - 6 

Outside 

Mirror LH 

Right 

Up 

4 - 1 

5 - 6 

4 - 7 

5 - 6 

< 2 Ω 

Down 

4 - 5 

7 - 6 



NO > Replace outside mirror remote control switch. 


OUTSIDE MIRROR LH) 

(a) 

(b) 

(c) 


Disconnect the D003 outside mirror connector. 


(d) 


table below. 



D003 (6) - D004 (7) 

D003 (4) - D004 (5) 


< 2 Ω 




Page 609

04-482 




(a) 

(b) 

(c) 




(d) 


table below. 



D003 (4) - D004 (5) 

D003 (5) - D004 (1) 


< 2 Ω 


YES > Replace the outside mirror assy. 


Page 610


04-483 

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE 


04 

04 

Page 611

04-484 






(a) 

(b) 



(c) 


the value(s) in the table below 

Item 

Condition 

Tester 

Connection 

Specified 

Condition 

Outside 

Mirror LH 

Up 

Down 

4 - 7 

5 - 6 

4 - 5 

7 - 6 

< 2 Ω 



NO > Replace the outside mirror remote control switch. 



(a) 

(b) 

(c) 




(d) 


table below. 



D003 (6) - D004 (7) 

D003 (4) - D004 (5) 


< 2 Ω 


YES > Replace the outside mirror assy LH. 


Page 612


04-485 

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE 


04 

04 

Page 613

04-486 






(a) 

(b) 



(c) 



Item 

Condition 

Tester 

Connection 

Specified 

Condition 

Outside Mirror LH 

Left 

Right 

4 - 5 

1 - 6 

4 - 1 

5 - 6 

< 2 Ω 






(a) 

(b) 

(c) 




(d) 


table below. 



D003 (4) - D004 (5) 

D003 (5) - D004 (1) 


< 2 Ω 




Page 614

DEFROSTER SYSTEM 

LOCATION 

DIAGNOSTICS - DEFROSTER SYSTEM 

04-487 

04 

04 

Page 615

04-488 


1 Rear Window Defroster 

2 Outside Mirror Assy 

3 Rear Window Defroster Switch 

4 Outside Mirror Defrost Switch 

Page 616


04-489 


1. GENERAL 

The defroster system consist of rear window defroster and outside mirror defroster(outside mirror assy). 

The heating element is the electric heating wire which are integrated in the rear window glass and both 

outside mirror glasses and defog the glasses quickly. The rear window defroster switch and outside 

mirror defrost switch are integrated on the centre switch panel in the instrument panel and can be operated 

separately. When each switch is pressed, the indicator lamp in the switch illuminates to indicate 

that the defroster is operating. 

2. FUNCTION OF MAIN COMPONENTS 

Component 

Description 

04 

04 

Rear window defroster relay 

Outside mirror defrost relay 

Rear window defroster 

Outside mirror (outside mirror defroster) 

Receives rear defrost control signals from rear window 

defrost switch and supplies power to rear window 

defroster. 

Receives defrost control signal from outside mirror 

defrost switch and supplies power to both outside mirror. 

Receives power from Rear window defroster relay and 

heats defroster. 

Receives power from outside mirror defrost relay and 


Page 617

04-490 




1 

Check battery voltage. 



Yes 

No 





2 

Check ignition switch. 

• The ignition switch should work correctly. 


Yes 

No 


Repair or replace ignition switch. Refer to 

“Chapter 91 vehicle control system - assy, 

removal & installation and disassembly & 

reassembly” 

3 

Check fuse. 

• Check fuse. 


Yes 

No 



4 

5 

6 

7 

Check rear window defroster switch. 

• Press the rear window defroster switch. 

• The rear window defrost switch should 

work correctly. 


Check outside mirror defrost switch. 

• Press the outside mirror defrost switch. 

• The outside mirror defrost switch should 



Check rear window defroster. 

• The rear window defrost grid should work 

correctly. 


Check outside mirror defroster. 

• The outside mirror defroster should work 

correctly. 



No 

Replace rear window defroster switch. Refer 

to “Chapter 83 instrument panel - dashboard, 



No 

Yes - 

No 

Yes - 

No 

Replace rear window defrost grid. Refer to 

“chapter 82 Windshield - windshield, 




Page 618


04-491 





04 

1. Fuse - 

2. Rear window defrost relay - 

Rear window defroster system is 

inoperative 

3. Rear window defrost switch 


instrument cluster, replacement 

04 

4. Rear window defrost grid 

Chapter 82 Windshield - rear window 

glass, replacement 


1. Fuse - 

2. Outside mirror defrost relay - 

Outside mirror defroster system is 

inoperative 








Page 619

04-492 


REAR WINDOW DEFROSTER IS INOPERATIVE 


Page 620


04-493 



(a) 


04 

(b) 

(c) 

Inspect the rear defroster fuse (25 A) in Co - pilot 


Inspect the outside mirror defrost fuse (7.5 A) in Co - pilot 


04 



NO > If the rear defroster fuse or outside mirror defrost fuse is blown, replace the fuse. 

2. INSPECT REAR DEFROSTER RELAY 

(a) 

(b) 


Remove the rear defroster relay. 

(c) 

Inspect the rear defroster relay according to the value(s) 





Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the rear defroster relay. 

Page 621

04-494 


3. INSPECT REAR WINDOW DEFROSTER SWITCH 

(a) 

(b) 



(c) 

Inspect the rear window defroster switch according to the 




Press 2 - 5 < 2 Ω 



NO > Replace the rear window defroster switch. 

4. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROSTER SWITCH - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



I016 (2) - Ground 






5. CHECK HARNESS AND CONNECTOR (REAR DEFROSTER RELAY - REAR WINDOW DEFROSTER 

SWITCH) 

(a) 

(b) 

(c) 



Remove the rear defroster relay. 

Page 622


04-495 

(d) 


table below. 



Specified 

Condition 

04 

Rear defroster relay (85) - I016 (5) 

< 2 Ω 

04 




6. CHECK HARNESS AND CONNECTOR (REAR DEFROST RELAY - GROUND) 

(a) 

(b) 


Remove the rear defrost relay. 

(c) 


table below. 



Rear defrost relay (86) - Ground 

Specified 

Condition 

< 2 Ω 




Page 623

04-496 


7. CHECK HARNESS AND CONNECTOR ( REAR DEFROST HEATING WIRE - GROUND) 

(a) 

(b) 

(a) 

(a) 


Disconnect the S001 rear defrost heating wire connector. 


Turn rear window defroster switch ON. 

(b) 


table below. 



S001 (1) - Ground 






8. CHECK HARNESS AND CONNECTOR ( REAR DEFROST HEATING WIRE - GROUND) 

(a) 

(b) 


Disconnect the T001 rear defrost heating wire connector. 

(c) 


table below. 



T001 (1) - Ground 


< 2 Ω 


YES > Replace the rear defrost heating wire. 


Page 624


04-497 

OUTSIDE MIRROR DEFROSTER IS INOPERATIVE 


04 

04 

Page 625

04-498 




(a) 


(b) 

Inspect the outside mirror defrost fuse (7.5 A) in Co - pilot 




NO > If the outside mirror defrost fuse is blown, replace the fuse. 

2. INSPECT REAR DEFROSTER RELAY 

(a) 

(b) 


Remove the outside mirror defrost relay. 

(c) 






Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the outside mirror defrost relay. 

Page 626


04-499 

3. INSPECT OUTSIDE MIRROR DEFROST SWITCH 

(a) 

(b) 


Disconnect the I017 outside mirror defrost switch connector. 

(c) 

Inspect the outside mirror defrost switch according to the 




Press 2 - 5 < 2 Ω 

04 

04 



NO > Replace the outside mirror defrost switch. 

4. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST SWITCH - GROUND) 

(a) 

(b) 

(c) 


Disconnect the I017 outside mirror defrost switch connector. 


(d) 


table below. 



I017 (2) - Ground 






Page 627

04-500 


5. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - OUTSIDE MIRROR 

DEFROST SWITCH) 

(a) 

(b) 

(c) 


Disconnect the I017 rear window defrost switch connector. 


(d) 


table below. 



Rear defrost relay (85) - I017 (5) 

Specified 

Condition 

< 2 Ω 




6. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - GROUND) 

(a) 

(b) 



(c) 


table below. 



Outside mirror defrost relay (86) - Ground 

Specified 

Condition 

< 2 Ω 




Page 628


04-501 

7. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - OUTSIDE MIRROR 

ASSY LH/RH ) 

(a) 

(b) 

(c) 


Disconnect the D003 outside mirror assy LH/ H003 outside mirror assy RH connector. 


04 

(d) 


table below. 



Specified 

Condition 

04 

Outside mirror defrost relay (87) - D003(3) 

Outside mirror defrost relay (87) - H003(3) 

< 2 Ω 




8. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR ASSY LH/RH - GROUND ) 

(a) 

(b) 



(c) 


table below. 



D003(2) - Ground 

H003(2) - Ground 

Specified 

Condition 

< 2 Ω 


YES > Replace outside mirror assy LH/ outside mirror assy RH. 


Page 629

04-502 

DIAGNOSTICS - INSTRUMENT CLUSTER 


PRECAUTION 

1. POWER OFF. 

(a) Before removing or installing any electrical device, please disconnect the negative battery cable to prevent 

damage to the device or personal injury. 

(b) Make sure ignition switch off if no specific instructions. 


AND THE CLOCK TO ‘ 0 ’. 

NOTE 

The total odometer can not be reset to ‘ 0 ’. 



NOTE 



Switch Type Ignition Switch (position) Engine (condition) 


Expression 




Page 630


04-503 

LOCATION 

04 

04 


2 Speedometer Sensor 

3 Fuel Level Sensor 

4 Coolant Temperature Sensor 

Page 631

04-504 


INSTRUMENT CLUSTER INFORMATION 

GAUGES 

No Content Description 

1 Speedometer The fuel gauge indicates the approximate fuel level in the tank. 

6 Fuel Gauge 

12 ECT Gauge 

15 Tachometer 

Receving signal from coolant temperature indicator, the ECT 

gauge indicates the engine coolant temperature. 

Receiving signal from the ECM, the tachometer indicates 

engine revolutions per minute (RPM). 

According to the signal received from the speedometer sensor, 

the speedometer indicates the vehicle running speed. 

Page 632


04-505 

WARNING / INDICATOR LIGHTS 


2 Lamplet indicator light 

Lamplet indicator light turns on when lamplet is on and receive 

lamplet relay signal. 

04 

3 

Engine coolant fluid level 

warning light 

Engine coolant fluid level warming light turns on when engine 

coolant level is lower than specification. 

4 

Left turn signal/hazard 

indicator light 

5 Seat belt warning light 

Left turn signal/hazard indicator light flashes when the turn 

signal switch or hazard switch is activated. 

Seat belt warning light turns on when receiving the seat belt 

warning signal. 

04 

7 

Engine coolant 

temperature indicator light 

Engine coolant temperature indicator light will illuminate when 

engine coolant temperature is between - 20 ℃ ~ 110 ℃ . 

8 Fuel level warning light 

9 High beam indicator light 

10 Door ajar warning light 

11 Brake warning light 

13 SRS warning light 

Fuel level warning light turns on when fuel level lower than 

specified level. 

High beam indicator light turns on when high beam is on and 

receive headlamp relay signal. 

Door ajar warning light turns on when receiving the door ajar 

signal. 

Brake warning light turns on when receiving signals from parking 

brake switch or brake fluid level sensor. 

SRS warning light will turn on when SRS is detected malfunction. 

14 

16 

Right turn signal/hazard 


Parking brake indicator 

light 

Right turn signal/hazard indicator light flashes when the turn 


Parking Brake indicator light turns on when receiving signals 

from parking brake switch. 

17 ABS warning light Warning light will turn on when ABS is detected malfunction. 

18 EBD warning light 

The ABS will illuminate EBD warning light when EBD is 

detected malfunction. 

19 

Engine oil pressure 


Engine oil pressure indicator light turns on according to the 

signal from engine oil pressure warning switch. 

20 Charging warning light Charging warning light turns on when charging system is fault. 

21 Malfunction indicator light 

The ECM will turn on malfunction indicator light when engine 

electronic control system is detected malfunction. 

22 

24 

25 

26 

Rear fog lamp indicator 

light 

Front fog lamp indicator 

light 

SVS indicator light 

(Gasoline) 

Vacuum warning light 

(Diesel) 

Rear fog lamp indicator light receive the rear fog lamp relay 

signal and turns on when rear fog lamp switch is pressed. 

Front fog lamp indicator light receive the front fog lamp relay 

signal and turns on when front fog lamp switch is pressed. 

SVS indicator light will be illuminated when the ECM detect 

general malfunctions. It will be always on until faults resolved. 

Vacuum warning light turns on when receiving the vacuum 


Page 633

04-506 


LIQUID CRYSTAL DISPLAY 


23 

Odometer Display driving distance and can not be reset to “0”. 

Clock 

Display time and can be reset. 

Page 634


04-507 

TERMINALS OF INSTRUMENT CLUSTER 

04 

04 

Terminals No. Wiring Color Description 

A1 B - L Instrument Power 

A2 - - 

A3 R Door Lamp Indicator 

A4 - - 

A5 - - 

I002 

A6 V - W Lamplet Signal Input 

A7 LG Front Fog Lamp Indicator 

A8 L Vehicle Speed Output 

A9 W - L Vehicle Speed Output 

A10 L - B Vehicle Speed Output 

A11 - - 

Page 635

04-508 



A12 - - 

A13 W - G Speed Signal Input 

A14 B Lighting Pwm Signal 

A15 W - R Door Open Indicator 

A16 R Instrument Power Output 

A17 - - 

A18 - - 

A19 W - B Instrument A Ground 

A20 R - B Instrument Ground 

A21 - - 

I002 

A22 - - 

A23 V Fuel Sensor + Output 

A24 Y - B Engine Stop Light 

A25 - - 

A26 B Vacuum Level Alarm + Input 

A27 G - Y Preheat Indicator 

A28 BR Engine Maintenance 

A29 - - 

A30 R - W Front Door Open Indicator 

A31 B - W Seat Belt Warning 

A32 G - Y Left Turn Indicator 

B1 - - 

B2 - - 

B3 - - 

I003 

B4 - - 

B5 - - 

B6 Y Instrument Parking Brake Light 

B7 V - B Coolant Level Sensor + Output 

B8 - - 

Page 636


04-509 


B9 B - W Seat Belt Alarm + Output 

B10 V - W Speed Input 

04 

B11 - - 

B12 - - 

B13 - - 

B14 - - 

04 

B15 - - 

B16 Y - G Water Temperature Gauge Sensor 

B17 - - 

B18 - - 

B19 - - 

I003 

B20 Y - G ABS Fault Light Signal Input 

B21 R - Y Rear Fog Lamp Indicator 

B22 L - Y Engine Oil Pressure Warning Light 

B23 L - W Engine Failure Warning Input 

B24 Y - R EBD Warning Light Signal Input 

B25 P - L Instrument Charging Indicator Input 

B26 - - 

B27 B - Y Airbag Warning Lamp Signal Input 

B28 R - W Brake Fluid Sensor + Output 

B29 - - 

B30 W - B Instrument B Ground 

B31 R - G High Beam Indicator 

B32 G - B Right Turn Indicator 

Page 637

04-510 



NOTE 

Do not perform basic inspection until engine temperature reaches the specified value. If on - road test 

is needed, must have at least two people to perform the test. 

Step Conditions Action 

1 

2 

3 


• The battery voltage should above 12 V. 


Check tachometer. 

• Connect hand - held tester, reading the engine 

rotating speed data. 

• Reading engine rotating speed data with 1000 ~ 

2000 r/min and 3000 ~ 6000 r/min. 

• The variation of error in ± 100 ~ 200 r/min,± 150 

~ 300 r/min. 


Check speedometer. 

• Connect hand - held tester, reading the vehicle 

speed data. 

• Reading vehicle speed data with 20 ~ 100 Km/h, 

120 Km/h and 140 Km/h. 

• The variation of error in + 5, + 6, + 7 Km/h. 

• The pointer should be without jump when vehicle 

is at constant speed or constant acceleration. 

NOTE 

Tire wear and incorrect tire pressure will lead 

inaccurate data. 


Yes Go to step 2. 

No 

Charge or replace the battery. 

Refer to “Chapter 20A starting 

and charging - battery”. 


No 

Go to the problem symptoms 

table. 


No 


table. 

4 

Check engine oil pressure warning light. 


• Engine oil pressure warning light should be illuminated. 

• After engine starts, engine oil pressure warning 

light should go off. 


Yes 

No 


table. 


table. 

Page 638


04-511 





04 

Malfunction in speedometer 

Malfunction in tachometer 

Malfunction in fuel gauge 

Malfunction in ECT gauge 

MIL never/always on 

SRS warning light never/ 

always on 

ABS warning light never/ 

always on 

Engine oil pressure warning 

light never/always on 

1. Speedometer sensor 

2. Speedometer circuits 

3. Speedometer 

1. CKP sensor 

2. Tachometer circuits 

3. Tachometer 

1. Fuel level sensor 

2. Fuel gauge circuits 

3. Fuel gauge 

1. Engine coolant temperature 

sensor 

2. ECT gauge circuits 

3. ECT gauge 

1. Engine electronic 

control system 

2. Malfunction indicator 

light circuits 


1. SRS warning light 

switch 

2. SRS warning light circuits 


1. ABS system 

2. ABS warning light circuits 


1. Engine oil pressure 

switch 


warning light circuits 


Chapter 04 diagnostics - instrument cluster, malfunction 

in speedometer 


in tachometer 


in fuel gauge 


in ECT gauge 

Chapter 04 diagnostics - gasoline engine control 

system, diagnostic trouble code chart 

Chapter 04 diagnostics - diesel engine control system, 

diagnostic trouble code chart 



Chapter 04 diagnostics - SRS system, problem 

symptoms table 


problem symptoms table 

Chapter 04 diagnostics - supplemental restraint system, 

engine oil pressure warning light never/always 

on 

04 

Page 639

04-512 



Seat belt warning light never/ 

always on 

Parking Brake indicator light 

never/always on 

Turn signal/hazard indicator 


High beam indicator light 


1. Seat belt warning 

switch 

2. Seat belt waring 

switch circuits 


1. Parking brake switch 

2. Parking brake circuits 

3. instrument cluster 

1. Fuses 


3. Hazard switch 

4. Turn signal/hazard 

indicator light circuits 


1. Fuses 


3. High beam indicator 




seat belt warning light never/always on 


parking brake indicator light never/always on 

Chapter 04 diagnostics - lighting, problem symptoms 

table (If exterior turn signal/hazard lights are 

normal, repair turn signal/hazard indicator light circuits 

for an open or replace the instrument cluster) 


table (If exterior high light are normal, repair 

high beam indicator light circuits for an open or 

replace the instrument cluster) 

Page 640


04-513 

MALFUNCTION IN SPEEDOMETER 


04 

04 

Page 641

04-514 



1. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - GROUND) 

(a) 

(b) 


Disconnect the A020 speedometer sensor connector. 

(c) 


table below. 



A020 (1) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SPEEDOMETER SENSOR) 

(a) 

(b) 

(c) 


Disconnect the I002 instrument cluster connector. 

Disconnect the A020 speedometer sensor connector. 

(d) 


table below. 



I002 (A13) - A020 (3) 


< 2 Ω 




3. INSPECT SPEEDOMETER SENSOR 

(a) 

(b) 

(c) 


Remove the speedometer sensor. 

Use a good sensor replacement 


YES > Replace the instrument cluster. 

NO > Replace the speedometer sensor. 

Page 642


04-515 

MALFUNCTION IN TACHOMETER 


04 

04 

Page 643

04-516 



NOTE 

An abnormal running engine will lead the tachometer pointer instable. 

Check if the engine has normal start. 


NO > Refer to “Chapter 04 diagnostics - gasoline engine control system, problem symptoms table” 

1. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECM) 

(a) 

(b) 

(c) 



Disconnect the E001(4G69) / A036(ISF2.8) ECM connector. 

(d) 


table below. 



I002 (A8) - E001(51) 

I002 (A8) - A036(E28) 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR 

(a) 

Start the engine until the engine temperature reaches to normal condition. 

(b) 

Measure the pulse signal between the instrument cluster 

connector I002, pin A8 and ground. 

Pulse signal: Appr 33.3 Hz (1000 r / min) 




Page 644


04-517 


NEVER OR ALWAYS ON 


04 

04 

Page 645

04-518 



• Turn the ignition switch ON and ensure fuel tank have enough fuel (more than 1/4 in fuel tank). 

• Fuel level warning light will be illuminated when fuel level sensor resistance greater than 96 ± 2.5 Ω. 

• Fuel level warning light will turn off when fuel level sensor resistance smaller than 96.5 ± 4 Ω. 

1. INSPECT FUEL LEVEL SENSOR 

(a) 

(b) 


Disconnect the A022 fuel level sensor connector. 

(c) 

(d) 

Measure the resistance between the fuel level sensor 

A022 pin 2 and pin 3. 

Remove the fuel level sensor and measure the resistance 

following the table below. 

Position Empty Warn threshold 1/4 1/2 3/4 Full 

Resistance(Ω) 

150 ± 2.5 120 ± 2.5 95 ± 2.5 74 ± 2.5 54 ± 2.5 30 ± 2.5 



NO > Replace the fuel level sensor.. 

2. CHECK HARNESS AND CONNECTOR (FUEL LEVEL SENSOR - GROUND) 

(a) 

(b) 


Disconnect the A022 fuel level sensor connector. 

(c) 


table below. 



A022 (2) - Ground 


< 2 Ω 




Page 646


04-519 


(a) 


(b) 


table below. 


04 


A022 (3) - Ground 


5 V 

04 



NO > Replace the fuel level sensor. 

4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - FUEL LEVEL SENSOR) 

(a) 

(b) 

(c) 


Disconnect the I002 instrument cluster connectors. 

Disconnect the A022 fuel level sensor connectors. 

(d) 

Measure the resistanceaccording to the value(s) in the 

table below. 



I002 (A23) - A022 (3) 


< 2 Ω 




Page 647

04-520 


MALFUCTION IN ENGINE COOLANT TEMPERATURE GAUGE 


Page 648


04-521 


• Ensure engine coolant level within specified value. 

• Ensure engine coolant temperature normal. 


04 

1. INSPECT ECT INDICATOR 


(b) Remove ECT indicator. 

CAUTION 

Whenever remove the ECT indicator, ensure the engine is cold (Engine coolant temperature lower than 

40 ℃ ). 

(c) Measure the ECT sensor resistance following the table below. 

04 

Temperature ( ℃ ) 40 72 105 120 

Resistance (Ω) 287.4 ± 30 98 ± 13.5 33 ± 2 21 



NO > Replace the ECT indicator. 

2. CHECK HARNESS AND CONNECTOR (ECT INDICATOR - GROUND) 

(a) 

(b) 

(c) 


Disconnect the E012 (4G69) / E037 (ISF2.8) ECT indicator connector. 


(d) 


table below. 



E012 (1) - Ground 

E037 (1) - Ground 


5 V 

5 V 


YES > Replace the ECT indicator. 


Page 649

04-522 


3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECT INDICATOR) 

(a) 

(b) 

(c) 




(d) 


table below. 



I003 (B16) - E012 (1) 

I003 (B16) - E037 (1) 


< 2 Ω 




Page 650


04-523 

ENGINE OIL PRESSURE WARNING LIGHT NEVER / ALWAYS ON 


04 

04 

Page 651

04-524 



• When turning the ignition switch ON, the engine oil pressure warning light will turn on. 

• Engine oil pressure warning light will turn off after engine starts. 

NOTE 

If the engine oil pressure warning light is always on after engine starts. Do not shut off engine immediately. 

Check oil level, if oil level is out of specification, it needs to be repaired first. 

Check if engine oil pressure warning light is always on or never. 

YES > (Always on) Go to step 1. 

NO > (Never on) Go to step 3. 

1. INSPECT ENGINE OIL PRESSURE WARNING LIGHT 

(a) 

(b) 

(c) 


Disconnect the A023 (4G69) / E036 (ISF2.8) engine oil pressure switch connector. 


Check if the engine oil pressure warning light turns off. 

YES > Replace the engine oil pressure switch. 


2. CHECK HARNESS AND CONNECTOR (ENGINE OIL PRESSURE SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 

Standard resistance (check for short 


A023 (1) - Ground 

E036 (1) - Ground 


< 2 Ω 




Page 652


04-525 

3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ENGINE OIL PRESSURE 

SWITCH) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 

Standard resistance (check for open 



04 

I003 (B22) - A023 (1) 

I003 (B22) - E036 (1) 

< 2 Ω 




Page 653

04-526 


SEAT BELT WARNING LIGHT NEVER / ALWAYS ON 


Page 654


04-527 



• Seat belt warning light will turn on. 

• Seat belt warning light will turn off when seat belt is fastened. 

Check if seat belt warning light always or never on. 



1. INSPECT SEAT BELT WARNING LIGHT 

04 

04 

(a) 

(b) 

(c) 


Disconnect the O001 the seat belt warning switch connector. 


Check if the seat belt warning light turns off. 

YES > Replace the seat belt warning switch. 


2. CHECK HARNESS AND CONNECTOR (SEAT BELT WARNING SWITCH - GROUND) 

(a) 

(b) 


Disconnect the O001 seat belt warning switch connector. 

(c) 


table below. 



O001 (1) - Ground 


≥ 1 MΩ 




Page 655

04-528 



(a) 

(b) 



(c) 


table below. 



O001 (2) - Ground 


< 2 Ω 




4. INSPECT SEAT BELT WARNING SWITCH 

(a) 

(b) 



(c) 


table below. 


Condition 

insert seat belt 

buckle 

Tester 

Connection 

O001 (1) - O001 (2) 

Specified 

Condition 

< 2 Ω 



NO > Replace the seat belt warning switch. 

Page 656


04-529 

5. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SEAT BELT WARNING 

SWITCH) 

(a) 

(b) 

(c) 


Disconnect the O001seat belt warning switch connector. 


04 

(d) 


table below. 




04 

I002 (A31) - O001 (1) 

< 2 Ω 




Page 657

04-530 


PARKING BRAKE INDICATOR LIGHT NEVER / ALWAYS ON 


Page 658


04-531 


• Fix four tires. 


• Pull and release the parking brake. 

Check if parking brake indicator light always/never on. 



1. INSPECT PARKING BRAKE INDICATOR LIGHT 

04 

04 

(a) 

(b) 

(c) 

(d) 


Release the parking brake. 

Disconnect the A026 parking brake switch connector. 


Check if the parking brake light turns off. 

YES > Replace the parking brake switch. 



(a) 

(b) 

(c) 



Disconnect the I003 instrument cluster. 

(d) 


table below. 



A026 (1) - O003 (B6) 


< 2 Ω 




Page 659

04-532 


3. CHECK HARNESS AND CONNECTOR (PARKING BRAKE SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



A026 (1) - Ground 


≥ 1 MΩ 




Page 660

DIAGNOSTICS - POWER DOOR LOCKS 

04-533 


PRECAUTION 


04 


LOCK 

ACC 

ON 

START 


Off 

On (ACC) 

On (IG) 

Start 

04 

2. POWER OFF. 



NOTE 

To prevent the key locked in the vehicle, do not leave the key in the vehicle when disconnecting the 


(b) If no specific instructions, the ignition switch must be off. 

3. Disconnecting the negative battery cable will reset both the trip odometer data and the clock to 

‘ 0 ’. 

NOTE 

The total odometer data can not be reset to ‘ 0 ’. 

4. The audio system will lose stored memory data if the negative battery cable is disconnected. 

NOTE 


Page 661

04-534 


LOCATION 

1 Front Door Lock Assy LH 

2 Door Control Switch 

4 Right Side Sliding Door Lock Assy 

5 Rear Hatch Lock Assy 

3 Front Door Lock Assy RH 

Page 662


04-535 

CENTRAL LOCKING CONTROLLER ASSY A 

04 

04 



2 R Lock Output 

3 G Unlock Output 

4 G Driver Side Window Down Output 

5 R Driver Side Window Up Output 

6 R - L Co - pilot Side Window Down Output 

7 G - R Co - pilot Side Window Up Output 

8 W - L Window Control Power Input 

9 L - O Key Lock Input 

10 L - R Key Unlock Input 

11 Y Collision Signal Input 

12 G - Y Left Turn Light Signal 

13 G - B Right Turn Light Signal 

14 R Door Lamp Indicator 

15 L - B Left Door Assy Switch (Data) Output 

16 L Left Door Assy Switch (Clock) Output 

17 W - L Vehicle Speed Signal 

18 R - B Ignition Switch 

Page 663

04-536 


CENTRAL LOCKING CONTROLLER ASSY B 


1 W - R Ignition Switch Illumination Control 

2 W - L Front Left Door Open Signal Output 

3 R Central Locking Spare Power 

4 G - R Horn 

5 - - 

6 O - L To Engine Hood Switch Output 

7 V - W Lamplet Forget To Turn Off Hints 

8 O - B Key Detection Switch 

9 - - 


11 - - 

12 - - 

Page 664


04-537 



1 


• The battery voltage should be above 12V. 



No 


“Chapter 20A starting and charging - battery” 

04 

2 

Check basic function 

• Using the key in driver‘s door cylinder to 

lock, all doors should be locked. 


unlock, all doors should be unlocked. 



No 

Go to problem symptoms table. 

04 

3 

Check remote control function 

• When all doors are closed, using the 

remote key to lock the doors, all doors 

should be locked. 


remote key to unlock the doors, all doors 

should be unlocked. 


Yes 

No 


Replace the remote key. 

Page 665

04-538 




cause of the problem. Check each part in order. If necessary, replace these parts 


The function of power door locks 

is inoperative (using the key) 

One door is inoperative (using 

the key) 

Door does not open / close 

(using the remote key) 


2. Power door lock control unit 

3. Harness 

1. Harness 

2. Door lock actuator 



2. Harness 


4. Remote key 

5. Remote keyless entry receiver 

Chapter 04 diagnostics - power door 

locks, the function of power door locks is 

inoperative (using the key) 








locks, one door is inoperative (using the 

key) 



key) 



key) 


locks, door does not open / close (using 

the remote key) 













Page 666


04-539 

THE FUNCTION OF POWER DOOR LOCKS IS INOPERATIVE 

(USING THE KEY) 


04 

04 

Page 667

04-540 



• Before operating this inspection procedure, make sure the door open warning light is operating normally. 

• If the door open warning light is inoperative, repair it. Refer to “Chapter 04 diagnostics - instrument 

cluster, problem symptoms table” 


(a) 


(b) 

Inspect the central locking fuse (20A) in driver side 





2. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING FUSE - CENTRAL LOCKING CONTROLLER 

ASSY) 

(a) 

(b) 


Disconnect the I008 central locking controller assy B connector. 

(c) 


table below. 



Central locking fuse (20 A) - I008 (B3) 


< 2 Ω 

Page 668


04-541 





04 

(a) 

(b) 

(c) 




(d) 


table below. 


04 



I008 (B10) - Ground 

Specified 

Condition 

< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY - FRONT 

DOOR LOCK ASSY LH) 

(a) 

(b) 

(c) 



Disconnect the D006 front door lock assy LH connector. 

(d) 


table below. 



I007 (A9) - D006 (9) 

I007 (A10) - D006 (10) 


< 2 Ω 




Page 669

04-542 


5. CHECK HARNESS AND CONNECTOR (FRONT DOOR LOCK ASSY LH - GROUND) 

(a) 

(b) 



(c) 


table below. 



D006 (7) - Ground 


< 2 Ω 




6. INSPECT FRONT DOOR LOCK ASSY LH 

(a) 

(b) 

(c) 



Replace a new front door lock assy LH. 


YES > Replace the front door lock assy LH. 


7. CHECK CENTRAL LOCKING CONTROLLER ASSY 

(a) 

(b) 



(c) 


table below. 


Condition 

Tester 

Connection 

Specified 

Condition 

Use key to unlock A2 - A3 Battery voltage 

Use key to lock A3 - A2 Battery voltage 


YES > Repair or replace harness or connector. 

NO > Replace the central locking controller assy. 

Page 670


04-543 

ONE DOOR IS INOPERATIVE (USING THE KEY) 


04 

04 

Page 671

04-544 



• This inspection procedure is an example of front door LH, other doors inspection procedure are similar 


(a) 

(b) 

(c) 

Remove the front door inner guard board LH. 

Remove the front door water - proof film LH. 


(d) 


table below 


Condition 

Tester 

Connection 


Use key to unlock 4 - 1 Battery voltage 

Use key to lock 1 - 4 Battery voltage 



NO > Replace the front door lock assy LH. 

2. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY - FRONT DOOR 

LOCK ASSY LH) 

(a) 

(b) 

(c) 




(d) 


table below. 



I007 (A2) - D006 (4) 

I007 (A3) - D006 (1) 


< 2 Ω 


YES > Replace the central locking controller assy. 


Page 672


04-545 

DOOR DOES NOT OPEN / CLOSE (USING THE REMOTE KEY) 


04 

04 

Page 673

04-546 







1. INSPECT REMOTE KEY 

(a) 

Check the remote key battery. If the battery voltage is low, change the battery. If the problem is also 

exist, replace the remote key. 


YES > Replace the battery or remote key. 



(a) 


(b) 

Inspect the central locking fuse (20A) in driver side 





Page 674


04-547 

3. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING FUSE - CENTRAL LOCKING CONTROLLER 

ASSY ) 

(a) 

(b) 



(c) Measure the resistance according to the value(s) in the 

table below. 


04 


central locking fuse (20 A) - I008 (8) 


< 2 Ω 

04 





(a) 

(b) 



(c) 


table below. 


Condition 

Use remote key to 

lock 


unlock 

Tester 

Connection 

A2 - A3 

A3 - A2 

Specified 

Condition 






Page 675

04-548 

SLIDING ROOF SYSTEM 

LOCATION 

DIAGNOSTICS - SLIDING ROOF SYSTEM 

1 Sliding Roof Assy 

2 Sliding Roof Control Motor 

3 Sliding Roof Control Switch 

4 Sliding Roof ECU 

Page 676


04-549 


1. GENERAL 

This system has the following functions: 

(a) 

(b) 

Manual slide open and close. 

Auto slide open and close. 


04 

Component 

Sliding roof control motor 

and sliding roof drive 

gear sub - assembly 

Sliding roof control 

module 

Function 

Sliding roof control module sends the signal to sliding roof control motor. The sliding 

roof control motor is then actived. Sliding roof control module controls sliding roof 

motor to rotate forward and backward. 

Sliding roof control switch sends the signal to sliding roof control module. The sliding 

roof control module analyses the signal and sends it to sliding roof control motor. 

04 

3. SYSTEM OPERATION 

The sliding roof has the following features: 

Function 

Manual slide open 

and close 

Auto slide open and 

close 

Description 

This function enables sliding roof to open (or close) when OPEN/CLOSE switch is pressed 

without release. Sliding roof stops as soon as the switch is released. 

This function enables sliding roof to fully open (or close) when OPEN/CLOSE switch is 

pressed and immediately released. 

Page 677

04-550 


TERMINALS OF MAIN COMPONENTS 

SLIDING ROOF CONTROL MODULE 


1 R 

Sliding roof ECU power supply 

input 

2 G Sliding roof control switch 

3 W - B To Sliding roof ECU 

4 R - B Sliding roof ECU - ACC input 

5 Y Sliding roof control switch 

6 - - 

Page 678


04-551 



1 




Yes 

No 


Charge or replace battery. Refer to 

“Chapter 20A/20B starting and charging - 

battery, replacement” 

04 

2 

Check the sliding roof opening operation. 


• Press the “OPEN” button. 

Does the sliding roof work correctly? 

Yes 

No 



04 

3 

Check the sliding roof closing operation. 


• Press the “CLOSE” button. 

Does the sliding roof work correctly? 

Yes 

No 


Replace the sliding roof. Refer to “Chapter 86 

sliding roof - sliding roof assy, replacement” 

Page 679

04-552 






1. Fuse - 

2. Relay - 

Sliding roof system is inoperative 

3. Sliding roof control switch 

4. Sliding roof ECU 

5. Sliding rail 

6. Sliding roof control motor 

Chapter 86 sliding roof - sliding roof 









Page 680


04-553 

SLIDING ROOF SYSTEM IS INOPERATIVE 


04 

04 

Page 681

04-554 




(a) 


(b) 

Inspect the sliding roof fuse (15 A) and cigarette lighter 

fuse(15 A) in driver side junction box (I001). 



NO > Replace the sliding roof fuse or cigarette lighter fuse. 

2. INSPECT SLIDING ROOF CONTROL SWITCH 

(a) 

(b) 

(c) 


Disconnect the F003 sliding roof control switch connector. 

Replace sliding roof control switch with a new one. 


YES > Replace the sliding roof control switch. 


3. INSPECT SLIDING ROOF CONTROL MOTOR 

(a) 

(b) 

(c) 


Disconnect the sliding roof control motor connector. 

Replace sliding roof control motor with a new one. 


YES > Replace the sliding roof control motor. 


4. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL SWITCH - GROUND) 

(a) 

(b) 

(c) 




Page 682


04-555 

(d) 


table below. 




04 

F003 (3) - Ground 

F003 (2) - Ground 


04 




5. CHECK HARNESS AND CONNECTOR (SLIDING ROOF ECU - GROUND) 

(a) 

(b) 

(c) 


Disconnect the F002 sliding roof ECU connector. 


(d) 


table below. 



F002 (1) - Ground 

F002 (4) - Ground 






6. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL SWITCH - SLIDING ROOF 

ECU) 

(a) 

(b) 

(c) 




(d) 


table below. 



F002 (2) - F003 (4) 

F002 (5) - F003 (1) 


< 2 Ω 

Page 683

04-556 





7. CHECK HARNESS AND CONNECTOR (SLIDING ROOF ECU/SLIDING ROOF CONTROL SWITCH 

- GROUND) 

(a) 

(b) 

(a) 




(b) 


table below. 



F002 (3) - Ground 

F003 (5) - Ground 


< 2 Ω 


YES > Replace the sliding roof ECU. 


Page 684

A 

ABBREVIATIONS USED IN THIS MANUAL(TERMS) ................01-33 

ABS CONTROL IS UNREASONABLE(ANTI-LOCK 

BRAKE SYSTEM) ......................................................................04-122 

ABS MODULE CONNECTOR(ANTI-LOCK 

BRAKE SYSTEM) ......................................................................04-101 


(LIGHTING SYSTEM) ................................................................04-301 



ALL INTERIOR ILLUMINATION LAMPS ARE INOPERATIVE(LIGHT- 

ING SYSTEM)............................................................................04-314 


(POWER WINDOWS) ................................................................04-456 



ANTI-LOCK BRAKE SYSTEM .....................................................04-98 

AUDIO SYSTEM ........................................................................04-392 

AUXILIARY POWER..................................................................04-406 

AXLE AND PROPELLER SHAFT .................................... 02-18, 03-20 



A/C SYSTEM IS INOPERATIVE(HEATER AND AIR CONDITIONING 

SYSTEM) ...................................................................................04-162 

B 

BASIC INSPECTION(DEFROSTER SYSTEM) .........................04-490 

BASIC INSPECTION(HEATER AND AIR CONDITIONING 

SYSTEM) ...................................................................................04-157 

BASIC INSPECTION(INSTRUMENT CLUSTER)......................04-510 

BASIC INSPECTION(OUTSIDE MIRROR) ...............................04-475 

BASIC INSPECTION(POWER DOOR LOCKS) ........................04-537 

BASIC INSPECTION(WIPER AND WASHER)..........................04-358 

BASIC SERVICE PROCEDURE(ENGINE 

CONTROL SYSTEM)...................................................................04-11 

BRAKE ............................................................................. 02-21, 03-23 


IN SPECIFIED DISTANCE (DISPLAYER IS NORMAL) 

(REVERSE RADAR SYSTEM) ..................................................04-442 

C 

CAPTURING DATA(ENGINE CONTROL SYSTEM)...................04-21 






(AUXILIARY POWER) ...............................................................04-408 

CLUTCH........................................................................... 02-25, 03-27 

COOLING......................................................................... 02-11, 03-12 

D 

DATA STREAM LIST/ACTIVE TEST(ENGINE 

CONTROL SYSTEM)...................................................................04-24 

DEFROSTER SYSTEM .............................................................04-487 



INDEX 

(ORGNIZED ALPHABETICALLY) 

DIAGNOSTIC HELP - INTERMITTENT FAULT(ENGINE CONTROL 

SYSTEM)....................................................................................... 04-9 

DIAGNOSTIC SYSTEM(ENGINE CONTROL SYSTEM)............ 04-17 

DIAGNOSTIC TROUBLE CODE CHART(ENGINE 

CONTROL SYSTEM) .................................................................. 04-28 

DIAGNOSTIC TROUBLE CODE CHART(SUPPLEMENTAL 

RESTRAINT SYSTEM) ............................................................. 04-133 

DIAGNOSTICS.............................................................................. 02-1 


(LIGHTING SYSTEM) ............................................................... 04-332 

DOOR LOCKS............................................................................. 02-35 

DOORS ............................................................................ 02-36, 03-36 

DTC DIAGNOSTIC(ENGINE CONTROL SYSTEM) ................... 04-33 

E 

ELECTRONIC CIRCUIT INSPECTION PROCEDURE 

(HOW TO TROUBLESHOOT)..................................................... 01-29 

EMISSION CONTROL ......................................................... 02-5, 03-5 

ENGINE CONTROL SYSTEM ....................................02-3, 03-2, 04-1 

ENGINE MECHANICAL ....................................................... 02-7, 03-6 

ENGINE SYMPTOM DIAGNOSTIC ............................................ 04-61 

EXHAUST......................................................................... 02-10, 03-11 

EXTERIOR AND INTERIOR TRIM.............................................. 03-37 

F 

FAIL-SAFE CHART(ENGINE CONTROL SYSTEM) .................. 04-22 








(POWER WINDOWS) ............................................................... 04-466 

FRONT POWER WINDOW LH IS INOPERATIVE 

(POWER WINDOWS) ............................................................... 04-461 

FRONT SUSPENSION..................................................... 02-15, 03-17 

FUEL .................................................................................... 02-4, 03-4 

G 

GENERAL INFORMATION(HOW TO TROUBLESHOOT) ......... 01-18 

GENERAL INFORMATION(HOW TO USE THIS MANUAL) ........ 01-1 

H 


TIVE(LIGHTING SYSTEM) ....................................................... 04-264 



HAZARD WARNING SWITCH ILLUMINATION IS NOT INOPERA- 

TIVE 



TIVE 


HEATER AND AIR CONDITIONING................................ 02-28, 03-31 

HEATER AND AIR CONDITIONING SYSTEM ......................... 04-156 

Page 685

HI-BEAM HEADLAMP IS INOPERATIVE 

(ONE SIDE)(LIGHTING SYSTEM)........................................... 04-218 

HORN IS ALWAYS ON(HORN SYSTEM) ................................ 04-422 

HORN IS INOPERATIVE(HORN SYSTEM).............................. 04-417 

HORN SYSTEM ........................................................................ 04-415 

HOW TO DIAGNOSTICS ANALYSE(ENGINE 

CONTROL SYSTEM) .................................................................... 04-6 

HOW TO PROCEED WITH TROUBLESHOOTING 

(HOW TO TROUBLESHOOT)..................................................... 01-20 

HOW TO TROUBLESHOOT ....................................................... 01-18 

HOW TO USE THIS MANUAL ...................................................... 01-1 

J 

IDENTIFICATION INFORMATION................................................ 01-6 

IGNITION..................................................................................... 03-14 



INSTRUMENT CLUSTER ......................................................... 04-502 





INSTRUMENT PANEL/INSTRUMENT........................................ 02-33 

INTAKE AIR........................................................................ 02-6, 03-10 

L 

LICENSE LAMP IS INOPERATIVE(LIGHTING SYSTEM)........ 04-350 

LIGHTING.................................................................................... 03-33 

LIGHTING SYSTEM.................................................................. 04-202 

LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE 

(ONE SIDE)(LIGHTING SYSTEM)............................................ 04-224 

LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)(LIGHTING 

SYSTEM)................................................................................... 04-212 

LOCATION ................................................................................ 04-473 

LOCATION(ANTI-LOCK BRAKE SYSTEM).............................. 04-100 

LOCATION(AUDIO SYSTEM)................................................... 04-393 

LOCATION(AUXILIARY POWER) ............................................ 04-406 

LOCATION(DEFROSTER SYSTEM)........................................ 04-487 

LOCATION(ENGINE CONTROL SYSTEM).................................. 04-4 

LOCATION(HEATER AND AIR CONDITIONING SYSTEM) .... 04-158 

LOCATION(HORN SYSTEM) ................................................... 04-415 

LOCATION(INSTRUMENT CLUSTER) .................................... 04-503 

LOCATION(LIGHTING SYSTEM) ............................................. 04-204 

LOCATION(OUTSIDE MIRROR) .............................................. 04-473 

LOCATION(POWER DOOR LOCKS) ....................................... 04-534 

LOCATION(POWER WINDOWS) ............................................. 04-449 

LOCATION(SLIDING ROOF SYSTEM) .................................... 04-548 

LOCATION(SUPPLEMENTAL RESTRAINT SYSTEM)............ 04-130 

LOCATION(WIPER AND WASHER)......................................... 04-357 

LUBRICATION ................................................................. 02-12, 03-13 

M 

MALFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT NEV- 

ER OR ALWAYS ON(INSTRUMENT CLUSTER) ..................... 04-517 

MALFUNCTION IN TACHOMETER(INSTRUMENT 

CLUSTER)................................................................................. 04-515 

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE(OUTSIDE 

MIRROR)................................................................................... 04-485 

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE(OUTSIDE 

MIRROR)................................................................................... 04-483 

N 

NO COOLING FROM REAR A/C SYSTEM(HEATER AND AIR CON- 

DITIONING SYSTEM) ............................................................... 04-191 

O 

ONE DOOR IS INOPERATIVE (USING THE KEY)(POWER DOOR 

LOCKS)......................................................................................04-543 

OUTSIDE MIRROR ...................................................................04-473 


INOPERATIVE(LIGHTING SYSTEM)........................................04-334 

P 

PARKING BRAKE.............................................................02-22, 03-24 

POWER DOOR LOCKS ............................................................04-533 

POWER STEERING .........................................................02-27, 03-29 

POWER WINDOWS ..................................................................04-448 

PRE - CHECK(ANTI-LOCK BRAKE SYSTEM) .........................04-105 

PRECAUTION(ANTI-LOCK BRAKE SYSTEM)...........................04-98 

PRECAUTION(AUDIO SYSTEM)..............................................04-392 

PRECAUTION(HEATER AND AIR 

CONDITIONING SYSTEM) .......................................................04-156 

PRECAUTION(INSTRUMENT CLUSTER)................................04-502 

PRECAUTION(LIGHTING SYSTEM) ........................................04-202 

PRECAUTION(POWER DOOR LOCKS) ..................................04-533 

PRECAUTION(POWER WINDOWS) ........................................04-448 

PRECAUTION(REPAIR INSTRUCTION) ......................................01-8 

PRECAUTION(REVERSE RADAR SYSTEM) ..........................04-424 

PRECAUTION(SUPPLEMENTAL RESTRAINT SYSTEM) .......04-129 

PRECAUTION(WIPER AND WASHER)....................................04-356 

PREPARATION(AXLE AND PROPELLER SHAFT)....................02-18 

PREPARATION(BRAKE).............................................................02-21 

PREPARATION(CLUTCH) ..........................................................02-25 

PREPARATION(COOLING) ........................................................02-11 

PREPARATION(DIAGNOSTICS) ..................................................02-1 

PREPARATION(DOOR LOCKS).................................................02-35 

PREPARATION(DOORS)............................................................02-36 

PREPARATION(EMISSION CONTROL).......................................02-5 

PREPARATION(ENGINE CONTROL SYSTEM)...........................02-3 

PREPARATION(ENGINE MECHANICAL) ....................................02-7 

PREPARATION(EXHAUST)........................................................02-10 

PREPARATION(FRONT SUSPENSION)....................................02-15 

PREPARATION(FUEL)..................................................................02-4 

PREPARATION(HEATER AND AIR CONDITIONING) ...............02-28 

PREPARATION(INSTRUMENT PANEL/INSTRUMENT)............02-33 

PREPARATION(INTAKE AIR).......................................................02-6 

PREPARATION(LUBRICATION).................................................02-12 

PREPARATION(PARKING BRAKE) ...........................................02-22 

PREPARATION(POWER STEERING)........................................02-27 

PREPARATION(REAR SUSPENSION) ......................................02-16 

PREPARATION(SEAT BELT) .....................................................02-30 

PREPARATION(SEAT) ...............................................................02-34 

PREPARATION(STARTING AND CHARGING)..........................02-14 

PREPARATION(STEERING COLUMN)......................................02-26 

PREPARATION(TIRE AND WHEEL) ..........................................02-17 

PREPARATION(TRANSMISSION) .............................................02-23 

PREPARATION(VEHICLE CONTROL SYSTEM) .......................02-37 

PREPARATION(WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW 

MIRROR) .....................................................................................02-32 

PREPARATION(WIPER AND WASHER)....................................02-31 

PROBLEM SYMPTOMS TABLE(ANTI-LOCK 

BRAKE SYSTEM)......................................................................04-104 

PROBLEM SYMPTOMS TABLE(DEFROSTER SYSTEM) .......04-491 

PROBLEM SYMPTOMS TABLE(ENGINE 

CONTROL SYSTEM) ..................................................................04-60 

PROBLEM SYMPTOMS TABLE(HEATER AND AIR 

CONDITIONING SYSTEM) .......................................................04-159 

PROBLEM SYMPTOMS TABLE(INSTRUMENT CLUSTER)....04-511 

PROBLEM SYMPTOMS TABLE(OUTSIDE MIRROR) .............04-476 

PROBLEM SYMPTOMS TABLE(POWER DOOR LOCKS) ......04-538 

PROBLEM SYMPTOMS TABLE(SLIDING ROOF SYSTEM) ...04-552 

Page 686

PROBLEM SYMPTOMS TABLE(SUPPLEMENTAL RESTRAINT 

SYSTEM) ...................................................................................04-134 

R 



RADIO RECEPTION IS POOR(AUDIO SYSTEM) ....................04-400 


(ENGINE CONTROL SYSTEM)...................................................04-19 


ERATIVE(LIGHTING SYSTEM).................................................04-330 



REAR SUSPENSION....................................................... 02-16, 03-18 

REAR WINDOW DEFROST ER IS INOPERATIVE 

(DEFROSTER SYSTEM)...........................................................04-492 

REAR WINDOW DEFROSTER SWITCH ILLUMINATION IS NOT IN- 

OPERATIVE(LIGHTING SYSTEM) ...........................................04-338 

REPAIR INSTRUCTION ................................................................01-8 


(SUPPLEMENTAL RESTRAINT SYSTEM)...............................04-131 

REVERSE RADAR SYSTEM.....................................................04-424 

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL(REVERSE 

RADAR SYSTEM)......................................................................04-429 

S 

SEAT................................................................................ 02-34, 03-35 

SEAT BELT...................................................................... 02-30, 03-32 

SERIAL NUMBER (SN)(IDENTIFICATION INFORMATION) ........01-7 

SERVICE DATA(AXLE AND PROPELLER SHAFT) ...................03-20 

SERVICE DATA(BRAKE) ............................................................03-23 

SERVICE DATA(CLUTCH)..........................................................03-27 

SERVICE DATA(COOLING)........................................................03-12 

SERVICE DATA(DOOR)..............................................................03-36 

SERVICE DATA(EMISSION CONTROL) ......................................03-6 

SERVICE DATA(ENGINE CONTROL SYSTEM) ..........................03-2 

SERVICE DATA(EXHAUST) .......................................................03-11 

SERVICE DATA(FRONT SUSPENSION) ...................................03-17 

SERVICE DATA(FUEL) .................................................................03-4 

SERVICE DATA(HEATER AND AIR CONDITIONING)...............03-31 

SERVICE DATA(IGNITION) ........................................................03-14 

SERVICE DATA(INTAKE AIR) ....................................................03-10 

SERVICE DATA(POWER STEERING) .......................................03-29 

SERVICE DATA(STARTING AND CHARGING) .........................03-15 

SERVICE DATA(STEERING COLUMN) .....................................03-28 

SERVICE DATA(TIRE AND WHEEL)..........................................03-19 

SERVICE DATA(TRANSMISSION) .............................................03-25 

SLIDING ROOF SYSTEM..........................................................04-548 

SPECIFIED TORQUE FOR SPECIFICATION BOLTS..................03-1 

STARTING AND CHARGING .......................................... 02-14, 03-15 

STEERING COLUMN ...................................................... 02-26, 03-28 

STEP LAMP ARE INOPERATIVE(LIGHTING SYSTEM) ..........04-304 



SUPPLEMENTAL RESTRAINT SYSTEM .................................04-129 

SYSTEM DESCRIPTION(DEFROSTER SYSTEM) ..................04-489 

SYSTEM DESCRIPTION(REVERSE RADAR SYSTEM)..........04-426 

SYSTEM DESCRIPTION(SLIDING ROOF SYSTEM)...............04-549 

T 

TAIL LAMPS ARE INOPERATIVE(LIGHTING SYSTEM)..........04-347 

TERMINALS OF INSTRUMENT CLUSTER(INSTRUMENT CLUS- 

TER)...........................................................................................04-507 


(OUTSIDE MIRROR) .................................................................04-474 

TERMS.........................................................................................01-33 

THE FUNCTION OF POWER DOOR LOCKS IS INOPERATIVE (US- 

ING THE KEY)(POWER DOOR LOCKS).................................. 04-539 

TIRE AND WHEEL ........................................................... 02-17, 03-19 

TORQUE SPECIFICATION(AXLE AND PROPELLER SHAFT) . 03-21 

TORQUE SPECIFICATION(BRAKE) .......................................... 03-23 

TORQUE SPECIFICATION(CLUTCH)........................................ 03-27 

TORQUE SPECIFICATION(COOLING)...................................... 03-12 

TORQUE SPECIFICATION(DOOR) ........................................... 03-36 

TORQUE SPECIFICATION(EMISSION CONTROL) ........... 03-5, 03-9 

TORQUE SPECIFICATION(ENGINE CONTROL SYSTEM) ........ 03-3 

TORQUE SPECIFICATION(EXHAUST) ..................................... 03-11 

TORQUE SPECIFICATION(EXTERIOR AND INTERIOR TRIM)03-37 

TORQUE SPECIFICATION(FRONT SUSPENSION) ................. 03-17 

TORQUE SPECIFICATION(FUEL) ............................................... 03-4 

TORQUE SPECIFICATION(HEATER AND AIR 

CONDITIONING)......................................................................... 03-31 

TORQUE SPECIFICATION(IGNITION) ...................................... 03-14 

TORQUE SPECIFICATION(INTAKE AIR) .................................. 03-10 

TORQUE SPECIFICATION(LIGHTING) ..................................... 03-33 

TORQUE SPECIFICATION(LUBRICATION) .............................. 03-13 

TORQUE SPECIFICATION(PARKING BRAKE)......................... 03-24 

TORQUE SPECIFICATION(POWER STEERING) ..................... 03-30 

TORQUE SPECIFICATION(REAR SUSPENSION).................... 03-18 

TORQUE SPECIFICATION(SEAT BELT)................................... 03-32 

TORQUE SPECIFICATION(SEAT)............................................. 03-35 

TORQUE SPECIFICATION(STARTING AND CHARGING) ....... 03-16 

TORQUE SPECIFICATION(STEERING COLUMN) ................... 03-28 

TORQUE SPECIFICATION(TIRE AND WHEEL)........................ 03-19 

TORQUE SPECIFICATION(TRANSMISSION)........................... 03-26 

TORQUE SPECIFICATION(VEHICLE CONTROL SYSTEM) .... 03-38 

TORQUE SPECIFICATION(WIPER AND WASHER) ................. 03-34 

TRANSMISSION .............................................................. 02-23, 03-25 

TRUNK LAMP IS INOPERATIVE(LIGHTING SYSTEM)........... 04-307 


LAMPS ARE NORMAL)(LIGHTING SYSTEM) ......................... 04-260 

W 

WASHER PUMP IS INOPERATIVE - REAR WINDOW(WIPER AND 

WASHER).................................................................................. 04-387 

WASHER PUMP IS INOPERATIVE - WINDSHIELD(WIPER AND 

WASHER).................................................................................. 04-374 

VEHICLE CONTROL SYSTEM........................................ 02-37, 03-38 

VEHICLE IDENTIFICATION NUMBER (VIN)(IDENTIFICATION IN- 

FORMATION)................................................................................ 01-6 

VEHICLE LIFT AND SUPPORT LOCATIONS(REPAIR INSTRUC- 

TION)........................................................................................... 01-16 


NOT RETRACT(WIPER AND WASHER) ................................. 04-378 

WIDTH LAMPS IS NOT INOPERATIVE(LIGHTING SYSTEM) 04-344 



WINDSHIELD/SIDE WINDOW GLASS/REAR 

VIEW MIRROR............................................................................ 02-32 

WIPER AND WASHER .......................................02-31, 03-34, 04-356 

WIPER IS INOPERATIVE - REAR WINDOW 

(WIPER AND WASHER) ........................................................... 04-381 

WIPERS ARE INOPERATIVE - WINDSHIELD(WIPER AND WASH- 

ER) ............................................................................................ 04-361 

WIPERS ARE INOPERATIVE AT HIGH SPEED - WINDSHIELD(WIP- 

ER AND WASHER) ................................................................... 04-369 

WIPERS ARE INOPERATIVE AT LOW SPEED - WINDSHIELD(WIP- 

ER AND WASHER) ................................................................... 04-367 


SHIELD(WIPER AND WASHER) .............................................. 04-371 

Page 687

Page 688


V O L U M E 2 

04 DIAGNOSTICS (RHD) 691 

05 VEHICLE MAINTENANCE 1203 

11A ENGINE CONTROL SYSTEM 1263 

12A FUEL SYSTEM 1327 

13A EMISSION CONTROL 1355 

14A INTAKE AIR 1365 

15A ENGINE MECHANICAL 1383 

16A EXHAUST SYSTEM 1465 

17A COOLING SYSTEM 1477 

18A LUBRICATION SYSTEM 1503 


20A STARTING AND CHARGING 1533 

Page 689

Page 690

DIAGNOSTICS(RHD) 


PRECAUTION.............................................................................. 04-1 

LOCATION................................................................................... 04-4 

HOW TO DIAGNOSTICS ANALYSE........................................... 04-5 

DIAGNOSTIC HELP - INTERMITTENT FAULT .......................... 04-8 

BASIC SERVICE PROCEDURE................................................ 04-10 

TERMINALS OF ECM................................................................ 04-11 

DIAGNOSTIC SYSTEM............................................................. 04-16 

READING AND ERASING DIAGNOSTIC TROUBLE CODE 

(DTC) ......................................................................................... 04-18 

CAPTURING DATA ................................................................... 04-20 

FAIL-SAFE CHART.................................................................... 04-21 

DATA STREAM LIST/ACTIVE TEST......................................... 04-23 


DTC DIAGNOSTIC .................................................................... 04-32 


ENGINE SYMPTOM DIAGNOSTIC........................................... 04-59 

ANTI-LOCK BRAKE SYSTEM......................................................... 04-96 

PRECAUTION............................................................................ 04-96 

ABS MODULE CONNECTOR ................................................... 04-98 



PRE - CHECK.......................................................................... 04-102 

POWER SUPPY VOLTAGE HIGH OR LOW........................... 04-104 

SOLENOID VALVES AND VALVES RELAY FAILURE........... 04-105 

PUMP MOTOR FAILURE ........................................................ 04-109 

WHEEL SPEED SENSOR CIRCUIT FAULT........................... 04-113 

WHEEL SPEED SENSOR SIGNAL FAULT ............................ 04-115 

ABS CONTROL IS UNREASONABLE .................................... 04-119 

ABS SYSTEM IS INOPERATIVE............................................. 04-122 

SUPPLEMENTAL RESTRAINT SYSTEM ..................................... 04-126 

PRECAUTION.......................................................................... 04-126 

RESTRAINT CONTROL MODULE (RCM) CONNECTOR 

PIN ........................................................................................... 04-127 



8101 - POWER SUPPLY VOLTAGE HIGH ............................. 04-131 

8102 - POWER SUPPLY VOLTAGE LOW.............................. 04-131 

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE ......... 04-133 

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE.......... 04-133 

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND...... 04-135 

8204 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY ..... 04-137 


RESISTANCE .......................................................................... 04-139 


RESISTANCE .......................................................................... 04-139 

8213 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO 

GROUND ................................................................................. 04-141 


BATTERY ................................................................................ 04-143 

04 

04 

04 

04 

Page 691

SRS WARNING LIGHT IS ALWAYS ON ................................. 04-145 

SRS WARNING LIGHT IS INOPERATIVE .............................. 04-147 

HEATER AND AIR CONDITIONING SYSTEM.............................. 04-149 

PRECAUTION.......................................................................... 04-149 



A/C SYSTEM IS INOPERATIVE.............................................. 04-153 

FRONT BLOWER MOTOR IS INOPERATIVE ........................ 04-157 

FRONT AIR FLOW IS INSUFFICIENT .................................... 04-163 

NO COOLING FROM FRONT A/C SYSTEM .......................... 04-167 

REAR HEATER IS INOPERATIVE OR INSUFFICIENT 

HEATING ................................................................................. 04-174 

LIGHTING SYSTEM ....................................................................... 04-181 

PRECAUTION.......................................................................... 04-181 


LOCATION............................................................................... 04-183 


LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ........ 04-191 

LO - BEAM HEADLAMPS ARE INOPERATIVE 

(BOTH SIDES) ......................................................................... 04-193 

HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ......... 04-197 


(BOTH SIDES) ......................................................................... 04-199 

LO - BEAM AND HI - BEAM HEADLAMPS ARE INOPERATIVE 

(ONE SIDE)............................................................................. 04-204 

ALL HEADLAMPS ARE INOPERATIVE .................................. 04-207 

FRONT FOG LAMPS ARE INOPERATIVE ............................. 04-213 

FRONT FOG LAMPS ARE ALWAYS ON ................................ 04-218 

REAR FOG LAMPS ARE INOPERATIVE................................ 04-221 

REAR FOG LAMPS ARE ALWAYS ON .................................. 04-226 

ALL FOG LAMPS ARE INOPERATIVE ................................... 04-229 






TIVE ......................................................................................... 04-245 

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)...... 04-254 

HAZARD WARNING LAMPS ARE ALWAYS ON .................... 04-258 

ALL STOP LAMPS ARE INOPERATIVE ................................. 04-260 

STOP LAMP IS INOPERATIVE (ONE SIDE) .......................... 04-265 

HIGH - MOUNTED STOP LAMP IS INOPERATIVE................ 04-267 

BACK - UP LAMP IS INOPERATIVE(ONE SIDE) ................... 04-269 

BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES) ....... 04-271 

IGNITION SWITCH ILLUMINATION IS INOPERATIVE .......... 04-275 

CENTRAL DOME LIGHT IS INOPERATIVE ........................... 04-278 

AIR PURIFIER LAMP IS INOPERATIVE ................................. 04-283 

STEP LAMP ARE INOPERATIVE ........................................... 04-286 

TRUNK LAMP IS INOPERATIVE ............................................ 04-288 

FRONT DOME LIGHT IS INOPERATIVE................................ 04-291 

ALL INTERIOR ILLUMINATION LAMPS ARE INOPERATIVE 04-295 

INSTRUMENT CLUSTER ILLUMINATION IS NOT IN 

OPERATIVE............................................................................. 04-300 

DIAGNOSIS SWITCH ILLUMINATION IS NOT 

INOPERATIVE ......................................................................... 04-303 

Page 692

CIGARETTE LIGHTER ILLUMINATION IS NOT 

INOPERATIVE......................................................................... 04-305 

A/C CONTROL PANEL ILLUMINATION IS NOT 

INOPERATIVE......................................................................... 04-307 

RADIO ILLUMINATION IS NOT INOPERATIVE ..................... 04-309 

REAR BLOWER FORWARD SWITCH ILLUMINATION IS NOT IN- 

OPERATIVE ............................................................................ 04-311 

DOME LIGHT SWITCH ILLUMINATION IS NOT 

INOPERATIVE......................................................................... 04-313 


INOPERATIVE......................................................................... 04-315 


TIVE ......................................................................................... 04-317 

INSTRUMENT DIMMER SWITCH ILLUMINATION IS NOT INOPER- 

ATIVE....................................................................................... 04-319 


TIVE ......................................................................................... 04-321 

WIDTH LAMPS IS NOT INOPERATIVE.................................. 04-323 

TAIL LAMPS ARE INOPERATIVE........................................... 04-325 

LICENSE LAMP IS INOPERATIVE ......................................... 04-328 


TIVE ......................................................................................... 04-330 

WIPER AND WASHER .................................................................. 04-334 

PRECAUTION.......................................................................... 04-334 



WINDSHIELD........................................................................... 04-338 

WIPERS ARE INOPERATIVE - WINDSHIELD........................ 04-339 

WIPERS ARE INOPERATIVE AT LOW SPEED - 

WINDSHIELD........................................................................... 04-344 

WIPERS ARE INOPERATIVE AT HIGH SPEED - 

WINDSHIELD........................................................................... 04-345 


SHIELD .................................................................................... 04-346 

WASHER PUMP IS INOPERATIVE - WINDSHIELD............... 04-348 


NOT RETRACT........................................................................ 04-351 

REAR WINDOW ...................................................................... 04-353 

WASHER PUMP IS INOPERATIVE - REAR WINDOW .......... 04-358 

AUDIO SYSTEM............................................................................. 04-361 

PRECAUTION.......................................................................... 04-361 



RADIO DOES NOT WORK...................................................... 04-364 

RADIO RECEPTION IS POOR................................................ 04-368 

POOR SOUND QUALITY....................................................... 04-369 

SPEAKER DOES NOT WORK ................................................ 04-370 

AUXILIARY POWER...................................................................... 04-374 


CIGARETTE LIGHTER IS INOPERATIVE .............................. 04-375 

12V POWER SUPPLY OUTPUT SOCKET IS INOPERATIVE 04-378 

HORN SYSTEM.............................................................................. 04-382 


HORN IS INOPERATIVE......................................................... 04-383 

HORN IS ALWAYS ON............................................................ 04-389 

04 

04 

04 

04 

Page 693

REVERSE RADAR SYSTEM ......................................................... 04-391 

PRECAUTION.......................................................................... 04-391 



REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL ........ 04-395 


VER IS OUT OF REVERSE POSITION .................................. 04-400 


DISTANCE (BACK-UP LAMP IS NORMAL) ........................... 04-402 


OBSTACLE BEHIND VEHICLE ............................................... 04-405 


IN SPECIFIED DISTANCE (DISPLAYER IS NORMAL) .......... 04-408 


(BUZZER IS NORMAL)............................................................ 04-411 

POWER WINDOWS ....................................................................... 04-414 

PRECAUTION.......................................................................... 04-414 

DOOR CONTROL SWITCH PIN.............................................. 04-415 

WINDOW CONTROL SWITCH LH PIN ................................... 04-416 

CENTRAL LOCKING CONTROLLER ASSY A PIN................. 04-417 

BASIC INSPECTION .............................................................. 04-418 


ALL POWER WINDOWS ARE INOPERATIVE ....................... 04-421 

FRONT POWER WINDOW RH IS INOPERATIVE .................. 04-427 

FRONT POWER WINDOW LH DOES NOT OPEN................. 04-430 

FRONT POWER WINDOW LH DOES NOT CLOSE............... 04-432 

FRONT POWER WINDOW RH IS INOPERATIVE (USE DOOR 

CONTROL SWITCH) ............................................................... 04-434 

FRONT POWER WINDOW LH IS INOPERATIVE (USE WINDOW 

CONTROL SWITCH RH) ......................................................... 04-436 

OUTSIDE MIRROR ........................................................................ 04-439 

TERMINALS OF OUTSIDE MIRROR SWITCH....................... 04-439 



MIRRORS ARE INOPERATIVE (BOTH SIDES) ..................... 04-442 

A SINGLE MIRROR IS INOPERATIVE ................................... 04-445 

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE ......... 04-448 

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE...... 04-450 

OUTSIDE MIRROR DEFROSTER SYSTEM................................. 04-452 


BASIC INSPECTION ................................... 04-453 


OUTSIDE MIRROR DEFROSTER IS INOPERATIVE............ 04-455 

INSTRUMENT CLUSTER .............................................................. 04-461 

PRECAUTION.......................................................................... 04-461 

LOCATION............................................................................... 04-462 

INSTRUMENT CLUSTER INFORMATION.............................. 04-463 

LIQUID CRYSTAL DISPLAY ................................................... 04-465 

TERMINALS OF INSTRUMENT CLUSTER ............................ 04-466 



MALFUNCTION IN SPEEDOMETER ...................................... 04-472 

MALFUNCTION IN TACHOMETER ........................................ 04-474 


NEVER OR ALWAYS ON ........................................................ 04-476 

Page 694

MALFUCTION IN ENGINE COOLANT TEMPERATURE 

GAUGE .................................................................................... 04-479 

ENGINE OIL PRESSURE WARNING LIGHT NEVER / ALWAYS 

ON............................................................................................ 04-482 

SEAT BELT WARNING LIGHT NEVER / ALWAYS ON.......... 04-485 

PARKING BRAKE INDICATOR LIGHT NEVER / ALWAYS 

ON............................................................................................ 04-489 

POWER DOOR LOCKS................................................................. 04-492 

PRECAUTION.......................................................................... 04-492 

CENTRAL LOCKING CONTROLLER ASSY A........................ 04-493 

CENTRAL LOCKING CONTROLLER ASSY B........................ 04-494 




(USING THE KEY)................................................................... 04-497 

ONE DOOR IS INOPERATIVE (USING THE KEY)................. 04-502 

DOOR DOES NOT OPEN / CLOSE (USING THE 

REMOTE KEY) ........................................................................ 04-504 

04 

04 

04 

04 

Page 695

Page 696


DIAGNOSTICS(RHD) 

PRECAUTION 

1. POWER OFF. 

DIAGNOSTICS(RHD) - ENGINE CONTROL SYSTEM 

04-1 

• The battery negative cable must be disconnected first before removing or installing any electric 

appliance and when tools or facilities will touch the exposed terminals. It should be connected 

eventually. This will prevent person injured and vehicle damaged. 


WARNING 

The ignition and illuminatioin switches must be OFF before disconnecting or connecting the battery 

negative cable (the semiconductor maybe damaged without doing that). 

CAUTION 

Do not leave the key in the vehicle in case the doores are locked before disconnecting the battery negative 

cable for the vehicle equipped with remote control central lock. 

2. RESET THE ODOMETER AND CLOCK IF DISCONNECTING THE COMBINATION INSTRUMENT 

BATTERY NEGATIVE CABLE. 

04 

04 

CAUTION 

The total course will not be reset. 

3. THE SAVING DATA SETTING WILL LOST IF DISCONNECTING THE BATTER NEGATIVE CABLE. 

CAUTION 

After connecting the battery negative cable, the audio system shoud be reset. 




Expression 




5. PRECAUTIONS FOR OVERHAULING THE ENGINE CONTROL SYSTEM FAILURE. 

CAUTION 

(a) Do not disconnect power circuit while engine is running at high speed in case the instantaneous overvoltage 

damage the ECM and sensors. 

(b) The ECM should be disconnected when welding on the vehicle body. It is special attention that performing 

the repair work beside the ECM or sensors. 

(c) The system will resume its normal state temporarily or competely by removing and reinstalling the suspicious 

faulty components when the connector terminals or the installing state of the components go 

out of order. 

(d) The high impedance type multimeter should be used to the test except the especial description of the 

procedure in place of the traditional analogue types multimeter. 

(e) Don’t check any electric appliance connecting the ECM with a test light. 

(f) Never connect the negative and positive battery cables wrong. The battery negative cable must be 

grounded. 

Page 697

04-2 


(g) ECM and sensors must be kept from moisture. No permission damaging the seal device of ECM and 

sensors and washing them more. 

(h) Prevent human body static electricity from damaging ECM: The operator body must be grounded when 

operator checks ECM or replace chips. 

(i) In order to identifying the faulty position, we must check the vehicle condition while vehicle goes out of 

order. For example, we check the faults through the DTC. We record these faults states before 


(j) We must remove and install ECM, actuators and independent sensors when the ignition switch is OFF 

unless there is additional specification in the checking procedure. 

(k) If the removed and installed ECM, actuators and sensors are to be reinstalled, the system should be 

checked after completing installation. Using the special diagnosis tool to check DTC. 

(l) Check the ECM connector terminals with a multimeter. 

• Connect the small probing pin to the probe of a multimeter. 

• Check voltage value of terminals referring to the inspection sheet by back probing ECM connectors 

terminals. 

(m) When diagnosis, the ignition switch turns “ON” and the connectors are disconnected. DTC of the other 

system will be set. After diagnosis, confirm DTC in all systems.Turn the ignition switch “LOCK” when 

the connectors are connected and disconnected. 

(n) The test probe must not be probed in wire harness. This will reduce the waterproofness. And it also 

cause corrossion. Using the test wire, wire connector, measure wire harness and so on. 

(o) Check the common connectors when they are in connection status by probing terminals in the wire 

harness. If the connector is too small to check, do not force inserting. 

(p) If check the common connectors when they are not in connection status (check male connectors): 

• Do not short terminals circuit by using a probe. This will damage the interior circuit in ECM. 


(q) If check the common connectors when they are not in connection status (check female connectors): 

• Use the special tools to check wire harness. 


(r) We shall have a short harness or connectors without taking cautions by wrong insertion. This will 

damage wire harness, sensor, ECM and other components So we must carefully handle when 

checking. 

(s) Do not check with the list order. 

• If the check results are different from the standard value, then check related sensors, actuators and 

wire harness. Repair or replace if necessary. 

• Check with the voltage meter again after repairing or replacing. Confirm if the faults have been 

eliminated. 

(t) Check resistance and continuity between terminals of ECM with multimeter. 

• Ignition switch: OFF 

• Disconnect ECM harness connector. 

(u) Ground inspection. 

• Ground connections are very important to the proper operation of electrical and electronic circuits. 

Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion 

(rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit 

works. 

• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can 

drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the 

circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. 

• When inspecting a ground connection follow these rules: 

Page 698


04-3 

04 

04 

1 Remove Bolt (Screw) 

3 Reinstall Bolt (Screw) Securely 

2 

Inspect Mating Surface For Tarnish, 

Dirt, Rust, Etc. Clear As Required To 

Assure Good Contact. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

Remove the ground bolt or screw. 

Inspect all mating surfaces for tarnish, dirt, rust, etc. 

Clean as required to assure good contact. 

Reinstall bolt or screw securely. 

Inspect for “add-on” accessories which may be interfering with the ground circuit. 

If several wires are crimped into one ground eyelet terminal, check for improper crimps. 

Make sure all of the wires are clean, securely fastened and providing a good ground path. 

If multiple wires are cased in one eyelet, make sure no ground wires have excess wire 

insulation. 

Page 699

04-4 


LOCATION 

1 Injector 


3 Spark Plug 


5 


Sensor 



9 





12 PCV Valve 


14 

Outlet Fuel (Return Back To Fuel 

Tank) 


Page 700


04-5 

HOW TO DIAGNOSTICS ANALYSE 

NOTE 

Use diagnostic scan tool to diagnose vehicle. 

1. VEHICLE INTO REPAIR SHOP 

04 


2. COLLECT AND ANALYSE CUSTOMER’S SYMPTOM 


04 

3. CONNECT THE DIAGNOSTIC SCANNER TO DLC3 


4. CHECK DTC AND DATA FREEZE-FRAME DATA 


5. ERASE DTC 


6. VISUAL CHECK 


7. CONFIRM FAULT SYMPTOM 

Check result (if engine can not start,check following first) 

Result 

Proceed To 

Fault present Step 9 

Normal Step 8 

8. SIMULATE FAULT SYMPTOM 


9. CHECK IF DTC PRESENT 

Check result 

Result 

DTC present 

Proceed To 

Next step 

10. REFER TO DTC TABLE 


Normal Step 11 

Page 701

04-6 


11. BASIC CHECK 

Check result 

Result 


Proceed To 

Next step 


12. REFER TO SYMPTOM TABLE 

Check result 

Result 

Fault can be confirmed circuit 

Proceed To 

Next step 

Fault can be confirmed part Step 15 

13. CHECK ECM POWER SUPPLY CIRCUIT 


14. CHECK ELECTRIC CIRCUIT 

Check result 

Result 


Proceed To 

Next step 


15. CHECK INTERMITTENT FAULT 


16. CHECK PARTS 


17. CONFIRM FAULT 


18. ADJUST OR REPAIR 


19. PERFORM CONFIRMATION TEST 

YES > END. 

Page 702


04-7 

THE MAIN POINTS OF REPAIRING BURNED FUSE OUT 

CAUTION 

DTC cause by burned fuse. 

(a) Remove the burned fuse. Check the resistance between 

the load side and ground where the fuse burned. Turn off 

all the switch that connecting to the fuse. If the resistance 

is almost zero, the switch and the load components 

circuit must be shorted somewhere. If the resistance is 

not zero, there is no circuit for short. But the temporaly 

shorted circuit also will cause the fuse burning. 

(b) The shortage caused by following: 

• Clipped harness 

• Damaged harness 

• Water seep into connection 

• Operation 

1 Battery 

2 Fuse 

3 Load switch 

4 Burned fuse 

5 Short position 

04 

04 

Page 703

04-8 


DIAGNOSTIC HELP - INTERMITTENT FAULT 

If an intermittent fault exists, perform diagnosis as follow: 

CAUTION 

• Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or 

circuit function returns to normal without intervention). It is important to realize that the 

symptoms described in the customer's complaint often do not recur on (1st trip) DTC visits. 

Realize also that the most frequent cause of intermittent incidents occurrences is poor 

electrical connections. Because of this, the conditions under which the incident occurred may 

not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may 

not indicate the specific malfunctioning area. 

• In this case, the maintenance staff must find out the situation in detail from the customer, ask 

the car owner for the details of driving conditions, weather conditions, frequency of occurrence 

and symptom of failure, take analysis and simulate the same or similar conditions and 

environment, then, determine if the symptom of failure is caused by vibration, temperature or 

other factors. No matter how experienced the maintenance staff are, how skilled their technique 

is, if analyzing the failure without checking, they would certainly neglect some important factors 

during repairing which causes wrong speculation and the repair work will take an indirect route 

or can’t go forward. The following checking will help to find out this kind of failure. 

1. VIBRATION METHOD. 

(a) Connector: Shake the connector lightly in vertical or 

horizontal directions, check if the wiring harness 

connector connecting the connector and corresponding 

parts is loose, the terminal is dirty, rusty, worn or bended 

and if the connection is loose because of the terminal 

extension. 

(b) Harness: Shake the harness lightly in vertical or 

horizontal directions, thoroughly check the harness 

breakaway condition in the connector connecting 

vibration section and engine/cab instruments. 

(c) Relay, part and sensor: Pat the sensor, relay and part 

considered as the failure cause lightly with hands, check 

them for failure, don't hit the relay with force, otherwise 

the relay may be open. 

Page 704


04-9 

2. HEATING METHOD. 

(a) 

If one doubtful region is considered to cause a failure, heat the part which is the most possible cause of 

failure with an electric blower or the like to check if the failure occurs. 

CAUTION 

Don’t heat to over 60℃ (the heating temperature should be in the limit of touching the part with hands); 

don’t heat the control module. 

3. SPRAYING METHOD. 

(a) If the failure is considered to occur in rainy day or wet weather, spray water to the vehicle to check if the 

failure occurs. 

CAUTION 

• Don’t spray water to the engine directly to cool the engine, sprinkle water on the front face of 

radiator to change the temperature and humidity indirectly. 

• Don’t spray water on electronic parts directly. 

• Please take extra care to sprinkle water on vehicle leaking water. 

4. ELECTRIC APPLIANCE CONNECTED FULLY METHOD. 

(a) If the failure is possible to be caused by electric overload, connect all electrical loads, including the 

heater blower, the headlamps and the rear-window defroster, to check if the failure occurs. The trouble 

location or failure part must be found out while the symptom is confirmed during the failure symptom 

simulation test. To do this, narrow the range of circuit which is possible to failure based on the symptom 

of failure before starting the test and the pre-connection of connectors, then carry out the symptom 

simulation test and judge if the circuit tested is normal. When a puzzling failure occurs, make full use of 

troubleshooting and diagnostic code list for fault analysis and diagnosis to narrow the failure range and 

find out the trouble location quickly. This method is very practical and effective. 

5. DATA FLOW CAPTURE WITH DIAGNOSTIC SCANNER. 

(a) Use the function of data flow capture on the diagnostic scanner. When seeing the data flow on the 

diagnostic scanner, make the rated data status to simulate the fault conditions based on the freezeframe 

on the diagnostic scanner. 

6. OSCILLOSCOPE METHOD. 

(a) Using the oscilloscope, capture waveform can be more helpful to find intermittent malfunction. 

7. OTHER METHODS. 

(a) Before replacing ECM of other electronic control modules in part replacing method, take full diagnosis 

for other external causes; ECM or other electronic control modules are expensive products with high 

reliability. 

04 

04 

CAUTION 

When replacing and testing possible damaged ECM or control modules, install the possible damaged 

ECM or control modules on a failure-free vehicle for testing; Don’t install new control modules on a 

failed vehicle for testing to avoid damaging the control modules. 

Page 705

04-10 


BASIC SERVICE PROCEDURE 

1. CHECK BATTERY VOLTAGE 

CAUTION 

Check when engine stops or ignition switch is OFF. 

Check result 

Result 

More than 11V 

Less than 11V 

Proceed To 

Next step 

Charge or change battery 

2. CHECK IF THE ENGINE STARTS 




3. CHECK FILTER 



NO > Replace or clean filter. 

4. CHECK IDLE SPEED 




5. CHECK FUEL PRESSURE 



NO > Eliminate fuel pressure fault, and go to next step. 

6. CHECK IGNITION 


YES > Go to fault symptom chart. 

NO > Eliminate ignition system fault. 

Page 706


04-11 

TERMINALS OF ECM 

04 

04 

ECM TERMINAL DEFINITION 


1 Ignition control L 43 - - 

2 Ground B 44 Main relay control G - W 

3 Ground B 45 - - 

4 Ignition control G 46 - - 

5 - - 47 

6 Injector 1 L - W 48 


signal + 

Downstream oxygen 

signal + 

7 Injector 3 L - P 49 ECT sensor + W - R 

8 Injector 2 L - V 50 - - 

9 Pump relay control G 51 Vehicle speed input W - G 

10 A/C low voltage output L 52 ECT sensor - W - B 

11 


sensor - 

P 53 - - 

12 SVS R - B 54 Air pressure MAP L - Y 

13 - - 55 - - 

14 - - 56 - - 

15 - - 57 - - 

16 - - 58 Knock sensor signal B - W 

17 High fan control W - B 59 Accelerator sensor + Br - G 

18 Vehicle speed R - W 60 - - 

W 

O 

Page 707

04-12 



19 MILL G - B 61 - - 

20 Idle control high A G - Br 62 - - 

21 Idle control low A G - Y 63 - - 

22 - - 64 EVAP control W - Y 

23 

24 

Heated downstream 


Heated upstream 


Y - H 65 Low fan control Y 

L-R 66 


pressure power 

25 Injector 4 L - O 67 ECU continued power W - L 

26 A/C MP IN R - W 68 ECU IG power B - G 

27 Throttle position signal V - G 69 - - 

28 - - 70 Sensor power SB 

29 - - 71 Air temperature L - W 

30 


sensor + 

31 - - 73 

O 72 - - 

Upstream/downstream 

oxygen sensor signal - 

32 - - 74 Sensor ground Br - R 

33 - - 75 ECU K signal R - L 

34 - - 76 


pressure signal - 

35 - - 77 - - 

36 - - 78 - - 

SB 

B 

Br - R 

37 Knock power O - V 79 A/C request Y - B 

38 - 80 - - 

39 - 81 - - 

40 - 

41 Idle control high B Y - P 

42 Idle control low B Br - Y 

13. 

Page 708


04-13 

CHECK ECM TERMINAL WITH MULTIMETER 

CAUTION 

The normal standard voltage of per terminal as follow “normal condition”. The table also points out the 

check condition 

04 





Idle: depress accelerator suddenly 


04 


20 Idle air control motor loop A 

41 Idle air control motor loop B 

Engine: warm condition, start 

engine 


9 Pump relay 


Engine: idle 


0 ~ 3 V 

64 EVAP solenoid 


Engine: warm condition, 3000 RPM 


0 ~ 3 V 



68 Continuity power supply 

Ignition switch: 

OFF 


79 A/C request signal Engine running, depress A/C switch - 

26 A/C feed back signal Engine running, depress A/C switch - 

19 MIL Ignition switch: OFF → ON 0 ~ 3 V 

44 Main relay 

Ignition switch: OFF 



0 ~ 3 V 

24 

Heated upstream oxygen 

sensor 



0 ~ 3 V 


23 

Heated downstream oxyge 

sensor 



0 ~ 3 V 


IAT: 0 ℃ 

3.2 ~ 3.8 V 

66 IAT sensor Ignition switch: ON 

IAT: 20 ℃ 

IAT: 40 ℃ 

IAT: 80 ℃ 

2.3 ~ 2.9 V 

1.5 ~ 2.1 V 

0.4 ~ 1.0 V 

Page 709

04-14 



47 Upstream oxygen sensor Engine: warm condition, 2000 RPM 0.1 ~ 0.9 V 

48 Downstream oxygen sensor Engine: warm condition, 2000 RPM About 100 mV 

49 ECT sensor Ignition switch: ON 

ECT: 20 ℃ 

ECT: 40 ℃ 

ECT: 80 ℃ 

2.3 ~ 2.9 V 

1.3 ~ 1.9 V 

0.3 ~ 0.9 V 

70 TPS Ignition switch: ON 

TPS: idle 0.3 ~ 1.0 V (0 %) 

Open widely 4.5 ~ 5.5 V (100 %) 

51 VSS 

30 CKP sensor 


Move forward slowly 

Start motor 

Idle 

0 ~ 5 V (repeat) 

0.4 ~ 4.0 V 

1.5 ~ 2.5 V 

3 Ground - 0 V 

Page 710


04-15 

CHECK ECM HARNESS-SIDE TERMINAL WITH A MULTIMETER 

Standard normal resistance and continuity as follow: 

No. Item Normal Condition (20 ℃ ) 


04 




5 Idle air control motor loop A, B terminal 

6 Idle air control motor loop C, D terminal 

13 ~ 16 Ω 

28 ~ 33 Ω 

04 

7 EGR solenoid valve 36 ~ 44 Ω 

8 EVAP solenoid valve 36 ~ 44 Ω 

9 ECM ground Continuity 

10 Heated oxygen sensor About 12 Ω 

5.3 ~ 6.7 Ω 

11 IAT sensor 

2.3 ~ 3.0 Ω 

1.0 ~ 1.5 Ω 

0.30 ~ 0.42 Ω 

5.1 ~ 6.5 Ω 

12 ECT sensor 

2.1 ~ 2.7 Ω 

0.9 ~ 1.3 Ω 

0.26 ~ 0.36 Ω 

Page 711

04-16 


DIAGNOSTIC SYSTEM 

1. The failure of engine electric control system is 

divided into 2 classes: 

(a) 

(b) 

(c) 

First is lighting MIL lamp (1); When the instrument MIL 

lamp lights, based on relevant requirements of national 

rules, it needs to be treated immediately, otherwise the 

system will limit the speed of the engine so as to affect 

the normal operating of vehicle. 

The other is lighting SVS lamp (2), indicating that the 

system fails and needs to be repaired in time. 

The failures of both classes should be checked with 

diagnostic scanner or special equipment with 

corresponding functions. 

NOTE 

The following matters should be noted during the engine running and service processes. 

2. The lighting of SVS lamp and MIL lamp is controlled by ECM; The special lighting of SVS lamp 

and MIL lamp after and before starting are described below: 

(a) For system without failure, the ignition switch is turned ON, the MIL lamp lights on, SVS lamp lights and 

then goes out (system self-checking). The SVS lamp and MIL lamp are off after engine starting and 

stalling. 

(b) For system with failure, the ignition switch is turned ON, the MIL lamp lights on, the SVS lamp is off and 

then lights on after self-checked; After engine starting, if the SVS lamp in failure class is defined as 

lighting on mode, the SVS lamp will light on after the requirements for SVS lamp lighting are met; if the 

MIL lamp in failure class is defined as lighting on mode, the SVS lamp will light on after the 

requirements for MIL lamp lighting are met; After engine stalling, the ignition switch is turned OFF and 

goes out after process (90s for the longest). 

3. If an engine failure that may involve the fuel injection system-electronic controlled is to be 

diagnosed and cleared, first determine if the failure is related with the fuel injection systemelectronic 

controlled. If the engine fails but the malfunction indicator lamp doesn't light, the failure 

is unrelated to the electronic control system generally. 

(a) 

The diagnostic trouble codes record and data related with sensors and actuators in ECM can be read 

by KT600 diagnostic scanner. Additional, the actuator can be positive driven by the scan tool under 

specified conditions. 

(b) 

(c) 

(d) 

DLC- data link connector. 

ECM communicate with DLC. 

Terminals in DLC arrange according to standard. 

Terminal No. Name Check Result 



6 Diagnostic signal 


commnicate) 

7 

Diagnostic 

communication K 


commnicate) 

16 Battery positive 9 ~ 14 V 

Page 712


04-17 

NOTE 

• Connect the diagnostic scanner cable to DLC. Turn the ignition switch ON. Try to open it. If 

displayed error communication on screen, then the diagnostic scanner faults . 

• If the diagnostic scanner communicates with other vehicle normally, then check the DLC on the 

original vehicle. 

04 

ENGINE CONTROL SYSTEM SELF-DIAGNOTIC ITEM 

No. 

Check Item 

04 

1 Injector 

2 Main Relay 

3 Fuel Pump 

4 Ignition Coil 

5 Oxygen Sensor 

6 EVAP Solenoid 



9 Poor Accelerator Sensor 

10 CKP Sensor 

11 Throttle Position Sensor 

12 ECT Sensor 

13 MAP/IAT Sensor 

Page 713

04-18 



NOTE 

The troubles are tested and determined by the engine control system and stored in the Engine Control 

Module (ECM); the system troubles can be current or history. 

(a) 

Current troubles: Exist in ECM currently. For example: The circuit of Engine Coolant Temperature 

(ECT) sensor is open. The current troubles must be repaired. Otherwise, they can’t be erased from 

memory. 

(b) History troubles: Have two storage types. 

• The trouble has been repaired and actual trouble has disappeared, but the memory hasn’t been erased 

from ECM. 

• The trouble occurred once and didn’t exist, but it is possible to occur again. For example: Poor contact 

of conducting wire. As the stored troubles are not current ones, it’s unnecessary to repair them before 

erased from the memory, or it can be processed referring to the trouble-shooting methods for 

intermittent malfunction. 

CAUTION 

• If the battery voltage is too low and the trouble code can’t be output normally from ECM, the 

battery voltage must be tested before checking and the voltage should not be less than 11 V. 

• When the battery or ECM connectors are disconnected, the trouble code stored in ECM will be 

erased. 

• Before connecting or disconnecting KT600 scan tool, be sure to confirm the ignition switch is in 

OFF (LOCK) position. 

CAUTION 

• Using the KT600 collective intelligence scan tool, read DTC. 

• Using the KT600 scan tool, perform the reading DTC procedure below: 

(a) Check and confirm the following conditions: 

• The throttle is closed. 

• Turn A/C switch OFF. 

• Shift transmission in neutral. 


(c) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software 

available. 


(e) Select the item, read dtc. 

(f) Check DTC and data stream. After recording, delete it (If DTC cannot be deleted, then perform the 

diagnosis procedure refering to “Diagnostics trouble code check”. Repair faults ). 

(g) Start engine and warm it to normal operating temperature. 

(h) Under one of the condition, run engine to MIL ON: 

• Simulate DTC setting condition. 

• Simulate the customer’s description. 

• Simulate the scan tool freeze data. 

(i) Use the scan tool to read the DTC in ECM. 

(j) If there are DTCs, but the data stream is normal or the function is good, then refer to the diagnostics 

help. If there are DTCs, but the stream is abnormal or the function is not good, then perform diagnosis 

procedure refering to “Diagnostics trouble code chart”. 

Page 714


04-19 

NOTE 

• Use the scan tool to delete DTCs. As soon as DTC is detected, ECM will record the vehicle and 

driving conditions as the type of freeze stream. When eliminating faults, the catching function 

will help to confirm the condition of the fault, such as warm condition, stop condition and lean 

or rich A/F ration and other data. 

• DTC setting condition: 

(a) Engine speed 

(b) VSS 

(c) ECT sensor 

(d) MAP sensor 

(e) Barometric sensor 

(f) IAT sensor 

(g) TPS 

(h) EVAP 

(i) Fuel pressure adjustment 

(j) A/C switch 

THE WAY OF CLEAR DTC 

1. Using the scan tool, clear DTC: 



available. 


(d) Select the item, clear DTC. 

04 

04 

Page 715

04-20 


CAPTURING DATA 

CAUTION 

Once DTC is captured and stored, ECM records the vehicle and driving conditions information as a 

form of rated data. During troubleshooting, the rated data can help determine if the vehicle was 

running or parked, and data of other sensors and actuators has been recorded when the trouble 

occurred. 

CAUTION 

If the DTC is detected but the trouble can’t reappear, confirm the freeze-frame rated data. ECM records 

the engine condition in form of freeze-frame data at regular intervals. The diagnostic scanner can be 

used to read several sets of freeze-frame data respectively. KT600 diagnostic scanner provides 

powerful random data flow help function. Select read data flow function menu in engine system, enter 

the data flow testing result display interface, click “?Help” button to eject the following windows: 

• Driving Record Playback 

• Calculator 

• Data Range Reference 

• Data Capture 

• Data Comparisons 

• Data Flow Settings 

• Data/Waveform Display 

• Driving Recorder Menu 

CAUTION 

The data can be used to simulate the vehicle conditions as the failure occurs. It also can help 

determine the cause of trouble and judge if it’s temporary fault. When the engine is running with 

trouble, select the menu items, read data flow (Click “?Help”)\Data Capture\Click Record\(Click 

“?Help”)\Data Comparisons. 

Page 716


04-21 

FAIL-SAFE CHART 

NOTE 

When the DTC listed below is detected, the ECM enters fail-safe mode and the MIL lights up. 


04 

1 Injector 

2 Relay 

3 Fuel pump 

4 Ignition coil 

5 Oxygen sensor 

6 EVAP solenoid valve 

7 KS 

8 VSS 

9 IAT sensor 






• Plugged injector. 


• System is out of work. 

• Can not start engine. 


• Noisy fuel pump operation. 








• Weak spark. 




• Sluggish acceleration. 



• The engine base fuel closed-loop control self-learning will be shut 

off. 

• The engine idle air control self-learning will be shut off. 

• Unstable idle or high idle. 


• The engine produces an engine knock. 

• Overheated engine. 




• Internal engine damage. 


• The engine RPM will be limited. 

• No VSS diaplay. 



• The IAT is equal to ECT. 

04 

Page 717

04-22 



10 Poor accelerator sensor 

11 CKP sensor 

12 TPS 

13 ECT sensor 

14 MAP/IAT sensor 


• Misfire. 




• Engine is hard to start. 

• The engine RPM will be limited after the engine starts. 

• The highest RPM is less than 3800 RPM. 


• No ignition signal to the ECM. 

• The tachometer does not work. 





• Engine hard to start when cold. 

• Engine hard to start when hot. 


• If the sensor circuit is shorted to power, the engine will run under the 

default values. 

• The temperature gauge indicates too high. 

• The temperature gauge indicates too low. 

• The cooling fan operates continuously on high speed. 

• The high temperature warning lamp will flash when the instrument 

panel indicates low temperature. 





Page 718


04-23 

DATA STREAM LIST/ACTIVE TEST 

1. DATA STREAM LIST. 

NOTE 

• Through reading the data stream displayed on scan tool sreen, we can check the sensor, 

actuator and switch data value but not removing any components. As the first step, this way is 

the best way to short diagnosis period . 

• The following arranged the data stream under the normal condition. It only offers to reference. 

Don’t judge a component normal or not only depend on these value. 

READ DATA STREAM PROCEDURE 

(a) 

(b) 

(c) 



Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software 

available. 


Select the item, read data sream. 

The table below lists the data found in inspection items at different states by the KT600 in “DATA LIST” 

items. 

• If no concrete specification of idle condition, the shift selector lever is in neutral position. The A/C and 

accessories switch are in the OFF position. 

(d) 

(e) 

(f) 

• Injector driving time means time is taken by crankshaft at speed of less than 250 RPM and power 

supply voltage of 11 V. 

• For new vehicle (within operation distance of 500 km), sometimes injector driving time is 10% more 

than standard time. 

• For new vehicle (within operation distance of 500 km), sometimes step length of stepper motor is more 

30 steps than standard step length. 

04 

04 

Page 719

04-24 



Oxygen sensor 



leaner when decelerating 


richer when accelerating 

Engine suddenly decelerate 

from 4000 RPM 

Engine suddenly accelerate 

≤ 0.2 V 

0.6 ~ 1 V 

MAP sensor 

IAT sensor 



sensor 

• ECT: 80 ~ 95 ℃ 

• Lamp and all other 

accessorie: OFF 



• Or engine is running 

Engine: Idle 

≤ 0.4 V 

2500 RPM 0.6 ~ 1 V 


2500 RPM - 


IAT: - 20 ℃ - 20 ℃ 

IAT: 0 ℃ 0 ℃ 

IAT: 20 ℃ 20 ℃ 

IAT: 40 ℃ 40 ℃ 

IAT: 80 ℃ 80 ℃ 

Engine: Idle 0.3 ~ 1 V (0%) 

TPS 


TP open slowly 

Increase proportionally 

Wide open 

4.5 ~ 5.5 V 

Power supply Ignition switch: ON System voltage 

Ignition switch 


Engine: Stop 

Engine: Start 

OFF 

ON 

ECT sensor 


ECT: - 20 ℃ - 20 ℃ 

ECT: 0 ℃ 0 ℃ 

ECT: 20 ℃ 20 ℃ 

ECT: 40 ℃ 40 ℃ 

ECT: 80 ℃ 80 ℃ 

Altitude: 0 m 

101 kPa 

Barometric sensor 




95 kPa 

88 kPa 


81 kPa 

A/C switch 

Engine: Idle 

(Turn A/C switch ON, A/C 

compressor works) 



OFF 

ON 

Page 720


04-25 


Injector 

Engine: Running 

ECT: 0 ℃ 

ECT: 20 ℃ 

60 ~ 90 ms 

30 ~ 5 ms 

04 

ECT: 80 ℃ 

6.7 ~ 10.1 ms 

Injector 

• ECT: 80 ~ 95 ℃ 



Engine: Idle 

2.2 ~ 3.4 ms 

2500 RPM 1.9 ~ 3.1 ms 

Engine runs at high speed 

suddenly 

Increase 

04 

Ignition coil • Engine: Warm 

Engine: Idle 

2 ~ 18 BTDC 

2500 RPM 27 ~ 47 BTDC 

Idle air control 

motor 

• ECT: 80 ~ 95 ℃ 



• Engine: Idle 

• A/C works 



2 ~ 25 steps 


A/C relay 

Engine: Warm and idle 



Not activate (Compressor 

clutch does not work) 

Activate (Compressor 

clutch works) 


• Tachometer: Connection 

Compare the values read 

from tachometer and KT600 

respectively 

The same 

ECT: -20 ℃ 

1275 ~ 1475 RPM 

CKP sensor 

ECT: 0 ℃ 

1225 ~ 1425 RPM 

Engine: Idle 

ECT: 20 ℃ 

1100 ~ 1300 RPM 

ECT: 40 ℃ 

950 ~ 1150 RPM 

ECT: 80 ℃ 

650 ~ 850 RPM 

Page 721

04-26 


2. ACTIVE TEST. 

CAUTION 

The active test function for us to check the sensor, actuator and switch data value but not removing 

any components. We can use the scan tool to perform the test. As the first step, this way is the best 

way to short diagnosis period. 

The displayed data stream when performing the active test. 



available. 


(d) Select the item, actice test. 

(e) Refer to the following chart, perform the active test. The following chart is the item which in the 

“ACTIVE TEST” of the KT600 scan tool. 

(f) When performing the function of the “ACTIVE TEST”, if there is fault phenomenon, check and repair. 

(g) After repairing, using the KT600 to perform again. 

(h) Clear DTC. 

(i) Disconnect KT600 scan tool. 

(j) Restart engine to perform test. Confirm the faults has been eliminated. 

Displayed Item Test Component Control Area Diagnosis Remark 

MIL Control MIL ON/OFF - 

EVAP EVAP solenoid valve ON/OFF - 

Fuel pump relay Fuel pump relay ON/OFF - 

Low fan Control low fan ON/OFF - 

High fan Control high fan ON/OFF - 

A/C relay Shut off A/C relay ON/OFF - 

Idle air control motor Control idle motor steps - - 

Idle air control motor Control idle motor speed - - 

Idle control motor reset Control Idle motor reset - - 

Ignition advance angle Ignition advance angle - - 

Gear signal learn 58X learn - - 

Injector (A/B/C/D) Shut off fuel injection ON/OFF - 

BLM learn - - - 

BLM reset - - - 

Fuel open control Open control - - 

Inspect catalysator at idle Check catalysator at idle - - 

Oxygen sensor response Oxygen sensor response - - 

Page 722


04-27 


Note 

If a malfunction code is displayed during the DTC check in the check mode, check the harness or connectors 

for the codes listed in the table below. For details of each code, refer to the DTC chart 

04 


P0106 

MAP / TPS Rationality 



connectors 

• ECM 

04 

P0107 

MAP Circuit Low Voltage or Open 


• Short in MAP sensor harness or connectors 

• ECM 

P0108 

MAP Circuit High Voltage 



connectors 

• ECM 

P0112 

IAT Circuit Low Voltage or Open 


• Short in IAT sensor harness or connectors 

• ECM 

P0113 

IAT Circuit High Voltage 


• Open or short in IAT sensor harness or 

connectors 

• ECM 

P0117 

Coolant Circuit Low Voltage 


• Short in ECT sensor harness or connectors 

• ECM 

P0118 

Coolant Circuit High Voltage 


• Open or short in ECT sensor harness or 

connectors 

• ECM 

P0122 

Throttle Position Low Voltage 


• Open or short in throttle position sensor 


• ECM 

P0123 

Throttle Position High Voltage 


• Short in throttle position sensor harness or 

connectors 

• ECM 

P0131 

Front Oxygen Sensor Short Low 



connectors 

• ECM 

Page 723

04-28 



P0132 

P0133 

P0134 

P0135 

P0137 

P0138 

P0140 

P0141 

Front Oxygen Sensor Short High 

Front Oxygen Sensor slow response 

Front Oxygen Sensor Inadequate 


Front Oxygen Heater Fault 

Rear Oxygen Sensor Short Low 

Rear Oxygen Sensor Short High 

Rear Oxygen Sensor Inadequate 


Rear Oxygen Heater Fault 



connectors 

• ECM 




• Upstream oxygen sensor heater 

• Relay 



• Injector 

• ECM 


• Open in upstream oxygensensor harness or 

connectors 

• ECM 


• Open or short in upstream oxygen heater 


• ECM 




• ECM 




• ECM 


• Open in downstream oxygen sensor harness 

or connectors 

• ECM 

• Downstream oxygen heater 

• Open or short in downstream oxygen heater 


• ECM 

Page 724


04-29 


P0171 

P0172 

Fuel Trim BLM Learn Too Lean 

Fuel Trim BLM Learn Too Rich 


• Injector blockage 



• Open or short in oxygen sensor circuit 


• ECM 

• Injector leak or blockage 


• Engine coolant temperature sensor 


• Gas leakage in exhaust system 

• Open or short in oxygen sensor harness or 

connectors 


• ECM 

04 

04 

P0201 




• ECM 

P0202 




• ECM 

P0203 




• ECM 

P0204 




• ECM 

P0230 

Fuel Pump Relay Fault 

• Pump relay 

• Pump relay harness or connectors 

• ECM 

P0300 

The Engine Misfire Fault 

• Open or short in engine wire 


• Injector 




• Valve timing 

• PCV hose connection 

• PCV hose 

• ECM 

Page 725

04-30 



P0324 

P0325 

P0335 

P0336 

Knock System Fault 

Knock Sensor Fault 

CKP Sensor Circuit No Signal 

CKP Sensor Circuit Noisy Signal 



• ECM 



• ECM 

• Open or short in CKP sensor harness or 

connectors 

• ECM 


• Open or short in CKP sensorharness or 

connectors 

• ECM 







P0420 

P0443 

P0480 

P0481 

P0502 

P0506 

P0507 

Catalyst failure 

Purge Solenoid Diagnostic 

Fan 1 Fault 

Fan 2 Fault 

Vehicle Speed Sensor No Signal 

Idle Speed Control - Low RPM 

Idle Speed Control - High RPM 

• Catalyst harness or connectors 

• Catalyst 

• Purge solenoid diagnostic harness or 

connectors open or short 

• Purge solenoid diagnostic 

• ECM 

• Fan1 


• ECM 

• Fan 2 


• ECM 

• Vehicle speed sensor 

• Vehicle speed sensor harness or connectors 




• ECM 




• ECM 

Page 726


04-31 


P0562 

Voltage Low Diagnostics 

• Battery 

• Generator 

• Power supply harness or connectors 

04 

P0563 

Voltage High Diagnostics 

• Generator 

• ECM 

P0645 

A/C clutch output circuit fault 

• A/C clutch 

• A/C clutch harness or connectors 

04 

P0650 

Malfunction Indicator Lamp Fault 

• Malfunction indicator lamp 

• Malfunction indicator lamp harness or 

connectors 

• ECM 

P0685 

Main Power Relay Fault 

• Main Power Relay 

• Main Power Relay harness or connectors 

• ECM 

P1167 

Front Oxygen Sensor Signal Rich in 

DFCO 







• ECM 

P1171 

Front Oxygen Sensor Signal Lean In PE 







• ECM 

P1336 

TEC Not Learned 

• CKP sensor is not installed 

• ECM 

P1391 

G Sensor Rationality 


• ECM 

P1392 

G sensor short low 



• ECM 

P1393 

G Sensor Short High 



• ECM 

P1659 

SVS Light Fault 

• SVS Light harness or connector 

• Instrument Panel 

Page 727

04-32 


DTC DIAGNOSTIC 

P0107 - MAP CIRCUIT LOW VOLTAGE OR OPEN 

P0108 - MAP CIRCUIT HIGH VOLTAGE 

P0112 - IAT CIRCUIT LOW VOLTAGE OR OPEN 

P0113 - IAT CIRCUIT HIGH VOLTAGE 

DESCRIPTION 

MT20U2 adopted speed-density air measurement method to check the air intake volume into the engine so as 

to control the fuel injection pulse width for the precise control of engine power output. Meanwhile, this system 

adopted intake pressure cylinder determination technology and the intake air sensor is installed near the inlet 

opening of cylinder 4 intake manifold. At the moment when the throttle is opened, there will be one 

instantaneous pressure drop at the sensor, of which the value is about 1 kPa. When the ECM detected and 

received this instantaneous pressure drop, the ECM will determine the compression upper dead center signal 

after software diagnosis treatment (its functions is similar with the camshaft position sensor of traditional 

electric injection system, also referred as phase sensor). 


Page 728


04-33 


P0107 

MAP sensor circuit low 





input signal is less than 



• MAP sensor loose connector 

• Open or short in MAP sensor 


• Short circuit in MAP sensor 


• Open circuit in MAP sensor 

5V circuit 

• Open in MAP sensor ground 

circuit 

• ECM 

04 

04 

P0108 

MAP sensor circuit high 

voltage 




input signal is higher than 



• Short in MAP sensor signal 

circuit 

• Short in MAP sensor 5V 

power circuit 

• ECM 

P0112 

IAT sensor circuit low 







continued to be 0.2 V or lower 

(corresponding to an intake air 

temperature of 125 ℃ or 

lower) for 4 seconds. 


• Short in IAT sensor 5 V 


• ECM 

P0113 

IAT sensor circuit high 

voltage 







higher (corresponding to an 

intake air temperature of -45 

℃ or lower) for 4 seconds. 


• Open in IAT sensor 5 V 


• ECM 

NOTE 





terminals. 


Page 729

04-34 




(a) 

(b) 

(c) 

(d) 



Perform the reading data stream procedure. 

Read IAT value displayed on the KT600 scan tool. 

Displayed DTC And Pressure Proceed To Malfunction 

• P0108 


Next step Short to voltage 

• P0107 


• P0107 or P0108 

• Pressure normal 

Next step 


Open or short to ground 




NO > If there an open or short circuit, go to next step. 


GROUND) 

(a) 

(b) 

(c) 




(d) 


below. 



E006 (2) - Ground 


5.0 ± 0.25 V 




Page 730


04-35 


ECM) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 



E001 (76) - E006 (4) 

E001 (71) - E006 (3) 


< 2 Ω 

04 




4. CHECK MAP SIGNAL 


(b) Disconnect the E006 intake air temperature pressure sensor. 

(c) Start engine. 

(d) 


below. 




E006(2) - Ground • Idle: 5.0 ± 0.25 V 

E006(4) - Ground 

• Idle: 1.3 V 

• No load condition, opening 

throttle slowly: 1.3 V 

• Open quickly: 4 V, then return 

back to 1.5 V 




Page 731

04-36 



GROUND) 

(a) 

(b) 

(c) 

(d) 






below. 



E006 (4) - Ground 


0 V 




Page 732


04-37 

P0117 - COOLANT CIRCUIT LOW VOLTAGE 

P0118 - COOLANT CIRCUIT HIGH VOLTAGE 

1 Electric Appliance Connector 

04 

2 Cabinet 

3 NTC Resistance 

04 

DESCRIPTION 

This sensor is one Negative Temperature Coefficient (NTC) thermistance, of which the resistance will reduce 

following the increasing of the temperature in non-linear relation. When the coolant temperature is low, the 

resistance in the thermistor increases. When the temperature is high, theresistance drops. The variations in 

resistance are reflected in the voltage output from the sensor. 

The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. 


Page 733

04-38 



P0117 



low voltage 





0.2 V or lower (corresponding to an intake 

airtemperature of 145 ℃ or higher) for 4 

seconds 


• Short in ECT 

sensor circuit 

• ECM 

P0118 



high voltage 





4.6 V or higher (corresponding to an 

intakeair temperature of -45 ℃ or lower) for 

4 seconds 


• Open or short in 

ECT sensor 

circuit 

• ECM 

NOTE 





terminals. 

• If the ECM detects the DTC P0117 or P0118, it operates the fail–safe function in which the 

engine coolant temperature is assumed to be a default value. At the same time, with the ignition 

switch ON, the cooling fans will operate at high speed. The fail–safe function will not untill the 

ECM detects the acceptance condition. 

• If any DTC is detected, using the scan tool, select the item, read the data stream. 

Displayed Temperature 

Malfunction 

-40 °C Open circuit 

140 °C Short circuit 

Page 734


04-39 



(a) Start the engine and warm it to normal operating temperature. 

(b) With the KT600 scan tool, perform the DTC confirming procedure. 

(c) Read sensor value displayed on the KT600 scan tool. 

(d) Read sensor value displayed on the KT600 scan tool. 

Display DTC And Temperature Proceed To Malfunction 

04 

04 

• P0118 

• - 40 °C 

• P0117 

• 140 °C or more 

• P0117 or P0118 

• 80°C - 100°C 

Next step 

Step 5 


Open or short to power 

Short to ground 




NO > If there is an open circuit, go to next step. 

If there is a short circuit, go to step 5. 


(a) 

(b) 

(c) 

(d) 

(e) 

(f) 


Disconnect the E010 ECT sensor connector 

Connect terminals 1 and 2 of the engine coolant temperature sensor connector E010 on the wire 

harness side. 


Select the item, read data stream. 

Read ECT value displayed on the KT600 scan tool. 

Temperature value: ≥ 140 °C 


YES > Replace engine coolant temperature sensor, clear the DTC. 


Page 735

04-40 


3. CHECK HARNESS AND CONNECTOR (COOLANT TEMPERATURE SENSOR - GROUND) 

(a) 

(b) 

(c) 




(d) 


below. 



E010 (2) - Ground 


4.5 ~ 5.0 V 




4. CHECK HARNESS AND CONNECTOR (COOLANT TEMPERATURE SENSOR - ECM) 

(a) 

(b) 

(c) 



Disconnect the E001 ECM. 

(d) 


table below. 



E010 (1) - E001 (52) 


< 2 Ω 


YES > Replace the coolant temperature sensor. 


Page 736


04-41 

P0122 - THROTTLE POSITION LOW VOLTAGE 

P0123 - THROTTLE POSITION HIGH VOLTAGE 

DESCRIPTION 

04 

MT20U2 Throttle Position Sensor (TPS) is used to provide throttle angle, angle speed and engine idle position 

information to the ECM, based on which the ECM can obtain the engine load information, operating mode 

(such as start, idle, reverse towing, partial load, full load) and acceleration & deceleration information. This 

sensor is of three-line type and the ECM will check the throttle open extent by monitoring the voltage variation. 


04 


P0122 

Throttle position low 

voltage 




• Sensor output voltage has continued 

to be 0.2V or lower for 4 seconds 


• Open or short in TPS circuit 

• ECM 

P0123 

Throttle position 

high voltage 




• Setting the closed throttle position 

switch ON, the sensor output 

voltage has continued to be 2 V or 

higher for 4 seconds 


• Short in TPS circuit 

• ECM 

NOTE 





terminals. 


Page 737

04-42 




(a) 

(b) 

(c) 

(d) 



Read TPS value displayed on the KT600 scan tool. 

Read TPS signal data displayed on the KT600 scan tool 


• P0122 ( < 0.2 V) Step 4 Short to voltage 

• P0123 ( > 2 V) Next step Open or short to ground 

• P0122 or P0123 

• TPS signal is normal 





NO > If there is an open or short circuit, go to next step. 


(a) 

(b) 

(c) 




(d) 


below. 



E009 (1) - Ground 


4.5 ~ 5.0 V 




3. CHECK THROTTLE POSITION SENSOR SIGNAL 


(b) Jump wire at terminals 2 and 3 of the E009 TPS connector. 

(c) Perform reading sensor data stream procedure with scan tool. 

Voltage value: 4 V 




Page 738


04-43 

4. CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - ECM) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

E009 (2) - E001 (74) 

< 2 Ω 





(a) 

(b) 

(c) 

(d) 





(e) 


below. 



E009 (3) - Ground 


0 V 


YES > Replace the throttle position sensor. 


Page 739

04-44 


P1167 - FRONT OXYGEN SENSOR SIGNAL RICH IN DFCO 

P1171 - FRONT OXYGEN SENSOR SIGNAL LEAN IN PE 

P0131 - FRONT OXYGEN SENSOR SHORT LOW 

P0132 - FRONT OXYGEN SENSOR SHORT HIGH 

P0133 - FRONT OXYGEN SENSOR RESPONSE 

P0134 - FRONT OXYGEN SENSOR OPEN 

P0135 - FRONT OXYGEN SENSOR HEATER FAULT 

DESCRIPTION 

1 Air 

2 Case 

3 Solid electrolyte 

4 Platinum electrode 

5 Heater 

6 Lining 

7 Exhaust gas 

8 Rich 

9 Air/fuel ratio 

10 Lean 

The Engine Control Module (ECM) supplies a voltage of about 450 mV between the ECM terminals 62 and 6. 

The oxygen sensor varies the voltage within a range of about 1V if the exhaust is rich, down to about 0.1 V if 

the exhaust is lean. The oxygen sensor is like an open circuit and produces no voltage when it is below 360 ℃ 

. An open oxygen sensor circuit or a cold oxygen sensor causes open-loop operation. 


P0131 


short low 

• The engine controls system 

is in closed loop 

• The engine speed is below 

6000 RPM 






sensor 


oxygen sensor 

circuit 

• ECM 

P0132 


short high 




higher for at least 0.2 

seconds 


sensor 


oxygen sensor 

circuit 

• ECM 

Page 740


04-45 


P0134 


open 



continued to be between 

0.42 ~ 0.48 V 


sensor 


oxygen sensor 

circuit 

• ECM 

04 

P0133 


response 





• DTC P0135、 P01167 are 

not set 


sensor 


oxygen sensor 

circuit 

• ECM 

04 

P0135 


heater fault 





• P1171DTC P0133、P01167 

are not set 


sensor 


oxygen sensor 

circuit 

• ECM 

P1167 


signal rich in dfco 





• DTC P01171、 P0133 are 

not set 


sensor 

• ECM 

P1171 


signal lean in pe 





• DTC P0135、 P01167 are 

not set 


sensor 

• ECM 

NOTE 





terminals. 


Page 741

04-46 


DIAGNOSIC HELP 

• Normal scan tool voltage varies between 0.1 to 1.0 V while in closed-loop. 

• Check oxygen sensor harness, maybe the oxygen sensor is not well installed. It touch the exhaust pipe. 

• Check if there is intermittent ground existent between ECM and oxygen sensor. 

• Perform an injector balance test. Check if the lean mixture was caused by injector blocking. 

• The vacuum leaking of crankcase cause lean mixture. 

• The out air enter into exhaust pipe and through the oxygen sensor by the leaking of exhaust manifold 

wsaher. 



(a) 

(b) 

(c) 

(d) 



Read oxygen sensor value displayed on the KT600 scan tool. 


Result 


P0131 ( < 0.21 V) Step 6 Short to ground 

P0132 ( > 4.8 V) Step 7 Short to power 

P0134 (0.42 V ~ 0.48 V ) Next step Open 


(a) 

(b) 

(c) 




(d) 


below. 



E007 (1) - E007 (2) 


0.45 V 


YES > Replace the front oxygen sensor. 


Page 742


04-47 


(a) 

(b) 

(c) 




04 

(d) 


below. 




04 

E007 (2) - Ground 

0.45 V 





(a) 

(b) 

(c) 




(d) 


table below. 



E007 (2) - E001 (47) 

E007 (1) - E001 (73) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 





Page 743

04-48 


(e) 


table below. 



E007 (2) - Ground 

E007 (1) - Ground 


≥ 1MΩ 





(a) 

(b) 

(c) 




(d) 


below. 



E007 (4) - Ground 







(a) 

(b) 

(c) 




(d) 


table below. 

Standard resistance(check for open) 


E007 (3) - E001 (24) 


< 2 Ω 

Page 744


04-49 





04 

(a) 

(b) 

(c) 




(d) 


table below. 


04 


E007 (3) - Ground 


≥ 1MΩ 




Page 745

04-50 


P0335 - CRANKSHAFT POSITION SENSOR CIRCUIT NO SIGNAL 

P0336 - CRANKSHAFT POSITION SENSOR CIRCUIT NOISY SIGNAL 

1 Shielded cable 

2 Permanent magnet 

3 Sensor case 

4 Mounting bracket 

5 Soft magnet iron core 

6 Coil 

7 Air clearance 

DESCRIPTION 

The 58X reference signal is produced by the Crankshaft Position (CKP) sensor. The Engine Control Module 

(ECM) uses the 58X reference signal to calculate engine RPM and CKP. The ECM constantly monitors the 

number of pulses on the 58X reference circuit and compares them to the number of MAP signal being 

received. If the ECM receives and incorrect number of pulses on the 58X reference circuit, DTC P0336 will be 

set. 


Page 746


04-51 


P0336 

CKP sensor circuit 

noisy signal 


• ECM received no or 

error signal 




circuit 

• ECM 

04 

P0335 

CKP sensor circuit no 

signal 

• ECM received no signal 




circuit 

• ECM 

04 

NOTE 





terminals. 



1. READ VALUE AND DTC USING SCAN TOOL 

(a) 

(b) 

(c) 

(d) 

(e) 



Read CKP sensor value displayed on the KT600 scan tool. 


Using scan tool, perform the CKP sensor waveform confirming procedure. 




2. CHECK CKP SIGNAL USING THE OSCILLOSCOPE 

(f) 





Page 747

04-52 


3. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM) 

(a) 

(b) 

(c) 




(d) 


table below. 



E008 (1) - E001 (30) 

E008 (2) - E001 (11) 


< 2 Ω 





(a) 

(b) 



(c) 


table below. 



E008 (3) - Ground 


< 2 Ω 




Page 748


04-53 

5. CHECK CRANKSHAFT POSITION SENSOR 

(a) 

Replace the CKP sensor with a known good one. 

(b) 


04 

04 


YES > Replace the crankshaft position sensor. 



(a) 

(b) 

(c) 





table below. 

• Standard resistance (check for short) 


E008 (3) - Ground 

E008 (1) - Ground 


≥ 1MΩ 





(a) 

(b) 

(c) 




Page 749

04-54 


(d) 


below. 



E008 (1) - Ground 


0 V 




8. CHECK CKP SENSOR SIGNAL PLATE 

(a) 


(b) 

(c) 

Check for a problem such as scrap, dirt, foreign body 

and loose with the 58X CKP signal plate and signal 

tooth. 

Check the mounting clearance of the CKP sensor. 

Clearance: 0.3 ~ 1.5 mm 

9. Is the check result normal? 


NO > Remove any foreign obstacles, clean 58X signal tooth. If there is fault present, replace 58X signal 

plate. 

Page 750


04-55 

P0324 - KNOCK SYSTEM FAULT 

P0325 - KNOCK SENSOR FAULT 

No. 

Item 

1 1 ms\DIV 

04 

04 

DESCRIPTION 

The Knock Sensor (KS) system is used to detect engine detonation, allowing the Engine Control Module 

(ECM) to retard ignition control spark timing based on the KS signal being received. The KS produces an AC 

signal. The KS signal’s amplitude and frequency depend upon the amount of knock being experienced. The 

ECM contains a non-replaceable knock filter module called a Signal-to-noise Enhancement Filter (SNEF) 

module. This filter module in the ECM determines whether knock is occurring by comparing the signal level on 

the KS circuit with the voltage level on the noise channel. The noise channel allows the ECM to reject any false 

knock signal by knowing the amount of normal engine mechanical noise present. Normal engine noise varies 

depending on engine speed and load. When the ECM determines that an abnormally low noise channel 

voltage level is being experienced, DTC P0324 & P0325 will be set. 


Page 751

04-56 



P0324 

Knock system fault 



2,500 RPM 

• ECM detect that the KS 

signal is out of the range 



• Open or short in KS circuit 

• ECM 

P0325 

Knock sensor fault 



2,500 RPM 

• The knock sensor voltage is 

below 0.2 V 



• Short in KS circuit 

• ECM 

NOTE 





terminals. 




(a) 

(b) 

(c) 



Driving vehicle, read knock sensor value displayed on the KT600 scan tool. 

Result: Feed back value change 

YES > Check intermittent problems. 


2. CHECK HARNESS AND CONNECTOR (KNOCK SENSOR - ECM) 

(a) 

(b) 

(c) 




(d) 


table below. 



E011 (1) - E001 (58) 

E011 (2) - E001 (37) 


< 2 Ω 

Page 752


04-57 





04 

(a) 

(b) 

(c) 




(d) 


table below. 


04 


E011 (1) - Ground 

E011 (2) - Ground 


≥ 1 MΩ 





(a) 

(b) 

(c) 

(d) 


Connect the E001 ECM connector. 



(e) 


below. 



E011 (1) - Ground 


5 V 


YES > Replace the knock sensor. 


Page 753

04-58 



Use the table below to help you find the cause of the problem. The numbers indicate thepriority of the likely 


ENGINE CONTROL SYSTEM SYMPTOM 

Symptom 

Check Order 

Communication with KT600 is impossible KT600 failed to communicate with ECM. 1 

Starting 

Idling stability (Improper idling) 

Idling stability (Engine stalls) 

Driving 

Engine cranks, but will not start. 2 

When engine is cold, it starts difficultly, body shock. 3 

Unstable idle (Rough idle, hunting). 4 

Idle speed is high (Improper idle speed). 5 

When the engine is cold, it stalls (At idle). 6 

The engine stalls when accelerating. 7 

Accelerated reaction is slow, acceleraton 

disturbance. 

Poor acceleration capability. 9 

8 

ENGINE CONTROL SYSTEM SYMPTOM DESCRIPTION 

Item 

Symptom 

Starting 


(Improper idling) 


(Engine stalls) 

Driving 

Failed to start 

Hard starting 

Hunting 

Incorrect idle speed 

Engine will stall when it is cold (Idle) 

Engine stalls when moving 

Accelerated reaction is slow, 

acceleraton disturbance 

Poor acceleration capability 

The starter is used to crank the engine, but there is 

no combustion within the cylinders, and the engine 

does not start. 

Engine starts after cranking a while. 

Engine speed does not remain constant. 

The engine does not idle at the usual correct speed. 

Engine stall easily when ECT is low after it start for 

a while. 

The engine stalls when the accelerator pedal is 

depressed. 

Hesitation is the delay in response of the vehicle 

speed that occurs when the accelerator is 

depressed in order to accelerate from the speed at 

which the vehicle is now traveling or a temporary 

drop in vehicle speed during such acceleration. 

Serious hesitation is called “sag”. 

Poor acceleration is the inability to obtain an 

acceleration corresponding to the degree of throttle 

opening (Even though acceleration is smooth) or 

the inability to reach maximum speed. 

Page 754


04-59 

ENGINE SYMPTOM DIAGNOSTIC 

CAUTION 

• Some symptom diagnostics require visual and outer inspection. Perform these inspections 

first. These inspection can select a problem that needn’t check deeply. And it can save the 

expensive time. 

• Inquiry customer about the fault after taking over vehicle: 

(a) The first time when the faults appear. 

(b) The engine temperature when the faults appear. 

(c) The vehicle roadhaul. 

(d) The road which the customer usually drives. 

(e) The vehicle maintenace log. 

(f) The vehicle maintenace record. 

(g) Is there any aftermarket retrofit device on vehicle? After the inspection, the checking time will be 

shorted. 

• Perform the primary inspection. 

(a) Confirm the engine MIL is normal. If it is not good, repair it first. 

(b) Confirm that no DTC exists in the ECM. If DTC exists, refer to the DTC chart to eliminate it. 

(c) With the scan tool to inspect the engine control system hot data stream. And confirm them in the normal 

range. 

(d) Confirm the fault and the reason. 

(e) When repairing the vehicle, confirm the repair record. 

• Visual inspection. 




(d) Check the ignition system for any broken or aging spark plug wires and verify the engine firing order is 

correct. 

(e) Check the engine ground cable and verify a clean and tight connection. 

(f) Check the sensors and actuators electrical connectors and verify good contact and tight connection. 

CAUTION 

• The carbon deposits in the back of the valve will cause the poor engine acceration, unsteady 

idling, starting difficulty in cold temperature, ect. 

• Valve, carbon deposits in the combustion chamber. 

Determined by the ECI (Electronic Controlled Injection) engine control features, the cylinder carries out 

the fuel injection first and then the ignition at each running. The ignition is cut off immediately the engine 

is shut off, but the petrol injected in this running cycle can’t be recovered and is attached on the intake 

valve and the combustion chamber wall. The petrol is volatile, but the waxes and colloids in the petrol 

remain. In the long term, the waxes and colloids become thick and hard after repeatedly heated, so the 

carbon deposits are formed. If the engine burns oil or the filled petrol quality is poor and with many 

impurities, the valve carbon deposits are more severe and the formation rate is faster. As the carbon 

deposit structure is similar to the sponge, after the valve carbon deposits are formed, part of fuel 

injected into the cylinder every time will be attached, making the air-fuel mixture strength actually into 

the cylinder thin, which causes poor engine running, difficult starting, rough idling, poor accelerating, 

backfire during emergency fueling, exhaust exceeding the standards, consumption increasing and 

other abnormal symptoms. If the carbon deposits are more severe, they may lead to improperly sealed 

valve, and the cylinder can't work without cylinder pressure, or even the valve is adhered and can’t 

return. Now the motion interference occurs between the valve and the piston which would damage the 

engine finally. 

04 

04 

Page 755

04-60 


• Carbon deposits in the intake manifold. 

As the running of each piston in the whole engine is not synchronous, when the engine is shut off, 

some intake valves in some cylinders can’t be fully closed, the unburned fuel evaporates and is 

oxidized continuously thus to form some softer black carbon deposits in the intake pipe, especially at 

the rear of the throttle valve. On the one hand, the carbon deposits make the intake pipe wall coarse; 

the air forms a spiral vortex at the coarse section, affecting the air intake effect and the quality of air-fuel 

mixture. On the other hand, the carbon deposits block the idling aisle, making the idling speed control 

device clamped or exceeding its regulation range, leading to low idling speed and rough idling. 

• If the carbon deposit in the cylinder is too much, usually it will cause the high pressure. But the 

vehicle has more mileage, there is much more carbon deposit in the cylinder. Because of the 

wear, the cylinder pressure will decline. So it is not the good way to judge if there is the carbon 

deposit in the cylinder . The good way is: 

(a) With the electronic endoscopy. 

(b) Inspect the feedback voltage. 

(c) Disassembly way. 

• It’s a gradual process from the carbon deposit formation to aggregation and to affecting engine 

normal running. When the engine cold starting is hard and the idling is rough, it shows that the 

carbon deposits are quite serious, if further it will cause misfire and cylinder fuel cut, until the 

engine unable to start. When the cold starting is hard, check the engine at once, clean the valve 

carbon deposits in time after removing other factors to avoid damage caused by removing the 

cylinder cover. 

• Should pay attention to the following for the danger of the carbon deposit: 

(a) Fill with the high quality gasoline. 

(b) Don’t idle long. 

(c) Run at high speed usually. 

Page 756


04-61 

COMMUNICATION WITH KT600 IS IMPOSSIBLE 

Symptom Diagnosic Logic Suspect Area 

Communication with KT600 is 

impossible 


1. READ VALUE OF SCAN TOOL 

• No power supply 

• Open in the harness of ECMand 


• ECM 

• ECM power supply 

• Open in the harness of ECM and 


• ECM 

04 

04 


(b) Connect the KT600 scan tool to the Diagnostic Link Connector (DLC) - use the most current software 

available, press the POWER key to start the KT600. 



(e) Using the KT600 scan tool, read data stream displayed on the screen. 

Whether the ECM data stream can be read? 



2. CHECK DLC COMMUNICATION K 


(b) Disconnect the E001ECM connector. 

(c) Check the continuity between the data link connector M002 terminal 7 - ECM connector terminal 75. 

Resistance:< 2 Ω 

(d) Using the multimeter, check the continuity between the data link connector M002 terminal 7 and 

ground. 

Resistance:≥ 1 MΩ 

(e) Turn the ignition switch ON, using the multimeter, check the voltage between data link connector M002 

terminal 7 and ground. 

Voltage: 0 V 




Page 757

04-62 


ENGINE CRANKS, BUT WILL NOT START 


Engine cranks, but will not 

start 

• Engine run normally 

• Battery is normal 


• No phenomenon of 

burning when cranking 

the engine 

• Spark plugs are fouled 

defective 

• No supply of fuel to the 

combustion chamber 

is defective 

• Cylinder pressure is 

not normal 




pump system 


injector 

• Leakage or 

malfunction of intake 

air system 

• ECM 

NOTE 

If the engine can’t be started with starting symptom, it shows the ignition system, fuel system and 

control system don’t fully lose the functions even though work normally. The cause of this starting 

failure is nothing but may be that the high tension sparks are too weak, the ignition is improper, the air/ 

fuel mixture is too thin or thick, or the cylinder pressure is too low. In general, first check the ignition 

system, then the air intake system, the fuel system, the control system, the engine cylinder pressure at 

last. 


1. INSPECTION MIL AND DTC 





2. VISUAL INSPECTION 
















Page 758


04-63 









04 

04 








(b) Read the displayed CKP sensor value. It should be within the specified value. 




7. CHECK THE THROTTLE BODY 

(a) Depress the accelerator slightly. 



YES > Check throttle body and idle air path. Clear the carbon deposit. Disconnect the idle air control motor 

connector, Check whether there is 12 V. And the resistance value is 28 ~ 33Ω when the temperature is 

20 ℃ . Check whether the idle air control motor is clip. If necesasary, repair or replace it. 

CAUTION 


makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The 

borning will not be normal. And the usual reasons of unnormal borning are: carbon and grease, grease 

beside the throttle air path, carbon and grease with the idle air control motor. 







(e) Read the displayed ECT and MAP/IAT sensor value. It should reach the specified value. 




Page 759

04-64 


9. CHECK THE FUEL SYSTEM CIRCUIT 

(a) 


(b) Check whether the pump relay and pump operate normally. 





(a) Release the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”) 

(b) Check the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”) 
















CAUTION 



WARNING 




• Service vehicles in well-ventilated areas and avoid ignition sources. 




NO > Clear the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault is 

not present. If not OK, go to next step. 


(a) Using the fuel return blocker, clamping the return pipe, make the system fuel can not return. 




Page 760


04-65 


(a) 


CAUTION 


(b) Turn the ignition switch ON (Do not start the engine). Apply pressure on the fuel pipe. Check whether 

fuel leaks at fuel pipe connection. 




04 

04 









15. CHECK ENGINE VALVE-TIMING 

(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose. Whether 

the jumping over teeth exists. 








• Disassembly the engine inner faults. 




Page 761

04-66 


ENGINE STARTS DIFFICULTILY WHEN IT IS COLD 


Engine starts difficultily 

when it is cold (idle) 

• Engine runs normally 


• It needs several times 

for engine starts 

successfully when it is 

cold 

1. A/F is not correct 

2. Carbon deposit at 

valve 

3. Operation condition is 

not equal between 

every cylinder 

4. ECT sensor is fault 

5. Others: 

• MAP/IAT sensor 

• Idle step motor 

• Fuel quality 


• Supply fuel system 

• Injector 

• Leakage of the inlet 

system 

• Cylinder compression 

pressure 

• Engine management 

system 

• Battery 

• ECM 

NOTE 

Hard engine starting refers to that the starter is able to drive the engine to run in normal speed with 

clear starting symptom, but the engine only run after continuous starting or the starter driving for a 

long time. For the failure of hard starting, determine whether the occurrence is in cold starting or hot 

starting, or both of them. The cause of this failure is from the fuel injection system generally. Check it 

in the following method. 





YES > Refer to DTC chart. Perform the diagnostic procedure. 




(b) Check following after opening the engine hood: 

• Air filter. 

• Leakage of the intake manifold. 




3. CHECK BATTERY 

(a) Check the battery voltage when cranking the engine. 

Battery voltage: ≥ 9.6 V 



NO > Charge or replace battery. 

Page 762


04-67 

4. CHECK STARTER 

(a) Check whether the starter or the starter circuit exist fault. 




04 



(b) Read the displayed CKP sensor value. 




04 

6. CHECK ECT SENSOR 


(b) With the multimeter to check the ECT sensor or feedback voltage. (or with a 1.5 kΩ resistance, replace 

the ECT sensor. Start engine. If OK, it means that the ECT sensor isnot normal). 




7. CHECK MAP SENSOR 

(a) Check MAP sensor after starting engine successfully. 

Pressure value: 35 ~ 55 kPa 



NO > Eliminate the leakage of intake system. 

8. CHECK THROTTLE BODY 

(a) Depress the accelerator slightly. Start egnine. 





CAUTION 


makes the ECM control the idle air impossilly. And it will cause the A\F too lean or too rich. The borning 




(a) Disconnect the idle air control motor connector. Check whether there is 12 V. And the resistance value 

is 28 ~ 33 Ω when the temperature is 20 ℃ . 

(b) Remove the idle air control motor to test: 


Page 763

04-68 





NO > Repair or replace the idle control motor. 





(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT sensor value. 


















(a) Remove the injector connector. 




CAUTION 



WARNING 








NO > Clean the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault 

isnot present. If not OK, go to next step. 

Page 764


04-69 


(a) 

(b) 

Using the fuel return blocker, and clamping the return pipe, make the system fuel not return. 

Check whether the system pressure can establish again quickly. 




(a) 


CAUTION 



leakage at fuel pipe connection. 





04 

04 













(b) Check whether there is carbon deposit in plug, carbon tracking,residual current in insulating ceramics 











Page 765

04-70 











(a) Check whether the engine valve-timing gear mark is aligned, damaged and the belt is loose. 












valve. 




Page 766


04-71 

UNSTABLE IDLE 


Unstable idle (Rough idle, 

hunting) 

The engine cannot keep 

stability 

• The ignition system, 

air-fuel. 

• Air ratio 

• IAC motor 

• Compression 

pressure is too low 



• Malfunction of air-fuel 



system 


• Drawing air into intake 

air system 

• ECM 

04 

04 

NOTE 

The unstable idle is the usually faulty. It has many kinds of types. It includes unstable, misfire, etc. 

When performing the diagnosis and elimination, should analyse according to the specific symptom. 










(c) Inspect the engine operating condition. 

(d) Inspect the tachometer if the pointer deviates the idle target value. 

(e) Inspect if the idle trembles is normal or load reasons, such as: A/C, lighting, push the lever into gear, 


(f) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses. 

(g) Check whether the exhaust pipe emit black smoke. 

(h) Check whether there is unburned petrol fumes. 

(i) Check whether the throttle cable is adjusted to be appropriate. 




3. CHECK THE THROTTLE AND IDLE CONTROL MOTOR 


(b) Start engine and runs at idle. 


(d) Perform the idle air control motor test. 



Page 767

04-72 


(e) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is 

28 ~ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary, 


(f) Remove the idle air control motor . Connect the connector: 

• Check whether the idle air control motor can extend-retract when turning the switch off. 




NO > Repair or replace idle control motor. 

4. CHECK ENGINE IGNITION SYSTEM 


(b) Brennschluss one by one. 


CAUTION 

It is better that use the active test function of the scan tool to perform the brennschluss test. If without 

the scan tool or the scan tool wirhout the function, the brennschluss period shoul not be too long, if 

not, the Three Way Catalytic Converter (TWC) will be damaged. 









• Connect the spark plug to spark plug wire. Ground the spark plug on the cylinder block. 

• Start the engine to test the secondary ignition system with the spark plugs removed. 

normal result: A strong blue spark visible is at each spark plug while cranking the engine 











Page 768


04-73 


(a) 










can feel vibration, or with the voice-tool, touch the injector, the action voice should be hearded). 




gasoline. If not OK, replace it. 

CAUTION 



WARNING 






04 

04 




















Page 769

04-74 



(a) 


CAUTION 

Check connectors for fuel leakage as following: 







12. CHECK INTAKE AND EXHAUST SYSTEM 




(d) Check the sensors and actuators electrical connectors and verify good contact and tight connection. 

(e) Check the PCV valve. 

(f) Check whether the EVAP system leakage. 

(g) Checkif the fuel pressure regulator vacuum pipe broken, kinked or crack. 

(h) Check whether the Three-Way Catalytic Converter (TWC) is blocked. 

(i) Check whether the throttle body gasket leakage. 

(j) Check whether the intake manifold gasket leakage. 



NO > Repair or replace the faulty components. 


(a) Check whether the installation of the MAP/IAT is normal? 





(f) With the 3 kinds of the basic types: idle tets, accerlerate suddenlly test and blocked test in exhaust 

system. Test the vaccum rate in the intake manifold. 



NO > Clear and reinstall or repair. If not OK, go to step 15. 

14. CHECK OXYGEN SENSOR 

(a) Engine idle. 

(b) Inspect the displayed scan tool data stream. 

(c) When the temperature is normal after the engine enter into the closed-loop control, inspect if the 

oxygen sensor operate normally. 

Oxygen Sensor Normal Value: 0 ~ 1 V. Change 5 ~ 8 times in 10 seconds periodically. 



NO > Replace xoygen sensor harness or connector. 

Page 770


04-75 










04 

04 







(b) Check the cylinder with the endoscopy. 

(c) Inspect the feedback voltage. 

(d) Disassembly the engine inner faults. 

(e) Clear the carbon deposit or remove and check the engine cylinder head. 

(f) Check valves, carbon deposit of manifold. For example: the clearance between the cylinder and the 


valve. 




Page 771

04-76 


IDLE IS TOO HIGH 


Idle is too high (The 

engine does not idle at the 

usual correct speed) 

Engine idle speed too 

high 

The cause is probably that the 

intake air volume during idle 

is too great 




throttle body 

• ECM 





















3. CHECK THE ACCELERATOR PEDAL 

(a) Check whether the accelerator pedal cable blocked. 



NO > Adjust or replace the accelerator cable. 

4. CHECK RELATED ACCESSORIES 

(a) Check EVAP. 

(b) Check the fuel pressure vacuum regualtor. 

(c) Check whether the PCV vacuum pipe installation is reliable. 

(d) Check whether the braking system vacuum booster pipe installation is reliable. 



NO > Adjust or replace. 

Page 772


04-77 

5. CHECK IDLE 


(b) Gear in N position. 

(c) Depress brake pedal. 

(d) Inspect if the idle speed is too high. 




6. CHECK THE VACUUM BOOSTER 

04 

04 

(a) Blocking the vacuum pipe, inspect if the idle become normal. 



NO > Repair or replace the vacuum booster. 

7. CHECK PCV VALVE 

(a) Clipping the PCV vacuum pipe, inspect if the idle become normal. 

(b) Check whether the PCV valve clip. If the opening degree is normal. 



NO > Replace PCV valve. 



(b) Using scan tool, select the item, active test. 

(c) Perform the idle air control motor test: 



• Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is 

28 - 33 Ω when the temperature is 20 ℃ . 

(d) Remove the idle air control motor to test: 





NO > Replace the idle control motor. 

9. CHECK THE INTAKE SYSTEM 

(a) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses. 

(b) Check the intake air pipe for being jammed, leaking, or damaged. 



NO > Repair or replace vacuum pipes. 

Page 773

04-78 



(a) Check whether the installation of the MAP/IAT sensor is normal? 



(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT value. It should be within the specified 

value. 









NO > Repair or replace related components of fuel system. 






CAUTION 



WARNING 







YES > Replace the injector washer. 

NO > Clean or replace the injectpor. 

Page 774


04-79 

WHEN THE ENGINE IS COLD, IT STALLS 


When the engine is cold, 

it stalls (At idle) 


that the air/fuel mixture is 

inappropriate when the 

engine is cold, or that the 

intake air 

volume is insufficient. 


that the intake air volume 

during idle is too great 


motor 


throttle body 


injector 



• ECM 

04 

04 















• Check whether the exhaust pipe emit black smoke. Check whether there is unburned petrol fumes. 







CAUTION 


makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The borning 






(e) When the scan tool control the rotation of expansion of the idle air control motor, the engine RPM 


Page 775

04-80 


(f) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is 

28 - 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary, 




NO > Clean, repair or replace idle control motor. 

4. CHECK THE ECT SENSOR 


20 ℃ : 2.1 ~ 2.7 kΩ 

80 ℃ : 0.26 ~ 0.36 kΩ 





5. CHECK THE IAT SENSOR 


20 ℃ : 2.3 ~ 3.0 kΩ 

80 ℃ : 0.3 ~ 0.42 kΩ 




NO > Replace the IAT sensor. 









gasline. If not OK, replace it. 

CAUTION 



WARNING 






Page 776


04-81 


(a) 













04 

04 








(a) 


CAUTION 





















Page 777

04-82 










valve. 




Page 778


04-83 

THE ENGINE STALLS WHEN ACCELERATING 



accelerating 


the accelerator pedal is 

depressed 

• Poor power when starting 

• Malfunction of the Idle air 

control motor 

• Malfunction of the throttle 

body 

• Malfunction of the injector 

• Malfunction of the ignition 

system 

• Malfunction of air-fuel ratio 


• ECM 

04 

04 

NOTE 

Start in idling mode: Put into gear without pressing the accelerator pedal, disengage the clutch and 

start the engine. This moment, as the throttle valve is closed and the idling electric shock is closed, 

ECM considers it as the idling mode. The control of idling mode is a cruise control without any load 

signal, namely a steady speed control that the engine is controlled in target speed range. Speedraising 

control is done if with load signal. During starting, the load signal is input into ECM, the later 

raises the engine speed, enhances the dynamic property and keeps the idling from the effect of load. 

This moment the starting is smoothly and hard to be shut off generally. If the starting is wobbled and 

easy to be shut off and the speed falls in idling mode, find the causes from the idling control. 












• Inspect if the idle trembles is normal or load reasons, such as: A\C, lighting, push the lever into gear, 









Page 779

04-84 



(a) 

Check throttle body and idle air path. Clear the carbon deposit and greasy dirt. 






(e) Disconnect the idle air control motor connector, Check whether there 12 V exists. And the resistance value 

is 28 - 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary, 


(f) Remove the idle air control motor. Connect the connector: 

• Check whether the idle air control motor can extend-retract when turning the switch off. 




NO > Clear, repair or replace idle control motor. 

4. CHECK THROTTLE POSITION 

(a) With the scan tool, check whether the throttle is normal. 

(b) Check whether the throttle open degree is normal when depressing the accelerator pedal. 



NO > Adjust the throttle position. 

5. CHECK THE LOAD SIGNAL 

(a) Check whether the gear signal is sent to ECM. 

(b) Check whether the A/C signal is sent to ECM. 

(c) Check whether the load signal is sent to ECM. 




6. CHECK THE IGNITION SYSTEM 


(b) Cut off spark plug wire one by one. 


CAUTION 

It is better that use the active test function of the scan tool to perform the cutoff test. If without the 

scan tool or the scan tool wirhout the function, the brennschluss period shoul not be too long, if not, 

the TWC will be damaged. 





Page 780


04-85 












04 

04 


(a) Check secondary ignition wire resistance. And clean the connector terminals. 



















NO > Repair or replace injector 

CAUTION 

If the spraying condition is not normal just as the “cylindrical growth”, or the 4 injectors spraying 

quantity is not equal much more under the same condition (more than 5 ml), then replace the injector. 

WARNING 






Page 781

04-86 



(a) 


















NO > Repair or replace the fuel supply pipe, pump, injector. 


(a) 


CAUTION 



leaks at fuel pipe connection. 

















Page 782


04-87 












04 

04 

Page 783

04-88 


ACCELERATED REACTION IS SLOW, ACCELERATON DISTURBANCE 


Accelerated reaction is 

slow, acceleraton 

disturbance 

When the accelerator is 

depressed in order to 

accelerate from the 

speed, the vehicle is now 

traveling or a temporary 

drop in vehicle speed 

during such acceleration. 


that ignition system, airfuel 

mixture or 

compression pressure is 

defective 




throttle body 





• Malfunction of fuel 

supply system 


• ECM 





















3. CHECK THE AIR FILTER 

(a) Check whether the air filter dirty, grease and blocked. 



NO > Clean or replace the air filter. 

Page 784


04-89 

4. CHECK IDLE 


(b) Check whether the idle speed is normal. 



NO > Refer to the symptom chart, eliminate the problems. 






(e) Read the scan tool displayed MAP/IAT sensor data stream value. 




04 

04 

6. CHECK TPS 


(b) With the analogue mulitimeter to check TPS resistance (resistance should be continuity). 

(c) Refer to engine DTC chart. 



NO > Repair or replace the throttle position sensor. 

7. CHECK FUEL SYSTEM PRESSURE 














(a) 

(b) 

(c) 

(d) 

Disconnect the injector connector. 

Remove the injector and fuel rail assy. 

Apply 12 V battery voltage to the injector directly. 

Check whether every injector can spray even and standard quantity gasline. 

Page 785

04-90 


CAUTION 



WARNING 








NO > Repair or replace the injector. 





NO > Repair or replace the fuel supply pipe, pump and injector. 


(a) 


CAUTION 








11. CHECK EXHAUST SYSTEM 

(a) Check the exhaust system and Three-Way Catalytic Converter (TWC). 

(b) Check whether the exhaust pipe blocked with the exhaust pressure meter. 



NO > Replace or clean the exhaust system. 









Page 786


04-91 


(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose. 




04 





• Disassembly the engine faults. 





YES > Repalce the ECM. 


04 

Page 787

04-92 


POOR ACCELERATION 


Poor Acceleration 

Poor acceleration is the 

inability to obtain an 

acceleration corresponding 

to the degree of throttle 

opening (even though 

acceleration is smooth) or 

the inability to reach 

maximum speed 

Defective ignition system, 

abnormal air-fuel ratio, poor 

compression, etc are 

suspected. 






supply system 

• Poor acceleration 

• Clogged exhaust 

system 

• ECM 



(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04 engine control 

system - read and clear DTC”) 




2. CHECK VISUAL INSPECTION 














3. CHECK THROTTLR POSITION SENSOR 


(b) With the analogue mulitimeter to check throttle position sensor resistance (resistance should be 

continuity). 




Page 788


04-93 










04 

04 



















CAUTION 



WARNING 








NO > Clean or replace the injector. 

Page 789

04-94 



(a) Using the fuel return blocker and clamping the return pipe, make the system fuel not return. Check 

whether the system pressure can establish again quickly. 





(a) 


CAUTION 
































Page 790


04-95 










04 

04 
















Page 791

04-96 

DIAGNOSTICS(RHD) - ANTI-LOCK BRAKE SYSTEM 


PRECAUTION 


(a) Before removing or installing any electrical device, please disconnect the negative cable to prevent 


(b) Make sure ignition switch is OFF if no specific instructions. 

NOTE 

If equipped with central locking, do not leave ignition switch in the car before disconnecting the 

battery negative cable. 

2. REMOVE INSTRUMENT CLUSTER OR DISCONNECT THE NEGATIVE CABLE WILL RESULT IN 

LOSS OF DATA. 

NOTE 

Total odometer will not be cleared. 

3. WHEN THE BATTERY TERMINAL IS REMOVED, ALL THE MEMORIES OF THE CLOCK, RADIO, 

DTCS, ETC. WILL BE ERASED. SO BEFORE REMOVING IT, CHECK THEM AND NOTE THEM 

DOWN. 

NOTE 

When service is finished, reset the clock and audio systems. 




Expression 




5. NOTES ABOUT ANTI-LOCK BRAKE SYSTEM. 

(a) The system will resumes its normal state temporarily or competely by removing and reinstalling the 

suspicious faulty components when the connector terminals or the installing state of the components go 

out of order. 

(b) In order to identify the faulty position, we must check the vehicle condition while vehicle goes out of 

order. For example, we check the faults through the DTC. And we record these fault states before 


(c) The sensor and ABS module can be removed or installed with the ignition switch in OFF position. 

(d) After repairing the anti-lock brake system is completed, check the ABS warning light. 

(e) Never use the multimeter to measure the terminal of ABS module. 

(f) The ABS system must be repaired by technicians trained and mastered maintenance skills, and only 

use original parts for replacement. 

(g) Before repairing the ABS system, if there are some failures with mechanical braking system, must be 

excluded. Such as: 

• Brake system noise. 

• Brake pedal is excellent. 

• Brake pedal or vehicle vibration when pressing pedal. 

• Vehicle deviation. 

• Parking brake system failure. 

Page 792


04-97 

(h) ABS control module (refer to the ABS electronic control unit and hydraulic control unit, not including 

brake lines, sensors ,etc.) can only be replaced as assembly, can not be overhauled or part 

replacement / swap. 

(i) The following two cases show that ABS system failure is detected: 

• Turn the ignition switch On, the system self-test is completed, but the warning light is on. 

• The warning light is always on when driving the vehicle. 

The driver can stop the vehicle conventionally, but it should be as far as possible to reduce the braking force to 

prevent the wheels from locking. Warning lamp lights need to be careful driving and immediately to the 

authorized service station overhaul to prevent more failures occurred, resulting in a traffic accident. 

(j) Pay attention to the following points when connect the ABS system connector: 

• Turn the igintion OFF before disconnecting ABS wiring harness and connector. 

• Ensure that the connector dry and clean, to avoid any foreign objects to enter. 

• ABS harness connector is installed in place, must be in the horizontal direction and a vertical direction 

to avoid damage to the connectors. 

(k) Ensure proper connection when connectiong the ABS system pipes. ABS control module can not 

detect that the brake lines are connected properly or not. The error connection may lead to a serious 

accident. Connecting the brake lines, must be in compliance with the ABS assembly on the mark: 



• FL: Brake line connected the wheel cylinders FL. 

• FR: Brake line connected the wheel cylinders FR. 

• RL: Brake line connected the wheel cylinders RL. 

• RR: Brake line connected the wheel cylinders RR. 

(l) There are noise with ABS system in the following cases: 

• Vehicle power or start the engine, it will produce a short sound of "Om", this is a normal phenomenon 

with the sound of the ABS self-check.. 

• There will be sound when ABS system work properly, mainly reflected in the following: 

1) Sound made by ABS hydraulic unit motor, solenoid valve and the reflux pump. 

2) Sound caused by brake pedal rebounding. 

3) Emergency brake caused the crash of the suspension and the body. 

04 

04 

Page 793

04-98 


ABS MODULE CONNECTOR 


1 R ABS motor power input 

2 - - 

3 Y - R EBD warning ligh output 

4 L Front sensor signal RH 

5 - - 

6 R - L Dinostic connector K 

7 - - 

8 W Front sensor signal LH 

9 - - 

10 - - 

11 - - 

12 - - 

13 W - B ABS motor ground 

14 - - 

15 - - 


20 - - 

21 - - 

22 - - 

23 - - 

24 - - 

25 R - W 

ABS solenoid valve power 

suppy input 

26 - - 

27 Y - G ABS warning ligh output 

28 R - W ABS-IG input 

29 LG Rear sensor signal RH 

30 G - W Brake signal 

31 Y - W 

Rear sensor power suppy 

LH 

32 - - 

33 - - 

16 G 

17 P 

Front sensor power suppy 

RH 

Rear sensor power suppy 

RH 

34 - - 

35 - - 

36 - - 

18 L - G Rear sensor signal LH 

37 - - 

19 B 

Front sensor power suppy 

LH 

38 W - B ECU ground 

Page 794


04-99 


NOTE 

If a malfunction code is displayed during the DTC checking, check the circuit listed below. For details 

of each code, turn to the relevant troubleshooting page in the DTC chart. 

04 

DTC No. 

C190004 

C190104 

C100004 

C101008 

C006B06 

C003108 

C003200 

C00A000 

C00A100 

C00A900 

C003408 

C003500 

C00A200 

C00A300 

C00AA00 

C003708 

C003800 

C00A400 

C00A500 

C00AB00 

C003A08 

C003B00 

C00A600 

C00A700 

C00AC00 

C109904 

ECU Power Suppy High 

ECU Power Suppy Low 


ECU Malfunction (Hardware, Central Controller Error) 

ECU Malfunction (Software Error) 

Abs Control Is Unreasonable (Controling Time Too Long) 

Front Wheel Speed Sensor LH Output Signal Malfunction: Beyond The Scope Of Loss, Noise, 

Intermittent Interruption 

Front Wheel Speed Sensor LH Wiring Malfunction: Open 

Front Wheel Speed Sensor LH Wiring Malfunction: Short For Ground 

Front Wheel Speed Sensor LH Wiring Malfunction: Short For Power Suppy 

Front Wheel Speed Sensor LH Malfunction: Unknow 

Front Wheel Speed Sensor RH Output Signal Malfunction: Beyond The Scope Of Loss, Noise, 


Front Wheel Speed Sensor RH Wiring Malfunction: Open 

Front Wheel Speed Sensor RH Wiring Malfunction: Short For Ground 

Front Wheel Speed Sensor RH Wiring Malfunction: Short For Power Suppy 

Front Wheel Speed Sensor RH Malfunction: Unknow 

Rear Wheel Speed Sensor LH Output Signal Malfunction: Beyond The Scope Of Loss, Noise, 


Rear Wheel Speed Sensor LH Wiring Malfunction: Open 

Rear Wheel Speed Sensor LH Wiring Malfunction: Short For Ground 

Rear Wheel Speed Sensor LH Wiring Malfunction: Short For Power Suppy 

Rear Wheel Speed Sensor LH Malfunction: Unknow 

Rear Wheel Speed Sensor RH Output Signal Malfunction: Beyond The Scope Of Loss, Noise, 


Rear Wheel Speed Sensor RH Wiring Malfunction: Open 

Rear Wheel Speed Sensor RH Wiring Malfunction: Short For Ground 

Rear Wheel Speed Sensor RH Wiring Malfunction: Short For Power Suppy 

Rear Wheel Speed Sensor RH Malfunction: Unknow 

Wheel Speed Sensor Group Malfunction (Wheel Speed Sensor Interchangeable, Each Of The 

Wheel Speed Difference Is Too Large, Wheel Speed Sensors Fault) 

04 

Page 795

04-100 


DTC No. 

C001004 

C001104 

C001404 

C001504 

C001804 

C001904 

C001C04 

C001D04 

C109504 

C002004 

C007208 


Front Inlet Hydraulic Valve LH Failure 

Front Outlet Hydraulic Valve LH Failure 

Front Inlet Hydraulic Valve RH Failure 

Front Outlet Hydraulic Valve RH Failure 

Rear Inlet Hydraulic Valve LH Failure 

Rear Outlet Hydraulic Valve LH Failure 

Rear Inlet Hydraulic Valve RH Failure 

Rear Outlet Hydraulic Valve RH Failure 

Valve Relay Failure 

Reflux Pump Motor Failure 

Valve Group Failure (Overheating Protection Signal Is Invalid, Hardw Is Damaged) 

Page 796


04-101 





04 

1. Brake pipe leakage, 

breakage, etc. 

- 

2. Lack of brake fluid - 

3. Differential fault 


assy, check and adjustment 

04 

4. Front brake fault Chapter 35 brake - front brake, overhaul 

5. Rear brake fault Chapter 35 brake - rear brake, overhaul 

ABS is inoperative. 

6. Hydraulic regulator assembly 

fault 

7. Parking light switch fault 

8. Brake fluid level sensor fault 

9. Brake switch fault 

10. Speed sensor fault 

11. Stop valve fault 

12. Pressure relief valve fault 

13. ABS module power supply 

fault 

14. ABS module ground fault 







Chapter 04 diagnostics - anti-lock brake system, 










- 

15. ABS module fault - 

Page 797

04-102 


PRE - CHECK 

Before diagnosis of the ABS system, check the ABS system failure and easily accessible components first, 

visual inspection can quickly determine fault, and thus do not need to do further diagnosis. 

1. CHECK TIRE. 

(a) Make sure that the vehicle only install the recommended 

size tires and wheels. coaxial style of tire tread depth 

must be the same. Specific tire models, refer to the 

vehicle owner's manual for details. 

2. CHECK THE ABS HYDRAULIC MODULATOR, BRAKE PIPES AND CONNECTIONS FOR 

LEAKING. 

3. CHECK ABS SYSTEM FUSES TO ENSURE THAT THE FUSES ARE NOT BURNED, AND THE 

MODEL IS CORRECT. ABS SYSTEM HAS THREE FUSES: 

• Pump motor fuse (40A) 

• Solenoid valve fuse (25A) 

• Electronic control unit Fuse (5A) 

4. CHECK THE BATTERY VOLTAGE, DETECT WHETHER THE BATTERY TERMINAL CORROSION 

OR LOOSE. ABS SYSTEM NORMAL OPERATING VOLTAGE RANGE IS 9.3V - 16.8V. 

5. CHECK ABS GROUND. 

(a) Check ABS grounding point is loose. The location is 

changed or not. 

(b) ABS ground has good sealing, in order to avoid water 

and moisture in capillary (siphon) effect through wiring 

harness of channel infiltration ABS control module, which 

cause function failure. 

Page 798


04-103 

6. VISUAL INSPECTION OF THE FOLLOWING 

ELECTRICAL COMPONENTS: 

(a) 

(b) 

NOTE 

ABS system harness and connectors of the related 

components are properly connected, to be pinched or cut 

or not. 

Harness routing is too close to high-voltage or highcurrent 

devices, such as high-voltage or parts, 

generators, motors or stereo amplifier. 

The high voltage or high current device may cause the 

circuit to generate the induced noise, and thereby interfere 

with the normal working of the circuit. 

(c) ABS parts are sensitive to electromagnetic interference 

(EMI). Suspected intermittent fault, check the 

aftermarket installation of anti-theft device, lights, or 

whether the mobile phone is not installed correctly. 

7. IF THE ABS NOISE IS TOO LARGE, IT MAY BE CAUSED BY THE FOLLOWING REASONS: 

(a) Loosening of ABS assembly with bracket. 

(b) Loosening of ABS bracket and body. 

(c) ABS plastic bracket washer missing or damaged. 

04 

04 

Page 799

04-104 


POWER SUPPY VOLTAGE HIGH OR LOW 


C190004; C190104 


It will be caused failure by one of the following conditions are met when the supply voltage of the ECU: 

(1) Voltage is lower than 4.5V when starting engine. 

(2) Voltage is lower than 7.7V or higher than 16.8V when ignition switch is ON. 

(3) Voltage is between 7.7V to 9.2V when vehicle speed is higher than 6km / h. 


1. PERFORM PRE-CHECK STEPS 




2. INSPECT BATTERY 


(b) Measure the battery voltage. 



NO > Repair or replace battery. 

3. ABS CONTROL MODULE CROSS-VALIDATION 


(b) Remove the ABS actuator. (Refer to “Chapter 35 brake - abs actuator, replacement”) 

(c) Install the removed ABS to another known vehicle with the same model. (Ensure that ABS connectors 

are securely installed without connecting pipes when vehicle was driven. ) 

(d) Start the engine and to ensure that the vehicle speed is not lower than 20km / h, so that the ABS 

dynamic self-check. 




Page 800


04-105 

SOLENOID VALVES AND VALVES RELAY FAILURE 


C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04; C109504; C007208 



(1) Valves power supply failure. (Power supply short for ground or ground open.) 

(2) Solenoid valve temperature is too high. (Overheating protection) 

(3) Solenoid valve is shorted. (Fuse) 

(4) Actuating the corresponding solenoid valve, but no feedback. 

(5) Solenoid valve failure. 

(6) Valves relay failure. 


(1) Solenoid valve short for power supply or ground, circuit open. 

(2) Fuses failure. 

(3) Overheating protection (Solenoid valve long working hours, common in vacuum filling and offline detection) 

(4) ABS damaged 


04 

04 




(c) Vehicle was allowed to stand for 5 minutes. 

(d) Connect the negative battery cable. 


YES > System is normal . 







(a) Selecte diagnostic mode in the disgnostic tool and read data stream. 

(b) Detect vehicle speed displayed on the instrument panel and diagnostic tool when vehicle is running, 

and compare whether they are consistent. 

NOTE 






Page 801

04-106 



(a) 


(b) 

(c) 

Inspect the ABS valve fuse in battery compartment 

junction box (Z048): 25 A. 

Inspect the ABS IG fuse in battery compartment junction 

box (Z048): 5 A. 








are securely installed without connecting pipes when vehicle was driven.) 


dynamic self-check 




Page 802


04-107 

6. CHECK HARNESS AND CONNECTOR (ABS VALVE FUSE- GROUND) 

(a) 


(b) 


table below. 


04 





04 





(a) 

(b) 


Disconnect the Z062 ABS module connector. 

(c) 


table below. 



ABS IG fuse - Z062 (28) 


< 2 Ω 




Page 803

04-108 


8. CHECK HARNESS AND CONNECTOR (ABS VALVE FUSE - ABS MODULE) 

(a) 

(b) 



(c) 


table below. 



ABS valve fuse - Z062 (25) 


< 2 Ω 


YES > Replace ABS MODULE. 


Page 804


04-109 

PUMP MOTOR FAILURE 


C002004 



(1) Pump motor is overloaded with work, the temperature is too high. (Overheat protection) 

(2) Reflux pump motor relay work over 60ms, reflux pump monitoring is still not detected voltage signal. 

(3) Reflux pump motor relay did not work, reflow pump monitoring detected voltage exceeds 2.5s. 

(4) Reflux pump motor relay stops working and the reflux pump monitoring detected voltage does not drop. 


(1) Pump motor is poorly grounded. 

(2) System overheating protection. 

(3) Pump motor power supply is not normal(Fuse, battery terminal) 

(4) Pump motor relay failure. 

(5) Pump motor failure. 


04 

04 




(c) Vehicle was allowed to stand for 5 minutes. 

(d) Connect the negative battery cable. 


YES > System is normal 







(a) 

(b) 


Detect vehicle speed displayed on the instrument panel and diagnostic tool when vehicle is running, 


NOTE 






Page 805

04-110 



(a) 


(b) Inspect the ABS pump fusible link in battery 

compartment junction box (Z048): 40 A. 

(c) 


box (Z048): 5 A. 














Page 806


04-111 

6. CHECK HARNESS AND CONNECTOR (ABS PUMP FUSIBLE LINK- GROUND) 

(a) 


(b) 


table below. 


04 


ABS pump fusible link - 

Ground 



04 





(a) 

(b) 



(c) 


table below. 



ABS IG fuse - Z062 (28) 


< 2 Ω 




Page 807

04-112 


8. CHECK HARNESS AND CONNECTOR (ABS PUMP FUSIBLE LINK - ABS MODULE) 

(a) 

(b) 



(c) 


table below 



ABS valve fuse - Z062 (1) 


< 2 Ω 




Page 808


04-113 

WHEEL SPEED SENSOR CIRCUIT FAULT 


C003200; C00A000; C00A100; C00A900; C003500; C00A200; C00A300; C00AA00; C003800; 

C00A400;C00A500; C00AB00; C003B00; C00A600; C00A700; C00AC00; C109904 


(1) ECU detects wheel speed sensor signal wire is shorted to ground. 

(2) Wheel speed sensor circuit open. 



(2) Wheel speed sensor signal circuit and the power suppy circuit is connected in reverse. 

(3) Signal circuit is shorted to ground. 

(4) Damage to the sensor head or connector pins. 


04 

04 






(a) 

(b) 




NOTE 
















Page 809

04-114 



(a) 

(b) 

(c) 


Disconnect the Z059 front wheel speed sensor connector LH. 


(d) 


table below 



Z059 (1) - Ground 

Z059 (2) - Ground 


≥ 1 MΩ 





(a) 

(b) 

(c) 


Disconnect the Z059 front wheel speed sensor connector LH. 


(d) 


table below. 



Z059 (1) - Z062 (8) 

Z059 (2) - Z062 (19) 


< 2 Ω 




Page 810


04-115 

WHEEL SPEED SENSOR SIGNAL FAULT 


C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08; C00AC00; C109904 

04 


(1) ECU detects wheel speed sensor signal circuit is shorted to power supply. 

(2) ECU detects wheel speed sensor power supply circuit is shorted to ground. 

(3) Wheel speed sensor signal is not normal. 



(2) Wheel speed sensor signal circuit is shorted to power supply. 

(3) Wheel speed sensor power supply is shorted to ground. 

(4) The ring gear is not installed, missing teeth, dirty dust and installed incorrectly. 

(5) The gap between the sensor and the ring is too large. 

(6) The wheel speed sensor is subjected to the external magnetic field interference. (Wheel or axle is not 

demagnetization) 

(7) The wheel speed sensor fault. 

(8) The number of teeth of the ring gear error. 

(9) Tire size does not meet specifications 

(10) ECU is damaged. 

04 






2. INSPECT WHEEL SPEED SENSOR 

(a) 

(b) 



(c) 

(d) 

(e) 

(f) 

Inspect whether the ABS speed sensor installation is 


Inspect whether the ABS speed sensor connector is 

loose or not. 

Inspect whether the ABS speed sensor tightening bolt is 

loose or not. 

Remove ABS speed sensor to inspect whether the 

speed sensor is damaged or the surface is dirty. 

Page 811

04-116 






(a) 

(b) 




NOTE 







(a) 

Position the front wheel speed sensor RH properly. 

NOTE 







(a) 


(b) 

Check wheel speed sensor tip. 

NOTE 





Page 812


04-117 


(a) 


NOTE 


If foreign object is attached, remove it. After reassembling, 

check the output voltage. 

04 

04 





(a) 

(b) 

(c) 


Disconnect the Z059 front wheel speed sensor connector. 


(d) 


table below. 



Z059 (1) - Ground 


≥ 1 MΩ 





(a) 

(b) 

(c) 


Disconnect the Z059 front wheel speed sensor connector. 


Page 813

04-118 


(d) 


table below. 



Z059 (1) - Z062 (8) 


< 2 Ω 




Page 814


04-119 

ABS CONTROL IS UNREASONABLE 


C006B06 

04 


ABS received continuous working instruction (more than 1 minute). 


(1) Continued brake on ice. 

(2) Wheel speed difference is too large. 

04 







(a) 

(b) 




NOTE 







(a) 

(b) 



(c) 

(d) 

(e) 

(f) 

Inspect whether the ABS speed sensor installation is 


Inspect whether the ABS speed sensor connector is 

loose or not. 

Inspect whether the ABS speed sensor tightening bolt is 

loose or not. 

Remove ABS speed sensor to inspect whether the 

speed sensor is damaged or the surface is dirty. 

Page 815

04-120 


(g) 

Position the front wheel speed sensor RH properly. 

NOTE 







(a) 


(b) 

Check wheel speed sensor tip. 

NOTE 






(a) 


NOTE 


If foreign object is attached, remove it. After reassembling, 

check the output voltage. 




Page 816


04-121 







dynamic self-check. 




04 

04 

7. CHECK HARNESS AND CONNECTOR (ABS MODULE- GROUND) 

(a) 

(b) 



(c) 


table below. 



Z062 (13) - Ground 

Z062 (38) - Ground 


< 2 Ω 




Page 817

04-122 


ABS SYSTEM IS INOPERATIVE 

WIRING DIAGRAM ( 

Page 818


04-123 



(a) 


04 

(b) 

Inspect the ABS valve fuse in battery compartment 

junction box (Z048): 25 A. 

(c) Inspect the ABS pump fusible link in battery 

compartment junction box (Z048): 40 A. 

(d) 

(e) 


box (Z048): 5 A. 

Inspect the stop lamp switch fuse in engine room junction 

box (Z063): 15 A. 

04 




2. INSPECT BACK-UP LAMP SWITCH 

(a) 

Disconnect the Z006 stop lamp switch connector. 

(b) 



Condition 


Specified 

Condition 

Release stop 

lamp switch 

Press stop lamp 

switch 

1 - 2 ≥ 1 MΩ 

1 - 2 < 2 Ω 




Page 819

04-124 


3. CHECK HARNESS AND CONNECTOR (ABS MODULE- GROUND) 

(a) 

(b) 



(c) 


table below. 



Z062 (13) - Ground 

Z062 (38) - Ground 


< 2 Ω 




4. CHECK ABS MODULE POWER SUPPLY 

(a) 


(b) 


table below. 




ABS IG fuse - Ground 



ABS pump fusible link - Ground 




Page 820


04-125 

5. CHECK HARNESS AND CONNECTOR (STOP LAMP FUSE - STOP LAMP SWITCH) 

(a) 

(b) 



04 

(c) 


table below. 



Stop lamp fuse - Z006 (2) 


< 2 Ω 

04 




6. CHECK HARNESS AND CONNECTOR (ABS MODULE - STOP LAMP SWITCH) 

(a) 


(b) 

(c) 

(d) 




table below. 



Z062 (30) - Z006 (1) 


< 2 Ω 




Page 821

04-126 

DIAGNOSTICS(RHD) - SUPPLEMENTAL RESTRAINT SYSTEM 


PRECAUTION 

WARNING 

• Fail to carry out the service operations in the correct sequence could cause the supplemental 

restraint system to unexpectedly deploy during servicing. It may lead to a serious accident. 

Furthermore, if a mistake is made in servicing the supplemental restraint system, it is possible 

that the SRS will fail to operate when requiring. Before servicing (including removal or 

installation of parts, inspection or replacement), be sure to read the following items carefully. 

Then follow the correct procedure described in this manual. 

• Work must be started after 90 seconds from the time that the ignition switch is turned to the 

”LOCK” position and the negative (–) terminal cable is removed from the battery. (The 

supplemental restraint system is equipped with a back–up power source, so if work is started 

within 90 seconds after disconnecting the negative (–) terminal cable from the battery, the SRS 

may deploy. 

• Do not directly expose the horn switch assy to hot air or flames. 

NOTE 

• Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the 

diagnostic trouble codes (DTC) become the most important source of information when 

troubleshooting. When repair the supplemental restraint system, always check the diagnostic 

trouble codes (DTC) before disconnecting the battery. 

• After completion of maintenance work,be sure to erase diagnostic trouble code (s) (DTC);If 

diagnostic trouble code (s) (DTC) can’t be erased,replace the restraint control module.Check for 

diagnostic trouble code (s) (DTC) again. 

• Even in case of a minor collision where the SRS does not deploy, the horn switch assy and 

restraint control module should be inspected. 

• Before repairing, remove the driver airbag and restraint control module if shocks are likely to be 

applied to the airbag and module during repairing. 

• Never use SRS related parts from another vehicle. If necessary, replace with new parts. 

• Never disassemble and repair the horn switch assy. 

• If the horn switch assy has been dropped, or if there are cracks, dents or other defects in the 

case, bracket or connector, replace them with new ones. 

• Use the multimeter with high impedance (10 kW/V minimum) for troubleshooting of an electrical 

circuit. 

• Information labels are attached to the SRS components. Follow the instructions on the notices. 

• After working on the supplemental restraint system is completed, check the SRS warning light. 

• When the negative (–) terminal cable is disconnected from the battery, memory of the clock and 

audio systems will lost. So, before starting work, make a record of the memorized contents in 

each memory system. Then, when work is finished, reset the clock and audio systems as 

before. To avoid erasing the memory in each memory system, never use a back–up power 

supply from another battery. 

Page 822


04-127 


04 

04 


1 - - 

2 - - 

3 - - 

4 - - 

5 B - O Power Supply 


7 B - Y SRS Warning Light 

8 - - 

9 R - L Diagnosis K 

10 Y Airbag + 

11 Y - B Airbag - 

12 - - 

13 G - B Airbag + 

14 G - R Airbag - 

15 - - 

16 - - 

17 - - 

18 - - 

19 - - 

20 - - 

21 - - 

22 - - 

23 - - 

24 - - 

25 - - 

Page 823

04-128 



26 - - 

27 - - 

28 - - 

29 - - 

30 Y Collision Output Interface 

Page 824


04-129 


NOTE 

If a malfunction code is displayed during the DTC check, check the circuit listed. For details of each 

code, turn to the relevant troubleshooting page in the DTC chart. 

04 

DTC No. Detection Item (DTC Definition) Trouble Area 

8101 Power supply voltage high 

8102 Power supply voltage low 

8201 Driver airbag fault - high resistance 

8202 Driver airbag fault - low resistance 

8203 Driver airbag circuit short to ground 

8204 Driver airbag circuit short to battery 

• Battery 

• Charging system 



• Fuse 



















04 

8211 

8212 

8213 

8214 

Co - pilot side airbag fault - High 

resistance 

Co - pilot side airbag fault - Low 

resistance 


ground 


battery 













8610 ACU internal error • Restraint control module 

Page 825

04-130 



NOTE 

• If there is no DTC,but supplemental restraint system isn’t normal ,use the table below to check 

the circuit. 

• Before replacement of restraint control module (RCM) and instrument cluster,turn the ignition 

switch OFF,and disconnect the battery negative cable. 

• Use the table below to help you find the cause of the problem. The numbers indicate the priority 

of the likely cause of the problem. Check each part in order. If necessary, replace these parts. 




always on 




, replacement 





inoperative 




, replacement 



Page 826


04-131 

8101 - POWER SUPPLY VOLTAGE HIGH 

8102 - POWER SUPPLY VOLTAGE LOW 


04 


8102 

With vehicle speed at 3 km/h or more, ignition 

switch terminal voltage is 10V or below for 10 

sec or longer. 


• Fuse 



04 


Page 827

04-132 



1. INSPECT FUSE (Co - pilot Side Junction Box) 

(a) 


(b) 


table below. 










2. CHECK HARNESS AND CONNECTOR (AIRBAG FUSE - RESTRAINT CONTROL MODULE) 

(a) 

(b) 

(c) 

(d) 


Disconnect the Z044 restraint control module connector. 



(e) Measure the voltage according to the value (s) in the 

table below. 



Z044 (5) - Ground 






Page 828


04-133 

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE 

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE 


04 


8201 

8202 












04 


Page 829

04-134 




(a) 

(b) 

(c) 

(d) 


Disconnect the Z012 clock spring connector. 


Connect the battery negative cable.Turn the ignition switch ON. 





(a) 

(b) 

(c) 




(d) 


table below. 



Z044 (10) - Z012 (3) 

Z044 (11) - Z012 (4) 


< 2 Ω 

(e) 


table below. 



Z012 (3) - Ground 

Z012 (4) - Ground 


≥ 1 MΩ 




Page 830


04-135 

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND 



04 

8203 


ground) 








04 


Page 831

04-136 




(a) 

(b) 

(c) 

(d) 

(e) 










(a) 

(b) 



(c) 


table below. 



Z044 (10) - Ground 

Z044 (11) - Ground 


≥ 1 MΩ 




Page 832


04-137 

8204 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY 



04 

8204 


battery) 








04 


Page 833

04-138 



1. CHECK HARNESS AND CONNECTOR (RESTRAINT CONTROL MODULE - CLOCK SPRING) 

(a) 

(b) 

(c) 

(d) 

(e) 






(f) 


table below. 



Z044 (10) - Ground 

Z044 (11) - Ground 


0 V 





(a) 

(b) 

(c) 

(d) 

(e) 









Page 834


04-139 

8211 - CO - PILOT SIDE AIRBAG FAULT - HIGH RESISTANCE 

8212 - CO - PILOT SIDE AIRBAG FAULT - LOW RESISTANCE 


04 


8211 

8212 










04 




(a) 

(b) 

(c) 

(d) 

(e) 


Disconnet the Z040 passenger airbag connector. 







Page 835

04-140 


2. CHECK HARNESS AND CONNECTOR (PASSENGER AIRBAG - RESTRAINT CONTROL 

MODULE) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z044 (13) - Z040 (1) 

Z044 (14) - Z040 (2) 


< 2 Ω 

(e) 


table below. 



Z040 (1) - Ground 

Z040 (2) - Ground 


≥ 1 MΩ 




Page 836


04-141 

8213 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO GROUND 



04 

8213 



ground) 






04 

Page 837

04-142 




(a) 

(b) 

(c) 

(d) 

(e) 









2. CHECK HARNESS AND CONNECTOR (PASSENGER AIRBAG - RESTRAINT CONTROL MODULE) 

(a) 

(b) 



(c) 


table below. 



Z044 (13) - Ground 

Z044 (14) - Ground 


≥ 1 MΩ 




Page 838


04-143 

8214 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO BATTERY 



04 

8214 



battery) 






04 

Page 839

04-144 




(a) 

(b) 

(c) 

(d) 

(e) 









2. CHECK HARNESS AND CONNECTOR (RESTRAINT CONTROL MODULE - PASSENGER 

AIRBAG) 

(a) 

(b) 

(c) 

(d) 

(e) 






(f) 


table below. 



Z044 (13) - Ground 

Z044 (14) - Ground 


0 V 




Page 840


04-145 

SRS WARNING LIGHT IS ALWAYS ON 


04 

04 

Page 841

04-146 




MODULE) 

(a) 

(b) 

(c) 


Disconnect the Z002 instrument B connector. 


(d) 


table below. 



Z044 (7) - Ground 


≥ 1 MΩ 





(a) 

(b) 

(c) 

(d) 

(e) 


Disconnect the Z003 instrument A connector. 


Replace instrument cluster. 





Page 842


04-147 

SRS WARNING LIGHT IS INOPERATIVE 


04 

04 

Page 843

04-148 




MODULE) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z002 (B27) - Z044 (7) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 

(e) 


Replace instrument cluster,and keep the Z002 instrument connector disconnecting. 

Connect Pin B27 of the Z002 instrument B connector to ground. 






Page 844

DIAGNOSTICS(RHD) - HEATER AND AIR CONDITIONING SYSTEM 


PRECAUTION 

8. DO NOT DEPOSIT REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME. 

04-149 

9. ALWAYS WEAR SAFETY GOGGLES. 

10. AVOID CONTACTING WITH LIQUID REFRIGERANT R-134A. 

If liquid refrigerant is in your eyes or on your skin: 

(f) Wash the area with lots of cold water. 

(g) Apply clean petroleum jelly to the skin. 

(h) Immediately go to a hospital or see a physician for professional treatment. 

11. DO NOT HEAT CONTAINER OR EXPOSE THE CONTAINER TO OPEN FLAME. 

12. DO NOT DROP DOWN CONTAINER OR APPLY PHYSICAL SHOCKS TO IT. 

13. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT 

SYSTEM. 

(a) If there is not enough refrigerant in the A/C system, oil lubrication will be insufficient and the 

compressor may be damaged. 

14. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING. 

(a) Open and close only the low pressure valve. 

If the high pressure valve is opened, refrigerant flowing in the reverse direction will cause the charging 

cylinder to rupture. 

15. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT. 

(a) If refrigerant is overcharged, it will cause problems such as insufficient cooling, poor fuel economy, 

engine overheating, etc. 

16. DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT. 


04 

04 



Expression 




Page 845

04-150 




1 

Check the refrigerant. 

• Open the cap of release valve. 

• Press the release valve. 


Yes 

No 


Charge the refrigerant system 

2 

Check the A/C switch. 


• Press the A/C switch. 

• Check the A/C switch. 


Yes 

No 



3 

Check the A/C clutch field coil. 

• check the A/C clutch field coil. 


Yes 

No 



4 

Check compressor belt. 

• Check compressor belt. 


Yes 

No 



5 

Check the compressor. 

• Check the compressor cluth for noisy. 


Yes 

No 



6 

Check the condenser. 

• Check the dirt between the condenser 

and radiator. 


Yes 

No 


Clear the dirt or repalce the condenser 

7 

Check pressure A/C liquid line. 

• Check the line for inhibition or leakage. 


Yes 

No 


Replace or reroute the pressure A/C liquid 

line 

Page 846


04-151 





04 

1. Fuse - 

A/C system is inoperative 

2. Relay - 


1. Fuse - 

04 

2. Relay - 

Front blower motor is inoperative 





conditioning - multi-media and A/C 







replacement 


Front air flow is insufficient 




4. Front A/C vent duct 









replacement 


conditioning - front A/C vent duct , 

replacement 


1. Fuse - 

2. Relay - 


3. A/C compressor 


5. Refrigerant 


conditioning - compressor, overhaul 





conditioning - refrigerant 

replacement 

Page 847

04-152 




6. Triple pressure switch 



conditioning - A/C pressure switch, 

replacement 


conditioning - front evaporator 

thermistor, replacement 


1. Fuse - 

2. Relay - 

Rear heater is inoperative or insufficient 

heating 

3. Rear heater blower switch 


5. Rear heater motor 


conditioning - rear heater blower 



conditioning - rear heater solenoid 

valve, replacement 


conditioning - rear heater blower, 

overhaul 

Page 848


04-153 

A/C SYSTEM IS INOPERATIVE 


04 

04 

Page 849

04-154 


Page 850


04-155 



(a) 


04 

(b) 

Inspect the A/C fuse (15 A) in driver side junction box 

(Z043). 

04 





(a) 

(b) 

(c) 




(d) 


table below. 




Specified 

Condition 


Page 851

04-156 






(a) 

(b) 

(c) 




(d) 


table below. 

Standard voltage (check for a short to battery) 



Specified 

Condition 

0 V 




Page 852


04-157 

FRONT BLOWER MOTOR IS INOPERATIVE 


04 

04 

Page 853

04-158 




(a) 


(b) 

(c) 

Inspect the front blower fusible link (30A) in Co-pilot 

Junction Box (Z043). 

Inspect the A/C controller fuse (7.5A) in Driver Side 

Junction Box (Z043). 




2. INSPECT FRONT BLOWER RELAY 

(a) 

(b) 



(c) 






Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the front blower relay. 

Page 854


04-159 

3. INSPECT FRONT BLOWER CONTROL MODULE 


(b) Disconnect the Z020 front blower control module connector. 

(c) Replace the front blower control module with a new one. 


YES > Replace the front blower motor resistor. 


4. INSPECT FRONT BLOWER MOTOR 

04 

04 


(b) Disconnect the Z019 front blower motor connector. 

(c) Replace a new front blower motor. 


YES > Replace the front blower motor. 


5. CHECK HARNESS AND CONNECTOR (FRONT BLOWER RELAY - FRONT BLOWER ) 

(a) 

(b) 

(c) 


Disconnect the Z019 front blower motor connector. 


(d) 


table below. 



Front blower relay (30) - Z019 (1) 

Specified 

Condition 

< 2 Ω 




Page 855

04-160 



MODULE) 

(a) 

(b) 

(c) 


Disconnect the Z019 front blower connector. 

Disconnect the Z020 front blower control module connector. 

(d) 


table below. 



Z019 (2) - Z020 (4) 


< 2 Ω 





(a) 

(b) 


Disconnect the Z020 blower control module connector. 

(c) 


table below. 



Z020 (8) - Ground 


< 2 Ω 





PANEL) 

(a) 

(b) 

(c) 



Disconnect the Z017 A/C control panel connector. 

Page 856


04-161 

(d) 


table below. 




04 

Z020 (2) - Z017 (35) 

Z020 (3) - Z017 (28) 

< 2 Ω 

04 




9. CHECK HARNESS AND CONNECTOR (FRONT BLOWER RELAY - A/C CONTROL PANEL) 

(a) 

(b) 

(c) 


Remove front blower relay. 


(d) 


table below. 



Front blower relay (86) - Z023 (8) 

Specified 

Condition 

< 2 Ω 




Page 857

04-162 



(a) 

(b) 

(c) 




(d) 


table below. 



Z023 (10) - Ground 

Z023 (19) - Ground 







(a) 

(b) 



(c) 


table below. 



Z023 (18) - Ground 

Z023 (20) - Ground 


< 2 Ω 


YES > Replace A/C control panel ( Multi-media and A/C controller assy). 


Page 858


04-163 

FRONT AIR FLOW IS INSUFFICIENT 


04 

04 

Page 859

04-164 



1. INSPECT FRONT BLOWER MOTOR RESISTOR 


(b) Disconnect the Z020 front blower control module connector. 

(c) Replace the front blower control moduler with a new one. 


YES > Replace the front blower control module. 



MODULE) 

(a) 

(b) 

(c) 


Disconnect the Z019 front blower connector. 


(d) 


table below. 



Z019 (2) - Z020 (4) 


< 2 Ω 





(a) 

(b) 


Disconnect the Z020 blower control module connector. 

(c) 


table below. 



Z020 (1) - Ground 


< 2 Ω 




Page 860


04-165 


PANEL) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

Z020 (2) - Z017 (35) 

Z020 (3) - Z017 (28) 

< 2 Ω 





(a) 

(b) 

(c) 




(d) 


table below. 



Z023 (10) - Ground 

Z023 (19) - Ground 






Page 861

04-166 



(a) 

(b) 



(c) 


table below. 



Z023 (18) - Ground 

Z023 (20) - Ground 


< 2 Ω 




Page 862


04-167 

NO COOLING FROM FRONT A/C SYSTEM 


04 

04 

Page 863

04-168 


Page 864


04-169 


1. INSPECT COMPRESSOR RELAY 

(a) 

(b) 



04 

(c) 





04 


Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the compressor relay 

2. CHECK HARNESS AND CONNECTOR (COMPRESSOR RELAY - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 










Page 865

04-170 


3. CHECK HARNESS AND CONNECTOR (COMPRESSOR - GROUND) 

(a) 

(b) 

(c) 


Disconnect the E013 compressor connector. 

Start the engine, turn A/C switch on. 

(d) 


table below.. 



E013 (1) - Ground 




YES > Replace the compressor. 


4. CHECK HARNESS AND CONNECTOR (COMPRESSOR RELAY - ENGINE ELECTRONIC CON- 

TROL MODULE(4G69) / ENGINE ECM(ISF2.8) ) 

(a) 

(b) 

(c) 



Disconnect the C016 blower switch connector. 

(d) 


table below. 



Compressor relay (86) - A036 (48) 

Compressor relay (86) - E001 (10) 

Specified 

Condition 

< 2 Ω 




Page 866


04-171 

5. INSPECT TRIPLE PRESSURE SWITCH 

(a) 

(b) 



(c) Inspect the triple pressure switch according to the 


04 


V031 (1) - V031 (4) 

V031 (2) - V031 (3) 


< 2 Ω 

04 



NO > Replace the triple pressure switch. 

6. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - ENGINE ELECTRONIC 

CONTROL MODULE(4G69) / ENGINE ECM(ISF2.8) ) 

(a) 

(b) 



(c) 


table below. 




V031 (4) - E001 (79) 

V031 (3) - E001 (26) 

V031 (4) - A036 (27) 

< 2 Ω 

V031 (3) - A036 (11) 




7. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - A/C CONTROL PANEL) 

(a) 

(b) 

(c) 




Page 867

04-172 


(d) 


table below. 



V031 (2) - Z023 (9) 


< 2 Ω 


YES > Go to next step for 4G69, go to step 9 for ISF2.8. 


8. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - GROUND)(4G69) 

(a) 

(b) 



(c) 


table below. 



V031 (2) - Ground 


< 2 Ω 




9. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - ENGINE ECM)(ISF2.8) 

(a) 

(b) 

(c) 



Disconnect the A036 engine ECM connector. 

(d) 


table below. 



V031 (2) - A036 (29) 


< 2 Ω 

Page 868


04-173 




10. INSPECT FRONT EVAPORATOR THERMISTOR 

04 

(a) 

(b) 


Disconnect the Z039front evaporator thermistor connector. 

(c) 

Inspect the front evaporator thermistor according to the 



04 



2 ℃ 14.5 ~ 15.2 

5 ℃ 12.5 ~ 13.0 

10 ℃ 9.7 ~ 10.3 

15 ℃ 7.6 ~ 8.1 

20 ℃ 6.1 ~ 6.4 

25 ℃ 4.8 ~ 5.1 



NO > Replace the front evaporator thermistor. 

11. CHECK HARNESS AND CONNECTOR (FRONT EVAPORATOR THERMISTOR - A/C CONTROL 

PANEL) 

(a) 

(b) 

(c) 


Disconnect the Z039front evaporator thermistor connector. 


(d) 

Inspect the resistance according to the value(s) in the 

table below. 


Z039(1) - Z017 (29) 

Z039(2) - Z017 (33) 


< 2 Ω 




Page 869

04-174 


REAR HEATER IS INOPERATIVE OR INSUFFICIENT HEATING 


Page 870


04-175 



(a) 


04 

(b) 

Inspect the rear heater fuse (15A) in Co-pilot Junction 

Box (Z043). 

04 




2. INSPECT REAR HEATER RELAY 

(a) 

(b) 


Remove the rear heater relay. 

(c) 

Inspect the rear heater relay according to the value(s) in 





Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the rear heater relay. 

Page 871

04-176 


3. INSPECT WATER VALVE RELAY 

(a) 

(b) 



(c) 

Inspect the water valve relay according to the value(s) in 





Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the water valve relay. 

4. INSPECT REAR HEATER BLOWER SWITCH 

(a) 

(b) 


Disconnect the Z047 rear heater blower switch connector. 

(c) 




L 

M 

H 

1 - 2 

3 - 4 

1 - 2 

3 - 5 

1 - 2 

3 - 6 

< 2 Ω 



NO > Replace the rear heater blower switch. 

5. CHECK HARNESS AND CONNECTOR (REAR HEATER RELAY / WATER VALVE RELAY - 

GROUND ) 

(a) 

(b) 

(c) 


Remove the rear blower relay and water valve relay. 

When ignition switch turns ON, press the rear blower forward switch. 

Page 872


04-177 

(d) 


table below. 



Specified 

Condition 

04 

Rear heater relay (85) - Ground 

Water valve relay (85) - Ground 


04 




6. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER SWITCH - REAR BLOWER 

RELAY/WATER VALVE REALY) 

(a) 

(b) 

(c) 

(d) 


Remove the rear blower relay. 



Page 873

04-178 


(e) 


table below. 



Z047 (2) - Rear heater relay (86) 

Z047 (2) - Water valve relay (86) 

Specified 

Condition 

< 2 Ω 




7. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



Z047 (3) - Ground 

Z047 (1) - Ground 


< 2 Ω 





(a) 

(b) 

(c) 



When ignition switch turns ON, press the rear heater blower switch. 

Page 874


04-179 

(d) 


table below. 




04 

P001 (1) - Ground 


04 





(a) 

(b) 



(c) 


table below. 



P001 (2) - Ground 

Specified 

Condition 

< 2 Ω 


YES > Replace rear heater solenoid valve. 


10. CHECK HARNESS AND CONNECTOR ( REAR HEATER RELAY - REAR HEATER MOTOR ) 

(a) 

(b) 

(c) 



When ignition switch turns ON, press the rear heater forward switch and rear heater blower switch. 

(d) 


table below. 



P002 (2) - Ground 



Page 875

04-180 





11. CHECK HARNESS AND CONNECTOR ( REAR HEATER MOTOR - REAR HEATER BLOWER 

SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 




P002 (4) - Z047 (4) 

P002 (1) - Z047 (5) 

< 2 Ω 

P002 (3) - Z047 (6) 


YES > Replace rear heater motor. 


Page 876


PRECAUTION 

DIAGNOSTICS(RHD) - LIGHTING SYSTEM 

04-181 

1. PRECAUTION FOR USING BATTERY DURING INSPECTION. 

(a) While using the battery during inspection, do not bring the positive and negative tester probes too close 

to each other as a short circuit may occur. 

2. PRECAUTION FOR HEADLIGHT BULB REPLACEMENT. 

(a) If even a thin film of oil is left on the surface of the halogen light, the bulb may be damaged because the 

light will burn at a higher temperature. 

(b) Handle any halogen light with great care. Dropping, hitting or damaging the bulb, in any way, may result 

in exploding and shattering because the internal pressure is high. 

(c) Always prepare a new bulb for immediate replacement. While replacing the bulb, the lens may attract 

dust and moisture if removed from the vehicle for too long. 

(d) Always use a bulb of the same wattage for replacement. 

(e) Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may 

fill with water through the gaps around the socket. 


04 

04 



Expression 




Page 877

04-182 




1 


• The voltage should not be below 12 V. 


Yes 

No 





2 

Check the LO - beam lamps. 


• Check the LO - beam lamps. 


Yes 

No 



3 

Check the HI - beam lamps. 



Yes 

No 



4 

Check the turn signal lamps. 



Yes 

No 



5 

Check the hazard lamps. 



Yes 

No 



6 

Check the Indoor Lamps. 



Yes 

No 

Check harness and connector 


Page 878


04-183 

LOCATION 

04 

04 

Page 879

04-184 







6 High - mounted Stop Lamp Assy 

7 License Lamp Assy 


Page 880


04-185 





04 

LO - beam headlamp is 


LO - beam headlamps are 


HI - beam headlamp is 


HI - beam headlamps are 




(One side) 

1. Fuse - 


1. Fuse - 

2. Relay - 



1. Fuse - 


1. Fuse - 

2. Relay - 



1. Bulb(s) 


1. Fuse 

2. Relay - 


replacement 


replacement 



04 



(Both sides) 


4. Bulb(s) 


replacement 




1. Fuse - 

Front fog lamps are 

inoperative 


3. Bulb(s) 


replacement 


replacement 

4. Relay - 


Page 881

04-186 



Front fog lamps are always 

on 


2. Front fog lamp relay - 


replacement 

1. Fuse - 

Rear fog lamps are 

inoperative 


3. Bulb(s) 


replacement 



4. Relay - 


Rear fog lamps are always 

on 


2. Rear fog lamp relay - 


replacement 

1. Fuse - 

2. Relay - 

All fog lamps are 

inoperative 

3. Bulb(s) 



replacement 




replacement 



inoperative (Turn signal 

lamps are normal) 

1. Fuse - 



1. Fuse - 

urn signal lamps are 

inoperative (Hazard 

warning lamps are normal) 




replacement 




inoperative 

1. Fuse - 


3. Flasher - 

Page 882


04-187 




inoperative 

4. Bulb(s) 







replacement 

04 

Turn signal lamps are 



always on 



2. Bulb(s) 



2. Flasher - 

1. Fuse - 


replacement 





04 

All stop lamps are 

inoperative 

2. Stop lamp switch 

3. Bulb(s) 

Chapter 35 brake - brake pedal, 

replacement 






Stop lamp is inoperative 

(One side) 

High - mounted stop lamp 


Back - up lamps are 

inoperative(Both sides) 

1. Bulb(s) 


1. Bulb(s) 


1. Bulb(s) 








1. Fuse - 








Page 883

04-188 





3. Bulb(s) 


Chapter 64 lighting - rear combination lamp, 

replacement 

1. Bulb(s) - 

Ignition switch illumination 


2. Central locking controller 

assy 


replacement 


Central dome light is 

inoperative 

Air purifier lamp is 

inoperative 

1. Bulb(s) 


1. Bulb(s) - 


Chapter 64 lighting - middle dome light assy, 

replacement 

1. Bulb(s) 

Chapter 64 lighting - step lamp assy, 

replacement 

Step lamp are inoperative 


3. Middle door lamp switch 

RH 

1. Bulb(s) - 

Trunk lamp is inoperative 

Front dome light is 

inoperative 


3. Rear hatch lock assy - 

switch 

1. Bulb(s) 


Chapter 64 lighting - front dome light assy, 

replacement 

1. Fuse - 

All interior illumination 

lamps are inoperative 

2. Relay - 



replacement 


Instrument cluster 


inoperative 

1. Fuse - 



Chapter 83 instrument - instrument cluster, 

replacement 

Page 884


04-189 


Diagnosis switch 


inoperative 

wiring diagram 

Cigarette lighter 


inoperative 

A/C control panel 


inoperative 

Rear blower forward switch 


inoperative 

Radio illumination is not 

inoperative 

Dome light switch 


inoperative 

Outside mirror defroster 


inoperative 

Headlamp dimmer switch 


inoperative 

Instrument dimmer switch 


inoperative 

Hazard warning switch 


inoperative 

WIdth lamps is not 

inoperative 

Tail lamps are inoperative 

License lamp is inoperative 

1. Diagnosis switch - 


1. Cigarette Lighter 




1. Rear blower forward switch - 


1. Radio 


1. Dome light switch - 



switch 


1. Headlamp dimmer switch - 


1. Instrument dimmer switch - 




1. Bulb(s) 


1. Bulb(s) 


1. Bulb(s) 


- 

Chapter 66 audio system - electric device 

accessories, replacement 

Chapter 61 heater and air conditioning -multi - 

media And Air - condition Controler Assy, 

replacement 

Chapter 66 audio system - multi - media And 

air - condition controler Assy, replacement 

- 

Chapter 64 lighting - front combination lamp 


Chapter 64 lighting - rear combination lamp 


Chapter 64 lighting - licence lamp assy, 

replacement 

04 

04 

Page 885

04-190 



1. Fuse - 

Width lamps tail lamps and 

license lamp are 

inoperative 

2. Relay - 



replacement 


Page 886


04-191 

LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) 


04 

04 

Page 887

04-192 



• This inspection procedure is an example of lo - beam headlamp LH, lo - beam headlamp RH inspection 



(a) 

(b) 

(c) 

(d) 





Does the lo - beam headlamp LH work correctly? 



2. CHECK HARNESS AND CONNECTOR (LO - BEAM LH FUSE - HEADLAMP LH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 

(d) 


table below. 



V020 (3) - Ground 


≥ 1 MΩ 


YES > Replace Lo - beam LH fuse (7.5A) in co-pilot side junction box (Z043). 


Page 888


04-193 

LO - BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES) 


04 

04 

Page 889

04-194 




(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







Do both lo - beam headlamps work correctly? 



2. INSPECT LO - BEAM RELAY 

(a) 

(b) 


Remove lo - beam relay in co-pilot side junction box (Z043). 

(c) 



Condition 


Specified 

Condition 

Normal 



86 - 85 breakover 

≥ 1 MΩ 

87 - 30 

< 2 Ω 



NO > Replace lo - beamheadlamp relay. 

Page 890


04-195 


(a) 

(b) 


Disconnect the Z011 combination switch (light) connector. 

(c) 



04 

Condition 


switch to OFF 


switch to ON 


7 - 10 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 

04 




4. CHECK HARNESS AND CONNECTOR (LO - BEAM RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 




(d) 


table below. 



Lo - beam Relay (85) - Z011 (10) 


< 2 Ω 




Page 891

04-196 


5. CHECK HARNESS AND CONNECTOR (LO - BEAM FUSES BOTH LH AND RH, LO - BEAM 

HEADLAMPS BOTH LH AND RH) 

(a) 

(b) 

(c) 




(d) 


table below. 




Lo - beam fuse RH (7.5A) - V022 (3) 


< 2 Ω 

(e) 


table below. 



V020 (3) - Ground 

V022 (3) - Ground 


≥ 1 MΩ 


YES > Replace lo - beam headlamp fuse (7.5A) both LH and RH in driver side fuse box (Z043). 


Page 892


04-197 

HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) 


04 

04 

Page 893

04-198 



• This inspection procedure is an example of hi - beam headlamp LH, hi - beam headlamp RH inspection 



(a) 

(b) 

(c) 

(d) 





Does hi - beam headlamp LH work correctly? 



2. CHECK HARNESS AND CONNECTOR (HI - BEAM LH FUSE - HEADLAMP LH) 

(a) 

(b) 



(c) 


table below. 



Hi - beam LH fuse (10A) - V020(2) 


< 2 Ω 

(d) 


table below. 



V020 (2) - Ground 


≥ 1 MΩ 


YES > Replace Hi - beam LH Fuse(10A) in co-pilot side junction box (Z043). 


Page 894


04-199 

HI - BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES) 


04 

04 

Page 895

04-200 




(a) 

(b) 

(c) 

(d) 

(e) 

(f) 





Replace headlamp Bulb RH. 


Do both hi - beam headlamps work correctly? 




(a) 


(b) 

Inspect the headlamp fuse (20A) in co-pilot side junction 

box (Z043). 




Page 896


04-201 

3. INSPECT HI - BEAM RELAY 

(a) 

(b) 


Remove hi - beam relay in co-pilot side junction box (Z043). 

04 

(c) 

Inspect Hi - beamheadlamp relay according to the 

value(s) in the table below 

Condition 

Namal 



Tester 

Connection 

Specified 

Condition 


30 - 87 

≥ 1 MΩ 

< 2 Ω 

04 



NO > Replace hi - beam relay. 


(a) 

(b) 



(c) 



Condition 


switch to OFF 


switch to ON 

Tester 

Connection 

9 - 7 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 




Page 897

04-202 


5. CHECK HARNESS AND CONNECTOR (HI - BEAM RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 




(d) 


table below. 



hi - beam relay (86) - Z043 (9) 


< 2 Ω 




6. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSES BOTH LH AND RH, HI - BEAM 

HEADLAMPS BOTH LH AND RH ) 

(a) 

(b) 

(c) 




(d) Measure the resistance according to the value(s) in the 

table below. 






< 2 Ω 

Page 898


04-203 

(e) 


table below. 




04 

V020 (2) - Ground 

V022 (2) - Ground 

≥ 1 MΩ 

04 


YES > Replace hi - beam fuses both LH and RH in driver side box (Z043). 


Page 899

04-204 


LO - BEAM AND HI - BEAM HEADLAMPS ARE INOPERATIVE (ONE 

SIDE) 


Page 900


04-205 


• This inspection procedure is an example of hi - beam headlamp and lo - beam headlamp LH, hi - beam 

headlamp and lo - beam headlamp RH inspection procedure is similar. 


(a) 

(b) 

(c) 

(d) 








04 

04 

2. CHECK HARNESS AND CONNECTOR (HEADLAMP LH - GROUND) 

(a) 

(b) 



(c) 


table below. 



V020 (1) - Ground 


< 2 Ω 




3. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSE AND LOW - BEAM FUSE LH - 

HEADLAMP LH) 

(a) 

(b) 



Page 901

04-206 


(c) 


table below. 



Hi - beam LH fuse (10 A) - V020 (2) 

Lo - beam LH fuse (7.5 A) - V020 (3) 


< 2 Ω 

(d) 


table below. 



V020 (2) - Ground 

V020 (3) - Ground 


≥ 1 MΩ 


YES > Replace hi - beam fuse and lo - beam fuse LH in co-pilot side junction box (Z043). 


Page 902


04-207 



04 

04 

Page 903

04-208 




(a) 

(b) 



(c) 


table below. 



Z011 (11) - Ground 


< 2 Ω 





(a) 

(b) 



(c) 


in the table below.. 

Condition 


switch to OFF 


switch to ON 


switch to OFF 


switch to ON 

Tester 

Connection 

9 - 7 

10 - 7 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 

≥ 1 MΩ 

< 2 Ω 




Page 904


04-209 


(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







Does both headlamp hulbs work correctly? 

YES > Replace headlamp bulbs both LH and RH. 


04 

04 

4. CHECK HARNESS AND CONNECTOR (HEADLAMP BOTH LH AND RH - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



V020 (1) - Ground 

V022 (1) - Ground 


< 2 Ω 




5. INSPECT HI - BEAM RELAY AND LO - BEAM RELAY 

(a) 

(b) 

(c) 




(d) 



Condition 

Tester 

Connection 

Specified 

Condition 

Namal 




≥ 1 MΩ 

30 - 87 

< 2 Ω 

Page 905

04-210 


(e) 



Condition 


Specified 

Condition 

Normal 




≥ 1 MΩ 

87 - 30 

< 2 Ω 




6. CHECK HARNESS AND CONNECTOR (HI - BEAM RELAY AND LO - BEAM RELAY - 

COMBINATION SWITCH) 

(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



Hi - beam relay (86) - Z011 (9) 

Lo - beam relay (85) - Z011 (10) 


< 2 Ω 




Page 906


04-211 

7. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSE AND LO - BEAM FUSE BOTH LH AND 

RH - HEADLAMP BOTH LH AND RH) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 



< 2 Ω 

(e) 


table below. 




Lo - beam RH fuse (7.5A) - V022 (3) 


< 2 Ω 

(f) 


table below. 



V020 (2) - Ground 

V020 (3) - Ground 


≥ 1 MΩ 

Page 907

04-212 


(g) 


table below. 



V022 (2) - Ground 

V022 (3) - Ground 


≥ 1 MΩ 





(a) 


(b) 

Inspect the headlamp fuse (20A) in co-pilot side junction 

box (Z043). 


YES > Replace hi - beam fuse (10A) and lo - beam fuse (7.5A) both LH and RH in the co-pilot side junction 

box (Z043). 

NO > Replace headlamp fuse (20A) and lo - beam fuse (7.5A) both LH and RH in the co-pilot side junction 

box (Z043). 

Page 908


04-213 



04 

04 

Page 909

04-214 




(a) 


(b) 

Inspect front fog lamp fuse (15 A) in co-pilot side junction 

box (Z043). 





(a) 

(b) 

(c) 

(d) 

(e) 


Remove front fog relay in co-pilot side junction box (Z043). 



Disconnect the Z003 instrument cluster A connector. 

(f) 


table below. 



C001 (1) - Ground 


≥ 1 MΩ 




Page 910


04-215 

3. INSPECT FRONT FOG LAMP BULBS 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 



relace front fog lamp bulb LH. 


relace front fog lamp bulb RH. 



YES > Replace front fog lamp bulb both LH and RH. 


04 

04 


(a) 

(b) 


Disconnect the Z011 combination switch connector. 

(c) 



Condition 

Tester 

Connection 

Specified 

Condition 


switch to ON 


switch to OFF 

3 - 1 < 2 Ω 

3 - 1 ≥ 1 MΩ 




5. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - COMBINATION SWITCH 

(LIGHT)) 

(a) 

(b) 

(c) 


Remove front fog lamp relay in co-pilot side junction box (Z043). 


Page 911

04-216 


(d) 


table below. 



Front fog lamp relay (86) - Z011 (3) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 





(e) 


table below. 






< 2 Ω 

Page 912


04-217 




7. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP - GROUND) 

04 

(a) 

(b) 

(c) 




(d) 


table below. 


04 


C001 (2) - Ground 

C002 (2) - Ground 


< 2 Ω 




Page 913

04-218 




Page 914


04-219 



(a) 

(b) 



04 

(c) 



Condition 

Tester 

Connection 

Specified 

Condition 

04 


switch to ON 


switch to OFF 

3 - 1 < 2 Ω 

3 - 1 ≥ 1 MΩ 




2. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - COMBINATION SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z011 (3) - Ground 


≥ 1 MΩ 




Page 915

04-220 




(b) Remove front fog lamp relay in co-pilot side junction box (Z043). 


NOTE 

The front fog lamps should not light. 




Page 916


04-221 



04 

04 

Page 917

04-222 




(a) 


(b) 

Inspect rear fog lamp fuse (10A) in co-pilot side junction 

box (Z043). 





(a) 

(b) 

(c) 

(d) 

(e) 


Remove rear fog lamp relay in co-pilot side junction box (Z043). 



Disconnect the Z002 instrument cluster B connector. 

(f) 


table below. 



F012 (5) - Ground 


≥ 1 MΩ 




Page 918


04-223 


(a) 

(b) 



(c) 



04 

Condition 


switch to ON 


switch to OFF 

Tester 

Connection 

Specified 

Condition 

2 - 1 < 2 Ω 

2 - 1 ≥ 1 MΩ 

04 




4. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 




(d) 


table below. 



Rear fog lamp relay (86) - Z011 (2) 


< 2 Ω 

Page 919

04-224 





5. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



F012 (2) - Ground 

G004 (2) - Ground 


< 2 Ω 




6. INSPECT REAR FOG LAMP BULBS 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 



Replace rear fog lamp bulb LH. 


Replace rear fog lamp bulb RH. 



YES > Replace rear fog lamp bulb both LH and RH. 


7. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - REAR FOG LAMP LH) 

(a) 

(b) 

(c) 

(d) 





Page 920


04-225 

(e) 


table below. 




04 



< 2 Ω 

04 




Page 921

04-226 


REAR FOG LAMPS ARE ALWAYS ON 


Page 922


04-227 



(a) 

(b) 



04 

(c) 



Condition 

Tester 

Connection 

Specified 

Condition 

04 


switch to ON 


switch to OFF 

2 - 1 < 2 Ω 

2 - 1 ≥ 1 MΩ 




2. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - COMBINATION SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z011 (2) - Ground 


≥ 1 MΩ 




Page 923

04-228 




(b) Remove rear fog lamp relay in co-pilot side junction box (Z043). 


NOTE 

The rear fog lamps should not light. 




Page 924


04-229 

ALL FOG LAMPS ARE INOPERATIVE 


04 

04 

Page 925

04-230 




(a) 


(b) 

(c) 

Inspect the front fog lamp fuse (15 A) in co-pilot side 

junction box (Z043). 

Inspect the rear fog lamp fuse (10 A) in co-pilot side 




NO > If front fog lamp fuse (15 A) is damage,go to next step. 

If rear fog lamp fuse (10 A) is damage,go to step 3. 

If both front and rear fog lamp fuses are damage,go to step 2 and step 3. 


(a) 

(b) 

(c) 

(d) 

(e) 






(f) 


table below. 



C001 (1) - Ground 


≥ 1 MΩ 




Page 926


04-231 


(a) 

(b) 

(c) 

(d) 

(e) 





Disconnect the Z002 instrument cluster B connector. 

04 

(f) 


table below. 


04 


F012 (5) - Ground 


≥ 1 MΩ 





(a) 

(b) 



(c) 


table below. 



Z011 (1) - Ground 


< 2 Ω 




Page 927

04-232 



(a) 

(b) 



(c) 



Condition 


switch to ON 


switch to OFF 


switch to ON 


switch to OFF 

Tester 

Connection 

3 - 1 

2 - 1 

Specified 

Condition 

< 2 Ω 

≥ 1 MΩ 

< 2 Ω 

≥ 1 MΩ 




6. NSPECT BOTH FRONT AND REAR FOG LAMP RELAYS. 

(a) 

(b) 

(c) 



Remove rear fog relay in co-pilot side junction box (Z043). 

(d) 

Inspect relays according to the value(s) in the table 

below.. . 

Condition 

Tester 

Connection 

Specified 

Condition 

Namal 




30 - 87 ≥ 1 MΩ 

30 - 87 < 2 Ω 

NOTE 

• Front fog lamp relay and rear fog lamp relay have 

same pins. 

• Both relays shoud be measured. 




Page 928


04-233 

7. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY AND REAR FOG LAMP 

RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 

(d) 





04 

(e) 


table below. 


04 


Front fog lamp relay (86) - Z011 (3) 

Rear fog lamp relay (86) - Z011 (2) 


< 2 Ω 




8. CHECK HARNESS AND CONNECTOR (FRONT AND REAR FOG LAMP RELAY - FRONT FOG 

LAMP LH AND RE ,REAR FOG LAMP LH AND RH) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 








Page 929

04-234 


(h) 


table below. 






< 2 Ω 

(i) 


table below. 






< 2 Ω 




Page 930


04-235 

9. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP LH AND REAR FOG LAMP LH AND 

RH - GROUND) 

(a) 

(b) 

(c) 

(d) 

(e) 






04 

(f) 


table below. 


04 


C001 (2) - Ground 

C002 (2) - Ground 


< 2 Ω 

(g) 


table below. 



F012 (2) - Ground 

G004 (2) - Ground 


< 2 Ω 


YES > Replace all fog lamp bulbs. 


Page 931

04-236 





Page 932


04-237 



(a) 


04 

(b) 

Inspect the hazard warning fuse (15A) in co-pilot side 


04 




2. CHECK HARNESS AND CONNECTOR (HAZARD WARNING FUSE - FLASHER) 

(a) 

(b) 


Disconnect the Z007 flasher connector. 

(c) 


table below. 



Z007(1) - Ground 


≥ 1 MΩ 




3. CHECK HARNESS AND CONNECTOR (FLASHER - HAZARD WARNING SWITCH) 

(a) 

(b) 

(c) 



Disconnect the Z034 hazard warning switch connector. 

Page 933

04-238 


(d) 


table below. 



Z007 (7) - Z034 (8) 


< 2 Ω 





(a) 

(b) 



(c) 


table below. 



Hazard warning fuse (15A) - Z007 (1) 


< 2 Ω 





(a) 

(b) 



Page 934


04-239 

(c) 


table below. 




04 

Z034 (7) - Ground 

< 2 Ω 

04 





(a) 

(b) 



(c) 



Condition 


switch OFF 


switch ON 

Tester 

Connection 

7 - 8 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 


YES > Replace the flasher. 

NO > Relace hazard warning switch. 

Page 935

04-240 





Page 936


04-241 



(a) 


04 

(b) 

Inspect the turn signal fuse (10A) in co-pilot side junction 

box (Z043). 

04 




2. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - COMBINATION SWITCH (TURN 

SIGNAL SWITCH)) 

(a) 

(b) 


Disconnect the Z011 combination switch (turn signal switch) connector. 

(c) 


table below. 



Z011 (12) - Ground 


≥ 1 MΩ 




Page 937

04-242 


3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - FLASHER) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z007 (12) - Ground 

Z007 (5) - Ground 


≥ 1 MΩ 




4. INSPECT COMBINATION SWITCH (TURN SIGNAL SWITCH) 

(a) 

(b) 



(c) 

Inspect combination switch (turn signal switch) according 


Condition 


switch OFF 


LEFT 


RIGHT 

Tester 

Connection 

12 - 11 

12 - 13 

12 - 11 

12 - 13 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 




Page 938


04-243 

5. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - COMBINATION SWITCH (TURN SIGNAL 

SWITCH)) 

(a) 

(b) 



04 

(c) 


table below. 




04 

Turn signal fuse (10A) - Z011 (12) 

< 2 Ω 





(a) 

(b) 

(c) 




(d) 


table below. 



Z007 (5) - Z011 (11) 

Z007 (12) - Z011 (13) 


< 2 Ω 

Page 939

04-244 



YES > Replace the flasher. 


Page 940


04-245 

HAZARD WARNING AND TURN SIGNAL LAMPS ARE INOPERATIVE 


04 

04 

Page 941

04-246 




(a) 


(b) 

(c) 

Inspect the hazard warning fuse (15A) in co-pilot side 


Inspect the turn signal fuse (10A) in co-pilot side junction 

box (Z043). 



NO > If hazard warning fuse (15A) is damage, go to next step. 

If turn signal fuse (10A) is damage,go to step 3. 

If both hazard warning fuse (15A) and turn signal fuse (10A) are damge,go to step 2 and step 3. 


(a) 

(b) 



(c) 


table below. 





≥ 1 MΩ 




Page 942


04-247 

3. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - COMBINATION SWITCH (TURN 

SIGNAL SWITCH)) 

(a) 

(b) 




table below. 


04 


Z011 (12) - Ground 


≥ 1 MΩ 

04 




4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - FLASHER) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z007 (12) - Ground 

Z007 (5) - Ground 


≥ 1 MΩ 




5. CHECK HARNESS AND CONNECTOR (FLASHER - GROUND) 

(a) 

(b) 



Page 943

04-248 


(c) 


table below. 



Z007 (8) - Ground 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 









(a) 

(b) 



(c) 



Condition 


switch OFF 


switch ON 

Tester 

Connection 

7 - 8 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 



NO > Relace hazard warning switch,and go to step 11. 

Page 944


04-249 


(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

Z034 (8) - Z007 (7) 

< 2 Ω 



NO > Repair or replace harness or connector, and go to step 11. 


(a) 

(b) 



(c) 


table below. 



Z034 (7) - Ground 


< 2 Ω 



NO > Repair or replace harness or connector,and go to step 11. 


(a) 

(b) 



Page 945

04-250 


(c) 


table below. 



Hazard warning fuse (15A) - Z007 (1) 


< 2 Ω 



NO > Repair or replace harness or connector,and go to step 11. 

11. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - COMBINATION SWITCH (TURN SIGNAL 

SWITCH)) 

(a) 

(b) 



(c) 


table below. 



Turn signal fuse (10A) - Z011 (12) 


< 2 Ω 




Page 946


04-251 


(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

Z007 (5) - Z011 (11) 

Z007 (12) - Z011 (13) 

< 2 Ω 


YES > Replace the combination switch (turn signal switch) . 



(a) 

(b) 

(c) 

(d) 

(e) 






(f) 


table below. 



V021 (1) - Ground 

F012 (2) - Ground 


< 2 Ω 

Page 947

04-252 


(g) 


table below. 



V025 (1) - Ground 

G004 (2) - Ground 


< 2 Ω 






(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



Z007 (4) - V021 (2) 

Z007 (9) - F012 (4) 


< 2 Ω 

Page 948


04-253 

(h) 


table below. 




04 

Z007 (10) - V025 (2) 

Z007 (2) - G004 (4) 

< 2 Ω 

04 


YES > Replace 4 turn signal lamp bulbs. 


Page 949

04-254 


TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE) 


Page 950


04-255 


• This inspection procedure is an example of turn signal lamp LH, turn signal lamp RH inspection 



NOTE 

If only one turn signal lamp is not bright,over this step. 

(a) 

(b) 


Disconnect the Z011 combination switch(turn signal lamp) connector. 

04 

04 

(c) 



Condition 


switch OFF 


LEFT 


RIGHT 

Tester 

Connection 

12 - 11 

12 - 13 

12 - 11 

12 - 13 

Specified 

Condition 

≥ 1 MΩ 

< 2 Ω 

NOTE 

• If only turn signal lamps LH is not bright,measure 12 

- 11. 

• If only turn signal lamps RH is not bright,measure 12 

- 13. 





(a) 

(b) 

(c) 




(d) 


table below. 



Z007 (5) - Z011 (11) 


< 2 Ω 

Page 951

04-256 






(a) 

(b) 

(c) 

(d) 








4. CHECK HARNESS AND CONNECTOR (FLASHER - TURN SIGNAL LAMP) 

NOTE 

• If only front turn signal lamps LH is not bright,step d isn’t performed. 

• If only rear turn signal lamps LH is not bright,step c isn’t performed. 


(b) Disconnect the Z007 flasher connector. 

(c) Disconnect the V021 front turn signal lamp LH connector. 

(d) Disconnect the F012 rear combination lamp LH connector. 

(e) 


table below. 



Z007 (4) - V021 (2) 

Z007 (9) - F012 (4) 


< 2 Ω 

NOTE 


Z007 (4) - V021 (2) only. 


Z007 (9) - F012 (4) only. 




Page 952


04-257 


NOTE 

• If only front turn signal lamps LH is not bright,step c isn’t performed. 

• If only rear turn signal lamps LH is not bright,step b isn’t performed. 

(a) 

(b) 

(c) 




(d) 


table below. 


04 

04 


V021 (1) - Ground 

F012 (2) - Ground 


< 2 Ω 


YES > Replace turn signal lamp bulb(s). 


NOTE 


V021 (1) - Ground only. 


F012 (2) - Ground only. 

Page 953

04-258 




Page 954


04-259 



(a) 

(b) 



04 

(c) 



Condition 

Tester 

Connection 

Specified 

Condition 

04 


switch OFF 

7 - 8 ≥ 1 MΩ 



NO > Replace hazard warning switch. 


(a) 

(b) 

(c) 




(d) 


table below. 



Z034 (8) - Ground 


≥ 1 MΩ 




3. CHECK HARNESS AND CONNECTOR (FLASHER - TURN SIGNAL LAMP) 

(a) 

(b) 

(c) 



Connect the battery negative cable,check the wire harness for shot to power supply, hazard warning 

lamp is shoud not be bright. 




Page 955

04-260 






(a) 


(b) 

Inspect the stop lamp fuse (15A) in engine room junction 

box(Z063). 




Page 956


04-261 

2. CHECK HARNESS AND CONNECTOR (BRAKE LAMP FUSE - STOP LAMP SWITCH) 

(a) 

(b) 



(c) 


table below. 


04 


Z006 (2) - Ground 


≥ 1 ΜΩ 

04 





(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



F012 (3) - Ground 


≥ 1 ΜΩ 




Page 957

04-262 


4. INSPECT STOP LAMP SWITCH 

(a) 

(b) 



(c) 



Condition 

Tester 

Connection 

Specified 

Condition 

Set stop lamp switch OFF 1 - 2 ≥ 1 MΩ 

Set stop lamp switch ON 1 - 2 < 2 Ω 




5. CHECK HARNESS AND CONNECTOR ( BRAKE LAMP FUSE - STOP LAMP SWITCH) 

(a) 

(b) 



(c) 


table below. 



Stop lamp fuse (15A) - Z006 (2) 


< 2 Ω 




Page 958


04-263 


(a) 

(b) 

(c) 

(d) 

(e) 






04 

(f) 


table below. 


04 


Z006(1) - F012 (3) 

Z006(1) - G004(3) 


< 2 Ω 

(g) 


table below. 



Z006(1) - U002 (2) 


< 2 Ω 




7. CHECK HARNESS AND CONNECTOR (STOP LAMP - GROUND) 

(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



F012 (2) - Ground 

G004 (2) - Ground 


< 2 Ω 

Page 959

04-264 


(f) 


table below. 



U002 (1) - Ground 


< 2 Ω 


YES > Replace stop lamp bulbs. 


Page 960


04-265 



04 

04 

Page 961

04-266 



• This inspection procedure is an example of stop lamp LH, stop lamp RH inspection procedure is similar. 

1. CHECK HARNESS AND CONNECTOR (REAR COMBINATION LAMP - GROUND) 

(a) 

(b) 



(c) 


table below. 



F012 (2) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - REAR COMBINATION LAMP) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z006 (1) - F012 (3) 


< 2 Ω 


YES > Replace stop lamp bulb. 


Page 962


04-267 

HIGH - MOUNTED STOP LAMP IS INOPERATIVE 


04 

04 

Page 963

04-268 



1. CHECK HARNESS AND CONNECTOR (HIGH - MOUNTED STOP LAMP - GROUND) 

(a) 

(b) 



(c) 


table below. 



U002 (1) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - HIGH - MOUNTED STOP LAMP) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z006 (1) - U002 (2) 


< 2 Ω 


YES > Replace high - mounted stop lamp bulb. 


Page 964


04-269 

BACK - UP LAMP IS INOPERATIVE(ONE SIDE) 


04 

04 

Page 965

04-270 



• This inspection procedure is an example of back - up lamp LH, back - up lamp RH inspection procedure 

is similar. 

(a) 

(b) 

(c) 

Check harness and connector (back - up lamp - ground) 



(d) 


table below. 



F012 (2) - Ground 


< 2 Ω 





(a) 

(b) 

(c) 


Disconnect the Z056 back - up lamp switch connector. 


(d) 


table below. 



Z056 (2) - F012 (6) 


< 2 Ω 


YES > Replace back - up lamp bulb. 


Page 966


04-271 

BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES) 


04 

04 



(a) 


(b) 

Inspect the back - up lamp fuse (10A) in co-pilot side 


Page 967

04-272 






(a) 

(b) 



(c) 


table below. 



Z056 (1) - Ground 


≥ 1 ΜΩ 





(a) 

(b) 

(c) 




(d) 


table below. 



F012 (6) - Ground 


≥ 1 ΜΩ 




Page 968


04-273 


(a) 

(b) 



04 

(c) 

Inspect the back - up lamp switch according to the 


Condition 


switch OFF 


switch ON 

Tester 

Connection 

Specified 

Condition 

1 - 2 ≥ 1 MΩ 

1 - 2 < 2 Ω 

04 





(a) 

(b) 



(c) 


table below. 



Back - up lamp (10A) - Z056 

(1) 


< 2 Ω 




Page 969

04-274 



(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



Z056 (2) - F012 (6) 

Z056 (2) - G004 (6) 


< 2 Ω 




7. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



F012 (2) - Ground 

G004 (2) - Ground 


< 2 Ω 


YES > Replace back - up lamp bulbs. 


Page 970


04-275 



04 

04 

Page 971

04-276 



1. INSPECT IGNITION SWITCH ILLUMINATION LAMP. 

(a) 

(b) 

(c) 

(d) 


Disconnect the Z014 ignition switch illumination connector. 

Replace ignition switch illumination lamp. 



YES > Replace ignition switch illumination lamp. 


2. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - IGNITION SWITCH ILLUMINATION) 

(a) 

(b) 



(c) 


table below. 



Dome light fuse (10A) - Z014 (1) 


< 2 Ω 




Page 972


04-277 

3. CHECK HARNESS AND CONNECTOR (IGNITION SWITCH ILLUMINATION - CENTRAL LOCKING 


(a) 

(b) 

(c) 



Disconnect the Z008 central locking controller assy connector. 

04 

(d) 


table below. 




04 

Z014 (2) - Z008 (B1) 

< 2 Ω 





(a) 

(b) 



(c) 


table below. 



Z008 (B10) - Ground 


< 2 Ω 


YES > Replace central locking controller asssy. 


Page 973

04-278 




Page 974


04-279 

04 

04 

Page 975

04-280 



1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - CENTRAL DOME LIGHT) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 

NOTE 

If central dome light can’t be contrled by door lamp switch,over 

this step. 

(d) 


table below. 





< 2 Ω 

NOTE 

If central dome light can be contrled by door lamp switch,over 

this step. 




2. CHECK HARNESS AND CONNECTOR (CENTRAL DOME LIGHT - DOME LIGHT SWITCH AND 


NOTE 

• If central dome light can be contrled by door lamp switch,perform this step. 

• If central dome light can’t be contrled by door lamp switch,over this step ,perform the next step. 


(b) Disconnect the F010 central dome light connector. 

(c) Disconnect the F014 middle door lamp switch RH connector. 

Page 976


04-281 

(d) 

Disconnect the Z031 dome light switch connector. 

(e) 


table below. 


04 


F010 (3) - Z031 (5) 

F010 (2) - F014 (1) 


< 2 Ω 

04 




3. CHECK HARNESS AND CONNECTOR (CENTRAL DOME LIGHT - DOME LIGHT SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



F010 (2) - Z031 (5) 


< 2 Ω 




4. INSPECT DOME LIGHT SWITCH 

(a) 

NOTE 

Turn the dome light switch ON. 

If the dome light switch has no problem,it should be bright. 



NO > Replace dome light switch. 

Page 977

04-282 



(a) 

(b) 



(c) 


table below. 



Z031 (2) - Ground 


< 2 Ω 




Page 978


04-283 



04 

04 

Page 979

04-284 


Page 980


04-285 


1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - AIR PURIFIER LAMP) 

(a) 

(b) 



04 

(c) 


table below. 




04 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (AIR PURIFIER LAMP - DOME LIGHT SWITCH AND 


(a) 

(b) 

(c) 

(d) 




Disconnect the F014 middle door lamp switch RH connector. 

(e) 


table below. 



F011 (3) - Z031 (5) 

F011 (2) - F014 (1) 


< 2 Ω 


YES > Replace air purifier. 


Page 981

04-286 


STEP LAMP ARE INOPERATIVE 



1. INSPECT STEP LAMP 

(a) 

(b) 

(c) 

(d) 


Disconnect the Z055 step lamp connector. 

Replace step lamp bulb. 

Connect the battery negative cable,trun the middle door lamp switch RH ON. 


YES > Replace step lamp bulb. 


Page 982


04-287 

2. CHECK HARNESS AND CONNECTOR (dome light FUSE - STEP LAMP) 

(a) 

(b) 



(c) 


table below. 


04 


dome light fuse (10A) - Z055 (1) 


< 2 Ω 

04 




3. CHECK HARNESS AND CONNECTOR (STEP LAMP - MIDDLE DOOR LAMP SWITCH RH) 

(a) 

(b) 

(c) 



Disconnect the F014 middle door lamp switch RH connector. 

(d) 


table below. 



Z055 (2) - F014 (1) 


< 2 Ω 


YES > Replace middle door lamp switch RH. 


Page 983

04-288 


TRUNK LAMP IS INOPERATIVE 


Page 984


04-289 


1. INSPECT TRUNK LAMP 

(a) 

(b) 

(c) 

(d) 



Replace trunk lamp bulb. 

Connect the battery negative cable,turn rear hatch lock assy - switch ON. 


YES > Replace trunk lamp bulb. 


04 

04 

2. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - TRUNK LAMP) 

(a) 

(b) 



(c) 


table below. 



Dome light fuse (10A) - J003 (1) 


< 2 Ω 




3. CHECK HARNESS AND CONNECTOR (TRUNK LAMP - REAR HATCH LOCK ASSY - SWITCH) 

(a) 

(b) 

(c) 




Page 985

04-290 


(d) 


table below. 



J003 (2) - J001 (1) 


< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (REAR HATCH LOCK ASSY - SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



J001 (2) - Ground 


< 2 Ω 


YES > Replace rear hatch lock assy - switch. 


Page 986


04-291 



04 

04 

Page 987

04-292 


Page 988


04-293 


1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - FRONT DOME LIGHT) 

(a) 

(b) 

Disconnect the battery negative cable.front dome light 


04 

(c) 


table below. 




04 



< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (FRONT DOME LIGHT - GROUND,FRONT DOOR LAMP 

DIODE RH,FRONT DOOR LAMP SWITCH RH,INSTRUMENT CLUSTER) 

(a) 

(b) 

(c) 

(d) 

(e) 



Disconnect the Z073 front door lamp diode RH connector. 

Disconnect the Z046 front door lamp switch LH connector. 


(f) 


table below. 



F009 (4) - Z073 (1) 

F009 (4) - Z046 (1) 


< 2 Ω 

Page 989

04-294 


(g) 


table below. 



F009 (4) - Z003 (A30) 

F009 (3) - Ground 


< 2 Ω 


YES > Replace front dome light assy. 


Page 990


04-295 

ALL INTERIOR ILLUMINATION LAMPS ARE INOPERATIVE 


04 

04 

Page 991

04-296 


Page 992


04-297 



(a) 

(b) 


Remove lamplet relay in co-pilot side junction box (Z043). 

04 

(c) 


table below 

Condition 

Tester 

Connection 

Specified 

Condition 

04 




87 - 30 < 2 Ω 




2. CHECK HARNESS AND CONNECTOR (LAMPLET RELAY - COMBINATION SWITCH) 

(a) 

(b) 

(c) 


remove lamplet relay in co-pilot side junction box (Z043). 


(d) 


table below. 



Lamplet relay (86) - Z011 (5) 


< 2 Ω 




Page 993

04-298 



(a) 

(b) 



(c) 


table below. 



Z011 (8) - Ground 


< 2 Ω 





(a) 


(b) 

(c) 

inspect lamplet fuse (7.5A) in co-pilot side junction box 

(Z043). 

inspect switch lighting fuse (7.5A) in co-pilot side junction 

box (Z043). 




Page 994


04-299 


(a) 

(b) 



(c) 


table below. 


04 


Z003 (A6) - Ground 


≥ 1 ΜΩ 

04 



NO > Repair or replace harness or connector,and go to next step. 

6. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - INTERIOR LAMPS) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

(j) 

(k) 



Disconnect the Z033 headlamp dimmer switch connector. 

Disconnect the Z032 instrument dimmer switch connector. 

Disconnect the Z024 outside mirror defroster switch connector. 

Disconnect the Z022 rear blower forward switch connector. 


Disconnect the Z030 cigarette lighter connector. 

Disconnect the Z025 radio A connector. 

Disconnect the Z017 A/C control panel B connector. 

Disconnect the Z029 diagnosis switch connector. 

(l) 


table below. 



Z034 (2) - Ground 


≥ 1 ΜΩ 




Page 995

04-300 




Page 996


04-301 



(a) 


04 

(b) 

Inspect lamplet fuse (7.5A) in co-pilot side junction box 

(Z043). 

04 





(a) 

(b) 



(c) 


table below. 





≥ 1 MΩ 




Page 997

04-302 


3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - GROUND) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 





(a) 

(b) 



(c) 


table below. 



Lamplet fuse (7.5A) - Z003 

(A6) 


< 2 Ω 


YES > Replace Instrument Cluster. 


Page 998


04-303 



04 

04 

Page 999

04-304 



1. CHECK HARNESS AND CONNECTOR (DIAGNOSIS SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



Z029 (1) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - DIAGNOSIS SWITCH) 

(a) 

(b) 



(c) 


table below. 



Switch lighting fuse (7.5A) - Z029 (3) 


< 2 Ω 


YES > Replace diagnosis switch. 


Page 1000


04-305 



04 

04 

Page 1001

04-306 




(a) 

(b) 



(c) 


table below. 



Z030 (1) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - CIGARETTE LIGHTER) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace cigarette lighter. 


Page 1002


04-307 



04 

04 

Page 1003

04-308 



1. CHECK HARNESS AND CONNECTOR (A/C CONTROL PANEL - GROUND) 

(a) 

(b) 


Disconnect the Z023 A/C control panel A connector. 

(c) 


table below. 



Z023 (20) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - A/C CONTROL PANEL) 

(a) 

(b) 


Disconnect the Z017 A/C control panel B connector. 

(c) 


table below. 





< 2 Ω 


YES > Replace A/C control panel. 


Page 1004


04-309 



04 

04 

Page 1005

04-310 




(a) 

(b) 



(c) 


table below. 





< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - RADIO) 

(a) 

(b) 



(c) 


table below. 



Switch lighting fuse (7.5A) - Z025 (A3) 


< 2 Ω 


YES > Raplace radio. 


Page 1006


04-311 


ERATIVE 


04 

04 

Page 1007

04-312 



1. CHECK HARNESS AND CONNECTOR (REAR BLOWER FORWARD SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



Z022 (1) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - REAR BLOWER FORWARD 

SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace rear blower forward switch. 


Page 1008


04-313 



04 

04 

Page 1009

04-314 




(a) 

(b) 



(c) 


table below. 



Z031 (1) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - DOME LIGHT SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace dome light switch. 


Page 1010


04-315 


INOPERATIVE 


04 

04 

Page 1011

04-316 



1. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROSTER SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



Z024 (1) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - OUTSIDE MIRROR DEFROSTER 

SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace outside mirror defroster switch. 


Page 1012


04-317 


TIVE 


04 

04 

Page 1013

04-318 



1. CHECK HARNESS AND CONNECTOR (HEADLAMP DIMMER SWITCH - Ground) 

(a) 

(b) 



(c) 


table below. 



Z033 (6) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - HEADLAMP DIMMER SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace headlamp dimmer switch. 


Page 1014


04-319 


TIVE 


04 

04 

Page 1015

04-320 



1. CHECK HARNESS AND CONNECTOR (INSTRUMENT DIMMER SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



Z032 (6) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - INSTRUMENT DIMMER SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 


YES > Replace instrument dimmer switch. 


Page 1016


04-321 

HAZARD WARNING SWITCH ILLUMINATION IS NOT INOPERATIVE 


04 

04 

Page 1017

04-322 




(a) 

(b) 



(c) 


table below. 



Z034 (3) - Ground 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - HAZARD WARNING SWITCH) 

(a) 

(b) 



(c) 


table below. 





< 2 Ω 




Page 1018


04-323 

WIDTH LAMPS IS NOT INOPERATIVE 


04 

04 


1. CHECK HARNESS AND CONNECTOR (WIDTH LAMPS - GROUND) 

NOTE 






(d) 


table below. 



V019 (1) - Ground 

V024 (1) - Ground 


< 2 Ω 

Page 1019

04-324 





NOTE 

• If only width lamp LH is not bright,measure V019 (1) - 

Ground onlyl. 

• If only width lamp RH is not bright,measure V024 (1) - 

Ground only. 

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - WIDTH LAMPS) 

NOTE 






(d) 


table below. 






< 2 Ω 

NIOTE 

• If only width lamp LH is not bright,measure lamplet 

fuse (7.5A) - V019 (2) only. 

• If only width lamp RH is not bright,measure lamplet 

fuse (7.5A) - V024 (2) only. 


YES > Replace width lamp bulbs. 


Page 1020


04-325 

TAIL LAMPS ARE INOPERATIVE 


04 

04 

Page 1021

04-326 



1. CHECK HARNESS AND CONNECTOR (TAIL LAMPS - GROUND) 

NOTE 






(d) 


table below. 



F012 (2) - Ground 

G004 (2) - Ground 


< 2 Ω 




NOTE 

• If only tail lamp LH is not bright, measure F012 (2) - 

Ground only. 

• If only tail lamp RH is not bright,measure G004 (2) - 

Ground only. 

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - TAIL LAMPS) 

NOTE 






Page 1022


04-327 

(d) 


table below. 




04 

Lamplet fuse (7.5A) - F012 (1) 

Lamplet fuse (7.5A) - G004 (1) 

< 2 Ω 

NOTE 

• If only tail lamp LH is not bright, measure Lamplet 

Fuse (7.5A) - F012 (1) only. 

• If only tail lamp RH is not bright,measure Lamplet 

Fuse (7.5A) - G004 (1) only. 

04 


YES > Replace tail lamp bulbs. 


Page 1023

04-328 


LICENSE LAMP IS INOPERATIVE 


Page 1024


04-329 


1. CHECK HARNESS AND CONNECTOR (LICENSE LAMP - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 




04 

J004 (2) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - LICENSE LAMP) 

(a) 

(b) 



(c) 


table below. 



Lamplet fuse (7.5A) - J004 (1) 


< 2 Ω 


YES > Replace license lamp bulbs. 


Page 1025

04-330 



TIVE 


Page 1026


04-331 



(a) 


04 

(b) 

Inspect the lamplet fuse (7.5A) in co-pilot side junction 

box (Z043). 

04 




2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - LAMPLET) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 


Disconnect the V019 front position lamp LH connector. 

Disconnect the V024 front position lamp RH connector. 




(g) 


table below. 



V019 (2) - Ground 


≥ 1 ΜΩ 




Page 1027

04-332 



(a) 

(b) 


Remove lamplet relay in co-pilot side junction box (Z043). 

(c) 


table below 

Condition 

Tester 

Connection 

Specified 

Condition 




87 - 30 < 2 Ω 




4. CHECK HARNESS AND CONNECTOR (LAMPLET RELAY - COMBINATION SWITCH (LIGHT)) 

(a) 

(b) 

(c) 


Remove the lamplet relay in co-pilot side junction box (Z043). 


(d) 


table below. 



lamplet relay (86) - Z011 (5) 


< 2 Ω 




Page 1028


04-333 


(a) 

(b) 



04 

(c) 


table below. 



Z011 (8) - Ground 


< 2 Ω 

04 




Page 1029

04-334 

DIAGNOSTICS(RHD) - WIPER AND WASHER 


PRECAUTION 



LOCK 

ON 

ACC 

START 


Ignition switch off 

Ignition switch on (IG) 

Ignition switch on (ACC) 

Engine start 

2. POWER OFF 

(a) Before removing or installing any electrical device, please disconnect the nagative battery cable to 


(b) Make sure ignition switch is OFF if no specific instructions. 

Page 1030


04-335 



1 




Yes 

No 





04 

2 

Check the wiper motor in HIGH position. 

• Set the wiper and washer switch in HIGH 

position. 

Does the wiper motor operate in high 

mode? 

Yes 

No 



04 

3 

Check the wiper motor in LOW position. 

• Set the wiper and washer switch in LOW 

position. 

Does the wiper motor operate in low 

mode? 

Yes 

No 



4 

Check the wiper motor in INT position. 

• Set the wiper and washer switch in INT 

position. 

Does the wiper motor operate in 

intermittent mode? 

Yes - 

No 


Page 1031

04-336 






1. Fuse - 

Wipers are inoperative - windshield 








Wipers are inoperative at low speed 

- windshield 








Wipers are inoperative at high 

speed - windshield 








Wipers are inoperative in 

intermittent mode - windshield 








Washer pump is inoperative - 

windshield 








When the wiper and washer switch 

is OFF, the wiper blade does not 

retract 








Wiper is inoperative - rear window 








Page 1032


04-337 


Washer pump is inoperative - rear 

window 

1. Washer pump - rear window - 





04 

04 

Page 1033

04-338 


WINDSHIELD 


Page 1034


04-339 

WIPERS ARE INOPERATIVE - WINDSHIELD 



04 

(a) 


(b) 

Inspect the windshield wiper fuse in driver side junction 

box (Z043): 15 A. 

04 



NO > If the fuse blows,check the line to normal after replacing the fuse. 

2. CHECK HARNESS AND CONNECTOR ( FRONT WIPER FUSE - WINDSHIELD WIPER) 

(a) 

(b) 


Disconnect the V030 windshield wiper assy connector. 


table below. 



Front wiper fuse - V030(3) 




Page 1035

04-340 


3. CHECK HARNESS AND CONNECTOR (FRONT WIPER FUSE - COMBINATION SWITCH) 

(a) 

(b) 


Disconnect the Z013 combination switch (wiper and washer control) connector. 


table below. 


Front wiper fuse - Z013 (3) 


< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (FRONT WIPER FUSE - FRONT WASHING RESERVOIR 

MOTOR) 

(a) 

(b) 


Disconnect the V028 front washing reservoir motor connector. 


table below. 





< 2 Ω 




Page 1036


04-341 


(a) 

(b) 




table below. 


04 




< 2 Ω 

04 





(a) 

(b) 

(c) 





table below. 




Z013(4) - V030(1) 

Z013(2) - V030(4) 

< 2 Ω 

Z013(5) - V030(2) 





(a) 

(b) 


Remove the windshield wiper assy. 

Page 1037

04-342 


(c) 

Inspect the windshield wiper. 

Condition 

Apply battery 

voltage to 


Apply battery 

voltage to 



Windshield wiper lowspeed 

operation 

Windshield wiper highspeed 

operation 

Specified 

Condition 

Motor does not 

work 

Motor does not 

work 



NO > Repair or replace windshield wiper. 

Page 1038


04-343 


(a) 

(b) 




table below. 


04 




< 2 Ω 

04 




Page 1039

04-344 


WIPERS ARE INOPERATIVE AT LOW SPEED - WINDSHIELD 



(a) 

(b) 



(c) Inspect combination switch (wiper and washer control) 


Condition 

Tester 

Connection 

Specified 

Condition 


switch to OFF 


switch to LOW 

3 - 4 ≥ 1 MΩ 

3 - 4 < 2 Ω 





(a) 

(b) 

(c) 





table below. 

Standard resisance 


V030(1) - Z013(4) 


< 2 Ω 


YES > Check windshield wiper, replace windshield wiper if necessary. 


Page 1040


04-345 

WIPERS ARE INOPERATIVE AT HIGH SPEED - WINDSHIELD 



04 

(a) 

(b) 





Condition 

Tester 

Connection 

Specified 

Condition 

04 


switch to OFF 


switch to HIGH 

2 - 3 ≥ 1 MΩ 

2 - 3 < 2 Ω 





(a) 

(b) 

(c) 




(d) Measure the resisitance according to the value(s) in the 

table below. 



Z013 (2) - V030(4) 


< 2 Ω 




Page 1041

04-346 



SHIELD 



(a) 

(b) 



(c) Inspect the windshield wiper in INT mode. 

Condition 

Apply battery 

voltage to terminal 

2 and 5 


Battery(+) - 2 

Battery(-) - Ground 

Specified 

Condition 

Front washing 

reservoir motor 

operates at low 

speed 



NO > Replace the windshield wiper. 

2. CHECK HARNESS AND CONNECTOR ( COMBINATION SWITCH - GROUND) 

(a) 

(b) 




table below. 


Z013 (6) - Ground 


< 2 Ω 

Is the inspecrtion result normal? 



Page 1042


04-347 

3. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER- GROUND) 

(a) 

(b) 




table below. 


04 


V030 (5) - Ground 


< 2 Ω 

04 




4. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER - COMBINATION SWITCH) 

(a) 

(b) 

(c) 





table below. 



Z013 (5) - V030 (2) 

Z013 (4) - V030 (1) 


< 2 Ω 




Page 1043

04-348 


WASHER PUMP IS INOPERATIVE - WINDSHIELD 



(a) 

(b) 





Condition 


Specified 

Condition 


switch to OFF 


switch to WASH 

6 - 7 ≥ 1 MΩ 

6 - 7 < 2 Ω 




Page 1044


04-349 

2. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - FRONT 

WASHER PUMP) 

(a) 

(b) 




table below. 


04 




< 2 Ω 

04 




3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT WASHER PUMP) 

(a) 

(b) 

(c) 





table below. 



V028 (1) - Z013 (7) 


< 2 Ω 




Page 1045

04-350 



(a) 

(b) 




table below. 



Z013 (6) - Ground 


< 2 Ω 


YES > Check the front washer pump, replace the front washer pump if necessary. 


Page 1046


04-351 

WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE DOES NOT 

RETRACT 



04 

(a) 

(b) 





04 

Condition 


Specified 

Condition 


switch to OFF 


switch to other position 

4 - 5 < 2 Ω 

4 - 5 ≥ 1 MΩ 




2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - WINDSHIELD WIPER ) 

(a) 

(b) 

(c) 





table below. 



Z013 (4) - V030 (1) 


< 2 Ω 




Page 1047

04-352 


3. CHECK HARNESS AND CONNECTOR ( COMBINATION SWITCH - WINDSHIELD WIPER) 

(a) 

(b) 

(c) 





table below. 



V030(2) - Z013 (5) 


< 2 Ω 


YES > Repair or replace windshield wiper. 


Page 1048


04-353 

REAR WINDOW 


04 

04 

Page 1049

04-354 




(a) 


(b) 


(Z043): 10 A. 



NO > If the fuse blows, check the line to normal after replacing the fuse 


(a) 

(b) 





Condition 


Specified 

Condition 


switch to OFF 

Set the rear wiper and 

washer switch to ON 

9 - 6 ≥ 1 MΩ 

9 - 6 < 2 Ω 




Page 1050


04-355 

3. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - COMBINATION 

SWITCH) 

(a) 

(b) 



(c) 


table below. 


04 


Rear wiper relay(85) - Z013 (9) 


< 2 Ω 

04 




4. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - REAR WIPER) 

(a) 

(b) 



(c) 


table below. 



Rear wiper relay(87) - U001 (2) 


< 2 Ω 




Page 1051

04-356 


5. INSPECT REAR WIPER RELAY 

(a) 


(b) 

Disconnect rear wiper relay. 

(c) 


table below. 


Condition 


Specified 

Condition 

Constant 30 - 87a < 2 Ω 

Constant 85 - 86 90Ω 

Apply 12V voltage to 


30 - 87a ≥ 1 MΩ 

30 - 87 < 2 Ω 



NO > Repair or replace rear wiper relay. 


(a) 

(b) 



(c) 


table below. 




(4) 


< 2 Ω 





(a) 

(b) 



Page 1052


04-357 

(c) 


table below. 




04 


(1) 

< 2 Ω 

04 




8. CHECK HARNESS AND CONNECTOR ( REAR WIPER - GROUND) 

(a) 

(b) 


Disconnect the U001 rear wiper relay connector. 


table below. 



U001(3) - Ground 


< 2 Ω 


YES > Check the rear wiper, Replace the rear wiper if necessary. 


Page 1053

04-358 


WASHER PUMP IS INOPERATIVE - REAR WINDOW 



(a) 


(b) 


(Z043): 10 A. 



NO > If the fuse blows, check the line to wiring after replacing the fuse. 


(a) 

(b) 





Condition 


Specified 

Condition 



SART 



OFF 

8 - 9 < 2 Ω 

8 - 9 ≥ 1 MΩ 




Page 1054


04-359 

3. CHECK HARNESS AND CONNECTOR (REAR WIPER FUSE - REAR WASHING RESERVOIR 

MOTOR) 

(a) 

(b) 




table below. 


04 


Rear wiper fuse (30)- V029 (2) 


< 2 Ω 

04 




4. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - COMBINATION SWITCH) 

(a) 

(b) 

(c) 


Disconnect the Z043 rear wiper relay connector. 



table below. 



Rear wiper relay (85) - Z013 

(9) 


< 2 Ω 




Page 1055

04-360 



(a) 

(b) 




table below. 





< 2 Ω 




6. CHECK HARNESS AND CONNECTOR ( REAR WASHING RESERVOIR MOTOR - COMBINATION 

SWITCH) 

(a) 

(b) 

(c) 





table below. 



V029(1) - Z013(8) 


< 2 Ω 


YES > Repair or replace rear washing reservoir motor. 


Page 1056

DIAGNOSTICS(RHD) - AUDIO SYSTEM 

04-361 

AUDIO SYSTEM 

PRECAUTION 

1. IT IS FORBIDDEN TO REFIT THE AUDIO SYSTEM. 

2. THE RADIO WAVE BANDS USED IN RADIO BROADCASTING ARE AS FOLLOWS. 

04 

Radio wave AM FM 

Modulation method Amplitude modulation Frequency modulation 

Designation AM1 AM2 FM1 FM2 FM3 

04 

Frequency 522 ~ 1620 KHz 87.5 ~ 108 MHz 

3. POWER OFF. 

(a) Before removing or installing any electrical device, please disconnect the negative battery cable to 

prevent the device damage or personal injury. 


Page 1057

04-362 




1 


• The voltage should be above 12V. 


Yes 

No 





2 

Check radio antenna. 

• Check whether the antenna is pulled out 

and pulled out to end. 

• Check whether the antenna is covered 

with obstacles. 

• Check whether the antenna is bended or 

deformation. 


Yes 

No 


Repair or replace the radio antenna assy. 

3 

Check radio. 

• Press the radio power button, check 

whether the radio work well. 


Yes 

No 



4 

Check speaker. 

• Set the radio volume level above 5 VOL, 

check whether the speaker sounds. 


Yes 

No 



5 

Check the radio broadcasting signal. 


Yes 

No 


Move the vehicle to the place where the 

signal is strong. 

Page 1058


04-363 





04 

1. Fuse - 

Radio does not work 



1. Setting impropriety Chapter 04 diagnositics - audio system, radio reception poor 

04 

Radio reception is poor 


signal 

Chapter 04 diagnositics - audio system, radio reception poor 

3. Antenna malfunction Chapter 04 diagnositics - audio system, radio reception poor 


1. Setting impropriety Chapter 04 diagnositics - audio system, sound quality poor 

Poor sound quality 


signal 

Chapter 04 diagnositics - audio system, sound quality poor 

3. Antenna malfunction Chapter 04 diagnositics - audio system, sound quality poor 



1. Setting impropriety 

Chapter 04 diagnositics - audio system, speaker does not 

work 

Speaker does not work 




Page 1059

04-364 


RADIO DOES NOT WORK 


Page 1060


04-365 



(a) 


04 

(b) 

(c) 

Check Radio ACC fuse (7.5 A) in junction box (Z043). 

Check Radio fuse (10 A) in junction box (Z043). 

04 



NO > If the dome light fuse is blown, go to next step. 

If the radio & cigarette fuse is blown, go to step 3. 



(b) Disconnect the Z025 radio connector. 

NOTE 


(c) 


table below. 



Z025(A7) - Ground 


≥ 1 ΜΩ 




Page 1061

04-366 





NOTE 


(c) 


table below. 





≥ 1 ΜΩ 




4. CHECK HARNESS AND CONNECTOR (RADIO FUSE - RADIO) 



NOTE 


(c) 


table below. 



Radio fuse (10 A) - Z025 (A4) 


< 2 Ω 




Page 1062


04-367 

5. CHECK HARNESS AND CONNECTOR (RADIO ACC FUSE - RADIO) 

(a) 


(b) 


table below. 


04 


Radio ACC fuse(15 A) - Z025 (A4) 


< 2 Ω 

04 





(a) 


(b) 


table below. 





< 2 Ω 




Page 1063

04-368 


RADIO RECEPTION IS POOR 



(a) 

(b) 

(c) 

(d) 









(a) 

(b) 

(c) 

(d) 

(e) 









NOTE 

• There is great difference in the size of the service area for AM, FM monaural, and FM stereo 

broadcasting. Thus it may happen that FM broadcast cannot be received even though AM comes in 

very clearly. Not only does FM stereo have the smallest service area, but also it picks up static and 

other types of interference most easilly. 

• AM broadcasts are susceptible to other types of interference, especially at night. This is because AM 

radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from 

the same transmitter that reach the vehicle’s antenna directly. 

• When a signal from broadcast transmitter antenna bounces off Mountains, tall buildings or other 

obstruction, it will interfere with the signal that is received directly. 


(a) 

(b) 

(c) 

(d) 








Page 1064


04-369 

POOR SOUND QUALITY 



(a) 

(b) 

(c) 

(d) 








04 

04 


(a) 

(b) 

(c) 

(d) 

(e) 










(a) 

(b) 

(c) 

(d) 








4. CHECK SPERKER 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 



Check whether the speaker is around with obstacles. 

Check whether the speaker cone diaphragm accumulates dust. 

Check the speaker cone diaphragm for damage. 

Replace the old speaker with a troubleprool one and check the system. 

Check whether the radio sound quality is good? 

YES > Repair or replace the speaker. 


Page 1065

04-370 


SPEAKER DOES NOT WORK 


Page 1066


04-371 



(a) 

(b) 

(c) 

(d) 








04 

04 


(a) 


(b) 


table below. 





< 2 Ω 





(a) 

(b) 



(c) 


table below. 



H006 (1) - Z026 (B3) 

H006 (2) - Z026 (B4) 


< 2 Ω 




Page 1067

04-372 



(a) 


(b) 


(c) 


table below. 



D011 (1) - Z026(B5) 

D011 (2) - Z026(B6) 


< 2 Ω 





(a) 


(b) 


(c) 


table below. 



G005 (2) - Z026 (B2) 

G005 (1) - Z026 (B1) 


< 2 Ω 





(a) 


(b) 


(c) 


table below. 



F013(1) - Z026 (B7) 

F013 (2) - Z026 (B8) 


< 2 Ω 

Page 1068


04-373 




7. CHECK SPEAKER 

(a) 

(b) 

(c) 



Check the speaker for damage. 


YES > Replace the speaker. 


04 

04 

Page 1069

04-374 

DIAGNOSTICS(RHD) - AUXILIARY POWER 






Cigarette Ligter is 

inoperative 

12V Power supply 

output socket is 

inoperative 

8. Fuse - 

9. Relay - 


1. Relay - 

2. Fuse - 


Page 1070


04-375 



04 

04 

Page 1071

04-376 




(a) 


(b) 

Inspect the cigarette lighter fuse in body junction box 

(Z043):Refer to “Circuit Guidance” document “the front 

passenger side fuse box” fuse F35. 





(a) 

(b) 



(c) 


table below. 



Z030 (2) - Ground 


≥ 1 ΜΩ 




Page 1072


04-377 

3. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER FUSE - CIGARETTE LIGHTER) 

(a) 

(b) 




table below. 


04 


Cigarette lighter fuse - Z030 (2) 


< 2 Ω 

04 





(a) 

(b) 




table below. 



Z030 (1) - Ground 


< 2 Ω 


YES > Replace the cigarette lighter. 


Page 1073

04-378 


12V POWER SUPPLY OUTPUT SOCKET IS INOPERATIVE 


Page 1074


04-379 



(a) 


(b) 

Inspect the IG2 fuse in body junction box (Z043):Refer to 

“Circuit Guidance” document “the front passenger side 

fuse box” fuse F19. 

(c) Inspect the power fuse in body junction box 

(Z043):Refer to “Circuit Guidance” document “the front 

passenger side fuse box” fuse F49. 

04 

04 



NO > If the fuse blows, check the line to normal after replacing the fuse. 


(a) 

(b) 


Remove the IG2 relay. 

(c) 

Inspect IG2 relay. 



Constant 85 - 86 90 Ω 

Apply 12V 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 




Page 1075

04-380 


3. CHECK HARNESS AND CONNECTOR (INSTRUMENT FUSE - IG2 FUSE) 

(a) 

(b) 


Disconnect the IG2 relay. 

(c) 


table below. 



IG2 (40A) - Instrument fuse(60A) 


< 2 Ω 




4. CHECK HARNESS AND CONNECTOR (POWER FUSE - 12V POWER SUPPLY OUTPUT SOCKET 

FUSE) 

(a) 

(b) 


Disconnect Z018 12v power supply output socket. 


table below. 



Power fuse (15A) - Z018(2) 


< 2 Ω 




Page 1076


04-381 

5. CHECK HARNESS AND CONNECTOR (12V POWER SUPPLY OUTPUT SOCKET FUSE - GRO- 

NUD) 

(a) 

(b) 


Disconnect Z018 12v power supply output socket. 


table below. 


04 




< 2 Ω 

04 


YES > Replace 12v power supply output socket. 


Page 1077

04-382 

DIAGNOSTICS(RHD) - HORN SYSTEM 

HORN SYSTEM 





6. Horn fuse - 




9. Clock spring 

10.Horn 


replacement 


replacement 


replacement 






replacement 


Page 1078


04-383 

HORN IS INOPERATIVE 


04 

04 

Page 1079

04-384 




(a) 


(b) Inspect the horn fuse in body junction box (Z043):15 A. 



NO > Replace the horn fuse. 


(a) 

(b) 



(c) 





Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 




3. CHECK HARNESS AND CONNECTOR (HORN RELAY - CENTRAL LOCKING CONTROLLER B 

ASSY) 

(a) 

(b) 

(c) 



Disconnect the Z008 central locking controller B connector. 

Page 1080


04-385 

(d) 


table below. 




04 

Z008 (B4) - Horn relay(86) 

< 2 Ω 

04 




4. INSPECT CENTRAL LOCKING CONTROLLER B ASSY 



(c) Replace the central locking controller B. (Refer to“Chapter 82 Windshiel window glass rearview mirror 

- power window, replacement”) 

(d) Connect the battery negative cable. 

(e) Turn the ignition switch ON. 


YES > Repair or replace central locking controller B. 


5. CHECK HARNESS AND CONNECTOR (HORN RELAY - CLOCK SPRING) 

(a) 

(b) 

(c) 

(d) 



Disconnect the horn relay connector. 

Disconnect the clock spring connector.(Refer to“Chapter 62 Supplemental Restraint System - clock 

spring, replacement”) 

Page 1081

04-386 


(e) 


table below. 



Horn relay (86) - Z012(2) 


< 2 Ω 





(a) 


(b) 

Replace the clock spring. (Refer to“Chapter 62 Supplemental 







(a) 

(b) 

(c) 

(d) 

Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 

Check the horn switch for corrosion or damaged pins. 

Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 

Press the horn switch. 

Page 1082


04-387 


YES > Repair or replace the horn switch. 


8. CHECK HARNESS AND CONNECTOR (HORN RELAY - HORN) 

04 

(a) 

(b) 

(c) 



Disconnect the V026 bass horn connector.. 

(d) 


table below. 

Standard resistance (check for open). 

04 





< 2 Ω 




9. CHECK HARNESS AND CONNECTOR (HORN - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 






< 2 Ω 

Page 1083

04-388 



YES > Replace horn. 


Page 1084


04-389 

HORN IS ALWAYS ON 


04 

04 

Page 1085

04-390 




(a) 

(b) 



(c) 





Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 





(a) 


(b) Replace the clock spring. (Refer to“Chapter 62 

Supplemental Restraint System - clock spring, 

replacement”) 






(a) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 

(b) Check the horn switch for corrosion or damaged pins. 

(c) Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 

(d) Press horn switch. 


YES > Replace the horn. 

NO > Replace the horn switch. 

Page 1086


PRECAUTION 

DIAGNOSTICS(RHD) - REVERSE RADAR SYSTEM 

04-391 

1. UNDER THE FOLLOWING CONDITIONS, THE DETECTION FUNCTION MAY NOT FUNCTION 

PROPERLY: 

(e) The sensor is covered with foreign matter, such as mud or snow (detection function returns to normal 

when the sensor is cleaned). 

(f) The sensor is frozen (detection function returns to normal when the temperature of the sensor is going 

high). 

(g) The sensor is covered with a hand. 

(h) In very cold weather where a malfunction display appears, the sensor may not be able to detect 

obstacles. 

2. THE DETECTION RANGE MAY BE AFFECTED BY THE FOLLOWING CONDITIONS: 

(a) The sensor is covered with foreign matter, such as mud or snow. 

(b) The vehicle is in an excessively hot or cold area. 

3. UNDER THE FOLLOWING CONDITIONS, A DETECTION ERROR MAY OCCUR: 

(a) Driving on a bumpy road, an unpaved road, or in tall grass. 

(b) Ultrasonic waves from items such as another vehicle's horn, motorcycle engine sounds, a large 

vehicle's air brake sound, or another vehicle's sonar are transmitted near the vehicle. 

(c) It is raining heavily or the sensor comes into contact with water (sprayed). 

(d) The vehicle is tilted at a large angle. 

(e) The vehicle is equipped with a commercial fender pole or a wireless mechanism antenna. 

(f) The sensor is covered with foreign matter, such as mud or snow. 

(g) The vehicle is moving toward a high curb or the corner of a pointed object. 

4. THE SENSOR CANNOT DETECT SOME OBJECTS SUCH AS THE FOLLOWING: 

(a) Thin objects, such as wires and ropes. 

(b) Materials that absorb ultrasonic waves, such as cotton, snow, etc. 

(c) Objects with sharp edges. 

(d) Short objects. 

(e) Tall, overhanging objects. 

5. OTHER NOTICES: 

(a) The sensor cannot detect objects directly under the bumper. (The sensor may detect low objects and 

thin poles, and then lose track of the objects.) 

(b) The sensor may not be able to detect obstacles that are too close to the sensor. 

(c) The sensor may not be able to detect obstacles if it is dropped or subjected to a strong impact. 

04 

04 

Page 1087

04-392 



1. GENERAL. 

This system uses ultrasonic sensors to send ultrasonic waves. The reverse radar sensors receive the 

echo. The reverse radar control unit then informs the driver of the distance between the sensors and 

the obstacles as well as their positions by indicating them on the combined display and by clearance 

warning buzzer. 

2. FUNCTION OF COMPONENTS. 

Components 

Reverse radar sensor 

Clearance warning buzzer 

Audio (multi-media and aircondition 

controler assy) 

Reverse radar control unit 

Camera 

Back-up lamp switch 

Function 

Detects the distance between the vehicle and an obstacle. 

Sounds from the buzzer to motify the driver for the distance between the vehicle 

and the obstacle. 

Displays the location of the obstacle and the approximate distance between the 

vehicle and the obstacle,and image in rear of vehicle. 

1. Judges the approximate distance between the vehicle and the obstacle based 

on the signals from the reverse radar sensor. 

2. Sounds the clearance warning buzzer. 

Shoot image information. 

Sends the back-up signal to the reverse radar control unit. 

3. DETECTION RANGE OF REVERSE RADAR SENSOR. 

(a) Detection range of reverse radar sensor (both sides). 

(b) 

Detection range of reverse radar sensor (middle). 

Page 1088


04-393 

4. DISTANCE TO AN OBSTACLE, FREQUENCY AND MODE OF CLEARANCE WARNING BUZZER. 


A 90 - 150 cm Long & Intermittent 1 Hz 

04 

B 60 - 90 cm Short & Intermittent 2 Hz 

C 40 - 60 cm Rapid & Intermittent 4 Hz 

D 40 ± 5 cm Continual Continual 

5. TERMINALS OF REVERSE RADAR CONTROL UNIT PIN. 

04 


1 B - R Power supply 

2 - - 

3 W - R Radar power supply 

4 R - W Reverse radar central sensor RH 

5 - - 

6 L - B Vehicle speed signal 

7 R - G Reverse radar sensor LH 

8 R - B Reverse radar central sensor LH 

9 Y Parking signal 

10 - - 

11 B Sensor ground 

12 - - 

13 - - 

14 - - 

15 R - L Reverse radar sensor RH 


Page 1089

04-394 






1. Fuse - 


inoperative at all 


3. Back-up lamp switch 









operative when the shift 

lever is out of reverse 

position 



3. Back-up lamp switch 










everse radar system is 

inoperative within specified 

distance (Back-up lamp is 

normal) 









operative but there is no 

obstacle behind the vehicle 








Buzzer is inoperative or 

operative incorrectly within 

specified distance ( 

displayer is normal) 

Display is inoperative 

within specified distance 

(Back-up lamp is normal) 








1. Displayer Chapter 81 communication system - multi-media 

and air-condition controler assy,replacement 

2. Camera Chapter 81 communication system - astern 

image, replacement 


Page 1090


04-395 

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL 


04 

04 

Page 1091

04-396 




(a) 


(b) 

Inspect the back-up lamp fuse (10 A) in co-pilot side 





2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP FUSE - BACK-UP LAMP SWITCH) 

(a) 

(b) 

(c) 


Disconnect the Z056 back-up lamp switch connector. 

Disconnect the Z042 reverse radar control unit connector. 

(d) 


table below. 



Z056 (1) - Ground 


≥ 1 ΜΩ 




Page 1092


04-397 


(a) 

(b) 



(c) 


table below. 


04 


1 - Ground 

2 - Ground 


≥ 1 ΜΩ 

04 



NO > Replace back-up lamp switch and fuse. 

4. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - REVERSE RADAR CONTROL 

UNIT) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z056 (2) - Ground 


≥ 1 ΜΩ 




Page 1093

04-398 


5. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROL UNIT - GROUND) 

(a) 

(b) 



(c) 


table below. 



Z042 (16) - Ground 


< 2 Ω 





(a) 

(b) 



(c) 

Inspect the back-up lamp switch according to the 


Condition 

Tester 

Connection 

Specified 

condition 


position 



1 - 2 < 2 Ω 

1 - 2 ≥ 1 ΜΩ 



NO > Replace back-up lamp. 

Page 1094


04-399 

7. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP FUSE - BACK-UP LAMP SWITCH) 

(a) 

(b) 



(c) 


table below. 


04 


Back-up lamp fuse (10A) - Z056 (1) 


< 2 Ω 

04 





UNIT) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z056 (2) - Z042 (1) 


< 2 Ω 




Page 1095

04-400 


REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE SHIFT 

LEVER IS OUT OF REVERSE POSITION 


Page 1096


04-401 



(a) 

(b) 



(c) Inspect the back-up lamp switch according to the 


04 

Condition 

Tester 

Connection 

Specified 

condition 

04 


position 



1 - 2 < 2 Ω 

1 - 2 ≥ 1 ΜΩ 



NO > Replace back-up lamp switch. 


UNIT) 

(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



Z042 (1) - Ground 


0 V 




Page 1097

04-402 



DISTANCE (BACK-UP LAMP IS NORMAL) 


Page 1098


04-403 



(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

Turn the ignition switch OFF.。 











04 

04 


SENSOR) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



Z042 (7) - R001 (1) 

Z042 (11) - R001 (2) 


< 2 Ω 

(h) 


table below. 



Z042 (8) - R002 (1) 

Z042 (11) - R002 (2) 


< 2 Ω 

Page 1099

04-404 


(i) 


table below. 



Z042 (4) - R003 (1) 

Z042 (11) - R003 (2) 


< 2 Ω 

(j) 


table below. 



Z042 (15) - R004 (1) 

Z042 (11) - R004 (2) 


< 2 Ω 




Page 1100


04-405 


OBSTACLE BEHIND VEHICLE 


04 

04 

Page 1101

04-406 




(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 













SENSOR) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



Z042 (7) - R001 (1) 

Z042 (11) - R001 (2) 


< 2 Ω 

(h) 


table below. 



Z042 (8) - R002 (1) 

Z042 (11) - R002 (2) 


< 2 Ω 

Page 1102


04-407 

(i) 


table below. 




04 

Z042 (4) - R003 (1) 

Z042 (11) - R003 (2) 

< 2 Ω 

04 

(j) 


table below. 



Z042 (15) - R004 (1) 

Z042 (11) - R004 (2) 


< 2 Ω 




Page 1103

04-408 


BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY WITHIN 

SPECIFIED DISTANCE (DISPLAYER IS NORMAL) 


Page 1104


04-409 



(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 












04 

04 


SENSOR) 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 







(g) 


table below. 



Z042 (7) - R001 (1) 

Z042 (11) - R001 (2) 


< 2 Ω 

(h) 


table below. 



Z042 (8) - R002 (1) 

Z042 (11) - R002 (2) 


< 2 Ω 

Page 1105

04-410 


(i) 


table below. 



Z042 (4) - R003 (1) 

Z042 (11) - R003 (2) 


< 2 Ω 

(j) 


table below. 



Z042 (15) - R004 (1) 

Z042 (11) - R004 (2) 


< 2 Ω 




Page 1106


04-411 


(BUZZER IS NORMAL) 


04 

04 

Page 1107

04-412 



1. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - CAMERA) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z056 (2) - J005 (2) 


< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (CAMERA - RADIO) 

(a) 

(b) 

(c) 



Disconnect the Z028 radio connector. 

(d) 


table below. 



J005 (3) - Z028 (1) 

J005 (4) - Z028 (2) 


< 2 Ω 




Page 1108


04-413 

3. CHECK HARNESS AND CONNECTOR (CAMERA - GROUND) 

(a) 

(b) 



(c) 


table below. 


04 


J005 (1) - Ground 


< 2 Ω 

04 




4. INSPECT CAMERA 

(a) 

(b) 

(c) 

(d) 

(e) 



Replace the camera. 



Does displayer work correctly? 

YES > Replace the camera. 


Page 1109

04-414 

DIAGNOSTICS(RHD) - POWER WINDOWS 

POWER WINDOWS 

PRECAUTION 




Expression 




2. POWER OFF. 

(a) Before removing or installing any electrical device, please disconnect the negative cable from battery to 


NOTE 

To prevent locking the key in the vehicle, do not leave the key in the vehicle when disconnecting the 




AND THE CLOCK TO ‘0’. 

NOTE 

The total odometer can not be reset to ‘0’. 



NOTE 


Page 1110


04-415 

DOOR CONTROL SWITCH PIN 

04 

04 


1 L - B Door control switch (date) 

2 L Door control switch (clock) 

3 L - Y Window control switch LH 

4 P - L Window control switch LH 

5 L - G Window control switch LH 

6 W - B Grond 

7 - - 

8 - - 

9 G - R Lamplet illumination 

10 - - 

11 - - 

12 - - 

Page 1111

04-416 


WINDOW CONTROL SWITCH LH PIN 


1 L - G Door control switch 

2 - - 

3 P - L Door control switch 

4 L - Y Door control switch 

5 - - 

Page 1112


04-417 

CENTRAL LOCKING CONTROLLER ASSY A PIN 

04 

04 



2 - - 

3 - - 

4 G Power window motor RH 

5 R Power window motor RH 

6 R - L Power window motor LH 

7 G - R Power window motor LH 

8 W - L Window control power input 

9 - - 

10 - - 

11 Y Collision signal 

12 - - 

13 - - 

14 R Door-status 



17 W - L Vehicle speed signal 

18 R - B Ignition switch 

Page 1113

04-418 




1 


• The battery voltage should be over than 

12 V. 


Yes 

No 



“Chapter 20A starting and charging - 

battery”. 

2 

Check the front power window motor LH. 




close. 


Yes 

No 



3 

Check power window auto open operation. 



operate the fornt window LH auto open. 


Yes 

No 



4 

Check power window motor LH. 

• Push or pull the front window switch RH to 


close. 


Yes 

No 



5 


• ush or pull the front window switch RH to 


close. 


Yes 

No 

Replace power window motor. 


Page 1114


04-419 





04 

All power windows are 

inoperative. 




replacement 


replacement 



04 

3. Power window motor LH and 

RH 





RH is inoperative. 






replacement 


replacement 




replacement 





RH does not open. 






replacement 



RH does not close. 






replacement 







3. Window control switch LH 


replacement 


replacement 





Page 1115

04-420 




LH is inoperative (use 



LH is inoperative (use 

window control switch 

LH). 



1. Window control switch LH 









Page 1116


04-421 



04 

04 

Page 1117

04-422 




(a) 


(b) 

Inspect the power window fusible link (20 A) in driver 

side junction box (Z043). 





(a) 

(b) 

(c) 


Disconnect the H010 door control switch connector. 

Disconnect the Z009 central locking controller assy A connector. 

(d) 


table below. 



H010 (12) - Ground 


≥ 1 MΩ 




Page 1118


04-423 


(a) 

(b) 

(c) 

(d) 








4. CHECK HARNESS AND CONNECTOR (POWER WINDOW FUSIBLE LINK - DOOR CONTROL 

SWITCH) 

04 

04 

(a) 

(b) 



(c) 


table below. 



Power window fusible link (20A) - H010 (12) 

Specified 

Condition 

< 2 Ω 




Page 1119

04-424 


5. CHECK HARNESS AND CONNECTOR (POWER WINDOW FUSIBLE LINK - CENTRAL LOCKING 


(a) 

(b) 



(c) 


table below. 



Power window fusible link (20A) - Z009 (A8) 

Specified 

Condition 

< 2 Ω 





(a) 

(b) 



(c) 


table below. 



H010 (6) - Ground 


< 2 Ω 




Page 1120


04-425 



(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

H010 (1)- Z009 (A15) 

H010 (2)- Z009 (A16) 

< 2 Ω 




8. INSPECT POWER WINDOW MOTOR LH AND RH 

(a) 

(b) 

(c) 

(d) 

(e) 


Disconnect the H007 power window motor LH connector. 

Disconnect the D007 power window motor RH connector. 

Replace power window motor LH and RH. 



YES > Replace power window motor LH and RH. 



WINDOW MOTOR LH AND RH) 

(a) 

(b) 

(c) 

(d) 





(e) 


table below. 



Z009 (A4) - H007 (2) 

Z009 (A5) - H007 (1) 


< 2 Ω 

Page 1121

04-426 


(f) 


table below. 



Z009 (A6) - D007 (2) 

Z009 (A7) - D007 (1) 


< 2 Ω 




Page 1122


04-427 

FRONT POWER WINDOW RH IS INOPERATIVE 


04 

04 

Page 1123

04-428 




(a) 

(b) 

(c) 

(d) 










(a) 

(b) 

(c) 




(d) 


table below. 



H010 (1)- Z009 (A15) 

H010 (2)- Z009 (A16) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 








Page 1124


04-429 



(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

Z009 (A4) - H007 (2) 

Z009 (A5) - H007 (1) 

< 2 Ω 




Page 1125

04-430 


FRONT POWER WINDOW LH DOES NOT OPEN 


Page 1126


04-431 



(a) 

(b) 

(c) 

(d) 








04 

04 


ASSY A) 

(a) 

(b) 

(c) 




(d) 


table below. 



H010 (1)- Z009 (A15) 

H010 (2)- Z009 (A16) 


< 2 Ω 




Page 1127

04-432 




Page 1128


04-433 



(a) 

(b) 

(c) 

(d) 








04 

04 



(a) 

(b) 

(c) 




(d) 


table below. 



H010 (1)- Z009 (A15) 

H010 (2)- Z009 (A16) 


< 2 Ω 




Page 1129

04-434 



TROL SWITCH) 


Page 1130


04-435 



(a) 

(b) 

(c) 

(d) 





Does power window LH work correctly? 



04 

04 



(a) 

(b) 

(c) 




(d) 


table below. 



Z009 (A6) - D007 (2) 

Z009 (A7) - D007 (1) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 





Does power windou LH work correctly? 

YES > Replace power window motor LH. 

NO > Replace central locking controller assy. 

Page 1131

04-436 



CONTROL SWITCH RH) 


Page 1132


04-437 


1. INSPECT WINDOW CONTROL SWITCH 

(a) 

(b) 

(c) 

(d) 


Disconnect the D009 window control switch LH connector. 

Replace window control switch LH. 



YES > Replace window control switch LH. 


04 

04 

2. CHECK HARNESS AND CONNECTOR (WINDOW CONTROL SWITCH LH - DOOR CONTROL SWITCH) 

(a) 

(b) 

(c) 


Disconnect the D009 window control switch LH connector. 


(d) 


table below. 



D009 (1) - H010 (5) 

D009 (3) - H010 (4) 


< 2 Ω 

(e) 


table below. 



D009 (4) - H010 (3) 


< 2 Ω 





(a) 

(b) 

(c) 

(d) 





Page 1133

04-438 






(a) 

(b) 

(c) 

(d) 





Does power window LH work correctly? 

YES > Replace power window motor LH. 




(a) 

(b) 

(c) 




(d) 


table below. 



Z009 (A6) - D007 (2) 

Z009 (A7) - D007 (1) 


< 2 Ω 




Page 1134

DIAGNOSTICS(RHD) - OUTSIDE MIRROR 

04-439 



OUTSIDE MIRROR SWITCH 

04 

04 


1 L - R 

Left Outside Mirror Left And Right 

Adjust Input 

2 - - 

3 L - Y 

Right Outside Mirror Left And Right 

Adjust Output 

4 G - R Outside Mirror Switch Power Input 

5 R - Y Outside Mirror- 

6 W -B Ground 

7 R 

8 R - L 

Left Outside Mirror Up And Down 

Adjust Input 

Right Outside Mirror Up And Down 

Adjust Output 

Page 1135

04-440 




1 





No 




2 

Check the outside mirror. 


• Adjust the outside mirror LH and the outside 

mirror RH. 


Yes 

No 


Replace the outside mirror. Refer to “Chapter 

82 windshield - outside mirror, replacement” 

Page 1136


04-441 


Use the table below to help you find the cause of the problem. The numbers indicate the probability of the 



04 

Mirrors are inoperative (Both sides) 

6. Fuse - 





04 

A single mirror is inoperative 


2. Outside mirror 






Mirror adjustment UP/DOWN is 

inoperative 








Mirror adjustment LEFT/RIGHT is 

inoperative 








Page 1137

04-442 


MIRRORS ARE INOPERATIVE (BOTH SIDES) 


Page 1138


04-443 



(a) 


04 

(b) 

Inspect the radio & ACC fuse (10 A) in Co-pilot junction 

box(Z043). 

04 




2. CHECK HARNESS AND CONNECTOR (RADIO & ACC FUSE - OUTSIDE MIRROR REMOTE 

CONTROL SWITCH) 

(a) 

(b) 

(c) 


Remove the radio & ACC fuse. 

Disconnect the H009 outside mirror remote control switch connector. 

(d) 


table below. 



Radio & ACC fuse (10A) - 

H009 (4) 


< 2 Ω 




Page 1139

04-444 



GROUND) 

(a) 

(b) 



(c) 


table below. 



H009 (6) - Ground 


< 2 Ω 


YES > Replace the outside mirror remote control switch. 


Page 1140


04-445 

A SINGLE MIRROR IS INOPERATIVE 


04 

04 

Page 1141

04-446 






(a) 

(b) 



(c) 


the value(s) in the table below. 

Item 

Condition 

Tester 

Connection 

Specified 

Condition 

Left 

4 - 5 

1 - 6 

Outside 

Mirror LH 

Right 

Up 

4 - 1 

5 - 6 

4 - 7 

5 - 6 

< 2 Ω 

Down 

4 - 5 

7 - 6 






(a) 

(b) 

(c) 




(d) 


table below. 



D008 (6) - H009 (7) 

D008 (4) - H009 (5) 


< 2 Ω 




Page 1142


04-447 



(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

D008 (4) - H009 (5) 

D008 (5) - H009 (1) 

< 2 Ω 


YES > Replace the outside mirror assy. 


Page 1143

04-448 


MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE 


Page 1144


04-449 





04 

(a) 

(b) 



(c) 



04 

Item 

Condition 

Tester 

Connection 

Specified 

Condition 

Outside 

Mirror LH 

Up 

Down 

4 - 7 

5 - 6 

4 - 5 

7 - 6 

< 2 Ω 



NO > Replace the outside mirror remote control switch. 



(a) 

(b) 

(c) 




(d) 


table below. 



D008 (6) - H009 (7) 

D008 (4) - H009 (5) 


< 2 Ω 




Page 1145

04-450 


MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE 


Page 1146


04-451 





04 

(a) 

(b) 



(c) 



04 

Item 

Condition 

Tester 

Connection 

Specified 

Condition 

Outside Mirror LH 

Left 

Right 

4 - 5 

1 - 6 

4 - 1 

5 - 6 

< 2 Ω 






(a) 

(b) 

(c) 




(d) 


table below. 



D008 (4) - H009 (5) 

D008 (5) - H009 (1) 


< 2 Ω 




Page 1147

04-452 

DIAGNOSTICS(RHD) - OUTSIDE MIRROR DEFROSTER SYSTEM 

OUTSIDE MIRROR DEFROSTER SYSTEM 


1. GENERAL 

The outside mirror defroster system consists of heating wires, switch, relay, fuse, indicator and wiring 

harness. The heating element is the electric heating wire which are integrated in both outside mirror 

glasses and defog the glasses quickly. The outside mirror defrost switch is integrated on the centre 

switch panel on the instrument panel. When the switch is pressed, the indicator lamp in the switch 

illuminates to indicate that the defroster is operating. 


Outside mirror defrost relay 

Component 

Outside mirror (outside mirror defroster) 

Description 

Receives defrost control signal from outside mirror 

defrost switch and supplies power to both outside mirror. 

Receives power from outside mirror defrost relay and 


Page 1148


04-453 



1 

Check battery voltage. 



Yes 

No 





04 

2 

Check ignition switch. 

• The ignition switch should work correctly. 


Yes 

No 


Repair or replace ignition switch. Refer to 

“Chapter 91 vehicle control system - assy, 

removal & installation and disassembly & 

reassembly” 

04 

3 

Check fuse. 

• Check fuse. 


Yes 

No 



4 

Check outside mirror defrost switch. 

• Press the outside mirror defrost switch. 

• The outside mirror defrost switch should 



Yes 

No 


Replace rear window defrost grid. Refer to 

“chapter 82 Windshield - windshield, 


5 

Check outside mirror defroster. 

• The outside mirror defroster should work 

correctly. 


Yes - 

No 


Page 1149

04-454 






1. Fuse - 

2. Outside mirror defrost relay - 

Outside mirror defroster system is 

inoperative 








Page 1150


04-455 

OUTSIDE MIRROR DEFROSTER IS INOPERATIVE 

OUTSIDE MIRROR DEFROSTER WIRING DIAGRAM 

04 

04 

Page 1151

04-456 




(a) 


(b) 

Inspect the outside mirror defrost fuse (7.5 A) in Co-pilot 

Junction Box (Z043), refer to “HOW TO USE MANUAL” 

in WIRING chapter to identify the fuse. 



NO > If the outside mirror defrost fuse is blown, prior to replacing the fuse, inspect the wiring harness. 

2. INSPECT OUTSIDE MIRROR DEFROST RELAY 

(a) 

(b) 


Remove the outside mirror defrost relay (refer to “HOW TO USE MANUAL” in WIRING chapter to 

identify the relay). 

(c) 





Constant 85 - 86 90 Ω 

Apply battery 

voltage to 

terminal 85 

and 86 

30 - 87 < 2 Ω 



NO > Replace the outside mirror defrost relay. 

Page 1152


04-457 

3. INSPECT OUTSIDE MIRROR DEFROST SWITCH 

(a) 

(b) 


Disconnect the Z024 outside mirror defrost switch connector. 

(c) 

Inspect the outside mirror defrost switch according to the 




Press 2 - 5 < 2 Ω 

04 

04 



NO > Replace the outside mirror defrost switch. 

4. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST SWITCH CONNECTOR - 

POWER SUPPLY) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z024 (2) - Ground 






Page 1153

04-458 


5. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - OUTSIDE 

MIRROR DEFROST SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



Rear defrost relay (85) - Z024 (5) 

Specified 

Condition 

< 2 Ω 





(a) 

(b) 

(c) 

Turn ignition switch OFF.. 


Turn ignition switch ON. 

(d) 


table below. 




Specified 

Condition 





Page 1154


04-459 


(a) 

(b) 



(c) 


table below. 


04 



Specified 

Condition 

< 2 Ω 

04 




8. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - OUTSIDE 

MIRROR ASSY LH/RH ) 

(a) 

(b) 

(c) 




(d) 


table below. 



Outside mirror defrost relay (87) - D008(3) 

Outside mirror defrost relay (87) - H008(3) 

Specified 

Condition 

< 2 Ω 




Page 1155

04-460 


9. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR ASSY LH/RH - GROUND ) 

(a) 

(b) 



(c) 


table below. 



D008(2) - Ground 

H008(2) - Ground 

Specified 

Condition 

< 2 Ω 


YES > Replace outside mirror assy LH/ outside mirror assy RH. 


Page 1156

DIAGNOSTICS(RHD) - INSTRUMENT CLUSTER 

04-461 


PRECAUTION 

1. POWER OFF. 



(b) Make sure ignition switch off if no specific instructions. 


AND THE CLOCK TO ‘ 0 ’. 

NOTE 

The total odometer can not be reset to ‘ 0 ’. 



04 

04 

NOTE 



Switch Type Ignition Switch (position) Engine (condition) 


Expression 




Page 1157

04-462 


LOCATION 


2 Speedometer Sensor 

3 Fuel Level Sensor 


Page 1158


04-463 

INSTRUMENT CLUSTER INFORMATION 

04 

04 

GAUGES 


1 Speedometer The fuel gauge indicates the approximate fuel level in the tank. 

6 Fuel Gauge 

12 ECT Gauge 

15 Tachometer 

Receving signal from coolant temperature indicator, the ECT 

gauge indicates the engine coolant temperature. 

Receiving signal from the ECM, the tachometer indicates 

engine revolutions per minute (RPM). 

According to the signal received from the speedometer sensor, 

the speedometer indicates the vehicle running speed. 

Page 1159

04-464 


WARNING / INDICATOR LIGHTS 


2 Lamplet indicator light 

Lamplet indicator light turns on when lamplet is on and receive 

lamplet relay signal. 

3 

4 

Engine coolant fluid level 

warning light 

Left turn signal/hazard 


Engine coolant fluid level warming light turns on when engine 

coolant level is lower than specification. 

Left turn signal/hazard indicator light flashes when the turn 


5 Seat belt warning light 

Seat belt warning light turns on when receiving the seat belt 


7 

Engine coolant 

temperature indicator light 

Engine coolant temperature indicator light will illuminate when 

engine coolant temperature is between -20 ℃ ~ 110 ℃ . 

8 Fuel level warning light 

9 High beam indicator light 

10 Door ajar warning light 

11 Brake warning light 

13 SRS warning light 

Fuel level warning light turns on when fuel level lower than 

specified level. 

High beam indicator light turns on when high beam is on and 

receive headlamp relay signal. 

Door ajar warning light turns on when receiving the door ajar 

signal. 

Brake warning light turns on when receiving signals from parking 

brake switch or brake fluid level sensor. 

SRS warning light will turn on when SRS is detected malfunction. 

14 

16 

Right turn signal/hazard 


Parking brake indicator 

light 

Right turn signal/hazard indicator light flashes when the turn 


Parking Brake indicator light turns on when receiving signals 

from parking brake switch. 

17 ABS warning light Warning light will turn on when ABS is detected malfunction. 

18 EBD warning light 

The ABS will illuminate EBD warning light when EBD is 

detected malfunction. 

19 

Engine oil pressure 


Engine oil pressure indicator light turns on according to the 

signal from engine oil pressure warning switch. 

20 Charging warning light Charging warning light turns on when charging system is fault. 

21 Malfunction indicator light 

The ECM will turn on malfunction indicator light when engine 

electronic control system is detected malfunction. 

22 

24 

25 

26 

Rear fog lamp indicator 

light 

Front fog lamp indicator 

light 

SVS indicator light 

(Gasoline) 

Vacuum warning light 

(Diesel) 

Rear fog lamp indicator light receive the rear fog lamp relay 

signal and turns on when rear fog lamp switch is pressed. 

Front fog lamp indicator light receive the front fog lamp relay 

signal and turns on when front fog lamp switch is pressed. 

SVS indicator light will be illuminated when the ECM detect 

general malfunctions. It will be always on until faults resolved. 

Vacuum warning light turns on when receiving the vacuum 


Page 1160


04-465 

LIQUID CRYSTAL DISPLAY 


Odometer Display driving distance and can not be reset to “0”. 

23 

Clock 

Display time and can be reset. 

04 

04 

Page 1161

04-466 


TERMINALS OF INSTRUMENT CLUSTER 

Terminals No Wiring Color Description 

A1 B - L Instrument Power 

A2 - - 


A4 - - 

A5 - - 

Z003 

A6 V - W Lamplet Signal Input 

A7 LG Front Fog Lamp Indicator 


A9 W - L Vehicle Speed Output 

A10 L - B Vehicle Speed Output 

A11 - - 

Page 1162


04-467 


A12 - - 

A13 W - G Speed Signal Input 

04 

A14 B Lighting Pwm Signal 

A15 W - R Door Open Indicator 

A16 R Instrument Power Output 

A17 - - 

04 

A18 - - 

A19 W - B Instrument A Ground 

A20 R - B Instrument Ground 

A21 - - 

Z003 

A22 - - 


A24 Y - B Engine Stop Light 

A25 - - 

A26 B Vacuum Level Alarm + Input 

A27 G - Y Preheat Indicator 

A28 BR Engine Maintenance 

A29 - - 

A30 R - W Front Door Open Indicator 

A31 B - W Seat Belt Warning 

A32 G - Y Left Turn Indicator 

B1 - - 

B2 - - 

B3 - - 

Z002 

B4 - - 

B5 - - 

B6 Y Instrument Parking Brake Light 

B7 V - B Coolant Level Sensor + Output 

B8 - - 

Page 1163

04-468 



B9 B - W Seat Belt Alarm + Output 

B10 V - W Speed Input 

B11 - - 

B12 - - 

B13 - - 

B14 - - 

B15 - - 

B16 Y - G Water Temperature Gauge Sensor 

B17 - - 

B18 - - 

B19 - - 

Z002 

B20 Y - G ABS Fault Light Signal Input 

B21 R - Y Rear Fog Lamp Indicator 

B22 L - Y Engine Oil Pressure Warning Light 

B23 L - W Engine Failure Warning Input 

B24 Y - R EBD Warning Light Signal Input 

B25 P - L Instrument Charging Indicator Input 

B26 - - 

B27 B - Y Airbag Warning Lamp Signal Input 

B28 R - W Brake Fluid Sensor + Output 

B29 - - 

B30 W - B Instrument B Ground 

B31 R - G High Beam Indicator 

B32 G - B Right Turn Indicator 

Page 1164


04-469 


NOTE 

Do not perform basic inspection until engine temperature reaches the specified value. If on-road test is 

needed, must have at least two people to perform the test. 

04 

Step Conditions Action 

1 


• The battery voltage should above 12 V. 



No 

Charge or replace the battery. 

Refer to “Chapter 20A starting 

and charging - battery”. 

04 

2 

Check tachometer. 

• Connect hand-held tester, reading the engine 

rotating speed data. 

• Reading engine rotating speed data with 1000 ~ 

2000 r/min and 3000 ~ 6000 r/min. 

• The variation of error in ± 100 ~ 200 r/min,± 150 

~ 300 r/min. 



No 


table. 

3 

Check speedometer. 

• Connect hand-held tester, reading the vehicle 

speed data. 

• Reading vehicle speed data with 20 ~ 100 Km/h, 

120 Km/h and 140 Km/h. 

• The variation of error in + 5, + 6, + 7 Km/h. 

• The pointer should be without jump when vehicle 

is at constant speed or constant acceleration. 

NOTE 

Tire wear and incorrect tire pressure will lead 

inaccurate data. 



No 


table. 

4 

Check engine oil pressure warning light. 


• Engine oil pressure warning light should be illuminated. 

• After engine starts, engine oil pressure warning 

light should go off. 


Yes 

No 


table. 


table. 

Page 1165

04-470 






Malfunction in speedometer 

Malfunction in tachometer 

Malfunction in fuel gauge 

Malfunction in ECT gauge 

MIL never/always on 

SRS warning light never/ 

always on 

ABS warning light never/ 

always on 

Engine oil pressure warning 


1. Speedometer sensor 

2. Speedometer circuits 

3. Speedometer 

1. CKP sensor 

2. Tachometer circuits 

3. Tachometer 

1. Fuel level sensor 

2. Fuel gauge circuits 

3. Fuel gauge 

1. Engine coolant temperature 

sensor 

2. ECT gauge circuits 

3. ECT gauge 

1. Engine electronic 


2. Malfunction indicator 



1. SRS warning light 

switch 

2. SRS warning light circuits 


1. ABS system 

2. ABS warning light circuits 



switch 


warning light circuits 



in speedometer 


in tachometer 


in fuel gauge 


in ECT gauge 

Chapter 04 diagnostics - gasoline engine control 

system, diagnostic trouble code chart 





Chapter 04 diagnostics - SRS system, problem 

symptoms table 


problem symptoms table 


engine oil pressure warning light never/always 

on 

Page 1166


04-471 


Seat belt warning light never/ 

always on 

1. Seat belt warning 

switch 

2. Seat belt waring 

switch circuits 


seat belt warning light never/always on 

04 


Parking Brake indicator light 


1. Parking brake switch 

2. Parking brake circuits 


parking brake indicator light never/always on 

04 

3. instrument cluster 

1. Fuses 

Turn signal/hazard indicator 



3. Hazard switch 

4. Turn signal/hazard 

indicator light circuits 


table (If exterior turn signal/hazard lights are 

normal, repair turn signal/hazard indicator light circuits 

for an open or replace the instrument cluster) 


1. Fuses 

High beam indicator light 



3. High beam indicator 



table (If exterior high light are normal, repair 

high beam indicator light circuits for an open or 

replace the instrument cluster) 


Page 1167

04-472 


MALFUNCTION IN SPEEDOMETER 


Page 1168


04-473 


1. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - GROUND) 


(b) Disconnect the Z057 speedometer sensor connector. 

04 

(c) 


table below. 




04 

Z057 (1) - Ground 

< 2 Ω 




2. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SPEEDOMETER SENSOR) 

(a) 

(b) 

(c) 


Disconnect the Z003 instrument cluster connector. 

Disconnect the Z057 speedometer sensor connector. 

(d) 


table below. 



Z003 (A13) - Z057 (3) 


< 2 Ω 




3. INSPECT SPEEDOMETER SENSOR 

(a) 

(b) 

(c) 


Remove the speedometer sensor. 

Install a new speedometer sensor. 



NO > Replace the speedometer sensor. 

Page 1169

04-474 


MALFUNCTION IN TACHOMETER 


Page 1170


04-475 


NOTE 

An abnormal running engine will lead the tachometer pointer instable. 

Check if the engine has normal start. 


NO > Refer to “Chapter 04 diagnostics - gasoline engine control system, problem symptoms table” 

1. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECM) 

(a) 

(b) 

(c) 



Disconnect the E001(4G69) / A036(ISF2.8) ECM connector. 

04 

04 

(d) 


table below. 



Z003 (A8) - E001(51) 

Z003 (A8) - Z072(E28) 


< 2 Ω 





(a) 

Start the engine until the engine temperature reaches to normal condition. 

(b) 

Measure the pulse signal between the instrument cluster 

connector Z003, pin A8 and ground. 

Pulse signal: Appr 33.3 Hz (1000 r / min) 




Page 1171

04-476 



NEVER OR ALWAYS ON 


Page 1172


04-477 


• Turn the ignition switch ON and ensure fuel tank have enough fuel (more than 1/4 in fuel tank). 

• Fuel level warning light will be illuminated when fuel level sensor resistance greater than 96 ± 2.5 Ω. 

• Fuel level warning light will turn off when fuel level sensor resistance smaller than 96.5 ± 4 Ω. 

04 


(a) 

(b) 


Disconnect the Z067 fuel level sensor connector. 

(c) 

(d) 

Measure the resistance between the fuel level sensor 

Z067 pin 2 and pin 3. 

Remove the fuel level sensor and measure the resistance 

following the table below. 

04 

Position Empty Warn threshold 1/4 1/2 3/4 Full 

Resistance(Ω) 

150 ± 2.5 120 ± 2.5 95 ± 2.5 74 ± 2.5 54 ± 2.5 30 ± 2.5 



NO > Replace the fuel level sensor.。 

2. CHECK HARNESS AND CONNECTOR (FUEL LEVEL SENSOR - GROUND) 

(a) 

(b) 


Disconnect the Z067 fuel level sensor connector. 

(c) 


table below. 



Z067 (2) - Ground 


< 2 Ω 




Page 1173

04-478 



(a) 


(b) 


table below. 



Z067 (3) - Ground 


5 V 



NO > Replace the fuel level sensor. 

4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - FUEL LEVEL SENSOR) 

(a) 

(b) 

(c) 


Disconnect the Z003 instrument cluster connectors. 

Disconnect the Z067 fuel level sensor connectors. 

(d) 

Measure the resistanceaccording to the value(s) in the 

table below. 



Z003 (A23) - Z067 (3) 


< 2 Ω 




Page 1174


04-479 

MALFUCTION IN ENGINE COOLANT TEMPERATURE GAUGE 


04 

04 

Page 1175

04-480 



• Ensure engine coolant level within specified value. 

• Ensure engine coolant temperature normal. 


1. INSPECT ECT INDICATOR 


(b) Remove ECT indicator. 

CAUTION 

Whenever remove the ECT indicator, ensure the engine is cold (Engine coolant temperature lower than 

40 ℃ ). 

(c) Measure the ECT sensor resistance following the table below. 

Temperature ( ℃ ) 40 72 105 120 

Resistance (Ω) 287.4 ± 30 98 ± 13.5 33 ± 2 21 



NO > Replace the ECT indicator. 

2. CHECK HARNESS AND CONNECTOR (ECT INDICATOR - GROUND) 

(a) 

(b) 

(c) 




(d) 


table below. 



E012 (1) - Ground 

E037 (1) - Ground 


5 V 

5 V 


YES > Replace the ECT indicator. 


Page 1176


04-481 

3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECT INDICATOR) 

(a) 

(b) 

(c) 




04 

(d) 


table below. 




04 

Z002 (B16) - E012 (1) 

Z002 (B16) - E037 (1) 

< 2 Ω 




Page 1177

04-482 


ENGINE OIL PRESSURE WARNING LIGHT NEVER / ALWAYS ON 


Page 1178


04-483 


• When turning the ignition switch ON, the engine oil pressure warning light will turn on. 

• Engine oil pressure warning light will turn off after engine starts. 

NOTE 

If the engine oil pressure warning light is always on after engine starts. Do not shut off engine immediately. 

Check oil level, if oil level is out of specification, it needs to be repaired first. 

Check if engine oil pressure warning light is always on or never. 



04 

04 

1. INSPECT ENGINE OIL PRESSURE WARNING LIGHT 

(a) 

(b) 

(c) 


Disconnect the Z078 (4G69) / E036 (ISF2.8) engine oil pressure switch connector. 


Check if the engine oil pressure warning light turns off. 

YES > Replace the engine oil pressure switch. 


2. CHECK HARNESS AND CONNECTOR (ENGINE OIL PRESSURE SWITCH - GROUND) 

(a) 

(b) 



(c) 


table below. 



Z078 (1) - Ground 

E036 (1) - Ground 


< 2 Ω 




Page 1179

04-484 


3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ENGINE OIL PRESSURE 

SWITCH) 

(a) 

(b) 

(c) 




(d) 


table below. 



Z002 (B22) - Z078 (1) 

Z002 (B22) - E036 (1) 


< 2 Ω 




Page 1180


04-485 

SEAT BELT WARNING LIGHT NEVER / ALWAYS ON 


04 

04 

Page 1181

04-486 




• Seat belt warning light will turn on. 

• Seat belt warning light will turn off when seat belt is fastened. 

Check if seat belt warning light always or never on. 



1. INSPECT SEAT BELT WARNING LIGHT 

(a) 

(b) 

(c) 


Disconnect the Z070 the seat belt warning switch connector. 


Check if the seat belt warning light turns off. 

YES > Replace the seat belt warning switch. 



(a) 

(b) 


Disconnect the Z070 seat belt warning switch connector. 

(c) 


table below. 



Z070 (1) - Ground 


≥ 1 MΩ 




Page 1182


04-487 


(a) 

(b) 



04 

(c) 


table below. 



Z070 (2) - Ground 


< 2 Ω 

04 




4. INSPECT SEAT BELT WARNING SWITCH 

(a) 

(b) 



(c) 


table below. 


Condition 

insert seat belt 

buckle 

Tester 

Connection 

Z070 (1) - Z070 (2) 

Specified 

Condition 

< 2 Ω 



NO > Replace the seat belt warning switch. 

Page 1183

04-488 


5. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SEAT BELT WARNING 

SWITCH) 

(a) 

(b) 

(c) 


Disconnect the Z070seat belt warning switch connector. 


(d) 


table below. 



Z003 (A31) - Z070 (1) 


< 2 Ω 




Page 1184


04-489 

PARKING BRAKE INDICATOR LIGHT NEVER / ALWAYS ON 


04 

04 

Page 1185

04-490 



• Fix four tires. 


• Pull and release the parking brake. 

Check if parking brake indicator light always/never on. 



1. INSPECT PARKING BRAKE INDICATOR LIGHT 

(a) 

(b) 

(c) 

(d) 


Release the parking brake. 

Disconnect the Z045 parking brake switch connector. 


Check if the parking brake light turns off. 

YES > Replace the parking brake switch. 



(a) 

(b) 

(c) 



Disconnect the Z002 instrument cluster. 

(d) 


table below. 



Z045 (1) - Z002 (B6) 


< 2 Ω 




Page 1186


04-491 

3. CHECK HARNESS AND CONNECTOR (PARKING BRAKE SWITCH - GROUND) 

(a) 

(b) 



04 

(c) 


table below. 



Z045 (1) - Ground 


≥ 1 MΩ 

04 




Page 1187

04-492 

DIAGNOSTICS(RHD) - POWER DOOR LOCKS 


PRECAUTION 



LOCK 

ACC 

ON 

START 


Off 

On (ACC) 

On (IG) 

Start 

2. POWER OFF. 



NOTE 

To prevent the key locked in the vehicle, do not leave the key in the vehicle when disconnecting the 


(b) If no specific instructions, the ignition switch must be off. 

3. Disconnecting the negative battery cable will reset both the trip odometer data and the clock to 

‘ 0 ’. 

NOTE 

The total odometer data can not be reset to ‘ 0 ’. 

4. The audio system will lose stored memory data if the negative battery cable is disconnected. 

NOTE 


Page 1188


04-493 

CENTRAL LOCKING CONTROLLER ASSY A 

04 

04 



2 R Lock Output 

3 G Unlock Output 

4 G Driver Side Window Down Output 

5 R Driver Side Window Up Output 

6 R - L Co-pilot Side Window Down Output 

7 G - R Co-pilot Side Window Up Output 

8 W - L Window Control Power Input 

9 L - O Key Lock Input 

10 L - R Key Unlock Input 

11 Y Collision Signal Input 

12 G - Y Left Turn Light Signal 

13 G - B Right Turn Light Signal 

14 R Door Lamp Indicator 

15 L - B Left Door Assy Switch (Data) Output 

16 L Left Door Assy Switch (Clock) Output 

17 W - L Vehicle Speed Signal 

18 R - B Ignition Switch 

Page 1189

04-494 


CENTRAL LOCKING CONTROLLER ASSY B 


1 W - R Ignition Switch Illumination Control 

2 W - L Front Left Door Open Signal Output 

3 R Central Locking Spare Power 

4 G - R Horn 

5 - - 

6 O - L To Engine Hood Switch Output 

7 V - W Lamplet Forget To Turn Off Hints 

8 O - B Key Detection Switch 

9 - - 


11 - - 

12 - - 

Page 1190


04-495 



1 


• The battery voltage should be above 12V. 



No 


“Chapter 20A starting and charging - battery” 

04 

2 

Check basic function 


lock, all doors should be locked. 


unlock, all doors should be unlocked. 



No 


04 

3 

Check remote control function 


remote key to lock the doors, all doors 

should be locked. 


remote key to unlock the doors, all doors 

should be unlocked. 


Yes 

No 


Replace the remote key. 

Page 1191

04-496 




cause of the problem. Check each part in order. If necessary, replace these parts 


The function of power door locks 

is inoperative (using the key) 

One door is inoperative (using 

the key) 

Door does not open / close 

(using the remote key) 



3. Harness 

1. Harness 




2. Harness 


4. Remote key 

5. Remote keyless entry receiver 












key) 



key) 



key) 
















Page 1192


04-497 


(USING THE KEY) 


04 

04 

Page 1193

04-498 







(a) 


(b) 

Inspect the central locking fuse (20 A) in driver side 





Page 1194


04-499 

2. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING FUSE - CENTRAL LOCKING 


(a) 

(b) 


Disconnect the Z008 central locking controller assy B connector. 

04 

(c) 


table below. 




04 

Central locking fuse (20 A) - Z008 (B3) 

< 2 Ω 





(a) 

(b) 

(c) 




(d) 


table below. 




Z008 (B10) - Ground 

Specified 

Condition 

< 2 Ω 




Page 1195

04-500 




(a) 

(b) 

(c) 



Disconnect the H011 front door lock assy LH connector. 

(d) 


table below. 



Z009 (A9) - H011 (9) 

Z009 (A10) - H011 (10) 


< 2 Ω 




5. CHECK HARNESS AND CONNECTOR (FRONT DOOR LOCK ASSY LH - GROUND) 

(a) 

(b) 



(c) 


table below. 



H011 (7) - Ground 


< 2 Ω 





(a) 

(b) 

(c) 



Replace a new front door lock assy LH. 


YES > Replace the front door lock assy LH. 


Page 1196


04-501 

7. CHECK CENTRAL LOCKING CONTROLLER ASSY 

(a) 

(b) 



04 

(c) 


table below. 


Condition 

Tester 

Connection 

Specified 

Condition 

04 

Use key to unlock A2 - A3 Battery voltage 

Use key to lock A3 - A2 Battery voltage 




Page 1197

04-502 


ONE DOOR IS INOPERATIVE (USING THE KEY) 


Page 1198


04-503 




04 

(a) 

(b) 

(c) 

Remove the front door inner guard board LH. 

Remove the front door water-proof film LH. 


(d) 


table below 


04 

Condition 

Tester 

Connection 


Use key to unlock 4 - 1 Battery voltage 

Use key to lock 1 - 4 Battery voltage 



NO > Replace the front door lock assy LH. 



(a) 

(b) 

(c) 




(d) 


table below. 



Z009 (A2) - D010 (4) 

Z009 (A3) - D010 (1) 


< 2 Ω 


YES > Replace the central locking controller assy. 


Page 1199

04-504 


DOOR DOES NOT OPEN / CLOSE (USING THE REMOTE KEY) 


Page 1200


04-505 






04 

1. INSPECT REMOTE KEY 

(a) 

Check the remote key battery. If the battery voltage is low, change the battery. If the problem is also 

exist, replace the remote key. 

04 


YES > Replace the battery or remote key. 



(a) 


(b) 

Inspect the central locking fuse (20 A) in driver side 





Page 1201

04-506 


3. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING FUSE - CENTRAL LOCKING 

CONTROLLER ASSY ) 

(a) 

(b) 




table below. 



central locking fuse (20 A) - Z008 (8) 


< 2 Ω 





(a) 

(b) 



(c) 


table below. 


Condition 


lock 


unlock 

Tester 

Connection 

A2 - A3 

A3 - A2 

Specified 

Condition 






Page 1202

VEHICLE MAINTENANCE 

MAINTENANCE SCHEDULE............................................................. 05-1 

PRECAUTION.............................................................................. 05-1 

MAINTENANCE CONTENT AND SCHEDULE IN GENERAL 

CONDITION................................................................................. 05-3 

INSPECTION...................................................................................... 05-8 

CHECK THE ELECTRICAL SYSTEM WORKING 

CONDITION................................................................................. 05-8 

CHECK THE BATTERY............................................................... 05-9 

CHECK THE AIRBAG................................................................ 05-10 

CHECK SEAT BELT .................................................................. 05-11 

CHECK PARKING BRAKE, BRAKE PEDAL ............................. 05-13 

CHECK DOOR LIMIT, DOOR LOCK AND DOOR HINGE ........ 05-14 

CHECK AND CLEAN WINDSHIELD FLUME ............................ 05-16 

CHECK ENGINE COMPARTMENT PARTS.............................. 05-17 

CHECK TIMING BELT............................................................... 05-18 

CHECK ACCESSORY BELT..................................................... 05-20 

CHECK THE TIE ROD BALL HEAD AND DUST COVER......... 05-21 

CHECK AND TIGHTEN THE CHASSIS BOLT REFER 

TO THE PRESCRIBED TORQUE ............................................. 05-22 

CHECK HEADLIGHTS............................................................... 05-23 

CHECK WINDSHIELD WIPERS, CLEANING DEVICE ............. 05-24 

CHECK CHASSIS...................................................................... 05-26 

CHECK SUSPENSION COMPONENTS ................................... 05-27 

CHECK SUSPENSION BALL JOINT AND DUST COVER........ 05-28 

CHECK STEERING FLUID LEVEL............................................ 05-29 

CHECK BRAKING SYSTEM...................................................... 05-30 

CHECK THE BRAKE DISC, BRAKE DRUM AND BRAKE 

FRICTION PLATE...................................................................... 05-31 

CHECK TIRES........................................................................... 05-32 

CHECK EXHAUST SYSTEM..................................................... 05-33 

CHECK COOLANT LEVEL........................................................ 05-34 

CHECK THE ENGINE OIL LEVEL (4G69) ................................ 05-35 

CHECK THE ENGINE OIL LEVEL (ISF2.8)............................... 05-36 

REPLACEMENT............................................................................... 05-37 

REPLACE AIR FILTER ELEMENT............................................ 05-37 

REPLACE AIR CONDITIONER FILTER ELEMENT.................. 05-38 

REPLACE ENGINE OIL (4G69)................................................. 05-40 

REPLACE OIL FILTER (4G69).................................................. 05-42 

REPLACE ENGINE OIL (ISF2.8)............................................... 05-44 

REPLACE OIL FILTER (ISF2.8) ................................................ 05-46 

REPLACE SPARK PLUG (4G69) .............................................. 05-48 

REPLACE FUEL FILTER ASSEMBLY (4G69) .......................... 05-50 

REPLACE FUEL FILTER ELEMENT (ISF2.8)........................... 05-51 

REPLACE COOLANT................................................................ 05-52 

REPLACE BRAKE FLUID.......................................................... 05-54 

REPLACE GEARBOX LUBRICATING OIL................................ 05-56 

REPLACE REAR MAIN REDUCER GEAR OIL......................... 05-57 

REPLACEMENT ........................................................................ 05-57 

05 

05 

05 

05 

05 

Page 1203

Page 1204

VEHICLE MAINTENANCE - 

MAINTENANCE SCHEDULE 

VEHICLE PRECAUTION 

MAINTENANCE ATTENTION 


05-1 

1. SAFETY INFORMATION 

(a) Maintenance project preparation. 

• Operators shall wear labor insurance shoes, working gloves, goggles, etc if necessary. 

• To ensure that the work site is ventilation and clean, tools and instruments are putted in good order, 

keep a fire extinguisher when needed. 

• Check the safety status of the instrument and equipment using, such as check lifting machine jack, etc. 

• Check the safety operation condition of the vehicle driving, ensure that the maintenance can be carried 

out smoothly. 

(b) Notes in the maintenance process. 

• Before driving into the Lift frame, ensure that there is enough distance between the vehicle bottom and 

sides with Lift frame, avoid scratch. 

• Before lifting the vehicle, ensure the vehicle weight does not exceed the lift rated load. 

• When lifting the vehicle, you should select the correct lifting point. 

• In the process of lifting vehicle, not allowed to start the engine and shift into gear when the driving 

wheel touches the ground. Otherwise the operator and vehicle are in danger. 

• Operator should strictly observe all safety rules and user rules in the maintenance process. Otherwise 

the operator and vehicle are in danger. 

• Replacement parts and consumption goods, to use the Beiqi Foton automobile Co. LTD. approved 

products, to ensure the safety and performance of the vehicle. 

(c) Notes after maintenance. 

• After the completion of maintenance, road test must be carried out. Special attention should be paid to 

the braking system and the occupant protection system inspection. 

• Vehicle should be cleared the failure messages in memory before transferred to the customer. 

2. PLANNING ISSUES 

(a) Planned maintenance interval, depends on the odometer or time interval, whichever comes first. Such 

as the schedule shows. 

(b) The next maintenance interval should be equal to the last maintenance interval. 

(c) Maintenance intervals of the various components refer to the maintenance schedule. 

(d) Some parts are particularly important in the maintenance objects. Hose if there is aging or damage 

should be replaced immediately. Please note, rubber hose is aging with time, this causing swelling, 

bruising or cracking. 

(e) Once the off-road passing through sand, mud or water, please check the following parts, and according 

to the conditions for maintenance or repair. 

• Brake pad and brake drum. 

• Brake pad and brake disc. 

• Brake pipeline and rubber hose. 

• Oil and working fluid used for transmission, transfer case and differential mechanism. 

• Air Filter elements. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1205

05-2 VEHICLE MAINTENANCE - MAINTENANCE SCHEDULE 

MAINTENANCE CONDITION 

1. IN DAILY CONDITIONS, THE VEHICLE NEEDS ACCORDING TO THE ORDINARY MAINTENANCE 

PERIOD TO THE IMPLEMENTATION OF THE MAINTENANCE. 

2. IF THE VEHICLE IS MAINLY IN THE FOLLOWING ANY ONE OR MORE SPECIAL CIRCUMSTANCES 

DRIVING, SOME OF THE PROJECTS MUST BE IMPLEMENTED MAINTENANCE MORE FREQUENTLY 

(REFER TO HARSH OPERATION CONDITION). 

(a) 

Road condition: 

• Drive on rough, muddy or dissolve snow road. 

• Drive on dusty road. 

• Drive on saline road. 

(b) Driving condition: 

• Drag the tail car, use camping frame or roof supporter. 

• Repeat within 8 kilometers of the short-range travel, and temperatures below 0 ℃ . 

• Vehicle which long term to long distance running at idle or low speed, such as the police car, taxi or 

house-to-house delivery truck. 

• Often continuous running at very high speed over 2 hours (Traveling at a rate of 80% of the maximum 

speed) 

NOTE 

The Content Involves Behind “4g69” Is Gasoline Engine Code,"2.8”and “4jb1t” Are Diesel Engine 

Codes. 

Page 1206



05-3 

MAINTENANCE CONTENT AND SCHEDULE IN GENERAL CONDI- 

TION 

4G69 GASOLINE ENGINE REGULAR INSPECTION AND REPAIR PARTS LIST: 

The projects are made clear distance and time (by the month), Check whichever comes first. 

I: Inspection, correction, or necessary replacement; R: Replacement, handling or lubrication; L: Lubrication; 

Empty: N/A. 

Item 

Interval (The odometer reading and the number of months of whichever comes first) 

Month - 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 

Odometer 

reading ×1000 

km 

The internal inspection of the engine compartment 

Check belt for crack, 

flying chip, wear, and 

adjust its tension 

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 

I I I I I I I I I 

Engine timing belt R R R R R R R R 

Check the crankcase 

system is normal or not 

(Including the crankcase 

ventilation air filter 

element) 

I I I I 

Replace the spark plugs R R R R 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Check the radiator hoses 

for damage, correct 

connection 

Check the engine 

cooling fluid level 

Replace engine cooling 

fluid 

Check whether the air 

filter clogging or damage 

Other iinspection 

Chang 

e the 

engine 

oil 

Chang 

e 

engine 

oil 

filter 

General 

condition 

Harsh 

condition 

General 

condition 

Harsh 

condition 

I I I I 

I I I I I I I I 

R 

R 

I I I I I I I I I I I I I I I I 

5000 kilometers for the first time, since then every 5000 km or 3 month intervals 

The replacement mileage with general conditions of use 



05 

05 

05 

05 

05 

05 

05 

05 

05 

Repla 

ce the 

fuel 

filter 

General 

condition 

Harsh 

condition 



Replace the air filter I I I R I I I R I I I R I I I R 

Check the engine idle 

speed 


Page 1207



ventilation hose 


ISF2.8 SERIES DIESEL ENGINE PARTS OF PERIODIC INSPECTION AND 

REPAIR LIST 


I: Inspection, correction, or necessary replacement; R: Replacement, handling or lubrication; L: Lubrication; 

Empty: N/A. 


Month - 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 

Item 

Odomete 

r reading 

×1000 

km 

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 


Check belt for crack, flying 

chip, wear, and adjust its 

tension 



connection 

Check the engine cooling 

fluid level 

I I I I I I I I I I I I I I I I I 




fluid 

R 

R 

Check whether the air filter 

clogging or damage 


Other inspection 

Replace 

engine oil 

Replace oil 

filter 

Replace 

diesel filter 

Replace air 

filter 

General 

condition 

Harsh 

condition 

General 

condition 

Harsh 

condition 

General 

condition 

Harsh 

condition 

General 

condition 

R Every 20,000 km or every 12 months 

R Every 10,000 km 



R 10,000 km for the first time, since then every 20,000 km or every 12 months 

R 5,000 km, since then every 10000 km or every 6 months 

R 5,000 km, since then every 10000 km or every 6 months 

Check the engine idle 

speed 

Timing belt 


Change every 80,000 km (drain the cooling liquid before disassembly, must use E049377000009 locating bolt in 

Installation and adjustment, refer to maintenance manual) 

Page 1208



05-5 

4JB1T SERIES DIESEL ENGINE PARTS OF PERIODIC INSPECTION AND 

REPAIR LIST 


I: Check the fluid level, tighten or adjust, replace if necessary; R: replace or lubricate; Empty: N/A. 


05 

05 

Item 

Month — 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 

Odometer 

reading 

×1000 km 

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 

05 

05 


Check belt for crack, flying 

chip, wear, and adjust its 

tension. 

Replace engine timing belt 



05 

05 

05 


ventilation control system 

(Including the crankcase 

ventilation air filter element) 



connection 

Check the engine cooling 

fluid level 

I I I I 

I I I I 


05 

05 

05 

05 


fluid 

R 

R 

05 

Check whether the air filter 

clogging or damage 

I Every 5,000 km or every 3 months 

05 

Other inspection 

05 

Replace 

engine oil 

General 

condition 

Harsh 

condition 


The replacement mileage with general condition 

05 

05 

Replace oil 

filter 

General 

condition 

Harsh 

condition 


The replacement mileage with general condition 

05 

05 

Replace 

diesel filter 

General 

condition 

R 2,000 km, check for the first time, since then replace every 10,000 km 

05 

Replace air 

filter 

General 

condition 

R 5,000 km for the first time, since then every 10,000 km or every 6 months 

05 

Check the engine idle I I I I I I I I I 


ventilation hose 


Page 1209


CHASSIS AND ELECTRICAL COMPONENTS OF PERIODIC INSPECTION AND 

REPAIR LIST 


I:Check the fluid level, tighten or adjust, replace if necessary; R:replace or lubricate; Empty: N/A.I ★:Inspection 


Item 

Month - 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 

Odometer 

reading 

×1000 km 

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 

Chassis parts 

Brake pedal and hand 

brake 

Brake lining and brake 

drum 

I I I I I I I I I I I I I I I I I 


Brake pipe and brake hose I I I I I I I I I 

Brake fluid (Including clutch 

oil) 

I I I I I I I I R I I I I I I I R 

Power steering fluid I I I I I I I I I I I I I I I I 

Manual transmission oil I I I R I I I R 

Main reducer and 

differential oil 

Steering wheel, steering 

linkage, steering 

I I I R I R 


Ball joint and dust cover I I I I I I I I I I I I I I I I 

Front and rear suspension 

system 

I I I I 

Four wheel alignment I I I I 

Tire and pressure I I I I I I I I I I I I I I I I 

Drive shaft connected 

components 


Drive shaft sliding fork R R R R R R R R R R R R R R R R 

Wheel bearing and ball pin 

grease 

I R I R I R I R 

Exhaust pipe, silencer I I I I I I I I 

Electric system 

Light. horn I I I I I I I I I I I I I I I I 

Air conditioning system and 

refrigerant 

SSRS Airbag 


First inspection at 120 months after licensed, since than every 24 months 

Battery I I I I I I I I I I I I I I I 

Clutch pedal I I I I I I I I I I I I I I I I I 

Wheel nut 

Tighten the wheel nuts at the specified torque, check every 5,000 km or 1,000 km. 

HARSH CONDITION MAINTENANCE PERIODIC TABLE 

Page 1210



05-7 

According to the driving conditions listed in the following table, maintain the project which should 

be increase the maintenance frequency (project not listed refer to general condition maintenance 

periodic table). 

A-1:Driving on rough, muddy or dissolve snow sections 

□ Check the brake friction lining and 

brake 

□ Check the brake pads and brake disc 

□ Check the brake line and the hose 

□ Check the steering wheel, steering 

linkage and gear box oil 

□ Replace wheel bearing grease 

□ Check front and rear suspension 

system 

Every 10,000 km or 6 months 


The first 1, 000 km, then every 10, 000 km or 6 months 




05 

05 

05 

05 

05 

05 

05 

05 

□ Tighten chassis and body connection 

bolt and nut 

A-2:Driving on much dust sections. 

□ Check the air filter element 



05 

05 

05 

□ Check the brake linings and brake 

drum 




B-1:Vehicle which long term to long distance running at idle or low speed, such as the police 

car, taxi or house-to-house delivery truck 

□ Check the brake linings and brake 

drum 




B-2:Often continuous running at very high speed over 2 hours (Traveling at a rate of 80% of the 

maximum speed) 

□ Replace differential gear oil 


05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1211

05-8 VEHICLE MAINTENANCE - INSPECTION 

INSPECTION 

CHECK THE ELECTRICAL SYSTEM WORKING CONDITION 

• Check the brightness and working conditions of front combination lamps, fog lamp, turn signal 

lamp, warning flashes, rear combination lamp, rear fog lamp, backup light and parking lamp. 

• Check the working condition of the interior lighting. 

• Check the working condition of buzzer, control unit, center tunnel, all switch in dashboard and 

horn. 

• Check the condition of power window, exterior mirror and central control door lock. 

• Check the radio reception conditions and interference immunity, and check the speaker. 

Page 1212

CHECK THE BATTERY 


INSPECTION 

05-9 

NOTE 

• Keep the battery cable clean and firm installation is benefit to the battery using performance 

and life. 

• When fastening the battery cable, pay attention to the battery cable installed correctly and 

firmly. Otherwise may affect appliances use and battery life. 

1. OPEN THE BATTERY CABLE COVER. 

05 

05 

05 

05 

05 

05 

05 

2. CHECK THE BATTERY. 

(a) Check the battery shell and cable whether they are 

corrosion or fracture. Replace it if necessary. 

(b) Shaking battery cable to check whether installation is 

firm. 

(c) If discover the battery positive cable is not fixed firmly. 

Disconnect the battery negative cable first. Tighten 

battery positive cable. Reinstall the fastening battery 

negative cable nut. 

3. CHECK THE BATTERY POWER DISPLAY LAMP 

COLOR. 

(a) If it displays blue, that indicate the battery is good. 

(b) If it displays white, that indicate the battery is in low level, 

charge the battery. 

(c) If it displays red, that indicate battery electrolyte 

shortage, replace the battery. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1213


CHECK THE AIRBAG 

CAUTION 

• No paste or add items on Airbag shell, forbidden to damage or hinder the airbag shell. To 

ensure the normal function of the airbag, remind the user. 

• Airbag housing is only allowed to use a dry or slightly damp cloth to clean. 

CHECK DRIVER SIDE AIRBAG 

1. DRIVER SIDE AIRBAG IS LOCATED IN THE 

CENTRAL POSITION OF THE STEERING WHEEL, 

VISUAL INSPECTION OF PLASTIC SHELL IS INTACT. 

CHECK ASSISTANT DRIVER SIDE AIRBAG 

1. ASSIATANT DRIVER SIDE AIRBAG IS LOCATED ON 

THE GLOVE BOX OF THE VICE CAB, VISUAL 

INSPECTION OF PLASTIC SHELL IS INTACT. 

Page 1214

CHECK SEAT BELT 


INSPECTION 

05-11 

NOTE 

• Check the safety belt completely pulled out of the belt automatic rewind device. 

• Check the safety belt is dirty. Clean with neutral soap liquid if necessary. 

1. CHECK THE BELT STRAP FOR THE FOLLOWING 

DAMAGE, REPLACE IT IF NECESSARY. 

(a) The seat belt fracture, torn or abrasion. 

05 

05 

05 

05 

05 

05 

(b) 

The webbing edge is torn down. 

05 

05 

05 

05 

05 

(c) 

Traces of cigarette burns. 

05 

05 

05 

05 

05 

(d) 

One side of the webbing edge is deformation or the seat 

belt edge is wavy. 

05 

05 

05 

05 

Page 1215


2. CHECK THE SEAT BELT LOCK. 

(a) 

Force quickly pulled down the safety belt to check 

whether the safety belt lock locking sensitive,replace it, 

if can’t be lock fast. 

3. CHECK ORIENTED BUCKLE AND LOCK TONGUE. 

(a) Check oriented buckle shell for deformation, shedding 

and dehiscence, replace it if necessary. 

(b) 

(c) 

Check the lock tongue for deformation and dehiscence, 

replace it if necessary. 

Insert the lock tongue into the oriented buckle. Check the 

lock tongue can be locked, after cross-checks more than 

5 times, the lock tongue once failed to lock in the 

oriented buckle, should be replaced. 

Page 1216


INSPECTION 

05-13 

CHECK PARKING BRAKE, BRAKE PEDAL 

1. CHECK THE PARKING BRAKE, BRAKE PEDAL. 

(a) Check the parking brake is flexible, handle pull strength 

is normal or not, whether the cable is worn, repair it if 

necessary. 

05 

05 

05 

05 

(b) 

Check whether the brake pedal is loose, whether the free 

stroke is normal, repair it if necessary. 

Free stroke:1 ~ 3 mm 

05 

05 

05 

05 

05 

05 

2. ROAD TEST, CHECK THE WORK CONDITION OF THE PARKING BRAKE AND BRAKE PEDAL, 

MAINTAIN IT IF NECESSARY. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1217


CHECK DOOR LIMIT, DOOR LOCK AND DOOR HINGE 

1. CHECK THE DOOR LIMIT. 

(a) 

Check the door limit is in good work condition. Apply 

grease to the activity place if lacking of the lubrication. 

2. CHECK THE DOOR LOCK, INSURANCE BUTTON, 

CHILD SAFETY LOCK. 

(a) 

(b) 

Lock the door, check the insurance button works normal 

or not. 

Press down the insurance button, then close the door, 

the insurance button will upspring to prevent false lock 

the door. 

(c) 

Switch the child safety lock from OFF to ON. The child 

safety lock locking. In this case the door can only be 

opened from the outside. 

3. CHECK THE LOCK CORE. 

(a) 

(b) 

Insert the key into the lock. 

Rotate the key left and right, the lock core should be able 

to rotate smoothly. 

Page 1218


INSPECTION 

05-15 

4. CHECK THE ENGINE HATCH AND REAR HATCH. 

(a) Continuously open and close the engine hatch to check 

whether the hinge catching, Apply grease to the activity 

place if lacking of the lubrication. 

05 

05 

05 

(b) 

Check the rear hatch closed, check the rear hatch look. 

05 

05 

05 

05 

05 

(c) 

Continuously open and close the rear hatch to check 

whether the hydraulic pole catching. Apply grease to the 

activity place if lacking of the lubrication. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1219


CHECK AND CLEAN WINDSHIELD FLUME 

1. OPEN THE ENGINE HATCH. 

2. CHECK WINDSHIELD FLUME WHETHER HAS 

IMPURITIES OR CLOGGED. 

3. CHECK THE SEALING STRIP FOR DAMAGE. 

4. CLOSE THE ENGINE HATCH. 

Page 1220


INSPECTION 

05-17 

CHECK ENGINE COMPARTMENT PARTS 

NOTE 

• Troubles once detected should be checked immediately 

• Replenish loss fluid timely, exclude leakage in pipes. 


2. CHECK THE FOLLOWING CATHETER, HOSE AND LAYUP FOR LEAKS, DAMAGE AND AGING. 

CHECK THE INTERSPACE BETWEEN THE PIPELINE AND THE BODY IS REASONABLE. 

ADJUST OR REPLACE IF NECESSARY. 

(a) Fuel system. 

(b) Air conditioning system pipeline and cooling system pipeline. 

(c) Brake equipment and pipeline. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1221


CHECK TIMING BELT 

1. TURN THE IGNITION SWITCH OFF. 

2. REMOVE THE RETAINING BOLT ON THE TIMING 

BELT FRONT COVER. TAKE DOWN THE TIMING 

BELT FRONT COVER. 

3. CHECK THE TIMING BELT HAS THE FOLLOWING SITUATION, REPLACE IT IF NECESSARY: 

NOTE 

• Water or grease adhere to the timing belt can reduce the services life of the belt. If the timing 

belt with oil and heavy polluted, do not wash, need to change a new one. 

• If the timing belt with traces of oil pollution, should check engine if there is oil leakage. 

(a) 

Inspect the timing belt back rubber for signs of aging and 

glistening. 

(b) 

(c) 

(d) 

(e) 

Cracks and stripping in the canvas. 

Cracks in the back rubber. 

Cracks in the grooves. 

Cracks in the side of the belt. 

(f) 

Inspect the timing belt for abnormal abrasion in the side 

of the belt. 

Page 1222


(g) 

(h) 

INSPECTION 

Timing belt for abnormal abrasion. 

Teeth missing from the belt. 

05-19 

05 

05 

05 

4. INSTALL THE TIMING BELT FRONT COVER, 

TIGHTEN BOLTS. 

Torque:18 ~ 26N•m 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1223


CHECK ACCESSORY BELT 



3. CHECK THE ACCESSORY BELT WHETHER THERE 

IS A FRACTURE, AGING, ETC. REPLACE IT IF 

NECESSARY. 

NOTE 

• Water or grease adhere to the belt can reduce the services life of the belt. If the belt with oil and 

heavy polluted, do not wash, needs to change a new one. 

• If the belt with traces of oil pollution, should check engine if there is oil leakage. 


Page 1224


INSPECTION 

05-21 

CHECK THE TIE ROD BALL HEAD AND DUST COVER 

1. LIFT THE VEHICLE. 

2. SLOSHING THE TIE ROD, SHOULD FEEL NO GAP. 

3. CHECK THE TIE ROD BALL HEAD FIXED NUT IS 

FIRMLY. 

05 

05 

05 

05 

05 

4. CHECK THE TIE ROD DUST COVER AND BALL 

HEAD RUBBER FOR DAMAGE. IF THERE IS ANY 

DAMAGE, REPLACE IT WITH A NEW ONE. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1225


CHECK AND TIGHTEN THE CHASSIS BOLT REFER TO THE PRE- 

SCRIBED TORQUE 

NOTE 

Pay attention to prevent dust, sand and other debris falling into the eyes when looking up to the 

chassis.To tighten the chassis bolts do wear a helmet and gloves and other safety measures. 

1. TURN OFF ALL ELECTRICAL APPLIANCES AND IGNITION SWITCH. 


3. CHECK ALL CHASSIS FASTENING BOLTS AND NUTS FOR TIGHTNESS AND CORROSION. 

4. RE-TIGHTEN ALL FASTENING BOLTS AND NUTS REFER TO SPECIFIED TORQUE. 

Page 1226


INSPECTION 

05-23 

CHECK HEADLIGHTS 

1. PREPARATION FOR HEADLIGHTS INSPECTION: 

(a) Park vehicle on a flat road. 

(b) The driver sitting in the car (or with weight 73 kg), and more than half of the fuel store in the fuel tank. 

(c) Tire pressure is normal. 

(d) Headlight internal structure normal. 

2. CHECK THE HEADLIGHTS: 

(a) Check the headlight assembly for damage and replace if necessary. 

(b) Test headlight function. Bulbs burnt out should be replaced. Headlight regulating function is normal or 

not. 

(c) Check whether there is water vapor in the headlight, or other foreign material. 

(d) If the headlight irradiation deviates from the normal range, required to adjust the headlight. (Refer to 

“Chapter 64 Lighting-LF combination lamp assembly, adjustment”) 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1227


CHECK WINDSHIELD WIPERS, CLEANING DEVICE 

1. CHECK THE WINDSHIELD WIPER BLADE LIMIT POSITION: 

NOTE 

• Check the wiper blade should be located in the rest position, adjust if necessary. 

• Wiper arm tightening torque:18 ~ 21N•m. 

(a) 

The driver's side. 

• The distance between the wiper blade rubber and the 

lower edge of the windscreen is 30mm. 

• If necessary, move and adjust the wiper arm. 

(b) The front passenger side. 

• The distance between the wiper blade rubber and the 

lower edge of the windscreen is 45mm。 

• If necessary, move and adjust the wiper arm. 

2. REPLACE WIPER BLADE. 

(a) Place the wiper arm in the maintenance position. Push 

the locking button of the wiper blade. Remove the wiper 

blade down. 

(b) Install wiper blade. Make sure locking button located in 

the lock position. 

(c) Turn on the ignition switch and operate the wiper arm in 

a short-term, stop the windshield wipers back at the 

automatic stop position. 

3. CHECK THE WINDSHIELD WASHER FLUID. 

(a) The windshield washer fluid level should be apart from 

the opening about 10cm, add if inadequate. 

NOTE 

The windshield washer fluid is consumable liquid. Please 

check regularly. 

Page 1228


INSPECTION 

05-25 

4. Check the windshield spray. 

(a) The washer fluid sprays on windshield within the range 

shown in the illustration. 

05 

05 

05 

(b) 

If the point which the washer fluid sprays on windshield is 

not in right position, adjust washer nozzle. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1229


CHECK CHASSIS 


2. CHECK THE FUEL LINE, BRAKE FLUID LINE FOR LEAKS. 

3. CHECK THE BOTTOM COVER, WHEEL COVER AND SIDE BEAM IF THERE IS DAMAGE. 

4. VISUAL CHECK THE EXHAUST PIPE LIFTING LUG FOR AGEING AND INSTALLATION FIRMLY. 

Page 1230


INSPECTION 

05-27 

CHECK SUSPENSION COMPONENTS 


2. CHECK ALL CONNECTING BUSHING FOR AGING OR DAMAGE. 

3. TIGHTEN ALL CONNECTING BOLTS AND NUTS BY SPECIFIED TORQUE. 

4. CHECK EACH CONNECTING PARTS FOR DEFORMATION AND CRACK. 

5. CHECK SHOCK ABSORBER FOR OIL LEAKAGE. CHECK DUST COVER FOR DAMAGE. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1231


CHECK SUSPENSION BALL JOINT AND DUST COVER 

1. CHECK UPPER ARM BALL JOINT DUST COVER FOR 

DAMAGE. IF THERE IS ANY DAMAGE, REPLACE IT 

WITH A NEW ONE. 

2. CHECK LOWER ARM BALL JOINT DUST COVER FOR 

DAMAGE. IF THERE IS ANY DAMAGE, REPLACE IT 

WITH A NEW ONE. 

Page 1232


INSPECTION 

05-29 

CHECK STEERING FLUID LEVEL 

1. PARK VEHICLE ON A FLAT ROAD. 

2. TURN IGNITION SWITCH OFF. 

3. TURN FRONT WHEELS TO STRAIGHT POSITION. 


5. UNSCREW POWER STEERING RESERVOIR FILLER 

CAP. 

05 

05 

05 

05 

05 

05 

05 

6. CHECK THAT THE FLUID LEVEL IS WITHIN THE 

RANGE OF MAX AND MIN, ADJUST THE FLUID IF 

NECESSARY. 

Steering fluid:ATF- Ⅲ 

05 

05 

05 

05 

05 

7. TIGHTEN THE POWER STEERING RESERVOIR 

FILLER CAP. 

05 

05 

05 

05 

05 


05 

05 

05 

Page 1233


CHECK BRAKING SYSTEM 

NOTE 

• Only use the brake fluid Foton approved. 

• Brake fluid can not mixed with other liquid, otherwise it may damage the braking system line 

and endanger vehicle. 

• Decide whether to add brake fluid according to the wear pattern of braking friction plate. 


2. CHECK THE BRAKE FLUID RESERVOIR LEVEL. 

(a) When braking friction plate wear close to the limit, brake fluid level should be partial to the lowest line. 

(b) When braking friction plate wear little, brake fluid level should be partial to the highest line. 

3. CHECK THE FOLLOWING PARTS WHETHER HAVE DAMAGE AND LIQUID LEAKAGE: 

(a) Brake master cylinder. 

(b) Brake booster. 

(c) Brake caliper. 

(d) Braking line. 

4. CHECK THE CLEARANCE OF BRAKE HOSE AND BODY, IT SHOULD BE APPROPRIATE. CHECK 

BRAKE HOSE IF IT IS ABRADED, CHECK WHETHER BRAKE LINE INTERFACE AND FIXED 

INSTALLATION IS FIRMLY. 

Page 1234


INSPECTION 

05-31 

CHECK THE BRAKE DISC, BRAKE DRUM AND BRAKE FRICTION 

PLATE 

NOTE 

If the brake disc, brake drum and brake friction plate thickness wear to limit, must inform the customer, 

replace it. 

1. CHECK FRONT BRAKE DISC AND THE BRAKE FRICTION PLATE. 

(a) Remove front wheel. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”) 

(b) Measuring braking friction plate (without rear panel) and 

brake disc thickness. 

• Standard thickness for brake friction plate (without 

rear panel) is: 12mm, limit thickness is: 2mm. 

• Standard thickness for brake disc is: 22mm, limit 

thickness is: 21mm. 

05 

05 

05 

05 

05 

05 

05 

05 

(c) Install the front wheel. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”) 

2. CHECK THE REAR BRAKE DRUM AND BRAKE FRICTION PLATE. 

(a) Remove rear wheel. 

(b) Measuring braking friction plate (without rear panel) and 

brake drum thickness. 

• Standard thickness for brake friction plate (without 

rear panel) is: 7.5mm, limit thickness is: 2.5mm. 

• Standard thickness for brake drum is: Φ295mm, limit 

thickness is: Φ296mm. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

(c) 

Install the rear wheel (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”) 

05 

05 

05 

Page 1235


CHECK TIRES 

NOTE 

When found tire wear to limit or damaged which affect the safe driving, must inform the customer, 

change the tire. 

1. CHECK THE TIRE ROLLING SURFACE AND SIDE WALL IS DAMAGE OR FOREIGN BODY, 

CHECK SIDE WALL IS LOOSE POROUS, INCISION AND FOREIGN BODY PIERCING. 

2. CHECK WHETHER THE TIRE ROLLING SURFACE WEAR IS UNILATERAL, IF UNILATERAL 

WEAR IS SERIOUS, NEED TO ADJUST BY FOUR-WHEEL LOCATION. 

3. CHECK THE TIRE TREAD DEPTH (INCLUDING 

SPARE TIRE), ENSURE TREAD GROOVE DEPTH 

THAN WEAR MARK THICKNESS, THE SIDE OF THE 

TIRE TRIANGLE WEAR MARK MUST NOT WEAR 

OUT. 

The minimum tread depth is: 1.6mm. 

4. Check and adjust tire inflation pressure (including spare tire): 

wheel specification Front wheel Rear wheel Spare wheel 

195R15C-106R 350 kPa 400 kPa 400 kPa 

Page 1236


INSPECTION 

05-33 

CHECK EXHAUST SYSTEM 

NOTE 

In the exhaust system operation, pay attention to prevent scalding. 


2. CHECK FRONT AND REAR EXHAUST PIPE, THE SILENCER, THE OXIDATION CATALYST SHELL 

IF THERE IS ANY BREAKAGE. 

3. CHECK IF THE EXHAUST SYSTEM CONNECTION BETWEEN COMPONENTS LEAKS. 

4. CHECK THE LIFTING LUGS WHETHER AGEING OR FRACTURE. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1237


CHECK COOLANT LEVEL 

NOTE 

• In the cooling system operation, pay attention to prevent water and heat steam scalding. 

• Can only use the cooling fluid Foton approved. 


2. WAIT UNTIL THE ENGINE COOLING TO ROOM TEMPERATURE. 


4. CHECK COOLANT LEVEL LINE, LIQUID LEVEL 

SHOULD BE IN MIN AND MAX (ENGINE IS ALREADY 

COOLING DOWN). 

5. PUT DOWN THE ENGINE HATCH. 

Page 1238


INSPECTION 

05-35 

CHECK THE ENGINE OIL LEVEL (4G69) 

1. PARK THE VEHICLE ON A FLAT ROAD. 

2. PREHEAT THE ENGINE TO NORMAL OPERATING TEMPERATURE. 


4. WAIT FOR ABOUT 3 MINUTES. 


6. PULL OUT OIL SCALE SLOWLY. 

05 

05 

05 

05 

05 

05 

05 

7. CHECK THE ENGINE OIL LEVEL, LEVEL SHOULD 

BE IN OIL SCALE MARK RANGE. 

05 

05 

05 

05 

05 

05 

8. CHECK THE ENGINE OIL, IF OIL IS DIRTY OR THINNED, DEBUGGING AND REPLACE ENGINE 

OIL. 

9. PUT BACK THE OIL SCALE. 

05 

05 

05 

05 

05 

05 


05 

Page 1239


CHECK THE ENGINE OIL LEVEL (ISF2.8) 

1. PARK THE VEHICLE ON A FLAT ROAD. 

2. PREHEAT THE ENGINE TO NORMAL OPERATING TEMPERATURE. 

3. TURN OFF THE IGNITION SWITCH. 

4. WAIT FOR ABOUT 3 MINUTES. 


6. PULL OUT OIL SCALE SLOWLY. 

7. CHECK THE ENGINE OIL LEVEL, LEVEL SHOULD 

BE IN THE SCOPE OF OIL SCALE MARK RANGE. 

8. CHECK THE ENGINE OIL, IF OIL IS DIRTY OR THINNED, DEBUGGING AND REPLACE ENGINE 

OIL. 

9. PUT BACK THE OIL SCALE. 


Page 1240


REPLACEMENT 

05-37 

REPLACEMENT 

REPLACE AIR FILTER ELEMENT 

1. REPLACE AIR FILTER ELEMENT. 

(a) Remove the 4 air filter fixed buckle from the vehicle 

bottom. 

05 

05 

05 

05 

05 

(b) Open the air filter lower cover, remove the air filter. 

NOTE 

Air filter is made of paper material, if necessary, can use the 

high pressure air gun to clean air filter from internal to 

external. don't rinse the air filter by water. 

(c) Clean or replace the air filter. 

05 

05 

05 

05 

05 

2. INSTALL AIR FILTER LOWER COVER AND FASTEN 

THE BUCKLE. 

NOTE 

When install air filter lower cover, ensure that install air 

filter in the right direction, then fasten the buckle. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1241

05-38 VEHICLE MAINTENANCE - REPLACEMENT 

REPLACE AIR CONDITIONER FILTER ELEMENT 

1. REMOVE THE GLOVE BOX. 

2. REMOVE THE AIR FILTER DECORATIVE COVER. 

(a) Press on both sides of the lock. take down the decorative 

cover. 

3. EXTRACT AIR-CONDITIONING FILTER. 

4. INSTALL AIR-CONDITIONING FILTER. 

NOTE 

Install the air conditioning filter in accordance with the marked 

direction at filter lateral. 

Page 1242


REPLACEMENT 

05-39 

5. INSTALL THE AIR FILTER DECORATIVE COVER, 

AND LOCK INTO TO THE CORRECT POSITION. 

05 

05 

05 

6. INSTALL THE GLOVE BOX. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1243


REPLACE ENGINE OIL (4G69) 

1. START ENGINE AND ENSURE ENGINE COOLANT TEMPERATURE WITHIN 80 ~ 90 ℃ . 

2. TURN IGNITION SWITCH OFF AND WAIT FOR 10 MINUTES. 

3. OPEN ENGINE COMPARTMENT COVER. 

(a) Loosen the driver seat clamp. 

(b) Turn over the driver seat and open engine compartment 

cover. 

4. OPEN OIL FILLER CAP. 

5. RAISE AND SUPPORT VEHICLE. 

6. REMOVE OIL DRAIN PLUG. 

(a) Drain engine oil. 

NOTE 

• The engine oil maybe hot, be careful, avoid personal 

injury. 

• Prolonged and repeated contact with engine oil will 

cause the skin fat to be removed, resulting in dry 

skin, allergies and dermatitis. In addition, used 

engine oil contains potentially harmful pollutants 

which may cause skin cancer. Therefore, the skin 

must be protected in appropriate methods and with 

cleaning equipment. 

• Using a special container, collect or dispose used oil 

as required. 

7. REPLACE WITH NEW DRAIN PLUG GASKET AND 

TIGHTEN PLUG. 

Torque: 34 ~ 45 N.m 

Page 1244


REPLACEMENT 

05-41 

8. LOWER VEHICLE. 

9. FILL ENGINE OIL. 

Engine oil: 4 L 

NOTE 

The Specification of engine oil allowed only is 10W-30 ,15W-40 or SL level as well as 5W-30 (GB11121) 

oil used in winter of North China. 

10. INSTALL OIL FILLER CAP. 

11. PARK THE VEHICLE ON LEVEL GROUND AND START ENGINE UNTIL IT IS WARM. CHECK AND 

ENSURE THERE IS NO OIL LEAKAGE. 


13. CHECK OIL LEVEL. 

(a) Pull out oil dipstick and wipe it clean . 

(b) Insert oil dipstick and pull it out to ensure oil level is 

within the range as shown in the figure. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

14. PUT DOWN DRIVER SEAT AND LOCK IT. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1245


REPLACE OIL FILTER (4G69) 

NOTE 

Without special circumstances, the oil filter should be replaced with engine oil to avoid oil pollution 

and keep engine normal operation. 





cover. 



5. DRAIN ENGINE OIL. (Refer to “Chapter 18A lubrication - engine oil, replacement”) 

6. USING SPECIAL TOOL TO REMOVE OIL FILTER. 

7. CLEAN THE CONNECT SURFACE OF OIL FILTER AND OIL FILTER BRACKET. 

8. APPLY OIL TO O-RING OF NEW OIL FILTER. 

Page 1246


REPLACEMENT 

05-43 

9. TIGHTEN OIL FILTER BY HAND UNTIL O-RING TOUCHES 

OIL FILTER BRACKET. USE A SUITABLE TOOL TO 

TIGHTEN OIL FILTER. 

Torque: 13 ~ 15 N•m 

05 

05 

05 

10. TIGHTEN DRAIN PLUG. 



12. OPEN OIL FILLER CAP AND FILL ENGINE OIL TO SPECIFIED LEVEL. 


14. PARK THE VEHICLE ON LEVEL GROUND AND START ENGINE UNTIL IT IS WARM. 

15. CHECK AND ENSURE THERE IS NO OIL LEAKAGE. 

16. TURN THE IGNITION SWITCH OFF AND WAIT FOR 10 MINUTES. 

17. PULL OUT OIL DIPSTICK TO ENSURE OIL LEVEL IS BETWEEN “MAX” MARK AND “MIN” 

MARK. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1247


REPLACE ENGINE OIL (ISF2.8) 

1. PARK VEHICLE IN LEVEL ROAD, SLOWLY PULL OUT OIL DIPSTICK, AND CHECK OIL LEVEL, 

OIL LEVEL MUST BE LOCATED WITHIN THE OIL DIPSTICK MARK. 

2. CHECK OIL WITHOUT EXCESSIVE POLLUTION, NO PETROL AND LIQUID MIXED. THERE MUST 

HAVE ENOUGH CONCENTRATIONS AND VISCOSITY. 





CAUTION 

The engine oil maybe hot, be careful, avoid personal injury. 

7. USING A SPECIAL CONTAINER, COLLECT OR DISPOSE USED OIL AS REQUIRED. 

8. REPLACE A NEW DRAIN PLUG GASKET AND TIGHTEN 

DRAIN PLUG. 




Engine oil: 5 ~ 5.5 L 

NOTE 

The specification of engine oil is CH - 4 level or above (15W-40 in summer and 15W-30 in winter). 



13. CHECK OIL FILTER OR OTHER PART AND ENSURE THERE IS NO OIL LEAKAGE. 

Page 1248



REPLACEMENT 

05-45 

15. AFTER 8 ~ 10 MINUTES, PULL OUT OIL DIPSTICK TO 

ENSURE OIL LEVEL IS BETWEEN “MAX” MARK AND 

“MIN” MARK. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1249


REPLACE OIL FILTER (ISF2.8) 

NOTE 

Without special circumstances, the oil filter should be replaced with engine oil to avoid oil pollution 

and keep engine normal operation. 


2. OPEN ENGINE COMPARTMENT COVER AND THEN OPEN OIL FILLER CAP. 

3. RAISE AND SUPPORT THR VEHICLE. 

4. REMOVE OIL DRAIN PLUG AND DRAIN ENGINE OIL. 

CAUTION 

Be careful, the engine oil maybe hot. 


6. USING SPECIAL TOOL, REMOVE OIL FILTER. 

7. CLEAN THE SURFACE BETWEEN OIL FILTER AND OIL FILTER BRACKET. 


9. FILL CLEAN OIL INTO OIL FILTER. 

Page 1250


REPLACEMENT 

05-47 


OIL FILTER BRACKET. USING SUITABLE TOOL, TIGHTEN 

OIL FILTER. 

Torqure: 25 ~ 30 N•m 

05 

05 

05 



05 

05 

05 

05 

05 

05 


13. FILL ENGINE OIL TO SPECIFIED LEVEL. 


15. START ENGINE AND RUN FOR 5 MINUTES WITH THE VEHICLE PARKING ON LEVEL GROUND. 

16. CHECK OIL FILTER AND ENSURE THERE IS NO OIL LEAKAGE. 





05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1251


REPLACE SPARK PLUG (4G69) 



(a) 

(b) 

Loosen the driver seat clamp. 

Turn over the driver seat and open engine compartment 

cover. 

3. REMOVE AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”) 

4. REMOVE SPARK PLUG WIRE. 

(a) Pull out spark plug wire by slightly turning. 

5. REMOVE SPARK PLUG.. 

(a) Using special socket tool ,remove spark plug. 

(b) Take spark plug out. 

6. INSTALL SPARK PLUG. 

(a) Using special socket tool, tighten spark plug. 


NOTE 

Install the spark plug, tightening torque to meet the 

technical specifications of Foton. Don’t screw it too loose 

or too tight to avoid leakage or damage to the spark plug 

and Spark plug holes. 

Page 1252


REPLACEMENT 

05-49 

7. INSTALL SPARK PLUG WIRE. 

(a) Place spark plug wire on the corresponding position 

according to the sequence as shown on igniton module. 

(b) Install spark plug wire. 

NOTE 

A click can be heard to confirm the spark plug wire is 

installed properly. 

05 

05 

05 

05 

8. INSTALL INTAKE HOSE. (Refer to “Chapter 14A intake air- intake air hose, replacement”) 


10. START ENGINE AND CONFIRM IT IS IN GOOD CONDITION. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1253


REPLACE FUEL FILTER ASSEMBLY (4G69) 

1. RELEASE FUEL PRESSURE. (Refer to “Chapter 12A fuel - fuel system, fuel system pressure 

release process”) 

2. RAISE AND SUPPORT THE VEHICLE. 

3. REMOVE THE FUEL FILTER. 

(a) Disconnect quick connector from both sides of fuel filter. 

NOTE 

• Depress the tab on both sides of quick connector, 

slide out the connector slowly. Do not pull excessively 

to prevent quick connector from damaging. 

• Keep the connecting portion clean and avoid damage 

and foreign materials, cover them completely with 

plastic bags or something similar. 

(b) 

(c) 

Loosen fuel filter mounting band retaining bolt. 

Remove fuel filter. 

4. INSTALL NEW FUEL FILTER. 

NOTE 

Follow the arrow on the fuel filter when install the fuel filter. 

(a) Install fuel filter and tighten the mounting band bolt. 


(b) Connect both sides quick connector. 

NOTE 

Connect fuel tube quick connectors until a click was heard, 

then pull the quick connector to check quick connectors 

are secured. 

5. LOWER THE VEHICLE. 

6. CHECK FUEL LINES. 

(a) When ignition switch is on, fuel pump will apply fuel pressure to fuel lines. inspect if there is fuel 

leakage from pipe connection. 

(b) Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose 

connections. 

Page 1254


REPLACEMENT 

05-51 

REPLACE FUEL FILTER ELEMENT (ISF2.8) 

1. DIESEL FILTER ASSY DESCRIPTION. 

(a) ISF2.8 Engine have a maintainable cylinder-type diesel 

filter which contains a integrated WIF sensor and fuel 

heater. The diesel filter is located between fuel pump and 

tank. 

05 

05 

05 

05 

2. RELEASE FUEL PRESSURE. (Refer to “Chapter 12B fuel - fuel system, fuel system pressure 


3. REPLACE DIESEL FILTER. (Refer to CUMMINS ISF SERIES ENGINE SERVICE MANUAL ) 

NOTE 

• If draining water is required frequently, it means that fuel is not qualified or there is water in fuel 

tank. Please drive the vehicle to service station for repair. 

• In order to ensure fuel clean, in strict accordance with maintenance requirement to operate fuel 

filter sechudle maintenance. Replacement cycle: 15,000 km. 

4. CHECK AFTER INSTALLATION. 

(a) After installation, turn ignition switch on and check the fuel gauge’s conditions in instrument panel. Start 

engine and check there are no fuel leakage at the diesel system tube and hose connections. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1255


REPLACE COOLANT 

CAUTION 

Do not open the reservior cap when the engine is hot. Coolant temperature should be reduced to 50 ° C 

(120 ° F) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may 

cause personal injury. 

1. COOL ENGINE TO NORMAL INDOOR TEMPERATURE. 

2. OPEN RESERVOIR CAP TO RELEASE PRESSURE 

BY TURN IT COUNTERCLOCKWISE. 

NOTE 

Wrap a thick cloth around the reservior cap. Slowly turn it a 

quarter of a turn to release built-up pressure. Then turn it all 

the way. 


4. REMOVE RADIATOR DRAIN PLUG AND DRAIN 

COOLANT. 

NOTE 

Using a suitable container, hold the coolant. if not to be 

used, dispose of them according to the regulations . 

5. CHECK ENGINE COOLANT. 

(a) Check drained engine coolant for contaminants such as rust, corrosion or discoloration. 

(b) If contaminated, flush the engine cooling system. 

6. FLUSH ENGINE COOLING SYSTEM. 

(a) Install and tighten radiator drain plug. 

NOTE 

Always clean coolant drain plug and replace O-ring with new one. 

(b) Fill radiator and reservoir with water and reinstall reservior cap. 

(c) Run the engine and warm it up to normal operating temperature. 

(d) Rev the engine two or three times under no-load. 

(e) Stop the engine and wait until it cools down. 

(f) Drain water from the cooling system. 

(g) Repeat the precedure above until clear water begins to drain from radiator 

7. ADD ENGINE COOLANT. 

(a) Install radiator drain plug. 

(b) Slowly fill the radiator with ”FOTON Long-effective coolant”. 

Standard volume: 13.5 L 

(c) Push the radiator inlet/outlet hose several times, check the coolant level. If coolant is at the low level , 

fill the coolant. 

Page 1256


REPLACEMENT 

05-53 

(d) Install the radiator cap and coolant reservoir cap. 

(e) Start and warm the engine until the cooling fan at high speed. 

(f) Stop the engine and check the coolant level. 

(g) Check the coolant level in reservoir. If necessary, add the coolant to specified position. 

NOTE 

The air in cooling system can be bled automatically. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1257


REPLACE BRAKE FLUID 

WARNING 

Brake fluid damages painted surfaces and irritates skin. If brake fluid is spilled on any painted surfaces 

or skin, wash it off immediately with water. 

1. FILL THE FLUID RESERVOIR WITH BRAKE FLUID. 

Brake fluid: DOT 3 or DOT 4 brake fluid 

WARNING 

Brake fluid damages painted surfaces and irritates skin. If 

brake fluid is spilled on any painted surfaces or skin, wash 

it off immediately with water. 

2. BLEED BRAKE MASTER CYLINDER ASSY. 

(a) Tighten tubing joint nut fitting brake tube to brake master 

cylinder. 

NOTE 

If the brake cylinder has been removed or if the brake fluid 

reservoir assy becomes empty, bleed the air from the 

master cylinder assy. 

(b) 

Rapidly depress the brake pedal and hold it. 

(c) 

(d) 

Loosen tubing joint nut separately, bleed the air and 

fluid,then tighten tubing joint nut immediately. 

Repeat steps (b) and (c) 3 or 4 times until all the air in the 

fluid has been bled out. 

Page 1258


REPLACEMENT 

05-55 

3. BLEED BRAKE LINE. 

(a) Connect the hose to the bleeder plug of rear wheel brake 

cylinder. 

(b) Rapidly depress the brake pedal several times, then 

loosen the bleeder plug. 

(c) When brake fluid stops flowing, tighten the bleeder plug, 

then release the brake pedal. 


(d) Repeat steps (b) and (c) 3 or 4 times until all the air in the 


05 

05 

05 

05 

05 

05 

(e) 

(f) 

(g) 

(h) 

(i) 

Connect the hose to the bleeder plug of front disk brake 

caliper. 

Rapidly depress the brake pedal several times, then 


When brake fluid stops flowing, tighten the bleeder plug, 



Repeat steps (f) and (g) 3 or 4 times until all the air in the 


Repeat the above procedures to bleed the air out of the 

brake line for each wheel. 

NOTE 

Sequence Of Brake Line Bleeding(sit in driver seat): Rear 

RH - Rear LH - Front RH - Front LH 

4. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. 

(a) Check the fluid level and fill the fluid reservoir with brake 

fluid if necessary. 

Brake fluid: DOT 3 or DOT 4 brake fluid 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

Page 1259


REPLACE GEARBOX LUBRICATING OIL 

1. REMOVE DRAIN PLUG BY DOWNSIDE AND DRAIN 

TRANSMISSION FLUID COMPLETELY. TIGHTEN DRAIN 

PLUG. 


NOTE 

• Keep vent plug unblocked and loosen the filler plug 

before draining fluid. In order to drain transmission 

fluid completely, drain the fluid when it is hot. 

• Use special container for transmission fluid when 

draining. 

2. REMOVE FILLER PLUG AND FILL TRANSMISSION 

FLUID. THEN TIGHTEN FILLER PLUG. 


CAUTIONN 

• According to demand, fill transmission fluid GL- 4 

75W/90 for 2.0 L. 

• Do not mix different kind of transmission fluid. 

• Parking the vehicle on the levelground when 

checking fluid level. The fluid level must be flush 

with lower edge of oil filler. 

Page 1260


REPLACEMENT 

05-57 

REPLACE REAR MAIN REDUCER GEAR OIL 

REPLACEMENT 

1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - rear axle, precaution”) 

2. DRAIN FINAL DRIVE OIL. 

(a) Remove the vent plug. 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

05 

(b) 

(c) 

Using a wrench, remove the drain plug. 

Drain the final drive oil completely. 

NOTE 

Use a container to collect final drive oil when performing 

this operation. 

05 

05 

05 

05 

05 

(d) 

Using a wrench, install the drain plug. 

05 

05 

05 

05 

Page 1261

MEMO 

Page 1262


GASOLINE ENGINE CONTROL SYSTEM.....................................11A-1 

PRECAUTION............................................................................ 11A-1 

SYSTEM OVERVIEW................................................................ 11A-2 

INTRODUCTION TO SYSTEM FUNCTION .............................. 11A-6 

BASIC PRINCIPLE .................................................................... 11A-8 

MAIN COMPONENTS ............................................................. 11A-13 

SYSTEM COMPONENTS DESCRIPTION.............................. 11A-14 

ENGINE CONTROL MODULE (ECM) ...........................................11A-15 

PRINCIPLE .............................................................................. 11A-15 

REPLACEMENT ...................................................................... 11A-16 

ENGINE COOLANT TEMPERATURE SENSOR...........................11A-18 

PRINCIPLE .............................................................................. 11A-18 

OVERHAUL ............................................................................. 11A-19 

THROTTLE BODY .........................................................................11A-21 

THROTTLE BODY CLEANING................................................ 11A-21 

THE FIXED SPEED ADJUSTING SCREW (SAS) 

ADJUSTMENT......................................................................... 11A-22 

BASIC IDLE SPEED ADJUSTMENT....................................... 11A-23 

OVERHAUL ............................................................................. 11A-24 

IDLE AIR CONTROL MOTOR .......................................................11A-28 

PRINCIPLE .............................................................................. 11A-28 

ON-VEHICLE INSPECTION .................................................... 11A-29 

OVERHAUL ............................................................................. 11A-30 

THROTTLE POSITION SENSOR (TPS)........................................11A-32 

PRINCIPLE .............................................................................. 11A-32 


OVERHAUL ............................................................................. 11A-34 

MANIFOLD ABSOLUTE PRESSURE/INTAKE 

TEMPERATURE SENSOR ............................................................11A-36 

PRINCIPLE .............................................................................. 11A-36 


OVERHAUL ............................................................................. 11A-38 

KNOCK SENSOR...........................................................................11A-40 

PRINCIPLE .............................................................................. 11A-40 

OVERHAUL ............................................................................. 11A-41 

CKP SENSOR ................................................................................11A-43 

PRINCIPLE .............................................................................. 11A-43 

OVERHAUL ............................................................................. 11A-44 

UPSTREAM OXYGEN SENSOR ...................................................11A-46 

PRINCIPLE .............................................................................. 11A-46 


OVERHAUL ............................................................................. 11A-48 

DOWNSTREAM OXYGEN SENSOR.............................................11A-49 

PRINCIPLE .............................................................................. 11A-49 


OVERHAUL ............................................................................. 11A-51 

CANISTER SOLENOID VALVE.....................................................11A-52 

PRINCIPLE .............................................................................. 11A-52 


OVERHAUL ............................................................................. 11A-54 

11A 

11A 

11A 

11A 

Page 1263

VEHICLE SPEED SENSOR ...........................................................11A-57 

PRINCIPLE ..............................................................................11A-57 

ON-VEHICLE INSPECTION ....................................................11A-58 

OVERHAUL .............................................................................11A-59 

IGNITION CONTROL MODULE.....................................................11A-60 

PRINCIPLE ..............................................................................11A-60 

OVERHAUL .............................................................................11A-61 

Page 1264

ENGINE CONTROL SYSTEM - 

GASOLINE ENGINE CONTROL 

SYSTEM 

GASOLINE ENGINE CONTROL SYSTEM 


PRECAUTION 

11A-1 

1. GASOLINE ENGINE CONTROL SYSTEM PRECAUTION. 

(a) Power off. 

• The battery negative cable must be disconnected at first before removing or installing any electric 

appliance and when tools or facilities will touch the exposed terminals. It should be connected eventually. 

This will prevent injured person and vehicle damage. 

• The ignition switch must be off without any special descriptions. 

WARNING 

The ignition and illumination switches must be shut off before removing or installing the battery 

negative cable (the semiconductor may be damaged without doing that). 

(b) Please do disassembly, assembly and testing in accordance with the provisions introduced in this 

manual during maintenance. 

(c) Clear off the sundries on the mounting surface with a sealant scraper or a wire brush and confirm the 

sealing face is level and smooth and no greasy dirt on it before the installation. Don’t forget to remove 

the sealant on the mounting hole, the threaded hole and the thread. 

(d) Tighten the fixing bolts with prescribed torque during installing the sensors, actuators or other parts. 

(e) The high impedance type digital multimeter should be used to the test except the especial description 

of the procedure in place of the traditional analogue types multimeter. 

(f) The oxygen sensor can not contact with water or other liquids. 

(g) When installing or carrying the sensor, ensure it not damaged. Any shock or drop may cause great 

damage to its performance. 

(h) Battery voltage is low or starter failure, not long time starting the engine, so as not to damage the 

catalytic converter. 

(i) Do not use the needle puncture method to inspect system signal of wire harness. 

(j) Fuel pump can not operate for a long time without gasoline, also it can not run in the air. 

(k) Because most electric sprayed parts are un-repairable, after confirming the part is damaged, replace it 

as necessary. 

(l) The system should use anti-type spark plugs and high-voltage, non-resistant phenotype will not only 

release high-voltage spark plug and interference wave, but also effect the ignition coil driver module in 

the ECM. 

(m) ECM can’t be disassembled for test and maintenance. 

11A 

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Page 1265

11A-2 ENGINE CONTROL SYSTEM - 

SYSTEM OVERVIEW 


SYSTEM 

1. INTRODUCTION. 

The electrically controlled Multi-point Injection (MPI) engine control systems – BJ491EQ – take DELPHI 

MT20U2 Engine Control Module (ECM) as the control center and measure various working parameters of the 

engine through various sensors mounted on different components of the engine. Then the fuel injection 

quantity is controlled precisely via the control injector according to the preset control program in the ECM, 

which enables the engine to obtain the mixture with optimal concentration under various working conditions. In 

addition, with the control program in the ECM, the electrically controlled fuel injection system can also enable 

the functions of start-up enrichment, warm-up enrichment, acceleration enrichment, full-load enrichment, 

deceleration dilution, forcible idle cutoff, automatic idle speed control etc, which meets the requirements for 

mixture under special working conditions of the engine and enables the engine to obtain good fuel economy 

and emission while enhancing the functional performance of the vehicle. In addition, ECM has some fault 

diagnosis modes which can simplify the fault location. 

2. ENGINE CONTROL SYSTEM FUNCTION. 

Knock control 

Mileage memory 

Over voltage pretection 

Fuel pump control 

Canister solenoid valve control 

ECM control function 

Idle air control motor control 

Totally main power relay control 

A/C, coolant water box fan control 

Direct ignition 

Closed-loop control multi-point squence fuel injection (MAP sensor pressure 

judgement) 

Intake pressure speed-density method air measurement 

Trouble self-diagnosis function 

Page 1266


3. ECM CONTROL STRUCTURE. 


SYSTEM 

11A-3 

11A 

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11A 

11A 

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Page 1267



SYSTEM 

4. ENGINE CONTROL SYSTEM DIAGRAM. 

1 Intake 

2 Air Filter 


4 Throttle Position Sensor (TPS) 

5 Canister Solenoid Valve 

6 Canister 

7 Fuel Pressure Regulation 

8 To Fuel Box 

9 

Positive Crankshift Ventilation (PCV) 

Valve 

10 



11 From Fuel Pump 

12 Injector 


14 Crankshaft Position Sensor 

15 Upstream Oxygen Sensor 

16 Downstream Oxygen Sensor 

17 Three-Way Catalyst (TWC) 

Page 1268



SYSTEM 

11A-5 

5. ENGINE CONTROL SYSTEM MAIN COMPONENTS DISTRIBUTION GRAPHIC. 

1 Injector 


3 Spark Plug 


5 


Sensor 




9 





12 PCV Valve 


14 Outlet Fuel (Return Back To Fuel Tank) 

11A 

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Page 1269


INTRODUCTION TO SYSTEM FUNCTION 


SYSTEM 

1. IDLE SPEED CONTROL. 

(a) Idle speed control function refers to system control of engine speed with the throttle valve closed. The 

system makes the actual speed consistent with the target idle speed by controlling idle parameters. 

(b) The system applies the idle air control motor and realizes high precision idle speed control. 

2. AIR METERING OF SPEED-DENSITY METHOD (INTAKE MANIFOLD PRESSURE/ TEMPERATURE 

SENSOR). 

With intake temperature sensor and intake manifold pressure sensor, ECM calculates and defines the 

air quantity entering the cylinder. Furthermore, ECM allows air/fuel ratio to meet the requirements of 

various working conditions by controlling the fuel supply. 

3. CYLINDER DETECTION SEQUENCE CONTROL. 

In order to realize engine sequence control, the system applies intake pressure cylinder detection 

technology. The intake pressure sensor is installed near the air inlet of the intake manifold for 4 

cylinders. At the moment, when the inlet valve opens, there is an instantaneous pressure drop of which 

the value is around 1 kPa at the sensor. ECM detects the instantaneous pressure drop. After receiving 

the signal, ECM identifies compression Top Dead Centre (TDC) signal through the software analysis 

and processing. 

4. CLOSED LOOP CONTROL. 

The system applies closed loop control for the engine fuel supply and idle speed. The advantage of 

closed loop control is that the system effectively eliminates the difference between the system and 

relevant mechanical parts due to the manufacture and usage wear, which enhances the integrated 

coherence of the whole vehicle and reduces the emission. 

5. GROUPING CONTROL. 

The system divides the engine cylinders into two groups of 1-4 and 2-3 which control the ignition 

respectively. The grouping control optimizes and simplifies the system structure. Ignition timing and fuel 

injection control (crankshaft position sensor) systems determine crankshaft position and measure 

engine speed according to 58X gear signal, which controls the engine ignition and fuel injection timing 

precisely. The opening and closing of the power transistor control the continuity of the primary current in 

the ignition coils. The ignition timing control is aimed to obtain the optimal ignition time so as to meet 

the requirements of various working conditions of the engine. ECM determines the ignition time 

according to the engine speed, intake vacuum degree, engine cooling water temperature and 

atmospheric pressure. 

Page 1270



SYSTEM 

11A-7 

6. SELF-DIAGNOSIS. 

(a) The system fault self-diagnosis is an essential function for the engine control system. When one or 

several parts in the system operate abnormally, the system will inform the vehicle owner to perform 

necessary check and repair timely with fault indicator lamp ON. When the fault occurs, the system can 

also control the engine operation with temporary emergency mode, so as to ensure the owner can drive 

the vehicle to repair. 

(b) When certain sensor and actuator is detected abnormal, the engine fault inspection lamp turns on to 

remind the driver. 

(c) When certain sensor and actuator is detected abnormal, the fault code corresponding to the fault will be 

exported. 

(d) RAM data related to the sensor and actuator in ECM can be read by fault diagnostic apparatus. In 

addition, in certain situation, the actuator can be forcibly driven. 

7. OVERVOLTAGE PROTECTION. 

When the voltage of the charging system is too high caused by the fault, the system will go to the 

protection status to restrict the engine speed to avoid the ECM damage. 

8. AIR CONDITIONING COMPRESSOR CONTROL. 

When the A/C switch is on, the system will receive a A/C request signal and make preparations for 

operating the A/C system based on engine working condition. And then switch on the A/C compressor. 

The system will switch on or switch off the A/C according to the protection demand for air-conditioner. 

To ensure the power output and protect the engine, the system will cut off the A/C system under 

specified working condition. 

9. THREE-WAY CATALYTIC CONVERTER. 

The function of three-way catalytic converter is to convert harmful exhaust gas from the engine to 

harmless gas to exhaust to the atmosphere. The internal structure of three-way catalytic converter 

applies the cellular pipeline design. The cellular pipeline wall has precious metal coating on it, including 

palladium, rhodium, platinum etc, which acts as catalytic reaction media. The three-way catalytic 

converter will cause 3% - 5% of the power consumption to the engine. 

10. OVERHEAT SYSTEM PROTECTION FUNCTION FOR THE THREE-WAY CATALYTIC CONVERTER. 

The system predicts the rising trend of the engine exhaust temperature according to actual working 

condition of the engine and reduces the engine combustion temperature by timely controlling the air/ 

fuel ratio, so as to protect the three-way catalytic converter. 

11. CONTROL OF THE COOLING FAN. 

(a) The vehicle is equipped with a silicon oil fan and an electronic fan. 

(b) Electrical fan control function: ECM determines to switch on various fans according to the engine 

coolant temperature. ECM also judges the temperature meets the condition for switching on the airconditioner 

or not, so as to reduce the engine internal power consumption accordingly.. 

11A 

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Page 1271


BASIC PRINCIPLE 


SYSTEM 

1. PRINCIPLE OF START CONTROL. 

(a) When turning the ignition switch on, the fuel pump will stop after running for 1.5 seconds. 

(b) When the engine starts to rotate, the fuel pump will start to operate after ECM detected 2 valid 58X 

signals. 

(c) The fuel pump stops operating 0.8 seconds after the engine speed disappears (the analogue signal is 

easy to be disturbed). 

(d) Pre-injection: The pre-injection only injects once during the normal start process (if the fuel is absorbed 

by the carbon deposition, the mixture dilutes, which makes it difficult to start). 

(e) Preliminary stage for starting: The intake manifold internal pressure is displayed as ambient 

atmospheric pressure. After the throttle valve closed, ECM specifies a fixed parameter according to the 

start temperature. 

(f) During the start process, the fuel injection quantity varies according to the change of the engine coolant 

temperature. The ignition advance angle also adjusts continually and changes with the engine coolant 

temperature, the intake air temperature and the engine speed. 

(g) End of the start process: When the engine speed exceeds 600 RPM, the start working condition ends. 

2. PRINCIPLE OF FUEL INJECTION CONTROL. 

(a) ECM controls the injector driving time and the injection timing, which enables the engine to obtain the 

mixture with optimal air/fuel ratio under various working conditions. 

(b) Each cylinder is equipped with an injector at the air inlet. The fuel pump in the fuel tank pumps out the 

fuel and delivers the fuel to the fuel high pressure rail. The fuel pressure regulator keeps the injection 

pressure stable. The injector injects the fuel directly to the air passage of each cylinder. During each 

working cycle (when the crankshaft rotates twice) of the cylinder, each cylinder injects the fuel once (the 

injection sequence is 1 - 3 - 4 - 2). This injection type is called as sequential injection. 

(c) When the engine operates under cold or high-load condition, ECM performs open loop control to supply 

dense mixture, so as to keep good performance. When the engine operates under the normal working 

condition (medium or small load), ECM performs closed loop control via the signal fedback by oxygen 

sensor to obtain optimal air/fuel ratio, which enables the three-way catalytic converter to get the optimal 

purifying effect. 

(d) Inject pulse width control 

A/F modify 

Signal Input ECM Control Output 

Closed loop feedback modify 

Intake manifold absolute pressure 

Air charging temperature 

Air charging efficiency 

Self-learning modify 

Power supply modify 

Exhaust cycle 

Accelerate deepen 

Decelerate fuel reduction 

Decelerate fuel cut 

Injector parameter 

Calculate fuel charge 

Inject pulse width 

Page 1272


3. CONTROL SIGNAL DESCRIPTION 

Modified Item 


SYSTEM 

Content 

11A-9 

Air/fuel ratio 

Closed loop feedback 

correction 

• Start air/fuel ratio. 

• Air/fuel ratio while engine is running. 

• Air/fuel ratio at low engine coolant temperature. 

• Air/fuel ratio at normal engine coolant temperature. 

• Theoretical air/fuel ratio. 

• Enriched air/fuel ratio. 

• Overheat protection air/fuel ratio. 

• Control the actual air/fuel ratio around the theoretical air/fuel ratio via the 

feedback signal from the oxygen sensor. 

11A 

11A 

11A 

11A 

11A 

Intake manifold pressure • Read directly via the MAP mounted on the intake manifold. 

Self-learning • Modify the engine internal slow change due to long time operation. 

Power voltage 

• When the battery voltage changes, the voltage modification can ensure the 

correct fuel injection quantity. 

11A 

11A 

11A 

Acceleration enrichment 

Deceleration dilution 

Deceleration cutoff 

• When ECM detects the intake manifold pressure and the opening value of the 

throttle valve increases greatly, the fuel injection quantity is increased to avoid 

the engine mixture dilutes momentarily, so as to improve the power 

performance. 

• When the system detects the vehicle is under deceleration status, it controls 

the fuel cutoff to reduce the emission and fuel consumption. 

• When the system detects the vehicle is under deceleration status, it controls 

the fuel cutoff to reduce the emission and fuel consumption. 

• When the engine speed is above the setting value, fuel cutoff starts. 

• When a fault occurs in the ignition system, the fuel cuts off. 

11A 

11A 

11A 

11A 

11A 

Fuel injection parameter • It provides the relation between the engine and the fuel injection quantity. 

(a) Modification for the engine mixture: 

• Partial load control of the engine is closed loop fuel control at the normal working temperature. Then 

the system modifies fuel injection quantity via ECM according to the feedback voltage signal from the 

oxygen sensor, so as to adjust the mixture concentration to around the theoretical air/fuel ratio, which 

ensures the conversion efficiency of the harmful emission gas by the three-way catalytic converter 

reaches the optimal status while ensuring good fuel economy. 

• When the engine operates with full-load within the normal working temperature range, it applies the 

open loop fuel control. At this time, in order to ensure the engine obtains the optimal power output, the 

system will control the fuel injection quantity with a thick air/fuel ratio. Furthermore, with the premise 

that no engine knock occurs, the engine will increase the ignition advance angle moderately. 

• The system will also control the exhaust gas temperature using the exhaust gas temperature 

mathematical model established during calibration, so as to protect the engine and the three-way 

catalytic converter. The system determines the full-load condition of the engine according to the signal 

supplied by the throttle valve position sensor. When the throttle valve opening is above 80% ~ 90%, the 

system considers the engine goes to the full-load status. When the driver presses the accelerator pedal 

to accelerate the vehicle, the system will increase the fuel injection quantity moderately to ensure the 

power demand when the engine accelerates. The increased fuel injection quantity goes a direct 

proportion with the changing rate of the throttle valve opening. When accelerating, ECM will retard the 

ignition advance angle moderately, then recover step by step. The aim is to avoid impacting to the drive 

train because the torque increases too rapid when the engine accelerates sharply. 

11A 

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Page 1273



SYSTEM 

• When the acceleration working condition is near the engine full-load, the system will automatically 

switch off the A/C system temporarily, so as to ensure the engine power output well when accelerating. 

Whatever the situation, when the engine speed exceeds the highest speed specified in the system, the 

system will cut off the fuel supply to restrict the speed increasing, so as to protect the engine and avoid 

the vehicle skidding. When the engine speed returns within specified in the system, the system will 

restore the fuel supply immediately. 

4. PRINCIPLE OF IGNITION CONTROL. 

(a) Start: The engine applies a fixed ignition advance angle when starting, which allows the gas in the 

cylinder to ignite and provide the positive torque. When the engine speed increases to certain speed, 

ECM caculates the ignition advance angle according to the input signal. 

(b) Ignition advance angle control. 

ECT modify 

IAT modify 

Elevation modify 

Idle modify 

Signal Modify ECM Output Control 

Main ignition angle 

Decelerate fuel reduction modify 

Accelerate modify 

Accelerate deepen modify 

A/C modify 

Calculate ignition advance angle 

Ignition advance angle 

(c) Main ignition advance angle: When the engine temperature reaches the normal value, the main ignition 

angle with the throttle valve opening is usually the minimum ignition angle at the optimal torque point. 

When the throttle valve closes, the ignition angle should be reduced to obtain the idle speed stability. 

(d) Correction of the ignition advance angle: 

• Acceleration correction: When the vehicle accelerates, ECM detects the knock and corrects the ignition 

advance angle until the knock disappears. Furthermore, it is also used to reduce the engine speed 

fluctuation caused by the drive train torsion. 

• Power enrichment correction: To obtain better power and torque near the exterior feature point, the air/ 

fuel ratio is enriched to the thinnest air/fuel ratio with the best torque. 

• Deceleration cutoff correction: When the deceleration cutoff exits, correct the ignition advance angle to 

get a stable transition. 

• A/C correction: Switch off the A/C when the engine is idle. Correct the ignition advance angle, which 

allows the speed to get a stable transition. 

5. PRINCIPLE OF IDLE CONTROL. 

(a) Idle control: 

• Control the air flow in the bypass of the throttle valve according to the idle condition and the engine idle 

load to maintain the idle speed at the optimal speed. According to the engine coolant temperature and 

the A/C load, ECM drives the IAC motor to make the engine operate under the preset target idle speed. 

In addition, when the engine operates at idle speed, turn on or turn off the A/C switch. The IAC motor 

will regulate the air flow in the bypass according to the engine load to avoid idle speed unstable . 

Page 1274



SYSTEM 

11A-11 

(b) 

Calculate the target idle speed. 

Basic target idle speed 

Input ECM Output Control 

11A 

Voltage compensation 

Vehicle speed compensation 

Fan compensation 

Calculate target idle speed 

Target idle speed 

11A 

11A 

Headlamp compensation 

11A 

A/C compensation 

Deceleration adjustment 

• Voltage compensation: When the voltage is below 12V, the system will automatically increase the target 

idle speed to increase the electrical energy production of the generator. 

• A/C compensation: Switch on the A/C when parking the vehicle at idle speed. To compensate the 

power loss of the compressor, the target idle speed increases by 150 RPM. 

• Headlamp compensation: After switching on the low beam, the target idle speed increases by 50 RPM 

to compensate the electricity loss. 

• Fan compensation: When the coolant temperature increases and the fan operates, the idle speed 

increases by 50 RPM to compensate the electricity loss for the fan operation. 

(c) Idle speed control parameters: 

• Control of idle air flow. 

• Control of fuel injection quantity. 

• Control of ignition timing. 

(d) Idle speed design control timing: 

• Calibration of idle stability. 

• Calibration of acceleration working condition. 

• Calibration of deceleration working condition. 

• Deceleration cutoff. 

• Calibration for the fuel supply under engine transient transition working condition. 

• Calibration of constant speed driving. 

• Calibration of increasing and reducing the mechanical and electricity load. 

(e) Decisive factors for the target idle speed: 

• When the coolant temperature is low, the system provides a high target idle speed to accelerate the 

warm-up. 

• When the additional load (e.g. various electrical appliances such as the headlamp, A/C, cooling fan 

etc.) opens, the system will raise the idle speed to compensate the increased load and keep the idle 

speed stable. 

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Page 1275



SYSTEM 

6. PRINCIPLE OF CARBON CANISTER SOLENOID VALVE CONTROL. 

(a) Used for controlling the air flow of carbon canister cleaning. The carbon canister is controlled by ECM 

sending the duration and frequency for the electrical impulse (duty cycle) through integrated 

computation according to a series of signals including engine load, engine coolant temperature, and 

engine speed etc. When too much gasoline vapor is accumulated in the activated carbon canister, it will 

cause the gasoline leakage, which pollutes the environment. Therefore, the effect of carbon canister 

solenoid valve is to open at the proper time to allow the excess gasoline vapor to enter the intake pipe 

after mixing with the air sufficiently in the carbon canister to involve in the combustion. 

(b) The carbon canister will not work in the following conditions: 

• During a period after the cold start of the engine. 

• When the cooling water temperature is low. 

• During the engine idle operation period. 

• During the engine big load period. 

• When the important sensors of the system have fault. 

Page 1276

MAIN COMPONENTS 



SYSTEM 

11A-13 

11A 

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Page 1277


SYSTEM COMPONENTS DESCRIPTION 


SYSTEM 

Component Summary Quantity Function 

ECM 16 bit CPU 1 

Upstream oxygen sensor With heated 1 

Downstream oxygen sensor With heated 1 

MAP sensor Piezoelectric type 1 

ECM optimization control system 

depends on the sensor signal. 

Check oxygen concentration in 

exhaust. 

ECM judges whether the TWC is 

good comparing the upstream with 

downstream oxygen sensor signal. 

Check the air inlet quantity and 

BTDC. 

CKP sensor Magnetron induction coil type 1 Check CKP and engine RPM. 

Injector 4 hole type 4 

Inject fuel depends on the sensor 

from ECM. 

Idle air control motor Electromagnetic coil type 1 Control air inlet. 

Carbon solenoid valve Electromagnetic type 1 

Control the exhaust depending on 

the digital pulse wave from ECM. 

TPS 

3- lines type carbon film 

resistor sliding indicator 

1 Check the open of throttle. 

ECT sensor NTC thermal resistance type 1 Check ECT. 

IAT sensor NTC thermal resistance type 1 Check IAT. 

Vehicle speed sensor Hall effect type 1 Check vehicle speed. 

Ignition coil Electromagnetic coil type 1 Ignite mixed gas. 

Fuel pump Electromagnetic type pump 1 

Supply the enough pressure fuel 

for system. 

Page 1278


ENGINE CONTROL MODULE (ECM) 

PRINCIPLE 


11A-15 

1. ECM DESCRIPTION. 

(a) ECM is the electric engine control center with the micro 

processor as the core that having sensor signal input 

interface and the executor drive circuit. The ECM 

receives and treats the engine status signal that inputted 

from all sensors, sends control signal to the executor to 

drive the engine running in accordance with the preset 

procedures so as to make the engine run under best 

status, ensure good power capability, fuel economy and 

exhaust capability. 

(b) Normal operating voltage: 9 ~ 16V. 

(c) Overvoltage protection: +24V/-12V < 60 s. 

(d) ECM has self-protection function. It may result the 

ignition failure during repair and it will resume normal 

after replacement of ECM. In fact, the ECM doesn’t get 

damaged, but just self-protection mode. ECM will 

resume normal after certain time period. 

11A 

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Page 1279

11A-16 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM) 

REPLACEMENT 


2. DISCONNECT BATTERY NEGATIVE CABLE. 

NOTE 

When disconnecting or connecting the battery cables, please first turn off the ignition switch and 

lighting switch and completely loosen the cable nut. Do not pry up the cable when peforming these 

operations. 

3. REMOVE ECM MODULE. 

(a) Pull passenger seat forward. 

(b) Lift the covering behind the assistant driver seat , loosen 

the ECM locking knob. 

(c) Remove the ECM cover. 

(d) 

Depress the connector locking tab, pull the latch upward 

to the end . 

(e) 

Disconnect ECM connector. 

NOTE 

After disconnecting the connector, keep the connection 

away from dirt, water and other foreign materials. 

(f) 

Remove 4 ECM mounting bolts. 

Page 1280


(g) 


Remove ECM. 

11A-17 

NOTE 

• Disconnect battery negative cable first, wait at least 

1 minute, then remove ECM. 

• Take care not to impact ECM while removing the 

ECM. 

• Keep ECM away water during operation. 

• Be careful of the terminals of ECM. 

4. INSTALL ECM. 

(a) 

Tighten 4 ECM mounting bolts. 

Torque: 19.6 N•m 

NOTE 

Pay attention to electrostatic protection when installation. 

11A 

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11A 

(b) 

Connect ECM connector. 

NOTE 

Pull the connector upward, be sure that it is installed in 

place properly . 

11A 

11A 

11A 

11A 

(c) 

(d) 

Install ECM cover and tighten the ECM cover locking 

knob. 

Cover the covering and push passenger seat back to its 

original position. 

11A 

11A 

11A 

11A 

11A 

5. CONNECT BATTERY NEGATIVE CABLE. 

11A 

11A 

Page 1281


ENGINE COOLANT TEMPERATURE 

SENSOR 

ENGINE COOLANT TEMPERATURE SENSOR 

PRINCIPLE 

1. ENGINE COOLANT TEMPERATURE DESCRIPTION. 

(a) The Engine Coolant Temperature (ECT) sensor uses a 

thermistor to control the signal voltage to the Engine 

Control Module (ECM). 

(b) This ECT sensor is a 2-line type. Normally a 1-line type is 

to provide coolant temperature signal to the instrument. 

Page 1282

OVERHAUL 




SENSOR 

11A-19 

2. OPEN THE ENGINE HOOD AND REMOVE THE 

COOLANT RESERVOIR PRESSURE CAP. 

NOTE 

Do not open the reservoir cap when the engine is hot. Such 

as coolant temperature should be reduced to 50 ° C (120 ° F) 

below, remove the reservoir cap. Otherwise, the cooling 

liquid or vapor emitting heat may cause personal injury. 

Drain coolant. (Refer to “Chapter 17A cooling - coolant, 

precaution”) 

3. RAISE THE VEHICLE, LOOSEN COOLANT DRAIN 

PLUG AT THE BOTTOM OF RADIATOR , THEN DRAIN 

COOLANT. 

NOTE 

Using a suitable container, collect the coolant. If do not 

reuse, dispose of coolant according to the local laws. 

11A 

11A 

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11A 

11A 

4. REMOVE ECT SENSOR. 

(a) Loosen the clamp and remove the hose. 

11A 

11A 

11A 

11A 

11A 

(b) 

(c) 

Disconnect ECT connnector. 

Remove ECT sensor. 

11A 

11A 

NOTE 

• Clear the installation surface after removing. 

• Clear the sensor hole after removing. 

• Clear the thread of sensor after removing. 

11A 

11A 

11A 

. 

Page 1283



SENSOR 

5. CHECK ECT SENSOR. 

(a) Dip the sensing part of ECT sensor into hot water. Using 

the multimeter, measure resistance of the sensor. 

(b) If the check result is not OK, replace it with a new one. 



0 ℃ 9098 ~ 9700 Ω 

10 ℃ 5494 ~ 5822 Ω 

20 ℃ 3420 ~ 3602 Ω 

30 ℃ 2184 ~ 2296 Ω 

CAUTION 

Don’t let the water go into terminals. After checking, dry the 

sensor. 

6. INSTALL ECT SENSOR. 

(a) Install ECT sensor. 

CAUTION 

Apply sealant to thread. The specified sealant: 3M NUT 

LOCKING PART or the equivalent. 

(b) Connect ECT sensor connector . 

(c) 

Attach the hose and tighten the clamp. 

7. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, precaution”) 

8. CHECK COOLING SYSTME FOR COOLANT LEAKAGE. 

Page 1284


THROTTLE BODY 

THROTTLE BODY CLEANING 

THROTTLE BODY 

1. CLEANING STEPS. 

(a) Start the engine and warm it up until the coolant is heated to 80 ℃ or higher. then stop the engine. 

(b) Remove the air intake hose from the throttle body. 

(c) Plug the bypass passage inlet (arrow) of the throttle body. 

CAUTION 

Do not allow cleaning solvent to enter the bypass passage. 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

(j) 

11A-21 

Spray cleaning solvent into the valve through the throttle 

body intake port and leave it for approximately five 

minutes. 

Start the engine, accelerate it several times and then idle 

it for about one minute. if the idle speed becomes 

unstable (or if the engine stalls) due to the bypass 

passage being plugged, slightly open the throttle valve to 

keep the engine running. 

If the throttle valve deposits are not removed, repeat 

steps d and e. 

Unplug the bypass passage inlet. 

Connect the air intake hose. 

Use the scan tool to erase any diagnostic trouble code. 

Adjust the basic idle speed. 

NOTE 

If the engine hunts while idling after adjustment of the basic 

idle speed, keep the battery negative cable disconnected 

for 10 seconds or more, and then reconnect it and run the 

engine at idle for about 10 minutes after the engine is 

warmed up. 

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Page 1285

11A-22 ENGINE CONTROL SYSTEM - THROTTLE BODY 

THE FIXED SPEED ADJUSTING SCREW (SAS) ADJUSTMENT 

1. SINCE FIXED SAS IS ADJUSTED AT FACTORY, PLEASE DO NOT ADJUST “FIXED SAS” IN 

NORMAL CASES UNLESS IT IS NECESSARY. 

2. IF “FIXED SAS” IS ROTATED RANDOMLY, PLEASE RE-ADJUST ACCORDING TO THE 

FOLLOWING STEPS: 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

Loosen the tension of the acceleration cable. 

Loosen the "fixed SAS” lock nut. 

Turn the idle switch counterclockwise until the throttle 

valve closes. 

Screw the “fixed SAS” clockwise until the point (i.e. the 

position when throttle is started to be opened) of throttle 

rail is reached. 

Keep the “fixed SAS” from moving when tightening the 

lock nut. 

Adjust the acceleration cable tension. 

Adjust the basic idle speed. 

Page 1286


THROTTLE BODY 

11A-23 

BASIC IDLE SPEED ADJUSTMENT 

1. THE STANDARD IDLE SPEED HAS BEEN ADJUSTED WITH THE SPEED ADJUSTING SCREW 

(SAS) BY THE MANUFACTURER, AND THERE SHOULD BE NO NEED FOR RE-ADJUSTMENT. 

2. IF THE ADJUSTMENT HAS BEEN CHANGED BY MISTAKE, THE IDLE SPEED MAYBE COME TOO 

HIGH OR TOO LOW WHEN LOADS A/C, DEFOGGER, ETC. ARE PLACED ON THE ENGINE. IF 

THIS OCCURS, ADJUST BY THE FOLLOWING PROCEDURE. 

NOTE 

If make the adjustment, it should be made after confirming that the spark plugs, the injectors, the idle 

air control motor, compression, etc., are all normal. 

(a) Place the car in good condition before the inspection and adjustment. 


(c) Connect the scan tool to the Data Link Connector (DLC). 

(d) Start the engine and run at idle speed. 

(e) Check the idle speed. 

Standard value: 750 ± 50 RPM 

NOTE 

• The engine speed may be 20 to 100 RPM lower than indicated above for a new vehicle, but this 

is normal and no adjustment is necessary. 

• If the engine stalls or the engine speed is low even though the vehicle has been driven 

approximately 500 km (300 mile) or more, it is probable that deposits are adhered to the throttle 

valve, clean it. 

(f) 

If it is not within the standard value range, turn the Speed 

Adjusting Screw (SAS) to make the necessary adjustment. 

NOTE 

If SAS gets to bottom completely, the idle speed is still more 

than standard value, then check if “fixed SAS” was rotated. 

If yes, re-adjust “fixed SAS”. 

• Turn the ignition switch OFF. 

• Disconnect the scan tool. 

• Start the engine again and let it idle for about 10 minutes. 

Check that the idling condition is normal. 

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2. LOOSEN COOLANT DRAIN PLUG AT THE BOTTOM OF 

RADIATOR , THEN DRAIN COOLANT. 

NOTE 

Using a suitable container, collect the coolant. If do not 

reuse, dispose of coolant according to the local laws. 



(b) Rotate the driver seat and open engine compartment 

cover. 


5. REMOVE THROTTLE BODY. 

(a) Disconnect IAC connector. 

(b) 

Disconnect TPS connector. 

Page 1288


THROTTLE BODY 

11A-25 

(c) 

Loosen accelerator cable locking nut on the throttle body 

and remove accelerator cable. 

(d) 

(e) 

Remove 2 preheating hoses from throttle body. 

Remove 4 throttle body mounting bolts. 

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(f) Remove throttle body. 

NOTE 

Check the seal gasket between throttle body and intake 

manifold for damage and replace it as necessary. 

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Page 1289



7. INSTALL THROTTLE BODY. 

(a) Tighten 4 throttle body mounting bolts . 

Torque:15 ~ 25 N•m 

(b) 

Connect 2 preheating hoses to throttle body. 

(c) 

Connect idle air control motor connector. 

(d) 

Connect TPS connector. 

Page 1290


THROTTLE BODY 

11A-27 

(e) 

Install accelerator cable and keep cable at the proper 

tension, then tighten the locking nut. 

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8. INSTALL AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”) 

9. PUT DOWN ENGINE COMPARTMENT COVER AND LOCK IT. 

10. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”) 

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Page 1291

11A-28 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR 

IDLE AIR CONTROL MOTOR 

PRINCIPLE 

1. IDLE AIR CONTROL MOTOR DESCRIPTION. 

(a) The idle air control motor is essentially one micro motor. 

since the motor will revolve in various directions when 

the motor coil is supplied with current in various 

directions. The motor revolution shaft will drive the 

moving of the leading screw so as to control the open 

extent of the valve indirectly. ECM will send the 

digitalized square wave signal to control the positive 

rotation and the reverse rotation of the motor so as to 

control the stroke of the idle air control motor. 

Page 1292



11A-29 

ON-VEHICLE INSPECTION 

1. OPERATING SOUND INSPECTION. 

(a) Check that coolant temperature of engine is below 20 ℃ . 

NOTE 

If coolant temperature of engine is above 20 ℃ , remove the harness connector of engine coolant temperature 

sensor, and use the less than 20 ℃ sensor for connection. 

(b) Check that when ignition switch is changed into the ON position (do not start engine), the operating 

sound of the IAC motor can be heard over the IAC motor. 

(c) If an operating sound can be heard, check the IAC motor drive circuit. If the circuit is good, a defective 

IAC motor or ECM is suspected. 

2. CHECK ENGINE RPM. 



(c) Connect the scan tool to the Data Link Connector (DLC) - use the most current software available. 


(e) Select the item ,perform the idle air control motor test. 

(f) When the scan tool control the rotation of expansion of the IAC motor, the engine RPM changes from 

high to low in synchronism (vibration can be felt when touching the IAC motor). 

(g) If it is not OK, check IAC motor control harness or connector. If harness or connector is OK, check IAC 

motor or ECM. 

3. CHECK IDLE AIR CONTROL MOTOR STEPS. 



(c) Connect the scan tool to the Data Link Connector (DLC) - use the most current software available. 


(e) Select the item .” 

(f) 

Displayed Item Detection Condition Specified Condition 

Idle air control motor 

• ECT: 80 ~ 95 ℃ 

• Accessories: OFF 

• Transmission: N 

• Engine: idle 

• A/C turns ON, A/C 

should works 



If it is not OK, check idle air control motor, harness, connector or ECM. 

Add 10 ~ 70 steps 

2 ~ 25 steps 

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11A-30 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR 

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cover. 

3. REMOVE IDLE AIR CONTROL MOTOR. 

(a) Disconnect idle air control motor connector. 

(b) 

Remove 2 idle air control motor retaining bolts. 

(c) 

Remove idle air control motor. 

NOTE 

• Clear surface after removing. 

• Clear the path of the idle. 

Page 1294



11A-31 

4. CHECK IDLE AIR CONTROL MOTOR COIL RESISTANCE. 

(a) Connect special tool (for test). 

(b) Check resistance between terminal A and B of idle air 

control motor connector. 

Standard resistance: 28 ~ 33 Ω (20 ℃ ) 

(c) Check resistance between terminal C and D of idle air 

control motor connector. 


(d) If it is not OK, replace it with a new one. 

5. INSTALL IDLE AIR CONTROL MOTOR. 

(a) Install idle air control motor and tighten 2 idle air control 

motor retaining bolts. 

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(b) 

Connect idle air control motor connector. 

NOTE 

• Do not apply any axially type of force to press or pull 

out the axle. 

• The axle must be in the place of the retreating before 

the idle air control motor being installed into the 

throttle body. 

• After removing battery or ECM, perform the idle air 

control motor self-learning. 

6. THE IAC MOTOR SELF-LEARNING. 

(a) Turn the ignition switch OFF, do not start at once. After 5 seconds, start it again. 


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Page 1295

11A-32 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS) 

THROTTLE POSITION SENSOR (TPS) 

PRINCIPLE 

1. THROTTLE POSITION SENSOR DESCRIPTION. 

(a) 

(b) 

(c) 

Throttle Position Sensor (TPS) is used to provide throttle 

angle, angle speed and engine idle position information 

to the ECM. Based on this the ECM can obtain the 

engine load information, operating mode (such as start, 

idle, reverse towing, partial load and full-load) and 

acceleration & deceleration information. This sensor is of 

3-line type and the ECM will check the throttle open 

extent by monitoring the voltage variation. 

The throttle position sensor is comprised of carbon film 

resistance and slide indicator. 

The sensor slide indicator connects with the throttle and 

rotates following the shaft. When the throttle open extent 

changes following the accelerator pedal, the position of 

the slide indicator will also change on the carbon film 

resistance, at that moment the resistance output will also 

change, which reflects the open extent of the throttle 

indirectly. 

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11A-33 


1. START THE ENGINE AND WARM IT TO NORMAL OPERATING TEMPERATURE. 


3. CONNECT THE SCAN TOOL TO THE DATA LINK CONNECTOR (DLC) - USE THE MOST 

CURRENT SOFTWARE AVAILABLE. 

4. TURN THE IGNITION SWITCH ON. 

5. SELECT THE ITEM BELOW. 


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TPS 


• Engine stop 

Idle position 0.3 ~ 1 V (0%) 

Open throttle slowly 

Directly proportional with 

the open degree 

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Open widely 4.5 ~ 5.5 V (100%) 

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6. IF IT IS NOT OK, CHECK TPS, HARNESS CONNECTORS AND ECM. 

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11A-34 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS) 

OVERHAUL 





cover. 

3. REMOVE TPS. 

(a) Disconnect TPS connector. 

(b) 

Remove 2 TPS retaining bolts. 

(c) 

Remove TPS. 

NOTE 

Clear the surface after removing. 

Page 1298



11A-35 

4. CHECK TPS RESISTANCE. 

(a) Measure the resistance between termal 1 and termal 2 of 

sensor. 

(a) Measure the resistance between termal 2 and termal 3 of 

sensor 



Terminal 1 and 2 • Resistance: 3.5 ~ 6.5 Ω (20 ℃ ) 

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Terminal 1 and 3 or 

Terminal 2 and 3 

• Open throttle from idle position to 

open wide.The output value is 

proportional change to the open 

degree. 

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(b) 

If the resistance is out of the range and the value 

changes unsteadily, replace it. 

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5. INSTALL TPS. 

(a) Install TPS and tighten 2 TPS retaining bolts. 

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(b) 

Connect TPS connector. 

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Page 1299


MANIFOLD ABSOLUTE PRESSURE/ 

INTAKE TEMPERATURE SENSOR 

MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPERA- 

TURE SENSOR 

PRINCIPLE 

1. MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPERATURE 

SENSOR DESCRIPTION. 

(a) The engine control system adopted speed-density air 

measurement method to check the air intake volume into 

the engine so as to control the fuel injection pulse width 

for the precise control of engine power output. 

Meanwhile, this system adopted intake pressure cylinder 

determination technology and the intake air sensor is 

installed near the inlet opening of cylinder 4 intake 

manifold. At the moment when the throttle is opened, 

there will be one instantaneous pressure drop at the 

sensor, of which the value is about 1 kPa. When the 

ECM detected and received this instantaneous pressure 

drop. The ECM will determine the compression upper 

dead center signal after software diagnosis treatment. 

(b) Intake air temperature sensor is a Negative Temperature 

Coefficient (NTC) of resistance, with the intake air 

temperature increases resistance decreases, the engine 

ECM contrast through the internal circuitry to detect an 

intake air temperature changes. 

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11A-37 








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IAT sensor 


• Engine: running 

IAT: -20 ℃ -20 ℃ 

IAT: 0 ℃ 0 ℃ 

IAT: 20 ℃ 20 ℃ 

IAT: 40 ℃ 40 ℃ 

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IAT: 80 ℃ 80 ℃ 

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6. TURN DIGITAL MULTIMETER TO VOLTAGE RANGE. 

CHECK VOLTAGE OF MAP SENSOR BETWEEN 

TERMINAL A OR D AND GROUND. 

(a) When engine runs at idle, terminal 3 is 5 V, terminal 4 is 

1.3 V. 

(b) When engine runs unload, open throttle slowly, the signal 

of terminal 4 is changed little. 

(c) Open throttle quickly, the signal of terminal 4 is to about 

4 V, then drop to 1.5 V. 

(d) Turn multimeter to voltage range. Black pin to ground, 

red pin to terminal 2 of the IAT sensor. Check IAT signal. 


IAT sensor 


IAT: 0 ℃ 3.2 ~ 3.8V 

IAT: 20 ℃ 

IAT: 40 ℃ 

2.3 ~ 2.9 V 

1.5 ~ 2.1 V 

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IAT: 80 ℃ 

0.4 ~ 1.0 V 

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AN 

(e) 

If it is not OK, check MAP/IAT sensor, harness or ECM. 

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Page 1301


OVERHAUL 







cover. 

3. REMOVE MAP/IAT SENSOR CONNECTOR. 

(a) Disconnect MAP/IAT sensor connector. 

(b) Remove MAP/IAT sensor retaining bolt. 

(c) 

Remove MAP/IAT sensor. 

NOTE 

Clear surface after removing MAP/IAT sensor. 

4. CHECK IAT SENSOR RESISTANCE. 

(a) Turn digital multimeter to Ohm range. Check resistance 

between terminal 2 and 3 of sensor. Using a hairdryer, 

blow air to sensor ( IMPORTANT:do not get too close to 

the sensor ). Inspect the change of the value, the value 

should decline. 

(b) If it is not OK, replace it. 

Page 1302




11A-39 


IAT: 0 ℃ 

5.3 ~ 6.7 kΩ 

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IAT sensor 


IAT: 10 ℃ 

IAT: 20 ℃ 

IAT: 30 ℃ 

2.3 ~ 3.0 kΩ 

1.0 ~ 1.5 kΩ 

0.30 ~ 0.42 kΩ 

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5. INSTALL MAP/IAT SENSOR. 

(a) Tighten MAP/IAT sensor retaining bolt. 

(b) Connect MAP/IAT sensor connector. 

NOTE 

Do not use any impact tools (such as a hammer, etc.) to 

knock sensor into mounting hole. 

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Page 1303

11A-40 ENGINE CONTROL SYSTEM - KNOCK SENSOR 

KNOCK SENSOR 

PRINCIPLE 

1. PRINCIPLE OF KNOCK SENSOR. 

(a) 

(b) 

(c) 

(d) 

Knock sensor is one vibrating acceleration sensor that 

installed on the engine cylinder body, normally between 

cylinder 2 and cylinder 3 to facilitate the engine knock 

balance. 

By means of the vibrating frequency signal output from 

the knock sensor, the ECM will judge for engine knock 

after the ECM internal wave filter. 

In case of the detection of the knock signal, the ECM will 

reduce gradually till the elimination of the knock and then 

resume gradually till the knock threshold. 

Above steps will be repeated again and again. 

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KNOCK SENSOR 

11A-41 

OVERHAUL 



3. REMOVE KS. 

(a) Remove 4 retaining bolts on intake manifold lower bracket 

. 

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(b) 

Disconnect KS connector. 

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(c) 

NOTE 

Remove knock sensor retaining bolt. 

• Clear the surface after removing. 

• Don’t contact all kinds of liqulds. For example: oil, 

coolant, brake fluid. 

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4. CHECK KS. 

(a) Measure the resistance according to the value in the 

table below. 

Sensor Terminal Terminal Resistance (20 ℃ ) 

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1 2 

1 Ground 

2 Ground 

> 1 MΩ 

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(b) 

If the check result is not OK, replace it. 

Page 1305

11A-42 ENGINE CONTROL SYSTEM - KNOCK SENSOR 

5. INSTALL KNOCK SENSOR. 

(a) Tighten knock sensor retaining bolt. 

Torque: 15 ~ 25N•m 

NOTE 

• Confirm the KS correct direction. 

• install it by applying pressure. Any impact tool is not 

allowed. 

• The metal surface should be pressed against the cylinder 

body. Any type of washer is not allowed. 

• Don’t let the signal cable resonance. To avoid it 

brokn. 

(b) Connect knock sensor connector. 

6. INSTALL INTAKE MANIFOLD LOWER BRACKET. 

(a) Tighten 4 retaining bolts on intake manifold lower 

bracket. 

7. INSTALL THE INTAKE MANIFOLD. (Refer to “Chapter 14A intake air - intake manifold, replacement”) 

Page 1306

CKP SENSOR 

PRINCIPLE 


CKP SENSOR 

11A-43 

1. CRANKSHAFT POSITION SENSOR DESCRIPTION. 

(a) The 58X reference signal is produced by the Crankshaft 

Position (CKP) sensor. The Engine Control Module 

(ECM) uses the 58X reference signal to caculate engine 

RPM and CKP. The ECM constantly monitors the 

number of pulses on the 58X reference circuit and 

compares them with the number of MAP signal being 

received. 

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11A-44 ENGINE CONTROL SYSTEM - CKP SENSOR 

OVERHAUL 



3. REMOVE CKP. 

(a) Disconnect CKP connector. 

(b) Remove CKP sensor retaining bolt on flywheel housing . 

(c) 

Remove knock sensor. 

NOTE 

Clear the surface after removing knock sensor. 

4. CHECK CKP SENSOR. 

(a) Turn digital multimeter to Ohm range, connect two 

probes to terminal 2 and 3 of sensor. Check resistance. 

Standard resistance: 560 Ω ± 10% (20 ℃ ) 

(b) If the check result is not normal, replace it. 

Page 1308


CKP SENSOR 

11A-45 

5. INSTALL CKP SENSOR. 

NOTE 

• Apply a layer of preventative oil on the O-ring of the 

CKP sensor. 

• Do not use any impact tools (such as a hammer, etc.) 

to knock sensor into mounting hole. 

(a) Insert CKP sensor into the mounting hole by turning . 

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(b) 

(c) 

Tighten CKP sensor retaining bolt. 

Connect the CKP sensor connector.. 

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11A-46 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR 

UPSTREAM OXYGEN SENSOR 

PRINCIPLE 

1. UPSTREAM OXYGEN SENSOR DESCRIPTION. 

(a) 

This sensor is used to provide the excess oxygen 

information after the injected fuel in the cylinder has 

passed the full combustion in the sucked air. By means 

of this information, the ECM can perform the closed loop 

control upon the fuel quantity so that the 3 main toxic 

substances in the exhaust, which named Hydrocarbon 

(HC), Carbon Oxides (CO) and nitrogen oxides, can be 

converted and purified in the three-way catalytic 

converter. 

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UPSTREAM OXYGEN SENSOR 

11A-47 









1. A/F: to be rich when 

acceleration 

2. A/F: to be lean when 

deceleration 

6. IF IT IS NOT OK, CHECK SENSOR, HARNESS AND ECM. 

Decelerate suddenly 

Accelerate suddenly 

Engine: idle 


≤ 0.2 V 

0.6 ~ 1 V 

0.1 ~ 0.9 V 

0.6 ~ 1 V 

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11A-48 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR 

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3. REMOVE UPSTREAM OXYGEN SENSOR. 

(a) Disconnect upstream oxygen sensor connector. 

(b) Using wrench, remove upstream oxygen sensor . 

CAUTION 

Remove the exhaust pipe after cooling completely. 

4. CHECK UPSTREAM OXYGEN SENSOR. 

(a) Turn digital multimeter to ohm range. Check resistance 

between terminal 3 and 4 of the sensor. 

Standard resistance: 9.6 ± 1.5 Ω (20 ℃ ) 


5. INSTALL UPSTREAM OXYGEN SENSOR. 

CAUTION 

Apply a layer of rust-proof oil on the thread. 

(a) 

(b) 

Install upstream oxygen sensor. 


Connect upstream oxygen sensor connector. 


Page 1312


DOWNSTREAM OXYGEN SENSOR 

11A-49 


PRINCIPLE 

1. DOWNSTREAM OXYGEN SENSOR DESCRIPTION. 

(a) The purpose of the rear oxygen sensor is to check the 

oxygen concentration in the exhaust that passed threeway 

catalytic converter and the sensor will convert such 

signal to dot signal and transmit to the ECM. After the 

comparison of the signals of the upstream/downstream 

oxygen sensors, the ECM will judge if the three-way 

catalytic converter functions well. 

(b) The structure of downstream oxygen sensor is same as 

the upstream oxygen sensor. 

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11A-50 ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR 









Downstream oxygen sensor 

• Engine: warm 


sensor 

Engine: running 

About 0.1 V 

6. IF IT IS NOT OK, CHECK SENSOR, HARNESS AND ECM. 

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11A-51 

OVERHAUL 


2. RAISE AND SUPPORT THE VEHCLE. 

3. REMOVE DOWNSTREAM OXYGEN SENSOR. 

(a) Disconnect downstream oxygen sensor connector. 

(b) Remove downstream oxygen sensor. 

CAUTION 


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4. CHECK DOWNSTREAM OXYGEN SENSOR. 

(a) Turn digital multimeter to ohm range, check resistance 

between terminal 3 and 4 of the sensor. 

Standard resistance: 9.6 ± 1.5 Ω (20 ℃ ) 


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5. INSTALL DOWNSTREAM OXYGEN SENSOR. 

CAUTION 


Apply a layer of rust-proof oil on the thread. 

(a) Install downstream oxygen sensor. 


(b) Connect downstream oxygen sensor connector. 

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Page 1315

11A-52 ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE 

CANISTER SOLENOID VALVE 

PRINCIPLE 

1. CARBON CANISTER SOLENOID VALVE DESCRIPTION. 

(a) 

The carbon canister solenoid valve is a kind of solenoid 

valve mechanism internally and contrilled by ECM. ECM 

will send digitalized square wave control pulse to control 

the open extent of the solenoid valve. The open extent of 

the carbon canister is different depending on the various 

engine operating modes. In case of the great load of 

engine or engine idle, the carbon canister solenoid valve 

doesn’t operation in order to ensure the engine power 

output well. 

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11A-53 







5. CHECK THE ACTION OF CARBON CANISTER SOLENOID VALVE. 

(a) Use the “action test” function of the diagnostic apparatus. 

• Touch the fuel Evaporative Emission Control (EVAP) system carbon canister solenoid valve with hand. 

• Perform the action test of carbon canister solenoid valve with the “action test” function of the diagnostic 

apparatus. 

• The carbon canister solenoid valve should vibrate slightly. If the carbon canister solenoid valve has no 

slight vibration, check solenoid valve, harness and ECM. 

(b) Vacuum test method. 

• When the engine operates at the idle status, pull out the vacuum hose from the activated carbon 

canister and check the vacuum hose for vacuum suction. If the carbon canister solenoid valve operates 

normally, the solenoid valve should be closed and there should be no vacuum suction in the vacuum 

hose. If there is vacuum suction in the vacuum hose now, remove the socket connector from the 

solenoid valve. If there is voltage in the terminals of the harness socket connector in the carbon 

canister solenoid valve, it indicates there is a fault in ECM. If there is no voltage, it indicates the carbon 

canister solenoid valve is stuck in the opening position. 

• Press the accelerator pedal to allow the engine speed reach above 2000 RPM and check the vacuum 

hose for the vacuum suction. If the vacuum suction exists, it indicates the carbon canister solenoid 

valve operates normally. If no vacuum suction exists in the vacuum hose and the voltage is normal on 

the terminal of harness socket connector in the carbon canister solenoid valve, it indicates there is a 

fault in the carbon canister solenoid valve. If the voltage is abnormal, it indicates there is a fault in ECM 

or harness. 

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OVERHAUL 





cover. 


4. REMOVE CANISTER SOLENOID VALVE. 


(b) Remove fuel pressure regulator vaccum line. 

(c) 

(d) 

Disconnect canister solenoid valve connector. 

Disconnect canister solenoid valve inlet hose clips and 

remove the hose ( to canister). 

NOTE 

When disconnecting these hoses which used for a long time. 

Twist hose to be loosed first, then operate disconnection. 

(e) 

(f) 

Disconnect canister solenoid valve outlet hose clips and 

remove hose ( to intake manifold below throttle body ). 

Using screw driver, pry canister solenoid valve away from 

mounting bracket and remove it. 

Page 1318



11A-55 

5. CHECK CANISTER SOLENOID VALVE. 

(a) Apply battery voltage to canister solenoid valve. Sound 

should be heard. At this time, blow air to the inlet port: 

• If air passes, then the canister solenoid valve is OK. If it 

is not OK, replace it. 

• If no power applied, the solenoid should be closed. No 

air pass. 

(b) Check carbon control solenoid valve resistance. 

• Turn digital multimeter to Ohm range. Check resistance 

between terminal A and B of canister solenoid valve. 


• If it is not OK, replace it. 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

6. INSTALL CANISTER SOLENOID VALVE. 

(a) Install canister solenoid valve on mounting bracket. 

(b) Connect canister solenoid valve outlet hose clip (to 

intake manifold below throttle body). 

11A 

11A 

11A 

11A 

(c) 

(d) 

Connect canister solenoid valve inlet hose clips ( to canister 

). 

Connect canister solenoid valve connector. 

11A 

11A 

11A 

11A 

11A 

(e) 

(f) 

Connect IAC connector. 

Connect fuel pressure regulator vaccum line. 

11A 

11A 

Page 1319




Page 1320


VEHICLE SPEED SENSOR 

11A-57 


PRINCIPLE 

1. VEHICLE SPEED SENSOR DESCRIPTION. 

(a) Vehicle speed sensor is the type of hall sensor. It works 

together with signal wheel on output shaft. Unified meter 

measures digital voltage signal through it and determines 

the current speed of the vehicle. 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

11A 

Page 1321

11A-58 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 




3. CONNECT SCAN TOOL TO THE DATA LINK CONNECTOR (DLC) - USE THE MOST CURRENT 

SOFTWARE AVAILABLE. 


5. DRIVE THE VEHICLE, READ THE SCAN TOOL DATA STREAM: VEHICLE SPEED. 

6. VEHICLE SPEED: THE SAME VALUE AS THE ACTUAL VEHICLE SPEED. 

7. IF THE DISPLAYED VALUE IS NOT EQUAL TO THE ACTUAL VALUE, CHECK SENSOR, HAR- 

NESS AND ECM. 

8. RAISE THE VEHICLE. 

9. TURN THE IGNITION SWITCH ON AND NOT START ENGINE. CHECK AS FOLLOWING: 

(a) 

(b) 

Set digital multimeter to voltage range. Check voltage 

between terminal 2 and 3 of the sensor. It should be 12V. 

If it is not OK, replace it. 

Start engine, pull into gear. Using the oscilloscope, check 

the wave output of terminal 3 of sensor. If it is not OK, 

check harness and sensor. 

Page 1322



11A-59 

OVERHAUL 



3. REMOVE VEHICLE SPEED SENSOR. 

(a) Disconnect vehicle speed sensor connector. 

(b) Remove vehcle speed sensor retaining bolt. 

11A 

11A 

11A 

11A 

11A 

11A 

(c) 

Pull out vehcle speed sensor straight by slightly turning. 

NOTE 

Clear surface after removeing. 

11A 

11A 

11A 

11A 

11A 

4. INSTALL VEHICLE SPEED SENSOR. 

(a) Install vehicle speed sensor and tighten 1 mounting bolt. 

NOTE 

Do not use any impact tools (such as a hammer, etc.) to 


(b) Connect vehicle speed sensor connector. 

11A 

11A 

11A 

11A 

11A 



(a) Start the vehicle and check vehicle speed sensor for fluid leakage and confirm that speedometer is 

operational. 

11A 

11A 

11A 

11A 

Page 1323

11A-60 ENGINE CONTROL SYSTEM - IGNITION CONTROL MODULE 

IGNITION CONTROL MODULE 

PRINCIPLE 

1. IGNITION CONTROL MODULE DESCRIPTION. 

(a) 

Adopting group ignition technology, taking advantage of the 

theory that the mutual induction of the electromagnetic coils 

can generate high energy, controlling the switch-on/switchoff 

time of the primary coil, and taking advantage of the high 

voltage power of the secondary coil to puncture the spark 

plug gap so as to generate strong spark to ignite the mixed 

air. Since the air ionization is very great and the resistance 

is very low during the engine exhaust process, only low 

voltage power is required to puncture the spark plug gap. 

Therefore, this system adopts group ignition technology so 

as not to waste the energy. 

Page 1324


IGNITION CONTROL MODULE 

11A-61 

OVERHAUL 




4. REMOVE IGNITION CONTROL MODULE. 

(a) Disconnect ignition control module connector. 

(b) Remove spark plug wires. 

NOTE 

Mark spark plug wires in the firing order in order to identify 

their positon when installing spark plug wires . 

11A 

11A 

11A 

11A 

11A 

11A 

(c) 

(d) 

Remove ignition control module retaining bolts. 

Remove ignition control module. 

11A 

11A 

11A 

11A 

11A 

5. INSTALL IGNITION CONTROL MODULE. 

(a) Tighten ignition control module 2 mounting bolts. 

11A 

11A 

11A 

11A 

11A 

(b) 

(c) 

Align the marks made previously and Install spark plug 

wire to ignition module. 

Connect ignition control module connector. 

11A 

11A 

11A 

11A 



Page 1325

MEMO 

Page 1326

FUEL SYSTEM 

FUEL SYSTEM.................................................................................12A-1 

PRECAUTION............................................................................ 12A-1 

FUEL SYSTEM PRESSURE RELEASE PROCESS ................. 12A-2 

DRAIN FUEL TANK PROCESS................................................. 12A-2 

FUEL TUBE CLEAN .................................................................. 12A-2 

PROBLEM SYMPTOMS TABLE................................................ 12A-3 

COMPONENTS ......................................................................... 12A-4 

FUEL TANK ASSY...........................................................................12A-6 

REPLACEMENT ........................................................................ 12A-6 

FUEL FILTER ASSY ........................................................................12A-9 

REPLACMENT........................................................................... 12A-9 

ELECTRIC FUEL PUMP ASSY .....................................................12A-10 

REPLACMENT......................................................................... 12A-10 

FUEL INJECTOR RAIL ASSY ......................................................12A-12 

OVERHAUL ............................................................................. 12A-12 

FUEL FILLER DOOR .....................................................................12A-17 

REPLACEMENT ...................................................................... 12A-17 

FUEL FILLER DOOR LOCK LATCH ASSY .................................12A-18 

REPLACEMENT ...................................................................... 12A-18 

FUEL FILLER CAP ........................................................................12A-20 

INSPECTION ........................................................................... 12A-20 

FUEL FILLING TUBE AND BREATHER TUBE ASSY .................12A-21 

INSPECTION ........................................................................... 12A-21 

ACCELERATE PEDAL ..................................................................12A-25 

REPLACEMENT ...................................................................... 12A-25 

12A 

12A 

12A 

12A 

12A 

Page 1327

Page 1328

FUEL SYSTEM 

PRECAUTION 

FUEL - FUEL SYSTEM 

12A-1 

1. FUEL SYSTEM PRECAUTION. 

(a) Before working on fuel system, disconnect battery negative cable. 

(b) When removing the fuel hose, use a suitable container to hold the fuel. 

(c) Do not smoke, carry lighted tobacco or work near an open flame when working on fuel system. 

Equipment with ventilator at woking area can avoid personal injury. 

(d) Fuel in the fuel pump , railway and tubes remain under high pressure. In order to avoid personal injury, 

do not loosen tube connector while engine is running. 

(e) Keep gasoline away from rubber and leather parts. 

(f) Before disconncting any of the fuel system lines or fuel system components, release the fuel system 

pressure to prevent accidental spraying of fuel, even when the engine is not running. failure to follow 

this instruction may result in serious personal injury. 

(g) Check if there is any dirt like mud around the fuel line connector before work. And clean it away, 

otherwise it can damage fuel system or engine. 

(h) Keep cleaner away from the O-ring of tube connector. Cleaner can corrode the seal of fuel system. 

(i) Don’t bend or twist the fuel system tube and pipe by force. 

(j) Before connceting fuel system tube, be sure there is no damage, otherwise, replace it with a new tube 

assy. 

12A 

12A 

12A 

Page 1329

12A-2 


FUEL SYSTEM PRESSURE RELEASE PROCESS 



(a) Loosen driver seat clamp. 

(b) Rotate driver seat and open engine compartment cover. 

3. REMOVE FUEL PUMP FUSE. 

(a) Remove the lid of battery compartment junction box, 

identify the fuel pump fuse with its name labelled inside 

the box lid. 

(b) Remove the fuse with special puller or plier. 

4. START THE ENGINE UNTILL IT STOPS. 

5. START THE ENGINE AGAIN FOR 5 SECONDS, ENSURE FUEL RAIL PRESSURE RELEASE 

COMPLETELY. 

6. TURN IGNITION SWITCH OFF, RE-INSERT FUEL PUMP FUSE BACK INTO BATTERY COMPART- 

MENT JUNCTION BOX. 

DRAIN FUEL TANK PROCESS 

1. CHECK FUEL LEVEL ON FUEL GAUGE. 

2. DRAIN FUEL TANK. 

(a) Turn ignition switch off. 

(b) Insert hose of less than 22mm in diameter into fuel filler hose through fuel filler port to draw fuel in fuel 

filler hose. 

(c) Disconnect fuel filler hose from fuel tank filler neck. 

(d) Insert the hose into fuel tank to draw fuel through fuel tank filler neck. 

FUEL TUBE CLEAN 

1. USE FUEL TREATMENT THAT FOTON RECOMMENDS TO CLEAN FUEL SYSTEM. 

2. USE FUEL ADDITIVES THAT FOTON RECOMMENDS TO CLEAN FUEL SYSTEM. 

Page 1330


12A-3 



cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts. 


12A 

Engine does not start 

1. Fuel pump (Damaged) Chapter 12A fuel - electric fuel pump assy, 

replacement 

2. Fuel tube (Choked) Chapter 12A fuel - fuel system, precaution 

3. Fuel pressure regulator (Fuel 

pressure too low) 

- 

4. Fuel tank (No fuel) Chapter 12A fuel - fuel tank assy, replacement 

5. Fuel pump relay(Damaged) - 

6. Fuel injector (Damaged) Chapter 12A fuel - fuel injector rail assy, 

overhaul 

1. Fuel tube (Obstructed) Chapter 12A fuel - fuel system, precaution 

12A 

12A 



Chapter 12A fuel - fuel injector rail assy, 

overhaul 

Engine start hard 

3. Fuel injector (Leaking or 

obstructed) 


overhaull 

4. Fuel pump (Out of order) Chapter 12A fuel - electric fuel pump assy, 

replacement 

Engine idles rough 

5. Fuel injector control system (Out 

of order) 

6. Fuel pressure regulator or fuel 

pump (Return valve damaged) 




obstructed) 

Chapter 04 diagnostics - engine control 

system 

- 


overhaul 


overhaul 





overhaul 

Engine loss of power 


obstructed) 


overhaul 

3. Fuel pump (Out of order) Chapter 12A fuel - electric fuel pump assy, 

replacement 


5. Fuel (Poor quality) - 

Page 1331

12A-4 


COMPONENTS 

1 Fuel Tank Assy 

2 Fuel Tank Rear Bracket 

3 Bolt, Spring Washer And Flat Washer 

5 Fuel Tank Retaining Belt Assy 




Page 1332


12A-5 

12A 

12A 

12A 



3 Three Line Clip 

4 Canister Vent Hose Bracket 

5 Fuel Line Clip 


7 Single Line Clip 

8 Electric Fuel Pump Assy 

9 Fuel Filter To Engine Fuel Line Assy 

10 Fuel Tank To Engine Fuel Line Assy 

11 Canister Vent Hose 1 

12 Fuel Filler Hose 


14 Fuel Filter 

15 Fuel Filter Bracket 

16 Nut 


18 Canister Vent Hose 2 

19 Canister Bracket 

20 Canister 

21 Fuel Filler Cap 

22 Fuel Filter To Engine Rear Fuel Line 



25 Band Clamp 



28 Dual Line Clip 


30 Locking Nut 

31 Steel Spring Band Clamp 

32 Steel Spring Band Clamp 

Page 1333

12A-6 

FUEL - FUEL TANK ASSY 


REPLACEMENT 

1. RELEASE FUEL PRESSUE. (Refer to “Chapter 12A fuel - fuel system, fuel system pressure 


2. DRAIN FUEL TANK. (Refer to “Chapter 12A fuel - fuel system, drain fuel tank process”) 


4. RAISE AND SUPPORT THE VEHICLE IN SUITABLE POSITION. 

5. SUPPORT FUEL TANK WITH A JACK. 

NOTE 

• The tank may have an uneven surface at the bottom so shims or something similar should be 

put on the lower side to keep tank stable when supporting the fuel tank with a jack. 

• Support the position that fuel tank retaining belt never engage 

6. REMOVE FUEL TANK ASSY. 

(a) Remove fuel tank breather pipe clamp. 

(b) Remove fuel tank filler tube clamp. 

(c) Disconnect fuel tank breather pipe and filling tube from 

fuel tank assy. 

NOTE 

• Disconnect fuel filler tube, check filler port rubber 

grommet for improper crack, damage or deterioration, 

replace if necessary. 




(d) 

(e) 

Remove 4 fuel tank retaining belt mounting bolts. 

Remove 2 fuel tank rear bracket mounting bolts. 

(f) 

(g) 

(h) 

(i) 

(j) 

Lower the fuel tank to a suitable position. 

Disconnect electric fuel pump assy connector. 

Disconnect feed tube quick connector. 

Disconnect return tube quick connector. 

Disconnect EVAP tube quick connector. 

NOTE 



to prevent quick connector from being 

damaged. 

Page 1334


12A-7 

• Mark the fuel tube and quick connector to avoid misassembling. 

• Keep the connecting portion clean and avoid 

damage and foreign materials, cover them 

completely with plastic bags or something similar. 

12A 

(k) 

Remove fuel tank assy. 

12A 

7. INSTALL FUEL TANK ASSY. 

(a) 

(b) 

(c) 

Support fuel tank to a suitable position with jack. 

Connect electric fuel pump connector. 

Connect feed tube, return tube and EVAP tube quick 

Connectors. 

12A 

NOTE 

Connect fuel tube quick connectors until a click is heard, 


are secured. 

(d) 

(e) 

Install 2 fuel tank retaining belts and tighten 4 mounting 

bolts. 

Tighten 2 fuel tank rear bracket mounting bolts. 


(f) 

(g) 

Connect fuel tank breather tube, then tighen the clamp. 

Connect fuel tank filling tube, then tighen the clamp. 



10. CHECK FUEL TUBE. 

Page 1335

12A-8 


(a) 

(b) 

When Turning ignition switch on, fuel pump will apply fuel pressure to fuel lines. Inspect if there is fuel 


Start engine and rev it up and check there is no fuel leakage at the fuel system tube and hose 

connections. 

Page 1336

FUEL - FUEL FILTER ASSY 

12A-9 

FUEL FILTER ASSY 

REPLACMENT 




12A 

3. REMOVE THE FUEL FILTER. 

(a) Disconnect quick connector from both sides of fuel filter. 

NOTE 



to prevent quick connector from damaging. 




12A 

12A 

(b) 

(c) 

Loosen fuel filter mounting band retaining bolt. 

Remove fuel filter. 

4. INSTALL NEW FUEL FILTER. 

NOTE 

Follow the arrow on the fuel filter when install the fuel filter. 

(a) 

(b) 

Install fuel filter and tighten the mounting band bolt. 


Connect both sides quick connector. 

NOTE 



are secured. 


6. CHECK FUEL LINES. 

(a) When ignition switch is on, fuel pump will apply fuel pressure to fuel lines. inspect if there is fuel 


(b) Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose 

connections. 

Page 1337

12A-10 

FUEL - ELECTRIC FUEL PUMP ASSY 

ELECTRIC FUEL PUMP ASSY 

REPLACMENT 



2. DRAIN FUEL TANK AS REQUIRED. (Refer to “Chapter 12A fuel - fuel system, drain fuel tank 

process”) 



5. REMOVE FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”) 

6. REMOVE ELECTRIC FUEL PUMP ASSY. 

(a) Loosen lock ring counterclockwise with special wrench. 

(b) 

Remove electric fuel pump assy. 

NOTE 

Be careful not to bend float arm during removing electric 

fuel pump assy. 

7. CHECK SEALING RING OF SEALING COVER. 

(a) Removing sealing ring as possible as early to avoid 

deformation caused by contacting the fuel. 

(b) Check seal ring for improper crack, damage or deterioration 

and replace if necessary. 

Page 1338

FUEL - ELECTRIC FUEL PUMP ASSY 

12A-11 

8. INSTALL ELECTRIC FUEL PUMP ASSY. 

(a) Position sealing ring onto the opening of fuel tank until it 

seat into place. 

(b) Position electric fuel pump assy into fuel tank. 

12A 

(c) 

(d) 

Press installation surface of the electric fuel pump assy 

into place, then install lock ring and rotate the lock ring 

clockwise. 

Tighten lock ring with special wrench to specific torque. 


NOTE 

When installation, align the mark on the installation surface 

of the fuel pump with the corresponding mark on top surface 

of fuel tank . 

12A 

12A 

9. INSTALL FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”) 


(a) 

(b) 

After disconnecting fuel pump connector, connect fuel level sensor connector, turn ignition switch on. 

Slide fuel level sensor position manually and then check the fuel gauge’s conditions in instrument 

panel. 


connections and confirm fuel pump works normally. 

Page 1339

12A-12 

FUEL - FUEL INJECTOR RAIL ASSY 

FUEL INJECTOR RAIL ASSY 

OVERHAUL 




3. REMOVE INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air- intake air pipe and 

hose, replacement”) 

4. REMOVE FUEL INJECTOR RAIL ASSY. 

(a) Disconnect 4 fuel injector connectors. 

(b) 

Disconnect fuel pressure vaccum hose from fuel pressure 

regulator. 

(c) 

Disconnect PCV hose from engine cylinder head cover. 

(d) 

Disconnect feed tube quick connector from fuel injector 

rail. 

NOTE 




damaged. 




Page 1340


12A-13 

(e) 

Disconnect return tube quick connector from fuel injector 

rail. 

12A 

(f) 

Remove 2 fuel injector rail retaining bolts. 

12A 

12A 

(g) 

Remove fuel injector rail assy carefully. 

NOTE 

Check the O-ring locating between injectors and intake 

manifold is in good condition. 

5. CHECK FUEL PRESSURE REGULATOR. 

(a) Pull clip and remove fuel pressure regulator. 

Note 

Inspect return spring of fuel pressure regulator operation. 

6. REMOVE INJECTOR. 

(a) Remove locking clip from the slot of injector. 

(b) Turn slightly and pull out inject from fuel injector rail. 

NOTE 

Be sure that the O-ring locating between injector and fuel 

injector rail is in good condition. 

Page 1341

12A-14 


7. CHECK INJECTOR. 

(a) Use an ohmmeter to measure resistance between two 

terminals of injector. 

Resistance: 13 ~ 16 Ω 

(b) Check if there is any carbon deposition or dirty aroud 

injector nozzle, clear it away if blocked. 

(c) 

If necessary, take injector on injector test table, check 

injector leakage or not. 

8. INSTALL INJECTOR. 

(a) Install new insulator to each fuel injector. 

NOTE 

• O-ring on both sides of injector are different, do not 

misassemble. 

• Apply a light coat of spindle oil or gasoline to a new 

o-ring, and install it to each fuel injector. Do not use 

engine oil or brake fluid. 

I 

(b) 

Install each fuel injector to fuel rail. 

NOTE 

Attempt to pull injector out to check the locking clip 

secured the injector in place firmly. 

9. INSTALL FUEL PRESSURE REGULATORS. 

NOTE 

Inspect it if fuel pressure regulator turns smoothly. If not, it means that O-ring is clamped. Reinstall it 

with new O-ring. 

Page 1342


12A-15 

10. INSTALL FUEL INJECTOR ASSY. 

(a) Slightly press injector rail to install injector into hole properly. 

(b) Tighten 2 fuel injector rail assy retaining bolts. 

12A 

(c) 

Connect feed tube to fuel injector rail assy. 

NOTE 



are secure. 

12A 

12A 

(d) 

Connect return tube to fuel injector rail assy. 

11. CONNECT 4 INJECTOR CONNECTORS. 

12. CONNECT VACCUM HOSE TO FUEL PRESSURE 

REGULATIOR. 

Page 1343

12A-16 


13. CONNECT VACCUM HOSE TO PCV. 

14. INSTALL INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air- intake air pipe and 



(a) 

(b) 

Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel 

pressure to fuel lines 

Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose 

connections. 

Page 1344

FUEL - FUEL FILLER DOOR 

12A-17 

FUEL FILLER DOOR 

REPLACEMENT 

1. REMOVE FUEL FILLER DOOR. 

(a) Pull fuel filler door handle. 

(b) Open fuel filler door. 

12A 

(c) 

(d) 

(e) 

Remove 2 fuel filler door retaining bolts. 

Remove the clip connected to fuel filler cap from fuel filler 

door. 

Remove fuel filler door. 

12A 

12A 

2. INSTALL FUEL FILLER DOOR. 

(a) 

(b) 

Install 2 fuel filler door retaining bolts. 

Install the clip connected to fuel filler cap to fuel filler 

door. 

3. ADJUST FUEL FILLER DOOR. 

NOTE 

Adjust fuel filler door or 2 retaining bolts position manually 

if fuel filler door is not closed completely 

Page 1345

12A-18 

FUEL - FUEL FILLER DOOR LOCK LATCH ASSY 

FUEL FILLER DOOR LOCK LATCH ASSY 

REPLACEMENT 

1. REMOVE FRONT SIDE WALL GUARD BOARD. (Refer to “Chapter 88 exterior and interior trim 

panel - side wall guard board, replacement”) 

2. REMOVE LEFT FRONT SEAT LOCK ASSY. 

(a) Remove 2 left front seat lock assy retaining bolts. 

3. REMOVE FUEL FILLER DOOR LOCK LATCH ASSY. 

(a) Open fuel filler door. 

(b) Remove lock latch retaining nut. 

(c) 

(d) 

Remove lock latch assy. 

Disconnect fuel filler door cable. 

4. INSTALL FUEL FILLER DOOR LOCK LATCH ASSY. 

(a) Connect fuel filler door cable to lock latch assy. 

Page 1346


12A-19 

(b) 

Position fuel filler door lock latch assy into place inside B 

pillar, then tighten retaining nut. 

12A 

5. CHECK FUEL FILLER DOOR LOCK LATCH ASSY. 

(a) Close fuel filler door, then pull fuel filler door handle. 

(b) Be sure that fuel filler door lock latch assy is operatonal. 

12A 

12A 

6. INSTALL LEFT FRONT SEAT LOCK ASSY. 

(a) Tighten 2 left front seat lock assy retaining bolts. 

7. INSTALL FRONT SIDE WALL GUARD BOARD. (Refer to “Chapter 88 exterior and interior trim 

panel - side wall guard board, replacement”) 

Page 1347

12A-20 

FUEL - FUEL FILLER CAP 

FUEL FILLER CAP 

INSPECTION 

1. PULL FUEL FILLER DOOR HANDLE AND OPEN 

FUEL FILLER CAP. 

2. REMOVE FUEL FILLER CAP. 

(a) Rotate the fuel filler cap counterclockwise to unlock it. 

(b) Remove the fixing clip from the plastic ring on the fuel 

filler cap. 

(c) Remove fuel filler cap. 

3. INSPECT FUEL FILLER CAP ASSY. 

(a) Visually inspect fuel filler cap and seal ring. If deformed 

or damaged, replace with a new one. 

(b) Termly lubricate the rotating part. 

4. INSTALL THE FUEL FILLER CAP. 

(a) Install the fuel filler cap fixing clip into plastic ring. 

(b) Rotate the fuel filler cap clockwise until a click is heard. 

Page 1348

FUEL - FUEL FILLING TUBE AND BREATHER TUBE ASSY 

12A-21 

FUEL FILLING TUBE AND BREATHER TUBE ASSY 

INSPECTION 


2. REMOVE BATTERY AND BATTERY TRAY. (Refer to “Chapter 20A starting and charging - battery, 

replacement” ) 

3. OPEN FUEL FILLER DOOR. 


5. DRAIN FUEL TANK AS REQUIRED. (Refer to “Chapter 12A fuel - fuel system, drain fuel tank 

process”) 

6. REMOVE FUEL FILLER AND BREATHER HOSES. 

(a) Remove 3 fuel filler port retaining bolts. 

12A 

12A 

12A 

(b) 

Remove fuel breather hose and fuel filler hose retaining 

bolts that are located below battery tray. 

(c) 

(d) 

(e) 

(f) 

Raise and support the vehicle. 

Remove upper fuel breather hose bracket retaining nut. 

Remove the clamp between upper and lower fuel 

breather hoses, then disconnect breather hoses. 

Pull upper fuel breather hose out of the hole on sidewall 

of the battery compartment . 

Page 1349

12A-22 


(g) 

(h) 

Loosen fuel filler hose retaining clamp at the fuel tank 

side, then disconnect fuel filler hose from fuel tank filler 

neck. 

Remove fuel filler hose retaining bolt from vehicle frame. 

(i) 

(j) 

Remove upper fuel filler hose retaining bolt from vehicle 

frame. 

Remove fuel filler hose and upper fuel breather hose. 

(k) 

Remove retaining bolt on the bracket of lower fuel 

breather, then pull fuel breather hose out of the hole on 

vehicle frame. 

(l) 

(m) 

(n) 

Remove retaining bolt between lower fuel breather hose 

bracket and side member NO.2. 

Remove fuel breather hose clamp at the fuel tank 

breather neck, then disconnect them. 

Pull lower fuel breather hose from the side member 

NO.2, then remove lower fuel breather hose. 

7. INSTALL FUEL FILLER AND BREATHER HOSES. 

(a) 

(b) 

Position upper fuel filler hose in place. 

Tighten 3 fuel filler port retaining bolts. 

NOTE 

Engage the groove of seal ring with the lip of fuel filler neck 

first securely when installing fuel filler hose assy. 

Page 1350


12A-23 

(c) 

Tighten fuel filler hose and upper fuel breather hose 

retaining bolt below the battery tray. 

12A 

(d) 

(e) 

(f) 


Connect upper and lower breather hoses, then tighten 

the clamp. 

Tighten upper breather hose retaining nut. 

12A 

12A 

(g) 

(h) 

(i) 

Install fuel filler hose through the hole on side member 

NO.1. 

Connect upper and lower fuel breather hoses, then 

tighten retaining clamp. 

Tighten the retaining bolt securing breather hose bracket 

to side member NO.1. 

(j) 

(k) 

(l) 

Install lower breather hose throuth the hole on side 

member NO.2. 

Tighten retaining bolt securing breather hose bracket to 

side member NO.2. 

Connect breather hose to fuel tank, then tighten the 

clamp. 

Page 1351

12A-24 


(m) 

Tighten retaining bolt securing upper fuel filler hose to 


(n) 

(o) 

Conncet fuel filler hose to fuel tank filler nect, then 


Tighten 1 fuel filler hose retaining bolt. 

8. INSTALL BATTERY AND BATTERY TRAY. (Refer to “Chapter 20A starting and charging - battery, 



(a) Fill fuel tank if necessary. Check filling is a smooth flow and no fuel leaks. 

10. INSTALL FUEL FILLER CAP, THEN CLOSE THE FUEL FILLER DOOR. 

Page 1352

FUEL - ACCELERATE PEDAL 

12A-25 

ACCELERATE PEDAL 

REPLACEMENT 


12A 




cover. 

12A 

3. REMOVE THROTTLE CABLE. 

(a) Push throttle linkage wide open and hold it there to withdraw 

throttle cable end from the recess in throttle linkage. 

12A 

4. REMOVE ACCELERATE PEDAL ASSY. 

(a) Remove 2 accelerate pedal retaining nuts. 

(b) Remove accelerate pedal with throttle cable and move it 

aside. 

Page 1353

12A-26 

FUEL - ACCELERATE PEDAL 

(c) 

(d) 

Release locking tab securing throttle cable to accelerate 

pedal, then disengage cable end from the recess in the 

accelerate pedal so that the cable can be removed 

completely. 

Remove accelerate pedal assy. 

5. INSTALL ACCELERATE PEDAL ASSY. 

(a) Engage throttle cabe end into the recess of accelerate 

pedal, then install locking tab to lock cable into place. 

(b) Position accelerate pedal and tighten 2 retaining nuts. 

6. ENGAGE THROTTLE CABLE IN THE THROTTLE 

MECHANISM IN THE ENGINE COMPARTMENT. 

7. PUT DOWN DRIVER SEAT AND LOCK THE CLAMP. 


(a) After installation, press accelerate pedal to check that the accelerator pedal operates smoothly without 

stuck phenomenon. 

Page 1354


FUEL FILLER CAP ..........................................................................13A-1 

INSPECTION ............................................................................. 13A-1 

CHARCOAL CANISTER..................................................................13A-2 

OVERHAUL ............................................................................... 13A-2 

CANISTER SOLENOID VALVE.......................................................13A-4 

OVERHAUL ............................................................................... 13A-4 

POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)....13A-7 

OVERHAUL ............................................................................... 13A-7 

11A 

11A 

11A 

11A 

11A 

11A 

Page 1355

Page 1356

EMISSION CONTROL - FUEL FILLER CAP 

13A-1 



INSPECTION 



13A 




filler cap. 


13A 

13A 


(a) Visually inspect fuel filler cap and seal ring. If deformed 


(b) Termly lubricate the rotating part. 




Page 1357

13A-2 

CHARCOAL CANISTER 

OVERHAUL 


EMISSION CONTROL - CHARCOAL CANISTER 


(a) 

(b) 



cover. 

3. REMOVE BATTERY AND BATTERY TRAY. (Refer to “Chapter 20A starting and charging - battery, 


4. REMOVE CHARCOAL CANISTER. 

(a) Loosen charcoal canister outlet hose clip and disconnect 

the hose (to canister solenoid ). 

NOTE 

When disconnecting these hoses which are used for a long 

time, twist hose first and make them loosed, then perform 

the disconnection. 

(b) 

Loosen charcoal canister outlet hose clip and disconnect 

the hose (to canister solenoid ). 

NOTE 

The end of EVAP hose connecting to fuel tank identifies 

with green mark. 

(c) 

Remove charocal canister directly. 

5. CHECK CHAROCAL CANISTER. 

(a) Visually check charcoal canister for crack and damage, 

replace with a new one if necessary 

(b) Blow compressed air into inlet port (to fuel tank), feel 

charcoal canister outlet port (to canister solenoid) with 

hand and check if air flows from the outlet port. 

NOTE 

If no air flows from the outlet port, charcoal canister is 

blocked, replace if necessary. 

Page 1358

EMISSION CONTROL - CHARCOAL CANISTER 

13A-3 

6. INSTALL CHARCOAL CANISTER. 

(a) Install the hose which connects fuel tank to charcoal 

canister and install clip. 

(b) 

(c) 

Install the hose which connects canister solenoid to 

charcoal canister and install clip. 

Install charcoal canister on bracket 

13A 

7. INSTALL BATTERY AND BATTERY TRAY. (Refer to “Chapter 20A starting and charging - battery, 


8. PUT DOWN THE DRIVER SEAT AND LOCK IT. 

13A 

13A 

Page 1359

13A-4 

EMISSION CONTROL - CANISTER SOLENOID VALVE 


OVERHAUL 





cover. 


4. REMOVE CANISTER SOLENOID VALVE. 


(b) Remove fuel pressure regulator vaccum line. 

(c) 

(d) 

Disconnect canister solenoid valve connector. 

Disconnect canister solenoid valve inlet hose clips and 

remove the hose ( to canister). 

NOTE 

When disconnecting these hoses which used for a long time. 

Twist hose to be loosed first, then operate disconnection. 

(e) 

(f) 

Disconnect canister solenoid valve outlet hose clips and 

remove hose ( to intake manifold below throttle body ). 

Using screw driver, pry canister solenoid valve away from 

mounting bracket and remove it. 

Page 1360


13A-5 

5. CHECK CANISTER SOLENOID VALVE. 

(a) Apply battery voltage to canister solenoid valve. Sound 

should be heard. At this time, blow air to the inlet port: 

• If air passes, then the canister solenoid valve is OK. If it 

is not OK, replace it. 

• If no power applied, the solenoid should be closed. No 

air pass. 

13A 

(b) Check carbon control solenoid valve resistance. 

• Turn digital multimeter to Ohm range. Check resistance 

between terminal A and B of canister solenoid valve. 


• If it is not OK, replace it. 

13A 

13A 

6. INSTALL CANISTER SOLENOID VALVE. 

(a) Install canister solenoid valve on mounting bracket. 

(b) Connect canister solenoid valve outlet hose clip (to 

intake manifold below throttle body). 

(c) 

(d) 

Connect canister solenoid valve inlet hose clips ( to canister 

). 

Connect canister solenoid valve connector. 

(e) 

(f) 

Connect IAC connector. 

Connect fuel pressure regulator vaccum line. 

Page 1361

13A-6 


7. INSTALL AIR INTAKE PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and 



Page 1362

EMISSION CONTROL - POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE) 

13A-7 

POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE) 

OVERHAUL 

1. TURN IGNITION SWITCH ON. 

13A 

2. OPEN ENGINE COMPARTMENT COVER 



cover. 

3. REMOVE PCV VALVE. 

(a) Disconnect PCV hose from engine cylinder head cover 

(b) Remove PCV valve. 

13A 

13A 

4. INSPECT PCV VALVE. 

(a) Disconnect PCV hose from engine cylinder head, start engine at idle speed. put finger at PCV port, 

check if vacuum of air intake manifold exits. if not, clean or replace with a new one. 

(b) 

Blow air from port that connect cylinder. Air can flow out 

from the other port. 

(c) 

Blow air from port that connect air intake mainfold. Air 

can’t flow out from the other port. 

Page 1363

13A-8 

EMISSION CONTROL - POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE) 

5. INSTALL PCV VALVE . 

(a) Install PCV valve into engine cylinder head cover. 

(b) Connect PCV hose to PCV valve. 


Page 1364

INTAKE AIR 

INTAKE AIR SYSTEM......................................................................14A-1 

PRECAUTION............................................................................ 14A-1 

INTAKE AIR PIPE AND HOSE ........................................................14A-2 

REPLACEMENT ........................................................................ 14A-2 

AIR FILTER ASSY ...........................................................................14A-6 

REPLACEMENT ........................................................................ 14A-6 

INTAKE MANIFOLD................................................................. 14A-10 

REPLACEMENT ...................................................................... 14A-10 

14A 

14A 

14A 

14A 

14A 

14A 

14A 

Page 1365

Page 1366

INTAKE AIR SYSTEM 

AIR 

PRECAUTION 

1. INTAKE AIR SYSTEM PRECAUTION. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

INTAKE AIR - INTAKE AIR SYSTEM 

14A-1 

Intake air must be filtered to avoid debris and dirt entering the engine. loose and damaged pipe or hose 

connection may cause unfiltered air to enter the engine leading to premature engine wear. 

The intake manifold hose connection must be reliable enough to avoid gaps and looseness, etc. 

Each cushion and bracket connection with intake manifold hose must be reliable. There are no cracks 

on the apperance or gaps in the connection portion. 

When using the solvent, acid or alkaline material washing, please follow the manufacturers’ advice to 

wear protective clothing and goggles to avoid personal injury. 

When dealing with corrosive work, use skin and eye protection device to reduce the possibility of 

personal injury. 

When using compressed air, wear appropriate goggles and protective mask. Both dust particles and 

dirt will cause injury. 

14A 

14A 

14A 

Page 1367

14A-2 

INTAKE AIR - INTAKE AIR PIPE AND HOSE 

INTAKE AIR PIPE AND HOSE 

REPLACEMENT 

1. REMOVE UPPER INTAKE AIR HOSE IN THE ENGINE 

COMPARTMENT. 

(a) 

Remove intake air hose clamp on throttle body side. 

(b) 

(c) 

Remove 2 intake air pipe retaining bolt. 

Disconnect crankcase vent hose on intake air pipe. 

(d) 

Remove the clamp at the end of intake air pipe. 

(e) 

Remove upper intake air pipe and hose. 

Page 1368


14A-3 

2. REMOVE MIDDLE INTAKE AIR PIPE AND HOSE. 

(a) Remove middle intake air ripple hose clamp under the 

vehicle. 

14A 

(b) 

Remove middle intake air ripple hose. 

14A 

14A 

(c) 

(d) 

Remove middle intake air pipe retaining bolt by the right 

front wheel side. 

Remove the clamp connecting middle intake air pipe to 

bending hose. 

(e) 

Remove middle intake air pipe. 

(f) Remove air filter assy. (Refer to “Chapter 14A intake air - 

air filter assy, replacement”) 

Page 1369

14A-4 


(g) 

Remove the clamp securing bending hose to air filter 

assy, then remove the bending hose. 

3. INSTALL MIDDLE INTAKE AIR PIPE AND HOSE. 

(a) 

(b) 

Install bending hose to air filter outlet pipe and tightnen 

the clamp. 

Install air filter assy. (Refer to “Chapter 14A intake air - air 

filter assy, replacement”) 

(c) 

(d) 

Positon middle intake air pipe in place, then install 

bending hose. 

Tighten middle intake air pipe retaining bolt and bending 

hose retaining clamp. 

(e) 

(f) 

Install middle intake air ripple hose. 

Tighten ripple hose clamp. 

4. INSTALL UPPER INTAKE AIR PIPE AND HOSE IN 

THE ENGINE COMPARTMENT. 

(a) 

Tighten the clamp securing intake air pipe to ripple hose. 

Page 1370


14A-5 

(b) 

Tighten intake air hose clamp to throttle body side. 

14A 

(c) 

(d) 

Tighten 2 intake air pipe retaining bolts. 

Connect crankcase vent hose to intake air pipe, then 

tighten clamp. 

14A 

14A 


(a) After installing air filter, check all parts and parts connection again to make sure engine operates properly. 

Page 1371

14A-6 

INTAKE AIR - AIR FILTER ASSY 

AIR FILTER ASSY 

REPLACEMENT 

1. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”) 

2. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper assy, 


3. REMOVE AIR FILTER INTAKE AIR DUCT. 

(a) 

(b) 

Remove retaining bolt and clamp of air filter intake air 

duct. 

Remove intake air duct. 

4. REMOVE AIR FILTER ASSY. 

(a) 

Remove retaining clamp securing bending hose to 

middle intake air pipe. 

Page 1372


14A-7 

(b) 

Remove 3 air filter assy retaining bolts. 

14A 

14A 

14A 

(c) 

Remove air filter together with bending hose. 

(d) 

loosen clamp securing bending hose to air filter and 

remove bending hose. 

5. INSTALL AIR FILTER ASSY. 

(a) 

Install bending hose to air filter assy outlet pipe, then 


NOTE 

Connect the end of benging hose which has a triangle mark 

to air filter when installation. 

Page 1373

14A-8 


(b) 

(c) 

Position air filter with bending hose in place. 

Connect bending hose to middle intake air pipe, then 


(d) 

Tighten 3 air filter assy retaining bolts. 


(e) 

(f) 

Install air filter intake air duct retaining bolt. 


Tighten the clamp securing intake air duct to air filter inlet 

pipe. 

Page 1374


14A-9 

6. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper assy, 


7. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”) 

14A 


(a) 

Release 3 retaining clips from air filter lower cover. 

(b) 

Open air filter lower cover and remove air filter element. 

NOTE 

Air filter element is made of paper. If necessary, clear the air 

filter element with high pressure air gun. Do not clean it 

with water. 

14A 

14A 

(c) 

(d) 

Clean or replace air filter element. 

Install air filter lower cover and lock the retaining clips. 

Page 1375

14A-10 


INTAKE MANIFOLD 

REPLACEMENT 

1. DRIAN THE COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”) 


(a) 

(b) 



cover. 


4. REMOVE INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and hose, 


5. DISCONNECT VACCUM BOOSTER HOSE ON INTAKE 

MANIFOLD. 

6. REMOVE THROTTLE BODY. (Refer to “Chapter 11A engine control system - throttle body, overhaul”) 

7. DISCONNECT ENGINE COOLANT TEMPERATURE 

SENSOR CONNECTOR. 

Page 1376


14A-11 

8. DISCONNECT IGNITION COIL CONNECTOR. 

9. REMOVE GROUND HARNESS. 

14A 

10. DISCONNECT INTAKE TEMPERATURE/ PRESSURE 


14A 

14A 

11. DISCONNECT A/C COMPRESSOR CONNECTOR. 

12. DISCONNECT KS CONNECTOR. 

13. DISCONNECT STARTER CONTROL WIRE CONNEC- 

TOR. 

Page 1377

14A-12 


14. DISCONNECT 4 INJECTOR CONNECTORS. 

NOTE 

Position wire harness aside for easy operation。 

15. REMOVE FUEL INJECTOR RAIL ASSY. (Refer to “Chapter 12A fuel - fuel injector rail assy, 


16. REMOVE CANISTER SOLENOID VALVE. (Refer to “Chapter 11A engine control system - canister 

solenold valve, overhaul”) 

17. REMVOE INTAKE MANIFOLD LOWER BRACKET. 

(a) Remove 4 intake manifold lower bracket retaining bolts. 

18. REMOVE WATER HOSES ON INTAKE MANIFOLD 

SIDE. 

(a) Remove 4 water hoses retaining clamps. 

(b) Disconnect 4 water hoses. 

(c) 

Remove 2 three-way water pipe retaining bolts. 

Page 1378


14A-13 

(d) 

Remove three-way water pipe. 

NOTE 

Check whether there are sign of coolant leakage for cap 

plug and coolant sensor. If it is present, replace cup plug or 

coolant sensor shim. 

14A 

19. REMOVE INTAKE MANIFOLD ASSY. 

(a) Remove intake manifold retaining bolts and nuts. 

14A 

14A 

(b) 

Remove intake manifold assy. 

(c) 

Remove intake manifold sealing gasket. 

NOTE 

Always replace a new sealing gasket after removing intake 

manifold. 

20. INSTALL INTAKE MANIFOLD ASSY. 

(a) install intake manifold sealing gasket. 

(b) install 9 intake manifold retaining bolts and nuts. 


Page 1379

14A-14 


(c) 

Install 4 intake manifold lower bracket retaining bolts. 


21. INSTALL THREE-WAY WATER PIPE. 

(a) Use scraper to remove all old sealant adhering to the 

groove on mating surface of three-way water pipe, and 

then apply sealant to the groove. 

(b) 

Install 2 three-way water pipe retaining bolts. 


(c) 

(d) 

Install 4 water hoses. 

Tighten 4 water hose clamps. 

22. INSTALL FUEL INJECTOR RAIL ASSY. (Refer to “Chapter 12A fuel - fuel injector rail assy, 


23. INSTALL CANISTER SOLENOID VALVE. (Refer to “Chapter 11A engine control system - canister 

solenold valve, overhaul”) 

24. INSTALL THROTTLE BODY. (Refer to “Chapter 11A engine control system - throttle body, overhaul”) 

Page 1380


14A-15 

25. CONNECT INTAKE MANIFOLD VACCUM BOOSTER 

HOSE. 

14A 

26. CONNECT STARTER CONTROL WIRE CONNECTOR. 

14A 

14A 

27. CONNECT KS CONNECTOR. 

28. CONNECT A/C COMPRESSOR CONNECTOR. 

29. CONNECT ENGINE COOLANT TEMPERATURE SEN- 

SOR CONNECTOR. 

Page 1381

14A-16 


30. TIGHTEN GROUND WIRE. 

31. CONNECT IGNITION COIL CONNECTOR. 

32. CONNECT INTAKE TEMPERATURE / PRESSURE 


33. INSTALL INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and hose, 



35. FILL COOLANT TO SPECIFIED LEVEL. (Refer to “Chapter 17A cooling - coolant, replacement”) 



(a) Start the vehicle, check all electrical component is functional and no gas, air and fluid leakage are 

found. 

Page 1382


ENGINE MECHANICAL PART ........................................................15A-1 

PRECAUTION............................................................................ 15A-1 

ENGINE ASSY .................................................................................15A-2 

REPLACEMENT ........................................................................ 15A-2 

TIMING PULLEY CASING .............................................................15A-14 

REPLACEMENT ...................................................................... 15A-14 

TIMING BELT.................................................................................15A-18 

COMPONENTS ....................................................................... 15A-18 

OVERHAUL ............................................................................. 15A-19 

ROCK ARM, ROCK ARM SHAFT, HYDRAULIC 

TAPPET & CAMSHAFT.................................................................15A-37 

COMPONENTS ....................................................................... 15A-37 

ROCK ARM, ROCK ARM SHAFT & HYDRAULIC TAPPET OVER- 

HAUL ....................................................................................... 15A-39 

CAMSHAFT OVERHAUL......................................................... 15A-49 

CYLINDER HEAD,VALVE .............................................................15A-51 

COMPONENTS ....................................................................... 15A-51 

CYLINDER HEAD OVERHAUL ............................................... 15A-52 

VALVE OVERHAUL................................................................. 15A-54 

PISTON & CONNECTING ROD ASSEMBLY................................15A-59 

COMPONENTS ....................................................................... 15A-59 

PISTON & CONNECTING ROD ASSEMBLY OVERHAUL..... 15A-60 

CRANKSHAFT, CYLINDER BLOCK & FLYWHEEL ....................15A-69 

COMPONENTS ....................................................................... 15A-69 

OVERHAUL ............................................................................. 15A-71 

15A 

15A 

15A 

15A 

15A 

15A 

15A 

15A 

Page 1383

Page 1384

ENGINE MECHANICAL - ENGINE MECHANICAL PART 

ENGINE MECHANICAL PART 

MECHANICAL 

PRECAUTION 

1. EMGINE MECHNANICAL PART PRECAUTION. 

(a) 

Follow the instructions of maintenance methods and regulations to adjust or maintain. 

15A-1 

(b) Before starting the engine, check the coolant level, fill or drain the coolant if necessary. Check the 

engine oil level, fill the engine oil if necessary. 

(c) Do not adjust the position of throttle valve screw. It will cause the throttle valve closed angle change 

and make the engine work abnormal. 

(d) Do not pull up the spark plug wire when the engine is running. 

(e) The clearance between ckp sensor and flywheel is 0.8 ~ 1.2 mm. Do not try to adjust it. 

(f) The fuel should use ron ≥ 93 unleaded gasoline, otherwise the catalytic converter will be damaged. 

(g) Use the oil as requirement, otherwise exacerbate engine wear. 

(h) Use the original fittings, otherwise it will damage the engine or affect the engine working condition. 

(i) Do not use the high pressure water cannons to wash the ecm shell. 

(j) The engine starting time should be less than 5s. Not more than 5 consecutive starting times. Interval 

time to next starting should not be less than 15 seconds. 

(k) Keep the normal coolant temperature 85 ~ 105 ℃ . 

(l) When the engine in high speed or high load, do not turn the ignition switch off. Keep the engine running 

in low speed for 3~5 mins that the engine radiates eventually. 

(m) Before opening the radiator cap, check the coolant level and must ensure the engine is cool. 

(n) Use the sealant scraper to clear the sundries in seal surface. Confirm seal surface flat and smooth, no 

oil stain there. 

15A 

15A 

15A 

Page 1385

15A-2 

ENGINE MECHANICAL - ENGINE ASSY 

ENGINE ASSY 

REPLACEMENT 

1. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioner - refrigerant, 


2. RELEASE FUEL SYSTEM PRESSURE. (Refer to “Chapter 12A fuel - fue system, fuel system 

pressure release process”) 


4. DRAIN COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”) 

5. DRAIN ENGINE OIL. (Refer to “Chapter 18A lubricantion - engine oil, replacement”) 

6. DRAIN TRANSMISSION FLUID. (Refer to “Chapter 41 transmission - transmission assy, replacement”) 





cover. 


10. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat, 


11. REMOVE ENGINE COMPARTMENT COVER UNDER 

ASSISTANT DRIVER SEAT. 

(a) Remove front floor covering. 

(b) Remove 5 engine compartment cover retaining bolts. 

(c) Remove engine compartment cover. 

12. REMOVE INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and 


Page 1386


15A-3 

13. LOOSEN CLAMP AND DISCONNECT ENGINE WATER 

OUTLET HOSE. 

14. LOOSEN CLAMP AND DISCONNECT WATER OUT- 

LET HOSE AND INLET HOSE TO FRONT HEATER. 

15A 

15. DISCONNECT WATER INLET HOSE TO REAR HEATER. 

16. REMOVE THROTTLE CABLE FROM THE THROTTLE 

BODY. 

17. REMOVE THE HOSE TO CANISTER SOLENOID VALVE. 

18. REMOVE FUEL RETURN TUBE. 

15A 

19. REMOVE FUEL FEED TUBE. 

NOTE 

After disconnecting fuel tubes, cover them completely with 

plastic bags or something similar to avoid damage and 

foreign materials. 

15A 

20. REMOVE VACUUM BOOSTER HOSE TO INTAKE 

MANIFOLD. 

21. REMOVE WATER OUTLET HOSE TO REAR HEATER. 

Page 1387

15A-4 


22. REMOVE ENGINE WATER INLET HOSE. 

23. REMOVE ENGINE ECM HARNESS CONNECTOR. 

(a) Remove the clip securing engine harness to cowl panel 

at engine compartment. 

(b) Pull rubber grommet securing engine harness out of the 

hole at ECM compartment sidewall. 

(c) 

(d) 

Remove ECM compartment cover, then disconnect ECM 

connector and the other 2 electrical connectors. 

Pull engine harness connectors and 2 electrical connectors 

through the hole of ECM compartment. 

24. REMOVE GENERATOR POSITIVE CABLE. 

25. DISCONNECT HIGH PRESSURE AND LOW PRESSURE 

PIPES TO COMPRESSOR. 

(a) Loosen 2 nuts securing high pressure and low pressure 

pipes to compressor, then disconnect them. 

NOTE 

Using clean cloth, block the A/C pipe and A/C compressor 

hole to avoid dust entering. 

Page 1388


15A-5 

26. RAISIE THE VEHICLE. 

27. REMOVE 2 FRONT WHEELS. (Refer to “Chapter 33 wheel and tire - wheel, replacement”) 

28. REMOVE STARTER POSITIVE CABLE. 

29. DISCONNECT THE GROUND CABLE TO ENGINE 

BLOCK. 

15A 

30. REMOVE LEFT FRONT SUSPENSION UNIT. 

(a) Separate left front shock absorber from lower control 

arm. (Refer to “Chapter 31 front suspension - front shock 

absorber, overhaul”) 

(b) Separate left front stabilizer bar from lower control arm. 

(Refer to “Chapter 31 front suspension - stalilizer bar, 


(c) Separate left front stabilizer bar from lower control arm 

ball joint seat. (Refer to “Chapter 31 front suspension - 

lower control arm, replacement”) 

(d) Separate left front steering tie rod from the steering 

knuckle arm. (Refer to “Chapter 52 power steering - 

power steering link assy, replacement”) 

15A 

15A 

31. REMOVE RIGHT FRONT SUSPENSION UNIT. 

NOTE 

The procedure to remove right front suspension unit is similar to the procedure above. 

32. REMOVE STEERING DRIVE SHAFT ASSY II. 

(a) Remove retaining bolts on both sides of steering drive 

shaft assy II. 

(b) Remove steering drive shaft assy II. 

NOTE 

Before disconnecting steering drive shaft assyII, mark 

steering drive shaft assy and steering gear output shaft for 

easier installation. 

33. REMOVE TRANSMISSION FLEXIBLE SHAFT ASSY. 

(a) Remove clamp NO.1 retaining bolt securing flexible shaft 

assy to sub-frame. 

Page 1389

15A-6 


(b) 

Remove clamp NO.2 retaining bolt securing flexible shaft 

assy to sub-frame.. 

(c) Remove locking nuts and locking clips securing 

transmission flexible shaft to transmission shift 

mechanism. 

34. REMOVE CLUTCH SLAVE CYLINDER. 

(a) Remvoe 2 retaining bolt mounting clutch slave cylinder to 

transmission assy. 

(b) Remove clutch slave cylinder. 

35. REMOVE CATALYTIC CONVERTER. (Refer to“Chapter 16 exhaust - exhaust pipe, replacement”) 

36. DISCONNECT VSS AND BACK-UP LAMP SWITCH 

HARNESS CONNECTORS. 

37. SUPPORT ENGINE SUB-FRAME AND TRANSMISSION ASSY WITH HYDRAUMATIC JACK. 

NOTE 

Lower the vehicle in suitable position and support bottom of engine sub-frame and transmission assy 

with hydraumatic jack securely. 

Page 1390


15A-7 

38. REMOVE SUB-FRAME RETAINING BOLTS. 

(a) 

Remove 5 retaining bolts securing sub-frame right side to 


(b) Left side is similar to the procedure above. Remove 5 

retaining bolts securing sub-frame left side to vehicle 

frame. 

NOTE 

Before removing sub-frame, mark the sub-frame to ensure 

align the reference line marked on the sub-frame with 

retaining bolts when installing 

15A 

39. SEPARATE PROPELLER SHAFT FROM TRANSMISSION ASSY. (Refer to “Chapter 34 axle and 

propeller shaft - prepeller shaft, overhaul”) 

40. REMOVE TRANSMISSION MOUNT. 

(a) Remove the retaining nut securing transmission mount to 


(b) 

After supporting the rear of transmission to a suitable 

height with jack, pull out the retaining bolt to separate the 

transmission mount from the vehicle frame. 

15A 

15A 

41. LOWER THE JACK SLOWLY TO SEPARATE ENGINE SUB-FRAME AND TRANSMISSION ASSY 

FROM VEHICLE FRAME. 

NOTE 

• Verify all vacuum hoses, fuel and coolant hoses, electrical connectors between engine/ 

transmission and vehicle are disconnected. 

• Lower engine about 150 mm slowly. verify all components between the engine/transmission and 

vehicle are disconnected again. 

42. SEPARATE ENGINE ASSY FROM TRANSMISSION ASSY. (Refer to “Chapter 41 transmission - 

transmission assy, replacement”) 

43. DISCONNECT HIGH PRESSURE AND LOW PRESSURE FLUID PIPES FROM POWER STEERING 

PUMP. (Refer to “Chapter 52 power steering - power steering link assy, replacement”) 

44. FIT ENGINE HOOK AND HANG ENGINE ASSY WITH A HOIST. 

45. REMOVE ENGINE MOUNTS ON BOTH SIDES OF 

ENGINE. 

(a) 

(b) 

Remove retaining nut securing left engine mount to subframe 

and separter them. 

Remove right engine mount, the procedure is similar to 

the left side. 

46. HOIST ENGINE UP AND SEPARATE ENGINE FROM SUB-FRAME. 

Page 1391

15A-8 


47. INSTALL ENGINE MOUNTS ON BOTH SIDES OF 

ENGINE. 

(a) 

(b) 

(c) 

Aligning the engine mount bracket with engine mount 

stud, lower and position engine onto sub-frame. 

Tighten retaining nut securing left engine mount to subframe. 

Tighten retaining nut securing right engine mount to subframe. 


48. CONNECT HIGH PRESSURE AND LOW PRESSURE FLUID PIPES TO POWER STEERING PUMP. 

(Refer to “Chapter 52 power steering - power steering link assy, replacement”) 

49. CONNECT TRANSMISSION TO ENGINE ASSY. (Refer to “Chapter 41 transmission - transmission 

assy, replacement”) 

50. POSITION THE HYDRAULIC JACK SUPPORTING ENGINE SUB-FRAME AND TRANSMISSION 

ASSY BENEATH THE VEHCLE. 

51. RAISE THE HYDRAULIC JACK UNTIL THE SUB-FRAME MOUNTING PIN WAS FULLY SEATED 

INTO THE VEHICLE FRAME AND TARANSMISSION MOUNT IS IN RIGHT PLACE. 

NOTE 

• Lift up the hydraulic jack slowly, make sure there is no interference with vehicle during raising 

the engine and transmission assy. 

• During raising slowly, handle lower control arm, steering tie rod and shock absorber related 

position with vehicle avoid interference. 

52. INSTALL SUB-FRAME RETAINING BOLTS. 

(a) Install 5 retaining bolts securing sub-frame left side to 


Torque: 150 ~ 170 N.m 

(b) Install 5 retaining bolts securing sub-frame right side to 


NOTE 

Align the mark on sub-frame while installation. 

53. INSTALL RETAINING NUT SECURING TRANSMISSION 

MOUNT TO VEHICLE FRAME. 

Torque: 126 ~ 154 N.m 

Page 1392


15A-9 

54. REMOVE GENERATOR RETAINING BOLTS AND 

SEPARATE GENERATOR FROM BRACKET. 

(a) 

(b) 

(c) 

(d) 

Connect left front shock absorber to lower control arm. 

(Refer to “Chapter 31 front suspension - front shock 


Connect left front stabilizer bar to lower control arm. 



Connect left front stabilizer bar to lower control arm ball 

joint seat. (Refer to “Chapter 31 front suspension - lower 

control arm, replacement”) 

Connect left front steering tie rod to the steering knuckle 

arm.(Refer to “Chapter 52 power steering - power 

steering link assy, replacement”) 

15A 

55. INSTALL RIGHT FRONT SUSPENSION UNIT. 

NOTE 


56. INSTALL 2 FRONT WHEEL. (Refer to “Chapter 33 wheel and tire - wheel, replacement”) 

57. INSTALL STEERING DRIVE SHAFT ASSY II. 

(a) Install steering drive shaft assy II. 

(b) Tighten retaining bolts on both sides of steering drive 


15A 

15A 

NOTE 

When installing steering drive shaft assyII, make sure steering 

wheel is in the center and front wheel stands straight 

ahead of the vehicle. 

58. INSTALL CATALYTIC CONVERTER. (Refer to“Chapter 16A exhaust - exhaust pipe, 


59. CONNECT PROPELLER SHAFT TO TRANSMISSION ASSY. (Refer to “Chapter 34 axle and 


60. INSTALL TRANSMISSION FLEXIBLE SHAFT ASSY. 

(a) Install locking nuts and locking clips securing transmission 

flexible shaft to transmission shift mechanism. 

(b) Tighten 2 clamp retaining bolts securing flexible shaft 

assy to sub-frame. 

Page 1393

15A-10 


61. INSTALL CLUTCH SLAVE CYLINDER. 

(a) 

Tighten 2 clutch slave cylinder retaining bolts. 

62. CONNECT VSS AND BACK-UP LAMP SWITCH 

HARNESS CONNECTOR. 

63. CONNECT ENGINE WATER INLET HOSE. 

64. INSTALL A/C PIPES TO COMPRESSOR. 

(a) Tighten mounting nuts securing high pressure and low 

pressure pipes to compressor. 


NOTE 

Always replace O-ring with new one. 

65. CONNECT STARTER POSITIVE CABLE. 

66. CONNECT GROUND CABLE TO ENGINE BLOCK. 

Page 1394


15A-11 

67. CONNECT WATER OUTLET HOSE TO REAR HEATER. 

15A 

68. CONNECT WATER INLET HOSE TO REAR HEATER. 

69. INSTALL THROTTLE CABLE TO THE THROTTLE 

BODY. 

70. CONNECT CANISTER SOLENOID VALVE HOSE. 

71. CONNECT RETURN TUBE TO FUEL INJECTOR RAIL 

ASSY. 

15A 

72. CONNECT VACCUM BOOSTER HOSE TO INTAKE 

MANIFOLD. 

15A 

73. CONNECT FEED PIPE TO FUEL INJECTOR RAIL 

ASSY. 

NOTE 



are secure. 

74. CONNECT ENGINE WATER OUTLET HOSE, THEN 

TIGHTEN CLAMP. 

75. CONNECT WATER OUTLET AND WATER INLET HOSES 

TO REAR HEATER, THEN TIGHTEN CLAMPS. 

Page 1395

15A-12 


76. CONNECT GENERATOR POSITIVE CABLE. 

77. INSTALL ENGINE ECM HARNESS. 

(a) Route the engine electrical harness throuth the mounting 

hole into ECM compartment. 

(b) Connect ECM connector and other 2 electrical connectors. 

(c) 

(d) 

Fasten the tie securing engine harness to cowl panel. 

Press the rubber grommet into place. 

78. INSTALL INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and 


79. ADD POWER STEERING FLUID TO SPECIFIED LEVEL. (Refer to “Chapter 52 power steering - 

steering fluid, replacement”) 

80. INSTALL ENGINE COMPARTMENT COVER UNDER 


(a) Tighten 5 engine compartment cover retaining bolts. 

(b) Cover front floor covering. 

Page 1396


15A-13 

81. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat, 




84. FILL ENGINE OIL. (Refer to “Chapter 18A lubricantion - engine oil, replacement”) 

85. FILL TRANSMISSION FLUID. (Refer to “Chapter 41 transmission - transmission assy, replacement”) 

86. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioner - refrigerant, replacement”) 

15A 

15A 

15A 

Page 1397

15A-14 

ENGINE MECHANICAL - TIMING PULLEY CASING 

TIMING PULLEY CASING 

REPLACEMENT 

1. Switch off the ignition. 

2. Disconnect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement") 

3. Remove the ignition coil and the spark plug cable. (refere to "Chapter 19A. Ignition - ignition 

module, high voltage cable, spark plug, overhaul") 

4. Remove the retaining bolts on the front upper cover 

of the toothen timing belt and then the cover. 

5. Remove the engine accessory belt. (Refer to "Chapter 15A. Engine mechanical system - engine 

accessory belt, overhaul") 

6. Remove the retaining bolts on the front middle cover 


7. Remove the retaining nuts of the water pump belt 

pulley and then the pulley. 

Page 1398


15A-15 

8. Remove the retaining nuts of the crank crankshaft 

damper wheel and then the pulley. 

15A 

9. Remove the retaining bolts on the front lower cover 


15A 

15A 

10. Clean the interior of the toothed timing belt front cover and the impurities at the side. 

11. Install the front lower cover of the toothed timing belt 

and tighten the retaining bolts. 

Torque: 11N·m 

Page 1399

15A-16 


12. Install the crank shock absorption belt pulley and 

tighten the retaining bolts. 

Torque: 25 N·m 

13. Install the water pump belt pulley and tighten the 

retaining nuts. 


14. Install the front middle cover of the toothed timing 

belt and tighten the retaining bolts. 


15. Install the engine accessory belt. (Refer to "Chapter 15A. Engine mechanical system - engine 


16. Install the front upper cover of the toothed timing 

belt and tighten the retaining bolts. 

Torque: 18 ~ 26N·m 

Page 1400


15A-17 

17. Install the ignition coil and the spark plug cable. (refere to "Chapter 19A. Ignition - ignition 

module, high voltage cable, spark plug, overhaul") 

18. Connect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement") 

15A 

15A 

15A 

Page 1401

15A-18 

TIMING BELT 

COMPONENTS 

ENGINE MECHANICAL - TIMING BELT 

1 Front Lower Cover of Timing Belt 

2 Front Middle Cover of Timing Belt 

3 Front Upper Cover of Timing Belt 

4 Toothed Camshaft Belt Pulley 

5 Harness Bracket 

6 Timing Belt 

7 Tensioner 

8 Tensioner Arm 

9 Timing Belt B Tensioner 

10 Balancing Shaft Belt Pulley 

11 Timing Belt B 

12 Flange 

13 Idler 

14 Crank TImming Belt Pulley B 

15 Crank Timing Belt Pulley Gasket 

16 Oil Pump Belt Pulley 

17 Crank TImming Belt Pulley 

18 Automatic Tensioner 

Page 1402


15A-19 

OVERHAUL 

1. Disconnect negative battery cable. (Refer to "Chapter 20. Start & charge - battery, replacement") 

2. Remove the engine harness. 

3. Remove the engine accessory belt. (Refer to "Chapter 15A. Engine mechanical system - engine 


4. Remove the front cover of toothed engine timing belt. (Refer to "Chapter 15A. Engine 

mechanical system - toothed timing belt casing, replacement") 

5. Mark down the rotation direction of the toothed 

timing belt to faciliate installation. 

15A 

6. Turn and align the crank to the timing mark: 

15A 

15A 

(a) 

Align the timing mark of the toothed camshaft belt pulley. 

Page 1403

15A-20 


(b) 

Align the timing mark of the toothed oil pump belt pulley. 

(c) 

Align the timing mark of the toothed crankshaft belt 

pulley. 

7. Use a specific tool to screw into the threaded hole, 

until the pin can be inserted into the locking hole on 

the automatic tensioner. 

8. Insert the pin into the locking hole on the automatic 

tensioner. 

Page 1404


15A-21 

9. Remove the retaining bolts of the automatic 

tensioner and then the tensioner. 

15A 

10. Check the automatic tensioner: 

(a) Check whether there is damage or leakage on the automatic tensioner and replace it if necessary. 

(b) Check whether there is wear or damage on the rod end and repalce it if necessary. 

(c) Measure the protrusion on the top of the automatic 

tensioner. If not qualified, replace it. 

Standard: 12 mm 

15A 

15A 

(d) 

Press the rod down in 98~196N while measuring the 

movement. If the value is 1mm less than Item 3) or 

above, replace the tensioner. 

Standard: ≤ 1mm 

Page 1405

15A-22 


(e) 

Hold the tensioner with vise with soft jaws. Turn the plier 

handles and push the tensioner rod into it. If it can be 

easily inserted, replace the tensioner. You shall feel 

certain resistance during the process. 

CAUTION 

There is a protruded plug at the bottom of the automatic 

tensioner. Insert a flat pad between the pliers and the plug 

to prevent them from touching each other. 

11. Loose the retaining bolts of the tensioner and then 

the toothed timing belt. 

12. Remove and check the toothed timing belt. Replace it in case of any of the following damages: 

CAUTION 

• Water or grease on the belt teeth will quickly reduce its useful life. Therefore, after removal, 

protect the belt teeth, the toothed belt pulley and the tensioner from water or grease. Do not 

clean these parts. In case of heavy contamination, replace it with a new one. 

• If any water or grease is found on the parts, check whether there is any leakage on the front 

cover oil seal, the crankshaft oil seal and water pump. 

(a) 

Aged and shiny rubber on the back, showing no nail 

scratch. 

Page 1406


15A-23 

(b) Cracked or peeled canvas. 

(c) Cracked rubber on the back. 

(d) Cracked belt tooth at the bottom. 

(e) Cracked belt tooth on the side. 

15A 

(f) 

Unusual tear and wear on the side of the belt. If the side 

of the tooth belt is as neat as cut, it is normal. 

(g) 

(h) 

Unusal tear wear of the toothed belt. 

Missing tooth. 

15A 

15A 

13. With a tool, remove the retaining bolts of the toothed 

camshaft belt pulley and then the pulley. 

14. Remove the toothed oil pump belt pulley: 

(a) 

Remove the plug at the side of the cylinder. 

Page 1407

15A-24 


(b) 

Insert a screwdriver to fix the left balancing shaft. 

Remove the toothed oil pump belt pulley nuts and then 

the pulley. 

(c) Remove the toothed oil pump belt pulley. 

15. Remove the toothed crank timing belt pulley: 

(a) Fix the flywheel with a tool. 

(b) 

Remove the retaining bolts of crank shock absorption 

belt pulley and toothed crank timing belt pulley, and then 

the crank shock absorption belt pulley. 

(c) 

Remove the toothed crank timing belt pulley. Use a tool 

in case of difficulty. 

Page 1408


15A-25 

16. Remove the retaining bolts of the tensioner arm and 

then the arm. 

15A 

17. Mark down the rotation direction of the toothed 

balancing shaft belt to faciliate installation. 

CAUTION 

• Water or grease on the belt teeth will quickly reduce 

its useful life. Therefore, after removal, protect the 

belt teeth. the toothed belt pulley and the tensioner 

from water or grease. Do not clean these parts. In 

case of bad contamination, replace it with a new one. 

• If any water or grease is found on the parts, check 

whether there is any leakage on the front cover oil 

seal, the crankshaft oil seal and water pump. 

18. Align the timing mark of the toothed balancing shaft 

belt pulley. 

15A 

15A 

(a) 

Align the timing mark of the toothed balancing shaft belt 

pulley. 

Page 1409

15A-26 


(b) 


pulley. 

19. Loose the retaining bolts of the toothed balancing 

shaft belt tensioner and then the toothed timing belt 

20. Remove and check the toothed balancing shaft belt. Replace it in case of any of the following 

damages: 

CAUTION 

Check all parts of the toothed belt carefully and replace it in case of the following damages. 

(a) 

Aged and shiny rubber on the back, showing no nail 

scratch. 

Page 1410


15A-27 

(b) 

(c) 

(d) 

(e) 

Cracked or peeled canvas. 

Cracked rubber on the back. 

Cracked belt tooth at the bottom. 

Cracked belt tooth on the side. 

15A 

(f) 



(g) 

(h) 

Unusal tear wear of the toothed belt. 


15A 

15A 

21. Fix the toothed balancing shaft belt pulley with a 

tool. 

22. Remove the retaining bolts of the toothed balancing 

shaft belt pulley and then the toothed balancing 

shaft belt pulley and sleeve. 

Page 1411

15A-28 


23. Remove the toothed timing belt pulley B. Use a tool 

in case of difficulty. 

24. Install the balancing shaft sleeve. 

CAUTION 

During installation, face the bevelled side towards the oil 

seal. 

25. Install the toothed crank timing belt pulley. 

26. Fix the toothed balancing shaft belt pulley with a tool 

and tighten the retaining bolts. 

Torque: 42 ~ 48 N·m 

Page 1412


15A-29 

27. Align the timing mark of the toothed balancing shaft 

belt pulley. 

15A 

(a) 

Align the timing mark of the toothed balancing shaft belt 

pulley. 

15A 

15A 

(b) 


pulley. 

Page 1413

15A-30 


28. Install the toothed balancing shaft belt pulley 

according to the rotation direction marked on the 

belt before disassembly. Do not allow loose part at 

the tension side. 

29. Push a finger against the toothed balancing shaft 

belt tensioner and impose a force along the arrow 

direction, while tightening the retaining bolts and 

fixing the tensioner. 


CAUTION 

When tightening the bolts, do not allow the shaft turning 

along with the toothed belt pulley, which will overly tension 

the belt. 

30. Confirm that the toothed belt pulley is aligned with 

the mark on the front cover. Press the center of the 

toothed timing belt B at the tensioner side, measured 

at 5 ~ 7 mm. 

31. Install the toothed crank timing belt pulley and the crank shock absorption belt pulley: 

(a) 

Fix the flywheel with a tool. 

Page 1414


15A-31 

(b) 

Install the toothed crank timing belt pulley and the crank shock absorption belt pulley. 

(c) 

Tighten the retaining bolts of the toothed crank timing 

belt pulley and the crank shock absorption belt pulley. 

Torque of toothed crank timing belt pulley bolts: 

165 N·m 

Torque of crank shock absorption belt pulley bolts: 

25N·m 

15A 

32. Install the toothed oil pump belt pulley: 

(a) 

Insert a screwdriver to fix the left balancing shaft. Install 

the toothed oil pump belt pulley and tighten the nuts. 


15A 

15A 

(b) 

Tighten the plug at the cylinder side. 

33. Install the tensioner arm and tighten the retaining 

nuts. 


34. Install the automatic tensioner: 

(a) If the automatic tensioner is in a protruding position, retract it in the following steps. 

Page 1415

15A-32 


(b) 

Hold the tensioner with a pair of pliers with soft jaws. 

CAUTION 

There is a protruded plug at the bottom of the automatic 

tensioner. Insert a flat pad between the pliers and the plug 

to prevent them from directly touching each other. 

(c) 

(d) 

With the pliers, slowly push in the rod until the hole is aligned to that on the tensioner. Insert the bolt into 

the holes. 

Loose the pliers and remove the automatic tensioner. 

35. Install the automatic tensioner and tighten the 



CAUTION 

Before adjusting the tension of the toothed timing belt, do 

not remove the bolt in the locking hole of the tensioner. 

36. Install the retaining bolts of the toothed camshaft 

belt pulley with a tool. 


Page 1416


15A-33 

37. Align the timing marks: 

15A 

(a) 

Align the timing mark of the toothed camshaft belt pulley. 

15A 

15A 

(b) 

Align the timing mark of the toothed oil pump belt pulley. 

Page 1417

15A-34 


(c) 


pulley. 

38. Insert a plus screwdriver into the hole. If it goes 

beyond 60 mm, it means that it is aligned to the 

timing mark. If the distance is less than 20~25mm, 

turn the toothed oil pump belt pulley around once 

and again align it to the timing mark. Check whehter 

it can go beyond 60mm. Keep the screwdriver 

inserted until the end of the belt installation. 

39. Install the toothed timing blet along the direction 

marked before. 

CAUTION 

Do not move the timing mark during the installation. 

40. Impose force to the tensioner along the arrow 

direction and temporarily tighten the retaining bolts. 

41. Check whether all timing marks are aligned. 

Page 1418


15A-35 

42. Pull out the inserted screwdriver from the cylinder 

body and tighten the cylinder plug. 


15A 

43. Turn 1/4 round of the crank counterclockwise and then turn it clockwise, until all timing marks 

are realigned. If the timing marks are unable to realign, reinstall the toothed timing belt until 

alignment is achieved. 

44. Equipped the tensioner belt pulley with the sleeve 

and wrench in the toolkit and loose the tensioner 

retaining bolts. 

CAUTION 

Or use a general torque wrench ranging from 0 to 3 N·m. 

15A 

15A 

45. Tighten the tensioner retaining bolts. 

Torque: 26 ~ 27N·m 

46. Press the toothed timing belt B tensioner by hand, 

along the arrow direction, while tightening the 



47. Turn the crank clockwise for two rounds and leave it 

for 15 minutes. Then check whether the retaining 

wire of the automatic tensioner can move freely. 

CAUTION 

If not, repeat Steps 3-4 until it moves. 

48. Remove the retaining bolts of the automatic tensioner. 

Page 1419

15A-36 


49. Measure the distance between the tensioner arm and 

the tensioner body. 

Standard: 3.8 ~ 4.5mm 

50. Install the engine timing casing. (Refer to "Chapter 15A. Engine mechanical system - engine 




52. Reconnect the engine harness. 

53. Connect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement") 

Page 1420

ENGINE MECHANICAL - ROCK ARM, ROCK ARM SHAFT, HYDRAULIC TAPPET & 

ROCK ARM, ROCK ARM SHAFT, HYDRAULIC TAPPET & 

CAMSHAFT 

COMPONENTS 

15A-37 

15A 

15A 

15A 

Page 1421

15A-38 


1 Rock Arm cover 

2 Rock Arm Cap Gasket 

3 Exhaust Rock Arm 

4 Intake Rock Arm 

5 Hydraulic Tappet 

6 Rock Arm Shaft Spring 

8 Intake Rock Arm Shaft 

9 Rock Arm Shaft Bolt 

10 O-ring 

11 Thrust Cap 

12 Camshaft 

13 Camshaft Oil Seal 

7 Exhaust Rock Arm Shaft 

Page 1422


15A-39 


HAUL 

1. Disconnect negative battery cable. (Refer to "Chapter 20: Start & Charge - Battery, 

Replacement") 

2. Remove the engine intake pipe. (Refer to "Chapter 14: Intake air - intake air pipe, replacement") 

3. Remove the engine accessory belt. (Refer to "Chapter 15A: Engine mechanical system - engine 


4. Loose the accelerator cable adjustment bolts on the 

throttle valve and remove the head clip and then the 

accelerate cable. 

15A 

5. Pull out the PCV valve hose on the rock arm cap. 

15A 

15A 

6. Remove the retaining bolts of heater pipe. 

Page 1423

15A-40 


7. Pull out the spark plug cable. 

8. Pull out the ignition coil connector. 

9. Unscrew the retaining bolts of the ignition coil. 

10. Remove the ignition coil and the spark plug cable assembly. 

CAUTION 

Before disconnecting the spark plug cable on the ignition coil, mark the cable positions of different 

cylinders on the coil, to faciliate installation. 

11. Remove the retaining bolts on the front upper cover 

of the toothen engine timing belt and then the cover. 

Page 1424


15A-41 

12. Remove the retaining bolts of the rock arm cap in 

numeric sequence. 

15A 

13. Remove the rock arm cap and the rock arm cap gasket. 

CAUTION 

The gasket is disposable and replace it with a new one before installation. 

14. Remove the oil seal. 

15A 

15A 

15. Remove the retaining bolts of the rock arm shaft in 


Page 1425

15A-42 


16. Before removing the rock arm and the rock arm shaft 

assembly, fix the hydraulic tappet with a tool, to 

prevent it from falling during the disassembly. 

17. Remove the rock arm shaft and the rock arm assembly. 

18. Remove the rock arm shaft spring and separate the rock arm from the rock arm shaft. 

19. Remove the hydraulic tappet. 

20. Check the rock arm: 

(a) Check the roller surface and replace the rock arm in case 

of any scratch or other damage. 

(b) Check whether the roller can rotate smoothly. If it's stuck 

or loose, replace the rock arm. 

(c) Check the inner diameter and replace the rock arm in 

case of any scratch or other damage. 

21. Check and clean the hydraulic tappet and replace it if any damage is detected: 

CAUTION 

• The hydraulic tappet is a precision component. No dust or impurity is allowed on the surface. 

• Do not disassemble the hydraulic tappet. 

• Clean the hydraulic tappet with clean diesel. 

(a) Prepare 3 containers and almost 5L diesel. Pull enough 

diesel into each container so that the tappet is fully 

immersed. Then follow the steps below. 

(b) 

Put the hydraulic tappet into Container A to clean its 

exterior. 

CAUTION 

Clear the hard impurities with a nylon brush. 

Page 1426


15A-43 

(c) 

Install a tool onto the hydraulic tappet and gently push 

the interior balls. Move the tappet plunger for 5-10 travels 

until it moves smoothly. In addition, it also eliminates the 

sliding resistance and the dirty grease. 

CAUTION 

• As the steel ball spring is particular soft, do not exert 

exceesive force when pushing it with an air-release 

metal wire, in order to avoid damaging the hydraulic 

tappet. 

• If the slide is blocked or the mechanical unit appears 

to be abnormal, replace the hydraulic tappet. 

(d) Take the hydraulic tappet from the container. Then gently 

push the ball and move the tappet plunger to remove 

diesel from the pressure vessel. 

15A 

15A 

(e) 

Install the tool onto the hydraulic tappet. Put it into 

Container B. With a tool, gently push the interior ball and 

move the tappet plunger for 5-10 travels, until it moves 

smoothly. This step cleans the pressure vessel of the 

hydraulic tappet. 

15A 

CAUTION 

As the steel ball spring is particular soft, do not exert 

exceesive force when pushing it with an air-release metal 

wire, in order to avoid damaging the hydraulic tappet. 

(f) 

Take the hydraulic tappet from the container. Then gently 

push the ball and move the tappet plunger to remove 

diesel from the pressure vessel. 

(g) 

Put it into Container C. And push the interior ball with a 

tool. 

CAUTION 

Do not clean the hydraulic tappet in Container C. Otherwise, 

contamination may get into the pressure vessel full of 

diesel. 

Page 1427

15A-44 


(h) 

Hold the hydraulic tappet vertically, with the tappet 

plunger at the top. Steady move the plunger downward 

up to its maximum travel. Then slowly move back the 

plunger. Release the ball so that the pressure vessel is 

full of diesel. 

(i) 

Remove the tool. 

(j) 

Take the hydraulic tappet from the container. Hold the 

hydraulic tappet vertically, with the tappet plunger at the 

top. Steady push the plunger and ensure it can no longer 

move. Compare its height to a new one. 

CAUTION 

If the height is reduced, repeat Steps 7-10 and fill the 

hydraulic tappet with diesel. If it is still lower after these 

steps, replace it. 

(k) 

Put the hydraulic acid on the tool. When the plunger is 

slightly lowered (0.2~0.5 mm), measure the time took for 

additional 1 mm. 

Standard: 3~20 seconds /1 mm (diesel at 15 ~ 20 ℃ ) 

CAUTION 

If unqualified, replace it. 

(l) 

Install the tool onto the hydraulic tappet. Put the 

hydraulic tappet into Container c again and gently push 

down the interior balls with a tool. Hold the hydraulic 

tappet vertically, with the tappet plunger at the top. 

Steady move the plunger downward up to its maximum 

travel. Then slowly move back the plunger. Release the 

ball so that the pressure vessel is full of diesel. 

(m) 

Remove the tool. 

(n) 

Take the hydraulic tappet from the container. Hold the 

hydraulic tappet vertically, with the tappet plunger at the 

top. Steady push the plunger and ensure it can no longer 

move. Compare its height to a new one. 

CAUTION 

If the height is reduced, repeat Steps 12-14 and fill the 

hydraulic tappet with diesel. If it is still lower after these 

steps, replace it. 

Page 1428


15A-45 

(o) Hold the hydraulic tappet vertically to prevent diesel from 

flowing out. Prevent dust or impurity from contaminating 

the hydraulic tappet. Install it onto the engine as soon as 

possible. 

• Insert the hydraulic tappet into the rock arm and 

make sure the diesel doesn't overflow. Then fix the 

hydraulic tappet with a tool to prevent it from falling 

during installation. 

• If the hydraulic tappet is reusable, clean it first. 

15A 

22. Install the rock arm onto the rock arm shaft. 

23. Temporarily tighten the air inlet rock arm with bolts until all rock arms no longer press the 

throttle valve. 

24. Install the rock arm shaft spring from the top and 

make sure it is vertical to the spark plug duct. 

CAUTION 

• Install the rock arm shaft spring and then tighten the 

air outlet rock arm bolts. 

• Align the oil hole on the rock arm shaft to the 

cylinder body, to ensure correct installation. 

15A 

15A 

25. Tighten the retaining bolts of the rock arm shaft in 



26. Remove the tools used to retain the hydraulic tappet. 

Page 1429

15A-46 


27. Ensure the notch on the rock arm shaft is located as 

illustrated. 

28. Install the oil seal. 

29. Install a new rock arm cap gasket. 

30. Install the rock arm cap. 

31. Tighten the retaining bolts of the rock arm cap in 


Torque: 4N·m 

Page 1430


15A-47 

32. Install the front upper cover of the toothed engine 

timing belt and tighten the retaining bolts. 

Torque: 4N·m 

15A 

33. Install the spark plug cable to the ignition coil. 

CAUTION 

Install the spark plug cable as marked. 

34. Install the ignition coil and tighten the retaining 

bolts. 

15A 

15A 

35. Install the ignition coil connector. 

36. Install the spark plug cable to the rock arm cap. 

Page 1431

15A-48 


37. Install the retaining bolts of heater pipe. 

38. Install the PCV valve hose to the rock arm cap. 

39. Install the accelerator cable head clip and tighten the 

bolts on the throttle valve. 

40. Install the engine accessory belt. (Refer to "Chapter 15A: Engine mechanical system - engine 


41. Install the engine intake pipe. (Refer to "Chapter 14: Intake air - intake air pipe, replacement") 

42. Connect battery negative cable. (Refer to "Chapter 20: Start & Charge - Battery, Replacement") 

Page 1432


15A-49 

CAMSHAFT OVERHAUL 

1. Remove the cylinder head. (Refer to "Chapter 15A: Engine mechanical system - cylinder head, 

throttle, cylinder head overhaul") 

2. Remove the retaining bolts of the toothed camshaft 

belt pulley with a tool. 

15A 

3. Remove the retaining bolts of the camshaft lock cap 

and then the cap. 

15A 

15A 

4. Pull out the camshaft. 

5. Check the camshaft: 

(a) 

(b) 

Check whether there is any corrosion, wear or crack on 

the surface of the camshaft. Replace it if any. 

Measure Camshaft Height 

Name Standard Limit 

Intake Cam 37.20mm 36.70mm 

Exhaust Cam 36.83mm 36.33mm 

6. Remove the camshaft oil seal. 

CAUTION 

Once removed, it is necessary to replace it with a new 

camshaft oil seal. 

Page 1433

15A-50 


7. Install the camshaft. 

8. Apply some engine oil on the outside of the camshaft oil seal lips and the front end. 

9. With a tool, install a new camshaft oil seal. 

10. Install a new camshaft lock cap O-ring. 

11. Install the camshaft lock cap and tighten the 



12. Install the toothed camshaft belt pulley and retaining 

bolts with a tool. 


13. Install the cylinder head. (Refer to "Chapter 15A: Engine mechanical system - cylinder head, 

throttle, cylinder head overhaul") 

Page 1434

CYLINDER HEAD,VALVE 

COMPONENTS 

ENGINE MECHANICAL - CYLINDER HEAD,VALVE 

15A-51 

15A 

15A 

15A 

1 Valve Spring Lock 

2 Upper Valve Spring Retainer 

3 Valve Spring 

4 Valve Oil Seal 

5 Valve Spring Retainer 

6 Valve Guide 

7 Vavle Seat 

8 Valve 

9 Cylinder Head 

10 Cylinder Head Gasket 

Page 1435

15A-52 


CYLINDER HEAD OVERHAUL 

1. Disconnect battery negative cable. (Refer to "Chapter 20. Start & Charge - Battery, 

Replacement") 

2. Drain coolant. (Refer to "Chapter 17A. Cooling - coolant, replacement") 

3. Remove the engine intake pipe. (Refer to "Chapter 14A. Intake air - intake air pipe, replacement") 

4. Remove the engine accessory belt. (Refer to "Chapter 15A: Engine mechanical system - engine 


5. Remove the toothed timing belt. (Refer to "Chapter 15A. Engine mechanical system - toothed 

timing belt, overhaul") 

6. Remove the rock arm and the rock arm shaft. (Refer to "Chapter 15A. Engine mechanical 

system - rock arm, rock arm shaft, hydraulic tappet & camshaft, rock arm, rock arm shaft & 

hydraulic tappet overhaul") 

7. Remove the retaining bolts of the cylinder head in 


CAUTION 

When loosing the bolts, exert evenl and gradual torque to 

ensure balanced force on the cylinder head. 

8. Remove the cylinder head and the cylinder head gasket. 

9. Clean the cylinder head and check whether there is crack or serious damage. Replace it if 

necessary. 

10. Check the evenness of the cylinder head bottom with 

a ruler and a feeler blade. In case of excessive 

deformation, polish it (both cylinder head and body) 

or replace it. 

Flatness Standard: 0.03 mm 

Flatness Limit: 0.2mm 

Correction Limit: 0.2mm 

11. Check the height of the cylinder head and replace it if unqualified. 

Standard: 119.9 ~ 120.1mm 

12. Install a new cylinder head gasket. 

DANGER 

It is important to correctly install the cylinder gasket, with the hole aligned to that on the cylinder 

surface, or it may lead to serious engine damage. 

13. Install the cylinder head and fix it until the dowel pin is installed. 

Page 1436


15A-53 

14. Before installing the cylinder head bolts, ensure the 

length is within the standard range and replace them 

out of limit. 

Standard: 97.4mm 

15A 

15. Tighten the retaining bolts of the cylinder head in the 

following steps and numeric sequence: 

CAUTION 

• Apply a proper amount of engine oil on the threaded 

part and gasket of the cylinder head bolts, to faciliate 

tightening. 

• In case of excess torque, loose the bolts completely 

and re-tighten them. 

15A 

15A 

(a) Tighten the retaining bolts of the cylinder head in numeric 

sequence. 


(b) Completely loose all bolts. 

(c) Tighten the cylinder head bolts. 


(d) Draw straight lines with paint, as marks on the bolt heads 

and the cylinder head. 

(e) Tighten the cylinder head bolts to 90° in the sequence of 

tightening. 

(f) Tighten the bolts to another 90° in the same sequence 

and ensure the mark on the bolt head is aligned to that 

on the cylinder head. 

16. Install the rock arm and the rock arm shaft. (Refer to "Chapter 15A. Engine mechanical system - 

rock arm, rock arm shaft, hydraulic tappet & camshaft, rock arm, rock arm shaft & hydraulic 

tappet overhaul") 

17. Install the toothed timing belt. (Refer to "Chapter 15A. Engine mechanical system - toothed 

timing belt, overhaul") 



19. Install the engine intake pipe. (Refer to "Chapter 14A. Intake air - intake air pipe, replacement") 

20. Fill the engine coolant. (Refer to "Chapter 17A. Cooling - coolant, replacement") 

21. Connect battery negative cable. (Refer to "Chapter 20. Start & Charge - Battery, Replacement") 

Page 1437

15A-54 


VALVE OVERHAUL 

1. Remove the cylinder head. (Refer to "Chapter 15A. Engine mechanical system - cylinder head, 

valve, cylinder head overhaul") 

CAUTION 

Mark the removed valve, valve spring and other parts with the cylinder number and installation 

position. Keep them well to ease installation. 

2. Use a appropriate tool to remove the valve lock and 

then the upper valve spring retainer, the valve spring 

and the valve spring shim. 

3. Remove the valve oil seal and then the valve. 

CAUTION 

The valve oil seal cannot be reused. 

4. Check the valve spring: 

(a) 

(b) 

Measure the free height of the valve spring. Replace it if 

below limit. 


Limit: 50.0mm 

Measure the uprightness of the central line of the spring 

to the bottom surface. Replace it if beyond limit. 

Standard: ≤ 2° 

Limit: 4° 

Page 1438


15A-55 

5. Check the valve: 

(a) 

Check whether the working surface of the valve and the valve seat is airtight. If not, polish it with a valve 

polisher. The contact surface of the valve seat shall be consistent with the center of the valve working 

face. 

(b) 

Check the thickness at the edge of the valve. Replace it if 

unqualified and polish it with a valve polisher: 

15A 

Thickness at 

Edge of Valve 

Standard 

Limit 

Intake 1.0mm 0.5mm 

Exhaust 1.2mm 0.7mm 

(c) 

Check the total height of the valve. Replace it if below 

limit: 

Total Valve 

Height 

Standard 

Limit 



15A 

15A 

6. Check the clearance between the valve guide and the 

valve rod. Replace either or both of them if beyond 

limit, until the clearance meets the requirement: 

Clearance Standard Limit 

Intake 0.02 ~ 0.05mm 0.10mm 

Exhaust 0.03 ~ 0.07mm 0.15mm 

7. Follow the steps to replace the valve guide: 

CAUTION 

Do not use a new valve guide of the same dimension as the removed one. 

(a) Heat the cylinder head and remove the valve seat. 

(b) With a tool, drive out the valve guide towards the lower surface of the cylinder head. 

(c) Treat the valve guide hole on the cylinder head so that the diameter meets the dimension of a larger 

guide: 

Diameter of Valve Guide Hole 

Larger 0.05mm 

Larger 0.25mm 

Larger 0.50mm 

11.05-11.068mm 

11.25-11.268mm 

11.50-11.518mm 

Page 1439

15A-56 


(d) 

Installl a new valve guide by pressing it down the top of 

the cylinder head until the protrusion part meets the 

requirement. 

Standard: 14 ± 0.3mm 

(e) 

CAUTION 

• Press down the valve guide from the top of cylinder 

head. 

• The guides of intake valve and exhaust valve are of 

different lengths (intake valve: 45.5mm; exhaust 

valve: 50.5mm). 

Once installed, insert a new valve and check whether it moves freely along the axis. 

8. Assemble the valve and measure the protruded 

height of the valve rod between the end of the rod 

and the valve spring retainer. Replace the valve seat 

if unqualified: 

Protruded Height Standard Limit 



9. Finish the valve seat: 

(a) Before finishing the valve seat, check the clearance 

between the valve guide and the valve rod. Finish it after 

replacement if necessary. 

(b) Finish the width and angle of the valve seat to the rated 

values with a grinder. 

(c) Once finished, polish the valve and the valve seat 

together with abrasive. Then measure the protruded 

height of the valve rod. 

Page 1440


15A-57 

10. Replace the valve seat: 

(a) Cut part of the valve seat to replace from inside and 

remove it. 

(b) Finish the valve seat hole on the cylinder head subject to 

the outer diameter of the larger valve seat. 

Diameter of valve seat: 

15A 

Intake Valve 

Exhaust Valve 

Larger Valve Seat 

Hole 

Larger 0.30mm 

Larger 0.60mm 

Larger 0.30mm 

Larger 0.60mm 

Diameter of Valve 

Seat 

34.435 ~ 34.455mm 

4.735 ~ 34.755mm 

31.935 ~ 31.955mm 

32.235 ~ 32.255mm 

(c) Before installing the valve seat, heat the cylinder head to 

250 ℃ , or chill the seat in liquid nitrogen, to avoid 

possible blockage inside the cylinder head. 

(d) With a valve seat miller, finish the seat to rated width and 

angle. 

11. Install the valve as marked during removal. 

12. Install the valve spring washer. 

13. Install a new valve oil seal with a tool. 

15A 

15A 

14. Install the valve spring. 

CAUTION 

When installing the valve spring, face the color-coded end towards the upper valve spring retainer. 

15. Install the upper valve spring retainer. 

Page 1441

15A-58 


16. With a tool, install the valve lock. 

17. Install the cylinder head. (Refer to "Chapter 15A. Engine mechanical system - cylinder head, 


Page 1442

ENGINE MECHANICAL - PISTON & CONNECTING ROD ASSEMBLY 

PISTON & CONNECTING ROD ASSEMBLY 

COMPONENTS 

15A-59 

15A 

15A 

15A 

1 1st Gas Ring 

2 2nd Gas Ring 

3 Oil Ring 

4 Piston Pin 

5 Connecting Rod 

6 Connecting Rod Bolt 

7 Piston 

8 Piston & Connecting Rod Assembly 

9 Upper Connecting Rod Bearing 

10 Lower Connecting Rod Bearing 

11 Connecting Rod Cap 

12 Nut 

Page 1443

15A-60 


PISTON & CONNECTING ROD ASSEMBLY OVERHAUL 

1. Remove the engine assembly. (Refer to "Chapter 15A. Engine mechanical system - engine 

assembly, replacement") 



3. Remove the oil tray. (Refer to "Chapter 18A. Lubrication - oil try, overhaul") 

4. Remove the engine oil strainer. (Refer to "Chapter 18. Lubrication - engine oil strainer, 

replacement") 

5. Mark the cylinder number on the larger side of the 

connecting rod to faciliate assembly. 

CAUTION 

Put down the connecting rod, the connecting rod cap and 

the connecting rod bearing in the order of the cylinder 

numbers, to avoid confusion. 

6. Remove the retaining bolts of the connecting rod cap 

in sequence. 

7. Gently knock out the piston & connecting rod 

assembly with a wooden or plastic stick. 

8. Separate the connecting rod bearing. 

Page 1444


15A-61 

9. Remove the piston pin with a tool: 

CAUTION 

Put down the piston, the piston pin and the connecting rod in the order of cylinder number, to avoid 

confusion. 

15A 

1 Push Rod 

2 Guide Block B 

3 Guide Block C 

4 Guide A 

5 Guide A 

6 Guide A 

7 Guide A 

8 Base 

15A 

(a) 

(a) 

Insert the push rod (special tool) into the piston from the 

side with arrow and attach the Guide Block C to the end 

of the push rod. 

15A 

(b) 

Keep the forward mark of the piston upward and install 

the piston & connecting rod assembly onto the base of 

the piston pin installer. 

(c) 

Press the piston pin out by force. 

10. Remove the 1st and 2nd gas rings and the oil ring. 

CAUTION 

• Clean the carbon residue on the surface of the piston and inside the gas ring, as well as the 

grease inside the oil ring. 

• Be careful not to scratch the piston surface. 

Page 1445

15A-62 


11. Check whether there is damage, over wear or crack on the piston ring and replace it if any. 

Replace the piston and the piston ring together. 

12. Check the side clearance between the piston ring 

and the groove. If the limit is exceeded, replace the 

ring or both the piston and the ring. 


Limit: 0.1mm 

13. Insert the piston ring into the cylinder. Put it into the 

correct position against the piston top and measure 

the end clearance of the piston ring with a feeler 

blade. 

Replace the ring if the end play exceeds the limit: 

1st Gas 

Ring 

2nd Gas 

Ring 

Oil Ring 

Standard 

0.25 ~ 

0.35mm 

0.40 ~ 

0.55mm 

0.10 ~ 

0.40mm 

Limit 0.8mm 0.8mm 1.0mm 

14. Check the oil clearance of the crankshaft pin with a 

plastigage: 

(a) Clear the engine oil on the connecting rod neck and 

bearing. 

(b) Cut the plastigauge into length as wide as the bearing. 

Lay the plastigauge across the crankshaft pin, parallel to 

its central axis. 

(c) Carefully install the connecting rod cap and tighten the 

nuts to its rated torque. 

(d) Carefully remove the connecting rod cap. 

Page 1446


15A-63 

(e) 

Using a measuring ruler imprinted on the plastigauge 

package, measure the width of the widest part of the 

plastigauge and calculate the clearance value. 


Limit: 0.1mm 

15A 

15. Install the piston pin: 

(a) 

(b) 

(c) 

Measure the following dimensions of the piston, the 

piston pin and the connecting rod: 

A: Length of piston pin in hole 

B: Width of pin socket 

C: Length of piston pin 

D: Width of connecting rod at smaller end 

Put the measurements into the following formula to 

calculate L. L = [(A - C) - (B - D)] / 2 

After inserting the push rod into the piston pin, install 

Guide A at the end of the push rod. 

15A 

15A 

(d) 

Install the piston and the connecting rod with both 

forward marks in the same direction. 

(e) 

(f) 

Lubricate the external diameter of the piston pin with engine oil. 

Once assembled in Step 3, insert the push rod, piston pin and guide assembly into the piston pin hole 

from the side with the forward mark. 

Page 1447

15A-64 


(g) 

Screw the Guide Block B into Guide A so that the 

clearance between Guide Block A and Guide Block B 

equals to L (L=((A-C)-(B-D)) / 2) plus 3 mm. 

(h) 

(i) 

Keep the forward mark of the piston upward and install 

the piston & connecting rod assembly onto the base of 

the piston pin installer. 

Press the piston pin in by force. If the force is below the 

standard, replace the piston pin and the piston assembly, 

or the connecting rod. 

Standard: 7500 ~ 17500N 

16. Once installed, check whether the piston and the 

connecting rod move freely. 

Page 1448


15A-65 

17. Install the oil ring: 

CAUTION 

• There is no difference between the upper and lower 

sides of the oil ring scraper and the main ring. 

• The new ring and oil ring scraper are color-coded to 

identify their dimensions. 

15A 

Dimension 

Standard 

Larger 0.50mm 

Larger 1.00mm 

Color Code 

N/A 

Red 

Yellow 

18. Install the 1st and 2nd gas rings: 

(a) 

(b) 

Install the main oil ring. 

Put the upper scraper in. During the installation, press 

one end of the scraper into the piston oil ring groove and 

press the remaining part into the groove with your thumb, 

as illustrated. 

CAUTION 

Do not install the scraper with a pair of piston ring pliers, 

which may break the scraper. 

(c) Install the lower scraper in the same process of Step 2. 

(d) Check whether the installed ring can rotate freely. 

(a) 

Install the 1st gas ring after the 2nd gas ring, with a pair 

of piston ring pliers. 

CAUTION 

During installation, turn the mark upward to the top of the 

piston. 

15A 

15A 

(b) 

There are identification marks at the opening of the gas 

ring. 1st gas ring: 1R, 2nd gas ring: 2R. 

The dimension marks are follows: 

Dimension 

Standard 

Dimension Mark 

N/A 

Larger 0.50 mm 50 

Larger 1.00 mm 100 

Page 1449

15A-66 


19. Adjust the opening directions of the gas rings and the oil ring: 

(a) 

Lubricate the piston ring groove, the gas rings and the oil ring with clean engine oil. 

(b) 

Adjust the openings of the gas rings and the oil ring to 

the position shown. 

1 Oil ring scraper opening 

2 Piston pin position 

3 Oil ring lower scraper opening 

4 

Sleeve ring and 2nd gas ring 

opening 

5 1st gas ring opening 

6 Crankshaft belt pulley side 

20. Turn the crankshaft so that the crankshaft pin is at the center of the cylinder. 

21. Before inserting the piston & connecting rod assembly into the cylinder block, take proper 

threat protection on the connecting rod bolts. Be careful not to damage the crankshaft pin. 

22. During installation, confirm the dot (forward mark) 

on the top of the piston faces the side of the toothed 

timing belt. 

23. Use a proper piston ring compression tool to install 

the piston & connecting rod assembly. 

CAUTION 

• When putting the assembly into the cylinder, be 

careful not to damage the crankshaft pin with the 

connecting rod cap bolts. 

• During the installation, gently press down the 

assembly with a wooden or plastic tool, without 

overly force, or it may break the piston ring or 

crankshaft pin. 

24. To replace the connecting rod bearing, choose and install it as follows: 

Page 1450


15A-67 

(a) 

Measure the outer diameter of the crankshaft pin, identify 

the dimensions with different paint colors as illustrated, 

and group them subject to the table below. 

15A 

(b) 

The identification mark of the connecting rod bearing is 

shown as followes: 

Crankshaft Pin 

Connecting Rod 

Bearing 

ID No. Dimension (mm/in) Mark 

I 44.995 ~ 45.000 1 

II 44.985 ~ 44.995 2 

III 44.980 ~ 44.985 3 

15A 

15A 

Inner diameter of connecting rod: 48.000 ~ 48.015mm 

(c) 

If the outer diameter of the crankshaft pin is marked as "1", for example, pick up the bearing marked as 

"1" as well. If there is no mark on the crankshaft, measure the outer diameter of the pin and pick up a 

connecting rod bearing with the matching bear ("1"). 

25. Install the connecting rod cap subject to the marks 

made during disassembly. If it a new connecting rod 

without combination mark, install the grooves of the 

upper bearing and the lower bearing on the both 

sides as illustrated. 

Page 1451

15A-68 


26. Measure the axial clearance of the connecting rod at 

the larger end with a feeler blade. 


Limit: 0.4mm 

27. Install the connecting rod nuts: 

CAUTION 

Before the installation, if the cylinder head is already in place, remove the spark plug first and install 

the connecting rod cap nuts. 

(a) Use plastic zone torque technique on the connecting rod bolts and nuts. Check whether there is any 

stretch in the bolt before reuse. 

CAUTION 

How to check: Tighten the nut along the thread of the bolt up to the full length. If the nut cannot be 

tightened smoothly, it means that the threaded part of the bolt might be stretched. Replace the bolt. 

(b) Lubricate the threaded part of the nuts and the surface with engine oil, before tightening the nuts. 

(c) Install each nut to the bolt and tighten it by hand. Then tighten the nuts alternately to install the cap 

properly. 

(d) Tighten the nuts for the first time. 


(e) Make a paint mark on the head of each nut. 

(f) Make a paint mark on the bolt at the position 90° ~ 100° 

from that made on the nut in the direction of tightening. 

(g) Turn additional 90° ~ 100° to the nut and make sure that 

the paint mark on the nut and that on the bolt are in 

alignment. 

CAUTION 

• If the nuts are tightened less than 90°, they may not 

hold the caps with sufficient strength. Pay attention 

to the angle during tightening. 

• If a nut is tightened exceeding 100°, completely 

remove all nuts and carry out the installation 

procedure again from Step 1. 

28. Install the engine oil strainer. (Refer to "Chapter 18. Lubrication - engine oil strainer, 

replacement") 

29. Install the oil tray. (Refer to "Chapter 18A. Lubrication - oil try, overhaul") 



31. Install the engine assembly. (Refer to "Chapter 15A. Engine mechanical system - engine 


Page 1452

ENGINE MECHANICAL - CRANKSHAFT, CYLINDER BLOCK & FLYWHEEL 

CRANKSHAFT, CYLINDER BLOCK & FLYWHEEL 

COMPONENTS 

15A-69 

15A 

15A 

15A 

1 Cylinder Block 

2 Crankshaft Rear Oil Seal Cap 

3 Crankshaft Rear Oil Seal 

4 Crankshaft Thrust Bearing 

6 Crankshaft 

7 Lower Crankshaft Bearing 

8 Main Bearing Cap 

9 Main Bearing Cap Bolt 

5 Upper Crankshaft Bearing 

Page 1453

15A-70 


1 Flywheel Bolt 

2 Ball Bearing 

3 Flywheel 

4 Rear Cover 

5 Bell Housing 

6 Crankshaft Rear Oil Seal 

7 Crankshaft Rear Oil Seal Cap 

8 Cylinder Block 

Page 1454


15A-71 

OVERHAUL 

1. Remove the engine assembly. (Refer to "Chapter 15A. Engine mechanical system - engine 




3. Fix the engine cylinder block onto the flip frame for disassembly. 

4. Remove the oil tray. (Refer to "Chapter 18A. Lubrication - oil try, replacement") 

5. Remove the retaining bolts and nuts of the engine oil 

strainer and then the strainer. 

15A 

6. Remove the retaining bolts of the engine oil pump 

front cover and then the cover. 

15A 

15A 

7. Fix the flywheel with a tool. 

Page 1455

15A-72 


8. Remove the retaining bolts of the flywheel in 

numeric order and then the flywheel. 

9. Remove the retaining bolts then the cover. 

10. Remove the crankshaft rear oil seal. 

Page 1456


15A-73 

11. Remove the retaining bolts of the crankshaft rear oil 

seal cap and then the cap. 

15A 

12. Flip over the engine so that the oil tray faces upward. 

13. Remove the retaining bolts of the crankshaft main 

bearing cap in numeric sequence. 

15A 

15A 

14. Remove the crankshaft main bearing cap and disassemble the lower crankshaft bearing. 

15. Remove the crankshaft and measure the crankshaft 

oil clearance with a plastgage: 

(a) 

(b) 

(c) 

(d) 

(e) 

Clear the oil on the surface of the crankshaft neck and 

inside the crankshaft. 

Install the crankshaft. 

Cut a piece of plastigage of the same width as the 

bearing and put it on the crankshaft neck, parallel to the 

latter. 

Carefully install the crankshaft main bearing cap and 

tighten the bolts to the rated toque. 

Torque: 25N•m+90° ~ 100° 

Remove the retaining bolts of the crankshaft main 

bearing cap and then the cap carefully. 

Page 1457

15A-74 


(f) 

Use the scale imprinted on the plastigauge package to 

measure the width of the widest part of the plastigauge. 


Limit: 0.1mm 

16. Remove the crankshaft and the bearing. 

17. Take the engine block assembly from the flip frame 

and inspect: 

(a) Check for scratches, rust, and corrosion, visually or with 

flaw detecting agent. If defects are evident, correct or 

replace it. 

(b) Use a straightedge and a feeler gauge to check the block 

top surface for warpage. Make sure that the surface is 

free from gasket chips and other impurities. 


Limit: 0.1mm 

(c) If the warpage is excessive, correct within the allowable 

limit or replace. 

Grinding limit: 0.2mm 

Max. sum of cylinder block and cover to grind off: 

0.2mm 

Block height (new part): 284mm 

(d) The cylinder walls should be checked for scratch or other 

damage. Finish or replace it if apparent. 

(e) Measure the inner diameter and cylindricity of the 

cylinder with a cylinder bore. In case of heavy wear, 

finish the cylinder to a greater dimension or replace the 

piston and the ring with matching dimensions. 

Item 

Inner Diameter of Cylinder 

Cylindricity 

Standard 

87mm 

≤ 0.01mm 

CAUTION 

Choose the diameter of the larger piston subject to the 

maximum cylinder diameter. 

Dimension 

Mark 

Larger 0.50mm 0.50 

Larger 1.00mm 1.00 

Page 1458


15A-75 

(f) 

(g) 

Measure the outer diameter of the piston to use, in the 

thrust direction as shown. 

Follow the above measurement to calculate cylinder bore 

dimension: 

Cylinder bore dimension = Outer diameter of piston 

+ (clearance between piston and cylinder) - 0.02 mm 

(grinding volume) 

15A 

CAUTION 

In case of finishing, finish four cylinders to the same 

dimension. 

(h) Finish the diameters of the cylinders to the said 

dimension. 

CAUTION 

During finishing, to avoid possible error caused by rising 

temperature, perform the operations in the following order: 

No.2 -> No.4 -> No.1 -> No.3 

(i) Finish it to the final diameter (piston diameter + 

clearance between piston and cylinder). 

(j) Check the clearance between the piston and the 

cylinder. 


18. Flip over the cylinder block onto the engine stand so that the oil tray faces upward. 

15A 

15A 

19. Pick up a suitable crankshaft bearing subject to the table below: 

Combination of Crankshaft Main Neck and Shaft Bore 

Crankshaft Main Neck 

Group Mark Outer Dia. (mm) 

Mark of Main 

Bore 

Mark of Neck 

Bearing 1, 2, 4 & 

5 

Mark of Neck 

Bearing 3 

0 1 0 

I 0 56.994 ~ 57.000 

1 2 1 

2 3 2 

0 2 1 

II 1 56.988 ~ 56.994 

1 3 2 

2 4 3 

Page 1459

15A-76 


0 3 2 

III 2 56.982 ~ 56.988 

1 4 3 

2 5 4 

For example: 

(a) If the outer diameter mark the crankshaft neck is "0" and that of the bearing bore is “1”, choose No. 1, 2, 

4 or 5 bearing marked as “2” and No.3 bearing marked as “1”. 

(b) 

If there is no mark on the crankshaft, measure the neck and pick up a matching bearing subject to the 

measurement. 

20. Install the thrust bearing as follows: 

(a) Install the bearing with groove at the cylinder block side. 

(b) Install the bearing without groove at the bearing cap side. 

(c) Install the crankshaft thrust bearing at the position of the 

No.3 main bore of the cylinder block. Lubricate the 

surface of the thrust bearing with some engine oil to 

faciliate installation. 

21. Install the crankshaft main bearing cap. 

CAUTION 

The arrow on the cap points to the side of the toothed 

timing belt. 

22. Install the crankshaft bearing cap bolts as follows: 

(a) Before tightening the retaining bolts of the bearing cap, 

measure the length of the bolts first. If beyond limit, 

replce them. 

Limit: 71.1mm 

(b) Lubricate the threaded part and surface of the bolts with 

engine oil. 

Page 1460


15A-77 

(c) 

Tighten the retaining bolts of the crankshaft main bearing 

cap in numeric sequence. 


15A 

(d) 

(e) 

(f) 

Mark the bolt heads with paint. 

Make a paint mark on the area around the bolt bearing 

surface at the position of 90° ~ 100° in the direction of 

tightening. 

Turn additional 90° ~ 100° to the bolts and make sure 

that the paint mark on the bolts and that on the cover are 

in alignment. 

15A 

15A 

CAUTION 

• If the nuts are tightened less than 90°, they may not 

hold the caps with sufficient strength. So pay 

attention to the angle during tightening. 

• If a bolt is tightened exceeding 100°, completely 

remove all bolts and carry out the installation 

procedure again from Step 1. 

23. After installation, check whether the crankshaft 

rotates freely as well as the axial clearance. If 

beyond limit, replace the bearing. 


Limit: 0.25mm 

Page 1461

15A-78 


24. Install the crankshaft rear oil seal with a tool. 

25. Install the crankshaft rear oil seal cap. 

CAUTION 

• Before installation, clear the impurities on the suface of the cap without scratching the surface. 

• Apply the sealant (Mistubishi MD970389) or comparable alternative to the surface of the oil seal 

cap. 

• Quickly install the rear oil seal cap in 15 minutes, before the sealant is dried. 

• After installation, keep the sealed parts away from lubricant and coolant for around 1 hour. 

26. Install the rear cover and tighten the retaining bolts. 


27. Install the flywheel and lock it with a tool. 

Page 1462


15A-79 

28. Tighten the retaining bolts of the flywheel in numeric 

sequence. 


15A 

29. Install the engine oil pump front cover and tighten 

the retaining bolts. 


15A 

15A 

30. Install the engine oil strainer and tighten the 


Nut torque: 19N·m 

Bolt torque: 19N·m 

31. Install the oil tray. (Refer to "Chapter 18A. Lubrication - oil try, replacement") 



33. Install the engine assembly. (Refer to "Chapter 15A. Engine mechanical system - engine 


Page 1463

MEMO 

Page 1464

EXHAUST SYSTEM 

EXHAUST PIPE ...............................................................................16A-1 

PRECAUTION............................................................................ 16A-1 

REPLACEMENT ........................................................................ 16A-2 

EXHAUST MANIFOLD.....................................................................16A-6 

REPLACEMENT ........................................................................ 16A-6 

36 

36 

36 

36 

36 

36 

36 

36 

16A 

Page 1465

Page 1466

EXHAUST - EXHAUST PIPE 

16A-1 

EXHAUST PIPE 

PRECAUTION 

1. BEFORE REMOVING MOUNTING RUBBER, ALWAYS APPLY A SMALL AMOUNT OF GREASE TO 

MOUNTING RUBBER FOR REMOVING OR INSTALLING EASILY. 

2. WHEN INSTALLING EXHAUST PIPE, ALWAYS USE NEW RING GASKET OTHERWISE GAS 

LEAKAGE WILL PRESENT. 

3. AFTER A LONG-TIME USED, THE EXHAUST PIPE GASKET WILL BE ADHERED TO EXHAUST 

PIPE. AFTER REMOVING THE MUFFLER, USE THE SCRAPER TO CLEAN THE SURFACE OF 

EXHAUST PIPE AND REPLACE WITH A NEW GASKET TO AVOID EXHAUST LEAKAGE. 

16A 

16A 

16A 

Page 1467

16A-2 


REPLACEMENT 


NOTE 

Exhaust pipe is a high temperature part. Never work around or attempt to service any parts of the 

exhaust system until it cools down. 


3. REMOVE REAR MUFFLER ASSY. 

(a) 

Remove 2 rear muffler assy nuts. 

NOTE 

Support one end of exhaust pipe with a jack first, and then 

remove the other end. 

(b) 

(c) 

Remove the rear muffler mounting rubber. 

Remove rear muffler assy. 

4. INSPECT REAR MUFFLER ASSY. 

(a) 

(b) 

Tap or shake the muffler, check to make sure that broken 

element inside the muffler is the cause of unusual noise, 

if it is found, replace it. 

Check the appearance of muffler for corrosion holes that 

caused by moisture in air or from burning, If it is found, 

replace it. 

NOTE 

After a long-time used, the exhaust pipe gasket will be 

adhered to exhaust pipe. After removing the muffler, use 

the scraper to clean the surface of exhaust pipe and replace 

with a new gasket to avoid exhaust leakage. 

5. REMOVE FRONT MUFFLER ASSY. 

(a) Remove front muffler rear mounting rubber. 

NOTE 

Support one end of exhaust pipe with a jack, and then 


Page 1468


16A-3 

(b) 

(c) 

(d) 

Remove 2 front muffler retaining nuts. 

Remove 2 support in the front of front muffler. 

Remove front muffler assy. 

16A 

6. INSPECT FRONT MUFFLER ASSY. 

(a) Tap or shake the muffler, check to ensure that broken 



(b) Check the appearance of muffler for corrosion holes that 


replace it. 

7. REMOVE MIDDLE EXHAUST PIPE. 

(a) loosen 2 retaining bolts fitting middle exhaust pipe to the 


(b) Remove the middle exhaust pipe. 

16A 

16A 

8. REMOVE CATALYTIC CONVERTER ASSY. 

(a) Disconnect front and rear oxygen sensor connectors. 

Page 1469

16A-4 


(b) 

Remove retaining nut securing catalytic converter mounting 

bracket to the rear of transmission. 

NOTE 



(c) 

(d) 

Loosen 2 retaining nuts securing catalytic converter to 

exhaust manifold. 

Remove the catalytic converter. 

9. INSPECT CATALYTIC CONVERTER. 

(a) Tap the catalytic converter, if hear any noise, replace with a new one. 

(b) Using a scan tool, check the oxygen sensor signal fluctuation range. If the catalytic converter damage, 

oxygen sensor signal fluctuation range will become larger. 

NOTE 

• When reinstalling exhaust pipe each time, always replace ring gasket with new one. 

• When installing each mounting rubber, avoid twisting or unusual extension in up/down and left/ 

right directions. 

10. INSTALL CATALYTIC CONVERTER ASSY. 

(a) Tighten 2 retaining nuts securing catalytic converter to 

exhaust manifold. 


Page 1470


16A-5 

(b) 

Connect front and rear oxygen sensor connectors. 

16A 

(c) 

Tighten retainng bolt securing catalytic converter mounting 

bracket to the rear of transmission. 

16A 

16A 

11. INSTALL MIDDLE EXHAUST PIPE. 

(a) Tighten 2 retaining bolts securing middle exhaust pipe to 



12. INSTALL FRONT MUFFLER ASSY. 

(a) Install 1 mounting rubber at the rear side of front muffler 

assy. 

Page 1471

16A-6 


(b) 

(c) 

Install 2 support in the front of front muffler. 

Install 2 front muffler retaining nuts. 


13. INSTALL REAR MUFFLER ASSY. 

(a) Install rear muffler rubber support. 

(b) 

Tighten 2 retaining bolts in the front of rear muffler. 



(a) Check clearance between exhaust pipe and rear bumper is uniform gap. 

(b) With engine running, check exhaust pipe joints for gas leakage and unusual noises. 

(c) Check to ensure that mounting bracket and mounting rubbers are installed properly stress.improper 

installation could result in excessive noise and vibration. 

Page 1472

EXHAUST - EXHAUST MANIFOLD 

16A-7 


REPLACEMENT 


NOTE 

Perform the operation with the exhaust system fully cooled down because the system will be hot just 

after engine stops. 


3. REMOVE CATALYTIC CONVERTER ASSY. (Refer to “Chapter 16A exhaust - exhaust pipe, replacement”) 

16A 

NOTE 

Ring gaskets are different on both sides of catalytic converter, take care not to misassemble them. 


5. REMOVE OIL DIPSTICK PIPE. 

(a) Pull out oil dipstick. 

(b) Remove oil dipstick pipe retaining bolt. 

(c) Pull out oil dipstick pipe. 

16A 

16A 

6. REMOVE EXHAUSE MANIFOLD HEAT SHIELD. 

(a) Remove 4 exhause manifold heat shield retaining bolts, 

then take off the exhaust manifold heat shield. 

NOTE 

The exhaust manifold heat shield retaining bolts will be 

rusted after a long-time running. Be careful to remove these 

bolts. 

7. REMOVE EXHAUST MANIFOLD. 

(a) Remove 9 exhaust manifold retaining nuts. 

NOTE 

The exhaust manifold retaining nuts will be rusted after a 

long-time running. Use derusting spray when loosen the 

nuts. 

Page 1473

16A-8 


(b) 

Remove the exhaust manifold. 

NOTE 

• Check whether parts have any damage or crack. 

• CHeck exhaust manifold and cylinder head surface 

for flatness by using a ruler and thickness gauge. 

Standard: 0.15 mm or less 

Limit value: 0.20 mm 

• Clean the dirt on exhaust manifold and cylinder head 

connect surface 

8. INSTALL A NEW EXHAUST MANIFOLD GASKET. 

NOTE 

If do not replace with a new gasket, use exhaust sealant to 

avoid exhaust leakage. 

9. INSTALL EXHAUST MANIFOLD. 

(a) Install exhaust manifold retaining nuts. 


NOTE 

• Apply rust-inhibiting lubricant on nuts for easier 

installation or removal next time. 

• Install the exhaust manifold retaining bolts diagonally. 

10. INSTALL EXHAUST MANIFOLD HEAT SHIELD. 

(a) Install 4 exhaust manifold heat shield retaining bolts. 


NOTE 

The exhaust manifold retaining nuts will be rusted after a 

long-time running. Use derusting spray when loosen the 

nuts. 

11. INSTALL OIL DIPSTICK PIPE. 

(a) Install oil dipstick pipe and tighten 1 retaining bolt. 

NOTE 

Replace oil dipstick pipe O-ring with a new one. 

(b) Insert oil dipstick completely into the dipstick pipe. 

Page 1474


16A-9 

12. INSTALL CATALYTIC CONVERTER ASSY. (Refer to “Chapter 16A exhaust - exhaust pipe, replacement”) 


(a) 

(b) 

Check to make sure exhaust manifold is installed properly between cylinder head and catalytic converter. 

With engine running, check exhaust manifold joints for gas leakage and unusual noises. 

16A 

16A 

16A 

Page 1475

MEMO 

Page 1476

COOLING SYSTEM 

COOLING SYSTEM .........................................................................17A-1 

PRECAUTION............................................................................ 17A-1 

COMPONENTS ......................................................................... 17A-2 


ON-VEHICLE INSPECT............................................................. 17A-4 

COOLANT ........................................................................................17A-6 

REPLACEMENT ........................................................................ 17A-6 

RESERVIOR.....................................................................................17A-8 

REPLACEMENT ........................................................................ 17A-8 

COOLING FAN ASSY....................................................................17A-10 

OVERHAUL ............................................................................. 17A-10 

RADIATOR.....................................................................................17A-13 

REPLACEMENT ...................................................................... 17A-13 

THERMOSTAT...............................................................................17A-18 

OVERHAUL ............................................................................. 17A-18 

COOLANT PUMP...........................................................................17A-23 

OVERHAUL ............................................................................. 17A-23 

17A 

17A 

17A 

17A 

17A 

17A 

17A 

17A 

17A 

17A 

Page 1477

Page 1478


PRECAUTION 

COOLING - COOLING SYSTEM 

17A-1 

1. COOLING SYSTEM PRECAUTION. 

(a) When disconnecting the cooling hose, use a suitable container to recycle the retains of coolant. If it is 

not to be used, dispose of them according to the regulations. 

(b) When disconnecting the pipes of cooling system, do not let debris go into the pipes of cooling system. It 

may damage the cooling system and engine. 

(c) When disconnecting the cooling system pipes connectors, a special plug must be used to cover the 

nozzle to prevent dirt and impurities. 

(d) Coolant is poisonous, always keep it away from children and pets. If it is not to be used, disposal them 

according to the regulations. 

(e) Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 ℃ 

(120 ℉) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may cause 


(f) Use foton specified coolant, do not use water instead of coolant. Water will damage the engine 

because of corrosion. 

(g) Clean radiator outside regularly, which can prevent mud and dust deposition from damaging radiator. 

17A 

17A 

17A 

Page 1479

17A-2 


COMPONENTS 

1 Radiator Assy 


3 Fan Cowl 

4 Locking Nut 

5 Cooling Fan Assy 




9 Washer 

10 Nut 

11 Cooling Fan Bracket 

12 Reservoir Refilling Hose 

13 Reservoir Assy 


15 Clamp 

16 Radiator To Reservoir Vent Hose 

17 Hose Clip 

18 Clamp 

Page 1480


17A-3 





17A 

1. Coolant (Lack or leaking) Chapter 17A cooling - coolant, replacement 

2. Coolant (Non-standard) Chapter 17A cooling - coolant, replacement 

3. Thermostat (Damaged) Chapter 17A cooling - thermostat, overhaul 

Engine overheated 

4. Engine (Rough work) - 

5. Radiator (Poor cooling) Chapter 17A cooling - cooling system, precaution 

6. Cooling fan (Damaged) Chapter 17A cooling - cooling fan assy, overhaul 

7. Cooling system (Blocked) - 

1. Radiator(Damaged) Chapter 17A cooling - radiator, replacement 

Coolant leaking 

Engine noise 

2. Cooling system hose 

(Broken) 

- 

3. Coolant pump(Damaged) Chapter 17A cooling - coolant pump, replacement 

4. Coolant reservoir(Damaged) Chapter 17A cooling - reservoir, replacement 

1. Cooling fan(Damaged) Chapter 17A cooling - cooling fan assy, overhaul 

2. Coolant pump(Damaged) Chapter 17A cooling - coolant pump, overhaul 

3. Cooling line - 

17A 

17A 

Page 1481

17A-4 


ON-VEHICLE INSPECT 

1. CHECK WHETHER COOLANT LEVEL IS NORMAL. 

2. IF COOLANT LACKS ABNORMALLY, CHECK COOLING SYSTEM FOR LEAKAGE. 

CAUTION 

Never remove the reservior cap while the engine and radiator are still hot, as fluid and steam can be 

blown out. 

(a) 

(b) 

(c) 

Fill the reservior with coolant and attach a reservior cap 

tester. 

Warm up the engine. 

Pump it to 110 kPa, and check that the pressure does not 

drop. 

NOTE 

If the pressure drops, check the hoses, reservior, radiator 

or water pump for leakage. If no external leakage is found, 

check the heater core, cylinder block and head. 

3. CHECK ENGINE COOLANT LEVEL IN COOLANT 

RESERVOIR. 

(a) When the engine is cool, the engine coolant level should 

be between the ”LOW” and ”FULL” line. 

4. CHECK ENGINE COOLANT QUALITY. 

(b) 

If the coolant level too low, check for leakage and add 

”FOTON Long-effective coolant” or equivalent up to the 

”FULL” line. 

NOTE 

Do not use water instead of coolant. 

CAUTION 


blown out. 

(a) Remove the reservior cap. 

(b) Place a container under the radiator to bloom the coolant from the coolant drain hole. 

(c) Loosen the coolant drain plug to drain the coolant and check if there is any excessive deposits of rust or 

scale around the radiator cap and radiator filler hole. The coolant should be free from oil. If excessively 

dirty, replace the coolant. 

(d) Tighten the drain plug and check the coolant level in the coolant reservoir. Fill the coolant if necessary. 

5. INSPECT FINS BLOCKAGE. 

(a) If fins are clogged, wash them with water or a steam cleaner and dry them with compressed air. 

NOTE 

• If the distance between the steam cleaner and core is too close, there is a possibility of 

damaging the fins. So keep the proper injection distance. 

Page 1482


17A-5 

• Be careful not to spray water directly onto electronic components. 

6. INSPECT COOLING FAN. 

(a) Disconnect the cooling fan connector. 

(b) Connect battery and ammeter to the connector. 

(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. 

Temperature: 20°C 

Current: 8.0 ~ 12.0 A 

(d) Connect the cooling fan connector. 

(e) No abnormal noise except fan itself when the fan is rotating at a high speed. 

17A 

17A 

17A 

Page 1483

17A-6 

COOLING - COOLANT 

COOLANT 

REPLACEMENT 

CAUTION 







NOTE 



the way. 



COOLANT. 

NOTE 








NOTE 












Page 1484


17A-7 







NOTE 


17A 

17A 

17A 

Page 1485

17A-8 

COOLING - RESERVIOR 

RESERVIOR 

REPLACEMENT 

1. DRAIN ENGINE COOLANT. (Refer to “Chapter 17A cooling- coolant, replacement”) 

2. REMOVE RESERVIOR. 

(a) Open reservior pressure cover by turn it slowly to release 

the built-up pressure. 

CAUTION 

Do not open the reservior cap when the engine is hot. 

Coolant temperature should be reduced to 50 ° C (120 ° F) 

below, remove the radiator cap. Otherwise, the cooling 


(b) 

(c) 

Loosen reservior vent hose clamp and disconnect vent 

hose. 

Remove reservior retaining bolt. 

(d) 

(e) 

Disconnect coolant fluid level sensor connector. 

Loosen reservior refilling hose clamp and disconnect 

reservior refilling hose. 

(f) 

Remove reserivor. 

NOTE 

Do not lose the rubber grommet located on radiator upper 

support when removing reservior. If damaged, replace 

them. 

Page 1486


17A-9 

3. INSTALL RESERVIOR. 

(a) 

(b) 

Connect reservior refilling hose and tighten retaining 

clamp. 

Connect coolant fluid sensor connector. 

17A 

(c) 

(d) 

(e) 

Position the lower support of reservior into rubber grommet 

on upper radiator frame. 

Tighten reservior retaining bolt. 

Connect reservior vent hose. 


(a) Fill the coolant to max level when cold, check coolant fluid level indicator is normal in instrument cluster 

and no coolant leakage is found. 

17A 

17A 

Page 1487

17A-10 

COOLING - COOLING FAN ASSY 

COOLING FAN ASSY 

OVERHAUL 


2. DISCONNECT COOLING FAN ASSY CONNECTOR. 

3. REMOVE COOLING FAN BRACKET. 

(a) Remove 4 cooling fan bracket retaining bolts/nuts. 

(b) Remove retaining nut securing A/C pipe clamp to vehicle 

frame. 

(c) Move A/C pipes slightly to one aside . 

(d) 

(e) 

Disengage A/C pipes from the dual line clip at the bottom of 

cooling fan bracket. 

Remove cooling fan bracket carefully. 

Page 1488


17A-11 

4. REMOVE COOLING FAN ASSY. 

(a) 

(b) 

Remove 6 cooling fan retaining bolts. 

Remove cooling fan assy from the left side under the 

vehicle. 

17A 


(a) Using an ohmmeter, measure the resistance between the terminals. 

Main cooling fan: 

• Resistance between white wire and brown wire:1.527±15%Ω ; 

• Resistance between white wire and red wire:1.2±15%Ω ; 

Secondary cooling fan: 



(b) Visually inspect cooling fan blade for cracks or unusual bend. 

(c) Rotate cooling fan by hand, the blades should be rotated smoothly. 

6. INSTALL COOLING FAN ASSY. 

(a) Position cooling fan assy into place from under the 

vehicle. 

(b) Tighten 6 cooling fan retaining bolts. 


17A 

17A 

7. INSTALL COOLING FAN BRACKET. 

(a) Positon cooling fan bracket properly in the original 

positon. 

(b) Tighten 4 bracket retaining bolts and nuts. 


(c) Engage A/C pipes into dual line clip at the bottom of 


Page 1489

17A-12 


(d) 

Tighten A/C pipes clamp retaining nut. 

8. CONNECT COOLING FAN ASSY CONNECTORS. 


(a) 

Start the vehicle, check cooling fan for normal operation and ensure that no unusual noise is heard 

when engine warms up and A/C switch is on. 

Page 1490

COOLING - RADIATOR 

17A-13 

RADIATOR 

REPLACEMENT 

CAUTION 


(120 ° F) below, remove the reservior cap. Otherwise, the cooling liquid or vapor emitting heat may 


1. DRAIN ENGINE COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”) 

2. REMOVE RESERVIOR. (Refer to “Chapter 17A cooling - reservior, replacement”) 

3. REMOVE COOLING FAN ASSY. (Refer to “Chapter 17A cooling - coolant fan assy, replacement”) 


5. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper, 


17A 

6. REMOVE ENGINE HOOD LOWER COVER PANEL. 

(a) Remove 4 engine hood lower cover panel retaining bolts. 

(b) 

(c) 

Remove 2 push pins from the back of lower cover panel. 

Remove engine hood lower cover panel. 

17A 

17A 

7. REMOVE THE FAN COWL. 

(a) Remove 2 retaining bolts in the upper fan cowl. 

(b) Remove reservior refilling hose from fan cow fixing clip. 

Page 1491

17A-14 


(c) 

(d) 

Push fan cowl upward until 2 lower support disengage 

from radiator lower mounting notch. 

Remove lower fan cowl. 

8. REMOVE RADIATOR UPPER AND LOWER WATER 

HOSES. 

(a) 

Remove engine water outlet hose to upper radiator. 

NOTE 

Check water hose for cracks and deterioration, replace if 

necessary. 

(b) 

Remove engine water inlet hose to lower radiator. 

NOTE 


necessary. 

9. REMOVE THE RADIATOR UPPER SUPPORT. 

(a) Pull out reservior vent hose from fixing clip on radiator 

upper support. 

(b) Disconnect engine hood switch connector and remove 

the wire harness clip from the radiator upper support. 

(c) 

(d) 

Disconnect washer motor connector. 

Remove 2 washer assy retaining bolts. 

Page 1492


17A-15 

(e) 

Remove 5 radiator upper support retaining bolts. 

17A 

(f) 

Remove radiator upper support and put it aside. 

NOTE 

Do not lose the upper mounting rubber installed on radiator 

upper mounting pin when removing radiator. if damaged, 

replace them. 

10. REMOVE THE RADIATOR. 

(a) 

(b) 

Remove 2 retaining bolts securing upper condenser to 

radiator. 

Remove 2 retaining bolts securing both upper air 

deflector to radiator. 

NOTE 

The vehicle was equipped with air deflector depend on 

different Model. 

17A 

17A 

(c) 

(d) 

Remove 2 retaining bolts securing lower condenser to 

radiator. 

Remove 2 retaining bolts securing both lower air 


CAUTION 

Hang and hold condenser with wire after removing the bolts 

securing condenser to radiator to prevent the A/C pipes or 

condenser from damaging. 

(e) 

Lift up and remove the radiator. 

NOTE 

Do not lose lower mounting rubbers of radiator when 

removing radiator and check the mounting rubbers for 

damage, replace them as required. 

Page 1493

17A-16 


11. INSTALL THE RADIATOR. 

NOTE 

Make sure lower mounting rubbers are seated onto raditaor 

lower support before installing radiator. 

(a) 

(b) 

Tighten 2 retaining bolts securing upper condenser to 

radiator. 

Tighten 2 retaining bolts securing both upper air deflector 

to radiator. 


NOTE 

The vehicle is equipped with air deflector depending on 

Model. 

(c) 

(d) 

Tighten 2 retaining bolts securing lower condenser to 

radiator. 

Tighten 2 retaining bolts securing both lower air deflector 

to radiator. 


12. INSTALL RADIATOR UPPER AND LOWER WATER 

HOSES. 

(a) 

Connect engine water inlet hose to radiator. 

(b) 

Connect engine water outlet hose to radiator. 

Page 1494


17A-17 

13. INSTALL THE FAN COWL. 

(a) Position fan cowl into place from under the vehicle. 

(b) Tighten 2 upper fan cowl retaining bolts. 

17A 

14. INSTALL THE RADIATOR UPPER SUPPORT. 

(a) 

Positon the radiator upper support. 

NOTE 

Make sure mounting rubbers are seated onto raditaor upper 

support pin. 

(b) Tighten 5 radiator upper support retaining bolts. 


15. INSTALL ENGINE HOOD LOWER COVER PANEL. 

(a) Position engine hood lower cover panel, then install 2 

push pins. 

17A 

17A 

(b) 

Tighten 4 lower cover panel retaining bolts. 

16. INSTALL COOLING FAN ASSY. (Refer to “Chapter 17A cooling - cooling fan, overhaul”) 

17. INSTALL RESERVIOR. (Refer to “Chapter 17A cooling - reservior, replacement”) 






(a) After installing radiator, let engine be running until cooling fan runs at high speed. Check coolant for 

leakage. 

Page 1495

17A-18 

COOLING - THERMOSTAT 

THERMOSTAT 

OVERHAUL 

CAUTION 









cover. 


NOTE 

It is recommended that the battery negative cable must be disconnected, prior to thermostat removing, 

to avoid touching generator positive retaining nut. 








Page 1496


17A-19 

7. REMOVE ENGINE WATER INLET HOSE NO. 2. 

(a) 

Remove engine water inlet hose NO. 2 clamp. 

(b) Disconnect engine water inlet hose NO. 2. 

NOTE 


necessary. 

17A 

8. REMOVE THERMOSTAT. 

(a) 

Remove 2 thermostat housing retaining bolts. 

17A 

(b) 

Remove thermostat housing. 

17A 

(c) 

Pull out thermostat. 

Page 1497

17A-20 


9. INSPECT THERMOSTAT. 

(a) The thermostat is numbered with the valve opening 

temperature. 

(b) 

(c) 

Immerse the thermostat in water and gradually heat the 

water. 

Check the valve opening temperature. 

Valve opening temperature: 

80 - 84 ℃ 

NOTE 

If the valve opening temperature is out of the specification, 

replace the thermostat. 

(d) 

Check the valve lift. 

Valve lift: 8 mm or more, at 95 ℃ . 

NOTE 

• If the valve opening temperature is out of the specification, replace the thermostat. 

• Check that the valve is fully closed when the thermostat is at low temperature (below 77 ℃ ). 

• If it is not closed, replace it with a new one. 

10. INSTALL THERMOSTAT. 

NOTE 

Always replace with a new thermostat rubber ring when 

performing thermostat operation. 

Page 1498


17A-21 

(a) 

Install thermostar and rubber ring. 

NOTE 

Make sure that rubber ring is fitting to the thermostat properly 

and they are fully seated. 

17A 

(b) 

(c) 

Install thermostat housing. 

Tighten thermostat housing retaining bolts. 


17A 

11. CONNECT ENGINE WATER INLET HOSE NO. 2. 

(a) Connect engine water inlet hose NO. 2, then tighten 

retaining clamp. 

17A 




(a) After installing thermostat, start the engine until cooling fan runs at high speed. check coolant for 

leakage. 

Page 1499

17A-22 




(a) 

(b) 

Tighten 5 engine compartment cover retaining bolts. 

Cover front floor covering. 




Page 1500

COOLANT PUMP 

OVERHAUL 

COOLING - COOLANT PUMP 

17A-23 

CAUTION 






3. REMOVE GENERATOR BELT. (Refer to “Chapter 20A starting and charging - generator, overhaul”) 

17A 

4. REMOVE COOLANT PUMP PULLEY RETAINING BOLTS. 

5. REMOVE ENGINE TIMING BELT HOUSING. 

6. REMOVE ENGINE TIMING BELT. 

7. REMOVE COOLANT PUMP. 

(a) Remove coolant pump retaining bolt. 

(b) Remove coolant pump. 

17A 

17A 

(c) 

(d) 

Remove coolant pump gasket. 

Using a scraper, clean dirt on coolant pump and engine 

block connect surface. 

NOTE 

Clean the dirt, do not damage coolant pump and engine 

block connect surface. 

8. INSPECT COOLANT PUMP. 

(a) Rotate coolant pump and it should turn smoothly. 

(b) There should be no clearance between coolant pump shaft and coolant punp bearing, and no abnormal 

noise when it turns. 

(c) No coolant leakage around coolant pump. 

9. INSTALL COOLANT PUMP. 

(a) Install coolant pump gasket. to avoid coolant leaking, use coolant pump sealant if necessary. 

Page 1501

17A-24 

COOLING - COOLANT PUMP 

NOTE 

After using the coolant pump sealant, wait for 15 minutes then fill the coolant. 

(b) 

Install coolant pump retaining bolts. 


10. INSTALL ENGINE TIMING BELT. 

11. INSTALL ENGINE TIMING BELT HOUSING. 

12. INSTALL COOLANT PUMP PULLEY RETAINING BOLTS. 


13. INSTALL GENERATOR BELT. (Refer to “Chapter 20A starting and charging - generator, overhaul”) 




(a) After replacing coolant pump, let engine be running until cooling fan runs at high speed. check coolant 

for leakage. 

Page 1502

LUBRICATION SYSTEM 

LUBRICATION SYSTEM .................................................................18A-1 

PRECAUTION............................................................................ 18A-1 

COMPONENT............................................................................ 18A-2 

ENGINE OIL .....................................................................................18A-4 

REPLACEMENT ........................................................................ 18A-4 

OIL FILTER ......................................................................................18A-6 

REPLACEMENT ........................................................................ 18A-6 

OIL PAN ...........................................................................................18A-8 

REPLACEMENT ........................................................................ 18A-8 

OIL PUMP ......................................................................................18A-11 

OVERHAUL ............................................................................. 18A-11 

18A 

18A 

18A 

18A 

18A 

18A 

18A 

18A 

18A 

18A 

18A 

Page 1503

Page 1504


PRECAUTION 

LUBRICATION - LUBRICATION SYSTEM 

18A-1 

WARNING 

Prolonged and repeated contact with engine oil will cause the skin fat to be removed, resulting in dry 

skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants which 

may cause skin cancer. Therefore, the skin must be protected in appropriate methods and with 


1. LUBRICATION SYSTEM PRECAUTION. 

(a) Avoid contacting with oil for a long time, especially the used engine oil. 

(b) Wear protective clothing including waterproof work gloves. 

(c) Avoid contaminated clothing, especially underwear containing the oil. 

(d) Never put rags contaminated with oil in pockets. 

(e) Avoid eyes contacting with oil, must wear goggles, In addition, equipment must be prepared to clean 

the eye. And wrapping the wound must be dealt with immediately. 

(f) Frequent use of soap and water can clean, especially before meals, and make sure all the oil has been 

removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is 

recommended to replace the natural skin oils cotton suet. 

(g) Do not use gasoline, kerosene, diesel, thinner or solvent to clean skin. 

(h) Before each work, apply cream to help skin cleaning after work. 

(i) If your skin is abnormal, consult a doctor immediately. 

18A 

18A 

18A 

Page 1505

18A-2 


COMPONENT 

1 Drain Plug 

2 Oil Pan Bolt 

3 Oil Filter 

4 Oil Pan 

5 Oil Strainer 

6 Oil Strainer Gasket 

7 Oil Pump Cover Bolt 

8 Engine Oil Pressure Switch 

9 Relief Plug 

10 Gasket 

11 Relief Spring 

12 Relief Plug 

13 Oil Filter Bracket 

14 Oil Filter Bracket Gasket 

15 Front Case Plug 

16 O-ring 

17 Front Case Inside Bolt 

18 Front Case 

19 Front Case Gasket 

20 Oil Pump Cover 

21 Oil Pump Driven Gear 

22 Oil Pump Drive Gear 

23 Front Crankshaft Oil Seal 

24 Balance Shaft Oil Seal 

Page 1506


18A-3 

25 Oil Pump Oil Seal 

26 Right Balance Shaft 

27 Left Balance Shaft 

28 Right Balance Shaft Front Bearing 

29 Right Balance Shaft Rear Bearing 

30 Left Balance Shaft Bearing 

18A 

18A 

18A 

Page 1507

18A-4 

LUBRICATION - ENGINE OIL 

ENGINE OIL 

REPLACEMENT 






cover. 




(a) Drain engine oil. 

NOTE 

• The engine oil maybe hot, be careful, avoid personal 

injury. 

• Prolonged and repeated contact with engine oil will 

cause the skin fat to be removed, resulting in dry 

skin, allergies and dermatitis. In addition, used 

engine oil contains potentially harmful pollutants 

which may cause skin cancer. Therefore, the skin 

must be protected in appropriate methods and with 


• Using a special container, collect or dispose used oil 

as required. 

Page 1508


18A-5 

7. REPLACE WITH NEW DRAIN PLUG GASKET AND 

TIGHTEN PLUG. 


18A 



Engine oil: 4 L 

NOTE 

The Specification of engine oil allowed only is 10W-30 ,15W-40 or SL level as well as 5W-30 (GB11121) 

oil used in winter of North China. 


11. PARK THE VEHICLE ON LEVEL GROUND AND START ENGINE UNTIL IT IS WARM. CHECK AND 

ENSURE THERE IS NO OIL LEAKAGE. 


13. CHECK OIL LEVEL. 

(a) Pull out oil dipstick and wipe it clean . 

(b) Insert oil dipstick and pull it out to ensure oil level is 

within the range as shown in the figure. 

18A 

18A 


Page 1509

18A-6 

LUBRICATION - OIL FILTER 

OIL FILTER 

REPLACEMENT 





cover. 



5. DRAIN ENGINE OIL .(Refer to “Chapter 18A lubrication - engine oil, replacement”) 

NOTE 

Without special circumstances, the oil filter should be replaced with engine oil, avoid oil pollution and 

keep engine operation. 

6. USING SPECIAL TOOL TO REMOVE OIL FILTER. 

7. CLEAN THE CONNECT SURFACE OF OIL FILTER AND OIL FILTER BRACKET. 


Page 1510


18A-7 


OIL FILTER BRACKET. USE A SUITABLE TOOL TO 

TIGHTEN OIL FILTER. 


18A 







15. CHECK AND ENSURE THERE IS NO OIL LEAKAGE. 


17. PULL OUT OIL DIPSTICK TO ENSURE OIL LEVEL IS BETWEEN “MAX” MARK AND “MIN” 

MARK. 


18A 

18A 

Page 1511

18A-8 

LUBRICATION - OIL PAN 

OIL PAN 

REPLACEMENT 




cover. 



4. DRAIN ENGINE OIL. (Refer to “Chapter 18A lubrication - engine oil, replacement”) 


6. PULL OIL DIPSTICK OUT. 

7. REMOVE OIL DIPSTICK PIPE. 

(a) Remove oil dipstick pipe mounting bolt. 

(b) Pull oil dipstick pipe out. 

NOTE 

Check O- ring at the bottom of oil dipstick pipe for damage 

and replace it as required. 


9. REMOVE OIL PAN. 

(a) Remove 4 bolts (or nuts) securing front cover to transmission. 

(b) Remove the front cover. 

(c) Remove bolts on the backside of oil pan. 

Page 1512


18A-9 

(d) 

Remove the bolts on the rightside of oil pan. 

18A 

(e) 

(f) 

Remove the bolts on the leftside of oil pan. 

Remove the bolts in the front of oil pan through the front 

crossmember. 

(g) 

Insert proper tool between cylinder block and oil pan, 

then separate them by hammer. 

NOTE 

Never use screwdriver or chisel to remove the oil pan. It will 

damage the oil pan flange and cause oil leakage. 

18A 

18A 

10. CLEAN CONNECT SURFACE OF OIL PAN AND ENGINE BLOCK. 

11. APPLY A 4MM WIDE SEALANT TO THE ENTIRE 

CIRCUMFERENCE OF OIL PAN FLANGE. 

NOTE 

Circle the bolt hole with sealant strips around. 

Page 1513

18A-10 


12. INSTALL OIL PAN. 

(a) Position oil pan and install oil pan mounting bolts. 

(b) Tighten the bolt according to the number as shown. 


NOTE 

Be sure to install the oil pan quickly while the sealant is wet 

(within 15 minutes).After installation, keep the sealant area 

away from the oil for about one hour. 

(c) 

Install front cover for transmission. 

13. INSTALL OIL DIPSTICK PIPE. 


15. INSERT OIL DIPSTICK. 




19. CHECK OIL PAN AND ENSURE THERE IS NO OIL LEAKAGE. 


21. PULL OIL DIPSTICK OUT AND ENSURE OIL LEVEL IS BETWEEN “MAX” MARK AND THE “MIN” 

MARK. 


Page 1514

LUBRICATION - OIL PUMP 

18A-11 

OIL PUMP 

OVERHAUL 



3. DRAIN ENGINE OIL.(Refer to “Chapter 18A lubrication - engine oil, replacement”) 

4. REMOVE OIL PAN.(Refer to “Chapter 18A lubrication - oil pan, replacement”) 

18A 




cover. 

6. REMOVE ENGINE TIMING BELT. 

7. REMOVE OIL PRESSURE SWITCH. 

18A 

18A 

8. REMOVE OIL FILTER BRACKET MOUNTING BOLT AND 

OIL FILTER BRACKET. 

9. REMOVE FRONT CASE PLUG WITH SPECIAL TOOL. 

Page 1515

18A-12 


10. REMOVE PLUG ON THE LEFT SIDE OF CYLINDER 

BLOCK AND INSERT A SCREWDRIVER INTO PLUG 

HOLE TO LOCK BALANCE SHAFT. 

11. REMOVE LEFT BALANCE SHAFT BOLT INSIDE 

FRONT CASE PLUG. 

12. TAKE OUT SCREWDRIVER FROM THE INSIDE OF PLUG ON THE CYLINDER BLOCK SIDE. 

13. REMOVE FRONT CASE RETAINING BOLTS. 

14. TAKE FRONT CASE AND BALANCE SHAFT AWAY AND INSPECT IT. 

(a) Check oil holes for blocking and clean if necessary. 

(b) Check the front case for cracks and other damage. Replace cracked or damaged front case if necessary. 

(c) Check the oil seal lip for wear and damage. Replace oil seal if necessary. 

(d) 

Check balance shaft front bearing section for wear, 

damage and seizure. If there are anything damaged with 

the section, replace the front case. 

Page 1516


18A-13 

15. REMOVE OIL PUMP COVER MOUNTING BOLTS. 

18A 

16. INSPECT OIL PUMP GEAR. 

(a) Using rules and feeler gauge, measure the gear 

clearance. 

Standard: 

Drive gear: 0.08 ~ 0.14 mm 

Dirven gear: 0.06 ~ 0.12 mm 

(b) Install the oil pump gear to the front case and rotate it to 

ensure smooth rotation with no looseness. 

(c) Ensure that there is no ridge wear on the contact surface 

between the front case and the gear surface of the oil 

pump cover. 

17. TAKE OIL PUMP DRIVE GEAR AND DRIVEN GEAR AWAY. 

18. REMOVE FRONT CRANKSHAFT OIL SEAL, BALANCE SHAFT OIL SEAL AND PUMP OIL SEAL. 

NOTE 

Oil seal can not be reused after removal and replace it with new one. 

19. USING SPECIAL TOOL, REMOVE BALANCE SHAFT 

FRONT BEARING FROM CYLINDER BLOCK. 

(a) Check balance shaft front bearing section for wear, 

damage and seizure, replace it as required. 

18A 

18A 

20. USING SPECIAL TOOL, REMOVE BALANCE SHAFT 

REAR BEARING FROM THE CYLINDER BLOCK. 

(a) Check balance shaft rear bearing section for wear, 

damage and seizure, replace it as required. 

NOTE 

Remove balance shaft front bearing first, then remove 

balance shaft rear bearing . 

Page 1517

18A-14 


21. INSTALL LEFT BALANCE SHAFT REAR BEARING. 

(a) Position tools into cylinder block. 

(b) Apply engine oil to the outer surface of bearing and 

bearing hole in the cylinder block. 

(c) 

Using special tool, install the rear bearing. 

NOTE 

The left rear bearing hasn’t oil holes. 

22. INSTALL RIGHT BALANCE SHAFT REAR BEARING. 

(a) Align the ratchet ball of the special tool with the oil hole in 

the rear bearing to install the bearing of the special tool. 

(b) Apply engine oil to the front bearing outer surface and 

bearing hole in the cylinder. 

(c) 

Using special tool, install the rear bearing. Make sure 

that the oil hole of the bearing is aligned with the oil hole 

of the cylinder block. 

Page 1518


18A-15 

(d) 

Remove rear bearing installing portion from special tool. 

18A 

(e) 

Using special tool, install front bearing. 

23. INSTALL OIL PUMP DRIVE GEAR AND OIL PUMP 

DRIVEN GEAR. 

(a) 

Apply engine oil generously to the gears and line up the 

alignment marks.Oil pump drive gear timing mark as 

shown in the figure. 

18A 

18A 

(b) 

Oil pump driven gear timing mark. 

Page 1519

18A-16 


24. INSTALL OIL PUMP COVER AND TIGHTEN RETAINING 

BOLTS. 

25. INSTALL A NEW FRONT CASE GASKET. 

26. POSITION FRONT CASE AND TIGHTEN RETAINING 

BOLTS TEMPORARILY. 

27. USING SPECIAL TOOL, INSTALL OIL PUMP SEAL. 

28. USING SPECIAL TOOL, INSTALL BALANCE SHAFT 

OIL SEAL. 

Page 1520


18A-17 

29. USING SPECIAL TOOL, INSTALL FRONT CRANKSHAFT 

OIL SEAL. 

18A 

30. INSTALL OIL FILTER BRACKET SEAL. 

31. POSITION OIL FILTER BRACKET AND TIGHTEN 

RETAINING BOLTS TEMPORARILY. 

32. INSTALL OIL PRESSURE SWITCH. 

(a) Clean the thread portion of oil pressure switch and apply 

sealant to the thread portion. 

18A 

18A 

(b) 

Using special tool, tighten the oil pressure switch. 


Page 1521

18A-18 


33. REMOVE PLUG ON THE LEFT SIDE OF CYLINDER 

BLOCK. INSERT A SCREWDRIVER INTO PLUG 

HOLE TO LOCK BALANCE SHAFT ON THE LEFT 

SIDE OF CYLINDER BLOCK. 

34. INSTALL LEFT BALANCE SHAFT MOUNTING BOLT 

INSIDE FRONT CASE PLUG HOLE. 


35. INSTALL PLUG ON THE CYLINDER BLOCK SIDE. 


36. TIGHTEN BOLTS ON THE FRONT CASE OF OIL 

PUMP. 


37. TIGHTEN OIL FILTER BRACKET MOUNTING BOLT. 


Page 1522


18A-19 

38. USING TOOL, INSTALL FRONT CASE PLUG. 


18A 

39. INSTALL ENGINE TIMING BELT. 

40. INSTALL OIL STRAINER RETAINING BOLTS. 


41. INSTALL OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”) 


43. FILL ENGINE OIL. (Refer to “Chapter 18A lubrication - enginge oil, replacement”) 


18A 

18A 

Page 1523

MEMO 

Page 1524


IGNITION SYSTEM ............................................................................ 19-1 

COMPONENTS ........................................................................... 19-1 

IGNITION MODULE/SPARK PLUG WIRE/SPARK PLUG................ 19-2 

OVERHAUL ................................................................................. 19-2 

19 

19 

19 

19 

19 

19 

19 

19 

19 

19 

19 

19 

Page 1525

Page 1526


COMPONENTS 

IGNITION - IGNITION SYSTEM 

19-1 

19 

19 

1 Engine Cylinder Head Cover 

2 Ignition Module Bracket 

3 Ignition Module 

4 Bolt 

5 Spark Plug 

6 Spark Plug Wire 

19 

Page 1527

19-2 

IGNITION - IGNITION MODULE/SPARK PLUG WIRE/SPARK PLUG 

IGNITION MODULE/SPARK PLUG WIRE/SPARK PLUG 

IGNITION 

OVERHAUL 



(a) 

(b) 



cover. 


4. REMOVE SPARK PLUG WIRE. 

(a) Pull out spark plug wire by slightly turning. 

(b) 

Remove spark plug wire from ignition module in a certain 

sequence. 

NOTE 

Mark spark plug wires in the firing order in order to identify 

their positon when installing spark plug wires . 

(c) 

Remove spark plug wire. 

Page 1528


19-3 

5. REMOVE IGNITION MODULE 

(a) 

Disconnect ignition module connector. 

19 

(b) 

Remove 2 ignition module retaining bolts. 

(c) 

Remove ignition module. 

19 

19 

6. REMOVE SPARK PLUG. 

(a) Using special socket tool ,remove spark plug. 

(b) Take spark plug out. 

7. INSPECT SPARK PLUG WIRE. 

• Check if the spark plug wire has been broken down. 

• Make sure the spark plug wire resistance is less than 4 KΩ. 

8. CHECK IGNITION MODULE. 

• Check if crack exists on the ignition module. 

• Check ignition module condition. 

(a) Using diagnostic tool, ensure there exists no DTC. If there exists DTC, record it. Ensure that the DTC 

fault is resolved even the DTC is unrelated with ignition system. 

(b) Pull out fuel pump relay. 

Page 1529

19-4 

(c) 

(d) 

(e) 

(f) 

(g) 


Lightly pull out spark plug wire and remove the spark plug. 

Install a new spark plug to the spark plug wire, touch spark plug negative to the engine cylinder block. 

Start engine, check the flash over. 

If the flash over is weak or no flash over, replace with a new ignition module. After replacing the new 

ignition module, if the flash over become strong, we can ensure the ignition module has been damaged. 

If there is still no flash over, check the ignition circuit and inspect the spark plug. 

Using diagnostic tool, ensure there appears no DTC, except for the DTC record in step (b). Clear all 

DTCs. 

9. INSPECT SPARK PLUG. 

• Check spark plug insulator outer surface for cracks. 

• Check spark plug flash over for carbon deposition. 

• Check spark plugs for burned off or melted positive and 

negative electrode. 

• Check spark plug gap. 

Standard value: 1 ~ 1.1 mm 

10. INSTALL SPARK PLUG. 

(a) Using special socket tool, tighten spark plug. 


11. INSTALL IGNITION MODULE. 

(a) Install 2 ignition module retaining bolts. 


12. INSTALL SPARK PLUG WIRE. 

(a) Place spark plug wire on the corresponding position 

according to the sequence as shown on igniton module. 

(b) Install spark plug wire. 

NOTE 

A click can be heard to confirm the spark plug wire is 

installed properly. 

(c) Connect ignition module connector. 

13. INSTALL INTAKE HOSE. (Refer to “Chapter 14A intake air- intake air hose, replacement”) 

Page 1530


19-5 


15. START ENGINE AND CONFIRM IT IS IN GOOD CONDITION. 

19 

19 

19 

Page 1531

MEMO 

Page 1532


STARTING AND CHARGING SYSTEM ..........................................20A-1 

PRECAUTION............................................................................ 20A-1 


GENERATOR...................................................................................20A-4 

COMPONENTS ......................................................................... 20A-4 

OVERHAUL ............................................................................... 20A-5 

STARTER.......................................................................................20A-12 

COMPONENTS ....................................................................... 20A-12 

OVERHAUL ............................................................................. 20A-13 

BATTERY.......................................................................................20A-21 

COMPONENTS ....................................................................... 20A-21 

USE AND MAINTENANCE...................................................... 20A-22 

INSPECTION ........................................................................... 20A-24 

BATTERY COMMON PROBLEMS, THE CAUSES ANALYSIS AND 

TROUBLESHOOTING............................................................. 20A-25 

REPLACEMENT ...................................................................... 20A-27 

20A 

20A 

20A 

20A 

20A 

20A 

20A 

20A 

20A 

20A 

20A 

20A 

20A 

Page 1533

Page 1534

STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 

STARTING AND CHARGING SYSTEM 

AND CHARGING 

PRECAUTION 

1. STARTING AND CHARGING SYSTEM PRECAUTION. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

20A-1 

Battery may have escaping explosive gas. in order to avoid personal injury, keep ventilated in engine 

room before maintaining battery. To avoid electric arc, disconnect battery negative cable first and 

connect the negative cable last. 

Battery electrolyte is very dangerous. It can damage the machine and cause serious burns. When 

maintaining battery, prepare neutralizers concentration soda water, wear safety eyepiece and wear 

protective clothing, which can avoid personal injury. 

When using compressed air, wear appropriate goggles and protective mask. Dust particles and dirt can 

cause injury. 

Don't tighten the electrical connectors excessively, which may damage the starter. 

Never short two cables of the battery, it will cause a rapid battery fever even an explosion occur. The 

escaping gas from battery is easily be burned by the spark, so do not use fire near battery. 

After the generator operation, do not try to use spark check whether the generator works. Use bulb or 

multimeter to perform the test. Otherwise it will damage the generator diode. 

Check the generator silicon rectifier devices, it is strictly forbidden to use multimeter or apply 220V 

directly for generator insulation check, otherwise it will make diode breakdown and damaged. 

20A 

20A 

20A 

Page 1535

20A-2 



Use the table below to help you find the cause of the problem. The numbers indicate the priority of 

the likely cause of the problem. Check each part in order. If necessary, replace these parts. 


1. Starter switch control circuit (Open) Check wire harness 

Starter out of operation 

2. Brush and rectifier (Poor 

connection) 

3. Starter inside circuit (Open or short) 

1. Battery (Low voltage) 

Chapter 20A starting and charging - starter, 

overhaul 


overhaul 


use and maintenance 

2. Starter wire (Poor connection) Check wire harness 

Starter lacks power, 

can not srart engine 

Starter keep working 

after engine start 

3. Rectifier (Surface damaged or 

stains) 

4. Brush (Wear) or Brush spring (Loss 

elastic force) 

5. Solenoid switch (Contacts ablation) 

6. Bearing (Wear),commutator (Wipe 

shell) 

1. Starter relay (Copper contacts bond) 

2. Starter commutator (Bend or break) 

3. Starter gear tooth surface contact 

(Roughening or stuck) 

-Chapter 20A starting and charging - starter, 

overhaul 


overhaul 


overhaul 


overhaul 


overhaul 


overhaul 


overhaul 

1. Generator connect wire (damaged) Check wire harness 

Generator out of operation 

2. Rotor winding (Open) 

3. Rectifier diode (Damaged) 

4. Brush (Poor connection) 

5. Regulator (Damaged) 

Chapter 20A starting and charging - generator, 

overhaul 


overhaul 


overhaul 


overhaul 

Page 1536


20A-3 


Generator lacks 

enough electricity 

1. Belt losing tensity 

2. Brush (Poor connection) or collector 

ring (Smeary) 


Chapter 15A engine mechanical - engine 

accessory belt, overhaul 


overhaul 


overhaul 

20A 

4. Battery lose electrolyte 



20A 

20A 

Page 1537

20A-4 

STARTING AND CHARGING - GENERATOR 

GENERATOR 

COMPONENTS 

1 Generator Belt Pulley 

2 Rotator Component 

3 Rear Bearing 

4 Bearing Carrier 

5 Front Bearing 

6 Front Cover 

8 Anchor Plate 

9 Regulator And Brush Carriage 

10 Brush 

11 Brush Ring 

12 Rectifier Component 

13 Back Cover 

7 Stator Component 

Page 1538


20A-5 

OVERHAUL 

1. TURN IGNITION SWITH OFF. 




cover. 

20A 


4. REMOVE A/C COMPRESSOR BELT. (Refer to “Chapter 61 heater and air conditioning - A/C compressor, 


5. REMOVE POWER STEERING PUMP BELT. (Refer to “Chapter 52 power steering - power steering 

pump and fliud reservior assy, replacement”) 

6. REMOVE GENERAOR BELT. 

(a) Loosen locking bolt securing belt tensioner. 

(b) Loosen adjustment bracket mounting bolt. 

(c) 

Loosen generator lower mounting nut. 

20A 

20A 

(d) Rotate adjustment bolt and adjust generator belt 

tension. 

(e) Remove generator belt. 

NOTE 

Check generator belt for crack and replace it as required. 

Page 1539

20A-6 


7. REMOVE GENERATOR. 

(a) Loosen generator positive cable connecting nut. 

(a) Disconnect generator connector. 

(b) 

(c) 

(d) 

Remove generator adjustment bolt. 

Remove generator lower support bolt. 

Remove generator. 

8. DISASSEMBLE GENERATOR. 

(a) 

Using pneumatic tools, loosen generator belt pulley retaining 

nut. 

(b) 

Loosen retaining bolts attaching generator front cover to 

stator component. 

(c) 

Insert a screwdriver between front cover and stator then 

separate them. 

NOTE 

• If it is difficult to be separated, slap the front cover 

slightly with rubber hammer and pry it with screwdriver. 

• Do not insert screwdriver too deep to prevent stator 

component being damaged. 

Page 1540


20A-7 

(d) 

Using a electric iron (180 ~ 250 w), remove stator. This 

operation should be within 4 seconds to prevent diode 

from heat. 

20A 

(e) 

Loosen 4 retaining bolts from rectifier. 

(f) 

Using a electric iron, remove rectifier from regulator. 

NOTE 

• Ensure that the heat is not transmitted from electric 

iron to diode for long time. 

• Do not let diode pin bear too much force. 

20A 

(g) 

Remove and inspect rotor. 

• Check the rotor coil is conductive, and confirm that the 

collector rings are conductive. Measure the resistance of 

rotor. If the resistance is less than specified value, it 

means the rotor is short circuit. If it is not conductive or it 

is short circuit, replace the rotor assy. 

Specified value: 3 ~ 5 Ω 

20A 

• Check that rotor coil ground. Confirm that it is insulative 

between collector ring and core. If not, replace the rotor 

assy. 

Page 1541

20A-8 


• Using a vernier caliper, measure the slip ring diameter. 

Standard: 14.2 ~ 14.4 mm 

Limit: 12.8 mm 

(h) Remove and inspect stator. 

• Check the stator for continuity. Confirm that the coil lead 

is conductive. If not, replace the stator assy. 

• Check the coil ground. Confirm that it is not conductive 

between coil and stator core. Replace the stator assy if 

conductive. 

(i) Inspect stator rectifier. 

• Diode group (three diodes) check: Using an ammeter to 

connect two ends of each diode, check if three diodes 

are conductive. If it is not conductive in both directions, it 

means the diodes are broken, and it is required to 

replace the rectifier assy. 

(j) 

Get rid of welding point of brush lead, then take out the 

brush. 

Page 1542


20A-9 

(k) 

If brush is so worn to reach wear limit line, replace brush. 

20A 

9. ASSEMBLE GENERATOR. 

(a) When installing new brush, weld brush lead in the 

condition when brush is pressed down to brush bracket 

as shown. 

(b) 

Tighten 4 retaining bolts of rectifier. 

(c) 

Weld rectifiers and stator. 

20A 

20A 

(d) 

Before mounting rotor on rear cover, insert a steel wire 

into small hole on rear cap, then erect mounted rotor by 

brush, pull out steel wire. 

Page 1543

20A-10 


(e) 

(f) 

Install rotor. 

Tighten the retaining bolts attaching generator front 

cover to stator component. 

10. POSITION GENERATOR BELT PULLY. USING PNEUMATIC TOOLS, INSTALL GENERATOR BELT 

PULLEY RETAINING NUT. 

11. INSTALL GENERATOR. 

(a) place generator into proper position. 

(b) Install generator adjustment bolt and lower suppor bolt. 

NOTE 

Position adjustment bolt and lower support bolt ,but just 

install, do not tighten. 

(c) 

(d) 

Connect generator connector. 

Tighten generator positive cable connecting nut. 

12. INSTALL GENERATOR BELT. 

(a) Adjust adjustment bolt until generator belt is in proper 

tension. 

Page 1544


20A-11 

(b) 

(c) 

Tighten belt tensioner locking bolt. 

Tighten adjustment bracket mounting bolt. 


20A 

(d) 

Tighten nut to generator lower support bolt. 


13. INSTALL POWER STEERING PUMP BELT. (Refer to “Chapter 52 power steering - power steering 

pump and fliud reservior assy, replacement”) 

14. INSTALL A/C COMPRESSOR BELT. (Refer to “Chapter 61 heater and air conditioning - A/C compressor, 




17. START THE VEHICLE AND CHECK GENERATOR FOR GOOD CONDITION. 

20A 

20A 

Page 1545

20A-12 

STARTING AND CHARGING - STARTER 

STARTER 

COMPONENTS 

1 Front Bracket 

2 Spring 

3 Starter Drive Lever 

4 Rubber Washer 

5 Planetary Gear Bracket 

6 Solenoid Component 


8 Steel Ball 

9 Planetary Gear 

11 Overdrive Clutch 

12 Locating Snap Ring 

13 Magnet Yoke Assy 

14 Commutator 

15 Brush 

16 Brush Bracket 

17 Starter Shell Bolt 


19 Rear Bracket 

10 Internal Gear 

Page 1546


20A-13 

OVERHAUL 




20A 

4. REMOVE STARTER. 

(a) Disconnect starter control wire connector. 

(b) 

Remove starter positive cable locking nut. 

(c) 

(d) 

Remove 2 starter retaining bolts. 

Remove starter. 

20A 

20A 

5. INSPECT STARTER. 

(a) Pinion gap adjustment. 

• Disconnect the field coil wire from the M-terminal of the 

magnetic switch. 

• Connect a 12-volt battery between the S-terminal and M- 

terminal. 

NOTE 

This test must be performed quickly (less than 10 seconds) 

to prevent the coil from being burned. 

• When the 12-volt battery is connected between the S- 

terminal and M-terminal, the pinion will move out. 

Page 1547

20A-14 


• Check the pinion-to-stopper clearance (pinion gap) with 

a feeler gauge. 


• If the pinion gap is out of specification, adjust by adding 

or removing gasket(s) between the magnetic switch and 

front bracket. 

(b) Magnetic switch pull-in test. 




terminal. 

NOTE 



• When turn ignition switch on, the pinion will move out. If 

the pinion moves out, the pull-in coil is good. If it doesn't, 

replace the magnetic switch. 

(c) Magnetic switch hold-in test. 



• Connect a 12-volt battery between the S-terminal and 

body. 

NOTE 



• Manually pull out the pinion as far as the pinion stopper 

position. 

• If the pinion remains out, everything is operating properly. 

If the pinion moves in, the hold-in circuit is open. 

Replace the magnetic switch. 

Page 1548


20A-15 

(d) 

Magnetic switch return test. 



• Connect a 12-volt battery between the M-terminal and 

body. 

20A 

NOTE 


to prevent the coil from burning. 

• Pull the pinion out and release. If the pinion quickly 

returns to its original position, everything is operating 

properly. If it doesn't, replace the magnetic switch. 

CAUTION 

Be careful not to get your fingers caught when pulling out 

the pinion. 

6. DISASSEMBLE STARTER. 

(a) Disconnect magnetic coil lead nut from magnetic switch. 

(b) 

Remove magnetic switch retaining bolts. 

20A 

20A 

(c) 

Remove starter shell retaining bolts. 

Page 1549

20A-16 


(d) 

NOTE 

Disassemble starter as components art shown. 

• When removing armature, do not lose the steel ball 

mounted in the bearing ends. 

• Using a proper control sleeve, push and press the 

locating snap ring to the overdrive clutch side, and 

make it be away from the clip spring. 

• Remove the snap spring with snap ring pliers, then 

remove the locating snap ring and overdrive clutch. 

7. CLEAN STARTER PARTS. 

(a) 

(b) 

(c) 

(d) 

Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation winding lead or rotor is 

immerged in detergent, their insulating ability will be damaged. 

Clean starter parts with cloth. 

Drive parts can not be immerged in detergent for cleaning. Before delivering out of factory, the 

overdrive clutch is greased. If clean it by detergent, its grease might be removed. 

Using a brush and dipping with detergent, clean drive parts then dry them with a cloth. 

8. INSPECT COMMUTATOR. 

(a) Support the commutator with a pair of V block and turn it 

to measure the runout of the surface using a dial gauge. 

Standard: ≤ 0.05 mm 

Limit: 0.1 mm 

(b) 

Measure the diameter of the commutator. 

Standard: 29.4 mm 


Page 1550


20A-17 

(c) 

Measure the depth of the undercut between segments. 


Limit: 0.2 mm 

20A 

9. INSPECT BRUSH AND BRUSH BRACKET. 

(a) Check that it is conductive between brush plate and brush bracket, if not, it is normal. 

(b) Check the commutator contact surface of each brush for abnormal roughness. Also check the height of 

the brush. Replace the brush holder if the height is lower than the limit. 

Limit: 7.0 mm 

(c) When the contact surface of the brush is rectified or the brush holder is replaced, recondition the 

contact surface with sandpaper wrapping around the commutator. 

10. INSPECT OVERDRIVE CLUTCH. 

(a) Make sure that the pinion can not be turned counterclockwise 

and can be turned clockwise freely. 

(b) Check the pinion for abnormal waring and damage. 

11. INSPECT ARMATURE COIL. 

(a) Set the armature in a growler. 

(b) While holding a thin strip of iron against the armature in 

parallel with its axis, turn the armature slowly. The 

armature is normal if the iron strip is not attracted to the 

armature or it does not vibrate. 

NOTE 

Clean the surface of the armature thoroughly before performing 

the test. 

20A 

20A 

(c) 

Check the insulation between commutator segments and 

armature coils. It is normal if there is not continuity. 

Page 1551

20A-18 


(d) 

Check continuity between a segment and another. It is 

normal if there is continuity. 

12. INSPECT MAGNETIC SWITCH. 

(a) Coil open circuit test. 

• Check that there is continuity between the M terminal 

and body A. 

• If there is no continuity, replace the magnetic switch. 

(b) 

Contact fusion check. 

• Check that there is no continuity between the B terminal 

and M terminal. 

• If there is continuity, replace the magnetic switch. 

(c) 

Switch contact check. 

• Push the indicated end of the magnetic switch with a 

strong force to close the internal contacts. Without 

releasing the switch end, check that there is continuity 

between the B terminal and M terminal. 


13. ASSEMBLE STARTER. 

(a) Using a suitable puller, pull stop ring until it gets over 

snap ring. 

Page 1552


20A-19 

(b) 

Install locating snap ring and overdrive clutch. 

20A 

(c) 

(d) 

Assemble starter as components art shown. 

Tighten the starter shell retaining bolts. 


(e) 

Tighten the magnetic switch retaining bolts. 


20A 

20A 

(f) 

Connect the magnetic coil lead nut to magnetic switch. 


Page 1553

20A-20 


14. INSTALL STARTER. 

(a) Tighten 2 starter retaining bolts. 


(b) 

(c) 

Connnect and tighten starter positive cable locking nut. 


Connect starter control wire connector. 



Page 1554

STARTING AND CHARGING - BATTERY 

20A-21 

BATTERY 

COMPONENTS 

20A 

1 Battery 

2 Battery Fix Frame 

3 Battery Fix Rod 

4 Mounting Nut 

5 Battery Tray 

6 Bolt And Washer 

20A 

20A 

Page 1555

20A-22 


USE AND MAINTENANCE 

1. CHARGING DEVICE. 

NOTE 

DC power supply must be used for battery charging, howerever, what is supplied by power plant is AC 

that it must be transformed into DC, After transform, the charging can be performed. 

(a) 

(b) 

Rectifier. 

Controllable silicone voltage regulation charger. 

2. CHARGE PRECAUTIONS. 

(a) Charging should choose in ventilated dry room, indoor temperature in 5 ℃ ~ 40 ℃ is advisable. 

(b) Battery can not be overlap shelved, also do not put them on the ground directly. It should be put on the 

wooden support, and cannot be set with alkaline battery or other chemicals. 

(c) Charging in field should be far away from fire and heat. 

(d) Liquid temperature should not exceed 45 ℃ and otherwise cooling measures shouldl be taken (by 

reducing filling current or stopping sharge or being cooled down in water tank). 

3. CHARGE CONNECTION. 

(a) The positive pole of charger is to be connected with the positive pole of battery, while the negative pole 

of charger should be connected with the negative pole of battery. Never connect them reversely. 

(b) Charge of most batteries may be determined based on the size of motor power. Connection for charge 

must be firm. 

4. CHARGING MODES. 

(a) Constant current charge. 

(b) Constant voltage charge. 

(c) Quick charge. 

5. AFTER CHARGING, USING THE BELOW METHODS, CHECK THE BATTERY CAPACITY IS 

RESTORED TO STANDARD. 

(a) Voltage method 

Voltage Determination Treatment 

above 12.5 v normal go on using 

11.5 ~ 12.5 v undercharge additional charge 

below 11.5 v over-discharge or internal failure to be further checked after charging 

(b) 

Capacity method 

Capacity Tester Display Determination Treatment 

white zone fully charged go on using 

green zone normal go on using 

yellow zone undercharge additional charge 

red zone over-discharge to be further checked after charging 

Page 1556


20A-23 

6. USING AND MAINTENANCE OF BATTERY IN WINTER 

(a) 

(b) 

Keep the battery is to be maintained under full charge status, avoid the electrolyte from being frozen 

arising from drop in density, which may give rise to breakage of container, curve of pole plats, as well as 

smash and dropout of active substances, and other failures. 

Because the battery capacity reduced in winter, when start the engine in cold status, preheated the 

engine and each time start the engine should not more than 15 seconds, two starting interval 2 ~ 3 

minutes, if can not start the engine in three times, troubleshooting, then restarting. 

20A 

20A 

20A 

Page 1557

20A-24 


INSPECTION 

1. APPEARANCE INSPECTION. 

(a) Observe whether the battery appearance in good condition. Check if fixed terminal and wires are 

connected firmly. 

(b) Observe whether the battery shell and the center partition cracks, and use a wooden beat shell and 

center partitions respectively, listen to the sound without breaking, especially the central baffle and shell 

side of shell wall at the junction of four, prone to crack, should be carefully examined. 

(c) Through mirrors, green for fully charged, red and white says lack of electricity and no electricity. Need 

of the following capacity, voltage detection. 

2. CAPACITY TEST. 

(a) The excel tester is also known as the discharging tongs. 

It consists of a DC voltmeter of three volts and one load 

resistance. 

(b) The tips of the two tongs shall be pressed on the anode 

and the cathode tightly and maintain for five seconds in 

the measurement. Observe the terminal voltage in the 

state of the big load discharging and the discharging 

content and the starting ability can be judged correctly. 

(c) For the excel tester of different brands, the readings of 

the current and the voltage shall be read according to the 

regulations of the factory manual. Generally, the single 

voltage of the battery in good state shall be above 1.5 V 

and keep steady within five seconds. If the voltage drops 

rapidly within five minutes or the voltage of one single 

cell is 0.1 V lower than that of others, it indicates there 

are troubles in the battery and it shall be repaired.Below 

is the use of excel tester of discharge plan detection 

income cross-references. 

Display Zone Determination Treatment 





3. VOLTAGE TEST. 

The following table is derived using the digital multimeter test table. 




under 112.5 v over-discharge or internal fault to be further checked after charging 

Page 1558


20A-25 


TROUBLESHOOTING 

1. ELECTRICAL QUALITY OF ONE FULL-CHARGED BATTERY REDUCE WITHOUT USE FOR A 

LONG PERIOD. 

• Causes analysis: 

The full-charged battery without use will lose its electrical quality gradually and this phenomenon is 

known as “self-discharge”. The important cause of self-discharge is the impure materials. If there are 

impurities in the material of the polar plate or in the electrolyte, there will be a potential difference 

between the impurity and the polar plate and between the impurities. A closed “local current” is formed 

and would make the discharge of the battery. 

• Troubleshooting: 

For the battery which has discharged seriously, it can be discharged completely or excessively. This will 

enable the impurities on the polar plate into the electrolyte. Then, pour the electrolyte out and clean the 

battery with distilled water. Finally, inject the new electrolyte and re-charge the battery. 

2. BATTERY EXPLODE. 


The water in the electrolyte hydrolyzes into hydrogen or oxygen and a lot of bubbles are generated; 

there are short circuit and vulcanization troubles in the battery; the temperature increases while 

charging and large amount of water are evaporated. Then if the vent holes of the injection hole cover 

are plugged or there are a lot of gases which are unable to escape, the battery will explode when the 

inner pressure comes to a limit (or there are sparks). 


(a) The vent holes of the injection hole cover shall be cleared. 

(b) In order to avoid sparks, the wirings on the polar stud shall be fastened. 

(c) The injection hole cover shall be opened first when check with the excel tester. 

(d) Control the charging amount and do not over-charge in order to reduce the releasing amount of the 

gases. Open flames are prohibited and the ventilation shall be ensured in the charging room. 

3. RAPID DECREASE OF THE LIQUID LEVEL DURING THE USE PROCESS OF THE BATTERY. 


(a) Excessive charging current lead to evaporation of water. 

(b) Battery shell broken. 


(a) Add distilled water. 

(b) Repair shell, add the electrolyte. 

4. A YELLOW OR WHITE PASTE APPEARS ON BATTERY COVER. 


The yellow or white paste surrounding the battery cover and the polar stud is caused by the corrosion of 

the polar studs, wiring clip and the fixed frame by the sulfuric acid sprayed. 


In order to avoid these pastes, clean the electrolyte sprayed on the battery cover and the shell with a 

cloth soaked with the soda solution of 10 percents. Then wipe with water and dry with a clean cloth. 

The paste on the wire ends and the studs shall be wiped with the cloth soaked with soda solution. If 

there are oxides of poor conductivity, scrape them with a little knife and clean them. It would be best to 

smear a coat of Vaseline or butter on the cover after the polar studs and wiring clips are fastened. 

20A 

20A 

20A 

Page 1559

20A-26 


CAUTION 

The vehicle for Foton View CS2 is equipped with maintenance-free battery. If battery is bad, replace the 

battery as a unit. To avoid personal injury, it is strictly prohibited to disassemble the battery. 

Disassembly is limited to find the cause of the problem and provide information through professional 

testing. 

Page 1560


20A-27 

REPLACEMENT 



(a) 

(b) 



cover. 

20A 

3. REMOVE BATTERY CABLE. 

(a) Open shield and disconnect battery negative cable. 

NOTE 

Disconnect the negative cable first when removal. 

(b) 

Open shield and disconnect battery positive cable. 

20A 

20A 

4. REMOVE BATTERY FIX FRAME. 

(a) Remove battery fix rod mounting nut. 

(b) Remove battery fix frame. 

5. REMOVE BATTERY. 

NOTE 

Battery should be put up, placing battery upside down is prohibited. 

Page 1561

20A-28 


6. REMOVE BATTERY TRAY. 

(a) Loosen 3 battery tray retaining bolts. 

(b) Remove battery tray. 

7. INSTALL BATTERY TRAY. 

(a) Install 3 battery tray retaining bolts. 


8. INSTALL BATTERY. 

(a) Position battery. 

(b) Place battery fix frame and tighten fix rod mounting nut. 

(c) 

(d) 

Connect battery positive cable, tighten mounting nut and 

cover shield. 

Connect battery negative cable, tighten mounting nut 

and cover shield. 

NOTE 

• If terminals has sediments, remove the impurities 

then apply thin layer of grease to terminal. 

• Connect positive battery cable first when installing. 


Page 1562

A 

A SINGLE MIRROR IS INOPERATIVE .....................................04-445 

ABS CONTROL IS UNREASONABLE ......................................04-119 

ABS MODULE CONNECTOR .....................................................04-98 

ABS SYSTEM IS INOPERATIVE...............................................04-122 

ACCELERATE PEDAL ............................................................. 12A-25 

AIR FILTER ASSY ...................................................................... 14A-6 

AIR PURIFIER LAMP IS INOPERATIVE ...................................04-283 

ALL FOG LAMPS ARE INOPERATIVE .....................................04-229 

ALL HEADLAMPS ARE INOPERATIVE ....................................04-207 

ALL INTERIOR ILLUMINATION LAMPS ARE 

INOPERATIVE ...........................................................................04-295 

ALL POWER WINDOWS ARE INOPERATIVE .........................04-421 

ALL STOP LAMPS ARE INOPERATIVE ...................................04-260 

ANTI-LOCK BRAKE SYSTEM .....................................................04-96 

AUDIO SYSTEM ........................................................................04-361 

AUXILIARY POWER..................................................................04-374 

A/C CONTROL PANEL ILLUMINATION IS NOT 

INOPERATIVE ...........................................................................04-307 

A/C CONTROL PANEL ILLUMINATION IS NOT INOPERA- 

TIVE(LIGHTING SYSTEM) ........................................................04-307 

A/C SYSTEM IS INOPERATIVE................................................04-153 

B 

BACK - UP LAMP IS INOPERATIVE(ONE SIDE) .....................04-269 

BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES) .........04-271 

BASIC IDLE SPEED ADJUSTMENT(THROTTLE BODY) ....... 11A-23 

BASIC INSPECTION ...........04-150, 04-182, 04-335, 04-362, 04-418, 

04-440, 04-453, 04-469, 04-495 

BASIC PRINCIPLE(GASOLINE ENGINE CONTROL 

SYSTEM) .................................................................................... 11A-8 

BASIC SERVICE PROCEDURE..................................................04-10 

BATTERY.................................................................................. 20A-21 


IN SPECIFIED DISTANCE (DISPLAYER IS NORMAL) ............04-408 

C 

CANISTER SOLENOID VALVE.....................................11A-52, 13A-4 

CAPTURING DATA .....................................................................04-20 

CENTRAL DOME LIGHT IS INOPERATIVE .............................04-278 

CENTRAL LOCKING CONTROLLER ASSY A..........................04-493 

CENTRAL LOCKING CONTROLLER ASSY A PIN...................04-417 

CENTRAL LOCKING CONTROLLER ASSY B..........................04-494 

CHECK ACCESSORY BELT(INSPECTION)...............................05-20 

CHECK AND CLEAN WINDSHIELD FLUME(INSPECTION)......05-16 

CHECK AND TIGHTEN THE CHASSIS BOLT REFER TO THE PRE- 

SCRIBED TORQUE(INSPECTION) ............................................05-22 

CHECK BRAKING SYSTEM(INSPECTION) ...............................05-30 

CHECK CHASSIS(INSPECTION) ...............................................05-26 

CHECK COOLANT LEVEL(INSPECTION)..................................05-34 

CHECK DOOR LIMIT, DOOR LOCK AND DOOR HINGE 

(INSPECTION).............................................................................05-14 

CHECK ENGINE COMPARTMENT PARTS(INSPECTION) .......05-17 

CHECK EXHAUST SYSTEM(INSPECTION) ..............................05-33 

CHECK HEADLIGHTS(INSPECTION) ........................................05-23 

CHECK PARKING BRAKE, BRAKE PEDAL(INSPECTION).......05-13 

CHECK SEAT BELT(INSPECTION)............................................05-11 

CHECK STEERING FLUID LEVEL(INSPECTION) .....................05-29 

INDEX 


CHECK SUSPENSION BALL JOINT AND DUST COVER(INSPEC- 

TION)........................................................................................... 05-28 

CHECK SUSPENSION COMPONENTS(INSPECTION) ............ 05-27 

CHECK THE AIRBAG(INSPECTION)......................................... 05-10 

CHECK THE BATTERY(INSPECTION)........................................ 05-9 

CHECK THE BRAKE DISC, BRAKE DRUM AND BRAKE FRICTION 

PLATE(INSPECTION)................................................................. 05-31 

CHECK THE ELECTRICAL SYSTEM WORKING CONDITION 

(INSPECTION) .............................................................................. 05-8 

CHECK THE ENGINE OIL LEVEL (ISF2.8)(INSPECTION)........ 05-36 

CHECK THE ENGINE OIL LEVEL (4G69)(INSPECTION) ......... 05-35 

CHECK THE TIE ROD BALL HEAD AND DUST COVER 

(INSPECTION) ............................................................................ 05-21 

CHECK TIMING BELT(INSPECTION) ........................................ 05-18 

CHECK TIRES(INSPECTION) .................................................... 05-32 

CHECK WINDSHIELD WIPERS, CLEANING DEVICE 

(INSPECTION) ............................................................................ 05-24 

CIGARETTE LIGHTER ILLUMINATION IS NOT 

INOPERATIVE .......................................................................... 04-305 

CIGARETTE LIGHTER IS INOPERATIVE................................ 04-375 

CKP SENSOR ...........................................................................11A-43 

COMPONENTS(COOLING SYSTEM) ........................................17A-2 

COMPONENTS(CRANKSHAFT, CYLINDER 

BLOCK & FLYWHEEL) .............................................................15A-69 

COMPONENTS(CYLINDER HEAD,VALVE).............................15A-51 

COMPONENTS(EXHAUST PIPE) ..............................................16A-1 

COMPONENTS(GENERATOR)..................................................20A-4 

COMPONENTS(PISTON & CONNECTING ROD 

ASSEMBLY) ..............................................................................15A-59 

COMPONENTS(ROCK ARM, ROCK ARM SHAFT, HYDRAULIC 

TAPPET & CAMSHAFT) ...........................................................15A-37 

COMPONENTS(STARTER)......................................................20A-12 

COMPONENTS(TIMING BELT)................................................15A-18 

COMPOSITION(BATTERY) ......................................................20A-21 

COOLANT ...................................................................................17A-6 

COOLANT PUMP......................................................................17A-23 

COOLING SYSTEM ....................................................................17A-1 

CRANKSHAFT, CYLINDER BLOCK & FLYWHEEL .................15A-69 

CYLINDER HEAD OVERHAUL(CYLINDER HEAD,VALVE) ....15A-52 

CYLINDER HEAD,VALVE.........................................................15A-51 

D 

DATA STREAM LIST/ACTIVE TEST .......................................... 04-23 

DEFROSTER SYSTEM............................................................. 04-452 

DIAGNOSIS SWITCH ILLUMINATION IS NOT INOPERATIVE04-303 

DIAGNOSTIC HELP - INTERMITTENT FAULT............................ 04-8 

DIAGNOSTIC SYSTEM .............................................................. 04-16 

DIAGNOSTIC TROUBLE CODE CHART ...........04-27, 04-99, 04-129 

DIAGNOSTICS GASOLINE ENGINE CONTROL SYSTEM 

(BJ491EQ).................................................................................... 04-1 


(BUZZER IS NORMAL) ............................................................. 04-411 

DOME LIGHT SWITCH ILLUMINATION IS NOT 

INOPERATIVE .......................................................................... 04-313 

DOOR CONTROL SWITCH PIN ............................................... 04-415 

DOOR DOES NOT OPEN / CLOSE 

(USING THE REMOTE KEY) .................................................... 04-504 

DOWNSTREAM OXYGEN SENSOR........................................11A-49 

DTC DIAGNOSTIC...................................................................... 04-32 

Page 1563

E 

ENGINE CONTROL MODULE (ECM) ......................................11A-15 

ENGINE CONTROL SYSTEM ...................................................... 04-1 

ENGINE COOLANT TEMPERATURE SENSOR ......................11A-18 

ENGINE MECHANICAL PART....................................................15A-1 

ENGINE OIL ................................................................................18A-4 

ENGINE OIL PRESSURE WARNING LIGHT NEVER / 

ALWAYS ON ............................................................................. 04-482 

ENGINE SYMPTOM DIAGNOSTIC ............................................ 04-59 

EXHAUST PIPE ..........................................................................16A-1 

F 

FAIL-SAFE CHART ..................................................................... 04-21 

FRONT AIR FLOW IS INSUFFICIENT...................................... 04-163 

FRONT BLOWER MOTOR IS INOPERATIVE.......................... 04-157 

FRONT DOME LIGHT IS INOPERATIVE ................................. 04-291 

FRONT FOG LAMPS ARE ALWAYS ON ................................. 04-218 

FRONT FOG LAMPS ARE INOPERATIVE............................... 04-213 

FRONT POWER WINDOW LH DOES NOT CLOSE ................ 04-432 

FRONT POWER WINDOW LH DOES NOT OPEN .................. 04-430 


CONTROL SWITCH RH) .......................................................... 04-436 

FRONT POWER WINDOW RH IS INOPERATIVE ................... 04-427 


TROL SWITCH)......................................................................... 04-434 

FUEL FILLER CAP........................................................ 12A-20, 13A-1 

FUEL FILLER DOOR LOCK LATCH ASSY ..............................12A-18 

FUEL FILLING DOOR ...............................................................12A-17 

FUEL FILLING TUBE AND BREATHER TUBE ASSY..............12A-21 

FUEL FILTER ASSY ...................................................................12A-9 

FUEL LEVEL SENSOR ASSY ..................................................12A-10 

FUEL SYSTEM............................................................................12A-1 

G 

GASOLINE ENGINE CONTROL SYSTEM ........................05-1, 11A-1 

GENERATOR..............................................................................20A-4 

H 


TIVE........................................................................................... 04-245 

HAZARD WARNING LAMPS ARE ALWAYS ON ..................... 04-258 


LAMPS ARE NORMAL) ............................................................ 04-236 


TIVE........................................................................................... 04-321 


TIVE........................................................................................... 04-317 

HEATER AND AIR CONDITIONING SYSTEM ......................... 04-149 

HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)........... 04-197 


(BOTH SIDES) ......................................................................... 04-199 

HIGH - MOUNTED STOP LAMP IS INOPERATIVE ................. 04-267 

HORN IS ALWAYS ON ............................................................. 04-389 

HORN IS INOPERATIVE .......................................................... 04-383 

HORN SYSTEM ........................................................................ 04-382 

HOW TO DIAGNOSTICS ANALYSE ............................................ 04-5 

J 

IDLE AIR CONTROL MOTOR...................................................11A-28 

IGNITION CONTROL MODULE................................................11A-60 

IGNITION SWITCH ILLUMINATION IS INOPERATIVE............ 04-275 

INSPECTION................................................................................. 05-8 

INSPECTION(BATTERY)..........................................................20A-24 

INSPECTION(FUEL FILLER CAP)................................12A-20, 13A-1 

INSPECTION(FUEL FILLING TUBE AND BREATHER TUBE 

ASSY) ....................................................................................... 12A-21 

INSTRUMENT CLUSTER..........................................................04-461 

INSTRUMENT CLUSTER ILLUMINATION IS NOT 

INOPERATIVE...........................................................................04-300 

INSTRUMENT CLUSTER INFORMATION ...............................04-463 


TIVE ...........................................................................................04-319 

INTAKE AIR PIPE AND HOSE ................................................... 14A-2 

INTAKE AIR SYSTEM ................................................................ 14A-1 

INTAKE MANIFOLD ................................................................. 14A-10 

INTRODUCTION TO SYSTEM FUNCTION(GASOLINE ENGINE 

CONTROL SYSTEM) ................................................................. 11A-6 

L 

LICENSE LAMP IS INOPERATIVE ...........................................04-328 

LIGHTING SYSTEM ..................................................................04-181 

LIQUID CRYSTAL DISPLAY .....................................................04-465 

LO - BEAM AND HI - BEAM HEADLAMPS ARE INOPERATIVE 

(ONE SIDE) ..............................................................................04-204 

LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)..........04-191 

LO - BEAM HEADLAMPS ARE INOPERATIVE 

(BOTH SIDES)...........................................................................04-193 

LOCATION.......................................................... 04-4, 04-183, 04-462 

LOCATION(SUPPLEMENTAL RESTRAINT SYSTEM) ............04-126 

LUBRICATION SYSTEM ............................................................ 18A-1 

M 

MAIN COMPONENTS(GASOLINE ENGINE CONTROL 

SYSTEM) .................................................................................. 11A-13 

MAINTENANCE CONTENT AND SCHEDULE IN GENERAL CONDI- 

TION(MAINTENANCE SCHEDULE) .............................................05-3 

MAINTENANCE SCHEDULE ........................................................05-1 

MALFUCTION IN ENGINE COOLANT TEMPERATURE 

GAUGE......................................................................................04-479 

MALFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT NEV- 

ER OR ALWAYS ON .................................................................04-476 

MALFUNCTION IN SPEEDOMETER........................................04-472 

MALFUNCTION IN TACHOMETER ..........................................04-474 

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE........04-450 

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE ...........04-448 

MIRRORS ARE INOPERATIVE (BOTH SIDES) .......................04-442 

N 

NO COOLING FROM FRONT A/C SYSTEM ............................04-167 

O 

OIL FILTER................................................................................. 18A-6 

OIL PUMP................................................................................. 18A-11 

ON VEHICLE INSPECTION(IDLE AIR CONTROL MOTOR)... 11A-29 

ON VEHICLE INSPECTION(THROTTLE POSITION SENSOR 

(TPS)) ...................................................................................... 11A-33 

ON VEHICLE INSPECT(COOLING SYSTEM)........................... 17A-4 

ONE DOOR IS INOPERATIVE (USING THE KEY)...................04-502 

ON-VEHICLE INSPECTION(CANISTER SOLENOID 

VALVE) ..................................................................................... 11A-53 

ON-VEHICLE INSPECTION(DOWNSTREAM OXYGEN 

SENSOR).................................................................................. 11A-50 

ON-VEHICLE INSPECTION(MANIFOLD ABSOLUTE PRESSURE/IN- 

TAKE TEMPERATURE SENSOR) ........................................... 11A-37 

ON-VEHICLE INSPECTION(VEHICLE SPEED SENSOR)...... 11A-58 

ON-VEHICLE INSPECTION(UPSTREAM OXYGEN 

SENSOR).................................................................................. 11A-47 

Page 1564

OVERHAUL(CANISTER SOLENOID VALVE)...............11A-54, 13A-4 

OVERHAUL(CKP SENSOR) .................................................... 11A-44 

OVERHAUL(COOLANT PUMP) ............................................... 17A-23 

OVERHAUL(CRANKSHAFT, CYLINDER BLOCK & 

FLYWHEEL).............................................................................. 15A-71 

OVERHAUL(DOWNSTREAM OXYGEN SENSOR) ................. 11A-51 

OVERHAUL(ENGINE COOLANT TEMPERATURE 

SENSOR).................................................................................. 11A-19 

OVERHAUL(FUEL INJECTOR RAIL ASSY) ............................ 12A-12 

OVERHAUL(GENERATOR) ....................................................... 20A-5 

OVERHAUL(IDLE AIR CONTROL MOTOR) ............................ 11A-30 

OVERHAUL(IGNITION CONTROL MODULE) ......................... 11A-61 

OVERHAUL(MANIFOLD ABSOLUTE PRESSURE/INTAKE TEM- 

PERATURE SENSOR) ............................................................. 11A-38 

OVERHAUL(OIL PUMP)........................................................... 18A-11 

OVERHAUL(POSITIVE CRANKCASE VENTILATION VALVE 

(PCV VALVE))............................................................................ 13A-7 

OVERHAUL(STARTER) ........................................................... 20A-13 

OVERHAUL(THERMOSTAT) ................................................... 17A-18 

OVERHAUL(THROTTLE BODY).............................................. 11A-24 

OVERHAUL(THROTTLE POSITION SENSOR (TPS)) ............ 11A-34 

OVERHAUL(TIMING BELT) ..................................................... 15A-19 

OVERHAUL(VEHICLE SPEED SENSOR) ............................... 11A-59 

OVERHAUL(UPSTREAM OXYGEN SENSOR) ....................... 11A-48 

OUTSIDE MIRROR....................................................................04-439 

OUTSIDE MIRROR DEFROST ER IS INOPERATIVE..............04-455 


INOPERATIVE ...........................................................................04-315 

P 

PARKING BRAKE INDICATOR LIGHT NEVER / 

ALWAYS ON..............................................................................04-489 

PISTON & CONNECTING ROD ASSEMBLY........................... 15A-59 

PISTON & CONNECTING ROD ASSEMBLY OVERHAUL 

(PISTON & CONNECTING ROD ASSEMBLY) ........................ 15A-60 

POOR SOUND QUALITY ..........................................................04-369 

POSITIVE CRANKCASE VENTILATION VALVE 

(PCV VALVE)............................................................................. 13A-7 

POWER DOOR LOCKS.............................................................04-492 

POWER SUPPY VOLTAGE HIGH OR LOW.............................04-104 

POWER WINDOWS ..................................................................04-414 

PRE - CHECK ............................................................................04-102 

PRECAUTION...........04-96, 04-126, 04-149, 04-181, 04-334, 04-361, 

04-391, 04-414, 04-461, 04-492 

PRECAUTION(COOLING SYSTEM).......................................... 17A-1 

PRECAUTION(ENGINE MECHANICAL PART) ......................... 15A-1 

PRECAUTION(FUEL SYSTEM) ................................................. 12A-1 

PRECAUTION(GASOLINE ENGINE CONTROL SYSTEM)....... 11A-1 

PRECAUTION(INTAKE AIR SYSTEM) ...................................... 14A-1 

PRECAUTION(LUBRICATION SYSTEM) .................................. 18A-1 

PRECAUTION(MAINTENANCE SCHEDULE) ..............................05-1 

PRECAUTION(STARTING AND CHARGING SYSTEM) ........... 20A-1 

PRINCIPLE(CANISTER SOLENOID VALVE) .......................... 11A-52 

PRINCIPLE(CKP SENSOR) ..................................................... 11A-43 

PRINCIPLE(DOWNSTREAM OXYGEN SENSOR).................. 11A-49 

PRINCIPLE(ENGINE CONTROL MODULE (ECM))................. 11A-15 

PRINCIPLE(ENGINE COOLANT TEMPERATURE 

SENSOR).................................................................................. 11A-18 

PRINCIPLE(IDLE AIR CONTROL MOTOR)............................. 11A-28 

PRINCIPLE(IGNITION CONTROL MODULE).......................... 11A-60 

PRINCIPLE(MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPER- 

ATURE SENSOR)..................................................................... 11A-36 

PRINCIPLE(THROTTLE POSITION SENSOR (TPS)) ............. 11A-32 

PRINCIPLE(VEHICLE SPEED SENSOR) ................................ 11A-57 

PRINCIPLE(UPSTREAM OXYGEN SENSOR) ........................ 11A-46 

PROBLEM SYMPTOMS TABLE....... 04-101, 04-130, 04-151, 04-185, 

04-336, 04-363, 04-374, 04-382, 04-394, 04-419, 04-441, 04-454, 

04-470, 04-496 

PROBLEM SYMPTOMS TABLE ................................................. 04-58 

PROBLEM SYMPTOMS TABLE(FUEL SYSTEM)......................12A-3 

PROBLEM SYMPTOMS TABLE(STARTING AND CHARGING 

SYSTEM).....................................................................................20A-2 

PUMP MOTOR FAILURE.......................................................... 04-109 

R 

RADIATOR ................................................................................17A-13 

RADIO DOES NOT WORK ....................................................... 04-364 

RADIO ILLUMINATION IS NOT INOPERATIVE....................... 04-309 

RADIO RECEPTION IS POOR ................................................. 04-368 

READING AND ERASING DIAGNOSTIC TROUBLE CODE 

(DTC).......................................................................................... 04-18 


ERATIVE ................................................................................... 04-311 

REAR FOG LAMPS ARE ALWAYS ON.................................... 04-226 

REAR FOG LAMPS ARE INOPERATIVE ................................. 04-221 

REAR HEATER IS INOPERATIVE OR INSUFFICIENT 

HEATING................................................................................... 04-174 

REPLACE AIR CONDITIONER FILTER ELEMENT 

(REPLACEMENT) ....................................................................... 05-38 

REPLACE AIR FILTER ELEMENT(REPLACEMENT) ................ 05-37 

REPLACE BRAKE FLUID(REPLACEMENT).............................. 05-54 

REPLACE COOLANT(REPLACEMENT) .................................... 05-52 

REPLACE ENGINE OIL (ISF2.8)(REPLACEMENT)................... 05-44 

REPLACE ENGINE OIL (4G69)(REPLACEMENT)..................... 05-40 

REPLACE FUEL FILTER ASSEMBLY (4G69) 

(REPLACEMENT) ....................................................................... 05-50 

REPLACE FUEL FILTER ELEMENT (ISF2.8) 

(REPLACEMENT) ....................................................................... 05-51 

REPLACE GEARBOX LUBRICATING OIL(REPLACEMENT).... 05-56 

REPLACE OIL FILTER (4G69)(REPLACEMENT) ...................... 05-42 

REPLACE REAR MAIN REDUCER GEAR OIL 

(REPLACEMENT) ....................................................................... 05-57 

REPLACE SPARK PLUG (4G69)(REPLACEMENT) .................. 05-48 

REPLACEMENT.......................................................................... 05-37 

REPLACEMENT(ACCELERATE PEDAL) ................................12A-25 

REPLACEMENT(AIR FILTER ASSY) .........................................14A-6 

REPLACEMENT(BATTERY).....................................................20A-27 

REPLACEMENT(COOLANT)......................................................17A-6 

REPLACEMENT(ENGINE ASSY)...............................................15A-2 

REPLACEMENT(ENGINE OIL)...................................................18A-4 

REPLACEMENT(ENGINE OIL)(REPLACEMENT) ..................... 05-46 

REPLACEMENT(EXHAUST MANIFOLD)...................................16A-7 

REPLACEMENT(EXHAUST PIPE) .............................................16A-2 

REPLACEMENT(FUEL FILLER DOOR LOCK 

LATCH ASSY) ...........................................................................12A-18 

REPLACEMENT(FUEL FILLING DOOR)..................................12A-17 

REPLACEMENT(FUEL TANK ASSY).........................................12A-4 

REPLACEMENT(INTAKE AIR PIPE AND HOSE) ......................14A-2 

REPLACEMENT(INTAKE MANIFOLD).....................................14A-10 

REPLACEMENT(OIL FILTER) ....................................................18A-6 

REPLACEMENT(RADIATOR)...................................................17A-13 

REPLACEMENT(REPLACEMENT) ............................................ 05-57 

REPLACEMENT(RESERVIOR) ..................................................17A-8 

REPLACEMENT(TIMING PULLEY CASING) ...........................15A-14 

REPLACMENT(FUEL FILTER ASSY) ........................................12A-9 

REPLACMENT(FUEL LEVEL SENSOR ASSY) .......................12A-10 

RESERVIOR ...............................................................................17A-8 

RESTRAINT CONTROL MODULE (RCM) 

CONNECTOR PIN .................................................................... 04-127 

REVERSE RADAR SYSTEM .................................................... 04-391 

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL ......... 04-395 


DISTANCE (BACK-UP LAMP IS NORMAL) ............................. 04-402 

REVERSE RADAR SYSTEM IS OPERATIVE BUT THERE IS NO OB- 

STACLE BEHIND VEHICLE...................................................... 04-405 

Page 1565


VER IS OUT OF REVERSE POSITION.................................... 04-400 


HAUL(ROCK ARM, ROCK ARM SHAFT, HYDRAULIC TAPPET & 

CAMSHAFT)..............................................................................15A-39 

ROCK ARM, ROCK ARM SHAFT, HYDRAULIC TAPPET & CAM- 

SHAFT.......................................................................................15A-37 

S 

SEAT BELT WARNING LIGHT NEVER / ALWAYS ON ........... 04-485 

SOLENOID VALVES AND VALVES RELAY FAILURE ............ 04-105 

SPEAKER DOES NOT WORK.................................................. 04-370 

SRS WARNING LIGHT IS ALWAYS ON .................................. 04-145 

SRS WARNING LIGHT IS INOPERATIVE................................ 04-147 

STARTER..................................................................................20A-12 

STARTING AND CHARGING SYSTEM......................................20A-1 

STEP LAMP ARE INOPERATIVE............................................. 04-286 

STOP LAMP IS INOPERATIVE (ONE SIDE)............................ 04-265 

SUPPLEMENTAL RESTRAINT SYSTEM................................. 04-126 

SYSTEM COMPONENTS DESCRIPTION(GASOLINE ENGINE 

CONTROL SYSTEM) ................................................................11A-14 

SYSTEM DESCRIPTION ............................................. 04-392, 04-452 

SYSTEM OVERVIEW(GASOLINE ENGINE CONTROL 

SYSTEM).....................................................................................11A-2 

T 

USE AND MAINTENANCE(BATTERY).................................... 20A-22 

Z 

12V POWER SUPPLY OUTPUT SOCKET IS 

INOPERATIVE...........................................................................04-378 

8101 - POWER SUPPLY VOLTAGE HIGH ...............................04-131 

8102 - POWER SUPPLY VOLTAGE LOW................................04-131 

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE ...........04-133 

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE............04-133 

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND .......04-135 

8204 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY.......04-137 


RESISTANCE ............................................................................04-139 


RESISTANCE ............................................................................04-139 


GROUND ...................................................................................04-141 


BATTERY ..................................................................................04-143 

TAIL LAMPS ARE INOPERATIVE ............................................ 04-325 

TERMINALS OF ECM ................................................................. 04-11 

TERMINALS OF INSTRUMENT CLUSTER.............................. 04-466 

TERMINALS OF OUTSIDE MIRROR SWITCH ........................ 04-439 

THE FIXED SPEED ADJUSTING SCREW (SAS) ADJUST- 

MENT(THROTTLE BODY)........................................................11A-22 


(USING THE KEY) ................................................................... 04-497 

THERMOSTAT..........................................................................17A-18 

THROTTLE BODY ....................................................................11A-21 

THROTTLE BODY CLEANING(THROTTLE BODY) ................11A-21 

THROTTLE POSITION SENSOR (TPS)...................................11A-32 

TIMING BELT ............................................................................15A-18 

TIMING PULLEY CASING ........................................................15A-14 

TRUNK LAMP IS INOPERATIVE.............................................. 04-288 


LAMPS ARE NORMAL) ............................................................ 04-240 

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE) ....... 04-254 

W 

VALVE OVERHAUL(CYLINDER HEAD,VALVE) ......................15A-54 

WASHER PUMP IS INOPERATIVE - REAR WINDOW............ 04-358 

WASHER PUMP IS INOPERATIVE - WINDSHIELD ................ 04-348 

VEHICLE SPEED SENSOR......................................................11A-57 

WHEEL SPEED SENSOR CIRCUIT FAULT ............................ 04-113 

WHEEL SPEED SENSOR SIGNAL FAULT.............................. 04-115 


NOT RETRACT ......................................................................... 04-351 

WIDTH LAMPS IS NOT INOPERATIVE ................................... 04-323 

WIDTH LAMPS TAIL LAMPS AND LICENSE LAMP ARE 

INOPERATIVE .......................................................................... 04-330 

WINDOW CONTROL SWITCH LH PIN .................................... 04-416 

WIPER AND WASHER ............................................................. 04-334 

WIPERS ARE INOPERATIVE AT HIGH SPEED - 

WINDSHIELD ........................................................................... 04-345 

WIPERS ARE INOPERATIVE AT LOW SPEED - 

WINDSHIELD ............................................................................ 04-344 


SHIELD...................................................................................... 04-346 

UPSTREAM OXYGEN SENSOR ..............................................11A-46 

Page 1566


V O L U M E 3 

11B ENGINE CONTROL SYSTEM 1571 

12B FUEL SYSTEM 1619 

13B EMISSION CONTROL 1671 

14B INTAKE AIR 1683 

15B ENGINE MECHANICAL 1705 

16B EXHAUST SYSTEM 2021 

17B COOLING SYSTEM 2037 

18B LUBRICATION SYSTEM 2067 


20B STARTING AND CHARGING 2105 

21 SUPERCHARGER 2141 

Page 1567

Page 1568

电控燃油喷射系统 - 燃油管路 10-1 


CONTROL SYSTEM OF ENGINE ..................................................... 11B-1 

Precautions ................................................................................... 11B-1 

BJ4JB1 Engine System Composition And Principle ................ 11B-2 

Table Of Fault Phenomena .......................................................... 11B-4 

ENGINE CONTROL SYSTEM MAINTENACNE ............................. 11B-13 

General Troubleshooting Procedure ........................................ 11B-13 

SERVICING Procedures Of Basic Inspection .......................... 11B-14 

General Steps For Fault Diagnosis .......................................... 11B-15 

REPAIR FOR SENSOR AND ACTUATOR ..................................... 11B-17 

Coolant Temperature Sensor .................................................... 11B-17 

Camshaft Position Sensor ......................................................... 11B-20 

Mass Air Flow Sensor ................................................................ 11B-23 

EGR Vacuum Adjuster ............................................................... 11B-25 

Preheat Controller ...................................................................... 11B-28 

Rail Pressure Sensor ................................................................. 11B-32 

Interior Pressure Control Valve ................................................ 11B-35 

Vehicle Speed Sensor ................................................................ 11B-37 

Crankshaft Position Sensor ...................................................... 11B-40 

Accelerator Pedal Position Sensor .......................................... 11B-42 

Electronic Control Module (ECU) ............................................. 11B-45 

11B 

Page 1569

10- 2 电控燃油喷射系统 - 燃油管路 

11B 

Page 1570

CONTROL SYSTEM OF ENGINE-CONTROL SYSTEM OF ENGINE 

11B-1 

CONTROL SYSTEM OF ENGINE 

PRECAUTIONS 

1. In dismantling the connector of ground wire of electric control system, firstly turn off ignition switch and 

disassembly the ground wire of negative pole of battery. If only electric control system will be inspected, 

then, it is necessary to turn off ignition switch. 

2. Make sure that the power supply system for vehicles have negative ground. In installing battery, pay 

special attention to negative pole and positive pole, which cannot be connected reversely. 

3. In installing or taking down ECU, operators shall make themselves grounded (contact with vehicle 

body). Otherwise, the physical static electricity will damage circuits of computer. 

4. When people enter or leave carriage, the static electricity of human body may generate high voltage. 

So, make sure to wear iron metal straps while carrying out service for computer operation and digital 

instrument or near such instrument with one end is winded to wrist and the other to vehicle body. 

5. For the dismantling of any oil line, firstly decompress fuel system. 

6. In servicing electric control system, avoid damaging electric control system due to overloading. For this, 

pay attention to the following points: 

• Do not use test lamp to check the sensors of electric control system and control unit of computer 

(including inspection on their terminal blocks). 

• In addition to special instructions in testing procedures of some vehicles, generally do not use 

analog multimeter to check the resistance of electric control system, but to use high impedance 

digital multimeter (above 10MΩ) or special detection instrument for electric control system. 

• On the vehicles installed with electric control system, avoid using grounding for fire test or 

dismantling wire for fire scrapping to inspect circuits. 

7. Do not use water to wash control unit of computer and other electronic device. If there is leakage for 

windscreen wiper, repair it timely and pay attention to protecting the control system of computer to 

avoid abnormal operation of circuit board, electrical elements and parts, integrated circuit and sensors 

due to damp. 

8. In general situation, do not open the computer cover, as most faults of electric control engine are faults 

of external equipment with a few computer faults. Even if the computer has faults, the opening of 

computer cover cannot solve any problems in the situation of without taking detection means 

(equipment to detect the oscilloscope and signal generator of computer). On the contrary, the opening 

of computer may lead to new faults due to improper operation. In affirming the computer faults, 

professional personnel shall be invited for its detection and repair. 

9. Do not unplug any line plug (connector) of any sensors while the engine is in operation. Otherwise, 

artificial fault code (a kind of pseudo code) will appear in computer, influencing the correct judgment of 

repair personnel for fault removal. 

11B 

Page 1571

11B-2 


BJ4JB1 ENGINE SYSTEM COMPOSITION AND PRINCIPLE 

1. Electronic Control System Composition 

Electronic control system comprises of fuel pump, fuel rail, injector, ECU, accelerator pedal position 

sensor, revolution speed sensor and some other sensors and actuators. 

11B 

1 High-Pressure Pump 

2 Interior Pressure Control Valve 

3 Fuel Filter 

4 Fuel Tank 

5 ECU 

6 Battery 

7 High-pressure Fuel Rail 

8 Fuel Rail Pressure Sensor 

9 Injector 

10 Engine Coolant Temperature Sensor 

11 Crankshaft Speed Sensor 

12 Accelerator Pedal Position Sensor 

13 Camshaft Speed Sensor 

14 Mass Air Flow Sensor 

15 Turbocharger 

16 EGR Valve 

17 Vacuum Pump 

18 Vacuum Solenoid Valve 

Page 1572


11B-3 

2. Electronic Control System Operational Principles 

ECU can figure out the amount of fuel injection, injection moment, injection frequency and injection 

pressure (the rail pressure when injecting) within ECU according to the driver’s demands that are the 

position of accelerator pedal position sensor (the signal of accelerator pressure input to ECU) and the 

current operational situation of the engine and the vehicle (engine speed, coolant temperature, current 

load and etc.). Meanwhile ECU will issue the directives to control the rail pressure within a limit and 

make the injector injects according to the calculation result. 

11B 

Page 1573

11B-4 


TABLE OF FAULT PHENOMENA 

The following table is helpful for troubleshooting. The serial number stands for the possible order of fault 

causes. According to this order, check each part and replace them if necessary. 

Phenomenon Possible Part Measures/References 

1. Cold start port (does not open) 

Chapter 4 Diagnosis - Electric Control 

System of Engine (BJ4JB1) 

2. Vehicle cold start relay 


(unconnected) 


Chapter 14B Engine Mechanical 

3. Preheat plug (invalid) 

System-Engine Disassembly, Disassembly 

EGR Controller 

4. Main relay (burnt down) 



5. Main relay fuse (burnt down) 



6. ECU connector (inappropriately 


connected) 


11B 

Diesel engine cannot 

start up or start up 

difficultly 

7. ECU (damaged) 

Chapter 11B Engine Control System - 

Sensor, Actuator Maintenance, Electronic 

Control Module (ECU) 

8. ECU(water entering) Blow ECU Dry 

9. ECU connector (water entering) Blow Connector Dry 

10. ECU (unmatched type) 

11. Fuel water separator (blocked) 

12. Sensor harness connector (become 

loose) 

13. Fuel filter (blocked) 

14. Fuel line (the curvature is too small 

or bent) 




Chapter 12B Fuel System - Fuel Filter (Fine 

Filter) And Replacement 



Chapter 12B Fuel System - Fuel Filter (Fine 

Filter) and Replacement 

Chapter 12B Fuel System - Fuel Lines and 

Replacement 

Page 1574


11B-5 


15. Low pressure fuel lines (interior 

diameter becomes small) 


Replacement 

16. Low pressure fuel lines (air flows in) 


Replacement 

17. Inlet and outlet fuel lines (reversely 

connected) 


Replacement 

18. Fuel tank (run out of fuel or short of 

fuel) 

Chapter 12B Fuel System - Fuel Tank, 

Service 

19. Harness (badly connected) 



20. Camshaft and crankshaft sensor 

(incredible signal) 





difficultly 

21. Camshaft sensor clearance (quite 

poor) 

22. Camshaft sensor (absorb foreign 

body or damaged) 

Chapter 11B Engine Control Systems - 

Sensor, Actuator Maintenance, Camshaft 

Position Sensor 




11B 

23.Crankshaft sensor clearance (quite 

poor) 





body or damaged) 




25. Accelerator pedal position sensor 

(incredible signal) 


System Of Engine (BJ4JB1) 

26. Air intake heater (ECU port does not 

open) 



27. Preheat device (burnt down) 



28. Injector (Needle valve blocked and 

does not work) 

Chapter 14B Engine Mechanical System - 

Engine Disassembly 

Page 1575

11B-6 





difficultly 

29. Injector solenoid valve (burnt down) 

30. Ignition lock (damaged) 

31. Battery (under voltage) 



Chapter 91 Vehicle Control System - 

Ignition Switch, Replacement 

Chapter 20B Start Up and Charge – 

Battery Assembly And Replacement 

32. Fuel (wrong type) Fuel Replacement 

1. Fuel (wrong type) 

Chapter 12B Fuel System - Fuel Tank, 

Service 


Chapter 12B Fuel System - Fuel Filter 

(Fine Filter) and Replacement 

3. Main diesel filter (blocked) 


(Rough Filter) 

4. Low pressure fuel lines (curvature is 

too small or bent) 


Replacement 

11B 

Engine lack of power 

5. Low pressure lines (interior diameter 

becomes small) 



Replacement 



7. Low pressure fuel lines (inlet and 

outlet reversely connected) 


Replacement 

8. Low pressure fuel lines (connector 

become loose and air flows in) 


(Fine Filter) And Replacement 


body) 




10. Camshaft sensor (wrong gap) 



Page 1576


11B-7 


Engine lack of power 

11. Coolant temperature sensor 

(damaged) 

12. Coolant temperature sensor 

(connector become loose or cut off) 

13. Thermostat (blocked or temperature 

is too high) 


(wrong signal) 

15. Injector solenoid valve (damaged) 

16. Injector (cut off or connector 

becomes loose) 

17. Injector (Harness short circuits) 





Chapter 11B Engine Control 

Systems-Sensor, Actuator Maintenance, 

Camshaft Position Sensor 









1. ECU (damaged) 

2. ECU (interior or connector water 

entering) 

3. ECU (connector become loose) 




Blow Dry 



11B 

Engine turns off 

automatically 

4. ECU (overheating protection) 

5. ECU (ground wire cut off) 

6. ECU main relay (burnt down) 

7. Main relay fuse (burnt down) 










Page 1577

11B-8 



Engine turns off 

automatically 

8. High pressure pump timing gear 

(damaged) 


(not the regulated type) 

10. Rail pressure sensor (damaged) 

11. Rail pressure sensor (connector 

becomes loose) 

12. Low pressure fuel lines (aging hose 

and sucked flat) 

13.Low pressure fuel lines (too much 

air) 

14. Harness (cut off or short circuits) 


System-Engine Disassemble, Injector 

Pump Assembly and Disassembly 


Sensor, Actuator Maintenance, Accelerator 

Throttle Pedal Position Sensor 


Sensor, Actuator Maintenance, Rail 

Pressure Sensor 




Replacement 





11B 

15. Fuel ( low quality) Fuel Replacement 

1. Fuel (low quality) Fuel Replacement 

Too thick smoke of 

engine 

When the accelerator 

throttle pedal reached 

its highest position, the 

maximum speed is not 

obtained 

2. Valve (wrong clearance) 

3. Injector (needle valve stuck or 

wears out) 

4. ECU (program runs disorderly) 

1. Accelerator pedal (lines connected 

wrong) 

2. Accelerator pedal (connecting lines 

become loose) 


System-Engine Disassembly 


System-Engine Disassembly 








Page 1578


11B-9 


When the 

accelerator throttle 

pedal reached its 

highest position, 

the maximum 

speed is not 

obtained 


(damaged) 

4. Accelerator throttle pedal 

(non-calibrated) 

Chapter 11B Engine Control System - Sensor, 

Actuator Maintenance, Accelerator Throttle Pedal 





1. Accelerator throttle pedal (lines 

connected wrong) 

Chapter 4 Diagnosis - Electric Control System of 

Engine (BJ4JB1) 

2. Accelerator throttle pedal 

(connecting lines become loose) 

Chapter 4 Diagnosis - Electric Control System of 

Engine (BJ4JB1) 

3. Accelerator throttle pedal position 

sensor (damaged) 




4. Rail pressure sensor (damaged) 


Actuator Maintenance, Rail Pressure Sensor 

5. Low pressure fuel lines (blocked) 


Replacement 

Lame home (speed 

and power 

decrease) 

6. Fuel metering unit (damaged) 

7. Metering valve (stuck, blocked) 


Actuator Maintenance, Rail Pressure Sensor 


Actuator Maintenance, Metering Valve 

11B 



Replacement 

9. Fuel water separator (blocked or 

too much water) 

Chapter 12B Fuel System - Fuel Filter (Fine Filter) 

and Replacement 

10. Diesel filter (blocked) 

Chapter 12B Fuel System - Fuel Filter (Rough 

Filter) 

11. Low pressure fuel lines (bent or 

curvature is too small) 

Chapter 12B Fuel System - Fuel Lines And 

Replacement 

12. Low pressure fuel lines (interior 

diameter is too small) 

Chapter 12B Fuel System - Fuel Lines And 

Replacement 

Page 1579

11B-10 





Replacement 

14. Return pipe (blocked) 


Replacement 

Lame home (speed and 

power decrease) 

15. Inlet and outlet fuel pipes (reversely 

connected) 


Replacement 


16. ECU (poor cooling) 



17. ECU (loose connection, heavy 

vibration) 




1. Harness (short circuit or cut off) 



2. ECU (supply state does 

nonconforming to calibrated data) 




11B 

Fault light is always on 

3. AC (line is not connected with ECU) 

4. Preheat relay (not connected with 




ECU) 


5. Fuel water separator (lines are not 


correctly connected) 


6. Water sensor (nonconforming to 

requirements of ECU) 


Sensor, Actuator Maintenance, Water 

Level Sensor 

Idle speed too high 

1. Accelerator pedal (connectors water 

entering) 

2. AC request switch (Is always on) 

Blow Dry 

Chapter 61 Heater and AC-AC and 

Maintenance 

1. ECU (the calibrated data does 


Wrong fuel water 

separator signal (water 

nonconforming to vehicle practical 

status) 



information) 

2. Harness (cut off or wrong 


connected) 


Page 1580


11B-11 


1. Fuel (wrong type) Fuel Replacement 

2. Fuel (contain air or water) 


(Fine Filter), Discharge Water 

Abnormal sound of 

deflagration 

3. Injector return fuel pipe fitting (fuel 

pore is too small) 

4. Injector return fuel pipe one-way 

valve (stuck) 

Chapter 12B Fuel System - Injector 

Overhaul 


Overhaul 

5. Return fuel jack (fuel does not return 

smoothly) 


Overhaul 

1. Accelerator throttle pedal harness 

(cut off) 

Chapter 04 Diagnose-Engine Electric 

Control System ( BJ4JB1) 

During 

accelerator pedal 

driving, 

2. Crankshaft and camshaft sensor 

(too dirty or wear out) 

3. ECU (poor cooling) 


Sensor and Actuator Maintenance 


Sensor, Actuator Maintenance, 

Electronic Control Module (ECU) 

4. ECU (heavy vibration during driving) 


Sensor, Actuator Maintenance, 

Electronic Control Module (ECU) 

11B 

1. Fuel water separator (inlet and 

outlet fuel pipes reversely 

connected) 






Hand fuel pump does 

not work 

3. Fuel water separator fuel pipes (too 

long) 


Replacement 

4. Fuel tank pipes (blocked) 


Replacement 

5. Fuel tank pipes (bent or curvature is 

too small) 


Replacement 

Page 1581

11B-12 



Rail pressure is too low 


2. Fuel water separator (blocked or 

contains too much water) 

3. Diesel filter (blocked) 

4. Low pressure fuel pipes (bent or 

curvature is too small) 

5. Low pressure fuel pipes (interior 

diameter is too small) 

6. Low pressure fuel pipes (air flows in) 

7. Fuel return pipe (blocked or does 

not return smoothly) 

8. Inlet and outlet fuel pipes (reversely 

connected) 


Replacement 




(Rough Filter) 


Replacement 


Replacement 




Replacement 


Replacement 

11B 

Page 1582

CONTROL SYSTEM OF ENGINE-ENGINE CONTROL SYSTEM MAINTENACNE 

11B-13 

ENGINE CONTROL SYSTEM MAINTENACNE 

GENERAL TROUBLESHOOTING PROCEDURE 

11B 

Page 1583

11B-14 


SERVICING PROCEDURES OF BASIC INSPECTION 

According to diagram fswx110041, carry out fault diagnosis for electric control engine. In order to determine 

the nature and position of fault and avoid many necessary operations, after visual inspection on engine, carry 

out basic inspection according to procedures shown in diagram fswx110042. In the basic inspection, the water 

temperature of engine must reach normal operating temperature (about above 80℃). Meanwhile, close all 

attached electrical device of vehicle, such as AC). What is more, carry out inspection adjustment before 

cooling fan is started for operation to avoid energy consumption of fan, which will influence the accuracy of 

inspection. 

11B 

Page 1584


11B-15 

GENERAL STEPS FOR FAULT DIAGNOSIS 

△ Tip: 

• The common faults of electric control engine are as follows: difficult starting, stop at once after starting, 

unstable idle speed, too high idle speed, powerless travelling, poor acceleration, tempering explosion, 

shaking and surging, smoking and large fuel consumption. 

General steps for fault diagnosis of electric control engine are as follows: 

1. Firstly, affirm whether there are faults of engine 

General methods to judge the operation of engine are as follows: 

• The engine cannot be started or in normal operation after starting, or there is explosion of exhaust 

pipe and tempering of intake pipe in the operation of engine, or there is obvious abnormal 

phenomenon like the obvious knocking sound. Then, it can be affirmed that there are faults for 

engine. 

• See whether the warning indicator of engine (check engine) installed with electric control system is 

on. If the indicator is on, this shows that there are faults for the electric control system of engine. 

• If large changes occur to the performance of engine in a short term, it can be affirmed that there 

are certain faults for engine, such as the power of engine is reduced greatly and its fuel 

consumption is obviously increased. 

• If the changes occurring to performance of engine are not obvious, the following methods can 

used for test: let engine operate in various simulated working conditions and carefully listen to that 

whether there is abnormal sound for exhaust pipe and intake pipe in the operation of engine, feel 

the vibrating situation of engine and whether there is obvious shaking and metal knocking sound 

and observe the changing situation of engine speed. 

NOTE: 

Slowly depress accelerator pedal and increase the engine speed from low to high gradually. Pay 

attention to judging whether above said phenomenon is existent. If they are existent, this shows that 

there may be faults for engine. It is necessary to carry out test repeatedly to provide basis for correct 

judgment of fault. Depress accelerator pedal suddenly and observe whether there are above said 

phenomenon and the increasing rate of engine speed is ideal. If there is abnormal situation or the 

increasing rate of engine speed is too slow, this shows that there are faults for engine. If under the 

above two situations, any abnormal phenomenon of engine is not found, then, loose accelerator pedal 

and observe the idle speed operation situation of engine. See whether the rotating speed in idle speed 

is too high or unstable and whether the shaking of engine is serious or not. 

△ Tip: 

Through above operations, if any abnormal phenomenon is not found, this shows the normal operation of 

engine. If carry out careful inspection on the dynamic property, economical efficiency and exhausting situation 

of engine, it is necessary to use detection line or special detection instrument to carry out fault inspection and 

diagnosis. 

2. Secondly, determine the nature of faults 

If there are faults for electric control engine, firstly observe the situation of self diagnosis warning 

indicator (CHECKENGINE) in electric control system of engine. If the indicator is on in the operation 

process of engine, this shows that there are faults monitored by the self diagnosis system of electric 

control engine. Faults are usually related with electric control system. At this moment, through certain 

11B 

Page 1585

11B-16 


11B 

methods, acquire the fault code in internal storage of computer and then find out the fault causes 

according to fault code. If there are faults for engine indeed, warning indicator “check engine” of engine 

on instrument panel is not on in the operation of engine, this shows that self diagnosis system of 

electric control unit cannot identify such faults for engine. At this moment, according to fault 

phenomenon, make initial diagnosis result like the way to diagnose traditional engine and analyze the 

possible fault causes. According to the principles of starting from the outside to inside, from the simple 

to the complex, carry out deep diagnosis. Under such situation, make sure not to disassembly the 

electric control system casually. Only after affirming the faults of electric control system, firstly check 

electric control system. Otherwise, check the other parts firstly. 

3. Carry out visual inspection 

Firstly check whether plugs of wire are loose in poor contact, open circuit and short circuit. Then, 

observe whether there is gas leakage and oil leakage for each intake pipe, vacuum pipe and oil way 

and carry out further inspection again. 

4. Locate the failed part 

In order to reduce the working quantity to remove faults, the method of reducing 1/2 can be used if 

there is abnormal response of engine. Narrow the suspected parts in the scope of 1/2. For this, firstly 

affirm whether there are faults for oil way or circuit. Most faults of engine are caused by oil way or 

circuit. So, if there are faults for engine and you can affirm the faults of oil way or circuit definitely, 1/2 

working quantity can be reduced and concentrate your energy in the scope of 1/2. For this, carry out 

the following steps. 

(a). For the fault judgment of oil way or circuit, as it is easy to carry out fault diagnosis for circuit visually, 

start to check whether there are faults for circuit. Unplug the central high tension line of ignition system 

and carry out spark over test for cylinder body to affirm whether the parts of high pressure ad low 

pressure are normal. If spark without high voltage or spark is too weak, faults of ignition system can be 

affirmed. If above said inspection is normal, unplug the high tension line of distributor of spark plug and 

check whether there is distributed fire. If there is no such fire, then there are faults for wire from the 

central high tension line to live wire of distributor. If above said inspection is normal and there is 

distributed fire in each cylinder, then circuits are normal. So, faults are mostly caused by oil way. 

(b). In order to judge whether faults are caused by poor operation of individualized cylinder or all cylinders, 

poor operation of engine, start from the analysis and inspection on the causes for the poor operation of 

individualized cylinder if individualized cylinder does not operate or in poor operation. If all cylinders of 

engine are in operation, but their operations are not very obvious, then start from the causes for the 

poor operation of all cylinders of engine. So, 1/2 working quality for diagnosis can be reduced. For this, 

carry out the following steps: start engine and let it operate in idle speed. After reaching normal 

temperature, carry out discontinuous fire cutoff test between distributed fire line and observe the 

response situation of engine. If intermittent fire cutoff and re-firing test are carried out discontinuously 

for single cylinder, but the operation of engine does not have any response, then, the cylinder is poor 

operation. Next, analyze and inspect the causes of poor operation of single cylinder in concentration. If 

intermittent fire cutoff and re-firing test are carried out for each cylinder, but there is no obvious change 

for the operating situation of engine, then, the operating situation of each cylinder is the similar. So, 

start from the causes for abnormal operation of each cylinder of engine. 

Page 1586

CONTROL SYSTEM OF ENGINE-REPAIR FOR SENSOR AND ACTUATOR 

11B-17 

REPAIR FOR SENSOR AND ACTUATOR 

COOLANT TEMPERATURE SENSOR 

1. Profile 

2. Location 

It is installed under the engine’s thermostat block. 

3. Instructions to parts 

It is used in the electronic fuel injection device to detect the engine coolant temperature, send the 

voltage signal to electronic control module which is taken as the load signal of the engine so as to 

evaluate the operational situation of the engine. 

4. Composition and principle 

The operational principle of coolant temperature sensor is sealed in a thermister with a negative 

temperature coefficient. By the temperature sensitive characteristics of the thermister, the change of 

environment temperature will be converted into the change of the thermal resistance and then 

converted to be voltage signal which will be sent to the electronic control unit. 

5. Technical parameters 

(a). Limit data 

11B 

Item Value Unit 

Rated voltage 

Only 5+0.15 of the rated voltage 

can be operated by ECU 

V 

20 ℃ rated resistance 2.5±6% KΩ 

100 ℃ rated resistance 0.186±2% KΩ 

Operation temperature range -40~130 ℃ 

Allowable vibration acceleration 300 m/s2 

Page 1587

11B-18 


6. Replacement 

(a). Park the vehicle on stable and flat ground. 

NOTE: 

After stopping the vehicle, turn off engine and shift into neutral gear and pull up the parking brake lever. 

(b). 

Lift the handle of bracing and locking wire of engine 

compartment cover up. 

(c). 

(d). 

Lift the engine compartment cover up. 

Discharge appropriate amount of coolant by a water drain 

switch until the engine is cooled down. 

11B 

(e). 

Disconnect the connector of coolant temperature sensor. 

(f). 

Remove the coolant temperature sensor and take it 

down. 

Page 1588


11B-19 

(g). Install and tighten the coolant temperature sensor. 

△Tip: 

The temperature sensor can be screwed into the tapped hole of 

thermostat block using the hexagon head on the socket with 

threads. 


(h). 

(i). 

Connect the connector of coolant temperature sensor. 

Add coolant. 

(j). Lift the engine compartment cover up to make the 

support bar move away from the support hole of 

compartment cover and clip the support bar into the slot. 

(k). Lower the room cover slowly and loose your hands 

when the room cover is about 20cm away from lock-up 

position and let it fall freely. 

NOTE: 

When closing engine compartment cover, people cannot 

stand in the rotating scope to avoid the personal injury. 

11B 

Page 1589

11B-20 


CAMSHAFT POSITION SENSOR 

1. Profile 

2. Location 

Position sensor PG is installed at the end of camshaft, 

cooperating with speed sensor and distinguishing 

compression TDC and exhaust TDC on No.1 cylinder. 

11B 


Position sensor is to detect the engine timing valve which is realized by the detection of camshaft 

sensor angle. 


Position sensor PG comprises of one Hall sensor and one signal rotor (semi-circular iron magnet). The 

rotation of camshaft will drive the rotation of the signal rotor installed at the end. By using Hall principles, 

when the signal rotor blade goes into the gap of permanent magnet circuit of Hall sensor, Hall sensor 

switch is in the position of “OFF” and the corresponding circuit output is high level. When the signal 

rotor blade goes into the gap of permanent magnet circuit of Hall sensor, Hall sensor switch is in the 

position of “ON” and the corresponding circuit output is low level. The corresponding rotation of the 

crankshaft has signal while the other one does not have it which then can distinguish the different TDC. 



Ambient Temperature 

Limit Life Expectancy 

-40~150℃ 

Ambient temperature in operation is 150℃ 

Ambient temperature without operation is 160℃ 

1000h 

250h 

Speed range 0~4500rpm (camshaft speed) 



Page 1590


11B-21 

NOTE: 

After stopping the vehicle, turn off engine and shift into neutral gear and pull up the parking brake 

lever. 

(b). Open the engine compartment cover and hold it. (Refer to Chapter 11B Engine Control System – 

Repair for Sensor and Actuator, Coolant Temperature Sensor). 

(c). 

Disconnect the connector of camshaft position sensor. 

(d). 

Remove the fixing bolts of camshaft position sensor. 

(e). 

Take down the camshaft position sensor. 

11B 

(f). 

Place the camshaft position sensor to mounting position. 

Page 1591

11B-22 


(g). 

Tighten the fixing bolts of camshaft position sensor. 

Torque: 8±0.5 N·m 

(h). 

(i). 

Connect the connector of camshaft position sensor. 

Close the engine compartment cover. (Refer to Chapter 

11B Engine Control System – Repair for Sensor and 

Actuator, Coolant Temperature Sensor). 

11B 

Page 1592


11B-23 

MASS AIR FLOW SENSOR 

1. Profile 

2. Location 

It is installed behind the engine air filter while before the 

engine turbocharger inlet. 


Inlet mass sensor is a heat flux sensor which comprises of inlet air temperature sensor and air mass flow 

sensor. It is used to detect the engine inlet temperature and inlet mass flow. By reporting the detection of inlet 

air mass to the electronic unit and its participation in control, the control of EGR system in the closed loop can 

be realized. 



11B 

Parameters 

Value 

Minimum Standard Maximum 

Unit 

Temperature tolerance -40 120 ℃ 

Transient temperature tolerance limit 120 130 ℃ 

Operational voltage 7.5 14 17.0 V 

Pressure drop 15 hPa 



NOTE: 


lever. 

Page 1593

11B-24 




(c). 

Disconnect the connector of mass air flow sensor. 

(d). 

(e). 

Remove 2 A-type worm drive hose clamps. 

Take down the mass air flow sensor. 

11B 

(f). Place the mass air flow sensor to mounting position, and 

install 2 A-type worm drive hose clamps. 

NOTE: 

The airflow direction is required to be consistent with the 

arrow direction on the sensor case when installing the 

sensor. Otherwise, the power is limited and the system 

operation degrades. 

(g). 

(h). 

Connect the connector of mass air flow sensor. 




Page 1594


11B-25 

EGR VACUUM ADJUSTER 

1. Profile 

2. Location 

It is installed in the engine compartment. 


It can control the pulse width, switching on time of EGR valve, control EGR rate, reduce NOx pollutants 

and optimize the emission. 



11B 

Parameters 

Value 


Unit 

Operational voltage 10 12 16 V 

Mass air flow 30 L/h 

Switch on response time 1 s 

Switch off response time 0.2 s 

Operational temperature range -30 130 ℃ 

Output resistance 14 Ω 



NOTE: 


lever. 

Page 1595

11B-26 




(c). 

Disconnect the vacuum line of EGR vacuum adjuster. 

(d). 

Disconnect the connector of EGR vacuum adjuster. 

(e). 

Remove the fixing bolts of EGR vacuum adjuster. 

11B 

(f). Take down the EGR vacuum adjuster. 

NOTE: 

Prevent contact with alkali-metal impurity and avoid 

invalidation due to entering the inner cavity of vacuum 

adjuster. 

Page 1596


11B-27 

(g). 

Place the EGR vacuum adjuster to mounting position. 

(h). 

Tighten the fixing bolts of EGR vacuum adjuster. 


(i). 

Connect the connector of EGR vacuum adjuster. 

11B 

(j). 

(k). 

Disconnect the vacuum line of EGR vacuum adjuster. 




Page 1597

11B-28 


PREHEAT CONTROLLER 

1. Profile 

2. Location 

It is installed in the engine compartment. 

11B 


(a) Preheat control unit (GCU) is controlled by electronic control unit (EDC) and it has the following 

functions: 

• By the input of the signal from ST and K port, GCU is applicable to 4, 5, or 6-cylinder engine. 

• Electronic control unit (EDC) control the switch signal of 4, 5 or 6 preheat plug of GSK. 

• Overcurrent cut off protection (electronic protection) 

• Preheat plug invalidity diagnose 

• Small volume and can be installed in the engine compartment. 

• High potential protection from electronic control unit (EDC). 

Page 1598


11B-29 


(a). 

Limit data 

Parameters 

Value 


Unit 

Preheat time 4 200 s 

Temperature tolerance of 200s maximum preheat time, 

the accumulated life expectancy is shorter than 1000h. 

Temperature tolerance of non-preheat, the 

accumulated life expectancy is shorter than 5000h. 

Temperature tolerance of non-preheat with heat load, 

the accumulated life expectancy is shorter than 5000h. 

-40 85 ℃ 

-40 85 ℃ 

-40 125 ℃ 

Power supply voltage of normal operation 8 12 16 V 

Allowable minimum voltage at the starting up stage 6 8 V 

Input current at 66 port ≤1000 mA 

Control current at ST/K port 1 50 mA 

Signal current at DI port 1 10 mA 

Operational current at 30 port 60 180 A 

Operational current at G port 10 30 A 

11B 

Energy consumption 10 18 W 

Output resistance at DI port 10±5 % KΩ 

Preheat pressure drop of each cylinder ≤250 mV 



NOTE: 


lever. 



Page 1599

11B-30 


(c). 

Disconnect the connector of preheat controller. 

(d). 

Remove the fixing bolts of preheat controller. 

(e). 

Take down the preheat controller. 

11B 

(f). 

Place the preheat controller to mounting position. 

(g). 

Install the fixing bolts of preheat controller. 

Torque: 5±1 N·m 

Broken torque: >7 N·m 

Page 1600


11B-31 

(h). 

(i). 

Connect the connector of preheat controller. 




11B 

Page 1601

11B-32 


RAIL PRESSURE SENSOR 

1. Profile 

2. Location 

It is installed at the ends of fuel rail. 


It is to detect the rail pressure and offer the input signal to electronic control unit. 



11B 

Parameters 

Symbol 

Value 


Unit 

Operational temperature T -40 130 ℃ 

Pressure range P 0 

150 

180 

200 

MPa 

Operational power supply voltage Us 4.75 5.0 5.25 V 

Current when Us=5V Is 12 15 A 

Load resistance when 0.1US


11B-33 


(a). 

NOTE: 

Park the vehicle on stable and flat ground. 


lever. 



(c). 

Disconnect the connector of rail pressure sensor. 

(d). 

Remove the rail pressure sensor. 

11B 

(e). 

Take down the rail pressure sensor. 

(f). 

Place the rail pressure sensor to mounting position. 

Page 1603

11B-34 


(g). 

Install the rail pressure sensor and tighten. 

(h). 

(i). 

Connect the connector of rail pressure sensor. 




11B 

Page 1604


11B-35 

INTERIOR PRESSURE CONTROL VALVE 

1. Profile 

2. Location 

It is installed on the fuel pump. 

3. Components 

Pressure control valve is connected to high-pressure pump by a mounting flange. In order to ensure 

that the gap between the high-pressure and the low-pressure section is well sealed, the pivot makes a 

ball valve resist against the seal gasket. Two forces act on the pivot: one is the spring force; the other is 

the acting force produced by electromagnet. In order to ensure lubrication and cooling, fuel must flow 

through the pivot. 


Pressure control valve comprises of two closed-loop control: 

• One is the electronic control loop used to set the low speed of the changing average common rail 

pressure. 

• The other is the mechanical hydraulic control loop used to compensate the quick-acting of 

high-frequency pressure fluctuations. 



NOTE: 


lever. 



11B 

Page 1605

11B-36 


(c). 

Disconnect the connector of interior pressure control 

valve. 

(d). Remove the interior pressure control valve. 

△Tip: 

Remove using the inner offset wrench. 

(e). 

Install the interior pressure control valve. 

11B 

(f). 

(g). 

Connect the connector of interior pressure control valve. 




Page 1606


11B-37 


1. Profile 

2. Location 

It is installed at the rear end of the transmission. 


Vehicle speed sensor is installed on output shaft of gearbox with mechanical gears transforming to 

electric pulse signal. Then, use wire to send electric pulse signal to odometer with pulse frequency 

indicating speed and pulse counter accumulating mileage. 

The vehicle speed sensor is to measure the vehicle speed in the travelling of car and it is also signal 

output part to accumulate total travelling mileage of vehicle. 

4. Components and principles 

Closed magnetic circuit revolution speed sensor is composed of external gear, internal gear, coil and 

permanent magnet installed on revolving shaft. Internal and external gears have the same number of 

teeth. If revolving shaft is connected to the shaft for measurement to revolution together, magnetic 

resistance will change due to relative motion of internal and external gears. So, AC induction potential 

will be generated in coil. Through the potential value, the corresponding revolving speed can be 

worked out. 

5. Common faults 

• Vehicle speed odometer does not move. 

• Vehicle speed odometer does not move at times. 

6. Operating characteristics 

Rated operating voltage: 12 V 

Power voltage scope (Vcc): 8 V~16 V 

Injection current at output end (lsink): ≤25 mA 

Power supply current (lcc): 10 mA (max) 

Output low level (Vol): 0.5 V (max) 

Output high level (Vol): Vcc-0.5 V (min) 

The number of signal pulses: 8 P (pulses/round) 

11B 

Page 1607

11B-38 


Operating temperature: - 40 ℃~120 ℃ 

Maximum revolving speed of sensor: 3000 r/min 


△Tip: 

· Turn off engine, remove the key and start parking brake to make sure that the vehicle does not move when 

dismantling. 

· When pulling out the connector of harnesses, press and hold the snap rings of connector and pull them 

out slowly to avoid pulling the lead to result in poor contact or open circuit. 

(a). 

Disconnect the connector of vehicle speed sensor. 

(b). 

Remove the fixing bolts of vehicle speed sensor. 

11B 

(c). 

Take down the vehicle speed sensor. 

(d). 

Install the vehicle speed sensor. 

Page 1608


11B-39 

(e). 

Tighten the fixing bolts of vehicle speed sensor. 

(f). 

Connect the connector of vehicle speed sensor. 

11B 

Page 1609

11B-40 


CRANKSHAFT POSITION SENSOR 

1. Profile 

2. Location 

It is installed on the clutch housing. 

11B 


It is used to check the engine speed, so, it is also known as revolving speed sensor. It is also used to 

check the position of top dead center of piston, so, it is also known as top dead center sensor, including 

checking of top dead center signal of each cylinder for ignition control and top dead center of first 

cylinder for sequence control of fuel injection. 


Crankshaft position sensor is electromagnetic sensor and 58X tooth top and tooth space pass sensor 

with different clearances. Sensor can induct the changes of magnetic resistance. Then, the alternating 

magnetic resistance will generate alternating output signal. ECM makes use of the signal to determine 

the revolving position and speed of crankshaft. 


• There is no contact or in poor contact for crankshaft position sensor. 


Operating clearance: 0.25~1.75 mm 

Coil resistance: 560 Ω 



NOTE: 


lever. 

Page 1610


11B-41 

(b). 

Disconnect the connector of crankshaft position 

sensor. 

(c). 

Remove the crankshaft position sensor and take it down. 

(d). Install the crankshaft position sensor and tighten. 

△Tip: 

Clean the mounting position of sensor and the sensor when 

installing. Otherwise, the clearance between sensor and gears 

will be influenced to affect the signals sent to electronic control 

module. 

Torque: 7~9 N·m 

11B 

(e). 

(f). 

Connect the connector of crankshaft position sensor. 




Page 1611

11B-42 


ACCELERATOR PEDAL POSITION SENSOR 

1. Profile 

2. Location 

It is installed on the accelerator pedal. 

11B 


Transfer the driver’s expectation of the vehicle to ECU. ECU will determine the basic demands of 

injection and torque according to the signal. 


• Operational voltage: 5 V±2% 

• Operational temperature: - 40~85 ℃ 

• Signal current: maximum 20 mA 

• Short-circuit protection: 16 V,20 min 

• Output error:


11B-43 

(b). 

Disconnect the connector of accelerator pedal position 

sensor. 

(c). 

Remove the fixing screws of accelerator pedal position 

sensor. 

(d). 

Take down the accelerator pedal position sensor. 

11B 

(e). 

Install the accelerator pedal position sensor. 

(f). 

Tighten the fixing screws of accelerator pedal position 

sensor. 

Page 1613

11B-44 


(g). 

Connect the connector of accelerator pedal position 

sensor. 

11B 

Page 1614


11B-45 

ELECTRONIC CONTROL MODULE (ECU) 

1. Profile 

2. Location 

It is installed under the driver’s seat. 


ECU is to receive the input signal of sensor and carry out calculation according to designed programs 

to generate corresponding control signal output and drive each actuator to carry out different actions. 

Meanwhile, make the engine operate according to specific control strategy. 


ECU (electronic control unit) is also known as “travelling computer” and “auto computer”. From its 

functions, it is special micro computer controlled for vehicle. So, it is also called special single-chip for 

vehicle. Like the ordinary single-chip, it is composed of microprocessor (CPU), memory (ROM and 

RAM), input/output interface (I/O), AD converter (A/D), shaping and driving large scale integrated 

circuit. Electronic control unit is to calculate process and make judgments on the input information of air 

flow meter and various sensors according to its memorized programs and data and then output orders 

to provide electric pulse signal of certain width for fuel injector to control fuel injection quantity. 

Electronic control unit is composed of microcomputer, input, output and control circuits. 


(a). Faults of power circuit. 

(b). Faults of output circuit. 

(c). Memory faults. 


Nominal operating voltage: DC12 V 

Operating voltage scope: 6.5~16 V 

Maximum operating current: 5 A 

Operating temperature: - 30 ℃~85 ℃ 

11B 

Page 1615

-MEMO- 



NOTE: 

After stopping the vehicle, turn off engine, place the transmission to empty gear, start parking brake 

system and disconnect the negative cable of battery. 

(b). Remove the driver’s seat (See Chapter 84 Seats - Main Driver’s Seat and Replacement). 

(c). Remove the connector of ECU. 

NOTE: 

Lift the fixing clips for connector of ECU up, and then pull 

out the connector of ECU. 

(d). Remove the fixing bolts of ECU assembly. 

(e). Take down the ECU assembly. 

NOTE: 

When taking down the ECU assembly, do not impact the 

ECU to avoid damaging the ECU. 

11B 

(f). 

Place the ECU assembly to mounting position, install the 

fixing bolts and tighten. 


(g). Connect the connector of ECU. 

NOTE: 

When connecting the connector of ECU, align the mounting 

position to avoid damaging the pins. When the ECU is 

inserted completely, pull up the clips to lock the connector 

of ECU. 

(h). Connect the negative cable of battery. 

(i). Install the main driver’s seat (See Chapter 84 Seats – 

MainDriver’s Seat and Replacement). 

Page 1616

模板 00 

FUEL SYSTEM 

FUEL SYSTEM .................................................................................. 12B-1 

Overview ........................................................................................ 12B-1 

Precautions ................................................................................... 12B-2 

System Composition and Its Principles..................................... 12B-3 

Diagram of Components .............................................................. 12B-7 

FUEL INJECTOR (ELECTRONIC).................................................. 12B-13 

Precautions ................................................................................. 12B-13 

Parameter of Technical Characteristics ................................... 12B-14 

Service ......................................................................................... 12B-15 

FUEL INJECTOR (MECHANICAL)................................................. 12B-19 

Diagram of Components ............................................................ 12B-19 

Testing ......................................................................................... 12B-20 

Disassembly and Cleaning ........................................................ 12B-21 

Service ......................................................................................... 12B-23 

Assembly and Adjustment ........................................................ 12B-25 

HIGH PRESSURE FUEL RAIL ....................................................... 12B-26 

Overview ...................................................................................... 12B-26 

Replacement ............................................................................... 12B-27 

FUEL INJECTION PUMP (VE PUMP) ............................................ 12B-31 

Adjustment .................................................................................. 12B-31 

FUEL PIPELINE (ENGINE PART) .................................................. 12B-33 

Precautions ................................................................................. 12B-33 

Replacement ............................................................................... 12B-34 

FUEL TANK ..................................................................................... 12B-37 

Service ......................................................................................... 12B-37 

FUEL FILTER (COARSE FILTER) .................................................. 12B-42 

Replacement ............................................................................... 12B-42 

FUEL FILTER (FINE FILTER) ......................................................... 12B-44 

Drainage of Water ....................................................................... 12B-44 

Replacement ............................................................................... 12B-46 

12B 

Page 1617

12B 

Page 1618

FUEL-FUEL SYSTEM 

12B-1 

FUEL SYSTEM 

OVERVIEW 

1. Introduction 

4JB1 EuroⅢ diesel engine fuel system matched with Sapupika diesel engine series is electronically 

controlled high pressure common rail system, and 4D20 diesel engine fuel system matched with it is 

electronically controlled VE pump system. 

2. Function of fuel system 

Function of fuel system is to inject diesel into combustion chamber at rated time, quantity and 

pressure to provide necessary conditions for good combustion of diesel and automatically adjust fuel 

delivery according to load condition of diesel engine to ensure steady running of diesel engine. 

12B 

Page 1619

12B-2 


12B 

PRECAUTIONS 

1. Safety precautions 

(a). Before service of fuel supply system, turn off the ignition switch first and disconnect negative terminal 

cable of battery. Open the fuel filler cap for short periods and screw it up. 

(b). When removing and installing the fuel tank, the vehicle should be stopped on a horizontal plane, and 

fuel in the tank should not occupy 3/4 of the gross capacity. If needed, empty the fuel tank. 

(c). Before the service, fix a plug-in emission hose of fuel vapor near installation port of fuel tank to empty 

the fuel vapor. 

△ Tip: 

If there is no fuel vapor emission device, you can use a centrifugal blower with over 15m 3 /h gas delivery. 

(d). Maintenance of the fuel tank and related accessories must be away from fire, the maintenance site 

should be well-ventilated and appropriate fire fighting equipment should be prepared. 

(e). The connection of fuel pipe and connectors should be reliable without any loosening, so as to avoid 

pipeline leakage. 

(f). Use the plastic strip assembly to fix with pipeline for each 250mm intervals in the frame, while use the 

tank band to fix the forepart of return pipe, so as to prevent friction with the stringer. 

(g). Add spiral protective sleeve at the contact part of pipeline and fuel tank, fuel tank bracket, frame to 

protect the pipe. 

(h). The pipe should be unified with the direction of harness, brake pipelines after entering the frame, and 

should keep the maximum distance with the harnesses and then fix. 

(i). Release the oil pump pressure (pressure relief) firstly when repairing the fuel system, in order to 

prevent the fuel injection causing the environment and human damages. 

(j). When starting the engine after installation of injection system, ensure the oil delivery pump and filter 

full of fuel. If needed, keep pressing on the start button to make it in active state. 

NOTE: 

High pressure connection part of fuel system needs no deflation for the high pressure common rail 

will emit air automatically under high pressure. If loosen tight cap of the high pressure fuel pipeline, 

fuel will leak out under pressure. 

2. Cleaning precautions 

(a). Clean thoroughly the connector and its nearby before switching off it. 

(b). The removed parts should be put on the clean surface and covered up. Don’t use fuzzy cloth. 

(c). Cover or lock up the open parts if you don’t repair them immediately. 

(d). Only clean parts can be assembled. Take out spare parts only before assembling. Don’t use scattered 

parts (for instance, in the tool box). 

Page 1620


12B-3 

SYSTEM COMPOSITION AND ITS PRINCIPLES 

1. Composition of fuel system 

(a). Fuel system composition of 4JB1 Euro Ⅲ high pressure common rail diesel engine 

It consists of diesel tank, diesel pipe, diesel filter, high pressure fuel pump, fuel rail, high pressure fuel 

pipe and fuel injector, etc. (See the following figure) 

12B 

1 High pressure fuel pipe 

2 Diesel pipe (fuel delivery) 

3 high pressure fuel pump 

4 Diesel pipe 

5 Fuel filter 


7 Fuel tank 

8 Strainer 

9 Fuel injector 

10 Diesel pipe (fuel return) 

11 Diesel pipe (fuel return) 

12 High pressure fuel rail 


Page 1621

12B-4 


(b). 

Fuel system composition of 4D20 electronically controlled VE pump diesel engine: 

It consists of diesel tank, diesel pipe, oil-water separator, diesel filter, fuel injector pump assembly, 

high pressure fuel pipe, fuel injector, etc. 

12B 

1 Fuel filter 

2 Diesel pipe(fuel delivery) 

3 Fuel injector pump 

4 Fuel return pipe 



7 High idle speed solenoid valve 

8 

Manual pump handle of oil-water 

separator 

9 Oil-water separator 

10 Fuel tank 


12 Diesel pipe (Fuel return) 

Page 1622


12B-5 

2. Working principle of fuel system 

(a). 

Working principle of 4JB1 Euro III high pressure common rail diesel engine. 

12B 

• High pressure part 

With continuous work of electronically controlled high pressure fuel pump, fuel is injected into the high 

pressure fuel rail, in which it accumulates pressure, and ECU controls the fuel pressure in the rail with fuel 

pump actuator in the pump. Rail pressure sensor in the rail feeds back information of rail pressure to form 

a closed-loop control for ECU. For high pressure fuel rail accumulates high pressure fuel at any time, ECU 

calculates proper fuel according to the inner rated data when it needs the injection of some vat and make 

the injector inject the calculated fuel according to the calculated time by controlling the magnetic solenoid 

valve of the fuel injector. 

• Low pressure part 

Low pressure fuel rail is divided into oil-inlet part and fuel return part. Fuel inlet means fuel is transferred 

from fuel tank into coarse filter, fuel filter and high pressure fuel pump. Fuel return means fuel return of fuel 

injector, high pressure fuel rail and electronically controlled high pressure pump connects together and 

fuel returns to the fuel tank. 

Page 1623

12B-6 


(b). 

Fuel system Working principle of 4D20 electronically controlled VE pump diesel engine. 

12B 

• High pressure part 

Raise the diesel pressure by the work of fuel injection pump and provide high pressure fuel for combustion 

chamber at rated time, quantity and pressure according to the working requirements of diesel engine. 

• Low pressure part 

Low pressure fuel rail is divided into oil-inlet part and fuel return part. Fuel inlet means fuel is transferred 

from fuel tank into coarse filter, fuel filter and fuel injection pump. Fuel return means Fuel return of injector 

and fuel injection pump connects together and fuel returns to the fuel tank. 

Page 1624


12B-7 

DIAGRAM OF COMPONENTS 

High pressure common rail fuel system (Engine Part) 

12B 

Page 1625

12B-8 



2 O-ring 

3 Fuel injector pad 

4 

Fuel injector and Fuel return pipe 

assembly 

5 High pressure clamp 

6 Fuel injector Fuel return rubber hose 

7 Fuel return T-pipe weldment 


9 

Fuel injection pump Fuel return rubber 

hose 

10 High pressure fuel pipe 1 




14 Bolt 

15 High pressure fuel rail 

16 

High pressure fuel pipe (from fuel 

injection pump to fuel rail) 

17 Fuel rail support 

18 Bolt 

19 Nut 

20 Bolt 

21 

Fuel injection pump pulley pressure 

plate 

22 Woodruff key 

23 Fuel injection pump pulley 

24 Fuel injection pump flange 

25 Bolt 

26 Fuel injection pump 

12B 

Page 1626


12B-9 

Electric VE pump fuel system (Engine Part) 

12B 

Page 1627

12B-10 


1 Fuel injection pump flange seal ring 

2 Bolt 

3 Fuel injection pump gear 

4 Flange plate 

5 Fuel injection pump parts 

6 Bolt 

7 Fuel injection pump support 

8 Fuel injection pump rear support 

9 Large washer 

10 Bolt 

11 Bolt 

12 Idle lift valve parts 

13 Bolt 

14 High pressure fuel pipe parts 1 




18 

19 

20 Bolt 

High pressure fuel pipe punch holder 

assembly 

High pressure fuel pipe die holder 

assembly 


22 O-ring 


24 Fuel injector fuel return pipe assembly 

25 Fuel return pipe clip 

26 Fuel injector Fuel return pipe 

27 Low pressure fuel pipe seal head 

12B 

Page 1628


12B-11 

Fuel system I (Body Part) 

12B 

1 Cross recess head screw 


3 Fuel filler cap assembly 

4 Spring hose clamp 

5 Rubber hose 

6 Rubber hose 

7 Air valve 

8 Nylon cable tie 

9 Fuel filler lower pipe 

10 EFI fuel hose II 

11 Rubber hose 

12 Diesel coarse filter 

13 Diesel settler support welding 


15 Fuel pipe clamp (blue) 

16 A-type worm drive hose clamp 

17 Fuel tank front pressure plate assembly 

18 All-metal hexagon flange lock nut 




22 Fuel delivery pipe 

Page 1629

12B-12 


Fuel system II (Body Part) 

12B 


2 Rubber hose 

3 Spring washer 

4 Rubber hose 

5 Hexagon bolt 

6 Flat washer 

7 Fine filter support 

8 Rubber hose 







15 Air valve 


17 Fuel filler lower pipe 


19 Fuel tank front pressure plate assembly 


21 Type 1 hexagon nut 



24 Fuel delivery pipe 

25 Fuel pipe clamp 

26 Fine filter 

Page 1630

FUEL-FUEL INJECTOR (ELECTRONIC) 

12B-13 

FUEL INJECTOR (ELECTRONIC) 

PRECAUTIONS 

1. Replace fuel injector assembly if there is any fault of fuel injector solenoid valve. Don’t remove the 

valve by yourself. 

2. Keeping fuel injector clean is the first requisite for normal operation of solenoid valve. 

3. Avoid short circuit of solenoid valve binding post and the engine. 

4. Take out protective cap only before assembling and cover the connector up immediately after 

removing. Ensure there is some spared clean protective cap and clean the used protective cap with 

ultrasonic wave. 

5. Grease all the O-ring with engine oil or diesel before assembling. 

6. Don’t overly bend or squeeze the cable or connect with sharp ends. Avoid vibration of circuits. 

7. Don't use any tool when installing and removing fuel return pipe. 

8. Fuel injector clamp bracket: don’t take it out or bend it. 

9. Don’t assemble fuel return pipe without clamp bracket or the fuel will leak out. 

10. If clamp bracket is removed by mistake, please replace with a new one. 

11. Bigger bend, rotation or deformation will narrow the fuel return pipe. All these should be avoided. 

12. Hose part of fuel return pipe should not be removed or loosened from the fuel return plug for it cannot 

ensure complete assembling. If something happens as above, the whole fuel return pipe must be 

replaced. 

13. When loosening high pressure pipe nut, ensure no pressure is on the connector. If the high pressure 

connector is already loosened, the whole fuel injector must be replaced. 

14. Replace with a new bronze seal ring after each fuel injector is removed. And all the nuts that need 

fastening must be replaced. 

12B 

Page 1631

12B-14 


PARAMETER OF TECHNICAL CHARACTERISTICS 

△ Tip: 

Due to various types of diesel engine matched with Sapupika, the following chart of technical characteristics 

parameter of the 4JB1 EuroⅢ diesel engine fuel injector is just for reference, and the practical maintenance 

of engine should be subject to parameter of technical characteristics supported by the suppliers based on 

different types of engines. 

Parameter 

Unit 

Value 

Minimum Typical Maximum 

Remark 

Peak current A 17.5 18 18.5 

Holding current A 11.5 12 12.5 

20~70℃ measuring 

resistor 

Ω 0.215 0.255 0.295 

Current on time Μs 4000 (Starting stage 300-450μs) 

Cold start Μs 6000 

Maximum 60s,frequency is lower than 

5Hz 

Pre-injection and 

main injection 

minimum interval 

μs 800 

Interval of current on time (from 

conclusion of pre-injection current signal 

to starting of main-injection current signal) 

Working pressure Bar 250 1450 Rail pressure 

Fuel return pressure 

(relative pressure) 

Bar 0.3 0.8 Relative to external pressure 

12B 

String leak pressure Bar 1700 1800 No current, eigenvalue 

nozzle opening 

pressure caused by 

combustion 

Bar 120 Eigenvalue, no system pressure 

Fuel temperature ℃ -30 

Fuel temperature ℃ 115 

In cold start condition, measurement 

point: fuel inlet of fuel injector 

working area, permitted temperature 

amounts to 135℃ in 15min, working time 

exceeding 100 hours, measurement point: 

fuel inlet of fuel injector 

Fuel return 

temperature 

℃ 125 

Permitted temperature amounts to 145℃ 

in 15min, working time exceeding 100 

hours, measurement point: fuel outlet of 

fuel injector 

External temperature ℃ -30 120 

Permitted temperature amounts to 130℃ 

in 15min, working time exceeding 100 

hours, measurement point: solenoid valve 

head of fuel injector 

Page 1632


12B-15 

SERVICE 

NOTE: 

After the engine stalls, any installation must be prohibited in 30s. For fuel is inflammable, the 

operating area should keep away from fire and should be equipped with ventilators when servicing 

the fuel system. 

1. Park the vehicle on steady road 

NOTE: 

Switch off the engine after parking, shut down the ignition switch, change the transmission into 

neutral gear and start parking braking system. 

2. Lift engine compartment cover assembly 

(a). Lift engine compartment cover lock cable handle. 

(b). Lift engine compartment cover. 

△ Tip: 

Reach your hand into the front of engine compartment cover, 

move the lock operation handle upward when touching it, then 

the hood is completely open. Finally, raise the hood with efforts 

and find the support bar to plug it into fixed position. 

12B 

3. Remove fuel injector 

(a). Disconnect the connector of fuel injector. 

NOTE: 

Don’t pull the lead directly when pulling the connector or it 

will cause short circuit or open circuit. 

Page 1633

12B-16 


(b). Switch off the connector of high pressure fuel pipe and 

high pressure fuel rail. 

△ Tip: 

Block the fuel pipe up with plug after removing, or the dirt will 

influence function of fuel system. 

(c). Switch off high pressure fuel pipe connecting between 

fuel injector and high pressure fuel rail. 

△ Tip: 

Use two wrenches to remove high pressure fuel pipe. Block the 

fuel pipe up with plug after removing, or the dirt will influence 

function of fuel system. 

(d). Push the fuel return pipe fixing clip to the direction of 

the opening and take out the fuel pipe. 

NOTE: 

Don’t remove or loosen the hose part of fuel injector fuel 

return pipe, if something happens as the above, please 

replace the whole fuel return pipe. 

12B 

(e). Remove fuel injector pressure plate fixing bolt. 

(f). Take out fuel injector pressure plate. 

△ Tip: 

Pull the fuel injector pressure plate backward before taking it 

out to make the removal easier. 

(g). Take out the fuel injector in sequence. 

4. Check the fuel injector 

(a). Fix fuel injector on the calibration stand to control fuel 

pressure, voltage and current duration and determine 

whether the fuel injector is normal by observing the 

pulverization of fuel injector and amount of fuel 

injection. 

NOTE: 

Fuel injector is precise hence non-professionals must not 

remove or maintain it. 

Page 1634


12B-17 

5. Install fuel injector 

(a). Assemble fuel injector and fuel injector pressure plate 

together. 

△ Tip: 

To prevent bronze washer shedding off when installing fuel 

injector, grease the bronze washer with some lithium-based 

lubricants. 

(b). Install fuel injectors in corresponding holes in 

sequence. 

(c). Install firmly fixing nuts of fuel injector pressure plate. 

△ Tip: 

Fastening of fuel injector pressure plate bolts is divided into 

two steps: first, rotate it for 7.5~9 N·m; then rotate it for 40~45 

degrees. 

(d). Connect the connector of each fuel return pipe and fuel 

injector. 

△ Tip: 

Directly press the connector of fuel return pipe and fuel injector 

onto the installation hole or clip will be stuck after being 

pressed down. 

(e). Connect high pressure fuel pipe with fuel injector and 

fasten the nuts. 

△ Tip: 

Fasten each high pressure fuel pipe in couple. 

12B 

(f). Connect the connector of each fuel injector. 

△ Tip: 

You can hear a sound of clatter when installing the connector. 

Slowly pull it up after installation to ensure it is installed in 

place. 

Page 1635

12B-18 


6. Close the engine compartment cover 

(a). Put the engine compartment cover support bar down into 

the clip slot. 

(b). Lower the compartment cover gently at the height of 

20cm from the lock and then drop it to fall free. 

△ Tip: 

Lock the compartment cover firmly for safety. Check whether 

the compartment cover is locked after closing it. The engine 

compartment cover must be flush with the vehicle’s body 

nearby. 

12B 

Page 1636

FUEL INJECTOR (MECHANICAL) 


FUEL-FUEL INJECTOR (MECHANICAL) 

12B-19 

12B 

1 Clip 


3 O-ring 


Page 1637

12B-20 


TESTING 

1. Remove fuel injector assembly 

(a). Removal of fuel injectors (See Chapter 15B Mechanical Part of Engine - fuel pipeline, fuel injector, 

removal) 

2. Detection of fuel injectors 

(a). Fix the fuel injector on the test stand and move the 

stand handle at the speed of 4~6 times/s. Check if 

there is any particle flying out, dripping backward or 

spraying abnormally, etc. Keep fuel injection pressure 

below 21.0MPa, if there is no leakage, it works well. 

The opening pressure is 27~28MPa, if it is abnormal, 

restore or replace parts of fuel injectors. 

3. Injection of fuel injectors 

(a). See the left figure of injection of fuel injectors. 

(b). Adjust and service it if the pulverization is abnormal. 

12B 

Page 1638


12B-21 

DISASSEMBLY AND CLEANING 

1. Clean the fuel injector 

(a). Brush the fuel injector’s outer surface clean in the fuel 

basin. 

NOTE: 

Be cautious of head of pin valve. Brush it with banister 

brush. 

2. Remove fuel injectors 

(a). Fasten the fuel injector on table vice placed with a 

copper sheet and make the nozzle upward. 

NOTE: 

If the pin valve is stuck in the nozzle nut by carbon deposit, 

it should be dipped in the diesel oil and taken out without 

being tapped or pulled. 

3. Clean parts of fuel injectors 

(a). Clean nozzle fixing nut, fuel injection body, pushing rod, 

lock nut, adjusting screw and pressure adjusting spring 

with clean diesel oil or kerosene. 

(b). Clean the oil passage of fuel injector body with copper 

needle. 

12B 

(c). 

Clean the carbon deposit outside the pin valve with 

banister brush or thin copper wire. 

Page 1639

12B-22 


(d). 

Clean the carbon deposit outside the pin valve with 

banister brush or thin copper wire. 

(e). 

Clean the oil passage of pin valve with copper needle. 

12B 

(f). Stretch the brass angle scraper into the pressure 

chamber and rotate it to scrape off the carbon deposit 

in the pressure chamber of pin valve. 

(g). Clean up the matching parts of pin valve again with 

clean diesel oil. 

NOTE: 

Matching parts of pin valve cannot be replaced or pieced 

together. 

Page 1640


12B-23 

SERVICE 

1. Check fuel injector body 

△ Tip: 

Ensure that the precise plate matched with matching parts of 

pin valve is flat and smooth without scratches. All screw 

threads are complete without scratches, the bearing pad is flat 

and all the inner holes are clean, unblocked. If it is not qualified, 

please replace it. 

2. Check fixing nuts of fuel injector nozzle 

△ Tip: 

Inside and outside surface are clean without scratches; the 

screw threads are complete without scratches; the matching 

parts of pin valve are clean without damage. If it is not qualified, 


3. Check the pushing rod 

△ Tip: 

The rod is upright; connection part with pin valve has no 

scratches. If it is not qualified, please replace it. 

12B 

4. Check the spring 

△ Tip: 

Both ends are flat with not overly abrasion, of good elasticity, 

and with no scratches on the surface. If it is not qualified, 


Page 1641

12B-24 


5. Check the pin valve 

Ways of checking as follows: 

Do sliding testing of the cleaned matching parts of pin valve to 

see whether it is still available. The checking method is that put 

the pin valve spotted with clean diesel oil into the valve body, 

tilt the matching parts of pin valve for 45 degrees, extract 1/3 

pin valve of the whole length and drop it to let it slide down 

slowly and smoothly by its own weight without blockage or 

detention. If the matching parts of pin valve are seriously 

defective, please replace them. As for those which are not 

seriously defective, such as due to the poor surface of pin 

valve and its body, the sliding testing fails, we can restore them 

by grinding. 

12B 

Page 1642


12B-25 

ASSEMBLY AND ADJUSTMENT 

1. Assemble fuel injectors 

(a). Fasten fuel injector body on the table vice placed with 

copper sheet and install the gasket, spring, pushing 

rod, spacer, fuel injection nozzle and fuel injector 

nozzle fixing nut in sequence. 

(b). 

Fasten fuel injector nozzle fixing nut to meet the 

standards. 

2. Adjust the fuel injector 

(a). Fix fuel injector on the testing stand and observe the 

condition of fuel injection by raising the pressure. 

Regulate gaskets properly until the pulverization is in 

good condition. 

(b). Take out the fuel injector after adjustment, fasten it on 

the table vice placed with copper sheet, and fasten 

fuel injector nozzle nuts to meet the standards. 

12B 

Page 1643

12B-26 

FUEL-HIGH PRESSURE FUEL RAIL 

HIGH PRESSURE FUEL RAIL 

OVERVIEW 

1. The fuel rail is integrated with rail pressure sensors. The fuel rail is for storage of high pressure fuel. 

Fluctuation of pressure caused by fuel supply and fuel injection of high pressure pump can be 

controlled in the common rail. Rail pressure sensor feeds back information of current rail pressure for 

ECU, with which the inner pressure control valve in the pump controls the rail pressure. 

2. High pressure common rail means several fuel injectors share the same high pressure rail. Rail 

pressure is created by high pressure pump. 

3. The fuel injection system eliminates mutual influence between creation of pressure and fuel injection 

in traditional fuel supply system. In this system, creation of injection pressure does not completely rely 

on rotation rate of the engine and fuel delivery and fuel stored in the high pressure fuel rail under 

pressure is ready to be injected at any time. 

4. Electronically controlled high pressure common rail diesel engine is completely controlled by ECU. 

ECU determines the running condition of engine according to the present rotation rate, coolant 

temperature, atmospheric pressure and throttle position (that is driver’s needs), etc. 

5. For the electronically controlled high pressure common rail system provides the ideal mixture of air 

and fuel, it hugely increases the whole noise of vehicle, driving comfort, dynamics and emission, etc 

compared with traditional diesel engine. 

12B 

Page 1644


12B-27 

REPLACEMENT 

NOTE: 

Block the fuel pipe up with plug after removing, or the dirt will enter in. 


NOTE: 






△ Tip: 





3. Remove high pressure fuel rail assembly 

(a). Disconnect the connector of rail pressure sensors. 

12B 

(b). Disconnect nuts of high pressure fuel pump and high 

pressure fuel pipe. 

△ Tip: 

Use two wrenches to remove. 

Page 1645

12B-28 


(c). 

Disconnect nuts of high pressure fuel pipe and high 

pressure fuel rail. 

(d). Disconnect nuts of fuel injectors and high pressure fuel 

pipe. 

△ Tip: 


(e). 

(f). 

Remove fixing nuts of high pressure fuel rail assembly. 

Take out high pressure fuel rail support assembly. 

12B 

(g). Remove fixing bolts of high pressure fuel rail and the 

support. 

(h). Check if the high pressure fuel rail is damaged, if it is, 


△ Tip: 

Rail pressure sensor is fixed by hexagon surface according to 

specific torque and supplied with fuel rail and it cannot be 

replaced personally. Try to avoid touching connector of the 

sensor in case of damage when installing the fuel rail. 

4. Install high pressure fuel rail assembly 

(a). Install the high pressure fuel rail on the support and 

fasten it with fixing bolts. 

Page 1646


12B-29 

(b). 

Install fixing bolts of high pressure fuel rail assembly. 

(c). 

Install nuts connecting high pressure fuel pipe and high 


(d). Install nuts connecting fuel injector and high pressure 

fuel pipe. 

△ Tip: 

Use two wrenches to install. 

12B 

(e). Install nuts connecting high pressure fuel pump and 

high pressure fuel pipe. 

△ Tip: 

Use two wrenches to install. 

(f). 

Connect rail pressure sensor connector. 

Page 1647

12B-30 







△ Tip: 




nearby. 

Fg 

12B 

Page 1648

FUEL INJECTION PUMP (VE PUMP) 

ADJUSTMENT 

FUEL-FUEL INJECTION PUMP (VE PUMP) 

12B-31 

1. Adjust fuel supply timing 

(a). Check if the notch line of fuel injection pump flange 

aligns with that of pump body. 

(b). Rotate the crankshaft and align the piston of the first 

cylinder with TDC position on compression stroke until 

the TDC reticle 1 on crankshaft pulley align with timing 

mark 2. 

NOTE: 

Check intake valve of the first cylinder and idle stroke of 

exhaust valve push rod. If there is idle stroke of first 

cylinder intake valve and valve push rod, the piston of first 

valve is on the TDC position of compression stroke. 

(c). 

(d). 

Remove cone screw plug of lower plunger hole end 

from fuel injection pump. 

Install measurement instrument3 of fuel supply 

advance angle. Detector of the instrument should be 

pressed inward for about 1mm. 

12B 

(e). 

Rotate crankshaft and adjust the dial gauge to zero 

when the first cylinder piston is on the 30-40 degrees 

position of TDC. Slowly rotate crankshaft pulley at both 

directions and check the reading of dial gauge. 

Page 1649

12B-32 

FUEL-FUEL INJECTION PUMP (VE PUMP) 

(f). 

(g). 

(h). 

(i). 

(j). 

(k). 

Rotate the crankshaft clockwise and check the reading 

on the instrument when the TDC mark of crankshaft 

pulley aligns with timing mark of gear cover. 

If fuel supply timing is incorrect, do the following steps. 

• Loosen fixing nuts of fuel injection pump and 

bracket bolts. 

• Adjust fuel supply advance angle. 

If the advance angle is too big or small, loosen bolts of 

high pressure fuel pump connection plate and adjust it. 

If the advance angle is too big, turn the high pressure 

fuel pump for a proper angle counter-clockwise. 

If the advance angle is too small, turn the high pressure 

fuel pump for a proper angle clockwise. 

Fasten the three bolts. Check the fuel supply advance 

angle again. 

Install high pressure fuel pipe of the first cylinder. 

12B 

Page 1650

FUEL-FUEL PIPELINE (ENGINE PART) 

12B-33 

FUEL PIPELINE (ENGINE PART) 

PRECAUTIONS 

1. Don't use any tool when installing and removing fuel return pipe. 

2. Don’t assemble fuel return pipe without clamp bracket or the oil will leak out. 

3. Hose part of fuel return pipe should not be removed or loosened from the fuel return plug for it cannot 

ensure complete assembling. If something happens as above, the whole fuel return pipe must be 

replaced. 

4. When loosening nuts of high pressure fuel pipe, switch off the power and operate after 30s. 

5. Cover the removed fuel pipe with protective cap to prevent the dirt from entering. 

12B 

Page 1651

12B-34 


REPLACEMENT 

NOTE: 

For fuel is inflammable, the operating area should keep away from fire and should be equipped with 

ventilators to decrease harm or death of personnel. Block the fuel pipe and parts pipe up with cap 

after removing, or the dirt will influence function of fuel system. 


NOTE: 






△ Tip: 





12B 

3. Remove high pressure fuel pipe 

(a). Disconnect nuts of high pressure fuel pump and high 

pressure fuel pipe. 

△ Tip: 


Page 1652


12B-35 

(b). 

Disconnect nuts of high pressure fuel pipe and high 


(c). Disconnect nuts of fuel injectors and high pressure fuel 

pipe. 

△ Tip: 


4. Remove Fuel return fuel pipe 

(a). Push fuel return fuel pipe clamp to the opening 

direction and take it out from fuel injectors. 

NOTE: 

Hose part of fuel injectors should not be removed or 

loosened from the fuel return plug. If something happens 

as above, the whole fuel return pipe must be replaced. 

12B 

(b). 

Disconnect fuel return fuel pipe and high pressure fuel 

pump. 

5. Install fuel return fuel pipe 

(a). Install connectors of fuel return pipe and each fuel 

injector in place. 

△ Tip: 

Directly press the connector of fuel return pipe and fuel injector 

onto the installation hole or clip will be stuck after being 

pressed down. 

Page 1653

12B-36 


(b). 

Fasten the spring hose clamp of fuel return fuel pipe 

and high pressure fuel pump. 

6. Install high pressure fuel pipe 

(a). Install fixing nuts connecting high pressure fuel pipe 

and fuel rail. 

△ Tip: 

When installing the high pressure fuel pipe, put high pressure 

fuel pipe down from the lower end of intake manifold. 

(b). Install firmly fixing nuts connecting high pressure fuel 

pipe and fuel injectors. 

△ Tip: 

Use two wrenches when installing. Fasten each high pressure 

fuel pipe in couple. 

12B 

(c). 

Install firmly fixing nuts connecting high pressure fuel 

pump and high pressure fuel pipe. 






△ Tip: 




nearby. 

Page 1654

FUEL-FUEL TANK 

12B-37 

FUEL TANK 

SERVICE 

1. Exhaust fuel 

(a). Park the vehicle on the lifter and pull the parking braking handle to the braking position. 

(b). Switch off negative terminal cable of the battery. 

(c). Open the fuel filler cap. 

△ Tip: 

The switch of fuel filler cap is at the lower left of driver’s seat. 

Pull up the switch and the fuel filler cap will open automatically. 

(d). 

(e). 

(f). 

Screw down the fuel tank cap. 

Lay oil drum or equivalent container down drain bolts 

under the fuel tank. 

Remove the drain bolts under the fuel tank. 

2. Check 

(a). Before removing the fuel tank, visually check whether there are leakage or leakage trace on the fuel 

tank, fuel tank pipeline and connector, make it for future maintenance and replacement if any. 

12B 

3. Remove the fuel tank 

(a). Remove the fixing screws of fuel tank filling pipe 

assembly with a screwdriver. 

(b). Put the bracket to the bottom of fuel tank. 

Page 1655

12B-38 


(c). Remove the fixing bolts of fuel tank assembly. 

△ Tip: 

After removing the fixing bolts of fuel tank assembly, drag it 

with the bracket, and lower the bracket to a proper position. 

(d). 

Disconnect the connector of the fuel level sensor lead. 

12B 

(e). Loose the fixing clips of fuel inlet and outlet pipes, pull 

out the fuel inlet and outlet pipes. 

NOTE: 

After disconnect the pipe, the pipe and the fuel inlet and 

outlet shall be blocked, and then mark on the fuel inlet and 

outlet pipes, so as to prevent wrong installation. 

(f). Lower the bracket to the appropriate position, and pull 

out the fuel tank. 

(g). 

Disconnect all the pipes connecting with the fuel tank 

and check whether the pipes are aged or fractured, 

please replace if damaged. 

Page 1656


12B-39 

(h). Remove the fuel pump. 

• Remove the fuel pump gland with special wrench. 

• Remove the fuel pump. 

△ Tip: 

Check whether the fuel stand pipe filter has any dirt, blockage 

or crack, if there is any dirt or blockage, clean it up with brush 

and petrol and if there is any crack, please replace it. 

(i). Remove the fuel level sensor. 

△ Tip: 

When removing the fuel level sensor, move up the sensor a 

little, and then incline to one side to remove it, must be careful 

not to damage the oil level float. 

4. Clean the fuel tank 

(a). Clean the fuel tank inner part from all angles with high 

pressure water jet, ensure no dirt and impurities remain 

in the fuel tank 

NOTE: 

• When cleaning, the waste water should be collected 

from the fuel outlet, in order to avoid environmental 

contamination. 

• The high pressure water jet can be put into the fuel 

tank to ensure that all parts could be cleaned. 

(b). Use compressed air to dry the fuel tank inner part 

thoroughly. 

12B 

5. Install the fuel tank assembly 

(a). Install the fuel level sensor. 

NOTE: 

Do not damage the oil level float during installation. 

Page 1657

12B-40 


(b). 

Install the fuel pump. 

• Place the fuel pump in installation position. 

• The fuel pump gland should be installed and 

fastened using special tools. 

(c). 

(d). 

Connect all the pipes connected with the fuel tank and 

use the flexible clip or A-type worm drive hoop to 

fasten. 

Place the fuel tank on the bracket and drag the fuel 

tank to the appropriate position of installation position 

under the car body. 

12B 

(e). Connect intake and outlet fuel pipes. 

NOTE: 

Install according to the tag, do not install the fuel inlet and 

outlet pipes wrongly. 

(f). Connect the connector of fuel level sensor lead. 

NOTE: 

When connecting the connector of fuel level sensor lead, 

it should sound "click", and gently pull back to ensure it 

installed in place. 

Page 1658


12B-41 

(g). 

Install the fixing bolts of fuel tank. 


(h). Install the screws of fuel tank filling pipe assembly and 

fasten. 

(i). Refill the fuel. 

NOTE: 

Check whether the fuel drain plug of the fuel tank installed 

in place. 

(j). Fasten the fuel tank cap. 

NOTE: 

Clockwisely rotate the fuel tank cap until it “click”, which 

means the fuel tank cap has been fastened. 

(k). Close the fuel filler cap. 

12B 

Page 1659

12B-42 

FUEL-FUEL FILTER (COARSE FILTER) 

FUEL FILTER (COARSE FILTER) 

REPLACEMENT 

1. Remove fuel filter assembly 

(a). Switch off the fuel inlet hose and fuel outlet hose on the 

fuel filters. 

NOTE: 

Check fuel inlet and outlet hoses, if there is any 

efflorescing, erosion or crack, please replace them. 

(b). 

Take out the filter element with special tools of the filter. 

(c). 

Remove the fuel filter base. 

12B 

2. Install fuel filter assembly 

(a). Install the fuel filter base. 

• Install firmly the fixing bolts of the fuel filter base. 

Torque:45~55 N·m 

Page 1660

FUEL-FUEL FILTER (COARSE FILTER) 

12B-43 

(b). Install the filter element with special tools of the filter. 

NOTE: 

When installing the fuel filter, inject proper clean fuel into 

the filter and grease the filter seal ring with some 

lubricants. 

(c). 

Hook the fuel inlet and outlet pipes with elastic clips on 

the inlet and outlet positions of the filter and fasten 

them. 

12B 

Page 1661

12B-44 

FUEL-FUEL FILTER (FINE FILTER) 

FUEL FILTER (FINE FILTER) 

DRAINAGE OF WATER 

△ Tip: 

When the engine fault indicator lights up, check whether there is any water in the diesel fine filter, if there is 

any, drain completely all the water in the drainer. 


NOTE: 





12B 


△ Tip: 





3. Water drainage of diesel fine filter 

(a). Loosen the water drain valve of diesel fine filter. 

△ Tip: 

Put drainage pipe of water drain valve into a vessel before 

loosening the water drain valve to prevent the drained water 

from polluting the environment. 

NOTE: 

Don't switch off the diesel fine filter water drain valve but 

loosen it. When the clean fuel comes out from the pipe, all 

the water in the fine filter is drained. Fasten the screws of 

water drain valve immediately. 

Page 1662


12B-45 






△ Tip: 




nearby. 

12B 

Page 1663

12B-46 


REPLACEMENT 


NOTE: 






△ Tip: 





12B 

3. Remove the fuel fine filter 

(a). Drain the fuel in the fuel fine filter by drainage of the 

fuel fine filter. 

(b). Disconnect fuel inlet and outlet pipes of the filter. 

NOTE: 

Put fuel inlet and outlet pipes into the fuel in the drainage 

pipeline in the vessel after switching off them. Seal it up 

with the cap after drainage. Check the fuel inlet and outlet 

hoses, if there is any efflorescing, erosion or crack, please 

replace them. 

(c). Disconnect the connector of fine filter lead. 

NOTE: 

Don’t pull the lead directly when disconnecting the 

connector of fine filter. 

(d). Remove fine filter sensors. 

Page 1664


12B-47 

(e). 

Remove the fine filter element with special tools of the 

filter. 

(f). 

Remove the fine filter base. 

4. Install the fuel filter 

(a). Install the fuel filter base. 


12B 

(b). Install the fine filter element with special tools of the 

filter. 

NOTE: 

Grease the filter seal ring with some engine oil to lubricate 

when installing the filter. If the fuel filter is screwed too 

firmly, it will cause the deformation of threads of screws, 

or the damage of the filter element or gasket or can. 

(c). Install the fuel fine filter sensors. 

(d). Connect the connector of fine filter lead. 

NOTE: 

The connector of fuel fine filter lead must be installed in 

place. 

Page 1665

12B-48 


(e). 

Hook the fuel inlet and outlet hoses of fine filter with the 

spring hose clamp and fasten them up. 

5. Drainage 

(a). Remove the air exhaust bolts of the fuel filter. 

NOTE: 

Air exhaust of fuel pipeline must be operated after 

maintaining the pipelines of fuel system or replacing the 

filter. 

(b). Operate the manual fuel pump of the filter several times 

for the exhaust of fuel system. 

NOTE: 

Don’t overexert when operating the manual fuel pump in 

case of damage. 

12B 

(c). 

Drainage is completed until the fuel appears in the 

exhaust hole of the filter without bubbles. 

Page 1666


12B-49 






△ Tip: 




nearby. 

12B 

Page 1667

-MEMO- 

12B 

Page 1668

驻车制动 - 驻车制动系统 

27-1 


EGR SYSTEM ·····································································13B-1 

Overview ········································································13B-1 

Working principle ····························································13B-2 

Diagram of Components···················································13B-3 

EGR PIPE ··········································································13B-4 

Service ···········································································13B-4 

EGR VALVE········································································13B-7 

Service ···········································································13B-7 

13B 

Page 1669

14 

13B 

Page 1670

EMISSION CONTROL--EGR SYSTEM 

13B-1 

EGR SYSTEM 

OVERVIEW 

1. EGR system is also called Exhaust Gas Recirculation system which mainly comprises of ECU, vacuum 

adjuster, EGR valve, valve position sensor, coolant temperature sensor, speed sensor, throttle position 

sensor, pressure maintaining valve, exhaust gas recirculation pipeline and vacuum connecting pipeline 

and etc. Its main functions are: make part of the exhaust gas in the exhaust pipe re-circulate into the 

intake manifold and mix with the fresh air to flow into the combustor so as to reduce the combustion 

temperature,reduce the generation of oxynitride and finally reduce the pollution of atmosphere. 

2. The function of EGR valve is to control the opening of vacuum valve by vacuum degree so as to control 

the mass of exhaust gas flow. The opening of the valve is sent back to ECU by valve position sensor. If 

EGR valve is seriously stuck, the engine will produce black smoke. 

3. When the car has driven for each 4000-5000km, check whether each nut on the exhaust connecting 

pipe is loose, there is any flaw or hole for the exhaust gas connecting pipe, and any damage or erosion 

for the gasket. 

13B 

Page 1671

13B-2 


WORKING PRINCIPLE 

EGR will prohibit the generation of NOx, CO and some other pollutants in the emission by guiding a small 

amount of engine exhaust gas to the intake manifold, diluting the fresh air to decrease the peak of combustion 

pressure and temperature. When the engine is working, throttle position sensor, speed sensor, coolant 

temperature sensor and etc. will input the signal of engine instant state to ECU and ECU will judge the instant 

operational situation according to these signals, and based on the data which has been stored in it, ECU can 

adjust different vacuum degree by vacuum adjuster. EGR valve will control the valve opening according to 

different vacuum degree. The valve opening is then sent back to ECU by the valve position sensor. During the 

whole operational process, each operational situation of the engine will have a perfect EGR rate (the ratio of 

mass of exhaust gas recirculation - mE and mass of fresh air - mA, that is, mE/mA). 

13B 

1 Joint of diagnostic tool 

2 Vacuum adjuster 

3 Pressure maintaining valve 

4 Vacuum pump 

5 Vacuum connecting pipe 

6 EGR valve 

7 ECU 

8 Coolant temperature sensor 

9 Speed sensor 

10 Throttle position sensor 

11 Exhaust gas connecting pipe 

Page 1672


13B-3 


1 Rubber plug 

2 Pressure maintaining valve 

3 Hose 

4 Hose 

5 Three-way 

6 Idling lift valve connecting hose 

7 770 hose 

8 EGR pipe connecting bolt 

9 EGR valve 

10 EGR pipe gasket 

11 EGR pipe 



14 Small washer 

15 Vacuum adjuster 

16 Stud 

17 ECU 

13B 

Page 1673

13B-4 

EMISSION CONTROL-EGR PIPE 

EGR PIPE 

SERVICE 

1. Disassemble EGR pipe 

(a). Disassemble the nut connecting EGR pipe and intake 

pipe. 

(b). 

Disassemble bolt connecting EGR pipe and EGR valve. 

(c) 

Take down EGR pipe. 

13B 

2. Clean and check EGR pipe 

(a) Clean the sealing surface of EGR pipe and intake pipe 

by relieving tool. 

Page 1674


13B-5 

(b) 

Clean the sealing surface of EGR pipe and EGR valve 

by relieving tool. 

(c). Clean EGR pipe by vapor. 

NOTE: 

When using the vapor cleaner, you shall put on safety 

glasses or protective mask and clothing as hot vapor may 

cause severe personal injury. 

(d). 

Check whether the sealing surface of EGR pipe is 

perfect. There shall be no severe flaw on the sealing 

surface. 

(e) 

Check whether the gasket of EGR is perfect. If there is 

any wear or damage, it shall be replaced. 

13B 

3. Install EGR pipe 

(a) Put the EGR pipe in the installation position. 

Page 1675

13B-6 


(b) 

Fasten the nut connecting the EGR pipe and intake pipe. 

(c) 

Fasten the bolt connecting the EGR pipe and EGR 

valve. 

13B 

Page 1676

EGR VALVE 

SERVICE 

EMISSION CONTROL-EGR VALVE 

13B-7 

1. Disassemble EGR pipe (see chapter 13B Emission control-EGR pipe, service) 

2. Disassemble EGR valve 

(a) Disassemble fixing bolt of EGR valve 

(b) 

Take down EGR valve. 

3. Clean and check EGR valve 

(a) Clean the sealing surface of EGR valve by relieving tool. 

△ Tip: 

Two sealing surfaces of EGR valve shall be cleaned. 

13B 

(b). 

Clean the dirt and debris in the EGR valve by blowing 

high-pressure gas. 

Page 1677

13B-8 EMISSION CONTROL-EGR VALVE 

(c). 

Check whether the sealing surface of EGR valve is 

perfect. The sealing surface shall have no severe flaw. 

(d). 

Check whether the gasket of EGR valve is perfect. If 

there is any wear or damage, it shall be replaced. 

(e). Provide EGR valve with 15Kpa vacuum degree by 

manual vacuum pump and EGR valve shall be able to be 

switched on. 

NOTE: 

When no vacuum degree is provided to EGR valve, EGR 

valve shall be able to be switched off. 

13B 

4. Install EGR valve 

(a). Put EGR valve in the installation position. 

(b). 

Install and fasten the fixing bolt of EGR valve. 

Page 1678

EMISSION CONTROL-EGR VALVE 

13B-9 

5. Install EGR pipe (see chapter 13B Emission control-EGR pipe, service) 

13B 

Page 1679

-MENO- 

13B 

Page 1680

1 

INTAKE SYSTEM 

INTAKE SYSTEM .............................................................................. 14B-1 

Overview ........................................................................................ 14B-1 

Precautions ................................................................................... 14B-2 

Working Principle ......................................................................... 14B-3 

INTAKE MANIFOLD .......................................................................... 14B-4 

Diagram of Components .............................................................. 14B-4 

Service ........................................................................................... 14B-5 

INTAKE PIPELINE ........................................................................... 14B-12 

Diagram of Components ............................................................ 14B-12 

Replacement ............................................................................... 14B-13 

AIR FILTER ...................................................................................... 14B-17 

Service ......................................................................................... 14B-17 

14B 

Page 1681

14B 

Page 1682

INTAKE-INTAKE SYSTEM 

14B-1 

INTAKE SYSTEM 

OVERVIEW 

1. The intake system mainly includes air filter, intake manifold and relevant hose, which supplies pure air 

for each cylinder. 

2. The function of intake system is to evenly supply combustible mixture or pure air for each cylinder as 

much as possible. 

3. The intake manifold distributes the pure air to the inlet of each cylinder. 

4. The function of air filter is to filter out the impurities and dust in the air, in order to avoid accelerating 

the cylinder wear, and reduce the service life of engine, while the air filter could reduce the intake 

noise. 

14B 

Page 1683

14B-2 


PRECAUTIONS 

1. Safety cautions 

(a). The operation should not be conducted at the road side or crowded places, the car should be parked 

on the flat ground if possible. 

(b). Ensure the parking brake lever is placed on the parking location. 

(c). Fix the wheel with a wedge or bunk block, wedge or bunk block should be placed in the position close 

to both sides of the tire, it’s preferred to fix on both sides of the rear wheels. 

(d). When maintaining and replacing the filter element, the car should be parked in a place without wind, 

dirt and dust. 

2. Important tips 

(a). The tightness of intake pipeline and air filter connection should be check frequently, any leakage 

should be dealt with timely, fasten the connector to avoid the abnormal wear. 

(b). After 4,000 ~ 5,000km drive, the exhaust pipe of the car should be checked as follows: 

• If any nut is loosen. Fasten the nuts of exhaust pipe with uniform force, or it may cause air 

leakage. 

• If there is any crack or perforation for exhaust pipe, and any damage or erosion for gasket. 

• The exhaust pipe gasket is suggested to use once only; in order to ensure the air tightness, 

timely replace the damaged gasket. 

(c). Unless replacing the filter element, do not Disassemble (or clean) the inner filter element (safe filter 

element) in the dual snorkel air filter. 

(d). When replacing the outer filter element, if the inner filter element is damaged originally, the inner filter 

element must be replaced. 

14B 

Page 1684


14B-3 


The outside air enters compressor room of turbocharger after being filtered by air filter, and enters intake 

manifold through intake connecting pipe after being compressed by turbocharger, then is distributed to inlet of 

each cylinder by intake manifold. The burned gas is discharged from exhaust manifold. The formed exhaust 

gas flow will impact turbine of turbocharger so that it can rotate at a high speed. The exhaust gas through 

turbine is finally discharged to the exterior by exhaust tail pipe. Part of exhaust gas in the exhaust manifold is 

discharged from EGR valve. Then this exhaust gas enters intake connecting pipe through EGR pipe, and is 

sent back to engine combustor for combustion again to suppress the generation of oxynitride. 

14B 

1 Exhaust tail pipe 

2 EGR pipe 

3 EGR valve 

4 Intake connecting pipe 

5 Intake manifold 

6 Exhaust manifold 

7 turbocharger 

8 Intake pipe 

9 Air filter 

Page 1685

14B-4 

INTAKE-INTAKE MANIFOLD 

INTAKE MANIFOLD 


14B 

1 Double wire clamp 66 

2 Intake hose 2 

3 

Hexagon head bolt and spring washer 

assembly 

4 Flange bolt 

5 Intake connecting pipe bracket 



8 Flat washer 

9 stud 


11 Intake elbow gasket 


13 

Hexagon head bolt, spring washer 

and flat washer assembly 

14 Harness clamp 

15 Intake manifold gasket 

Page 1686


14B-5 

SERVICE 

1. Disassemble the intake manifold assembly 

(a). Disassemble the connecting bolts between EGR pipe 

and intake connecting pipe. 

(b). 

Disassemble the connecting bolts between EGR pipe 

and EGR valve. 

(c). 

Remove the EGR pipe. 

(d). 

Disassemble the breather outlet hose clamp. 

• Remove the breather outlet hose. 

14B 

Page 1687

14B-6 


(e). 

(f). 

Disassemble the fixing bolts of turbocharger intake 

connecting pipe assembly bracket. 

Remove the turbocharger intake connecting pipe 

assembly. 

(g). 

Disassemble the fixing bolts of exhaust pipe bracket. 

(h). 

(i). 

Disassemble the fixing bolts of intake connecting pipe. 

Remove the intake connecting pipe. 

14B 

(j). 

Disassemble the fixing bolts of oil level gauge bracket 

and remove the oil level gauge assembly. 

(k). 

Disassemble the fixing bolts of oil cooling water pipe 

bracket. 

Page 1688


14B-7 

(l). 

Disassemble the fixing nuts of high-pressure oil pipe 

and remove the high-pressure oil pipe. 

(m). 

Disassemble the fixing nuts of intake manifold. 

(n). 

Remove the intake manifold. 

• Remove the intake manifold gasket. 

2. Clean and check all the parts 

(a). Clean the sealing surface that combines cylinder head 

and intake manifold with a relieving tool and a clean 

cloth. 

NOTE: 

Prevent the sealing materials and other impurities from 

entering the intake port. 

14B 

△ Tip: 

When cleaning the sealing surface with a relieving tool, it is 

preferred to plug the intake port with a clean cloth, and prevent 

the dirt and debris from entering the intake manifold. 

Page 1689

14B-8 


(b). 

Clean the sealing surface that combines intake 

connecting pipe and intake manifold with a relieving 

tool. 

(c). 

Clean the sealing surface of intake pipe connector and 

the interior of intake manifold connector with a clean 

cloth. 

(d). 

Check the intake connecting pipe. If there is any crack 

or any severe defect for sealing surface, repair or 

replace it with a new. 

14B 

(e). 

Clean the sealing surface of intake manifold with a 

relieving tool and a clean cloth. 

(f). 

Blow away the dirt and debris in the intake manifold 

with high-pressure gas. 

Page 1690


14B-9 

(g). 

Measure the junction surface flatness of intake 

manifold and cylinder head with high-precision ruler 

and feeler (or on the plat calibration console). If the 

flatness exceeds technical range, the intake manifold 

shall be machined or replaced. 

3. Install the intake manifold 

(a). Install the intake manifold gasket. 

(b). Place the intake manifold to installation position. 

NOTE: 

Replace a new intake manifold gasket when installing the 

intake manifold connector. 

(c). 

Install and fasten the fixing bolts of intake manifold. 

(d). 

Install and fasten the nuts of high-pressure oil pipe. 

14B 

(e). 

Install the oil cooling water pipe and fasten the fixing 

bolts of oil cooling water pipe. 

Page 1691

14B-10 


(f). 

Install the oil level gauge and fasten the fixing bolts of 

oil level gauge assembly. 

(g). 

Install the intake connecting pipe and fasten the fixing 

bolts of intake connecting pipe. 

(h). 

Install and fasten the fixing bolts of exhaust pipe 

bracket. 

14B 

(i). Install the turbocharger intake connecting pipe 

assembly and fasten the fixing bolts of turbocharger 

intake connecting pipe assembly. 

(j). 

(k). 

Install the breather outlet hose. 

Install the breather outlet hose clamp. 

Page 1692


14B-11 

(l). 

Install the EGR pipe. 

(m). 

Install the connecting bolts between EGR pipe and 

EGR valve. 

(n). 

Install the connecting bolts between EGR pipe and 

intake connecting pipe. 

14B 

Page 1693

14B-12 

INTAKE-INTAKE PIPELINE 

INTAKE PIPELINE 


14B 

1 


and flat washer assembly 


3 Hexagon head bolt 

4 Air filter assembly 

5 

Intake pipe with resonance box 

assembly 

6 Air filter bracket 2 

7 Air filter bracket 1 


9 Intake connecting pipe assembly 

10 Air flow meter 


12 Intake bellows 

Page 1694


14B-13 

REPLACEMENT 

1. Park the car on flat and stable road 

NOTE: 

Flame out the engine after parking the car, the transmission should be located in neutral, and enable 

the parking brake system 

2. Lift the engine compartment cover assembly 

(a). Pull up the lock line handle of engine compartment 

cover. 

(b). 

Lift the engine compartment cover. 

3. Disassemble the intake pipe 

(a). Loose the A-type worm drive hose clamp connecting 

between the intake rubber hose of turbocharger and 

turbocharger. 

14B 

(b). 

Loose the A-type worm drive hose clamp connecting 

between the intake rubber hose of turbocharger and 

the intake bellows. 

Page 1695

14B-14 


(c). Remove the bolts of intake rubber hose clamp for 

turbocharger. 

(d). Remove the intake rubber hose of turbocharger. 

△ Tip: 

It is necessary to block the turbocharger outlet port with plug 

after removing the intake rubber hose of turbocharger to 

prevent the dirt from entering the engine. 

(e). 

(f). 


between the intake bellows and air flow meter. 

Remove the intake bellows. 

(g). 

Disconnect the connector of air flow meter. 

14B 

(h). 

(i). 


between air flow meter and intake connecting pipe 

assembly. 

Remove the air flow meter. 

(j). 


between intake connecting pipe assembly and air filter 

assembly. 

Page 1696


14B-15 

4. Check the intake pipeline 

(a). Check whether the intake bellows aged, fractured or 

cracked, replace the intake bellows if any. 

5. Install the intake pipeline 

(a). Install the intake connecting pipe assembly. 

• Fasten the A-type worm drive hose clamp 

connecting between the intake connecting pipe 

assembly and the air filter assembly. 

△ Tip: 

Clean the pipeline before installation. 

(b). 

Install the air flow meter. 


connecting between air flow meter and intake 

connecting pipe assembly. 

(c). Install the intake bellows. 


connecting between intake bellows and air flow 

meter. 

△ Tip: 


14B 

(d). Install the intake rubber hose of turbocharger. 

• Install the A-type worm drive hose clamp 

connecting between intake rubber hose of 

turbocharger and intake bellows. 

△ Tip: 


Page 1697

14B-16 



connecting between intake rubber hose of 

turbocharger and turbocharger. 

(e). 

Install the intake rubber hose clamp of turbocharger 

and fasten the bolts. 

(f). 

Connect the connector of air flow meter. 

14B 

6. Cover the engine compartment cover 

Lower the support bar of engine compartment cover, and cover the engine compartment cover. 

Page 1698

AIR FILTER 

SERVICE 

△ Tip: 

INTAKE-AIR FILTER 

14B-17 

The filter element of air filter should be cleaned for every 10,000Km drive, and the filter element of air filter 

should be replaced for every 20,000Km drive. 

1. Disassemble the intake pipe with resonance box 

assembly 

(a). Loose the A-type worm drive hose clamp connecting 

between intake pipe with resonance box assembly and 

air filter device. 

(b). 

(c). 

Disassemble the fixing bolts of intake pipe with 

resonance box assembly. 

Remove the intake pipe with resonance box assembly. 

2. Check the dust exhausting bag 

(a). Press the dust exhausting bag of the air filter with hand, 

check whether there is any dust blew out. 

△ Tip: 

If any dust blew out, checking and maintenance are needed. 

14B 

3. Disassemble the air filter assembly 

(a). Lift the fixing lock catch of air filter upper cover. 

Page 1699

14B-18 


(b). 

(c). 

Remove the filter element. 

Remove the fixing bolts of filter bracket. 

(d). Disassemble the fixing bolts of the filter device. 

(e). Remove the filter device lower part 

△ Tip: 

The operation procedure for c and d is performed when the 

filter device is replaced as a unit. 

(f). 

Clean the dust in the housing and dust on the cover 

and surface of gasket for air filter. 

14B 

(g). Clean the filter element. 

NOTE: 

The filter element should be cleaned periodically, do not use 

compressed air to clean the filter element from the outside, this 

may cause dust entering the filter element, rotate the filter 

element with hands and use compressed air (below 7kg/cm2) 

to blow the dust on the surface inside the filter element at the 

same time. 

4. Install the air filter assembly 

(a). Install the fixing bolts of filter device. 

Page 1700


14B-19 

(b). 

(c). 

Install and fasten the fixing bolts of filter bracket. 

Install the filter element. 

(d). 

Lock the fixing lock catch on air filter upper cover. 

5. Install the intake pipe with resonance box 

assembly 

(a). Place the intake pipe with resonance box assembly to 

installation position. 

(b). Install the fixing bolts of intake pipe with resonance box 

assembly. 

(c). 

Install and fasten the A-type worm drive hose clamp 

connecting between intake pipe with resonance box 

assembly and air filter device. 

14B 

Page 1701

-MEMO- 

14B 

Page 1702


ENGINE ASSEMBLY ......................................................................... 15B-1 

Overview ........................................................................................ 15B-1 

Precautions ................................................................................... 15B-2 

Diesel Engine Fault Diagnosis .................................................... 15B-3 

ENGINE MAINTENANCE ................................................................ 15B-63 

Precautions ................................................................................. 15B-63 

Operations ................................................................................... 15B-66 

Maintenance ................................................................................ 15B-70 

Basic Maintenance ..................................................................... 15B-74 

DISASSEMBLY/INSTALLATION OF COMPLETE ENGINE .......... 15B-77 

Precautions ................................................................................. 15B-77 

Disassembly Procedure ............................................................. 15B-79 

Installation Procedure ................................................................ 15B-84 

Instruction of Essentials ............................................................ 15B-90 

PRESERVATION OF COMPLETE ENGINE ................................... 15B-91 

Precautions ................................................................................. 15B-91 

Maintenance ................................................................................ 15B-91 

DISASSEMBLY OF ENGINE (4JB1) .............................................. 15B-92 

Instruction of Disassembly ....................................................... 15B-92 

Disassembly of Pipeline and Harness ..................................... 15B-93 

Disassembly of High and low Pressure Fuel Pipes and Fuel 

Injector ......................................................................................... 15B-95 

Disassembly of dipstick and Breather ..................................... 15B-97 

Disassembly of Turbocharger, Intake Manifold and Exhaust 

Manifolds ..................................................................................... 15B-99 

Disassembly of Cylinder Head Cover and Rockshaft .......... 15B-101 

Disassembly of Tappet and Cylinder Head ........................... 15B-103 

Disassembly of Thermostat Assembly and Valve ................ 15B-104 

Disassembly of Hook and A/C Bracket .................................. 15B-106 

Disassembly of starter motor and High Pressure Fuel Rail 15B-107 

Disassembly of oil Filter and Generator ................................ 15B-108 

Disassembly of fan and Crankshaft Pulley ............................ 15B-110 

Disassembly of Observation Chamber Cover and Water Pump 

Pulley Chamber Cover Assembly ............................................ 15B-111 

Disassembly of Pressure Plate and Timing Belt.................... 15B-112 

Disassembly of Injection Pump Assembly ............................. 15B-114 

Disassembly of Idle Pulley and Camshaft Gear ..................... 15B-115 

Disassembly of Clutch Components and Flywheel Assembly ...... 15B-118 

Disassembly of oil pan and Gear Chamber ........................... 15B-120 

Disassembly of Camshaft and Engine support .................... 15B-122 

Disassembly of oil Pump, oil Injection Pipe and Tappet ...... 15B-123 

Disassembly of Piston and Crankshaft.................................. 15B-125 

15B 

Page 1703

15B 

Assembly of Engine (4JB1)........................................................ 15B-128 

Instruction of Assembly ················································15B-128 

Installation of Crankshaft and Piston······························15B-129 

Installation of Tappet, oil Injection Pipe and oil Pump ······15B-137 

Installation of Engine support and Camshaft ···················15B-139 

Installation of Gear Chamber and oil Pan ························15B-141 

Flywheel Assembly and Clutch Components ··················15B-143 

Camshaft Gear and Idle Pulley ······································15B-145 

Installation of Injection Pump Assembly ·························15B-148 

Installation of Timing Belt and Pressure Plate ·················15B-149 

Installation of Water Pump Pulley Chamber Cover Assembly 

and Observation Chamber Cover .......................................... 15B-151 

Installation of the Crankshaft Pulley and the Fan ·············15B-152 

Installation of High Pressure Fuel Rail and starter motor ··15B-153 

Installation of Hook and A/C Bracket ······························15B-154 

Installation of Valve and Thermostat Assembly ···············15B-155 

Installation of Cylinder Head and Tappet ························15B-158 

Installation of Rockshaft and Cylinder Head Cover ··········15B-160 

Installation of Intake and exhaust MANIFOLDS and 

Turbocharger ······························································15B-162 

Installation of Breather and dipstick ·······························15B-164 

Installation of Fuel Injector and High & low Pressure Fuel 

Pipe ···········································································15B-166 

Generator and oil Filter ·················································15B-168 

Installation of Pipeline and Harness ·······························15B-170 

Disassembly of Engine (4D20)................................................... 15B-172 

Installation of Disassembly ···········································15B-172 

Disassembly of Heater Water Inlet/Outlet Pipe Weldment ·15B-173 

Disassembly of Cylinder Head Cover ·····························15B-174 

Disassembly of EGR Controller ·····································15B-175 

Disassembly of Intake and exhaust MANIFOLDS and 

Turbocharger ............................................................................ 15B-177 

Disassembly of Generator and Breather ·························15B-180 

Disassembly of fan, fan Pulley and Crankshaft Pulley ······15B-183 

Disassembly of dipstick ················································15B-185 

Disassembly of High & low Pressure Fuel Pipe and Fuel 

Injector ·······································································15B-186 

Disassembly of Rockshaft and Tappet ····························15B-188 

Disassembly of Cylinder Head ·······································15B-189 

Disassembly of the Water Outlet Pipe Connector, Valve and 

Hook ··········································································15B-190 

Disassembly of oil Filter and oil Radiator ·······················15B-192 

Disassembly of Clutch Components and Flywheel 

Assembly ····································································15B-194 

Page 1704

Disassembly of oil pan and oil Pump ..................................... 15B-196 

Disassembly of oil Seal Cover and oil Seal ........................... 15B-198 

Disassembly of Gear Chamber Cover, Fuel Injection Pump 

and Water Pump Assembly ..................................................... 15B-199 

Disassembly of Camshaft Gear and Crankshaft Gear.......... 15B-202 

Disassembly of Camshaft, Piston and Crankshaft ............... 15B-204 

Assembly of Engine (4D20)......................................................... 15B-208 

Introduction of Assembly ........................................................ 15B-208 

Installation of Crankshaft, Piston and Camshaft .................. 15B-209 

Installation of oil Seal and oil Seal Cover .............................. 15B-218 

Installation of Crankshaft Gear and Camshaft Gear ............. 15B-219 

Installation of Fuel Injection Pump and Gear Chamber 

Cover ··········································································15B-220 

Installation of oil Pump and oil Pan ....................................... 15B-222 

Installation of Flywheel Assembly and Clutch Components 15B-224 

Installation of oil Radiator and oil Filter................................. 15B-226 

Installation of Hook, Valve, and Water Outlet Pipe 

Connector .................................................................................. 15B-228 

Installation of Cylinder Head ................................................... 15B-231 

Installation of Tappet and Rockshaft ...................................... 15B-233 

Installation of Fuel Injector and High & low Pressure Fuel 

Pipe ············································································15B-234 

Installation of dipstick .............................................................. 15B-236 

Installation of Crankshaft Pulley, fan and fan Pulley ............ 15B-237 

Installation of Breather and Generator .................................. 15B-238 

Installation of Intake and exhaust Manifolds and 

Turbocharger ........................................................................... 15B-241 

Installation of EGR Controller ................................................. 15B-244 

Installation of Cylinder Head Cover ....................................... 15B-246 

Installation of Heater Water Inlet/Outlet Pipe Weldment ...... 15B-247 

Cylinder Head Cover .................................................................... 15B-248 

Diagram of Components .......................................................... 15B-248 

Service ········································································15B-250 

Rocker Assembly ......................................................................... 15B-255 


Service ········································································15B-256 

Cylinder Head ............................................................................... 15B-262 


Service ········································································15B-264 

Valve .............................................................................................. 15B-269 

Overview .................................................................................... 15B-269 

Adjustment ................................................................................ 15B-270 

Service ········································································15B-273 

Camshaft and Tappet ................................................................... 15B-282 

15B 

Page 1705

Diagram of Components ···············································15B-282 

Service ·······································································15B-283 

Piston and Connecting Rod Assembly ..................................... 15B-292 


Service ·······································································15B-293 

Crankshaft and Flywheel Assembly .......................................... 15B-301 


Service ·······································································15B-302 

Cylinder Block ............................................................................. 15B-307 


Service ·······································································15B-309 

15B 

Page 1706

ENGINE MECHANICAL PART-ENGINE ASSEMBLY 

15B-1 

ENGINE ASSEMBLY 

OVERVIEW 

This chapter analyzes and resolves the common faults of diesel engine and provides solutions for these 

common faults of the diesel engines equipped on the SUP product series. 

During the operation of the diesel engine, due to the causes such as the wear and deformation or the 

improper use and technical maintenance of the parts, the technical status is gradually deteriorated in various 

portions of the diesel engine. When any technical index is out of the allowable limit, it indicates that the diesel 

engine is malfunctioned. In event of the fault of the diesel engine, the diesel engine may not continue for 

normal functioning if such fault is not timely and correctly resolved. This will not only lead to the reduction of 

power and economy, the deterioration of the operation performance, and the reduction of exhaust level, but 

also cause the early wear of parts. 

Some faults of the diesel engine, such as the air contained in the fuel system, blockage of filter, and loose 

drive belt, can be resolved by means of the necessary technical maintenance and adjustment. However, 

some faults, such as the defect of the mechanisms, can’t be resolved by means of the regular maintenance 

and adjustment, which include the damage of cylinder gasket, serious wear of piston ring, wear of valve cone, 

and excessive wear of bearing bush. Such faults shall be resolved by removing the diesel engine and 

repairing or replacing some parts of the diesel engine. 

Generally speaking, the engine fault is complex, and one fault is influenced by various reasons; when a fault 

happens, by no means should we disassemble the parts blindly, but we should firstly have a clear 

understanding of the whole condition of the car, then analyze the possible reasons according to the specific 

phenomena, and investigate the faults one by one in an order from easy to complicated. 

15B 

Page 1707

15B-2 


PRECAUTIONS 

1. Collect all the actual condition of the fault phenomena. 

2. Thoroughly analyze the fault. 

3. Connect the fault symptom with basic engine system and parts. 

4. Consider whether the recent maintenance and repair measurements are related to the fault 

phenomena. 

5. Recheck once more carefully before any disassembly work. 

6. Judge the fault type, use the fault diagnosis table, and firstly choose the easiest problem to resolve. 

7. Confirm the fault cause and repair. 

8. After the repair, start the engine and ensure the fault cause has been thoroughly removed. 

15B 

Page 1708


15B-3 

DIESEL ENGINE FAULT DIAGNOSIS 

1. The engine cannot be started 

△ Tip: 

Generally, the reasons why the engine cannot be started are mainly the problems of fuel system, electric 

system, the compressing pressure in the cylinder, oil, fuel supply advance angle and ambient temperature. 

(a). 

(b). 

(c). 

(d). 

(e). 

The fuel system goes wrong 

The details are as follows: 

• There is no fuel in the fuel tank or the drain switch is not turned on. 

• There is the air in the fuel system. 

• Fuel pipe or the fuel filter is blocked. 

• The fuel delivery pump does not supply oil or interruptedly supply oil. 

• The advance angle is not correct. 

• The fuel injection atomization is bad. 

• The draw bar does not return to the maximum fuel supply position. 

The electric system goes wrong 


• The circuit connection is wrong or there is a bad contact. 

• The power of the battery is not adequate. 

• The carbon brush of the starter motor and the commutator are in a bad contact. 

• The generator does not work. 

The viscosity of the oil is too high and causes the reducing of the starting speed. 

The ambient temperature is too low. 

The compressing pressure in the cylinder is low. 


• The cylinder liner, piston and piston ring are worn. 

• The valve and the valve seat do not match closely. 

• There is no valve clearance. 

• The valve stem is stuck in the conduit. 

• The cylinder head gasket leaks air. 

• The fuel injector seat hole leaks air. 

• Valve timing is not correct. 

NOTE: 

When the engine cannot be started, firstly consider whether it is caused by misoperation or lack of 

maintenance. 

15B 

Page 1709

15B-4 


(f). Fault diagnosis and troubleshooting 

△ Tip: 

Check the possible causes for the difficult start or start failure of the engine one by one as per procedure 

below. Check in an order from easy to complicated, in order to effectively save the diagnosis time. Any cause 

clearly unlikely to occur through analysis may be omitted directly. This diagnosis procedure is for reference 

only. 

Step Diagnosis Description Measure 

1 

Check whether the ambient 

temperature is too low 

Yes 

Add hot water or adopt the preheating start 

No Go to Step 2 

2 

Check whether the starting circuit is in 

a good contact 

Yes Go to Step 3 

No 

Screw down the circuit connection screw 

3 

Check whether the battery voltage is 

normal 


No 

Charge the battery according to the technical 

requirements 

4 

Check whether there is diesel in the 

fuel tank or whether the drain switch 

is not turned on 

Yes 

Add diesel or turn on the switch 



5 

Check whether the fuel draw bar has 

returned to the maximum fuel supply 

position 

No 

When the engine is started, more tension shall 

be added to the speed adjusting lever to make 

the draw bar return to the maximum fuel supply 

position 

15B 

6 

Check whether the fuel pipe or the 

diesel filter is blocked 

Yes 

Clean the fuel pipe and clean or replace the 

diesel filter to solve the blockage problem 


Use the manual pump to remove the air. And 

7 

Check whether there is any air in the 

fuel system 

Yes 

check whether there is air leakage at each 

connecting pipe and solve the problem 


Page 1710


15B-5 


Check whether there is air leakage at the fuel 

inlet pipe, and whether the filter screen at the 

8 

Check whether the fuel delivery pump 

dose not supply fuel or interruptedly 

supply fuel 

Yes 

connector of the fuel inlet pipe is blocked; Check 

whether the fuel supply solenoid valve is open; 

turn on and off the switch and listen, if there is 

any sound of movement, the solenoid valve shall 

be replaced. 


9 

Check whether the fuel injection 

atomization is bad 

Yes 

Clean the nozzle parts, adjust the fuel injection 

pressure or replace the fuel injector 


Check whether the fuel supply 

Yes 

Readjust the fuel supply advance angle 

10 

advance angle meets the 

requirement 


11 

Check whether the connection is 

correct and stable 


No Reconnect and screw down 

12 

Whether the carbon brush of the 

starter motor and communtator are 

in a bad contact 

Repair or replace carbon brushes and use 

Yes sand paper to clean the surface of the 

communtator and blow off. 


13 

Whether the generator does not 

work 

Yes Repair or replace 


15B 

14 

Check whether the viscosity of the 

oil is too high and makes the 

Yes 

Turn the crankshaft for several turns with the 

handle or add preheated oil 

starting speed too low 


15 

Check whether the air valve 

contains no clearance or the 

Yes 

Adjust the air valve clearance according to the 

requirement 

clearance is too small 


16 

Check whether the valve stem is 

stuck in the conduit 

Yes Clean carefully with kerosene or diesel 


17 Check whether the air valve and the Yes Grind the air valve, and replace the damaged 

Page 1711

15B-6 



air valve seat do not match closely. 

air valve spring. 


Check whether the nut is screwed down; 

18 

Check whether there is air leakage 

at the fuel injector seat hole 

Yes 

whether the fuel injector gasket is undamaged; 

replace the damaged parts 


19 

20 

Check whether there is air leakage 

or blow-by phenomena at the 

cylinder head gasket 

Check whether the valve timing is 

incorrect 

Yes 

Fasten according to the Torque of the cylinder 

head bolt; replace the cylinder head gasket 


Yes Adjust the timing according to the timing mark 


21 

Check whether the cylinder liner, 

piston and piston ring are worn 

Yes 

No 

Replace the cylinder liner, piston and piston 

ring; remove the reason causing wear 

Check carefully according to the above steps, 

find out the fault position and remove timely 

15B 

Page 1712


15B-7 

2. Low temperature start difficulty of diesel engine 

(a). The diesel goes wrong 

When the winter comes or after we enter the severe cold region and do not choose the diesel 

according to the requirement, diesel becomes turbid and solidified under the condition of low 

temperature. 

(b). The lubricating oil goes wrong 

When the winter comes or after we enter the severe cold region and do not choose the oil according 

to the requirement, the viscosity of the oil is too high under the condition of low temperature, and 

internal friction increased, and starting resistance moment of the diesel engine increased. 

(c). The battery goes wrong 

When working at the severe cold region, and do not choose the battery according to the requirement, 

the battery capacity is less than 100Ah. 

(d). The preheating system goes wrong 

The electrical element fault makes the preheating system does not work, the preheat plug is 

unheated. 

15B 

Page 1713

15B-8 


(e). Fault diagnosis and troubleshooting 

△ Tip: 

Check the causes for the difficult start of the engine one by one as per procedure below, check in an order 

from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly unlikely to occur 

through analysis may be omitted directly. This diagnosis procedure is for reference only. 


1 

When the winter comes or after we enter the 

severe cold region, whether choose the diesel 

according to the requirement, the diesel 

becomes turbid and solidified under the condition 

of low temperature 

Choose low condensing point diesel 

No according to the ambient temperature 

in which the diesel engine works 


When the winter comes or after we enter the 

Choose low viscosity oil according to 

severe cold region, whether choose the oil 

according to the requirement, the viscosity of 

No 

the ambient temperature in which the 

diesel engine works to reduce the 

2 

the oil is too high under the condition of low 

power required for the start 

temperature, and internal friction increased, 

and starting resistance moment of the diesel 

engine increased 

Yes 

Go to Step 3 

3 

When working at the severe cold region, 

whether choose the battery according to the 

requirement, the battery capacity is less than 

100Ah 

Choose low temperature battery with 

capacity higher than 100Ah according 

No 

to the ambient temperature in which 

the diesel engine works 


Check the voltage of each preheat 

15B 

4 

The electrical element fault makes the 

preheating system does not work, whether the 

No 

plug in preheating system, and judge 

whether it is the preheat plug fault or 

the circuit fault 

preheat plug is heated 

Check carefully according to the 

Yes 

above steps; find out the fault position 

and remove timely 

Page 1714


15B-9 

3. Low engine power 

△ Tip: 

Low engine power means that the engine power can’t reach the design requirement so that the vehicle lacks 

of power, with poor color of exhaust emission, while driving under heavy load or climbing an abrupt slope. 

The reasons causing low engine power are mainly problems of fuel system, intake system, exhaust system, 

cooling system, low compressing pressure in the cylinder, abnormal oil temperature, incorrect fuel supply 

advance angle and low ambient temperature and so on. 

(a). 

(b). 

(c). 

(d). 

(e). 

When the intake system goes wrong, it generally represents as: at the urgent acceleration, the engine 

revolution speed cannot be accelerated to the corresponding speed, and the exhaust pipe exhausts 

blue smoke with sharp flavor of the incomplete combustion of the diesel. 


• The dust in the filter element of the air filter is too much and causes blockage. 

• The intake pipe of the air filter is damaged. 

• The intake pipe is not sealed closely. 

When the exhaust system goes wrong, it generally represents as: at the acceleration, the exhaust 

pipe muffler makes abnormal sound and sometimes there is abnormal dense smoke exhausted from 

the exhaust port. 


• The exhaust pipe or muffler is damaged and causes blockage. 

• The turning radius of the exhaust pipe is too small or there are too many bends. 

• Exhaust brake has faults, and the brake valve is normally closed. 

When the fuel system goes wrong, it generally represents as: after the acceleration is increased, the 

power or revolution speed still cannot be increased, and the engine tends to flameout. 


• No fuel in the fuel tank or the fuel level is too low. 

• There is air in the fuel system. 

• The fuel pipe or diesel filter is blocked. 

• The fuel supply of the fuel injector pump is low. 

• The atomization of fuel injector is bad. 

• The fuel injection pressure is low. 

• Few fuel injectors are blocked. 

• The fuel injector pump accelerate handle is not properly adjusted. 

Fuel supply advance angle changes, revolution speed and performance of each gear decrease. 


• The fuel supply advance angle is changed. 

• The air valve clearance is incorrect. 

The abnormal oil temperature generally represents as: the oil warning light flickers or is normally on; 

too high or too low oil temperature will cause the oil deterioration and bad lubrication; this kind of 

phenomenon can be caused by problems of ambient temperature, engine cooling system or engine 

internal machine. 


• Oil filling amount cannot meet the standard. 

• Oil brand is not suitable for the ambient temperature. 

• The abnormal engine cooling system causes the too high oil temperature. 

• The ambient temperature is too low. 

15B 

Page 1715

15B-10 


(f). 

(g). 

(h). 

(i). 

Low compressing pressure in the cylinder generally represents as: phenomena of low engine power, 

decreased performance, air leakage, black smoke and abnormal knocking sound. 


• The cylinder liner, piston and piston ring are worn. 

• Air vale and air vale seat do not match closely. 

• There is no air valve clearance. 

• The valve stem is stuck in the conduit. 

• The cylinder head gasket leaks air. 

• The fuel injector seat hole leaks air. 

• Valve timing is not correct. 

Diesel engine is overheated 


• The temperature of air coolant is too high. 

• The temperature of oil is too high. 

• The temperature of exhaust gas is too high. 

Cylinder head fault: at this time, not only the power is low and the performance is decreased, but also 

there are phenomena of air leakage, black smoke and abnormal knocking sound. 


• The joint surface of cylinder head and the engine body leaks air, the cylinder head bolt is loose or 

the cylinder gasket is damaged. 

• Intake valve and exhaust valve leak air. 

• The air valve clearance is incorrect. 

• The fuel injector hole leaks air or the copper washer is damaged. 

Crank-link mechanism fault 


• Connecting rod small end copper sleeve is seized with piston pin. 

NOTE: 

The low engine power often comes with start difficulty, they are closely related; we can take it as a 

reference to analyze, but we shall firstly consider whether it is caused by lack of maintenance. 

15B 

Page 1716


15B-11 

(j). Fault diagnosis and troubleshooting 

Tip: 

Check the possible causes for the low engine power one by one as per procedure below. Check in an order 

from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly unlikely to occur 

through analysis may be omitted directly. This diagnosis procedure is for reference only. 


Check whether the filter element of 

Yes 

Clean or replace the air filter element. 

1 

the air filter is blocked because of 

dirtiness. 


2 

Check whether the intake pipe of the 

air filter is damaged. 

Yes 

Replace the damaged pipe and clean the dust 

and other things in the undamaged pipe. 



3 

Check whether the intake pipe is well 

sealed. 

No 

Fasten the pipe connector clamp according to 

the technical requirements 

Check whether the fixing bolt at the 


4 

connector of exhaust gas pipe is fixed 

firmly 

No 

Fasten the loose blot to specified torque. 

5 

Check whether the exhaust gas pipe 

or the muffler is blocked. 

Yes 

Remove the exhaust gas pipe and muffler to 

clean; replace the muffler if necessary. 


6 

Whether the modified exhaust gas 

pipe caused low exhaust gas amount 

or too small turning radius and too 

many bends. 

Yes 

Install the exhaust gas pipe according to factory 

design to ensure the free flowing of exhaust gas. 


15B 

Check whether fault happens to 

Yes 

Remove the brake valve fault. 

7 

exhaust gas brake or the brake valve 

is normally closed 


8 

Check whether the fuel in the fuel tank 

is sufficient. 


No 

Fill fuel which suits for local climate condition 

Page 1717

15B-12 



Loosen the oil return valve on the fuel injector 

pump or the air bleeding bolt on the diesel filter, 

9 

Check whether there is air in the fuel 

pipe 

Yes 

and use the fuel delivery pump to pump the fuel 

and bleed the air. Ensure there is no air in the 

fuel pipe and fasten the air bleeding bolt. 


10 

Check whether the fuel pipe and fuel 

filter are blocked 

Yes 

Clean the fuel pipe and replace the fuel filter if 

necessary 


11 

Check whether the fuel supply of the 

fuel injection pump is sufficient 

Yes 

Check, repair and replace the fuel injection 

pump. 


12 

Check whether the atomization of the 

fuel injector is bad 

Yes 

Check the fuel injector and repair or replace the 

fuel injector with bad atomization 


13 


pressure is low 

Yes 

Use the adjusting hot gasket to adjust the fuel 

injection pressure 


14 

Check whether few fuel injector is 

stuck 

Yes Repair or replace fuel injector couple 


15B 

15 

Check whether the fuel supply 

advance angle is changed 

Yes Adjust the fuel supply advance angle 


16 


clearance is correct 


No Adjust the air valve clearance 

17 


pump acceleration handle is well 

adjusted 

Adjust the acceleration handle to the maximum 

Yes fuel supply amount according to the requirement; 

check the fuel injection pump if necessary 


Page 1718


15B-13 



18 

Check whether the oil meets the 

standard 

No 

If the oil amount is low, add more; if the amount 

is too high, discharge the redundant oil and find 

out the reason of the redundance. 

19 

20 

21 

22 

23 

Check whether the oil brand is not 

suitable for the ambient temperature 

Check whether there is any fault at the 

engine coolant level and the cooling 

system and causes too high engine 

temperature 

Whether the too low ambient 

temperature made the viscosity of the 

oil too high and caused the bad 

lubrication 

Check whether the air valve stem is 

stuck in the conduit 

Check whether the air valve well 

matches with the air valve seat 

Yes 

Replace with the oil suitable for local climate 

condition 


Fill the coolant to the standard level and find out 

Yes the reason of the high temperature and remove 

the fault 


Replace the oil suitable for the local climate 

Yes condition; add suitable warm-keeping 

components in front of the radiator 


Yes Clean carefully with kerosene or diesel 


Yes 

Grind the air valve; replace the damaged air 

valve spring 


24 

Check whether the fuel injector seat 

hole leaks air. 

Yes 

Check whether the nut is screwed down and the 

fuel injector gasket is undamaged; replace the 

damaged parts 

15B 

25 

26 

Check there is air leakage or blow-by 

phenomena at the cylinder head gasket 


correct 


Yes 

Fasten according to the Torque of cylinder head 

bolt; replace the cylinder head gasket 


Yes Adjust the timing according to the timing mark 


Page 1719

15B-14 



27 

Check whether the cylinder liner, piston 

and piston ring are worn. 

Yes 

Replace the cylinder liner, piston and piston ring; 

remove the reason causing wear. 


Check the cooling system; clean the scale; check 

28 

Check whether the coolant temperature 

is too high 

Yes 

the tightness of the belt and adjust; check the 

thermostat 


Check the oil amount, add more if it is low; if the 

29 

Check whether the oil temperature is 

too high 

Yes 

bearing bush or one moving member radiates, 

find out the radiation part and the reason, and 

remove it 


Check and revise the static fuel supply advance 

30 

Check whether the exhaust 

temperature is too high 

Yes 

angle, fuel injection pressure and atomization 

condition of the fuel injector 

31 

Check whether there is air leakage at 

the joint surface of cylinder head and 

the engine body, and whether the 

cylinder head bolt is loosen or the 

cylinder gasket is damaged. 


Screw down the cylinder head bolt according to 

Yes the specified torque or replace the cylinder 

gasket 


Disassemble and check the intake, exhaust 

15B 

32 

Check whether there is air leakage at 

the intake, exhaust valves 

Yes 

valves; grind the air valve or grind the joint 

surface of the air valve seat 


33 

34 

Check whether the air valve clearance 

is correct 

Check the air leakage of the fuel 

injector hole or whether the copper 

gasket is damaged 


No 

Revise the air valve clearance to the specified 

value 

Yes 

Remove, service, clean and replace the 

damaged parts 


Page 1720


15B-15 


Remove the oil pan, check whether the 

35 

Check the seizure of the connecting 

rod small end copper sleeve and the 

piston pin 

Yes 

No 

connecting rod big end can conduct the axial 

wobble, if not, remove the connecting rod of the 

piston and service 



15B 

Page 1721

15B-16 


4. Engine sudden flameout 

△ Tip: 

Engine sudden flameout means that in the normal work of engine, it suddenly shuts down and cannot run 

again. There are two situations for engine sudden flameout: one is that it can start again after the flameout 

but cannot run normally, which means the fuel supply system fault; another one is that it cannot start again 

after the flameout, even with the starter driving it, which means the machine part fault caused by the bad 

internal lubrication of the engine. 

(a). 

(b). 

When a fault happens in the fuel supply system, it generally represents as after the flameout, when 

restart and increase the accelerator, the engine is about to start and there are a little blue smoke 

discharged from the exhaust gas pipe, but it stopped if the ignition switch is loosen. 


• The fuel in the fuel tank ran out. 

• There is air in the fuel system. 

• The fuel filter or pipe is blocked. 

• The diesel contains water. 

The engine internal parts fault generally represents as when restart the engine after the flameout, the 

engine cannot run with the starter or runs very slowly. 


• The oil pressure is too low or too little. 

• Oil pump has faults. 

• The piston is stuck with the cylinder liner. 

• The connecting rod small end or connecting rod bearing bush is seized with crankshaft. 

• Crankshaft main bearing bush is seized. 

NOTE: 

When the engine suddenly shut down, first use tool to turn the start claw to judge whether the engine 

can run, if it can run and runs normally, it means the fuel system goes wrong; if it can not run, it 

means the seizure phenomenon appears on the engine internal parts, then disassemble and check to 

avoid unnecessary loss. 

15B 

Page 1722


15B-17 

(c). Fault diagnosis and troubleshooting 

△ Tip: 

Check the possible causes for the engine sudden flameout one by one as per procedure below, and check in 

an order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly unlikely 

to occur through analysis may be omitted directly. This diagnosis procedure is for reference only. 


1 

Check whether the fuel in the fuel 

tank ran out 

Yes 

No 

Fill the fuel and bleed the air in the fuel pipe 

Go to Step 2 

2 

Check whether the fuel system 

contains air 

Yes 

Find out the reason of air admission and remove 

it; bleed the air in the fuel pipe 


3 

Check whether the fuel filter or the 

pipe is blocked 

Yes 

Clean the fuel pipe, replace the fuel filter if 

necessary. 


4 

Check whether the fuel contains 

water 

Yes 

Drain the fuel in the fuel tank and add new fuel, 

or deposit the drained fuel and use it again 


Check whether the lack of oil caused 

Fill the fuel to the standard scale, use tool the 

the bad lubrication of the engine parts 

Yes 

turn the start claw and start the engine after it 

5 

which caused the slight damage 

(there is damping when use tool to 

turn the start claw but it can be 

turned) 

No 

runs smoothly 

Go to Step 6 

15B 

6 

Disassemble the oil pan and check 

whether the oil pump goes wrong 

Yes 

Replace or repair the oil pump; repair the worn 

parts 


7 

Check whether the piston is stuck 

with the cylinder liner 

Yes 

Replace the damaged piston and cylinder liner 

and find out the reason and remove it 


Page 1723

15B-18 



8 

Check whether the connecting rod 

small end or connecting rod bearing 

bush is seized with the crankshaft 

Yes 

Replace the damaged parts, find out the reason 

and remove it 


9 

Check whether the crankshaft main 

bearing bush is seized with the 

crankshaft 

Yes 

No 

Replace the main bearing bush; repair or replace 

the crankshaft 



15B 

Page 1724


15B-19 

5. Engine abnormal sound 

△ Tip: 

Engine abnormal sound means the obvious knocking or impact sound inside of or on the top of the engine 

that can be heard during the normal working. The size and the frequency of such sound increase following 

the increasing of the engine rotation speed. Once occurred, such sound is hard to disappear without the 

adoption of the remedy measure. Firstly differentiate the type of the engine abnormal sound as the impact 

sound arising from the abnormal detonation or from the abnormal movement of parts and then find out the 

root cause depending on the noise characteristic and portion of noise source in combination with the 

structure theory. 

(a). Air valve mechanism abnormal sound. It generally represents as: in the running process of the car, 

there is obvious abnormal sound at the upper part of the engine, and the volume and frequency of the 

sound will increase along with the increase of the engine revolution speed; once the sound happens, 

it is difficult to vanish without taking any measurements. 


• The viscosity of the oil is too dilute. 

• The air valve tappet contains no oil. 

• The air valve clearance is too large. 

• The rocker or the rockshaft is worn. 

• The air valve is stuck; the air valve seat is inclined or contains too much carbon deposit. 

(b). Fuel supply time too early or too late abnormal sound. When the fuel supply is too early, it generally 

represents as that it makes clear metal knocking sound form the cylinder at the urgent acceleration; 

while when the fuel supply is too late, it generally represents as that it makes low and deep but not 

clear knocking sound from the cylinder; and generally it exhausts air with dense smoke. 


• The fuel supply time is too early. 

• The fuel supply time is too late. 

• The fuel injector is stuck. 

(c). Piston and piston ring abnormal sound. It generally represents as grinding sound “Da Da Da” from the 

upper part of the cylinder block and the cylinder head, the sound and frequency will increase with the 

increase of the engine revolution speed, and it comes out with possible exhaust gas and blue smoke 

and decreased engine power. 


• The piston ring is severely worn. 

• The piston is severely worn. 

• The cylinder barrel is severely worn. 

• The clearance between the cylinder barrel and the piston is too large. 

(d). The piston pin and connecting rod small end bush match loosely. It generally represents as that the 

engine will make slight and blunt sound when it is running, and this kind of sound is particularly clear 

at the idle operation. 


• The connecting rod small end bush is worn. 

• The piston pin is worn. 

(e). The clearance between the piston and cylinder liner is too large. It generally represents as that a 

crashing sound can be heard from the outer wall of the engine when it is running, and the sound will 

15B 

Page 1725

15B-20 


(f). 

(g). 

be louder when the revolution speed increases. 

The air valve and piston crash abnormal sound. It generally represents as that it makes deep, uniform 

and rhythmed knocking sound form the upper part of the cylinder block and cylinder head. 


• The valve timing is incorrect. 

• The clearance of the air valve is too small. 

The transmission gear is worn, and the clearance is too large. It generally represents as that it makes 

abnormal sound from the gear chamber, and a crashing sound can be heard at sudden decreased 

speed. 

(h). 

(i). 

The wear of the connecting rod bearing bush and the main bearing bush makes the clearance too 

large. It generally represents as that when the engine is running, a crashing sound can be heard at 

the crank case and it becomes louder when the revolution speed increases. 

The clearance of intake valve and exhaust valve are too large. It generally represents as that a loud 

and rhythmed sound can be heard at the cylinder head. 

NOTE: 

When the engine makes abnormal sound and fault sound, we shall not let it continue to work; after 

hearing the abnormal sound, we shall urgently stop the car, check and diagnose, judge the reason 

and position of the fault and timely remove it to avoid unnecessary loss. 

15B 

Page 1726


15B-21 

(j). Fault diagnosis and troubleshooting 

△ Tip: 

Check the possible causes for the sudden flameout of engine one by one as per procedure below, and check 

in an order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly 

unlikely to occur through analysis may be omitted directly. This diagnosis procedure is for reference only. 


Replace the lubricating oil suitable for the climate 

1 

Check whether the viscosity of the oil 

is too dilute 

Yes 

condition; check the engine parts damage 

caused by the too dilute oil and replace them 


2 

Check whether the air valve tappet is 

severely worn because of the lack of 

Yes 

Fill engine lubricating oil; replace the damaged 

air valve tappet 

oil 


3 

Rumble sound can be heard at the 

intake or exhaust port, meaning 

whether the clearance of the air valve 

is too large 

Yes 

Adjust all air valve clearance according to the 

requirements 


4 

Check whether the rocker are or 

rockshaft is worn 

Yes 

Replace the damaged parts; readjust the air 

valve 


Clean the stuck air valve, replace the air valve 

5 

Check whether the air valve is stuck, 

the air valve seat is inclined or 

contains too much carbon deposit 

Yes seat and grind the air valve; find out the reason 

of too much carbon deposit and remove it 


15B 

Adjust the static fuel supply advance angle, 

6 

Check whether the fuel supply time is 

too early. 

Yes 

check the fuel injection condition of the fuel 

injector, repair or replace if necessary 


Adjust the static fuel supply advance angle, 

7 

Check whether the fuel supply time is 

too late 

Yes 

check the fuel injection condition of the fuel 

injector, repair or replace if necessary 


8 Check whether few fuel injectors are Yes Replace or repair the damaged fuel injector 

Page 1727

15B-22 



stuck No Go to Step 9 

9 

10 

11 

12 

13 

14 

Check whether the piston ring is 

severely worn. 

Check whether the piston is severely 

worn 

Check whether the cylinder barrel is 

severely worn 

Check whether the too large 

clearance between the cylinder barrel 

and the piston caused the crashing 

sound 

Check whether the piston ring is 

severely worn. 

Check whether the piston is severely 

worn 

Yes 

Replace the piston ring; if necessary, replace the 

piston, too. 


Yes 

Replace the damaged piston and cylinder liner; 

find out the reason and remove it 


Yes 

Replace the damaged cylinder barrel; if 

necessary, replace the piston, too. 


Yes 

Replace the damaged parts; if necessary, 

replace the whole set 


Yes 

Replace the piston ring; if necessary, replace the 

piston, too. 


Yes 

Replace the damaged piston and cylinder liner, 

find out the reason and remove it. 


15B 

15 


small end bush is worn 

Yes 

Replace the connecting rod small end bush; if 

necessary, replace the piston or the connecting 

rod 


16 Check whether the piston pin is worn 

Yes 

Replace the piston pin; if necessary, replace the 

connecting rod small end bush 


Page 1728


15B-23 


17 

18 

Whether the clearance between the 

piston and cylinder liner is too large, a 

crashing sound can be heard at the 

outer wall of the engine body while 

running and it becomes louder when 

the revolution speed increases 


correct 

Yes 

Replace the piston, or replace the cylinder liner 

according to the wear condition 



No Adjust the timing gears 

19 


clearance is too small or closed 

Yes 

Adjust the air valve clearance according to the 

requirements 

20 

21 

Check whether the transmission 

gears are worn and caused too large 

clearance 


bearing bush and the main bearing 

bush are worn and caused the too 

large clearance 


Yes 

Check the gear clearance, replace the gear 

according to the wear condition 


Disassemble and check the bearing bush; if 

Yes necessary, replace and keep the required fit 

clearance 


22 

Whether the clearance of intake valve 

and exhaust valve is too large and a 

loud and rhythmed sound can be 

heard at the cylinder head 

Yes 

No 

Revise the air valve clearance again 



15B 

Page 1729

15B-24 


6. The oil pressure is abnormal 

△ Tip: 

Whether the oil pressure is too high or too low belongs to abnormal situation, in which the too low oil pressure 

is rather common. When the pressure is too low, the oil pressure alarm will flicker, meaning the oil pressure is 

low or there is no oil. There are many reasons causing oil pressure problems, and the driver or maintenance 

personnel shall treat seriously, check the reason of the fault carefully and remove the fault. 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

The oil pressure sensor or the oil gauge is damaged. 

The oil level is too low. 

The viscosity of the oil is too dilute. 


• The oil brand is not suitable for the local climate condition. 

• The temperature of the engine is too high. 

• The cylinder head gasket is damaged and the coolant is mixed into the oil. 

• The water-blocking seal ring of the cylinder barrel is damaged, and the coolant is mixed into the 

oil. 

• The cylinder head or cylinder block is cracked and the coolant is mixed into the oil. 

The oil filter is blocked 

The clearance between the main bearing bush and the connecting rod bearing bush is too large 

Oil pump fault 


• The inner and outer rotors of the oil pump are severely worn or it leaks oil. 

• The oil inlet pipe of the oil pump is blocked. 

• The pressure regulating valve of the oil pump has a fault or the lubricating oil pipe is cracked 

• The oil filter gasket is installed in the reverse direction. 

NOTE: 

When the oil pressure is abnormal, we shall not let the engine continue to work, we shall urgently 

stop the car after we find it, shut down the engine, check the reason and position of the fault and 

timely remove it to avoid unnecessary loss. 

15B 

Page 1730


15B-25 

(g). Fault diagnosis and troubleshooting 

△ Tip: 

Check the possible causes for the abnormal oil pressure one by one as per procedure below, and check in an 

order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly unlikely to 

occur through analysis may be omitted directly. This diagnosis procedure is for reference only. 


1 

Check whether the oil pressure sensor or the oil 

gauge is damaged 

Yes 

Replace the oil pressure sensor or the 

oil gauge 


2 Check whether the oil level is too low 

Yes 

Add suitable amount of oil, and find 

out the reason causing the too low oil 

level and remove it 


3 

Judge the reason causing too high or too low 

engine temperature and whether the oil is 

deteriorated influencing by the ambient 

temperature 

Yes 

Replace the oil suitable for the local 

climate temperature condition 


4 

Check whether the cylinder head gasket is 

damaged and whether the damaged cylinder 

Yes 

Replace the cylinder head gasket and 

the oil 

gasket makes the coolant mixed into the oil 


5 

Check whether the water-blocking seal ring of 

the cylinder barrel is damaged, and whether the 

damaged water-blocking seal ring of the cylinder 

Yes 

Replace the water-blocking seal ring 

of the cylinder barrel and replace the 

oil 

barrel makes the coolant mixed into the oil 


15B 

6 

Check whether the cylinder head of the cylinder 

block is cracked and whether the cracked 

cylinder head of cylinder block makes the coolant 

mixed into the oil 

Yes 

Replace the damaged parts and the 

oil 


7 Check whether the oil filter is blocked 

Yes 

Replace the oil filter; if necessary, 

replace the oil 


Page 1731

15B-26 



Replace the main bearing bush or the 

8 

The clearance between the main bearing bush 

and the connecting rod bearing bush is too large 

Yes 

connecting bearing bush; if 

necessary, replace or repair the 

connecting rod or the crankshaft 

9 

The oil filter gasket is installed in the reverse 

direction 


Yes Reinstall or replace 


10 Check whether the oil pump goes wrong 

Yes 

Replace or repair the oil pump 


11 

Check whether the inner and outer rotors of the 

oil pump are severely worn or leaks oil. 

Yes 

Replace or repair the oil pump 


12 The oil inlet pipe of the oil pump is blocked 

Yes 

Dredge the oil inlet pipe of the oil 

pump and replace the filter screen of 

the oil inlet pipe 


Yes 

Replace or repair the damaged parts 

13 

The pressure regulating valve of the oil pump or 

the lubricating oil pipe is cracked 

No 


above steps, find out the fault position 


15B 

Page 1732


15B-27 

7. Engine overheating or supercooling 

△ Tip: 

The overheating or supercooling of the engine will influence the overall performance of the engine. Engine 

overheating is rather common, and it generally represents as that the pointer of the coolant temperature 

gauge points at the red dangerous scale, the radiator is easy to boil, and vapor can be seen from the radiator 

when the engine cover is opened. Drivers or maintenance personnel shall treat it seriously, check the reason 

of the fault carefully, and remove the fault. 

(a). 

(b). 

(c). 

The cooling system overheating 


• The water tank lacks water. 

• The cooling pin out of the water tank is blocked with sundries. 

• The scale in the water tank is too much and caused blockage and bad circulation. 

• The belts of the fan and water pump are too loose, causing that the output volume of the water 

pump and fan is too little. 

• The distance between the water tank and the fan is inappropriate. 

• The water inlet and outlet pipes are deformed and blocked. 

• The valve of the thermostat cannot be opened. 

• Water pump has faults. 

• The fuel supply timing is not correct. 

Engine supercooling 


• The valve of the thermostat cannot be closed. 

• The coolant temperature gauge does not work. 

The fuel injection is too late or the fuel injector leaks oil. 


• The timing phase is not correct. 

• Engine operates with overload for a long time. 

NOTE: 

• In event of engine overheating, do not stop the engine or add the coolant immediately, or it will 

lead to personal injuries or damage of parts. In such case, release the accelerator pedal, run under 

unloaded condition or splash a small amount of water onto the surface of coolant tank. After the 

coolant in the cooling system cools down, stop the engine for checking. 

• Do not remove the cap of coolant tank while the engine is still hot, in order to prevent scalding. 

While refilling the coolant, special caution shall be taken. 

• If the causes for engine overheating can’t be found and resolved, contact the service station or 

service plant immediately, or it will lead to damage of other parts. 

15B 

Page 1733

15B-28 


(d). Fault diagnosis and troubleshooting 

△ Tip: 

Check the causes for the engine overheating or supercooling one by one as per procedure below, and check 

in an order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly 



1 Check whether the engine lacks coolant 

Yes 

Remove the reason of losing coolant 

and fill the coolant 


Clean the sundries with hairbrush and 

2 

Check whether the cooling pin of the water tank 

is blocked because of too much dust or sundries 

Yes 

clean the dust in the cooling pin with 

compressed gas 


Add aqueous alkali into the water tank 

(ten liters of water with 750 grams of 

3 

Check whether the scale in the water passage is 

too much 

Yes 

washing soda), run the engine for 4-8 

hours and drain the water, and 

cyclically clean the water passage 

with the clean water 


4 

Check whether the belts of the fan and the water 

pump are too loose or fractured 

Yes 

Adjust the tightness of the belts; if 

necessary, replace the belts 


15B 

5 

Check whether the distance between the water 

tank and the fan is not installed properly 

Yes 

Adjust the distance between the water 

tank and the fan properly 


6 

Check whether the water inlet and outlet pipes 

(rubber hoses) are deformed 

Yes 

Replace the deformed rubber hoses 


7 

Check whether the thermostat valve does not 

work normally 

Yes 

Replace the thermostat 


8 Check whether the water pump goes wrong 

Yes 

Replace or repair 


Page 1734


15B-29 


9 Check whether the fuel supply timing is correct 


No 

Adjust the fuel supply timing correctly 

Check the temperature of the coolant, 

10 

Check whether the coolant temperature gauge 

does not work 

Yes 

replace the coolant temperature 

gauge and sensor 


Adjust the fuel supply timing, check 

12 

Check whether the fuel injection of the fuel 

injector is too late or the fuel injector leaks oil 

Yes 

the fuel injector and replace if 

necessary 


13 Check whether the timing phase is correct 


No 

Readjust the timing phase 

Yes 

Properly decrease the load to operate 

14 

Whether the long time overloading operation of 

engine caused the high temperature 

No 




15B 

Page 1735

15B-30 


8. The smoke color of the exhaust gas of the engine is abnormal 

△ Tip: 

Observing the color of the exhaust gas of the engine and judge whether the engine goes wrong is an easy 

and effective way. If the engine is under the normal working temperature, its exhaust gas color shall be 

colorless or light gray, (the so-called colorless does not mean completely colorless like the diesel engine, but 

colorless with slight gray) this is the normal exhaust gas color. The exhaust gas color of the diesel engine 

under idle operation, urgent acceleration and high speed and high loading will be darker, the abnormal 

exhaust gas colors generally contain: exhaust gas with blue smoke, exhaust gas with white smoke and 

exhaust gas with black smoke; more observation of the normal exhaust gas color at ordinary time will be 

helpful for having a clearly understanding of the abnormal exhaust gas color. 

15B 

(a). 

(b). 

(c). 

Engine exhaust gas with blue smoke (oil entersthe cylinder) 


• The piston ring and the cylinder liner are worn; the piston ring is bonded or the piston ring gap 

alignment. 

• The conduit hole near the exhaust valve is worn. 

• The oil level in the oil pan is too high. 

• The piston ring is stuck or excessively worn, the elasticity is low; the piston chamfer is reversely 

installed and makes the oil enters the combustor. 

• With long time low loading operation, the clearance between the piston and cylinder liner is 

rather large and makes the oil enters the combustor. 

Engine exhaust gas with white smoke (the diesel is not completely combusted under the condition of 

engine supercoolling and low loading) 


• The fuel supply of the fuel injector is too much. 

• The fuel atomization is bad, and the fuel injection is too low. 

• The fuel supply is too late. 

• The cylinder compressing pressure is too low. 

• The diesel contains water or the cylinder contains water. 

• When the diesel engine is just started, no combustion in few cylinders (especially in winter) 

Engine exhaust gas with black smoke (uncompleted combustion) 


• The diesel engine works with overloading. 

• The diesel is not atomized well or there is an oil leakage phenomenon. 

• The fuel supply time is too late. 

• The intake pipe or the air filter is blocked. 

• The fuel injection quantity is too much. 

• The fuel supply amount of each cylinder is not equal. 

• The air valve clearance is not correct and the bad sealed air valve caused the air leakage of the 

exhaust valve. 

• The too small fuel supply advance angle and the too late fuel injection make part of the fuel 

combusted in the exhaust gas pipe. 

• The cylinder liner and the piston ring are severely worn. 

• The EGR system solenoid valve is damaged. 

Page 1736


15B-31 

• The EGR valve cannot be closed well. 

• The fuel injector is damaged. 

NOTE: 

When the smoke color of the engine exhaust gas is abnormal, firstly consider whether it is caused by 

improper operation or lack of maintenance. 


△ Tip: 

Check the possible causes for the abnormal smoke color of engine exhaust gas one by one as per procedure 

below, and check in an order from easy to complicated, in order to effectively save the diagnosis time. Any 

cause clearly unlikely to occur through analysis may be omitted directly. This diagnosis procedure is for 

reference only. 

• Exhaust gas with blue smoke fault diagnosis and troubleshooting 


1 

Check whether the exhaust gas with blue smoke 

is caused by the wear of piston and cylinder liner, 

the bonding of piston ring, the low elasticity or the 

piston ring gap alignment 

Yes 

Repair carefully, and replace the worn 

parts if necessary 


2 

Check whether the conduits of the intake and 

exhaust pipes are worn 

Yes 

Replace the worn parts and grind the 

air valve 


3 

Check whether the oil level in the oil pan is too 

high 

Yes 

Exhaust the excessive oil 


4 

Check whether the piston ring is stuck or 

excessively worn, and whether the elasticity is 

Yes 

Disassemble and check the piston 

ring, replace if necessary 

low 


15B 

5 

Whether the long time low loading operation and 

the rather large clearance between the piston 

and cylinder liner make the oil enter the 

combustor 

Yes 

No 

Properly increase the loading or 

disassemble, check and repair 




Page 1737

15B-32 


• Diagnosis and troubleshooting of exhaust gas with white smoke. 


1 

Check whether the fuel supply of the fuel 

injection pump is too much 

Yes 

Adjust the fuel supply amount of the 

fuel injector 



2 

Check whether atomization and pressure of 

fuel injector is normal. 

No 

Check and adjust pressure of the 

fuel injector, and replace the fuel 

injector when necessary. 

3 

Check whether fuel supply of fuel injection 

pump is too late. 

Yes 

Adjust fuel supply advance angle. 


Service cylinder liner, piston, piston 

4 

Check whether the compressing pressure of 

the cylinder is too low 

Yes 

ring , grind the air valve, and 

replace the worn parts when 

necessary. 


5 Check whether there is water in the diesel 

Yes 

Replace diesel, and replace fuel 

filter 



15B 

6 

Whether there is combustion in few cylinders 

immediately when the diesel engine starts 

(Especially in winter). 

Yes 

No 

above steps, find out the fault 

position and remove timely 

Properly increase the rotation speed 

and the load, and run it for more 

time. 

Page 1738


15B-33 

• Diagnosis and troubleshooting of exhaust gas with black smoke 


1 

Make sure whether it is caused by overload work 

of the diesel engine 

Yes 

Decrease the load. 


Check and adjust the fuel injector 

2 

Check whether the fuel injector atomization is 

bad or leaks oil. 

Yes 

pressure and replace the fuel 

injector when necessary. 

3 

Check whether the fuel supply of the oil pump is 

too late 


Yes Adjust the fuel supply advance angle. 


Clean the air filter and intake pipe and 

4 

Check whether the intake pipe or air filter is 

blocked. 

Yes 

replace the filter element when 

necessary 


Adjust the amount of fuel supply, and 

5 

Check whether the amount of fuel supply is too 

much. 

Yes 

check the fuel injection pump when 

necessary. 



6 

Check whether the fuel supply amount of each 

cylinder is equal. 

No 

Adjust the amount of fuel supply in the 

cylinders of each injection pump and 

make them equal. 

15B 

7 

Check whether the valve clearance is correct, 

and whether the valve is not sealed well and 

caused the air leakage of the exhaust valve 

Yes 

Adjust the valve clearance and check 

the sealing cone. 


8 

Check whether fuel supply advance angle is too 

small and whether fuel injection is too late which 

can makes few fuel combusted in the exhaust 

pipe. 

Yes Adjust the static fuel supply advance 

angle. 


Page 1739

15B-34 



9 

Check whether the cylinder liner and piston ring 

are seriously worn 

Yes 

Replace the piston ring and the 

cylinder liner 


Unplug the hose between the 

solenoid valve and EGR valve at the 

10 

Check whether the solenoid valve in ERG 

system is broken. 

Yes 

ERG valve end, and if the pheromone 

of smoke disappears, it means the 

solenoid valve is broken, then replace 

new part 


11 Check whether ERG valve is not closed well. 

Yes 

Disassemble the ERG valve and 

clean the carbon deposition 


12 Check whether the fuel injector is broken. 

Yes 

No 

To decide which fuel injector goes 

wrong using the cylinder fuel cut 

method, and the details are as 

follows. 




15B 

Page 1740


15B-35 

9. Fault of the fuel injection pump 

△ Tip: 

The fuel injection pump is the main part for the fuel supply to engine, so the problems in the fuel pump can 

influence the normal working of the engine directly. The faults in engine resulting from the problems of the fuel 

injection pump are as follows: the engine cannot get started, improper engine idling, runaway in engine and 

knocking of the engine. The driver should take these seriously, and the injection pump is precise unit and 

non-professionals cannot disassemble and adjust it. 

(a). The injection pump does not supply oil. 


• The delivery valve is worn or is lined with dirt and stains 

• The delivery valve spring or plunger spring is deformed or broken off. 

• The adjustment spring is dropped. 

• The adjustment arm and the shifter fork are struck. 

• The mandril of the delivery pump is struck. 

(b). The fuel injection pump does not stop supplying fueland causes runway in engine”(The engine 

rotation speed cannot be reduced or is not controlled by the accelerator pedal) 


• The oil shifting yoke is blocked. 

• The adjustment arm is dropped. 

• The shaft sleeve of governor is burned because it is not lubricated well. 

• The draw bar stroke is not enough. 

• The fly hammer components are loose. 

• The draw bar spring is dropped. 

(c). The speed governing rate is too high. 


• The speed governing torsional spring is deformed or worn or the stiffness is too large. 

• The corrector plays a part too early. 

(d). The fuel supply is not stable. 


• There is air or water in the fuel 

• The fuel delivery pump is broken. 

• The plunger spring is fractured. 

(e). Engine hunting 


• Frictional resistance in the governor is too large. 

• The axial clearance in camshaft is too large. 

• The speed governing torsional spring is deformed or worn or the stiffness is too large. 

• The fly hammer components are loose. 

• The lubricating oil is too much. 

(f). The rated oil amount is not enough. 


• The plunger and barrel assembly or the delivery valve is worn. 

• The corrector is adjusted improperly. 

• The high speed limit is incorrect. 

15B 

Page 1741

15B-36 


(g). 

(h). 

The fuel supply amount of each cylinder is not equal suddenly. 


• The adjustment arm is loose. 

• The plunger spring is fractured. 

• There is dirt and stains in the delivery valve and fuel nozzle. 

Low speed and unstability 


• Idle speed adjustment screw is not adjusted properly. 

• The low speed oil amount is not equal. 

NOTE: 

• In event of engine overheating, do not stop the engine or add the coolant immediately, or it will 

lead to personal injuries or damage of parts. In such case, release the accelerator pedal, run under 

unloaded condition or splash a small amount of water onto the surface of coolant tank. After the 

coolant in the cooling system cools down, stop the engine for checking. 

• Do not remove the cap of coolant tank while the engine is still hot, in order to prevent scalding. 

While refilling the coolant, special caution shall be taken. 

• If the causes for engine overheating can’t be found and resolved, contact the service station or 

service plant immediately, or it will lead to damage of other parts. 

15B 

Page 1742


15B-37 

(i). Fault diagnosis and troubleshooting 

△ Tip: 

Check the reason causing the fault of the fuel injection pump one by one according to the following steps. 

Check in an order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly 


• Fuel njection pump not pumping oil fault diagnosis and troubleshooting. 


1 

Check whether the delivery valve is worn or 

lined with dirt and stains 

Yes 

Replace the delivery valve or clean it. 


2 

Check whether the delivery valve spring or 

the plunger spring is deformed or broken off. 

Yes 

Replace the damaged components. 


3 

Check whether the adjustment spring is 

dropped. 

Yes 

Replace and compress the adjustment 

arm tightly. 


4 

Check whether the adjustment arm and the 

shifter fork is struck 

Yes 

Replace or repair 


Yes 

Replace or repair. 

5 

Check whether the mandril of the delivery 

pump is struck. 

No 

Check carefully according to the above 

steps, find out the fault position and 

remove timely 

· 

15B 

Page 1743

15B-38 


• The diagnosis and troubleshooting of the “runway in engine”caused by continuous fuel supply of the fuel 

injection pump 


1 

2 

3 

4 

5 

Check whether the adjustment arm or 

shifter fork is struck 

Check whether the adjustment arm is 

dropped. . 

Check whether the governor shaft 

sleeve is burned resulted from the 

improper lubrication. 

Check whether the draw bar stroke 

is too small. 

Check whether the fly hammer 

components are loose. 

Yes Replace or repair 


Yes 

Replace and compress the adjustment arm 

tightly. 


Yes Replace or repair 


Yes Adjust the draw bar stroke 


Yes Fasten the loose components. 


6 

Check whether the draw bar circlip is 

dropped. 

Yes 

No 

Install the circlip and readjust 



• The diagnosis and troubleshooting of the too high speed governing rate 

15B 


1 

Check whether the speed governing 

torsional spring is deformed or worn 

or the stiffness is too large. 

Yes 

Replace the speed governing torsional spring. 


2 

Check whether the oil pump corrector 

works too early. 

Yes 

No 

Readjust the corrector. 



Page 1744


15B-39 

• Unstable fuel supply amount diagnosis and troubleshooting. 


1 

2 

Check whether there is air or water in 

the fuel tank. 

Check whether the fuel delivery 

pump is damaged. 

Yes Bleed the air or water. 


Yes Replace or repair the fuel delivery pump. 


3 

Check whether plunger spring is 

damaged or fatigue. 

Yes 

No 

Replace the plunger spring and check the fuel 

injection pump. 



• The diagnosis and troubleshooting of engine hunting 


1 

Check whether the frictional 

resistance in the governor is high. 

Yes Repair and remove the fault. 


2 

Check whether the axial clearance in 

camshaft is too large. 

Yes Readjust the axial clearance 


3 

Check whether the speed governing 

torsional spring is deformed or worn 

or the stiffness is too large. 

Yes Replace the speed governing torsional spring 


4 

Check whether the fly hammer 

components are loose. 

Yes 

Fasten the loose components to the specified 

standard. 


15B 

5 

Check whether the lubricating oil is 

too much. 

Yes 

No 

Add the lubricating oil according to the standard. 



Page 1745

15B-40 




1 

2 

Check whether the plunger elements 

or the delivery valve is worn 

Check whether the corrector is 

adjusted improperly. 

Yes 

Replace the plunger elements or whether the 

delivery valve is worn 


Yes Readjust the corrector 


3 

Check whether the high speed limit is 

adjusted improperly. 

Yes 

No 

Readjust the high speed limit screw. 





1 

2 

Check whether the adjustment arm is 

loose. 

Check whether the plunger spring is 

fractured. 

Yes Anew replace and compress it tightly. 


Yes 

Replace the plunger spring and check the fuel 

injection pump. 


15B 

3 

Check whether the delivery valve is 

worn or is lined with dirt and stains. 

Yes 

No 

Replace the delivery valve or clean it. 





1 

Check whether is the position of idle 

speed fixing bolt is adjusted 

incorrectly. 

Yes 

Renew adjust the idle speed fixing screw. 


2 

Check whether the fuel supply of the 

fuel injection pump at a low speed is 

wrong 

Yes 

No 

Check the fuel injection pump and adjust the 

amount of fuel supply at a low speed. 



Page 1746


15B-41 

10. Coolant temperature in the cooling system of diesel engine is abnormal ,there is short of 

(a). 

(b). 

(c). 

coolant and there is noise. 

Diesel engine overheating 


• The coolant level is too low (lack of liquid) 

• The fan belt is loose or fractured. 

• The thermostat valve cannot be opened. 

• The water pump has faults. 

• Fuel supply timing is not correct. 

• The core of radiator is blocked. 

Diesel engine supercooling 


• The thermostat valve cannot be closed completely. 

• The coolant temperature gauge is out of order. 

Frequent lack of water. 


• The radiator leaks. 

• The hose connector of radiator is loose or the hose is damaged. 

• The water pump leaks. 

• The hose connector of heater is loose or the hose is damaged. 

NOTE: 

• When meet the engine overheating, you should not stop the diesel engine from working 

immediately or add coolant suddenly. You should decrease the accelerator and make it operate 

with no load. Check after flameout when the coolant temperature in the cooling system falls. 

• When the diesel engine is still hot, do not take down the filler cover in case of scald. Pay special 

attention to safety when adding the coolant. 

• If the overheat reason cannot be found and removed, you should contact with the service station 

or the service plant, or it will lead to damage of the parts. 

15B 

Page 1747

15B-42 



△ Tip: 





1 

Check whether the coolant level is too 

low (lack of liquid) 

Yes 

Replenish the coolant and check whether there 

is leakage. Repair according to the demand. 


2 

Check whether the fan belt is loose or 

fractured. 

Yes 

Adjust or replace the fan belt. 


3 

Check whether the thermostat valve 

can be opened. 


No 

Replace the thermostat assembly 

4 

Check whether there is fault of the 

water pump 

Yes 

Replace the water pump assembly. 


5 

Check whether the fuel supply timing 

is correct. 


No 

Adjust correctly the fuel supply timing. 

6 

Check whether the core of radiator is 

blocked. 

Yes 

Clean the radiator. 


15B 

7 

Check whether the thermostat valve 

can be closed completely 


No 

Replace the thermostat. 

8 

Check whether the coolant 

temperature gauge is out of order. 

Yes 

Measure the coolant temperature, and replace 

the coolant temperature gauge. 


9 

Check whether there is leakage of 

radiator 

Yes 

Repair or replace the radiator 


Check whether the hose connector of 

Yes 

Fastening the connectors or replace the hose. 

10 

radiator is loose or the hose is 

damaged. 


11 Check whether there is leakage of Yes Replace the water pump assembly. 

Page 1748


15B-43 


water pump. No Go to Step 12 

Check whether the hose connector of 

Yes 

Fastening or replace the hose. 

12 

heater is loose or the hose is 

damaged. 

No 



15B 

Page 1749

15B-44 


11. Fuel consumption of lubricating system of diesel engine is large with low pressure. 

(a). 

(b). 

(c). 

Consumption of oil is too large. 


• Use the oil without conforming to requirements. 

• Gasket and oil seal are invalid, causing oil leakage. 

• Piston ring or ring slot is damaged. 

• Piston ring is clamped in stagnation. 

• Oil seal of valve guide pipe, valve guide pipe or valve stem are damaged. 

• Cylinder is worn. 

The pressure of oil is too low. 


• Use the oil without conforming to requirements. 

• Safety valve is clamped in stagnation. 

• Screen filter of oil pump is blocked. 

• Driving gear and driven gear of oil pump are worn. 

• Oil pipe is cracked or broken or connectors are loosing. 

• Faults of oil pump. 

• Main bush or connecting rod bearing bush is worn excessively. 

• Oil pressure gauge is damaged. 

Oil cannot reach valve system. 


• Oil hole between cylinder block and cylinder head is blocked. 

• Oil hole on rockshaft is blocked. 

• Oil hole on the support of rockshaft is blocked. 

• Oil hole on rocker is blocked. 

NOTE: 

If the oil pressure is too lower for lubricating system, diesel engine cannot be operated. In such 

situation, stop vehicle at once for inspection and Disassembly of faults. 

15B 

Page 1750


15B-45 


△ Tip: 





1 

Check whether oil without 

conforming to requirement is used. 

Yes 

Replace the oil of specified brand 


2 

Check whether gasket and oil seal 

are invalid and whether there is oil 

leakage. 

Yes 

Replace gasket and oil seal 


3 

Check whether piston ring or ring 

slot is worn. 

Yes 

Replace piston ring or piston 


4 

Check whether piston ring is 

clamped in stagnation 

Yes 

Replace piston ring or piston 


5 

Check whether oil seal of valve 

guide pipe, valve guide pipe or 

valve stem are worn. 

Yes 

Replace oil seal, valve or valve guide pipe 


6 Check whether cylinder is worn. 

Yes 

Repair cylinder bore or replace cylinder liner 


7 

Check whether safety valve is 

clamped in stagnation. 

Yes Replace safety valve 


15B 

8 

Check whether screen filter of oil 

pump is blocked. 

Yes Clean or replace screen filter. 


9 

Check whether driving gear and 

driven gear of oil pump are worn. 

Yes 

Replace oil pump assembly 


10 

Check whether oil pipe is cracked or 

broken or connectors are loosing. 

Yes 

Repair or replace 


Page 1751

15B-46 



11 

12 

13 

14 

15 

16 

Check whether there are faults for 

oil pump 

Check whether main bush or 

connecting rod bearing bush is worn 

excessively. 

Check whether oil pressure gauge 

is damaged. 

Check oil hole on cylinder block and 

cylinder head is blocked. 

Check whether oil hole on rockshaft 

is blocked. 

Check whether oil hole on the 

support of rockshaft is blocked. 

Yes Replace oil pump assembly 


Yes 

Replace main bush or connecting rod bearing 

bush 


Yes Repair or replace the oil pressure gauge. 


Yes Clean or repair. 






Yes 

Clean or repair. 

17 

Check whether oil hole of rocker is 

blocked. 

No 


find out the fault position and remove faults in 

time 

15B 

Page 1752


15B-47 

12. Faults of supercharging system of diesel engine. 

(a). Inadequate power. 


• Impurities in oil are accumulated at the seal of turbine. 

• Oil temperature is too high and fuel supply is not adequate. Floating bearing is damaged by 

burning. 

• Oil return pipe of turbocharger is blocked or deformed to cause oil leakage from turbine and shaft 

end of compressor. 

• Gasket of turbocharger is damaged or invalid. 

• Rotor of turbine shaft loses balance. 

• Turbine blade and compressor blade are in friction and damaged. 

• Air filter is blocked (too dirty). 

• Air guide pipe of supercharging compensator is broken. 

• There is too much dirt for intake pipe and exhaust pipe or connecting parts have air leakage. 

• Turbocharger is in poor operation or damaged. 

(b). Fuel injection pump does not supply fuel or provide inadequate fuel. 


• The connection of delivery valve is poor or delivery valve is stuck. 

• Mebrane of supercharging compensator is damaged. 

(c). Fuel consumption is too large. 


• There is too much dirt on intake pipe and exhaust pipe or connecting parts have air leakage. 

• The property of turbocharger is poor. 

• Fuel injector is in poor operation. 

• Piston ring is worn. 

(d). Consumption of oil is too large. 


• Seal ring of turbocharger is worn or damaged. 

• There is oil leakage at impeller end of compressor. 

• Screws at the connecting place of intake pipe and oil return pipe are loosing and gasket is 

damaged. 

• Oil is in poor quality. 

(e). Abnormal sound 


• There is too much dirt at air channel for turbine and turbine is obviously reduced. 

• There is too much dirt at compressor and air channel is reduced obviously. 

• The wear of floating bearing is too large and friction is generated among turbine, impeller of 

compressor and shell. 

(f). Friction is generated among turbine, impeller of compressor and shell to produce vibration. 


• Entrance of foreign matter 

• The wear of floating bearing is too large. 

• Dynamic balance of turbine shaft is weak. 

15B 

Page 1753

15B-48 


NOTE: 

• In the process to remove faults and disassemble and install diesel engine, prevent the entrance of 

foreign matter to intake and exhaust system strictly, as the rotor of turbocharger is rotating at a 

extremely high speed and the clearance between rotor and shell is very small. The entrance of no 

matter what kind of foreign matter to impeller will influence the operation of rotor and damage 

blade. If the blade is damaged, turbocharger will produce abnormal vibration and noise. At this 

moment, stop the vehicle for service of turbocharger. 

• If there is oil leakage for turbocharger, but the impeller of spindle does not touch inner shell and 

rotates flexibly, do not replace turbocharger casually, but to remove the fault of oil leakage for 

continuing use. 

15B 

Page 1754


15B-49 

(g). Fault diagnosis and troubleshooting 

△ Tip: 





1 

Check whether impurities in oil are accumulated 

at the seal of turbine. 

Yes 

Replace oil and repair turbocharger. 


2 

Check whether the oil temperature is too high 

and fuel supply is adequate and whether floating 

bearing is damaged by burning. 

Yes 

Check fuel supply system and repair 

turbocharger. 


3 

Check whether oil return pipe of turbocharger is 

blocked or deformed to cause oil leakage from 

turbine and shaft end of compressor. 

Yes 

Repair and replace oil return pipe. 


4 

Check whether the seal ring of turbocharger is 

damaged or invalid. 

Yes 

Replace seal ring. 


5 

Check whether rotor of turbine shaft loses 

balance. 

Yes 

Repair and replace the rotor of turbine 

shaft. 


Check whether the turbine blade and 

6 

compressor blade are in friction or damaged. 

7 Check whether the air filter is blocked (too dirty) 

Yes 

Repair or replace turbine blade and 

compressor blade. 


Yes 

Maintain air filter and replace filter 

element. 


15B 

8 

Check whether the air guide pipe of 

supercharging compensator is broken. 

Yes 

Service or replace air guide pipe. 


9 

Check whether there is too much dirt on intake 

pipe and exhaust pipe or connecting parts have 

air leakage. 

Yes 

Clean, service or replace intake pipe 

and exhaust pipe. 


Page 1755

15B-50 



10 

11 

12 

13 

Check whether the operation of turbocharger is 

good or whether it is damaged. 

Check whether the connection of delivery valve 

is poor or delivery valve is stuck. 

Check whether the mebrane of supercharging 

compensator is damaged. 

Check whether the turbocharger is in good 

operation. 

Yes Service or replace turbocharger. 


Yes Repair or replace parts 


Yes Repair and replace mebrane 


Yes Clean, adjust or replace turbocharger. 


14 Check whether fuel injector is in good operation. 

Yes 

Repair or replace the fuel injector or 

nozzle. 


15 Check whether piston ring is damaged. 

Yes 

Check or replace piston ring. 


16 

Check whether the seal ring of turbocharger is 

worn or damaged. 

Yes Replace seal ring. 


17 

Check whether there is oil leakage for the 

impeller of compressor. 

Yes Service 


15B 

18 

Check whether the screws at the connecting 

place of intake pipe and oil return pipe are 

loosing and whether gasket is damaged. 

Yes Service and replace gasket. 


19 Whether the quality of oil is weak. 

Yes 

Replace oil according to 

requirements. 

20 

Whether there is too much dirt at the air channel 

and turbine is becoming smaller obviously. 


Yes Clean and replace 


Page 1756


15B-51 


21 

22 

23 

Check whether there is too much dirt at 

compressor and air channel is becoming smaller 

obviously. 

Whether the wear of floating bearing is too large 

and whether friction is generated among turbine, 

impeller of compressor and shell. 

Check whether there is entrance of foreign 

matter. 



Yes Replace the floating bearing 




Yes 

Service or replace turbine shaft. 

24 

Check whether the dynamic balance of turbine is 

weak. 

No 



and remove faults in time 

15B 

Page 1757

15B-52 


15B 

13. The capacity of battery is inadequate with difficult starting and too large self discharge. 

(a). 

(b). 

The capacity of battery is inadequate and it is difficult to start diesel engine. 

• The level of electrolyte is too low. 

• Short circuit between polar plates 

• Vulcanization of polar plate 

• Connectors of wire are in poor contact and there is too much oxide on polar column with 

inadequate charging. 

Self discharge of battery is too large. 


• There are impurities in electrolyte. 

• There is short circuit at external wire of battery. 

• There is electrolyte spilling out at the surface of battery to cause short circuit of passive and 

negative polar column. 

• Place metal tools or rod between positive polar column and negative polar column, causing 

serious short circuit. 

• Active substance of polar plate is at loss. Too much accumulation makes polar plate in short 

circuit. The damage of clapboard causes short circuit form polar plate. The warping of polar plate 

causes short circuit for positive and negative plates. 

NOTE: 

• It is easy for the discharged gas of battery to be burnt by sparks. In service and maintenance of 

battery, avoid striking fire, open fire and smoking. In repair, do not let electrolyte of battery contact 

skin and clothes and wear goggles. 

• Do not make the two connecting poles of battery become short circuit. Otherwise, the battery will 

be heated rapidly and may cause explosion. 

• In order to prevent short circuit, dismantle the bond strap of battery firstly in removing and 

installing electrical equipment. But in changing bulb, it is only necessary to cut off related 

switches. 

• In removing battery, firstly disassemble bond strap and then disassemble positive pole line. Next, 

disassembly battery baffle and take battery out from the support. The order to install battery is 

opposite to the order of disassembly. 

Page 1758


15B-53 

(c). Fault diagnosis and troubleshooting 

△ Tip: 





According to requirements, add the distilled 

1 

Check whether the level of electrolyte 

is too low. 

Yes 

water or dilute sulfuric acid solution with its 

density of 1.1. 


2 

Check whether there is short circuit 

between polar plates. 

Yes 

Remove sediment and replace electrolyte. 


3 

Check whether vulcanization occurs to 

polar plates. 

Yes 

Carry out charging and discharging repeatedly to 

remove vulcanization. 


Check whether line connectors are in 

Yes 

Fasten connection and remove oxide. 

4 

good contact, there is too much oxide 

on pole column and whether the 

charging is adequate. 

No 

Go to Step 5 

5 

Check whether there are impurities in 

electrolyte. 

Yes 

According to regulations, inject electrolyte made 

of chemical pure sulfuric acid and distilled water. 


6 

Check whether there is short circuit for 

external wire of battery. 

Yes 

Check the part of short circuit and remove faults. 


15B 

Use alkaline water or warm water to clean pole 

7 

Check whether there is electrolyte 

spilling on the surface of battery to 

cause short circuit for negative and 

positive pole column. 

column head of battery surface and keep the 

Yes 

outside clean. (water cannot be leaked into 

battery) 


Page 1759

15B-54 



8 

Whether serious short circuit is caused 

by placing metal tool or rods between 

positive pole column and negative pole 

column. 

Yes 

Do not place metal tools or rods on the surface of 

battery. 


9 

Whether the active substance of polar 

plate is at loss and too much 

accumulation causes short circuit of 

polar plate. Damage of clapboard also 

causes short circuit of polar plate. 

Warping of polar plate causes short 

circuit for positive pole plate and 

negative pole plate. 

Yes 

No 

Repair or replace the battery 



time 

15B 

Page 1760


15B-55 

14. Faults of starter 

△ Tip: 

Starter is used to transfer the electric energy of battery to mechanical energy and generate electromagnet to 

drive engine to operate at regulatory rotation speed and make engine start and operate. The fault of starter is 

usually reflected as follows: turn on ignition switch, but starter does not operate and the starting of starter is 

powerless to make starter in empty operation. In starting, there is abnormal sound for driving gear and 

approach action of flywheel ring gear. 

(a). Turn of ignition switch, but starter does not operate. 


• The wire is in poor contact. 

• Battery is lack of electricity seriously or there is short circuit inside. 

• There is short circuit inside starter. 

• There is short circuit inside starter. 

• Bearing or bushing of starter is worn. 

• The line is broken for control circuit of starting switch. 

• Carbon brush is in poor contact with commutator. 

(b). Starter is powerless. 


• The charging of battery is not adequate. 

• There is short circuit for the lead of starter. 

• Battery terminal is corrosive or wiring clip is loosing. 

• There is short circuit for field winding of starter or armature winding. 

• The assembly of starter is too tight or there is sweeping phenomenon. 

• The resistance of engine is too large. 

• Capacity of battery is not adequate. 

• There is burning damage or oily dirt on the surface of commutator. 

• Carbon brush is worn excessively or elasticity of carbon brush is not adequate, causing its poor 

contact with commutator. 

• Main contact of electromagnetic switch is ablated, causing poor contact. 

• Bearing wear is serious and armature is in contact with shell. 

(c). Idle operation of starter. 


• One-way clutch is damaged. 

• Check whether the electromagnetic switch of starter is damaged. 

(d). There is abnormal sound for driving gear and approach action of flywheel ring gear. 


• Driving gear or flywheel ring gear is worn seriously. 

• Electromagnetic switch of starter is damaged. 

(e). Diesel engine is started, but starter is still in idle operation and sound sharp noise. 


• Inner copper contact disc of starter relay is in adhesion with two contacts. 

• Armature shaft of starter is broken or bended. 

• Sgraffito of gear surface is stuck. 

15B 

Page 1761

15B-56 


NOTE: 

Do not exceed 15s in starting starter for operation and the time interval of two starting shall be more 

than 2 minutes to avoid too hot starter damaging internal parts. If it can not be started for three times 

continuously, check engine, fuel system, electromagnetic switch, starter, battery and wiring terminal 

and re-start it after removing faults. Loose the ignition switch right away once engine is started for 

operation and back the self meshing position of engine gear and stop operation. 

(f). 

△ Tip: 

Fault diagnosis and troubleshooting 




• Diagnosis and removal for the non-operation of starter 


1 

2 

3 

4 

Check whether there is poor contact 

in connecting line. 

Check whether battery is lack of 

electricity serious or open circuit 

inside. 

Check whether the internal line of 

starter is broken. 

Whether there is short circuit for 

internal line of starter. 

Yes 

Fasten the connectors of line and replace 

connectors if necessary. 


Yes 

Charge the battery and replace battery if 

necessary. 


Yes 

Repair of replace starter 


Yes 

Repair or replace starter. 


15B 

5 Check whether fuse is broken. 

6 

Check whether the bearing or 

bushing of starter is seriously worn. 

Yes Replace the fuse. 


Yes Repair or replace starter. 


7 

Check whether the line of starting 

switch and control circuit is broken. 

Yes 

Check whether the circuit is in reliable 

connection. 


8 

Check whether carbon brush is in 

good contact with commutator. 

Yes 

No 

Adjust the spring pressure of carbon brush and 

clean commutator. 



time 

Page 1762


15B-57 

• Diagnosis and Disassembly of powerlessness of starter 


1 

Check whether battery charging is 

adequate. 

Yes Charge the battery 


2 

Check whether the connectors of lead of 

started is in good contact or short circuit. 

Yes 

Fasten the connectors of line and replace 

them if necessary. 


3 

Check whether the wiring terminal of 

battery is corrosive or wiring clip is loosing. 

Yes 

Remove the corrosive and fasten the fixing 

bolt of wiring clamp. 


4 

Check whether there is short circuit for 

field winding or armature winding of starter. 

Yes Repair or replace starter. 


5 

Check whether the assembly of starter is 

too tight or swept. 

Yes 

Repair starter and replace the worn parts if 

necessary. 


6 

Check whether the resistance of engine is 

too high. 

Yes Remove the resistance causes of engine. 


7 

8 

Check whether the capacity of battery is 

adequate. 

Check whether there is burning damage or 

oily dirt on the surface of commutator. 

Yes 

Charge the battery according to 

regulations. 


Yes 

Polish the surface of commutator or 

remove the oily dirt. 


15B 

9 

Whether the wear of carbon brush is too 

much or the spring elasticity of carbon 

brush is inadequate, causing its poor 

contact with commutator. 

Yes 

Replace carbon brush or adjust the spring 

pressure of carbon brush. 


10 

Check whether the main contact of 

electromagnetic switch is ablated to poor 

contact. 

Yes Use “0” non-metal sand paper for polishing. 


Page 1763

15B-58 



11 

Check whether the bearing is worn 

seriously and whether the armature 

touches the shell. 

Yes 

No 

Replace the bearing 



remove faults in time 

• Diagnosis and Disassembly of idle operation of starter 


1 Check whether one-way clutch slips. 

Yes 

Replace one-way clutch 


Yes 

Replace electromagnetic switch of starter. 

2 

Check whether electromagnetic switch of 

starter is damaged. 

No 




• Diagnosis and Disassembly of abnormal sound for driving gear and approach action of flywheel ring gear 


1 

Check whether driving gear or flywheel 

ring gear is worn seriously. 

Yes 

Replace the worn parts 


15B 

2 

Check whether electromagnetic switch of 

starter is damaged. 

Yes 

No 

Replace the electromagnetic switch of 

starter. 




Page 1764


15B-59 

• Start the diesel engine and starter continues to operate, then, carry out diagnosis and Disassembly of 

sharp noise. 


1 

Check whether copper contact disc in 

starter relay is in adhesion with two 

contacts. 

Yes 

Cut off power at once, check the line and 

repair contacts. 


2 

Check whether the armature shaft of 

starter is broken or bended. 

Yes 

Cut off power at once and replace starter. 


Yes 

Cut off power at once and trim gear surface 

3 

Check whether sgraffito of gear surface 

is stuck. 

No 



time 

15B 

Page 1765

15B-60 


15. Faults of generator 

(a). Generator does not generate power. 


• The line is in poor contact, wrong connector or broken. 

• The line of stator and rotor is in short circuit or broken. 

• The rectifying valve is damaged, causing short circuit or open circuit. 

• Electric brush is in poor contact, there is oily dirt for slip ring and the belt of generator is too 

loosing. 

• Regulator is damaged. 

(b). Charging of generator is inadequate. 


• The transmission belt is loose. 

• Carbon brush is in poor contact and there is oily dirt for slip ring. 

• Regulator is damaged. 

• There is too little electrolyte for battery of the vulcanization of polar plate is too serious or it is too 

aged. 

(c). Charging current is not stable. 


• Short circuit is to occur to rotor coil and stator coil. 

• Electric brush is in poor contact, spring pressure of electric brush is small and line is in poor 

contact. 

(d). Generator produces abnormal sound. 


• The installation of generator is not proper and bearing is damaged. 

• Rectifying valve and rotor coil are in short circuit. 

15B 

Page 1766


15B-61 

(e). Fault diagnosis and troubleshooting 

△ Tip: 




• Diagnosis and Disassembly of the faults for no power generation of generator 


1 

Check whether line is in poor contact or wrong 

connection. 

Yes 

Check and repair 


2 

Check whether rotor coil and stator coil is in short 

circuit. 

Yes 

Service or replace 


3 

Check whether rectifying valve is damaged, 

causing short circuit or open circuit. 

Yes 

Repair or replace as a unit. 


4 

Check whether electric brush is in poor contact, 

there is oily direct for slip ring and belt of 

generator is too loosing. 

Yes 

Repair or clear or adjust the tension of 

belt. 


Yes 

Repair or replace regulator. 

5 Check whether the regulator is damaged. 

No 




• Diagnosis and removal for the faults of inadequate charging of generator 


15B 

1 Check whether transmission belt is loose. 

Yes 

Adjust the tension rate of belt. 


2 

Check whether carbon brush is in poor contact or 

there is oily dirt for slip ring. 

Yes 

Adjust and clean 


3 Check whether regulator is damaged. 

Yes 

Replace regulator 


Page 1767

15B-62 



Supplement electrolyte to regulatory 

4 

Check whether there is too little electrolyte for 

battery of vulcanization of polar plate is serious 

Yes 

height. For the battery without 

recoverable vulcanization of polar 

plate, replace it. 

or it is too aged. 


No 



• Diagnosis and removal for unstable charging current 


1 

Check whether short circuit occurs to rotor coil 

and stator coil. 

Yes 



2 

Check whether electric brush is in poor contact 

and the spring pressure of electric brush is too 

small and line is in poor contact 

Yes 

No 



above steps, find out the fault 

position and remove faults in time 

• Diagnosis and removal for unstable charging current 


1 

Check whether the installation of generator is 

proper and bearing is damaged. 

Yes 



15B 

Yes 


2 

Check whether rectifying valve and stator 

coil are in short circuit. 

No 




Page 1768

ENGINE MECHANICAL PART-ENGINE MAINTENANCE 

15B-63 

ENGINE MAINTENANCE 

PRECAUTIONS 

1. General Precautions 

(a). 

(b). 

(c). 

(d). 

(e). 

During the operation, perform the adjustments and maintenances in accordance with the 

maintenance methods and various regulations specified in the manual. 

The new engine or the engine after being serviced shall not be allowed to run with full load at high 

speed. The engine shall run for 45h from at a low speed with no-load to a high speed with full load, 

and then the engine shall run with normal load. 

The fuel which is used by the engine shall be precipitated for a week or be filtered by a silk before it is 

used. 

The normal coolant temperature shall be 80 ℃ -90 ℃ and the normal oil pressure shall be 

280-400kPa. 

During the process of running, if a abnormal phenomenon is found out, stop the car and check it. 

2. Precautions for Running and stop of Engine 

(a). 

(b). 

(c). 

Gradually and equably perform the engine’s load and rotation speed and car’s running speed 

increasing and decreasing. Except in special circumstances, do not suddenly change the load and 

speed. 

During the process of engine’s running and the car’s running, pay attention to whether the registration 

of each meter is normal or the running conditions of engine (running sound and the discharge smoke 

color). If the registration is abnormal, please take measures or stop running. 

The running coolant temperature shall be about 358K (85℃) and the oil pressure is 196~490kPa 

under normal circumstances. 

NOTE: 

The car cannot adopt the operational approach of “accelerate-shut down-neutral position’s 

slide-ignite by putting the clutch into gear”. 

The reasons are as follows: 

• The engine suddenly shuts down with high speed and high temperature, the oil pump and water 

pump will stop working, which can not make the lubricating oil and coolant carry off the heat of the 

engine. 

• For the ignition by putting the clutch into gear, if the speed is about 40km per hour, it indicates that 

(d). 

the engine starts at a rotation speed of 1300r/min with large impact force, which is harmful to the 

engine. 

Before stopping the car, the engine shall decrease the load and speed. After the car stops, the engine 

will run for 3-5min and then stops. The aim is to gradually and equably cool down the engine to avoid 

overheating the engine and damaging some parts. 

3. Precautions for Generator 

(a). 

(b). 

(c). 

The center of the generator pulley shall be aligned with that of the drive wheel and the tension of the 

belt shall not be too tight or too loose, or it will impair the reliability and service life of the generator. 

The generator shall be in parallel connection with the battery and shall be matched with appropriate 

model of regulator, in which the wiring shall be secure and reliable. 

Both the generator and the battery shall be negative grounded (earthed), or it will burn out the 

generator and the regulator. 

15B 

Page 1769

15B-64 


15B 

(d). 

(e). 

(f). 

(g). 

(h). 

Use a multi-meter, instead of using the test method of ignition to ground, to check whether the 

generator is generating power. 

Frequently remove the dust and oil sludge from the generator and maintain the good wiring. 

Maintain the generator at interval of 1,000h. Check the electric brush for presence of wear, clean the 

bearings and add an appropriate amount of lubricating oil (The amount added shall be 2/3 of the 

bearing chamber). No maintenance is required for the double sealed bearing. 

During the running of the generator, it’s absolutely prohibited to disconnect the connecting wires, in 

order to prevent short-circuit from burning out the silicone rectifying unit 

When the silicone rectifying unit is connected with the stator coil, it’s absolutely prohibited to check 

the insulation status of the generator with mega-meter or 200V AC, or it will lead to puncture of diode 

and damage 

4. Precautions for vacuum pump 

(a). 

(b). 

(c). 

(d). 

(e). 

The pressure oil connects with the connector of oil inlet, the vacuum pump connects with the 

connector of exhaust gas and the engine body connects with the connector of oil return. Each 

connector shall be sealed. 

Check whether the pump body and pump base have crack and whether the pump core and generator 

spline shaft fit and the inner working face have wear and scratches. If any damage is found out, and 

then replace them. 

The blade width shall be ≥3mm, which can ensure the exhaust gas property. If any damage is found 

out, and then replace them. 

If the oil leak is found, find out the place of leaking oil and then maintain and replace it. 

Ensure the lubricating oil’s cleanness and proper viscosity during its use. Do not make the engine 

work without lubricating oil, or else it can seriously damaging the vacuum pump. 

5. Precautions for starter motor 

(a). 

(b). 

(c). 

Before the use, check the engine and use the starter motor after it’s determined that the engine can 

run normally. 

When connecting the starter’s circuit, the copper wire sectional area for connecting electric power 

storage shall not be less than 25mm2 , the sectional area for connecting switch wire shall not be less 

than 4mm2 and the wire shall be short as much as possible. Before starting, check whether the starter 

circuit connection is correct, the connection is tight and whether the battery is fully charged. 

After the preparations, press down the electromagnetic switch, the starter’s gear meshes starter’s 

flywheel ring gear, and then it begins to run. Under normal circumstances, it can be started once. If it 

cannot be started once, after the starter’s armature and gear are completely at a standstill, it can be 

started for the second time, or else the starter will fiercely hit against the starter ring gear and the 

starter will be damaged. 

NOTE: 

In cold days, pre-warm the engine, and then use it. 

(d). 

(e). 

(f). 

(g). 

The start time for starter shall not be more than 15s, and the interval between two times of start shall 

be more than 2min to avoid overheating the starter. 

When the starter cannot normally start for consecutive three times, please eliminate fault and then 

start the starter. 

When the starter begins to run, please immediately loosen the switch button to make starter gear 

return from meshing position and stop running in order to avoid damaging the starter. 

Frequently check whether the connection of starter’s fastening pieces are tight, whether the lead 

Page 1770


15B-65 

connection is tight. And eliminate the pollution, put a little vaseline to avoid corrosion. 

(h). Frequently check whether the wire insulation is damaged. 

(i). Disassemble dustproof belt at regular intervals to check whether the surface of commutator is bright 

and clean and whether the brush has hysteresis phenomenon and the spring pressure is normal. 

Clean the dust, and if the brush wears a lot, the surface of commutator singes and other faults are 

found out, please immediately disassemble it to make repairs and supply replacements. 

(j). The starter motor shall be overhauled once a year. Depending on the actual condition, the overhaul 

interval may be shortened or prolonged appropriately. 

6. Precautions for turbocharger 

(a). The lubrication of floating bearing of turbocharger shall use CF-4 lubricating oil. Clean the oil filter at 

regular intervals and replace the lubricating oil. 

(b). After starting diesel engine, immediately decrease the accelerator to make the diesel engine run at 

low speed. When the oil pressure rises, accelerate “heating of turbine”. 

(c). The diesel engine shall not suddenly stop with high load at high speed. 

(d). The new diesel engine or the diesel engine after being repaired, replaced diesel engine or the engine 

with cleaned turbocharger, replaced oil or with cleaned filter shall screw off the oil inlet connector of 

turbocharger and turn off the injection pump before start. Drive the diesel engine by starting engine for 

few seconds (less than 10s), screw up the diesel engine when lubricating oil spills from the oil inlet 

connector of turbocharger. Fill 60~100ml lubricating oil (oil) in the oil inlet of turbocharger, and then 

start the diesel engine. 

(e). Frequently check the tightness of intake pipeline and exhaust pipeline to avoid air leakage. 

(f). Pay attention whether the turbocharger has abnormal sound during the running of diesel engine. 

(g). If the diesel engine’s rotation speed is not stable during the running, turbocharger fiercely shake and 

the intake pipe has rumble sound, which means that the turbocharger surges, please clean the air 

filter element and intake pipeline. 

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15B 

OPERATIONS 

1. Fuel, Oil, and Coolant 

(a). 

Fuel 

User can select diesel according to local ambient temperature. In summer 0# light diesel oil is be 

suitable and in winter -10# light diesel oil is suitable in general area in China. In cold area, -35# and 

-20# light diesel can be used. 

NOTE: 

• When the working temperature for diesel is low, wax material shall be separated out if using 

incorrect grade, then the oil line will be blocked. Therefore, the diesel with correct grade shall be 

determined according to ambient temperature. 

• Do not fill oil in the fuel tank when the diesel engine is running. If the car runs in hot weather, the 

(b). 

fuel tank cannot be fully filled, or else the fuel will spill because of expansion. Once the fuel spills, 

clean it immediately. 

Oil 

Please respectively select lubricating oil with viscosity grades of 5W/50 ( used in the temperature 

range of -30℃~+ 40℃) and 10W/30 ( used in the temperature range of -25℃~+40℃), property 

grade of CD, CE or higher grade according to local atmospheric temperature. The Great Wall brand, 

Uniform brand and Kunlun brand are recommended. Disassemble the filter cap from the cylinder 

head cover and then fill oil in the engine. Disassemble the oil outlet bolts from the oil pan and then let 

the oil out. 

NOTE: 

• After the diesel engine is supercharged by air turbine, both mechanical load and thermal load are 

greatly raised. The turbocharger which is a precision running component with high speed and 

high temperature has strict requirements for the quality of lubricating oil. Therefore, the clean oil 

according to required brand cannot be replaced by low grade or poor quality oil to avoid faults 

such as scuffing of cylinder bore, bush burning and turbocharger damaged. 

• The oil in the diesel engine shall not include impurities and moisture. When changing oil for 

(c). 

technical service, the old and new oil can be mixed to use. 

Water coolant 

The water which is processed by anti-erosion and anti-corrosion can be taken as coolant in the area 

with temperature of more than 0℃. This kind of coolant contains the anti-erosion and restrainable 

type of glycol. The anti-corrosion inhibitor adopts sodium nitrite/ sodium benzoate. Anti-freezing 

mixed liquor shall be characterized by good cooling property and shall provide anti-corrosion 

protection under any ambient temperature. The specification of anti-freezing mixed liquor at least 

meets the requirements of BS6580 or MODAL39. When the engine is used under the ambient 

temperature of lower than 0℃, avoid the coolant to be frozen to make the relevant parts frost crack. 

The engine which adopts closed cycle coolant system can use antifreeze solution with proper 

condensation point or fill hot water before start according to ambient temperature. But when it stops, 

please immediately turn on the water. 

NOTE: 

• Anti-freeze solution is poisonous, so the anti-freeze shall be stored in the original container to 

avoid contacting people. 

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15B-67 

2. Preparation before start 

(a). Check whether each connection for starter is tight and whether the operating handle (accelerator and 

shutdown handle and etc.) are flexible. 

(b). Rotate the crank a few rotation to check whether the motion parts are flexible without being stopped 

phenomenon. 

(c). Check whether the oil pan and oil surface of oil pump are in upper limit position in the range of oil 

gauge’s scale. 

(d). Check whether the water tank is full and whether each water pipe connector leaks. 

(e). Check whether the fuel tank is full of diesel, the fuel line is unblocked and whether each oil pipe 

connector is sealed or has no leakage. 

(f). Check whether the engine accessories’ connection is dependable (fuel injection pump, diesel filter, oil 

filter, water pump, fan, generator and generator support, fan belt, starter, water tank and etc. ) 

(g). Check whether each connector of electrical system is correct, tight and dependable. The battery shall 

be sufficient and silicon rectification generator’s negative pole shall be grounded. Pay attention that 

the battery wiring’s negative pole shall be grounded. 

3. Start diesel engine 

△ Tip: 

Do not start the diesel engine until the preparations before start are fulfilled. Before starting the engine, check 

the surrounding area of the diesel engine for the presence of any article obstructing the working of the diesel 

engine. Start the engine only after such article is kept away. 

(a). Start with normal temperature (higher than -5℃) 

• Shift the gearshift lever of the transmission to neutral position. · 

• Put the lock switch on the position “ON”, and then pause for about 2-3 seconds and then check 

whether each meter display is normal. Please power up ECU. The engine shall not be directly 

stared without electricity. 

• When the fault lamp is on, stop the car immediately, and then contact the service station to treat 

fault and eliminate the fault code. 

• If the diesel engine does not start, the electric switch lock shall return “OFF” position. After the 

starter motor stops rotating, start the diesel engine. 

• ·After the diesel starts, keep the diesel engine run at idle speed. Check whether the oil pressure is 

normal, whether the turbocharger has no abnormal sound and vibration, the oil pressure shall be 

less than 0.1MPa. The supercharged and cooling diesel engine shall not run at idle speed for 5 

minutes. 

(b). Start with low temperature (lower than -5℃) 

• Put the gear lever of transmission in the neutral position and depress the clutch pedal to reduce 

starting load. 

• Put the lock switch in ON position, pause for 2-3 seconds at least, then check whether each meter 

display is normal. Please power up ECU. The engine shall not be directly stared without electricity. 



• When the coolant temperature is lower, the preheating indicator on the fascia is usually on, which 

indicates that the preheating system is working and the heater plug powers on and is preheated. 

After finishing preheating, the preheating indicator is off, then the operator can start diesel engine. 

If the operator does not start the diesel engine timely, turn off the switch lock for 20 seconds, and 

15B 

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15B 

then repeat the above steps to preheat and start again. 

• When the heater plug finishes preheating and the preheating indicator is off, depress the clutch 

pedal, put the ignition switch in START position to start the diesel engine. 

• If the diesel engine does not start smoothly, the electric switch lock shall return OFF position. After 

the starter motor stop running, try to start the diesel engine again. When the diesel engine stops to 

start again, the interval time shall be more than 60 seconds. 

• After the diesel engine successfully starts, put the lock switch on the ON position from START 

position. 



• When the temperature is lower than -25℃ and there is trouble for start, let the anti-freezing and 

anti-corrosion solution out and then preheat the diesel engine with boiled water. Fill higher than 

90℃ hot water in radiator, after the water becomes cool then let the water out, fill hot water again 

to start and run, and then let hot water out again, finally fill anti-freezing and anti-corrosion solution 

again. During the period of preheating, after the diesel engine starts, the coolant’s cycle shall not 

pass through radiator because the thermostat valve is closed. Therefore, in order to reduce the 

chance of coolant’s freeze in the radiator, adopt hot water and put a radiator blind in front of the 

radiator. 

• After the diesel engine starts, keep the diesel engine running at idle speed and check whether the 

oil pressure is normal and turbocharger has abnormal sound and vibration. The oil pressure shall 

be no less than 0.1Mpa. But the supercharging and cooling diesel engine shall not run at idle 

speed for more than 5 minutes. When the temperature is lower than -25℃, after start the diesel 

engine, the diesel engine shall run with no load at low and medium speed and preheat for several 

minutes to “heat the engine”. In order to raise the coolant temperature as much as possible, do not 

turn on the heater switch when heat the engine. When the coolant and lubricating oil temperature 

is higher than 50℃ and each system is in normal working condition, turn on the heater switch and 

allow the diesel engine works with full load at the maximum rotation speed. 

NOTE; 

• The time for each start shall not exceed 15 seconds in order to protect the starter motor and 

battery. If one start fails, wait for at least 2min before retry. If the engine can't be started by three 

consecutive starts, find out and resolve the cause before retry. 

• When starting the diesel again, please return the lock in OFF position, else the ECU fault will 

happen. 

4. Run diesel engine 

(a). 

(b). 

(c). 

When the cooling coolant temperature is higher than 50℃, the diesel engine can work with load. The 

outlet coolant temperature shall be higher than 80℃ when using rated power. 

The increasing and decreasing for engine’s load and rotation speed shall be gradually and uniformly 

carried on. Under general circumstance, do not suddenly increase or decrease the load. 

During the period of running, please pay much attention whether meter reading is normal, whether 

fuel, cooling system and lubrication system have leakage and pay much attention to the discharged 

smoke color and running sound. If there is abnormal sound, please stop the car and check it. 

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15B-69 

5. Stop diesel engine running 

(a). Before the diesel engine stops running, please decrease load and reduce the rotation speed to idle 

speed and the coolant temperature shall be lower than 75℃, and then operate the shutdown handle 

to make the diesel engine stop running. 

(b). After the engine stops running, screw the ignition switch in neutral position. 

(c). When the ambient temperature is lower than 5℃ in winter, then the engine shall stop running after 

the coolant temperature is lower than 60℃. Switch on the water drain switch of engine body and 

water tank, let the coolant out to avoid frost crack. If the antifreeze solution is used, and then do not let 

the water out. 

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15B 

MAINTENANCE 

1. Regular Maintenance 

△ Tip: 

In order to increasing the diesel engine’s service life, the following procedures shall be adopted for 

maintenance during the process of service. 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

(g). 

(h). 

(i). 

Check whether the oil level in the oil pan is in the position between two scribed lines of dipstick. Fill oil 

in the new engine or the engine which stops running for a long time until the oil being at the scribed 

line, then make the engine run at a low speed for 5-10 minutes and stop the engine diesel, and then 

measure the oil level height with dipstick. 

Check the water amount of water tank. 

Check the injection pump and oil level of governor, if the oil is not enough, then supplement the oil 

until the oil level is at specified position. 

Check and eliminate the phenomena of oil leak, water leakage and air leakage. 

Check each accessory’s tightness of engine. 

Check the tightness of engine’s bracket and coupling. 

Keep the engine clean and eliminate the greasy dirt and dust and specially keep the electric 

equipment dry and clean. 

After the new engine runs in with light load for 45 hours, please timely replace the oil (including the oil 

in injection pump and governor) and please clean oil filter element. 

Eliminate all abnormal phenomena which are founded out. 

2. Maintenance after running for 100 hours 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

(g). 

(h). 

Replace the oil in the oil pan. 

Clean or replace the oil filter element. 

Clean or replace diesel filter element (or carry on after accumulative total 200 hours) 

Check the tightness of bolts of cylinder head. 

Check whether the value clearance is in accordance with the regulations. If necessary, please adjust 

it. 

Check the tension of fan belt. If necessary, please adjust it. 

Eliminate the dust on intake pipe and air filter. 

Check the situation of fuel injection pressure and fuel injection after accumulative 200 hours. If 

necessary, please clean and adjust it. 

(i). Check battery voltage. The electrolyte proportion shall be 1.28-1.29 (atmospheric temperature is 15℃) 

(g). 

(k). 

and shall not lower than 1.27. Check whether the electrolyte liquid level is 10-15mm higher than pole 

plate, or else the distilled water shall be supplemented. 

Replace coolant according to the water quality’s turbidity. Take out thermostat, reinstall outlet water 

pipe and start the engine while changing rotation speed from time to time. Wash the precipitate of 

cooling system with coolant’s flow velocity and then stop the engine running, open the water tank and 

switch on the water drain switch to let water out. Continuously inject clean water from the water tank 

and then start the engine to run at idle speed to make the water flow. Check water quality timely until 

the water is clean. Switch off each water drain switch and stop the engine running and then reinstall 

the thermostat. 

Reassemble the parts and components which are maintained in correct installation position. 

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15B-71 

3. Maintenance after running 500 hours 

△ Tip: 

The maintenance after running 500 hours includes the procedures of maintenance after 100 hours and shall 

contain the following procedures too. 

(a). Check the fuel injection pressure of fuel injector and observe atomization quality. Clean and adjust it. 

(b). Check fuel injection advance angle. If necessary, please adjust it. 

(c). Disassemble cylinder head and eliminate carbon deposit. Check the tightness of air valve, if it is not 

accordance with the requirements, and then grind it. 

(d). Check the tightness of connecting rod bolts, main bearing bolts and flywheel bolts. 

(e). Re-screw up cylinder head bolts in order and adjust the valve clearance according to regulations. 

(See Chapter 08 Assembly of Engine) 

(f). Clean or replace air filter element (according to the amount of environmental dust, perform the 

“maintenance after 100 hours” in advance or after shorter time) 

(g). Replace the oil of injection pump and governor. 

(h). Clean the cooling system. The cleanout fluid consists of 150g caustic soda (Na OH) and 1L water. 

Before cleaning, let all water of cooling system out, and then fill cleanout fluid. When the coolant 

temperature reaches the working temperature, stop the engine, let the cleanout liquid out to avoid the 

water scale which floats in the cleanout fluid precipitating and then clean the cooling system with 

clean water. 

(i). Check the working situation of thermostat. 

(j). Check each part of electric equipment for start. Check whether the fastening pieces are tight and 

whether the contact of wire is tight. If there is burned mark, please replace it. 

(k). Check each parts of engine. If necessary, please maintain and adjust them. 

△ Tip: 

The user can carry out more careful maintenance according to situation in addition with the above regular 

maintenance. 

4. Seal up for safekeeping 

(a). Thoroughly clean engine appearance. 

(b). The fuel system can be full of common fuel, but when the storage period expires, let the fuel out. And 

the fuel and the fuel’s filter element are declared worthless. 

(c). Run the engine until the engine is hot, and then discharge fuel. When the engine stops running, let 

lubricating oil of oil pan out. 

(d). Replace lubricating oil filter element. 

(e). Fill the new clean lubricating oil in the oil pan until the dipstick has full scale. 

(f). Fill the antifreeze solution which has anti-corrosion function in order to avoid the cooling system 

corrode. 

(g). Run the engine for a short time to cycle the engine’s lubricating oil and coolant. 

(h). Clean the engine’s air-pipe and seal the pipe ends. 

(i). Disassemble the air filter. If necessary, disassemble the connecting pipe between the air filter and 

intake manifold and seal the intake manifold with waterproof tape. 

(j). Seal the intake manifold, fuel tank’s air pipe and with waterproof tape. 

(k). Disconnect the battery and then store the battery after the battery is fully charged. Before storing the 

battery, carry out anti-corrosion treatment for battery. 

(l). Disassemble the transmission belt of generator and store it well. 

15B 

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15B-72 


5. Running in 

△ Tip: 

Make the new engine running in before it is used to make each kinematic pair operate normally and to avoid 

abnormal wear and damaged. The experience proves that the service life of engine, economical efficiency 

and dependability of work are greatly determined by the situation of running in for engine at the initial 

operation, so please strictly carry out the maintenance regulations for running in. 

(a). Running in specification 

• Running in period: 

The running period is about 50 hours; the whole car can carry out running in together. The running 

in mileage is 1500~2500 kilometers. 

• The running in period’s requirements for load and speed are as follows: 

Mileage (kilometer) Highest load Highest speed 

0~200 No load — 

300~1000 50% rated load 70% rated speed 

1000~1500 75% rated load 75% rated speed 

1500~2000 Full load Not faster than the highest speed 

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15B-73 

(b). 

Running maintenance content and standard: 

Number Content Standard 

1 Replace lubricating oil of oil pan 

The brand shall be selected according to ambient 

temperature 

2 

Clean the oil pan and replace the paper oil 

filter element 

The parts and components shall be produced by 

formal accessory manufacturers 

3 Clean the air filter element 

4 Replace paper diesel filter element 





5 Check connecting rod bolt torque 155N·m 

6 Check cylinder head bolt torque 75N·m 

7 Check and adjust valve clearance 

8 Check fan belt tension 

9 Check fuel supply advance angle 

Cold car, Inlet valve 0.2mm 

Exhaust valve 0.45mm 

Add 45N force on vertical single belt, deflection 

is10 mm 

According to requirements of Operating Instruction 

Manual 

10 Fasten the exposed bolts and nuts According to requirements 

11 

Clean oil inlet filter screen of fuel delivery 

pump 

No dirt and no damage 

15B 

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15B-74 


BASIC MAINTENANCE 

1. Determine the maintenance period 

(a). 

(b). 

(c). 

Growth rate of oil consumption 

Suppose that the new oil consumption rate (mileage every hour or the running hours) is 100%, when 

the oil consumption rate reduces to 50%, and then the engine shall be maintained. 

Growth rate of fuel consumption 

Suppose that the new engine fuel consumption (mileage every hour or the running hours) is 100%, 

when the oil consumption rate reduces to 60%, and then the engine shall be maintained. 

The inside has abnormal sound 

There are various reasons for abnormal sound, for example, the engine has lots of wear or is 

overheated or the operation and maintenance are improper. So the engine shall be maintained early. 

2. Determine cylinder bed quality 

△ Tip: 

The cylinder head gasket is placed on the connection of cylinder head’s bottom and the engine body’s top 

surface to form air sealed chamber under the function of high strength cylinder bolt and to make burning 

gasses push forward the pistons work and not leakage outward. At the same time, it can carry out seal 

function for cycling coolant and pressure oil which leads to cylinder head and lubrication rocker mechanism. 

There are high requirements for cylinder gasket’s tightness and heat resistance, so the engine adopts 

composite plate cylinder gasket and the cylinder hole edge is sealed with steel plate. And the inside has steel 

wire protecting ring, and the edges of water hole and oil hole are sealed with copper sheet or are processed 

specially. They have good tightness and longer service life. 

(a). Check whether the cylinder bed has cracks and whether the water hole and oil hole are connected 

together. If yes, then replace the cylinder bed. 

(b). Measure the clearance of piston head when replacing cylinder, and the piston head clearance shall 

be in the range of 0.9~1.1mm. 

15B 

3. Adjust the valve clearance 

△ Tip: 

Check and adjust the valve clearance when the engine is serviced or maintained. 

(a). Check and screw up the nuts of valve rockshaft bracket when removing the cylinder head. 

(b). Rotate the crank in the dead center of the first cylinder piston, at the this moment the observation 

mark of flywheel housing is rightly aligned with “O” scribed line of flywheel or the “O” scribed line of 

crankshaft pulley is aligned with the indicator of timing gears cap. 

(c). Insert a thickness gauge thinness gauge into the first cylinder, exhaust valve and rocker respectively. 

Check and adjust the inlet valve clearance and exhaust valve clearance. The clearances are 

respectively 0.2 and 0.45mm when cold starting. Rotate the cranks of four cylinders 180°according to 

working order of 1-3-4-2 and adjust each cylinder’s valve clearance. 

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15B-75 

4. Adjust the fuel supply advance angle 

△ Tip: 

In order to obtain the most economic fuel consumption and good running property, properly adjust fuel supply 

advance angle. 

(a). Eliminate the air of fuel system and repeatedly rotate the crank to make the injection pump full of fuel. 

(b). Disassemble the first cylinder’s high-pressure oil pipe and pull the accelerator operating handle in the 

position with maximum fuel supply amount. Rotate the crank in a clockwise direction from engine 

head to make the first cylinder piston is at compressed dead center. 

(c). Rotate the crank more than 60°in reverse direction, then slowly rotate the crank in clockwise direction 

and observe the oil outlet situation of outlet valve support. When the oil level begins to wave, it 

indicates that the first cylinder begins to supply oil. At this moment, please stop rotating the crank and 

check the difference between the scribed line of timing gear chamber cover and the scribed line of 

pulley to determine the fuel supply advance angle. If the scribed line of pulley is in front of the scribed 

line of timing gear chamber cover, it indicates fuel supply in advance. If the scribed line of pulley is on 

the back of the scribed line of timing gear chamber cover, it indicates fuel supply hysteresis. The 

engine’s fuel supply advance angle shall be 10°±1°. 

(d). If the fuel supply advance angle does not meet the requirements, loosen the bracket of injection pump 

and the nuts of pump end flange and adjust it by using the of pump end flange. When the pump body 

is close to the engine body, then the fuel supply advance angle is increased. And when the pump end 

body is far away the engine body, then the fuel supply advance angle is reduced. The outer edge of 

pump body flange rotates 1mm arc length, and the fuel supply advance angle is increased or reduced 

about 1°of crank angle. 

5. Adjust fuel injector 

△ Tip: 

The fuel injector is tested and adjusted on the tester of fuel injector to adjust the fuel injection pressure and to 

observe the atomization quality and to treat faults. When the fuel injection pressure of injector is too high or 

too low and the fuel injection is abnormal and the parts are damaged, the engine will appear faults, such as 

pouring up smoke, the power and rotation are reduced, discharging temperature rises or piston slap. The 

method of stop cylinder in turn can be adopted to determine the fuel injector with fault. The method is: 

gradually loosen the coupling nut between fuel injector and high-pressure oil pipe and stop fuel injection, at 

the same time observe the exhaust smoke color. If the fuel injector has fault, the exhaust will stop smoking, 

and the engine rotation has no change or little change. Rotate the flywheel to listen to injection sound of each 

cylinder one by one, when the ringing injection sound is not heard, it indicates that the fuel injector may have 

fault. 

(a). Install the fuel injector in the tester of fuel injector. 

(b). The gauge pressure shall be 180×10pa by manual pump. Continuously slowly press the manual 

pump to raise the gauge pressure to 200×10pa and to inject oil. Observe the fuel spray nozzle’s oil 

hole and make it has no oil drip and leakage. If after test for many times, if there is also oil drip, 

disassemble the injection nozzle couple to clean. After checking and grinding it, please test again. 

(c). Adjust the fuel injection pressure, disassemble the pressure regulating nut of fuel injector, and then 

unscrew or screw up the pressure regulating bolts to make the fuel injection pressure is 200×10pa. 

Screw the pressure regulating nut and test it again. 

15B 

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15B-76 


(d). 

Observe atomization quality and carry out atomization test with fuel injection speed every minute. The 

oil mist shall be fine mist. And the splashed oil which can be seen with naked eyes shall not be 

appeared, and the phenomena of uneven concentration and one side’s fuel injection shall not be 

appeared. And the ringing sound shall be heard when cutting off the fuel. 

NOTE: 

The abnormal fuel injection is normally caused by inflexible motion of injection nozzle. Oil drip of jet 

orifice is caused by damaged seal surface. Oil injection branch is caused by the head carbon deposit 

and thermal deformation of injection nozzle. 

6. Adjust oil pressure 

(a). Loosen the lock nut. 

(b). Twist the pressure regulating bolts with wrench to make the oil is 280~400kpa (the oil can be higher 

when cold starting). 

(c). After adjustment, screw up the nut. 

7. Adjust injection pump 

△ Tip: 

The injection pump has already been adjusted and checked before factory. If the injection pump needs to be 

adjusted again, the injection pump shall be adjusted on the professional injection pump tester with standard 

fuel injector and standard length of high-pressure oil pipe. 

8. Adjust the fan pulley 

(a). Add 45N force on the single belt which is in the middle position of two wheels and the deflection is 

about 10mm. 

△ Tip: 

If the fan pulley is not accordance with the requirements, please adjust it with the following method. 

• Loosen the adjusting screw of the bracket of engine. 

• Pry out the generator from the outboard of engine with strength pipe and then lock the screw of bracket of 

generator until it is up to the standard. 

15B 

9. Exhausting of fuel system 

△ Tip: 

If the pipeline from fuel tank to fuel delivery pump has air, please exhaust it when replacing diesel filter 

element. 

(a). Screw the manual oil pump handle out, press up and down to supply oil for fuel system. 

(b). Loosen the small oil return pipe of fuel filter and exhausting bolt of injection pump and continue to 

supply oil with manual oil pump until the oil runs out and no bubble exhausts. 

(c). Screw the bolts and screws and at the same time screw the manual oil pump handle. 

Page 1782

ENGINE MECHANICAL PART-DISASSEMBLY/ASSEMBLY OF COMPLETE ENGINE 

15B-77 

DISASSEMBLY/INSTALLATION OF COMPLETE ENGINE 

PRECAUTIONS 

1. Park the vehicle on the vehicle trough or the vehicle service bench. 

2. Shift the parking brake lever to parking position. 

3. Block the wheels with triangular wood or wedge. The triangular wood or the wedge shall be placed 

closely before and after the wheels, preferable the rear wheels. 

4. Switch off of ignition switch before removing the complete engine (the ignition switch shall be at OFF 

position) and take down the ignition lock. 

5. Put a warning sign “No start” in steering wheel or the driver’s seat when working under the car. 

6. Keep away from the fire source while removing the complete engine. 

7. When disconnecting each connecting pipeline of engine or assembly component, put the 

disconnected pipeline or assembly component in the position where has no influence on the position 

of removing the engine and make the corresponding mark for installation. Fix the air condition 

compressor, clutch slave cylinder assembly on the frame with a rope to avoid falling off and 

damaging. 

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15B-78 


DISASSEMBLY PROCEDURE 

1. Open the engine hood 

15B 

2. Discharge the engine lubricating oil and discharge 

the engine coolant 

NOTE: 

• When the engine temperature is higher, do not open 

the radiator’s pressure cap or discharge coolant. The 

radiator’s pressure cap can be opened when the 

coolant temperature reduces to lower than 50℃, or 

else the coolant with high temperature and erupted 

steam may cause personal injury. 

• The coolant is poisonous, so the coolant shall be 

stored in the original container to avoid contacting 

people. 

• When replacing coolant, waste treatment shall be 

carried out according to local regulations. 

• Whether to maintain the engine determines whether to 

discharge lubricating oil. 

3. Disconnect the battery’s positive and negative wire 

△ Tip: 

and disconnect the ground wire, generator and 

connecting wire of starter 

• Disassemble battery negative pole first when removing to 

avoid the ground producing spark and causing losses and 

damage. 

• After disconnect the battery’s negative pole, wait for 60s 

then disassemble other electric equipment. 

NOTE: 

The battery may have explosive gas escapes. Therefore, in 

order to avoid damaging human body, good ventilation 

shall be ensured for engine compartment before 

maintaining battery. 

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15B-79 

4. Disassemble fuel inlet pipe and fuel return pipe 

which connects the engine 

△ Tip: 

After removing the fuel pipeline, please seal it to ensure no fuel 

leakage takes place. 

NOTE: 

• The fuel is inflammables, so it will far away from naked 

flame, work light and power connector and etc. 

• The disassembly shall be made with good ventilation 

to avoid damaging human body and property losses. 

5. Disconnect all cooling pipelines which connect 

with the engine. If necessary, disassemble the 

cooling pipeline gradually. 

△ Tip: 

Disassemble the engine’s inlet pipe and outlet pipe possibly to 

avoid blocking or damaging them when removing the complete 

engine. 

6. Disassemble the fixing clamp of intake hose and 

take down the intake hose. 

△ Tip: 

After take down the intake hose, the intake manifold port shall 

be sealed. 

7. Disconnect the connection of heater water pipe 

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15B-80 


8. Disassemble the fixing clamp of engine assembly, 

pull out the connector of the main harness and take 

down the main harness 

9. Disconnect the vacuum connecting pipe of EGR 

valve 

10. Disconnect the connection between exhaust pipe 

and turbocharger 

△ Tip: 

Disassemble the front section of pipeline of exhaust pipe 

possibly in order to conveniently disassemble the complete 

engine. 

15B 

11. Remove the fan 

△ Tip: 

Avoid collision and damaging the fan when removing. 

12. Disconnect the ground wire from the transmission 

and at the same time remove the generator 

connecting lead. 

Page 1786


15B-81 

13. Disconnect the lead connection of starter and 

disassemble the starter. 

14. Remove the A/C compressor assembly. 

15. Disassemble power steering pump assembly and 

hang the assembly on the frame 

16. Remove the propeller Shaft from the transfer case 

and at the same time remove the propeller Shaft on 

the other side of transfer case (Refer to Chapter 33 

Propeller Shaft) 

15B 

17. Disconnect the lead of clutch and the connection of 

odometer lead 

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15B-82 


18. Remove the transfer case. 

19. Disconnect the lead of reverse gear switch and the 

connection of lead of vehicle speed sensor 

20. Remove the shift lever (Refer to Chapter 31 

Transmission). 

15B 

21. Remove the clutch slave cylinder. 

△ Tip: 

Once removed, fix the clutch slave cylinder onto the 

crossbeam, in order to prevent the trouble of empty drainage. 

22. Remove the fixing bolts between the transmission 

and the suspension. 

△ Tip: 

To prevent the tilting of the engine, lift the tail of the engine with 

jack while removing the transmission suspension. 

Page 1788


15B-83 

23. Remove the fixing bolts between engine and 

transmission 

24. Remove the fixing bolts for connecting the engine 

suspension and the frame 

25. Hoist the engine steadily to lift the engine suspension from the suspension bracket and slowly 

move the engine to an appropriate angle. Pull the hoist to move the engine from the 

installation location of the frame and slowly place and fix the engine assembly onto the 

disassembly stand. 

△ Tip: 

Before removing the engine, recheck whether all connections on all sides of the engine are disconnected. 

15B 

Page 1789

15B-84 


INSTALLATION PROCEDURE 

1. Lift the engine with hoist and move the hoist to position the engine at the engine installation 

△ Tip: 

location. 

• As the engine assembly is really heavy, to prevent the occurrence of accidents, it’s preferable to perform 

the installation by two or more operators. 

• By adjusting the adjusting bolts of the hoist, slowly lower the engine in such manner that the engine 

suspension closes to the suspension bracket on the crossbeam and aligns with the fixing bolt holes 

2. Install and fasten the fixing bolts of the engine front 

suspension. 

△ Tip: 

Lift the tail of the engine with jack, in order to prevent the tilting 

of the engine. 

3. Install and fasten the fixing bolts for connecting the 

engine and the transmission. 

4. Install and fix the fixing bolts for connecting the 

transmission and the suspension. 

15B 

5. Install and fasten the clutch slave cylinder and its 

fixing bolts. 

Page 1790


15B-85 

6. Install the shift lever (Refer to Chapter 41 

Transmission) 

7. Connect the leads of reverse gear switch and 

vehicle speed sensor. 

8. Install and fasten the fixing bolts of transfer case 

9. Connect the leads of the transfer case and the 

odometer. 

15B 

10. Install and fasten the fixing bolts and propeller 

shaft (see Chapter 34 Transaxle and Propeller Shaft 

- Propeller Shaft Assembly, Assembly Service for 

Detail) 

Page 1791

15B-86 


11. Install power steering pump and fasten the fixing 

bolts. 

12. Install A/C compressor assembly 

13. Install the starter motor and connect the starter 

motor lead. 

14. Install and fasten the engine ground wire onto the 

transmission housing 

15B 

15. Install the fan. 

Page 1792


15B-87 

16. Connect the connection of exhaust pipe and 

turbocharger and fasten the connecting bolts 

17. Install the lead of generator on the corresponding wiring terminal or in the connector 

18. Connect the vacuum connecting pipe of EGR valve 

19. Install the clamps of engine’s main harness and 

plug the main harness’s connector 

20. Install the heater water pipe 

15B 

Page 1793

15B-88 


21. Install the intake hose of engine 

22. Install engine’s fuel inlet pipe and fuel return pipe 

△ Tip: 

• Fuel pipeline shall be evacuated when removing the fuel 

pipeline. 

• Make sure that there is no air in the fuel pipeline and then 

the engine can normally start. 

23. Install the cooling pipeline of engine and fasten the 

fixing clamps of hose. 

15B 

24. Fill the lubricating oil with the right amount. Make sure the lubricating oil is enough by 

observing the dipstick and fill the coolant until the coolant is up to standard level. 

25. Observe the surrounding connecting pieces of engine to make sure that the installation is firm 

and dependable. Make sure to put the transmission in the neutral position and then test the 

engine. 

26. Connect the battery leads. 

△ Tip: 

While installing the battery leads, firstly install the positive 

wiring terminal and fix, seal and insulate the bolt before 

installing the negative wiring terminal and fixing, sealing, and 

insulating the bolt. 

Page 1794


15B-89 

27. Turn on the ignition switch, and observe the instruments to ensure that all functions are 

normal, and then start the engine. 

△ Tip: 

After the engine is started, observe the instruments to ensure that the readings of oil pressure gauge and the 

coolant temperature gauge are normal and enter into the vehicle trough to observe the surrounding area of 

the engine for the presence of water leakage, oil leakage, and gas leakage. In event of any leakage, stop the 

engine immediately and resolve the malfunctions. 

28. Cover the engine hood 

15B 

Page 1795

15B-90 


INSTRUCTION OF ESSENTIALS 

15B 

1. Disconnection and Connection Instruction of 

Battery Ground Wire 

Instruction: 

• Before the Disassembly of the engine, firstly disconnect the 

negative wire of the battery. 

• In order to ensure that all disassembly works of the engine 

are fulfilled under power cut condition. 

• After all operation are finished, check all again. After all is 

right and then connect the battery’s negative pole. 

2. Disassembly and Installation Instruction of Fuel 

Pipes 

Instruction: 

• While removing the fuel pipes, it’s necessary to cover the 

connectors disconnected with fuel pipe caps. 

• The fuel is one flammable substance. While handling the 

fuel system, make sure to keep the cigarette, open fire, 

indicator lamp, electric arc equipment, and switch away 

from the operation area and equip with ventilation 

equipment in the operation area, in order to minimize the 

possibility of serious personal injuries or even death 

3. Instruction of Engine Protection Measures 

Instruction: 

The presence of minor foreign materials inside the engine will 

often lead to engine failure for normal functioning or even lead 

to serious harm of the engine. Therefore, while disconnecting 

all connecting pipes of the engine, it’s necessary to cover all 

openings of the engine, in order to prevent the ingress of dirt or 

scrap into the engine. 

4. Instruction of Disassembly of Engine and Installation Mode 

Instruction: 

Disassemble the complete engine from engine compartment with lifting frame when removing. And when 

installing, lift the complete engine with lifting frame from the top of engine compartment. 

Page 1796

ENGINE MECHANICAL PART- PRESERVATION OF COMPLETE ENGINE 15B-91 

PRESERVATION OF COMPLETE ENGINE 

PRECAUTIONS 

1. Make the coolant of radiator, cylinder blocks and water pump exhausted. 

2 Disassemble the battery. 

3. Screw out each cylinder’s heater plug and fill 30g oil in each cylinder. Rotate the crank for 15~20 

times and then install the heart plug. 

4. Put the dehydration vaseline (heat to 100~200℃) on the contact of electric equipment, connector and 

some metal surface which are not painted. 

5. Fill lubrication in each lubricating point. 

6. Loosen the fan belt. 

7. Make the diesel of diesel tank exhausted and clean the fuel tank. 

8. Wrap the engine with protective materials (such as canvas, waterproof cloth and oiliness) to avoid 

dust. 

9. The room for storing engine shall be clean, warm and keep out of the sun, the indoor temperature 

shall not lower than 5℃ and the relative humidity is 40~70%. 

MAINTENANCE 

1. Charge the battery with 5~12A current once every month. 

2. Screw out the heater plug and fill 30g oil every 12 months and rotate the crank for 15~20 times to 

avoid inside corrosion and install the heater plug again. 

3. Eliminate the lubricating grease on the lubricant housings every 12 months and replace the 

lubricating grease. 

15B 

Page 1797

15B-92 

ENGINE MECHANICAL PART- DISSASSEBLY OF ENGINE 

DISASSEMBLY OF ENGINE (4JB1) 

INSTRUCTION OF DISASSEMBLY 

15B 

1. This section provides one complete set of procedure for disassembly of diesel engine. The 

disassembly mode is illustrated in both graphs and texts step by step from top to bottom and from 

outside to inside. 

2. Before removing the engine, place the engine assembly onto the disassembly stand or place it on one 

clean and level ground and prepare the necessary disassembly tools and professional container or 

environment for placement of parts. 

3. The disassembly environment shall be kept away as far as possible from the fire source and other 

objects (such as children) that impair the safety. 

Page 1798


15B-93 

DISASSEMBLY OF PIPELINE AND HARNESS 

1. Disassemble EGR pipeline 

(a). Disassemble two fixing bolts which connect EGR pipe 

and intake pipe. 

△ Tip: 

All bolts removed shall be centrally placed, in order to prevent 

loss. 

(b). Disassemble the fixing bolts which connect EGR pipe 

and exhaust pipe. 

△ Tip: 


loss. 

(c). 

Take down EGR pipe. 

2. Disassemble breather pipe 

(a). Disassemble the connectors between breather exhaust 

pipe and intake pipe of turbocharger and disconnect 

the connector of breather intake pipe. 

15B 

Page 1799

15B-94 


(b). 

Disassemble the connectors between breather exhaust 

pipe and breather and disconnect and take down the 

breather intake pipe. 

(c). 

(d). 

Disassemble the clamps between breather intake pipe 

and valve chamber cover and disconnect the connector 

of breather intake pipe. 

Disassemble the clamps between breather intake pipe 

and breather and disconnect and take down the 

breather intake pipe. 

3. Disassemble intake pipe of turbocharger 

(a). Disassemble the fixing bolts of intake pipe of 

turbocharger, disassemble the fixing bolts which 

connect intake pipe of turbocharger and turbocharger 

and then take down the intake pipe of turbocharger. 

△ Tip: 


loss. 

15B 

4. Disassemble intake pipe 

(a). Disassemble the fixing bolts between intake pipe and 

intake manifold and take down the intake pipe. 

△ Tip: 


loss. 

5. Disassemble the engine’s harness 

(a). Disassemble the engine’s ECU harness connector 

from the installation position and take it down. 

Page 1800


15B-95 

DISASSEMBLY OF HIGH AND LOW PRESSURE FUEL PIPES AND 

FUEL INJECTOR 

NOTE: 

The fuel is one flammable substance. While handling the fuel system, make sure to keep the cigarette, 

open fire, indicator lamp, electric arc equipment, and switch away from the operation area and equip 

with ventilation equipment in the operation area, in order to minimize the possibility of serious 

personal injuries or even death. 

1. Disassemble the high pressure fuel pipe 

(a). Disconnect the connection between injection pump and 

high pressure fuel rail. 

(b). 

Disconnect the connection between injection nozzle 

and high pressure fuel rail. 

(c). Disconnect the connection between the high pressure 

fuel pipe and high pressure fuel rail and take down the 

high pressure fuel pipe. 

△ Tip: 

When removing the high pressure fuel pipe, take down the high 

pressure fuel pipe from the lower end of intake manifold, cover 

the connector cover of high pressure fuel pipe and install the 

high pressure fuel pipe with clean plastic packing bag. 

15B 

2. Disassemble the low pressure oil pipe 

(a). Disassemble and take down the low pressure oil pipe. 

△ Tip: 

Push the connectors of low pressure oil pipe towards the 

opening position and take it down from the fuel injector. 

Page 1801

15B-96 


3. Disassemble the fuel injector 

(a). Disassemble the fixing bolts of the pressure plate of 

fuel injector and take down the pressure plate of fuel 

injector and the fuel injector. 

15B 

Page 1802


15B-97 

DISASSEMBLY OF DIPSTICK AND VENTILATOR 

1. Disassemble the dipstick 

(a). Disconnect the oil return pipe connectors which 

connect the dipstick and breather and disassemble the 

fixing bolts of dipstick. 

△ Tip: 


loss. 

(b). 

Take down the dipstick. 

2. Disassemble the breather assembly 

(a). Disassemble the fixing bolts of breather. 

△ Tip: 


loss. 

(b). 

Take down the breather assembly 

15B 

Page 1803

15B-98 


(c). Disassemble the fixing bolts of breather support. 

△ Tip: 


loss. 

(d). 

Take down the breather support. 

15B 

Page 1804


15B-99 

DISASSEMBLY OF TURBOCHARGER, INTAKE MANIFOLD AND 

EXHAUST MANIFOLDS 

1. Disassemble the turbocharger 

(a). Disassemble fuel inlet pipe and oil return pipe of 

turbocharger. 

(b). Disassemble heat insulating pad assembly and 

disassemble the fixing bolts of turbocharger. 

△ Tip: 


loss. 

(c). 

Take down the turbocharger assembly. 

2. Disassemble exhaust manifold 

(a). Disassemble the fixing bolts of exhaust manifold. 

△ Tip: 


loss. 

15B 

Page 1805

15B-100 


(b). 

Take down the exhaust manifold. 

3. Disassemble the intake manifold 

(a). Disassemble the fixing bolts of intake manifold. 

△ Tip: 


loss. 

(b). Take down the intake manifold. 

△ Tip: 

After taking down the intake manifold, block the exit and 

entrance with sealed cap or equivalent to prevent other things 

from entering. 

15B 

Page 1806


15B-101 

DISASSEMBLY OF CYLINDER HEAD COVER AND ROCKSHAFT 

1. Remove the cylinder head cover. 

(a). Remove the fixing nuts of the cylinder head cover. 

△ Tip: 

All nuts removed shall be centrally placed, in order to prevent 

loss 

(b). 

Take down the cylinder head cover assembly. 

2. Disassemble electric heater plug assembly 

(a). Disassemble and take down four electric heater plugs. 

3. Remove the rockshaft. 

(a). Remove the fixing bolts of the rocker assembly 

△ Tip: 


loss. 

15B 

Page 1807

15B-102 


(b). 

Remove the rockshaft assembly 

15B 

Page 1808


15B-103 

DISASSEMBLY OF TAPPET AND CYLINDER HEAD 

1. Disassemble tappet 

(a). Take down all valve tappets one by one from 


△ Tip: 

Put all tappets which are taken down together to avoid losses. 

2. Remove the cylinder head. 

(a). Remove the fixing bolts of the cylinder head 

△ Tip: 


loss. 

NOTE: 

Screw off the bolts of cylinder head many times according 

to the order on the left and assembly the bolts. 

(b). Remove the cylinder head assembly. 

△ Tip: 

This assembly is really heavy. To prevent causing serious 

personal injuries, make sure to ask another operator for 

assistance or use appropriate lifting equipment to hoist this part 

or assembly 

15B 

Page 1809

15B-104 


DISASSEMBLY OF THERMOSTAT ASSEMBLY AND VALVE 

1. Disassemble the thermostat assembly 

(a). Disassemble the fixing bolts of water pipe assembly 

and take down the water pipe assembly. 

△ Tip: 


loss. 

(b). 

Take down the thermostat. 

(c). Disassemble and take down the fixing bolts of 

thermostat housing assembly. 

△ Tip: 


loss. 

15B 

2. Remove the valve. 

(a). Disassemble the valve lock clamp. 

NOTE: 

Please wear goggles to avoid damaging persons. 

Page 1810


15B-105 

(b). 

Disassemble the spring bottom seat of valve, valve 

spring and the spring upper seat of valve and 

disassemble the valve oil seal. 

(c). 

Take down the valve and knock out the valve guide 

pipe from the bottom of cylinder head with special tools. 

15B 

Page 1811

15B-106 


DISASSEMBLY OF HOOK AND A/C BRACKET 

1. Disassemble hook 

(a). Disassemble the fixing bolts of hook 

△ Tip: 


loss. 

(b). 

Take down the hook 

2. Disassemble the A/C bracket 

(a). Disassemble the fixing bolts of A/C bracket and take it 

down. 

15B 

Page 1812


15B-107 

DISASSEMBLY OF STARTER MOTOR AND HIGH PRESSURE FUEL 

RAIL 

1. Disassemble the starter motor 

(a). Disassemble the fixing bolts of starter motor 

△ Tip: 


loss. 

(b). 

Take down the starter motor. 

2. Disassemble the high pressure fuel rail 

(a). Disassemble fixing bolts of high pressure fuel rail 

△ Tip: 


loss. 

(b). 

Take down the high pressure fuel rail assembly 

15B 

Page 1813

15B-108 


DISASSEMBLY OF OIL FILTER AND GENERATOR 

1. Disassemble the oil filter assembly 

(a). Disconnect the connection of coolant pipe of oil filter. 

(b). Disassemble the fixing bolts of oil filter assembly. 

△ Tip: 


loss. 

(c). 

Take down the oil filter assembly. 

15B 

2. Disassemble the generator 

(a). Disconnect the connection of vacuum pump oil inlet 

pipe and oil outlet pipe at the rear end of generator. 

Page 1814


15B-109 

(b). Disassemble the adjusting bolts of generator and 

release all belt tension. 

△ Tip: 


loss. 

(c). 

Take down the generator belt. 

(d). 

△ Tip: 

Disassemble the fixing bolts at the low end of generator 

and take down the generator assembly. 


loss. 

NOTE: 

While removing the fixing bolts, pull the generator with 

hand to prevent the fall-off of generator due to loss of 

bracket from damaging the generator. 

15B 

Page 1815

15B-110 


DISASSEMBLY OF FAN AND CRANKSHAFT PULLEY 

1. Disassemble the fan 

(a). Disassemble the fixing bolts of fan assembly 

△ Tip: 

Make the studs reverse stuck with screwdriver when removing 

and at the same time disassemble the near nuts with wrench. 

(b). 

Take down the fan assembly 

2. Disassemble the crankshaft pulley 

(a). Disassemble the fixing bolts of crankshaft pulley 

△ Tip: 


loss. 

15B 

(b). 

Take down the crankshaft pulley 

Page 1816


15B-111 

DISASSEMBLY OF OBSERVATION CHAMBER COVER AND 

COVER ASSEMBLY OF WATER PUMP PULLEY CHAMBER 

1. Disassemble the observation chamber cover 

(a). Disassemble the fixing bolts of observation chamber 

cover. 

△ Tip: 


loss. 

(b). 

Take down the observation chamber cover. 

2. Disassemble the cover assembly of water pump 

pulley chamber 

(a). Disassemble the fixing bolts of cover assembly of water 

pump pulley chamber . 

△ Tip: 


loss.。 

(b). 

Take down the cover assembly of water pump pulley 

chamber. 

15B 

Page 1817

15B-112 


DISASSEMBLY OF PRESSURE PLATE AND TIMING BELT 

1. Disassemble the pressure plate 

(a). Disassemble the fixing bolts of camshaft pulley 

pressure plate. 

△ Tip: 


loss. 

(b). 

Take down the camshaft pulley plate. 

(c). Disassemble the fixing bolts of injection pump pulley 


△ Tip: 


loss. 

15B 

(d). 

Take down the injection pump pulley pressure plate. 

Page 1818


15B-113 

2. Disassemble the timing belt 

(a). Disassemble the fixing bolts of tensioning pull rod. 

△ Tip: 


loss. 

(b). Adjust the tightness of timing belt through tensioning 

pull rod through special tool and loosen the fixing bolts 

of the low idle pulley. 

△ Tip: 

Firstly screw up the fixing nuts of tensioning pull rod and then 

adjust the tightness of timing belt through the tensioning pull 

rod. 

(c). 

Take down the timing belt. 

15B 

Page 1819

15B-114 


DISASSEMBLY OF INJECTION PUMP ASSEMBLY 

1. Disassemble the injection pump 

(a). Disassemble the fixing bolts of injection pump 

assembly. 

△ Tip: 


loss. 

(b). Take down the injection pump pulley, injection pump 

flange and injection pulley. 

△ Tip: 

Take down the injection pump pulley, injection pump flange and 

injection pulley together. 

15B 

Page 1820


15B-115 

DISASSEMBLY OF IDLE PULLEY AND CAMSHAFT GEAR 

1. Disassemble the idle pulley 

(a). Disassemble and take down the fixing bolts of 

tensioning pull rod. 

△ Tip: 


loss 

(b). Disassemble the positioning bolts and take down the 

tension pulley assembly. 

△ Tip: 


loss 

(c). Disassemble and take down the fixing bolts of idle 

pulley. 

△ Tip: 


loss 

2. Disassemble the camshaft gear 

(a). Disassemble the fixing bolts of camshaft pulley. 

△ Tip: 

• When removing the bolts of camshaft gear, the camshaft 

gear will rotate. Therefore the camshaft gear can be 

positioned with special positioned. 

• The camshaft gear can be also positioned with tools like 

screwdriver or solid wrench according to actual situation. 

15B 

Page 1821

15B-116 


(b). 

Take down the camshaft gear. 

(c). Disassemble the fixing bolts of pressure plate. 

△ Tip: 


loss. 

(d). 

Take down the pressure plate. 

(e). 

Take down the flange of camshaft pulley. 

15B 

(f). Disassemble the fixing bolts of the front oil seal seat of 

camshaft. 

△ Tip: 


loss. 

NOTE: 

Before removing the front oil seal seat of camshaft, first 

disassemble the flat key of camshaft. 

Page 1822


15B-117 

(g). 

Take down the front oil seal seat of camshaft. 

15B 

Page 1823

15B-118 


DISASSEMBLY OF CLUTCH COMPONENTS AND FLYWHEEL 

ASSEMBLY 

1. Disassemble the clutch components 

(a). Remove the fixing bolts of the clutch components. 

△ Tip: 


loss. 

(b). 

Disassemble the clutch friction plate and clutch 


2. Remove the Flywheel assembly 

(a). Disassemble the flywheel bolts and the flywheel bolt 

plate. 

15B 

(b). 

Take down the flywheel. 

Page 1824


15B-119 

(c). 

△ Tip: 

Disassemble the fixing bolts of the rear joint plate. Take 

down the rear joint plate and pry out the rear crank oil 

seal with screwdriver. 

• All bolts removed shall be centrally placed, in order to 

prevent loss. 

• The oil seal which is disassembled cannot be used again. 

Please replace oil seal. 

15B 

Page 1825

15B-120 


DISASSEMBLY OF OIL PAN AND GEAR CHAMBER 

1. Remove the oil pan 

(a). Roll over the engine body 

(b). Remove the fixing bolts of oil pan. 

△ Tip: 

• Do not disassemble a bolt randomly. The fixing bolts of oil 

pan shall be crossly disassembled with the method of from 

the middle to both sides or from both sides to the middle. 


prevent loss. 

(c). 

Remove the oil pan. 

2. Disassemble the gear chamber 

(a). Disassemble the fixing bolts of timing gear chamber . 

△ Tip: 


loss. 

15B 

(b). 

Take down the timing gear chamber. 

Page 1826


15B-121 

(c). Take down the gear chamber gasket. 

△ Tip: 

The gear gasket which is disassembled cannot be used again. 

Please replace gear chamber gasket. 

15B 

Page 1827

15B-122 


DISASSEMBLY OF CAMSHAFT AND ENGINE SUPPORT 

1. Remove the camshaft. 

(a). Pull out the camshaft from the installation location. 

△ Tip: 

Slowly rotate and pull out the camshaft. 

2. Remove the engine support. 

(a) Remove 4 fixing bolts of engine support. 

△ Tip: 


loss. 

(b). 

Take down the engine support. 

15B 

Page 1828


15B-123 

DISASSEMBLY OF OIL PUMP, OIL INJECTION PIPE AND TAPPET 

1. Disassemble the oil pump 

(a). Disassemble 2 fixing bolts of oil pump. 

△ Tip: 


loss. 

(b). 

Disconnect the connection of oil outlet pipe of oil pump 

and oil pump. 

(c). 

Take down the oil pump. 

2. Disassemble the oil Injection pipe 

(a). Disassemble the fixing bolts of oil Injection pipe and 

pressure-limiting valve components. 

15B 

Page 1829

15B-124 


(b). Take down the oil Injection pipe assembly. 

△ Tip: 

Make sure that the oil Injection pipe is clean especially the 

nozzle shall be clean. 

3. Disassemble the tappet 

(a). Attract the tappets one by one from the installation 

position with high performance magnet. 

△ Tip: 

Put the tappets which are taken down in the clean container. 

15B 

Page 1830


15B-125 

DISASSEMBLY OF PISTON AND CRANKSHAFT 

1. Remove the piston assembly. 

(a) Rotate the crankshaft to position the journal of 

connecting rod to be removed at bottom dead center. 

(b). Disassemble the fixing bolts of with kilo wrench. 

△ Tip: 

Screw off the bolts in pairs. 

(c). Lightly shake and pull out the connecting rod cover. 

(d). Take down the connecting rod bearing bush. 

NOTE: 

Pay attention not to damage the connecting rod bearing 

bush. 

(e). Eliminate the carbon deposition of piston cylinder. 

NOTE: 

• Please abide by the use recommendations of the 

manufacturer while using the solvent, acid or alkaline 

material for cleaning. Please wear the goggles and 

protective clothing to prevent causing personal 

injuries. 

• Some solvents are flammable and toxic. Please read the 

manual of the manufacturer before use. 

15B 

Page 1831

15B-126 


(f). Push out the piston assembly 

△ Tip: 

Push out the piston assembly with wooden or rubber object. Do 

not use metallic object, in order to prevent damaging the end 

face of connecting rod. 

(g). 

Remove the piston assembly from the other side. 

(h). Install the disassembled pistons together and put the 

mark number in a clean container. 

(i). Disassemble the pistons in other cylinders with the 

same method. 

△ Tip: 

If the piston is not used immediately, mark the number on each 

piston and connecting rod assembly with label and put the 

connecting rod and pistons in the contained to avoid being 

damaged. 

15B 

2. Remove the crankshaft assembly. 

(a) Loosen the bolts of main bearing cap in turn. 

△ Tip: 

Loosen all bolts in turn in diagonal manner, but do not remove 

the bolts. 

NOTE: 

Remove the bolts as per disassembly sequence shown in 

the left figure. 

Page 1832


15B-127 

(b). Remove the main bearing cap and the main bearing 

cap bolts and arrange them in order and remove the 

main bearing bush. 

△ Tip: 

• Grasp the bolts of main bearing cap with two hands, shake 

the main bearing cap or knock loose with rubber hammer, 

and then remove the main bearing cap. 

• The top of each main bearing cap has marking to help the 

remembering. 

(c). Remove the crankshaft. 

NOTE: 

This part is a little heavy. To prevent causing serious 

personal injuries, make sure to lift this part or assembly 

with the assistance of other operators or with appropriate 

lifting equipment. 

(d). Remove the upper bushes of the main bearing bushes. 

△ Tip: 

Take out each upper bearing bush and mark the number on the 

movable lug and write down the installation position and the 

front and back side. 

15B 

Page 1833

15B-128 

ENGINE MECHANICAL PART-ASSEMBLY OF ENGINE 

ASSEMBLY OF ENGINE (4JB1) 

INSTRUCTION OF ASSEMBLY 

15B 

1. This section provides one complete set of procedure for assembly of diesel engine. The assembly 

mode is illustrated in both graphs and texts step by step from bottom to top and from inside to outside. 

2. The assembly environment shall be kept away as far as possible from the fire source and other 


3. During the assembly, install the parts removed to the original positions, without part shortage and 

missing part. 

4. During the assembly, replace all paper gaskets and never reuse these paper gaskets. 

5. During the assembly, make sure that the parts installed are intact and contamination-free and ensure 

that every part is installed securely in place. 

Page 1834


15B-129 

INSTALLATION OF CRANKSHAFT AND PISTON 

1. Install the crankshaft. 

(a) Face upward the cylinder block crankcase and place 

steadily. 

△ Tip: 

Make sure that there is no foreign material within the 

crankcase. 

(b). Install the upper bearing bush of main bearing bush in 

the specified position. 

△ Tip: 

• Carefully install the upper bushes of the main bearing 

bushes to the specified positions in turn and ensure that the 

back faces of the bearing bushes are clean without any 

scrap. The upper bush of each main bearing bush shall be 

in the center position of the bearing bush groove and the top 

faces of all bearing bushes shall be level. 

• After installation, uniformly put oil with right amount or the 

equivalent lubricating oil on the inside of bearing pad’s 

arched surface. 

NOTE: 

During the installation, make sure that the positioning lug 

is aligned with the positioning groove of the main bearing 

bush cylinder saddle. 

(c). Install the crankshaft thrust bearing in the specified 

position. 

△ Tip: 

In this engine, there are two thrust bearings installed at the 3rd 

main bearing bush of the cylinder block. 

NOTE: 

During the installation of the thrust bearings, notice to 

face the oil grooves outward 

15B 

Page 1835

15B-130 


(d). Drip clean oil or equivalent lubricating oil to the inner 

side of the main bearing bushes. 

NOTE: 

Do not drip oil to the outer side of the main bearing 

bushes. 

(e). Install the crankshaft to the specified position. 

N OTE: 

• This part is a little heavy. To prevent causing personal 

injuries, make sure to lift this part or assembly with the 

assistance of other operators or with appropriate lifting 

equipment. 

• Install the crankshaft with care, in order to prevent 

damaging the crankshaft main bearing, specially the 

thrust/main bearing journals. The damage of the 

crankshaft will shorten the service life of the engine. 

(f). After installing the crank, put the clean oil or the 

equivalent lubricating oil on the main bearing journals 

of crank. 

15B 

(g). Apply the oil to the lower bushes of the main bearing 

bushes and install onto the main bearing cap. 

△ Tip: 

Slide the lower bushes of the main bearing bushes from one 

side into the main bearing bush cap and press level the end 

faces. 

Page 1836


15B-131 

NOTE: 

During the installation, make sure that the positioning lugs 

of bearing bushes are aligned with the positioning 

grooves of the main bearing cap. 

(h). Install the main bearing cap in turn. 

△ Tip: 

Install the main bearing cap to the original position as per 

markings and do not wrongly install any part. 

△ Tip: 

Each main bearing cap of the crankshaft is marked with 

identification number. Install the bearing caps in order and do 

not wrongly install any one. 

NOTE: 

Install the main bearing caps of the crankshaft onto the 

main bearing block of the crankcase and ensure that the 

arrow of each main bearing cap points to the front 

direction (pulley direction). 

(i). Install the fixing bolts of the main bearing caps to 

specified installation holes in turn and fasten lightly with 

hand 

△ Tip: 

Put oil with the right amount on the head bolt of main bearing 

cap. 

15B 

(j). 

Screw up the main bearing bolts according to assigned 

order and torque. 

Page 1837

15B-132 


△ Tip: 

• Fasten the bolts to the specified torque by several times, 

instead of fastening by one time. 

• Fasten the fixing bolts of the main bearing as per specified 

sequence (as shown in left figure). 

2. Install the piston assembly. 

(a) Install the connecting rod bolts to the connecting rod. 

15B 

(b). Install the upper bush of piston connecting rod bearing 

bush. 

△ Tip: 

• Before assembly, all parts shall be clean. 

• Clean the connecting rod and bearing brush with a clean 

and non-cottony cloth. 

NOTE: 

• Make sure that the back faces and side faces of the 

connecting rod and connecting rod bearing are clean, 

without any scrap. 

• Do not lubricate the back face and side face of the 

connecting rod bearing. 

NOTE: 



grooves of the connecting rod. 

Page 1838


15B-133 

(c). 

Drip clean oil or equivalent lubricating oil to the inner 

side of the bearing bushes. 

(d). 

Use clean oil to lubricate the piston ring and the piston 

skirt. 

(e). As shown in the figure, rotate and adjust the positions 

of the piston ring openings. 

△ Tip: 

Each opening of piston ring shall not align at the piston pin and 

other openings of piston rings. If the opening position of piston 

ring is not correct, then the piston ring cannot correctly be 

sealed. 

(f). Use piston ring compressor to compress the piston 

rings to the working position. 

△ Tip: 

An annular cylinder can be self made with iron sheet if without 

special tools. 

15B 

(g). 

Rotate the crankshaft to position the journal of 

connecting rod to be installed at bottom dead center. 

Page 1839

15B-134 


(h). 

Put a thin clean oil on the wall of cylinder block. 

(i). Insert the connecting rod into the cylinder bore, till the 

piston ring compressor comes into contact with the top 

of the cylinder block 

△ Tip: 

• Align at the arrows of the top of piston to make it point at the 

front of engine. 

• The long end of connecting rod and the gap of piston skirt 

shall be on the exhaust side of engine, if not, please make 

sure that the piston is installed on the connecting rod. 

NOTE: 

The engine will be seriously damaged if not according to 

the above operational steps. 

15B 

(j). Press the piston ring compressor to the cylinder block, 

insert the piston into the cylinder bore through the 

piston ring compressor, and align with the installation 

position of the connecting rod. 

NOTE: 

If the piston can’t move smoothly, remove the piston and 

check the piston rings for breakage or damage. 

Page 1840


15B-135 

(k). Install the lower bush of the connecting rod bearing 

bush onto the connecting rod bearing bush cap. 

NOTE: 


connecting rod cover and connecting rod bearing are 

clean, without any scrap. Do not lubricate the back face 

and side face of the connecting rod bearing. 

• If not replaced with new one, install the old bearing 

onto the original connecting rod cover from which it’s 

removed. 

NOTE: 



grooves of the connecting rod cover. 

(l). 

Use clean oil to lubricate the inner side of the lower 

bush of the connecting rod bearing bush. 

(m). 

Install each connecting rod cover to corresponding 

journal of the crankshaft. 

15B 

Page 1841

15B-136 


NOTE: 

The middle portion of the connecting rod and the head of 

the connecting rod cap are forged with markings. During 

assembly, face these markings towards the front of the 

engine (Pulley end) 

15B 

(n). Install and fasten the connecting rod nuts. 

△ Tip: 

• Fasten the nuts many times with torque wrench with the 

method of angle fastening. 

• Check whether the piston assembly is installed correctly. 

• Measure the gap between the connecting rod body and the 

crankshaft and the protrusion amount of the piston top 

respectively. 

NOTE: 

If the piston, crankshaft, connecting rod or cylinder block 

is ever changed/replaced, it’s necessary to measure the 

protrusion amount of the piston on the combustion face of 

the cylinder block. 

The procedure is as below: 

• Install micrometer on the cylinder head and reset to 

zero. 

• Move the micrometer right above the top of the piston, 

in order to eliminate all lateral movements. 

• Rotate the crankshaft to the top dead center and then 

rotate the crankshaft clockwise and counter-clockwise, 

find out the maximum reading of the micrometer, and 

record the measurement result. 

Page 1842


15B-137 

INSTALLATION OF TAPPET, OIL INJECTION PIPE AND OIL PUMP 

1. Install tappet 

(a). Put clean oil and the equivalents on the tappet and 

tappet holes. 

(b). Install eight tappets on the installation holes one by 

one. 

△ Tip: 

• Make sure that the surface is clean and has no scratches 

before installation. 

• When installing the tappets, make sure that when 

installation holes incline at an angle of 45°~60°, the tappet 

slowly slide and do not have blockade phenomenon. 

2. Install oil Injection pipe 

(a). Install the oil Injection pipe in the specified position. 

△ Tip: 

Make sure the oil Injection pipe is clean especially the nozzle. 

(b). 

Install the fixing bolts of oil Injection pipe and 

pressure-limiting valve components. 

15B 

Page 1843

15B-138 


3. Install the oil pump assembly 

(a). Install the oil pump assembly in the specified position. 

△ Tip: 

When installing, put the lubricating oil on the oil pump gear. 

(b). 

Connect the connection between oil pump’s oil outlet 

pipe and engine body. 

(c). 

Install and fasten the fixing bolts of oil pump assembly. 

15B 

Page 1844


15B-139 

INSTALLATION OF ENGINE SUPPORT AND CAMSHAFT 

1. Install the engine support. 

(a). Install the engine right support to the specified position. 

(b). 

(c). 

Install and fasten four fixing bolts of the engine support. 

Install the left support with the same method. 

2. Install the camshaft. 

(a). Apply an appropriate amount of lubricating grease or 

equivalent lubricant onto the inner walls of the 

installation bore of the rear camshaft. 

NOTE: 

When installing the camshaft, the engine can be placed 

vertically in order to avoid sliding the tappet and the 

engine body shall be placed with certain angle. 

(b). Apply an appropriate amount of lubricating grease or 

equivalent lubricant onto the cam of the camshaft and 

the journal. 

△ Tip: 

Before the installation, make sure that all machined surfaces 

are clean without any scratch. 

15B 

Page 1845

15B-140 


(c). Slowly install the camshaft in the specified position. 

NOTE: 

• Before installing the camshaft, make sure that the 

tappet inserts completely in the tappet holes. If the 

tappets do not insert completely, the camshaft may be 

damaged when installing. 

• Rotate the camshaft and carefully insert the camshaft 

into the camshaft sleeve. When each camshaft journal 

passes through the sleeve, slightly lower the camshaft 

to fix the camshaft cam into the sleeve. Rotate the 

camshaft to separate the cam from the restraint of the 

sleeve, in order to install the camshaft smoothly. 

15B 

Page 1846


15B-141 

INSTALLATION OF GEAR CHAMBER AND OIL PAN 

1. Install the gear chamber 

(a). Install the gasket of gear chamber 

△ Tip: 

The gear chamber’s gasket shall be replaced. Clean the 

incomplete gaskets of engine body before replacing gasket. 

(b). 

Install the timing gear chamber in the specified 

position. 

(c). Install and fasten the fixing bolts of timing gear 

chamber. 

△ Tip: 

Do not excessively screw up a bolt. The fixing bolts of timing 

gear chamber shall be screwed up alternately and gradually. 

2. Install oil pan 

(a). Paint sealant on the front and rear ends of oil pan. 

15B 

Page 1847

15B-142 


△ Tip: 

Paint sealant with right amount on the contact surface between 

oil pan and engine body. 

(b). 

Install the front and rear ends of oil pan on the oil pan. 

(c). Install the oil pan to the specified position. 

NOTE: 

Clean and check the thread and the sealing surface of the 

drainage screw plug and replace the damaged one (if any). 

△ Tip: 

During the installation of oil pan, use the front and rear fixing 

bolts of the oil pan to help the orientation. 

15B 

(d). Install and fasten the fixing bolts of oil pan. 

△ Tip: 

Cross fasten the fixing bolts of oil pan from the middle to the 

sides or from the sides to the middle, instead of excessively 

fastening any bolt by one time. 

Page 1848


15B-143 

FLYWHEEL ASSEMBLY AND CLUTCH COMPONENTS 

1. Install the Flywheel assembly. 

(a). Install the rear oil seal of crank in the specified position with special oil seal installer. 

△ Tip: 

The crank is sealed with frame oil seal with good sealing property and thread groove. 

(b). 

Install the rear joint plate in the specified position and 

install the fixing bolts of rear joint plate. 

(c). 

Install flywheel and flywheel bolt plate in the specified 

position. 

(d). Install the flywheel bolt in the specified position and 

fasten it. 

△ Tip: 

• Install the flywheel at the rear end of crank with 8 bolts to 

ensure the dependable installation strength. 

• When installing flywheel bolts, paint oil on bolts and contact 

surface then fasten them according to diagonal. 

15B 

2. Install the clutch components 

(a). Install the clutch friction plate and clutch plate in the 

specified position with positioning tool. 

Page 1849

15B-144 


(b). 

Install the fixing bolts of clutch in the specified position 

and fasten them. 

15B 

Page 1850


15B-145 

CAMSHAFT GEAR AND IDLE PULLEY 

NOTE: 

When installing the gear, one shall strictly align the gear with the mark without any mistake in case of 

the non-start, power decrease, oil consumption increase and even the unnecessary loss which may 

cause the damage of distribution device parts. When the marks of gears are indistinct or wear, the 

gear mechanism shall be displaced as a set or be repaired in a maintenance station of Beijing Foton 

Environment Engine Co., Ltd if necessary. 

1. Install the camshaft gear 

(a). Install the front oil seal of camshaft gear on the 

camshaft gear. 

(b). Fasten the fixing bolt of camshaft gear front oil seal 

seat. 

NOTE: 

After installing the front oil seal seat of camshaft gear, the 

flat key of camshaft gear also shall be installed on the 

camshaft in case of omission. 

(c). Install the camshaft pulley flange plate on the front oil 

seal seat of camshaft. 

△ Tip: 

Install the camshaft pulley flange plate correctly and make the 

location pin through pin hole. 

15B 

(d). 

Install the pressure plate onto the specified position. 

Page 1851

15B-146 


(e). 

Fasten the bolt of pressure plate. 

(f). Install the camshaft gear to the specified position. 

NOTE: 

When installing the camshaft gear, the groove of camshaft 

gear shall be aligned and the pin hole of camshaft shall be 

installed align with the location pin. 

(g). Fasten the fixing bolt of camshaft pulley. 

△ Tip: 

• When fastening the camshaft gear bolt, the camshaft gear 

will revolve with it. For this reason, one shall locate the 

camshaft gear with special locator instead of wrench. 

• According to the actual situation, one may also use tools 

such as screwdriver and solid wrench to locate the 

camshaft gear. 

15B 

2. Install the idle pulley 

(a). Install the bolt equipped with location skirt and the 

timing belt transition wheel assembly together. 

(b). 

Install the location skirt and the timing belt transition 

wheel assembly into the gear chamber. 

Page 1852


15B-147 

(c). 

Fasten the location skirt bolt. 

△ Tip: 

Install the tensioner assembly and hexagon flange locating bolt 

into the gear chamber with the same method and fasten them. 

NOTE: 

The tensioned shall be fastened again when installing in 

order to facilitate the following adjustment of belt. It 

means to slightly fastening it. 

(d). 

Install the tensioning pull rod onto the gear chamber. 

△ Tip: 

When installing the tensioning pull rod, one shall install the 

internal teeth serrated lock washer, hexagon flange nut and the 

bolt equipped with locating rod onto the tensioning pull rod all 

together. 

15B 

Page 1853

15B-148 


INSTALLATION OF INJECTION PUMP ASSEMBLY 

1. Install the injection pump assembly 

(a). Install the injection pump pulley, injection pump flange 

and injection pump onto the gear chamber. 

△ Tip: 

Install the injection pump onto the gear chamber from the rear 

of gear chamber. 

NOTE: 

The timing marks on the injection pump pulley shall be 

installed aligning with the timing marks on gear chamber. 

(b). 

Fasten the fixing bolt of injection pump assembly. 

15B 

Page 1854


15B-149 

INSTALLATION OF TIMING BELT AND PRESSURE PLATE 

1. Install the timing belt 

(a). Install the timing belt to the specified position. 

(b). Adjust the tension of timing belt with special tools and 

tensioning pull rod. 

△ Tip: 

When the tension of belt being adjusted to proper position, one 

shall just Fasten the hexagon flange locating bolt. 

(c). 

Fasten the fixing bolt of tensioning pull rod. 

2. Install the pressure plate 

(a). Install the pressure plate of injection pump pulley. 

15B 

Page 1855

15B-150 


(b). 

Install and fasten the fixing bolt of injection pump pulley 


(c). 

Install the pressure plate of camshaft pulley. 

(d). 

Install and fasten the fixing bolt of camshaft pulley 


15B 

Page 1856


15B-151 

INSTALLATION OF WATER PUMP PULLEY CHAMBER COVER 

ASSEMBLY AND OBSERVATION CHAMBER COVER 

1. Install the cover assembly of water pump pulley 

chamber 

(a). Install the cover assembly of water pump pulley 

chamber onto the gear chamber. 

(b). 

Install and fasten the fixing bolt of water pump pulley 

chamber cover assembly. 

2. Install the observation room cover 

(a). Install the observation room cover to the specified 

position. 

(b). 

Install and fasten the fixing bolt of observation room 

cover. 

15B 

Page 1857

15B-152 


INSTALLATION OF THE CRANKSHAFT PULLEY AND THE FAN 

1. Install the crankshaft pulley 

(a). Install the crankshaft pulley to the specified position. 

△ Tip: 

When installing the crankshaft pulley, in order to avoid the 

Disassembly of crankshaft pulley due to the crankshaft pulley 

rotating together with it, one shall firstly secure the flywheel 

with flywheel locator or other equivalent objects. Meanwhile, 

one shall smear oil onto the bolt threads. 

(b). 

Install and fasten the crankshaft pulley bolt. 

2. Install the fan 

(a). Install the fan assembly to the specified position. 

15B 

(b). Install and fasten the fixing nuts of fan assembly. 

△ Tip: 

Clamp the double-end strut backward with screwdriver and 

fasten the sideward nut with wrench. 

Page 1858


15B-153 

INSTALLATION OF HIGH PRESSURE FUEL RAIL AND STARTER 

MOTOR 

1. Install the high pressure fuel rail assembly 

(a). Install the high pressure fuel rail assembly to the 

specified position 

(b). 

Install and fasten the fixing bolt of high pressure fuel 

rail assembly. 

2. Install the starter motor 

(a). Install the starter motor onto the rear cover plate of 

cylinder block. 

△ Tip: 

When installing the starter motor, the bolt hole of starter motor 

shall be aligned to the bolt hole of cylinder block rear cover 

plate. 

(b). 

Install and fasten the fixing bolt of starter motor. 

15B 

Page 1859

15B-154 


INSTALLATION OF HOOK AND A/C BRACKET 

1. Install the hook. 

(a). Install the hook to the specified position and ensure the 

alignment of it with the installation hole. 

(b). 

Install and fasten the fixing bolt of hook. 

2. Install the A/C bracket 

(a). Install the A/C bracket to the specified position and 

ensure the alignment of it with the installation hole. 

(b). Install and fasten the fixing bolt of A/C bracket. 

15B 

Page 1860


15B-155 

INSTALLATION OF VALVE AND THERMOSTAT ASSEMBLY 

1. Install the valve assembly 

(a). Lubricate the valve guide pipe hole and the outer wall 

of valve guide pipe which are required to be replaced 

with lubricating oil. 

△ Tip: 

The lubrication for the outer wall of air guide pipe is conducted 

to make it installing into the cylinder head guide pipe hole. 

(b). Knock the valve guide pipe into the inside from the top 

of cylinder head with special tool. 

NOTE: 

The outer surface of valve guide pipe shall be covered 

with oil when installing. Also, one shall install the valve 

guide pipe and check the height of it. 

(c). Lubricate all the valve guide pipe hole and the valve 

stem with oil. 

△ Tip: 

• Without the lubrication for the valve guide pipe and valve 

stem, the valve guide will be worn early. 

• Before installing the valve, one shall lubricate the valve 

stem with oil. 

(d). Install the valve and install the valve oil seal onto the 

valve guide pipe with installer for valve oil seal. 

NOTE: 

• If the valve isn’t replaced, one shall install the valve at 

the same position of the valve disassembly. 

• If the cylinder head will not be applied immediately, one 

shall also lubricate the valve stem with assembly 

lubricating agent or equivalent object. 

• The valve oil seal shall be replaced when it is 

disassembled. 

15B 

Page 1861

15B-156 


(e). 

Install the lower seat of upper valve spring, valve spring 

and the upper seat of valve spring. 

(f). 

Compress the valve spring with the valve 

springcompressor to expose the installation position of 

valve lock clamp. 

(g). Install the upper valve lock clamp, release the valve 

spring and lock the valve with valve lock clamp. 

△ Tip: 

After assembly, one shall knock the valve spring seat with 

rubber hammer to ensure the correct installations of locking 

plate. 

NOTE: 

• If the lock clamp is installed improperly, the lock clamp 

will dash off when knocking the valve spring seat with 

plastic hammer. 

(h). Install all the valves with the same method. 

15B 

2. Install the thermostat assembly 

(a). Install and fasten the thermostat housing assembly and 

fixing bolt to the specified position. 

Page 1862


15B-157 

(b). 

Install the thermostat. 

(c). 

Install and fasten the outlet pipe assembly and fixing 

bolt. 

15B 

Page 1863

15B-158 


INSTALLATION OF CYLINDER HEAD COVER AND TAPPET 

1. Install the cylinder head assembly. 

(a) Lubricate the bolts with clean oil. 

(b). 

Install the gasket of the cylinder head to the specified 

position. 

(c). Align the installed cylinder head with the specified 

position. 

△ Tip: 




or assembly. 

15B 

(d). Install and fasten the fixing bolts of the cylinder head 

△ Tip: 

Lubricate the threads and lower part of end of fixing bolt with 

clean oil. 

Page 1864


15B-159 

NOTE: 

Fasten the fixing bolts of the cylinder head to the specified 

torque by several times as per sequence shown in left 

figure. 

2. Install the tappet 

(a). Fill clean oil into the installation position hole of each 

valve tappet. 

(b). Install the valve tappets to the specified position one by 

one. 

△ Tip: 

Be sure that the installation position and removing position of 

each valve tappet are same. 

15B 

Page 1865

15B-160 


INSTALLATION OF ROCKSHAFT AND CYLINDER HEAD COVER 

1. Install the rockshaft assembly. 

(a). Before installing the rocker assembly, the clean oil shall 

be dropped into each bowl-shape groove of tappet. 

(b). Install the rocker assembly to the specified position. 

△ Tip: 

It shall be handled with care when installing. The alignment 

with installation hole shall also be ensured. 

(c). Install the fixing bolt of rocker assembly. 

△ Tip: 

Temporarily, the installed bolt will not be fastened in order till 

the installation completion of the fixing nut of rocker assembly. 

(d). Adjust the clearance of valve (see Chapter 15B Valve 

of Engine Mechanical Part, Adjustment) 

15B 

2. Install the electric heater plug assembly 

(a). Install and fasten four electric heater plug assemblies. 

Page 1866


15B-161 

3. Install the cylinder head cover assembly 

(a). Install the cylinder hear cover assembly to the specified 

position. 

(b). 

Install and fasten the fixing nuts of the cylinder head 

cover. 

15B 

Page 1867

15B-162 


INSTALLATION OF INTAKE AND EXHAUST MANIFOLDS AND 

TURBOCHARGER 

1. Install the intake and exhaust manifolds 

(a). Install the intake manifold gasket and the intake 

manifold to the specified position. 

NOTE: 

The gasket of intake manifold shall be replaced by a new 

one. 

(b). 

Install and fasten the fixing bolt of intake manifold. 

(c). Install the exhaust manifold gasket and exhaust 

manifold to the specified positions. 

△ Tip: 

One shall remember to install the ring and heat shield fixed 

together with the exhaust manifold when installing the exhaust 

manifold. 

15B 

(d). 

Install and fasten the fixing bolt of exhaust manifold to 


Page 1868


15B-163 

2. Install the turbocharger 

(a). Install the turbocharger assembly to the specified 

position. 

(b). 

Install the heat shield assembly. 

(c). 

Install the turbocharger into the oil return pipe. 

15B 

Page 1869

15B-164 


INSTALLATION OF BREATHER AND DIPSTICK 

1. Install the breather 

(a). Install the breather bracket to the specified position. 

(b). 

Install and fasten the fixing bolt of breather bracket. 

(c). Install the breather onto the breather bracket. 

△ Tip: 

The breather is installed inside the starter. 

15B 

(d). 

Install and fasten the fixing bolt of breather. 

Page 1870


15B-165 

2. Install the dipstick 

(a). Install the dipstick to the specified position. 

△ Tip: 

Plug the lower port of dipstick assembly in the installation hole 

of dipstick when installing. 

(b). 

Install the fixing bolt of dipstick and connect the 

connection of dipstick and the oil return pipe of 

breather. 

15B 

Page 1871

15B-166 


INSTALLATION OF FUEL INJECTOR AND HIGH & LOW PRESSURE 

FUEL PIPE 

1. Install the fuel injector 

(a). Install the fuel injector and the pressure plate of fuel 

injector together, install them to the specified position 

and install the fixing bolt fastening the fuel injector 


△ Tip: 

In case of unnecessary troubles caused by the falling off of 

copper washer when installing the fuel injector, the copper 

washer shall be covered with a little lithium oil when installing. 

2. Install the low pressure fuel pipe 

(a). Install the low pressure fuel pipe to the specified 

position. 

△ Tip: 

Push the clamp of low pressure fuel pipe in the direction of 

openness, install it onto the fuel injector and connect the 

connection of low pressure fuel pipe and fuel injector. 

3. Install high pressure fuel pipe 

(a). Connect the connection of high pressure fuel pipe and 

fuel rail. 

△ Tip: 

As for the installation of high pressure fuel pipe, one shall 

embed the lower end of intake manifold into the high pressure 

fuel pipe and shall not remove the cover of high pressure fuel 

pipe connector early. 

15B 

(b). Connect the connectors of high pressure fuel pipe and 

fuel injector and fasten the nut. 

△ Tip: 

Currently, the high pressure fuel pipe can be fastened couple 

by couple. 

Page 1872


15B-167 

(c). 

Install the high pressure fuel pipe between the injection 

pump and the high pressure fuel rail and fasten the nut. 

15B 

Page 1873

15B-168 


GENERATOR AND OIL FILTER 

1. Install the generator 

(a). Install the generator assembly to the specified position 

and install the fixing bolt fastening the lower end of 

generator. 

NOTE: 

When installing the fixing bolt, one shall hold up the 

generator with a hand in case of the damage of generator 

caused by falling of generator due to the lack of bracing 

force. 

(b). 

Adjust the position of generator and install the 

generator belt. 

(c). Install the adjusting bolt on the upper end of generator. 

△ Tip: 

Do not screw up the adjusting bolt of the generator too tightly 

when installing to facilitate the adjustment of generator belt. 

15B 

(d). Adjust the belt tension by adjusting the position of 

generator. 

△ Tip: 

Press the generator belt with great force to check whether the 

belt is installed in place. 

Reference Standard: 39N. The deflection is about 10~15mm. 

Page 1874


15B-169 

(e). 

Be sure the generator belt is installed in place and 

fasten the adjusting bolt of generator. 

(f). 

Connect the oil inlet and outlet pipe of vacuum pump at 

the rear end of generator. 

2. Install the oil filter assembly. 

(a) Install the oil filter assembly to the specified position. 

(b). 

Install and fasten the fixing bolts of oil filter assembly. 

15B 

(c). 

Connect the connection of oil filter coolant pipe. 

Page 1875

15B-170 


INSTALLATION OF PIPELINE AND HARNESS 

1. Install the harness of engine 

(a). According to the installation position relation, the 

generator ECU harness shall be installed in place one 

by one. 

2. Install the intake connecting pipe 

(a). Install the intake connecting pipe to the specified 

position and fasten the fixing bolt of it. 

3. Install the turbo-supercharging intake pipe 

(a). Install and fasten the turbocharger intake connecting 

pipe assembly and the fixing bolts of it. 

15B 

4. Install the breather pipeline 

(a). Install and connect the intake pipe of breather. 

Page 1876


15B-171 

(b). 

Install and connect the exhaust pipe of breather. 

(c). 

Install the clamp connecting the exhaust pipe of 

breather and the intake hose of turbocharger and 

connect to the connector of breather intake hose. 

5. Install the EGR pipeline 

(a). Install the EGR pipe to the specified position. 

(b). 

Install and fasten the fixing bolt connecting with the 

EGR pipe and exhaust pipe. 

15B 

(c). 

Install 2 fixing nuts connecting with the EGR pipe and 

intake pipe. 

Page 1877

15B-172 

ENGINE MECHANICAL PART-DISASSEMBLY OF ENGINE 

DISASSEMBLY OF ENGINE (4D20) 

INSTRUCTION OF DISASSEMBLY 

15B 

1. This section provides one complete set of procedure for disassembly of diesel engine. The 

disassembly mode is illustrated in both graphs and texts step by step from top to bottom and from 

outside to inside. 

2. Before removing the engine, place the engine assembly onto the disassembly stand or place on one 

clean and level ground and prepare the necessary disassembly tools and professional container or 

environment for placement of parts. 

3. The disassembly environment shall be kept away as far as possible from the fire source and other 


Page 1878

ENGINE MECHANICAL PART- DISASSEMBLY OF ENGINE 

15B-173 

DISASSEMBLY OF HEATER AND WATER OUTLET-INLET PIPE 

WELDMENT 

1. Disassemble the weldment of heater and water 

outlet-inlet pipe 

(a). Disassemble the fixing bolt of heater and water 

outlet-inlet pipe weldment. 

△ Tip: 


loss. 

(b). 

Disassemble the rubber hose connecting with the 

heater and water outlet-inlet pipe weldment and the 

thermostat. 

(c). 

Take down the heater and water outlet-inlet pipe 

weldment. 

15B 

Page 1879

15B-174 


DISASSEMBLY OF CYLINDER HEAD COVER 

1. Disassemble the cylinder head cover 

(a). Disassemble the fixing nut of cylinder head cover. 

△ Tip: 


loss. 

(b). 

Take down the cylinder head cover assembly. 

15B 

Page 1880


15B-175 

DISASSEMBLY OF EGR CONTROLLER 

1. Disassemble the EGR controller 

(a). Disconnect the connection of EGR valve vacuum 

pipeline. 

(b). 

Disconnect the connection of preheat controller oil inlet 

pipe. 

(c). Disassemble the fixing bolt of air compressor bracket 

and take down the fixing bracket of air compressor. 

△ Tip: 


prevent loss. 

• In order to facilitate the disassembly, the air compressor 

fixing bracket and EGR controller shall be taken down 

together. 

NOTE: 

Before taking down the air compressor bracket, the 

connection between the generator and EGR controller 

vacuum pipeline shall also be disconnected. 

15B 

Page 1881

15B-176 


(d). Disassemble the fixing bolt of EGR controller and take 

down EGR controller. 

△ Tip: 


loss. 

15B 

Page 1882


15B-177 

DISASSEMBLY OF INTAKE AND EXHAUST MANIFOLDS AND 

TURBOCHARGER 

1. Disassemble the intake and exhaust manifolds 

assembly 

(a). Disassemble the fixing bolt of intake and exhaust 

manifolds. 

△ Tip: 


loss. 

(b). Disassemble the fixing bolt connecting with EGR valve 

connecting pipe weldment and the exhaust manifold. 

△ Tip: 


loss. 

(c). Disassemble the fixing bolt connecting with EGR valve 

and intake manifold. 

△ Tip: 


loss. 

(d). 

Take down EGR valve connecting pipe weldment. 

15B 

Page 1883

15B-178 


(e). Disassemble the fixing bolt of turbocharger oil inlet pipe 

weldment. 

△ Tip: 


loss. 

(f). 

Disconnect the connection of turbocharger oil return 

rubber hose. 

(g). Take down the intake and exhaust manifolds and 

turbocharger. 

△ Tip: 

In order to facilitate the Disassembly of generator, the intake 

and exhaust manifolds and turbocharger shall be taken down 

altogether. 

15B 

(h). Take down the washers of intake and exhaust 

manifolds. 

△ Tip: 

It is not proper to reuse the disassembled washers. They shall 

be replaced by new washers. 

(i). 

Disassemble the rubber hose clamp connecting with 

turbocharger and intake manifold and disconnect its 

connection. 

Page 1884


15B-179 

(j). 

Take down the intake manifold assembly. 

2. Disassemble the turbocharger 

(a). Disassemble the fixing bolt of turbocharger air inlet 

port. 

△ Tip: 


loss. 

(b). Disassemble the fixing bolt connecting with the 

turbocharger and its bracket. 

△ Tip: 


loss. 

(c). 

Take down the turbocharger and its gasket. 

15B 

Page 1885

15B-180 


DISASSEMBLY OF GENERATOR AND BREATHER 

1. Disassemble the generator assembly 

(a). Disassemble the fixing bolt of vacuum pump oil inlet 

pipe assembly. 

△ Tip: 


loss. 

(b). 

Disassemble the fixing clamp of vacuum pump oil 

return pipe and disconnect the connection of oil return 

pipe. 

(c). 

Disassemble the adjusting bolt of generator and 

release the whole tension of belt. 

15B 

(d). Disassemble the fixing bolt of generator. 

△ Tip: 

• In order to prevent the direction of bolt rotating with the force 

when removing, one shall firstly lock the bolt and then 

disassemble the nut of fixing bolt. 

• When removing the fixing bolt, one shall hold up the 

generator with a hand in case of generator damages or 

personal injuries caused by the falling off of generator due 

to the lack of bracing force. 

Page 1886


15B-181 

(e). 

Take down the generator assembly. 

(f). 

Disassemble the fixing bolt of generator bracket and 

take down the bracket on generator. 

(g). 

Disassemble the fixing bolt of generator bracket and 

take down the generator lower bracket. 

2. Disassemble the breather 

(a). Disassemble the fastening clamp of lower oil return 

pipe of breather and disconnect the connection of lower 

oil pipe. 

15B 

(b). Disassemble the fixing bolt of breather. 

△ Tip: 


loss. 

Page 1887

15B-182 


(c). 

Take down the breather assembly 

15B 

Page 1888


15B-183 

DISASSEMBLY OF FAN, FAN PULLEY AND CRANKSHAFT PULLEY 

1. Disassemble the fan 

(a). Disassemble the fixing nut of fan assembly. 

△ Tip: 

• When removing, the fan will rotate in the direction of force. 

In order to prevent this, the stud shall be clamped in a 

reverse direction with a screwdriver. 

• All nuts removed shall be centrally placed, in order to 

prevent loss 

(b). 

Take down the fan pulley. 

(c). 

Take down the fan and its pulley. 

2. Disassemble the crankshaft pulley 

(a). Disassemble the fixing bolt of crankshaft pulley. 

△ Tip: 


loss. 

15B 

Page 1889

15B-184 


(b). 

Take down the crankshaft pulley. 

15B 

Page 1890


15B-185 

DISASSEMBLY OF DIPSTICK 

1. Disassemble the dipstick 

(a). Disassemble the fixing bolt of dipstick bracket. 

(b). 

Remove the dipstick 

15B 

Page 1891

15B-186 


DISASSEMBLY OF HIGH & LOW PRESSURE FUEL PIPE AND FUEL 

INJECTOR 

1. Disassemble the high pressure fuel pipe 

(a). Disconnect the connection with high pressure fuel pipe 

and fuel injector. 

(b). 

Disconnect the connection of high pressure pipeline 

and high pressure oil pump. 

(c). 

Take down the high pressure fuel pipe. 

15B 

(d). 

Disconnect the connection with low pressure rubber 

fuel pipe. 

Page 1892


15B-187 

(e). 

Take down each low pressure rubber fuel pipe 

connecting to fuel injectors successively. 

2. Disassemble the fuel injector 

(a). Disassemble the fixing bolts of fuel injector pressure 

plate successively. 

(b). 

Take down the fuel injector pressure plate and fuel 

injector successively. 

15B 

Page 1893

15B-188 


DISASSEMBLY OF ROCKSHAFT AND TAPPET 

1. Disassemble the rockshaft 

(a). Disassemble the fixing bolts and nuts of rockshaft. 

△ Tip: 

• Do not disassemble a certain bolt or nut at a time. On e shall 

uniformly disassemble the fixing bolts or nuts of rockshaft 

for several times. 

• All bolts and nuts removed shall be centrally placed, in order 

to prevent loss. 

(b). 

Take down the rockshaft. 

2. Disassemble the tappet 

(a). Take out the tappets successively and place them 

centrally. 

15B 

Page 1894


15B-189 

DISASSEMBLY OF CYLINDER HEAD 

1. Disassemble the cylinder head 

(a). Disassemble the connecting hose clamp of oil radiator 

and cylinder head, disconnect the hose connection and 

take down the hose. 

(b). 

Disassemble the rubber hose connecting with the water 

pump and thermostat. 

(c). Disassemble the fixing bolt of cylinder head. 

NOTE: 

When removing, the cylinder head bolt shall be 

disassembled once a couple for several times as the 

sequence from middle to two sides. 

(d). Remove the cylinder head assembly 

△ Tip: 




or assembly. 

15B 

Page 1895

15B-190 


DISASSEMBLY OF THE WATER OUTLET PIPE CONNECTOR, 

VALVE AND HOOK 

1. Remove the water outlet pipe connector. 

(a). Remove the fixing bolts of water outlet pipe connector. 

△ Tip: 


loss. 

(b). 

Remove the water outlet pipe connector. 

2. Remove the valve 

(a). Compress the valve spring with valve spring 

compressor to expose the installation location of valve 

lock clamp. 

15B 

(b). Remove the valve lock clamp 

NOTE: 

To prevent causing personal injuries, please wear the 

goggles. 

Page 1896


15B-191 

(c). Remove the valve spring upper seat, valve spring, and 

valve spring lower seat and remove the valve oil seal. 

NOTE: 

The oil seal removed can’t be reused and shall be replaced 

with new one. 

(d). 

Remove the valve 

(e). Remove the valve guide with special disassembly tool. 

△ Tip: 

The valve guide removed can’t be reused. Therefore, remove 

the valve guide depending on the actual condition. 

3. Remove the hook. 

(a). Remove the fixing bolts of front hook. 

△ Tip: 


loss. 

15B 

(b). 

(c). 

Remove the front hook. 

Remove the rear hook as per same method. 

Page 1897

15B-192 


DISASSEMBLY OF OIL FILTER AND OIL RADIATOR 

1. Disassemble the oil filter 

(a). Disassemble the connecting pipe weldment fixing bolt 

of oil radiator and oil filter. 

△ Tip: 


loss. 

(b). Disassemble the fixing bolt of oil filter. 

△ Tip: 


loss. 

(c). 

Take down the oil filter. 

15B 

(d). Disassemble the fixing bolt connecting with the 

connecting pipe weldment and oil radiator. 

△ Tip: 


loss. 

Page 1898


15B-193 

(e). Take down the O-ring of weldment and the weldment of 

connecting pipe. 

△ Tip: 

It is not proper to reuse the disassemble O-ring. It shall be 

replaced by a new one. 

(f). Disassemble the fixing bolt of oil radiator. 

△ Tip: 


loss. 

(g). 

Take down the oil radiator. 

15B 

Page 1899

15B-194 


DISASSEMBLY OF CLUTCH COMPONENTS AND FLYWHEEL 

ASSEMBLY 

1. Remove the Clutch Components. 

(a) Remove the fixing bolts of clutch. 

(b). 

Remove the clutch disc and clutch cover components. 

2. Remove the flywheel assembly. 

(a). Remove the fixing bolts of clutch. 

△ Tip: 


loss. 

15B 

(b). Remove the flywheel assembly. 

△ Tip: 

Caution shall be taken during the removal, as the flywheel has 

certain weight. 

Page 1900


15B-195 

(c). Remove the fixing bolts of support rear cover. 

△ Tip: 


loss. 

(d). 

Remove the support rear cover. 

(e). 

Remove the sealing strip of rear oil seal cover. 

15B 

Page 1901

15B-196 


DISASSEMBLY OF OIL PAN AND OIL PUMP 

1. Remove the oil pan. 

(a). Overturn the engine body. 

△ Tip: 

The oil shall be completely discharged in prior of the 

Disassembly of oil pan. 

(b). Disassemble the fixing bolt of oil pan. 

△ Tip: 

• When removing, the fixing bolt of oil pan shall be 

disassembled in a crossing way as the sequence from 

middle to two sides and then the sequence from two sides 

to middle. 


prevent loss. 

(c). 

Take down the oil pan. 

15B 


(a). Disassemble the fixing bolt of oil pump driving gear 

chamber cover. 

Page 1902


15B-197 

(b). 

Take down the cover and take out the driving gear of oil 

pump. 

(c). Disassemble the fixing bolt of oil pump. 

△ Tip: 


loss. 

(d). Take out the oil pump. 

△ Tip: 

Take out slowly and avoid the impact. 

15B 

Page 1903

15B-198 


DISASSEMBLY OF OIL SEAL COVER AND OIL SEAL 

1. Remove the oil seal cover and oil seal. 

(a). Remove the fixing bolts of the oil seal cover. 

(b). 

Remove the oil seal and the oil seal cover. 

(c). 

Separate the oil seal from the oil seal cover. 

15B 

Page 1904


15B-199 

DISASSEMBLY OF GEAR CHAMBER COVER, INJECTION PUMP 

AND WATER PUMP ASSEMBLY 

1. Disassemble the gear chamber cover 

(a). Disassemble the fixing bolt of gear chamber cover. 

△ Tip: 


loss. 

(b). Take down the injection pump gear chamber cover. 

△ Tip: 


loss. 

(c). Take down the gear chamber cover and the gasket. 

2. Disassemble the injection pump 

(a). Disassemble the fixing bolt of injection pump gear. 

15B 

Page 1905

15B-200 


(b). 

Disassemble the injection pump gear with an extractor. 

(c). Disassemble the fixing bolt of injection pump. 

△ Tip: 


loss. 

(d). Disassemble the fixing bolt connecting with injection 

pump and injection pump bracket. 

△ Tip: 


prevent loss. 

• When removing, the injection pump shall be hold up with a 

hand in case of damage or personal injuries due to the 

falling of pump. 

15B 

(e). Take down the injection pump. 

△ Tip: 

Take it out carefully and avoid the impact. 

3. Remove the water pump components 

(a). Remove the fixing bolts of the water pump 

components. 

△ Tip: 


loss. 

Page 1906


15B-201 

(b). Remove the water pump components and water pump 

gasket. 

△ Tip: 

It is not proper to reuse the disassembled gasket. It shall be 


15B 

Page 1907

15B-202 


DISASSEMBLY OF CAMSHAFT GEAR AND CRANKSHAFT GEAR 

1. Disassemble the camshaft gear 

(a). Disassemble the fixing bolt of camshaft gear. 

△ Tip: 


loss. 

(b). Take down the camshaft gear. 

△ Tip: 

Do not forget to take down the woodruff key. 

(c). Disassemble the fixing bolt of camshaft pressure plate. 

△ Tip: 


loss. 

15B 

(d). 

Take down the pressure plate of camshaft. 

Page 1908


15B-203 

2. Disassemble the crankshaft gear 

(a). Take down the oil baffle disk. 

(b). Take down the crankshaft gear and the woodruff key. 

△ Tip: 

• Do not forget to take down the woodruff key. 

• All woodruff keys removed shall be centrally placed, in 

order to prevent loss. 

15B 

Page 1909

15B-204 


DISASSEMBLY OF CAMSHAFT, PISTON AND CRANKSHAFT 

1. Disassemble the camshaft 

(a). Turn over the engine body and take out the camshaft. 

△ Tip: 

• Take out the camshaft without influencing the tappet. 

• The camshaft shall be taken out by slowly revolving. 

(b). Take out the tappets successively. 

△ Tip: 

• Draw out the tappets from their installation positions 

successively with high performance magnet. 

• The tappet taken out shall be put in a clean vessel. 

2. Disassemble the piston assembly 

(a). Rotate the crankshaft to locate the journal of 

disassembled connecting rod on the bottom dead 

center. 

15B 

(b). Disassemble the fixing nut of connecting rod cover. 

△ Tip: 

Unscrew every two nuts a time. 

Page 1910


15B-205 

(c). 

Lightly shake and pull out the connecting rod cover and 

remove the connecting rod bearing bush. 

(d). 

Remove the carbon deposit from the piston cylinder. 

(e). Push out the piston assembly 

△ Tip: 

Push out the piston assembly with wooden or rubber object. Do 

not use metallic object, in order to prevent damaging the end 

face of connecting rod 

(f). Remove the piston assembly from the other side. 

△ Tip: 

Install the piston assembly removed together, add the marking, 

and place into a clean container. 

(g). Remove the pistons of other cylinders as per same 

method. 

15B 

3. Remove the crankshaft assembly. 

(a). Loosen the bolts of main bearing cap in turn. 

△ Tip: 

Loosen all bolts in turn in diagonal manner, but do not remove 

the bolts. 

Page 1911

15B-206 


NOTE: 

Remove the bolts as per disassembly sequence shown in 

the left figure. 

(b). Take down the main bearing cap and align them in 

sequence. 

△ Tip: 

• Grasp the bolts of main bearing cap with two hands, shake 

the main bearing cap or knock loose with rubber hammer, 

and then remove the main bearing cap. 

• The top of each main bearing cap has marking to help the 

remembering. 

(c). 

Take down the main bearing bush. 

15B 

(d). Lift out the crankshaft 

NOTE: 

This part is a little heavy. To prevent causing serious personal 



equipment. 

(e). Remove the upper bushes of the main bearing bushes. 

△ Tip: 

Take out every upper bush successively and mark the cylinder 

number at the movable lug. 

Page 1912


15B-207 

(f). Take down the crankshaft thrust halfring. 

△ Tip: 

Take down the crankshaft thrust halfring and mark the 

installation position and its front and back to facilitate the 

correct installation when assembling. 

15B 

Page 1913

15B-208 

ENGINE MECHANICAL PART- ASSEMBLY OF ENGINE 

ASSEMBLY OF ENGINE (4D20) 

INTRODUCTION OF ASSEMBLY 

15B 

1. This section provides one complete set of procedure for assembly of diesel engine. The assembly 

mode is illustrated in both graphs and texts step by step from bottom to top and from inside to outside. 

2. The assembly environment shall be kept away as far as possible from the fire source and other 


3. During the assembly, install the parts removed to the original positions, without part shortage and 

missing part. 

4. During the assembly, replace all paper gaskets and never reuse these paper gaskets. 

5. During the assembly, make sure that the parts installed are intact and contamination-free and ensure 

that every part is installed securely in place. 

Page 1914


15B-209 

INSTALLATION OF CRANKSHAFT, PISTON AND CAMSHAFT 

1. Install the crankshaft. 

(a). Face upward the cylinder block crankcase and place 

steadily. 

△ Tip: 

Make sure that there is no foreign material within the 

crankcase. 

(b). Install the thrust halfring of crankshaft 

△ Tip: 

There are only two thrust halfrings for this engine, installing at 

the 4th main bearing bush of cylinder block. 

NOTE: 

The oil groove shall face outward when installing the 

thrust halfrings. 

(c). Install the upper bushes of the main bearing bushes to 

the specified positions. 

△ Tip: 

• Carefully install the upper bushes of the main bearing 

bushes to the specified positions in turn and ensure that 

the back faces of the bearing bushes are clean without 

any scrap. The upper bush of each main bearing bush 

shall be in the center position of the bearing bush groove 

and the top faces of all bearing bushes shall be level 

• After installation, the inside of bearing bush arching 

surface shall be evenly covered with proper amount of oil 

or equivalent. 

NOTE: 

During the installation, make sure that the positioning lug 

is aligned with the positioning groove of the main bearing 

bush cylinder saddle. 

15B 

Page 1915

15B-210 


(d). Drip clean oil or equivalent to the inner side of the main 

bearing bushes. 

NOTE: 

Do not drip oil to the outer side of the main bearing 

bushes. 

(e). Install the crankshaft to the specified position. 

NOTE: 

• This part is a little heavy. To prevent causing personal 



equipment. 

• Install the crankshaft with care, in order to prevent 

damaging the crankshaft main bearing, specially the 

thrust/main bearing journals. The damage of the 

crankshaft will shorten the service life of the engine. 

(f). After the installation of crankshaft, drop clean oil or 

equivalent onto the main journal of the crankshaft and 

rotate the crankshaft to lubricate its surfaces. 

15B 

(g). Apply the oil to the lower bushes of the main bearing 

bushes and install onto the main bearing cap. 

△ Tip: 

Slide the lower bushes of the main bearing bushes from one 

side into the main bearing bush cap and press level the end 

faces. 

Page 1916


15B-211 

NOTE: 



grooves of the main bearing cap. 

(h). Install the main bearing cap and its fixing bolts in order. 

△ Tip: 

• Install the main bearing cap to its original position when 

removing as the mark without any mistake. 

• There are identification numbers on main bearing cap of 

each crankshaft. The installation shall be conducted in order 

without any mistake. 

NOTE: 

When placing the crankshaft main bearing cap onto the 

main bearing seat of crank case, the arrow on each cover 

shall point to the front (the direction of pulley) 

(i). Screw up the main bearing bolt according to some 

sequence and torque. 

△ Tip: 

• Do not screw up the bolt at one time. The bolt shall be 

screwed up a little and generally be fastened to the 

specified torque. 

• The main bearing bolt shall be fastened according to a 

certain sequence (see left diagram) 

15B 

Page 1917

15B-212 


2. Install the piston assembly. 

(a). Install the connecting rod bolts to the connecting rod. 

(b). Install the upper bush of piston connecting rod bearing 

bush. 

△ Tip: 

In prior of assembly, the cylinder block and all of the parts shall 

be clean. The connecting rod and bearing bush shall be 

cleaned with a piece of clean and lint-free cloth. 

NOTE: 

Make sure that the back faces and side faces of the 

connecting rod and connecting rod bearing are clean, 

without any scrap. Do not lubricate the back face and side 

face of the connecting rod bearing. 

NOTE: 



grooves of the connecting rod. 

15B 

(c). 

Drip clean oil or equivalent oil to the inner side of the 

bearing bushes. 

Page 1918


15B-213 

(d). 

Use clean oil to lubricate the piston ring and the piston 

skirt. 

(e). As shown in the figure, rotate and adjust the positions 

of the piston ring openings. 

△ Tip: 

The opening of each piston ring can’t be aligned with the 

opening of the piston pin or other piston rings, otherwise the 

piston rings can’t achieve correct sealing effect. 

(f). Use piston ring compressor to compress the piston 

rings to the working position. 

△ Tip: 

One can make a piston ring with iron sheet without any special 

tool. 

(g). 

Rotate the crankshaft to position the journal of 

connecting rod to be installed at bottom dead center. 

15B 

(h). 

Side overturn the cylinder block and apply one film of 

clean oil onto the walls of the cylinder block 

Page 1919

15B-214 


(i). 

Insert the connecting rod into the cylinder bore, till the 

piston ring compressor comes into contact with the top 

of the cylinder block. 

△ Tip: 

• Align the arrow on the top of the piston with the front of the 

engine. 

• The longer end of the connecting rod and the notch on the 

piston skirt shall be at the exhaust side of the engine. If not, 

verify whether the piston is at the correct installation 

position on the connecting rod. 

NOTE: 

The failure to install as per above procedure will lead to 

serious damage of the engine. 

(j). Press the piston ring compressor to the cylinder block, 

insert the piston into the cylinder bore through the 

piston ring compressor, and align with the installation 

position of the connecting rod. 

NOTE: 

If the piston can’t move smoothly, remove the piston and 

check the piston rings for breakage or damage. 

15B 

(k). Install the lower bush of the connecting rod bearing 

bush onto the connecting rod bearing bush cap. 

NOTE: 


connecting rod cover and connecting rod bearing are 

clean, without any scrap. Do not lubricate the back face 

and side face of the connecting rod bearing. 

• If not replaced with new one, install the old bearing 

onto the original connecting rod cover from which it’s 

removed. 

Page 1920


15B-215 

NOTE: 



grooves of the connecting rod cover. 

(l). 

Use clean oil to lubricate the inner side of the lower 

bush of the connecting rod bearing bush. 

(m). Install each connecting rod cover to corresponding 

journal of the crankshaft. 

NOTE: 

The middle portion of the connecting rod and the head of the 

connecting rod cap are forged with markings. During assembly, 

face these markings towards the front of the engine (Pulley 

end). 

(n). Install the connecting rod nuts. 

△ Tip: 

Use torque wrench to fasten the nuts by two times as per 

angular fastening method. 

Specified Torque: 

(o). Check whether the piston assembly is installed 

correctly 

• Measure the gap between the connecting rod body 

and the crankshaft and the protrusion amount of the 

piston top respectively. 

△ Tip: 

Measure the gap between the connecting rod body and the crankshaft and the protrusion amount of the 

piston top respectively. 

NOTE: 

If the piston, crankshaft, connecting rod or cylinder block is ever changed/replaced, it’s necessary to 

measure the protrusion amount of the piston on the combustion face of the cylinder block. 

The procedure is as below: 

• Install micrometer on the cylinder head and reset to zero. 

• Move the micrometer right above the top of the piston, in order to eliminate all lateral movements. 

15B 

Page 1921

15B-216 


• Rotate the crankshaft to the top dead center and then rotate the crankshaft clockwise and 

counter-clockwise, find out the maximum reading of the micrometer, and record the measurement 

result. 

The volume of bulge on the top of piston 

3. Install the camshaft assembly 

(a). Install the tappet into a specified installation hole 

successively. 

(b). Apply an appropriate amount of lubricating grease or 

equivalent lubricant onto the inner walls of the 

installation bore of the rear camshaft. 

NOTE: 

When installing the camshaft, instead of being placed 

vertically, the engine body shall be placed at a certain 

angle in case of gliding downward of tappet. 

(c). Apply an appropriate amount of lubricating grease or 

equivalent lubricant onto the cam of the camshaft and 

the journal. 

△ Tip: 

Before the installation, make sure that all machined surfaces 

are clean without any scratch. 

15B 

(d). Rotate and install the camshaft to the specified 

position. 

NOTE: 

• Rotate the camshaft and carefully insert the camshaft 

into the camshaft sleeve. When each camshaft journal 

passes through the sleeve, slightly lower the camshaft 

to fix the camshaft cam into the sleeve. 

• Rotate the camshaft to separate the cam from the 

restraint of the sleeve, in order to install the camshaft 

smoothly. 

Page 1922


15B-217 

(e). 

Install the camshaft pressure plate to a specified 

position. 

(f). Install and fasten the fixing bolt of camshaft pressure 

plate. 

△ Tip: 

Rotate the camshaft to check whether the cam shaft can rotate 

freely 

NOTE: 

If the camshaft can’t rotate freely, do not rotate the 

camshaft with force, or it will damage the camshaft sleeve. 

Analyze the cause and reassemble the camshaft. 

15B 

Page 1923

15B-218 


INSTALLATION OF OIL SEAL AND OIL SEAL COVER 

1. Install the oil seal and the oil seal cover. 

(a) Install the oil seal and the oil seal cover together. 

(b). 

Apply oil onto the lips of the oil seal. 

(c). 

Install the oil seal and the oil seal cover to the specified 

positions. 

15B 

(d). Install and fasten the fixing bolts of the oil seal cover. 

△ Tip: 

Cross fasten the bolts from the middle to the sides or from the 

sides to the middle, instead of excessively fastening any bolt 

by one time. 

Page 1924


15B-219 

INSTALLATION OF CRANKSHAFT GEAR AND CAMSHAFT GEAR 

NOTE: 

When installing the gear, one shall strictly align the gear with the mark without any mistake in case of 

the non-start, power decrease, oil consumption increase and even the unnecessary loss which may 

cause the damage of distribution device parts. When the marks of gears are indistinct or wear, the 

gear mechanism shall be displaced as a set or be repaired in a maintenance station of Beijing Foton 

Environment Engine Co., Ltd when necessary. 

1. Install the crankshaft gear 

(a). Install the crankshaft gear to the specified position. 

NOTE: 

When installing the crankshaft gear, the woodruff key shall 

be installed to the specified position. Also, it shall be 

installed aligning with the installation mark to ensure the 

correctness of installation. 

(b). 

Install the oil baffle disk to a specified position. 

2. Install the camshaft gear 

(a). Install the camshaft gear to a specified position. 

NOTE: 

Before installing the camshaft gear, the woodruff key of 

camshaft shall be installed to the specified position. 

15B 

(b). 

Install and fasten the fixing bolt of camshaft gear. 

Page 1925

15B-220 


INSTALLATION OF INJECTION PUMP AND GEAR CHAMBER 

1. Install the injection pump 

(a). Install the injection pump to the specified position 

NOTE: 

The marks made when removing shall be aligned with 

when installing to ensure the installation correctness. 

(b). Install and fasten the fixing bolt of injection pump. 

△ Tip: 

One shall hold up the injection pump with a hand when 

installing in case of the damages or personal injuries caused 

by the falling of pump. 

(c). 

Install and fasten the fixing bolt connecting with 

injection pump and its bracket. 

15B 

(d). Install the injection pump gear to the specified position. 

△ Tip: 

The installation marks shall be aligned with when installing to 

ensure the installation correctness. 

Page 1926


15B-221 

(e). 

Install and fasten the fixing nut of injection pump gear. 

2. Install the gear chamber cover 

(a). Install the gear chamber gasket and gear chamber 

cover to the specified position. 

△ Tip: 

The gasket of gear chamber shall be replaced by a new one. 

(b). 

Install and fasten the fixing bolt of gear chamber. 

(c). 

Install the injection pump gear chamber cover to the 

specified position and Install and fasten the fixing bolt. 

15B 

Page 1927

15B-222 


INSTALLATION OF OIL PUMP AND OIL PAN 

1. Install the oil pump assembly. 

(a). Install the oil pump assembly to the specified position. 

(b). 

Install and fasten the fixing bolts of oil pump assembly. 

(c). Install the oil pump driving gear to the specified position 

and install the oil pump driving gear cover. 

△ Tip: 

Be sure the oil pump driving gear and the oil pump propeller 

shaft are all installed in place. 

15B 

(d). 

Install and fasten the fixing bolt of cover. 

Page 1928


15B-223 

2. Install the oil pan. 

(a). Install the oil pan to the specified position. 

△ Tip: 

• Before installation, the surface of contact position of oil pan 

and cylinder block are covered by sealant. 

• Before smearing the sealant, one shall be sure that the 

used sealant on the oil pan and engine block shall be 

cleaned up. 

(b). Install and fasten the fixing bolts of oil pan. 

△ Tip: 

• When installing the fastening bolt on oil pan, one shall 

lubricate each fastening bolt with oil. 

• Cross fasten the fixing bolts of oil pan from the middle to the 

sides or from the sides to the middle, instead of excessively 

fastening any bolt by one time. 

15B 

Page 1929

15B-224 


INSTALLATION OF FLYWHEEL ASSEMBLY AND CLUTCH 

COMPONENTS 

1. Install the flywheel assembly 

(a). Install the sealing strip of the rear oil seal cover to the 

specified position. 

(b). 

Install the support rear cover to the specified position. 

(c). 

Install and fasten the fixing bolts of the support rear 

cover. 

15B 

(d). Install the flywheel to the specified position. 

△ Tip: 

One shall be careful when installing for the weight of flywheel. 

Page 1930


15B-225 

(e). Install and fasten the fixing bolts of flywheel. 

△ Tip: 

While installing the flywheel bolts, apply oil to the threads and 

the contact face and then fasten in diagonal manner. 

3. Install the Clutch Components. 

(a). Install the clutch disc and the clutch cover assembly 

with installation positioning tool to the specified 

positions. 

(b). 

Install and fasten the fixing bolts of clutch. 

15B 

Page 1931

15B-226 


INSTALLATION OF OIL RADIATOR AND OIL FILTER 

1. Install the oil radiator 

(a). Install the oil radiator and its gasket to the specified 

position. 

△ Tip: 

The oil radiator gasket shall be replaced by a new one. 

(b). Install the O-ring to the specified position. 

△ Tip: 

O-ring shall be replaced by a new one. 

(c). 

Install and fasten the fixing bolt of oil radiator. 

15B 

(d). 

Install the connecting pipe weldment of oil radiator and 

oil filter and install the fixing nut. 

Page 1932


15B-227 

2. Install the oil filter 

(a). Install the oil filter to the specified position. 

△ Tip: 

Apply sealant onto the oil filter installation position of the 

cylinder block and replace with new gasket. 

(b). 

Install and fasten the fixing bolt f oil filter. 

(c). 

Install and fasten the fixing bolt connecting the 

weldment and oil filter. 

15B 

Page 1933

15B-228 


INSTALLATION OF HOOK, VALVE, AND WATER OUTLET PIPE 

CONNECTOR 

1. Install the hooks. 

(a) Install the front hook to the specified position. 

(b). 

(c). 

Install and fasten the fixing bolts of hook. 

Install the rear hook in place as per same method. 

2. Install the valves. 

(a). Knock in the valve guide from the top of the cylinder 

head with special tool. 

NOTE: 

Before the installation, apply oil to the outer surfaces of 

the valve guide. After the installation, check the height of 

the valve guide. 

15B 

(b). Lubricate all valve guide bores and the valve stems. 

△ Tip: 

Lubricate with oil, otherwise it will lead to early wear of valve 

guides 

Page 1934


15B-229 

(c). Install valve to the specified position. 

NOTE: 

• If the installed valve and disassembled valve are same, 

the valve shall be installed on the position at which the 

valve is disassembled. 

• If the cylinder head can’t be used immediately, lubricate 

the valve stems with assembly lubricant or equivalent. 

(d). Install the valve oil seal and install the valve spring 

lower seat, valve spring, and valve spring upper seat. 

△ Tip: 

The valve spring upper seat for intake valve is different from 

that for exhaust valve. 

NOTE: 

Replace with new valve oil seal. 

(e). Compress the valve spring with valve spring 

compressor to expose the installation location of valve 

lock clamp. 

(f). Install the valve lock clamp and then release the valve 

spring to enable the valve lock clamp to lock the valve. 

△ Tip: 

After the assembly, knock the valve spring seat with rubber 

hammer to ensure the correct installation of locking plate. 

NOTE: 

If the lock clamp is not installed correctly, the lock clamp 

will fly out while knocking the valve spring seat with 

plastic hammer. To minimize the possibility of the 

personal injuries, please wear the goggles. 

(g). 

Install all valves as per same method. 

15B 

Page 1935

15B-230 


3. Install the water outlet pipe connector. 

(a) Install the water outlet pipe connector assembly to 


(b). 

Install and fasten the fixing bolts of the water outlet pipe 

connector assembly. 

15B 

Page 1936


15B-231 

INSTALLATION OF CYLINDER HEAD 

1. Install the cylinder head 

(a). Install the cylinder head gasket and cylinder head to 


△ Tip: 

• For the heavy cylinder head, it shall be lifted with assistant 

and proper hoisting equipment to prevent severe personal 

injuries. 

(b). Install and fasten the fixing bolts of the cylinder head. 

△ Tip: 

Before the installation, lubricate the threads of the fixing bolts 

of cylinder head and the lower portion of the bolt head with 

clean oil. 

NOTE: 

During installation, the cylinder head bolt shall be 

disassembled in pairs for several times as the sequence 

from middle to two sides. 

(c). 

Install the rubber hose connecting the water pump and 

thermostat and install the fastening clamp. 

(d). 

Install the oil radiator and cylinder head connecting 

hose to the specified position. 

15B 

Page 1937

15B-232 


(e). 

Fasten the hose clamp and ensure the fastness of 

connection. 

15B 

Page 1938


15B-233 

INSTALLATION OF TAPPET AND ROCKSHAFT 

1. Install the tappet 

(a). Fill clean oil into the installation hole of each valve 

tappet. 

(b). Install the valve tappet to the specified position. 

△ Tip: 

Put the valve tappet into the installations hole as the reversed 

sequence of disassembly. 

2. Install the rockshaft 

(a). Install the rocker assembly to the specified position. 

(b). Install the fixing bolt and fixing nuts of rockshaft. 

△ Tip: 

Do not disassemble a certain bolt or nut at a time. One shall 

uniformly disassemble the fixing bolts or nuts of rockshaft for 

several times. 

15B 

Page 1939

15B-234 


INSTALLATION OF FUEL INJECTOR AND HIGH & LOW PRESSURE 

FUEL PIPE 

1. Install the fuel injector 

(a). Install the fuel injector and its pressure plate to the 


△ Tip: 

Ensure the fuel injector and its pressure plate is installed in 

place. 

(b). 

Install and fasten the fixing bolt of fuel injector pressure 

plate. 

(c). 

Install the low pressure rubber fuel pipe connecting to 

each fuel injector in order and fasten the clamp. 

15B 

(d). 

Connect the connection of low pressure rubber fuel 

pipe. 

Page 1940


15B-235 

2. Install the high & low pressure fuel pipe 

(a). Install the high pressure fuel pipe to the specified 

position. 

(b). 

Fasten the fixing bolt connecting the high pressure fuel 

pipe and high pressure oil pump. 

(c). 

Connect the connection of high pressure fuel pipe and 

fuel injector and ensure the fastness of connection. 

15B 

Page 1941

15B-236 


INSTALLATION OF DIPSTICK 

1. Install the dipstick. 

(a). Install the dipstick to the specified position. 

△ Tip: 

Ensure the dipstick is installed in place. 

(b). 

Install and fasten the fixing bolts of dipstick. 

15B 

Page 1942


15B-237 

INSTALLATION OF CRANKSHAFT PULLEY, FAN AND FAN PULLEY 

1. Install the crankshaft pulley 

(a). Install the crankshaft pulley to the specified position. 

(b). 

Install and fasten the fixing bolt of crankshaft pulley. 

2. Install the fan and its pulley 

(a). Install the fan and its pulley to the specified position. 

(b). Install and fasten the fixing bolt of fan assembly. 

△ Tip: 

When installing, the fan will rotate in the direction of force. In 

order to prevent this, the stud shall be clamped in a reverse 

direction with a screwdriver. 

15B 

Page 1943

15B-238 


INSTALLATION OF BREATHER AND GENERATOR 

1. Install the breather 

(a). Install the breather assembly to a specified position. 

(b). 

Install and fasten the fixing bolt of breather. 

(c). 

Connect the connection of lower oil pipe of breather 

and the breather and install the fastening clamp. 

15B 

2. Install the generator 

(a). Install the lower bracket of generator to the specified 

position and install the fixing bolt fastening the lower 

bracket of generator. 

Page 1944

ENGINE MECHANICAL PART- INSTALLATION OF BREATHER AND GENERATOR 

15B-239 

(b). 

Install the upper bracket of generator to the specified 

position and install the fixing bolt fastening the upper 

bracket of generator. 

(c). 

Install the generator assembly to the specified position. 

(d). Install the lower fixing bolt of generator. 

△ Tip: 

• In order to prevent the direction of bolt rotating with the force 

when installing, one shall firstly lock the bolt and then 

disassemble the nut of fixing bolt. 

• When installing the fixing bolt, one shall hold up the 

generator with a hand in case of generator damages or 

personal injuries caused by the falling off of generator due 

to the lack of bracing force. 

(e). Install the adjusting bolt of generator. 

△ Tip: 

The adjusting bolt shall be fastened after the fan belt is 


15B 

(f). Adjust the tension of belt and fasten the adjusting bolt 

of generator. 

△ Tip: 

Adjust the tension of fan belt through the generator adjusting 

bolt. 

Page 1945

15B-240 


(g). 

Install the hose clamp of vacuum pump oil return pipe 

and connect the connection of oil return pipe. 

(h). 

Connect the connection of vacuum pump oil inlet pipe 

and generator and fasten the fixing bolt. 

15B 

Page 1946


15B-241 

INSTALLATION OF INTAKE AND EXHAUST MANIFOLDS AND 

TURBOCHARGER 

1. Install the intake and exhaust manifolds and 

turbocharger 

(a). Install the turbocharger gasket and turbocharger onto 

the exhaust manifold pipe. 

(b). 


turbocharger and turbocharger bracket. 

(c). 

Install and fasten the fixing bolt of turbocharger air inlet 

port. 

(d). 

Install the intake manifold assembly. 

15B 

Page 1947

15B-242 


(e). Install the rubber hose connecting the turbocharger and 

intake manifold, Fasten the clamp and ensure the 

fastness of installation. 

△ Tip: 

Ensure the assembly of intake and exhaust manifolds and 

turbocharger is correct and secure. 

(f). Install the intake and exhaust manifolds gaskets to the 


△ Tip: 

The gaskets of intake and exhaust manifolds shall be replaced 

by new ones. 

(g). Install the intake and exhaust manifolds and 

turbocharger to the specified positions. 

△ Tip: 

In order to facilitate the installation of generator, the intake and 

exhaust manifolds and turbocharger shall be installed all 

together. 

(h). 

Connect the connection of turbocharger oil return 

rubber hose and cylinder block. 

15B 

(i). 

Install the turbocharger oil inlet pipe weldment to the 

specified position and install the fastening and fixing 

bolt. 

Page 1948


15B-243 

(j). 

Install EGR valve connecting pipe weldment to the 


(k). 


connecting pipe weldment and intake manifold. 

(l). 


connecting pipe weldment and the exhaust manifold. 

(m). 

Install and fasten the intake and exhaust manifolds bolt. 

15B 

Page 1949

15B-244 


INSTALLATION OF EGR CONTROLLER 

1. Install EGR controller 

(a). Install EGR controller onto the fixing bracket of air 

compressor and install the fastening and fixing bolt. 

(b). Install EGR controller equipped with air compressor 

bracket to the specified position and install the fixing 

bolt which can fasten the air compressor bracket. 

△ Tip: 

For the convenience of disassembly, the air compressor fixing 

bracket and EGR controller shall be taken down all together. 

(c). 

Connect the connection of generator and EGR 

controller vacuum pipeline. 

15B 

(d). 

Connect the connection of preheat controller and the 

controller oil inlet pipe. 

Page 1950


15B-245 

(e). 

Connect the connection of EGR valve vacuum pipeline. 

15B 

Page 1951

15B-246 


INSTALLATION OF CYLINDER HEAD COVER 

1. Install the cylinder head cover 

(a). Install the cylinder head cover to the specified position. 

(b). 

Install and fasten the fixing nut of cylinder head cover. 

15B 

Page 1952


15B-247 

INSTALLATION OF HEATER AND WATER OUTLET-INLET PIPE 

WELDMENT 

1. Install the weldment of heater and water outlet-inlet 

pipe 

(a). Install the weldment of heater and water outlet-inlet 

pipe to the specified position. 

(b). 

Install the rubber hose connecting the weldment of 

heater and water outlet-inlet pipe and the thermostat. 

(c). 

Install and fasten the fixing bolt of weldment of heater 

and water outlet-inlet pipe. 

15B 

Page 1953

15B-248 

ENGINE MECHANICAL PART-CYLINDER HEAD COVER 

CYLINDER HEAD COVER 


15B 

Page 1954

ENGINE MECHANICAL PART- CYLINDER HEAD COVER 

15B-249 

1 


assembly 


3 

4 

Anti-vibration cover plate assembly of 

valve chamber cover 

Anti-vibration pad of valve chamber 

cover 

5 Oil filler cap 

7 Gasket of valve chamber cover 

8 Gasket of valve chamber cover nut 

9 Fixing nut of valve chamber cover 

10 Crankshaft vent valve component 



6 Valve chamber cover assembly 

15B 

Page 1955

15B-250 


SERVICE 

NOTE: 

During the disassembly, the parts of valve assembly shall be concentrated together and marked with 

identification code to return to their own origin positions when reinstalling; one shall conduct a 

compression test and record its result before removing the cylinder head from generator and 

disintegrating the valve mechanism. 

1. Preliminarily check the engine. 

(a). Clean the outside of generator with steam or high 

pressure gun. 

NOTE: 

Hot steam may cause serious personal injuries. While 

using the steam cleaner, please wear the safety goggles or 

protective mask and wear the protective clothing 

(b). 

Run the engine at low idle speed and check for leakage 

of oil or coolant between cylinder head and engine 


15B 

(c). Listen whether there is “chirp” sound between the 

cylinder head and the engine cylinder block. 

△ Tip: 

Fill water into the coolant tank, till the overflow pipe within the 

coolant tank is immersed. Then, run the engine at high idling 

speed, till the thermostat turns on. In such case, observe the 

water solvent for the presence of steam bubbles, which will 

determine whether there is leakage in the combustion 

chamber. 

NOTE: 

Upon the detection of leakage, disassemble and check the 

cylinder head and all related parts. 

2. Remove the cylinder head cover assembly (Refer to Chapter 15B Engine Mechanical system – 

Disassembly of Engine 4JB1). 

Page 1956


15B-251 

3. Disassemble and service the cylinder head cover 

assembly. 

(a). Take down the oil filler cap 

△ Tip: 

As required, screw off the oil filler cap. 

(b). Dismantle the fixing bolt of anti-vibration cover plate 

assembly of valve chamber cover. 

△ Tip: 


loss. 

(c). 

Disassemble the anti-vibration cover plate assembly of 

valve chamber cover 

(d). 

Check the anti-vibration cover plate assembly of valve 

chamber cover to see whether it is damaged. If it is, 

please replace the damaged one. 

15B 

(e). 

Disassemble the anti-vibration pad of valve chamber 

cover. 

Page 1957

15B-252 


(f). 

Check the anti-vibration pad of valve chamber cover to 

see whether it is aging, corroded or deformed. If any of 

those phenomena occurs, it shall be replaced by a new 

one. 

(g). 

Disassemble the fixing bolt of crankcase vent valve 

component with cross screwdriver and take down the 

crankcase vent valve component 

(h). Check the oil filler cap for the presence of cracking and 

corrosion. If yes, replace with new one. 

△ Tip: 

Observe for the presence of water vapor within the oil filler cap. 

If yes, it indicates the ingress of coolant into the cylinder block. 

In such case, carefully check the cylinder gasket, cylinder head, 

and waterway for damage. If yes, maintain or replace the 

damaged parts. 

15B 

(i). Clean the cylinder head cover with solvent, acid or 

alkaline material. 

NOTE: 



material for cleaning. 

• Please wear the goggles and protective clothing to 

prevent causing personal injuries. 



Page 1958


15B-253 

(j). Blow dry the cylinder head cover with compressed air. 

NOTE: 

While using the compressed air, please ware appropriate 

goggles and protective mask to prevent the scraps and 

dirt splashed from causing personal injuries. 

(k). 

Check the cylinder head cover for presence of damage. 

If yes, replace with new one. 

(l). 

Check the gasket of cylinder head cover for aging, 

corrosion or deformation. If yes, replace with new one. 

4. Install the cylinder head cover assembly. 

(a). Install the crankcase vent valve component to the 

specified position and install the fixing bolt of crankcase 

vent valve component. 

15B 

(b). 

Install the anti-vibration pad of valve chamber cover. 

Page 1959

15B-254 


(c). 

Install the anti-vibration cover plate assembly of valve 

chamber cover. 

(d). 

Install and fasten the fixing bolt of valve chamber cover 

anti-vibration cover plate assembly. 

(e). 

Install the oil filler cap 

5. Install the cylinder head cover assembly (Refer to Chapter 15B Engine Mechanical system – 

Assembly of Engine 4JB1) 

15B 

Page 1960

ENGINE MECHANICAL PART-ROCKER ASSEMBLY 

15B-255 

ROCKER ASSEMBLY 


1 Rockshaft plug 

2 Retainer ring 

3 Rocker assembly 

4 Valve adjusting bolt 

5 Valve adjusting nut 

6 Rockshaft seat 

7 Small washer 

8 Hexagon head stud 

9 Rocker spring washer 

10 Rockshaft spring 

11 Rockshaft 

12 Rockshaft bearing bolt 

13 Long hexagon stud 

15B 

Page 1961

15B-256 


SERVICE 

NOTE: 

If any excessively worn or damaged part is detected during the service, perform the necessary 

adjustment, repair and replacement. 

1. Remove the rockshaft assembly (Refer to Chapter 15B Engine Mechanical system – 

Disassembly of Engine 4JB1). 

2. Clean and Test for the electric heater plug 

(a). Clean the electric heater plug by washing. 

(b). 

Test the electric heater plug as shown in left diagram. 

• When the electric heater plug connecting with 

battery, if A end emits heat, it means that the 

electric heater plug is working well. 

• When the electric heater plug connecting with 

battery, if A end doesn’t emit heat, it means that 

the electric heater plug is damaged. 

3. Disassemble the rockshaft assembly (see Chapter 15B Engine Mechanical System – 

Disassembly of Engine 4JB1) 

15B 

4. Disassemble the rockshaft assembly. 

(a). Disassemble the rockshaft plug and take down the 

circlip at the rocker assembly end with circlip pliers. 

Page 1962


15B-257 

(b). Take down the rocker processing assembly and rocker 

bracket. 

△ Tip: 

When taking out the rocker processing assembly, the revolving 

method is a relatively easy way. 

(c). 

Take out the rockshaft. 

(d). 

Disassemble the adjusting nut of valve and disintegrate 

the rocker assembly assembly. 

(e). Disassemble the shaft seat and rocker assembly. 

△ Tip: 

• The position of each disassembled one shall be marked. 

• During the installing, it shall be installed at the origin 

position and in the origin direction when removing. 

15B 

3. Check the rocker assembly. 

(a). Clean all parts with high concentration detergent and 

hot water solvent. 

Page 1963

15B-258 


(b). 

Clean off the deposits on rocker seat and rocker 

assembly with steel brush and mild steel wire rotary 

brush. 

(c). Blow dry all parts with compressed air. 

NOTE: 




(d). 

Check the adjusting bolt and fixing nut of valve 

clearance to see whether there are cracks or 

deformation of threads. If there is one of phenomena 

mentioned above, it shall be replaced. 

15B 

(e). 

Check whether the adjustable threads of valve 

clearance is deformed or the wear condition of bolt with 

fillister head. If there is one of phenomena mentioned 

above, it shall be replaced. 

(f). 

Check the rocker bore for the presence of cracking or 

excessive wear. If yes, replace with new one. 

Page 1964


15B-259 

(g). 

Check whether the oil holes on the rocker are blocked. 

If yes, clean the oil holes on the rockshaft with 

compressed air. 

(h). Measure the inside diameter of the rocker with vernier 

caliper or micrometer. 

The parameters are shown in the table below: 

Engine Model 

Specified Value mm 

4JB1 19.010~19.030 

4D20 19.010~19.030 

(i). Measure the external diameter with dial indicator at the 

position of rocker swing on the rockshaft. 


Engine Model 

Specified Value: mm 

4JB1 18.980~19.000 

4D20 19.979~20.000 

(j). Place the rockshaft onto the V-blocks and measure the 

radial run-out in the middle of the rockshaft with 

micrometer. 

Note: 

If the radial run-out is minor, the bench press may be used 

to correct the radial run-out of the rockshaft. If the run-out 

is out of the specified range, replace the rockshaft. 

15B 

Page 1965

15B-260 


4. Install the rockshaft assembly. 

(a). Lubricate the rockshaft with clean oil. 

(b). 

Lubricate the rocker and the inner bore of rocker seat 

with clean oil. 

(c). 

Install the rocker assembly, valve adjusting bolt and 

adjusting nut together. 

15B 

(d). Install the rocker, rocker spring, rockshaft bracket into 

the rockshaft in the reversed sequence of disassembly. 

△ Tip: 

The rocker, rockshaft bracket hole and rockshaft surface shall 

be covered with clean oil. 

(e). Install the rocker retainer ring and rockshaft plug with 

circlip pliers. 

NOTE: 

As an elastic part, the retainer ring is likely to rush out. For 

this reason, it is recommended to wear goggles and 

handle this part carefully. 

Page 1966


15B-261 

5. Install the rocker assembly (Refer to Chapter 15B Engine Mechanical system – Assembly of 

Engine 4JB1). 

15B 

Page 1967

15B-262 

ENGINE MECHANICAL PART-CYLINDER HEAD 

CYLINDER HEAD 


15B 

Page 1968


15B-263 

1 Hexagon head bolt assembly 

2 


assembly 

3 A/C bracket 

4 Bowl-Bowl-shaped tabular plug 12 


6 Stud 

7 

Pressure plate cushion block of fuel 

injector 

8 Pressure plate of fuel injector 

9 

Pressure plate bolt gasket of fuel 

injector 

10 Pressure plate bolt 

11 Valve key 

12 Valve spring upper seat 

13 Valve spring 

14 Valve guide pipe oil seal 

15 Valve spring lower seat 

16 Intake and exhaust valve guide pipes 


18 Cylinder Head 

19 Cylinder head bolt 


21 Electric heater plug 

22 Preheat plug pad 

23 Rear hook of generator 

24 


assembly 


26 Plain washer 

27 Stud 

28 Exhaust valve seat 

29 Exhaust valve 

30 Exhaust valve 

31 Intake valve seat 


33 Cylinder head bolt 

15B 

Page 1969

15B-264 


SERVICE 

1. Remove the tappet (Refer to Chapter 15B Engine Mechanical system – Disassembly of Engine 

4JB1) 

2. Remove the cylinder head assembly (Refer to Chapter 15B Engine Mechanical system – 


3. Check the bolts of cylinder head. 

(a). Clean the bolts with diesel engine solvent. 

△ Tip: 

Thoroughly remove the sediment from the bolt stems and the 

threads with wire brush, soft wire wheel brush, or non-abrasive 

sand blasting. 

NOTE: 








• Do not clean the bolts with alkaline or acid solvent, or it 

will lead to damage of bolts. 

(b). Visually observe the bolts of the cylinder head for 

corrosion and observe the threads for damage. If yes, 

replace with new ones. 

15B 

4. Disassemble the thermostat assembly (see Chapter 15B Engine Mechanical System – 


5. Remove the valves (see Chapter 15B Engine Mechanical System – Disassembly of Engine 

4JB1) 

6. Preliminarily clean the cylinder head. 

(a). Clean the sealing surfaces of the cylinder head and the 

intake pipe. 

Page 1970


15B-265 

(b). 

Clean the combustion surfaces of the cylinder block 

and cylinder head. 

7. Deep cleaning and maintenance for the cylinder 

head 

(a). Clean up the carbon deposits on the fuel injector seat 

with fuel injector pore brush or equivalent tools. 

(b). 

Clean the valve retainer with brush. 

(c). Clean the foreign materials with compressed air 

NOTE: 




15B 

(d). Immerse the cylinder head into the acid solvent tank to 

remove the sediments. 

△ Tip: 

Firstly remove the expansion plug. If necessary, clean the 

sediment from the coolant way. 

Page 1971

15B-266 


(e). After the cleaning, clean the cylinder head combustion 

surface with hand grinding pad or equivalent cleaning 

pad and solvent. 

NOTE: 







manual of the manufacturer before use 

(f). Clean the valve seat and valve guide 

NOTE: 

• While cleaning the carbon deposit, wear the goggles to 

prevent personal injuries. 

• The rotation of wire wheel will damage the valve seat. 

Therefore, it’s necessary to machine the new valve seat 

or install new valve retainer. 

• Poor quality wire wheel will drop wires during the 

working, which will lead to additional contamination. 

Use quality wire wheel installed onto the drill or the 

mould polishing machine to remove the carbon deposit 

from the valve guide. 

(g). Remove the sediment from the installation hole of the 

valve retainer with wire brush and solvent (The valve 

seat is already removed) 

15B 

(h). Blow dry the surfaces of cylinder head with 

compressed air. 

NOTE: 




Page 1972


15B-267 

(i). 

Clean the cylinder head with hot soapy solvent and 

then flush the cylinder head with clean water. 

(j). Blow dry the cylinder head with compressed air. 

NOTE: 




8. After the cleaning, recheck the cylinder head. 

(a). Check the cylinder head for the presence of cracking, 

corrosion and discoloration. If any cracking, corrosion, 

or discoloration detected will influence the further 

service, replace with new cylinder head. 

NOTE: 

Pay close attention to the following areas of the cylinder 

head: 

Combustion surfaces, valve seat, and valve guide. 

△ Tip: 

• The cylinder head can be further used if the cracking 

detected does not extend to the valve seat. 

• If the cracking extends to the valve seat or passes through 

the valve seat, replace the cylinder head, otherwise such 

cracking will lead to fall-off of the valve retainer and further 

lead to damage of engine. 

NOTE: 

If the cylinder head is not replaced, the cracks extending 

to or passing by the valve seat pore may lead to the falling 

off of the valve retainer and further lead to the damage of 

generator. 

15B 

Page 1973

15B-268 


(b). 

Check the valve seat for presence of cracking and 

ablation points. If yes, depending on the working 

surface and the lower limit of the valve retainer, replace 

the valve retainer. 

(c). 

Check the threaded holes on the rockshaft bracket and 

the cylinder head to see whether the threads are 

damaged or deformed; if they are, the chambering or 

repair will be conducted if possible and be replaced 

when necessary. 

(d). Measure the length of diagonal line of the cylinder head 

lower surface to decide whether the housing cap is 

deformed. 

NOTE: 

If the 2 diagonal lines are not equal, it means the cylinder 

head is deformed and required to be replaced. 

15B 

(e). Clean the oil passage and water passage on the top of 

the cylinder head with water gun. 

NOTE: 

Carefully clean the oil passage holes and water passage 

holes in turn 

9. Install the valve assembly (Refer to Chapter 15B Engine Mechanical System– Assembly of 

Engine 4JB1). 

10. Install the thermostat assembly (Refer to Chapter 15B Engine Mechanical System– Assembly 

of Engine 4JB1). 

11. Install the cylinder head assembly (Refer to Chapter 15B Engine Mechanical System– 

Assembly of Engine 4JB1). 

12. Install the tappet (Refer to Chapter 15B Engine Mechanical System– Assembly of Engine 

4JB1). 

Page 1974

ENGINE MECHANICAL PART- VALVE 

15B-269 

VALVE 

OVERVIEW 

1. The valve distribution mechanism is of direct influence over the normal functioning of the engine. The 

valve distribution mechanism shall guarantee that the clean air can timely enter into the cylinder with 

maximum inflation amount during the intake stroke and the exhaust gas in the cylinder can be timely 

drained from the cylinder and the residual exhaust gas can be minimized as far as possible during the 

exhaust stroke. Meanwhile, the valves shall be tightly closed during the compression and power 

strokes. 

2. Within the valve distribution mechanism, some parts are subject to the impact of high temperature gas 

and the impact load and some parts are poorly lubricated. Under long-term service, these parts get 

worn, ablated, or deformed so that the technical performance and fit relationship are impaired to 

cause malfunction and failure of parts. 

15B 

Page 1975

15B-270 


ADJUSTMENT 

△ Tip: 

The valve clearance plays an important role in the technical state of diesel engine, so the valve clearance 

shall be checked in accordance to the maintenance regulate or actual operation condition. The cold state 

clearance of intake valve shall be about 0.40±0.050mm, while the cold state clearance of exhaust valve shall 

be about 0.40±0.050mm. The adjustment methods are as follows: 

1. Rotate the crankshaft till the pulley scale marks of crankshaft vibration damper shall aligning 

with timing indicator. Currently, the 1st cylinder piston or the 4th cylinder piston locates at the 

dead center of compression travel. 

NOTE: 

The engine is in cold state. 

15B 

2. Judge whether is the piston of the 1st cylinder or 

the piston of the 4th cylinder locating at the dead 

center of compression travel. 

△ Tip: 

Shake the exhaust valve rocker of the 1st cylinder or the 4th 

cylinder, if there is clearance when shaking the 1st cylinder 

valve rocker, it means that the 1st cylinder is locating on the 

dead center of compression travel; if the rocker of the 1st 

cylinder valve cannot shake, then one shall shake the rocker of 

4th cylinder valve; if there is clearance on the rocker of 4th 

cylinder, it means the 4th cylinder is locating at the dead center 

of compression travel. 

3. Adjust the valve clearance 

(a). When the 1st cylinder is at the dead center of 

compression travel, the valve clearance shall be 

checked with feeler gauge. 


Engine Value for Clearance of Value for Clearance of 

Model Intake Valve mm Exhaust Valve mm 

4JB1 0.4 0.4 

4D20 0.35 0.35 

Page 1976


15B-271 

(b). When the clearance of valve is too small, one shall 

anticlockwise rotate the adjusting bolt of valve 

clearance till the feeler gauge can be inserted into it 

and meet a little resistance. 

NOTE: 

When adjusting the valve clearance and revolving the 

adjusting bolt of valve clearance, it is recommended to 

conduct the adjustment with a screwdriver and a wrench. 

(c). 

When the valve clearance is too large, one shall 

clockwise rotate the adjusting bolt of valve clearance till 

the feeler gauge can be inserted into it and meet a little 

resistance. 

(d). 

(e). 

When the 1st cylinder is at the dead center of 

compression travel, the adjustment sequence is as 

shown on the left diagram: 1, 2, 3 and 6 valve 

clearances. 

Rotate the crankshaft 360°, align the crankshaft 

anti-vibration pulley mark with the timing indicator and 

adjust the other clearances of valve. 

(f). 

When the 4th cylinder is at the top dead center in 

compression travel the valve clearance shall be 

checked by feeler gauge. 

15B 

(g). 

When the clearance of valve is too small, one shall 

anticlockwise rotate the adjusting bolt of valve 

clearance till the feeler gauge can be inserted into it 

and meet a little resistance. 

Page 1977

15B-272 


(h). 

When the clearance of valve is too large, one shall 

clockwise rotate the adjusting bolt of valve clearance till 

the feeler gauge can be inserted into it and meet a little 

resistance. 

(i). 

△ Tip: 

When the 4th cylinder is at the dead center of 

compression travel, the adjustment sequence is as 

shown on the left diagram: 4, 5, 7 and 8 valve 

clearance. 

After the valve clearance has been adjusted for two times, one 

shall recheck the adjusting bolt and locking nut of valve to see 

whether they are fastened properly and recheck the valve 

clearance with feeler gauge when necessary to ensure the 

valve clearance has already reached the specified standard. 

15B 

Page 1978


15B-273 

SERVICE 

1. Disassemble the valve (see Chapter 15B Engine Mechanical System - Disassembly of Engine 

4JB1) 

2. Service the valve parts. 

(a). Check the valve lock clamp for the presence of 

cracking and damage. If yes, replace with new one. 

(b). Measure the perpendicularity of valve spring with steel 

square. 


Engine Model 


4JB1 ≤1.7 

4D20 ≤1.7 

NOTE: 

If the measurement is out of the specified range, replace the 

valve spring. 

(c). Compress the spring to the installation height with 

spring tester and measure the tension of the 

compression spring 


15B 

Engine Model 

Spring Height When 

Assembly is 

Completed mm 

Spring Tension When 

Assembly is 

Completed N 

4JB1 38.9 272~320 

4D20 39 279~314 

Page 1979

15B-274 


Note: 

If the tension measurement is below the specified limit, 

replace the valve spring. 

(d). Measure the free height of valve spring with vernier 

caliper. 


Engine Model 


4JB1 48 

4D20 50 

NOTE: 

If the measurement is out of the specified range, replace 

the valve spring. 

(e). Polish the valve stems with grinding pad and solvent. 

(f). 

Visually observe the tip of the valve stems for presence 

of excessive wear. If yes, replace the valve. 

15B 

(g). 

If the cylinder head and valve seat are excessively 

worn, replace with new ones. 

Page 1980


15B-275 

(h). Measure the valve thickness with steel square. If the 

measurement is below the specified limit, replace the 

valve and valve guide in pair. 


Engine Model 

Specified value: mm 

4JB1 2.25±0.075 

4D20 2±0.075 

(i). Measure the contact conical angle of the valve seat. If 

the measurement is out of the specified range, replace 

the valve, valve guide, and valve seat in group. 


Engine Model 

Specified value: mm 

4JB1 Inlet valve 30°, Exhaust valve 45° 

4D20 Inlet valve 30°, Exhaust valve 45° 

(j). Measure the outside diameter of valve stems with 

micrometer. 


Engine 

Model 

Specified Value for 

Intake Valve 


Exhaust Valve 

4JB1 7.946~7.961 7.921~7.936 

15B 

4D20 7.945~7.960 7.945~7.960 

△ Tip: 

Measure and record the result. 

Page 1981

15B-276 


(k). Measure the radial run-out of each valve cone with dial 

gauge and V-block. 


Engine 

Model 


Intake Valve 


Exhaust Valve 

4JB1 0.02 0.02 

4D20 0.02 0.02 

15B 

△ Tip: 

This measurement is intended to guarantee the air-tightness 

between valve and valve seat. 

(l). Polish the valve seat 

△ Tip: 

Polish the valve seat by two steps. Firstly apply coarse 

polishing paste onto the valve surfaces and then apply fine 

polishing paste. Polish the surfaces with regular polishing 

method after each application of polishing paste. 

NOTE: 

After the polishing, wipe away the polishing paste from the 

surfaces of the valve and valve seat and use red lead to 

perform the contact inspection. Make sure to check that 

the contact color belt is within the width of the valve seat, 

without any gap. If necessary, install the cylinder head and 

the valve parts and adjust the valve gap. 

(m). Measure the drop amount of the valve from the bottom 

face of the cylinder head with depth gauge or ruler. If 

the measurement is out of the specified range, make 

sure to replace the valve seat. 


Engine Model 


4JB1 0.50~0.80 

4D20 0.55~0.85 

Page 1982


15B-277 

(n). Check the roughness and unevenness of the valve 

contact surface. If the measurement is out of the 

specified range, make sure to replace the valve seat. 


Engine Model 


4JB1 3.2 

4D20 3.2 


3. Service the valve guide. 

(a). Measure the outside diameter of the valve stem and 

the inside diameter of valve guide with micrometer. 

△ Tip: 

The valve and the valve guide shall be replaced in pair. While 

measuring the outside diameter of the valve stems, measure 

the inside diameter of valve guide with micrometer and 

subtract the measured inside diameter of the valve guide by 

the measured outside diameter of the valve stem. If the above 

difference is out of the specified limit, replace the valve and 

valve guide in pair. 

Engine Model 4JB1 4D20 

Gap between intake valve and valve guide mm 0.039 ~ 0.071 0.015~0.045 

Gap between exhaust valve and valve guide mm 0.064~0.096 0.015~0.045 

15B 

Page 1983

15B-278 


(b). 

If the valve guide needs to be replaced, knock out the 

valve guide from the bottom of the cylinder head with 

special tool. 

4. Install the valve guide. (see Chapter 15B Engine Mechanical System – Assembly of Engine 

4JB1) 

5. Service the valve seat. 

(a). Check the valve seat for presence of wear. If yes, 

remove and replace the valve seat. Removal method of 

valve seat: Perform the arc welding at the inner side of 

the valve seat, cool down the valve seat, and pry out 

the valve seat with screwdriver. 

NOTE: 

During disassembly, caution shall be taken to prevent 

damaging the cylinder head. 

6. Install the valve seat. 

(a). Install the valve seat. 

△ Tip: 

During the installation, apply force onto the accessory 

gradually with bench press to press the valve seat in place. 

NOTE: 

Do not apply excessive force with bench press, otherwise 

it will lead to damage of valve seat. 

15B 

(b). Remove the carbon deposit from the surfaces of the 

valve seat and machine with valve milling tool to 

minimize the area of scratch and other rough surfaces, 

which can restore the contact width to standard value. 

NOTE: 

Only machine away the scratch and rough portions and do 

not machine away too much. 

Page 1984


15B-279 

(c). Measure the drop amount of the valve from the 

bottom face of the cylinder head with depth gauge or 

ruler. If the measurement is out of the specified range 


Engine Model 


4JB1 0.50~0.80 

4D20 0.55~0.85 

7. Grind the valve seat. 

(a). Brush a small amount of oil or Prussian blue onto the 

surfaces of the valve seat 

△ Tip: 

Use new or repaired valve to check whether the fit between the 

valve and the valve seat is perfect. 

(b). 

Install the valve 

(c). 

Rotate leftward and rightward by 1/4 turn for several 

times. 

15B 

Page 1985

15B-280 


(d). 

Remove the valve. 

(e). Observe the contact face with the valve seat. 

△ Tip: 

The valve seat shall be uniformly covered with oil or Prussian 

blue, which shall form a complete color belt. 

(f). 

If the contact color belt fails to meet the requirement 

and is situated on the upper portion of the valve cone, 

repair the valve seat with 30ºand 45ºmilling tool. 

15B 

(g). 

If the contact color belt fails to meet the requirement 

and is situated on the lower portion of the valve cone, 

repair the valve seat with 60ºand 45ºmilling tool. 

(h). 

Apply polishing paste onto the surfaces of valve seat. 

Page 1986


15B-281 

(i). 

(j). 

Polish the valve, till the valve and valve seat achieves 

perfect fit. 

After the polishing, thoroughly clean the valve, valve 

seat, and valve guide. 

8. Install the valve (see Chapter 15B Engine Mechanical System – Assembly of Engine 4JB1) 

15B 

Page 1987

15B-282 

ENGINE MECHANICAL PART-CAMSHAFT AND TAPPET 

CAMSHAFT AND TAPPET 


15B 

1 Camshaft gear bolt 

2 Upper idler shaft pressure plate 

3 Timing pulley assembly of camshaft 

4 


assembly 

5 Camshaft front oil seal component 

6 Camshaft flat key 

7 Camshaft 

8 Tappet 

9 Tappet weldment 

Page 1988


15B-283 

SERVICE 

1. Service the tappet 

(a). Take out the tappets in order 

NOTE: 

Carefully clean off all the oil, soot and carbon deposit on 

the cylinder head bolt and cylinder head. The electronic 

metallic brush cannot be applied to the gasket. 

(b). 

Wash and clean the tappet with hot soap-suds. 

(c). Blow dry the tappets with compressed air. 

NOTE: 




(d). 

Check the two ends of tappet to see whether they are 

worn, pulled or damaged with other causes. 

15B 

Page 1989

15B-284 


(e). 

Visually check the tappet to see whether it is crooked. If 

it is obviously crooked, it shall be replaced directly. 

(f). If it is not obviously crooked or likely crooked, one shall 

check its straightness by rolling it on a horizontal 

surface. 

△ Tip: 

If the tappet is crooked, replace it. 

2. Remove the camshaft (Refer to Chapter 15 Engine Mechanical Part – Disassembly of Engine 

4JB1) 

3. Service the camshaft. 

(a). Clean the parts with solvent. 

NOTE: 






15B 

(b). 

Remove the sediment from the camshaft with wire 

brush and soft wire wheel brush. 

Page 1990


15B-285 

(c). Clean the camshaft by blowing it with compressed air. 

NOTE: 




(d). 

Check the bore of camshaft for the presence of 

cracking and blockage and check the inner side of the 

camshaft for the deposit of oil or oil sludge. If yes, clean 

and when necessary replace with new one. 

(e). Place the camshaft onto the V-blocks and measure the 

radial run-out of camshaft with micrometer. If the radial 

run-out is out of the specified range, replace the 

camshaft. 


Engine Model 


4JB1 0.02 

4D20 0.025 

15B 

Page 1991

15B-286 


(f). Measure the outside diameter of each camshaft journal 

with screw micrometer in two directions perpendicular 

with each other respectively. If any measurement is 

below the specified limit, replace the camshaft. 


Engine Model 

Standard Value: mm 

4JB1 49.945~49.975 

4D20 43.897~43.910 

(g). Measure the height of each cam with micrometer. If the 

measurement is below the specified limit, replace the 

camshaft. 


Engine Model 


4JB1 26.2635 

4D20 21.8±0.03 

(h). 

Visually check the surfaces of the camshaft for the 

presence of corrosive pitting, cracking or other 

abnormalities. If yes, replace the camshaft. 

15B 

Page 1992


15B-287 

4. Service on the camshaft gear 

(a). Clean the camshaft gear with solvent 

NOTE: 






(b). 

Clean off the deposits on camshaft gear with steel 

brush and mild steel wire rotary brush. 

(c). Clean the camshaft gear by blowing it with compressed 

air. 

NOTE: 




(d). 

Check the bolt hole on the camshaft gear to see 

whether there are cracks or corrosion. If there are, 

repair it or replace it when necessary. 

15B 

(e). 

Check the gear teeth of camshaft to see whether there 

is corrosion or cracks. If there is, repair it or replace it 

when necessary. 

Page 1993

15B-288 


(f). Use the grinding pad to remove the corrosion, burr and 

bulge metal from the camshaft 

△ Tip: 

If the corrosion, burr and bulge metal can’t be removed by the 

grinding pad, replace the camshaft 

5. Service on the front oil seal seat part of camshaft 

(a). Clean the front oil seal seat part of camshaft with 

solvent. 

NOTE: 






(b). 

Clean off the deposits on the front oil seal seat part of 

camshaft with steel brush and mild steel wire rotary 

brush. 

(c). 

Clean the front oil seal seat part of camshaft by blowing 

it with compressed air. 

15B 

(d). 

Check the front oil seal seat part of camshaft and the 

bolt hole to see whether there is corrosion or cracks. If 

there is, repair it or replace it when necessary. 

Page 1994


15B-289 

(e). Use the grinding pad to remove the corrosion, burr and 

bulge metal from the camshaft timing sprocket 

△ Tip: 

If the corrosion, burr and bulge metal can’t be removed by the 

grinding pad, replace the gear. 

6. Remove and service the tappets 

(a). Draw out the tappets from their installation positions 

successively with high performance magnet. 

△ Tip: 

The tappets taken out shall be put in a clean vessel. 

(b). Clean the tappet with solvent. 

NOTE: 






(c). Blow dry the tappet with compressed air. 

NOTE: 




15B 

(d). Check the tappet seat, lever handle and tappet surface 

for presence of wear and cracks. If yes, repair or 

replace when necessary. 

△ Tip: 

• Normal contact (increasing) 

• Do not continue to use in irregular contact. 

Page 1995

15B-290 


(e). Check the surface of tappet for cavitation. 

△ Tip: 

The following standards define the allowable range of the 

cavitation on the surface of tappet. 

• Single cavitation point shall not beyond 2mm. 

• The cavitations are not allowed to gather to one piece. 

• The total diameter of accumulated cavitations shall not 

beyond 6mm or 4% of the area of tappet gauge. 

• The cavitations of tappet are not lowed to exist above or 

under the wear surface. 

(f). Measure the outside diameter of the tappets with screw 

micrometer 

△ Tip: 

Measure the inner diameter of tappet hole with micrometer 

calipers and subtract the inner diameter value of tappet hole 

from the outer diameter value of tappet. If the D-value is more 

than the specified limiting value, it means the tappet shall be 

replaced. 



Specified outside diameter of tappet mm 12.927~12.990 12.666~12.684 

Specified inside diameter of tappet mm 13.000~13.018 12.7~12.718 

Specified limit mm 0.010~0.041 0.016~0.052 

7. Install the tappets 

(a). Cover the tappet and tappet hole with oil or equivalent. 

15B 

Page 1996


15B-291 

(b). 

Install 8 tappets into the installation holes one by one. 

8. Install the camshaft assembly (see Chapter 15B Engine Mechanical System – Assembly of 

Engine 4JB1) 

15B 

Page 1997

15B-292 

ENGINE MECHANICAL PART-PISTON AND CONNECTING ROD ASSEMBLY 

PISTON AND CONNECTING ROD ASSEMBLY 


15B 

1 Top compression ring 

2 Second compression ring 

3 Coil spring oil ring 

4 Piston 

5 Piston pin 

6 Snap ring of piston 

7 Connecting rod body 

8 Connecting rod bearing bushing 

9 Connecting rod bolt 

10 Connecting rod bearing bush 

11 Connecting rod cap 

12 Connecting rod nut 

Page 1998


15B-293 

SERVICE 

1. Remove the piston assembly (Refer to Chapter 15 Engine Mechanical Part – Disassembly of 

Engine 4JB1) 

2. Disassemble the piston assembly. 

(a). Remove three piston rings with the special piston ring 

remover. 

(b). 

Disassemble the retainer rings on both sides of piston 

(2 retainer rings). 

(c). 

Punch out the piston pin with punch bar. 

3. Service the connecting rod bearing bush 

(a). Check the connecting rod bearing bush for presence of 

sink erosion, peeling-off, corrosion, damage of locking 

piece, and scratch. If yes, replace with new one. 

15B 

Page 1999

15B-294 


4. Service the connecting rod 

(a). Measure the inside diameter of the smaller end bore of 

the connecting rod and measure the outside diameter 

of the piston pin. 



Outside diameter of piston pin mm 30.995~31.000 27.994~28.000 

Inside diameter of connecting rod bore mm 34.000~34.025 30.987~31.000 

Inner diameter of connecting rod bushing mm 31.008~31.015 28.025~28.038 

Specified gap mm 0.008~0.020 0.025~0.045 

△ Tip: 

If the gap between the smaller end bore of the connecting rod and the piston pin is out of the specified range, 

replace the bush and the piston pin and when necessary replace the connecting rod. 

(b). Remove the bush with bar and hammer. 

NOTE: 

• The hammer can be used during the installation. The oil 

hole of the bush shall be aligned with that of the 

connecting rod. 

• After the new bush is installed, grind the bush bore with 

pin bore grinding machine. 

15B 

(c). Clean the connecting rod with solvent. 

NOTE: 




• Please wear the goggles and protective clothing to prevent 

causing personal injuries. 

Page 2000


15B-295 

(d). Clean the contact surface between the connecting rod 

and the connecting rod cap with nylon hairbrush. 

NOTE: 

The contact surface between the connecting rod and the 

connecting rod cap is not a machined surface. Cautions 

shall be taken during the handling, in order to prevent 

damaging the parts. 

(e). Thoroughly clean the connecting rod with compressed 

air. 

NOTE: 

• The pressure of the compressed air used for cleaning 

shall not exceed 207KPa. 



(f). Check the connecting rod cap for the presence of wear, 

cracking, burr, scratch, or wear. If yes, replace with new 

one. 

NOTE: 

In event of obvious wear at any portion of the connecting 

rod or the connecting rod cap, replace one part as a whole 

assembly. 

(g). Check the connecting rod for the presence of wear, 

cracking, burr, scratch, or wear. If yes, replace with new 

one. 

NOTE: 

In event of obvious wear at any portion of the connecting 

rod or the connecting rod cap, replace one part as a whole 

assembly. 

15B 

(h). Check the contact surface between the connecting rod 

and the connecting rod cap 

NOTE: 

The contact surface between the connecting rod and the 

connecting rod cap is not a machined surface. Unless 

there is really deep wear or cracking on the surface, the 

contact surface can be further used, instead of being 

considered as damaged. 

Page 2001

15B-296 


(i). Check the piston pin bore of the connecting rod for 

damage. If yes, replace with new one. 

NOTE: 

There is no oil passage to be aligned with the bush hole 

within the smaller end bore of the connecting rod. The 

bore on the bush is only used during the manufacturing. 

5. Service the piston pin. 

(a). Visually check the piston pin for presence of cracking, 

scratch, or other damages and when necessary 

replace with new one. 

(b). Measure the outside diameter of the piston pin with 

micrometer at three different positions in two different 

directions. 


Engine Model 


4JB1 30.995~31.000 

4D20 27.994~28.000 

15B 

6. Service the piston. 

(a). Immerse the piston into cold cleaning fluid. 

△ Tip: 

Generally, immersing the piston for a whole night can loosen 

the carbon deposit. 

NOTE: 

• Do not clean the piston with sand blasting, as the sand 

blasting material will embed into the aluminum and 

thus lead to damage of piston. 

• Do not clean the piston in the acid solvent tank, or it will 

lead to damage of piston. 

Page 2002


15B-297 

(b). Use the mixture from high concentration detergent and 

hot water to clean the piston. 

NOTE: 

Do not use the wire brush, or the wire brush will damage 

the piston ring grooves. 

(c). Again clean the piston with detergent fluid or solvent 

and rinse the piston with clean hot water. 

NOTE: 






• Do not clean the piston or connecting rod in the acid 

solvent tank. Otherwise it will damage the piston and 

connecting rod. 

(d). Blow dry the piston with compressed air. 

NOTE: 




(e). 

Check the skirt, pin bore, head, and ring grooves of the 

piston for presence of damage and wear. If yes, replace 

with new one. 

15B 

Page 2003

15B-298 


(f). 

Measure the piston outer diameter with screw 

micrometer at other positions of piston assembly. 


Engine 

Model 

Group 1 

Standard 

value: 

mm 

Group 2 

Standard 

value: 

mm 

Group 3 

Standard 

value: 

mm 

Group 4 

Standard 

value: 

mm 

Group 5 

Standard 

value: 

mm 

Group 6 

Standard 

value: 

mm 

Group 7 

Standard 

value: 

mm 

Group 8 

Standard 

value: 

mm 

4JB1 

93.025~9 

3.034 

93.015~9 

3.024 

93.005~9 

3.014 

92.995~9 

3.004 

92.985~9 

2.994 

92.975~9 

2.984 

92.965~9 

2.974 

92.955~9 

2.964 

4D20 

85.930~8 

5.940 

85.940~8 

5.950 

85.950~8 

5.960 

- - - - - 

(g). Insert the piston pin into the piston pin seat bore and 

rotate. 

△ Tip: 

If the piston pin rotates smoothly without any gap, it indicates 

that the gap is normal. If there is a gap or the rough rotation can 

be felt, the gap needs to be measured. If the gap measured is 

out of the specified range, replace both the piston and the 

piston pin. 


Engine Model 


15B 

4JB1 0.002~0.015 

4D20 -0.05~0.018 

(h). Install the piston ring into the cylinder sleeve and 

measure the opening gap with feeler gauge. 

△ Tip: 

It may use the piston head to push the piston rings in the 

direction perpendicular to the cylinder walls to the minimum 

bore diameter position of the cylinder sleeve. 

Page 2004


15B-299 

(i). Measure the gap between the piston ring grooves and 

the piston rings with feeler gauge 

△ Tip: 

If the gap between the piston ring grooves and the piston rings 

is out of the specified range, replace the piston rings. If the 

new piston rings installed still can’t meet the specified gap, 

replace the piston. 

NOTE: 

The piston rings shall be replaced in set 



Standard gap between 1st piston ring and piston ring groove mm 0.090~0.125 0.06~0.10 

Standard gap between 2nd piston ring and piston ring groove mm 0.050~0.085 0.04~0.08 

Standard gap between oil ring and piston ring groove mm 0.030~0.070 0.02~0.06 

7. Check the piston rings 

(a). Check the abrasive wear of the piston rings 

△ Tip: 

If the frontal black grinding painting of the piston rings is 

reduced or even becomes invisible sometimes, it indicates that 

the abrasive wear occurs in the middle ring. Generally, it can 

be considered as the complete wear of the ring surface. The 

reduced painting generally will keep sharp the bottom edge of 

the middle ring. In addition, the central longitudinal wear on the 

top ring indicates the occurrence of the abrasive wear. 

The following causes may lead to abrasive wear: 

• Suction of grinding material. 

• Incomplete cleaning during previous services. 

• Particles embedded in the cylinder bore. 

• Prolonged oil drainage interval so that the soot content in 

the oil becomes high. 

• Wear and scratch. 

15B 

(b). Check the oil ring for blocking 

△ Tip: 

The phenomenon of oil ring blocking is caused by the deposits 

existing in oil ring groove. 

The oil ring blocking may be caused by the following reasons: 

• The operating temperature of engine is relatively low; 

long-time idling or the fault of cooling system. 

• The replacement interval of oil is extended. 

• The grade of applied oil is improper. 

• The quality of oil is poor. 

Page 2005

15B-300 


NOTE: 

The oil return blocking of oil ring limits the return of oil, make the area of piston ring full of oil and 

cause the defect in terms of oil control. 

8. Install the piston assembly (Refer to Chapter 15 Engine Mechanical Part – Assembly of Engine 

4JB1) 

15B 

Page 2006

ENGINE MECHANICAL PART-CRANKSHAFT AND FLYWHEEL ASSEMBLY 

15B-301 

CRANKSHAFT AND FLYWHEEL ASSEMBLY 


1 Crankshaft pulley bolt 

2 Crankshaft pulley 

3 Crankshaft timing pulley 

4 Crankshaft flat key 

5 Crankshaft 

6 Rolling bearing 6203-Z 

7 Flywheel ring gear 

8 Pin 

9 Flywheel 

10 Cylindrical pin 

11 Flywheel bolt plate 

12 Flywheel bolt 

15B 

Page 2007

15B-302 


SERVICE 

1. Remove the flywheel (Refer to Chapter 15 Engine Mechanical Part – Disassembly of Engine 

4JB1) 

2. Service the flywheel. 

(a). Visually check the working surfaces of the flywheel. In 

event of any wear, grooving, or gear ring wear, repair 

and, when necessary, replace with new one. 

(b). 

Visually check the flywheel gear teeth. If the gear teeth 

are worn or broken, please repair them. If necessary, 

please replace them. 

3. Preliminarily measure the axial gap of the 

crankshaft. 

(a). Measure the axial gap of crankshaft with micrometer 

and magnetic base. 


Engine Model 

Standard value mm 

15B 

4JB1 0.040~0.201 

4D20 0.14~0.25 

△ Tip: 

The sizes of the thrust bearing and the crankshaft journal 

determine the size of the axial gap. 

4. Remove the main bearing bush and crankshaft (Refer to Chapter 15 Engine Mechanical Part – 


Page 2008


15B-303 

5. Service the main bearing bush and the main 

bearing cap 

(a). Clean the parts such as main bearing caps with steam 

or hot soapy solvent. 

NOTE: 

The hot steam may cause serious personal injury. So wear 

safety goggles or protective mask and protective clothing 

when using steam to clean things. 

(b). Blow dry the parts with compressed air. 

NOTE: 




(c). Check whether all main bearing caps and main bearing 

cap bolts have scratches or overheating phenomenon. 

NOTE: 

If the main bearing cap is damaged, replace the cylinder 

block. 

(d). Check whether the main bearing bush have cracks, 

scratches or overheating phenomenon. 

NOTE: 

If the main bearing bush is damaged, replace the complete 

set of main bearing bush. 

15B 

(e). Check the mating surface of the bearing bush seat for 

presence of scratch and burr. 

△ Tip: 

In event of scratch or burr, grind with grinding pad. If the 

scratch or burr can’t be removed by the grinding pad or 

equivalent, replace the bearing. 

Page 2009

15B-304 


(f). 

Check the rear main bearing cap to make sure the 

annular location pin is installed. 

6. Service the crankshaft. 

(a). Clean the crank with hot suds. 

(b). 

Clean the oil holes with non-metallic hard brush. 

15B 

(c). Blow dry the crankshaft with compressed air 

△ Tip: 

Make sure that the water drips are blown out from the threaded 

holes and oil passage on each end of the crankshaft. 

NOTE: 

Please wear proper goggles and protective mask when 

using compressed air to avoid the splashing chips and dirt 

causing personal injury. 

(d). Check whether the screw threads on both ends of 

crank are damaged. If they are damaged, please 

replace the crank. 

NOTE: 

The threads of crank shall not need dressing, or else the 

engine will be seriously damaged. 

Page 2010


15B-305 

(e). 

Visually check whether the middle of crank arm, crank 

arm and the top end of connecting rod journal have 

scratches or cracks. If they have, please replace them. 

(f). 

Measure multiple points on the same cross section of 

the crankshaft with outside diameter micrometer. 



Specified outside diameter of crankshaft main journal mm 69.917~69.932 70.904~70.920 

Specified inside diameter of crankshaft main bearing bush mm 69.838~69.899 69.811~69.859 

Specified gap mm 0.033~0.079 0.061~0.093 

△ Tip: 

The main journal of the crankshaft is to be fitted with the bore of main bearing bush. While measuring the 

outside diameter of the crankshaft main journal, measure the inside diameter of the main bearing bush bore 

with micrometer as well. If the difference between two measurements is out of the specified range, replace 

the main bearing bush in pair. 

15B 

Page 2011

15B-306 


(g). Place the crankshaft onto the V-blocks, rotate the 

crankshaft slowly, and measure the radial run-out. If the 

radial run-out of the crankshaft is out of the specified 

range, replace or correct by cold pressing the crankshaft. 


Engine Model 


4JB1 0.03 

4D20 0.025 

(h). Correct the crankshaft. 

△ Tip: 

To correct the bending of the crankshaft, knock the 

non-machined surfaces of the crank arm to deform the crank 

so that the axis of the crankshaft is displaced to fulfill the 

correction. 

7. Install the crankshaft (Refer to Chapter 15 Engine Mechanical Part – Assembly of Engine 4JB1) 

8. Measure the axial gap of the crankshaft. 

(a). Measure the axial gap of crankshaft with micrometer 

and magnetic base. 


Engine Model 


15B 

4JB1 0.040~0.201 

4D20 0.14~0.25 

△ Tip: 

The sizes of the thrust bearing and the crankshaft journal 

determine the size of the axial gap 

9. Install the flywheel (Refer to Chapter 15 Engine Mechanical Part – Assembly of Engine 4JB1) 

Page 2012

ENGINE MECHANICAL PART-CYLINDER BLOCK 

15B-307 

CYLINDER BLOCK 


15B 

Page 2013

15B-308 


15B 

1 Front bush of crankshaft 

2 Middle and rear bush of crankshaft 


4 Blocked oil passage 

5 Fuel supply connector of vacuum pump 

6 Hexagon head bolt and spring washer 

assembly 

7 


assembly 

8 Water inlet pipe weldment 

9 Water inlet pipe gasket 

10 

Cylinder block and cylinder head’s 

location pin 

11 Cylinder liner 

12 aluminum plug 


14 Bowl-shaped tabular plug 18 



17 Cylinder head gasket 

18 Hexagon bolt with location pin 

19 Back plate of cylinder block 

20 Flat washer 

21 Heavy spring washer 

22 Nut M10×1.25 


24 Fixing bolts of rear joint plate 

25 Rear oil seal of crankshaft 





30 

Hexagon head bolt, spring washer and 

flat washer assembly 


32 Water drainage plug screw 

33 Plug screw gasket 

34 oil pressure sensor plug 

35 Oil pressure sensor head 

36 Oil Injection pipe weldment 

37 Red copper gasket 

38 Pressure-limiting valve components 

39 Crankshaft upper bearing bush 

40 Crankshaft low bearing bush 

41 The fifth main bearing cap 

42 

The first, second and fourth 

bearing caps 

43 The third main bearing cap 

44 Thrust bearing 

45 Main bearing bolts 

46 

47 

main 


assembly 



48 Cylinder block 

Page 2014


15B-309 

SERVICE 

1. Disassemble the cylinder block (See Chapter 15B Engine Mechanical System - Disassembly of 

Engine) 

2. Remove the cylinder gasket. 

(a). Remove the cylinder head gasket 

△ Tip: 

The gasket which is disassembled cannot be used again. 

Please replace the gasket. 

(b). Measure the bore diameter of the cylinder sleeve with 

inside diameter micrometer in two or more different 

directions and record each measurement result. 


Engine Model 

Specified value mm 

4JB1 93.020~93.061 

4D20 86.000~86.030 

△ Tip: 

If the measurement results are out of the specified range, bore 

the cylinder or replace the cylinder block. 

NOTE: 

For measuring the external diameter of cylinder liner and 

cylinder hole diameter, it can be effective to measure the 

smooth surface of top and bottom section. 

15B 

(c). Disassemble cylinder liner. 

△ Tip: 

Install the cylinder-liner dismantling gear in the cylinder liner. 

Check whether the base of cylinder-liner dismantling gear is 

firmly connected with the bottom edge of cylinder liner and then 

slowly rotate the dismantling bearing hand wheel 

counterclockwise to pull the cylinder liner out. 

Page 2015

15B-310 


3. Service the cylinder block. 

(a). Put the cylinder block in the cleaning tank to clean. 

NOTE: 






• Clean with solvent that will not damage the camshaft 

sleeve. 

• Please abide by the operation instructions of the 

manufacturer for the operations of the cleaning tank. 

• Please abide by the instructions of the solvent 

manufacturers while using the solvent. 

(b). Thoroughly clean the cylinder block with steam and 

then blow dry the cylinder block with compressed air. 

NOTE: 

The hot steam may cause serious personal injury. So wear 

safety goggles or protective mask and protective clothing 

when using steam to clean things. 

NOTE: 

• To minimize the damage of the engine, make sure to 

remove all scraps from the threaded holes and the oil 

passage. 

• If the cylinder block will not be used immediately, apply 

one film of protective oil for anti-rusting protection and 

cover the cylinder block to guard against the 

contamination of dirt to the oil. 

15B 

(c). After the cleaning, recheck the cylinder block for 

presence of cracking, corrosion, and discoloration and 

check the camshaft bore for presence of scratch, wear, 

and excessive wear. 

△ Tip: 

If the bore is damaged to beyond the allowable range, replace 

the cylinder block 

Page 2016


15B-311 

(d). Measure the length for four sides and diagonal lines of 


△Tip: 

If the degree of damage for hole exceeds the allowable limit, 

replace the cylinder block. If the dimension of cylinder block 

does not be changed, then the cam bush can be still used. 

(e). Measure the lengths for four sides and diagonal lines of 


△Tip: 

If the measurement results are out of the specified range, 

replace the cylinder block. 

(f). Measure the surface levelness of the cylinder block with 

ruler and feeler gauge. 


Engine 

Model 

4JB1 

4D20 


Planeness:0.06,Depth of Parallelism:0.06 

Planeness:0.05,Depth of Parallelism:0.08 

△ Tip: 

If the measurement results are out of the specified range, 

repair the cylinder block and when necessary replace the 


15B 

(g). 

Visually check whether the cylinder head gasket is 

damaged or has cracks. If the gasket if damaged or 

has cracks please replace it. 

Page 2017

15B-312 


(h). 

Visually check the gasket of the cylinder head for 

presence of cracking and damage. If yes, replace the 

gasket. 

(i). 

After taking down all accessories of cylinder block, 

clean the oil passage and water passage of cylinder 

block with water syringe. 

4. Install cylinder liner 

(a). Install cylinder liner with special tools. 

△ Tip: 

• Before installation, thoroughly clean the surface of cylinder 

liner and cylinder hole with new kerosene or diesel and blow 

dry the surface of cylinder liner and cylinder hole. 

• Eliminate all other things carefully on the cylinder liner and 

cylinder hole before installing cylinder liner. 

15B 

(b). 

Install the gasket of the cylinder head to the specified 

position. 

5. Install the cylinder block (Refer to Chapter 15 Engine Mechanical Part – Assembly of Engine 

491EQ1 and 491EQ3). 

Page 2018

1 


EXHAUST SYSTEM ............................................................................... 16B-1 

Overview ............................................................................................ 16B-1 

Precautions ....................................................................................... 16B-2 

Working Principle ............................................................................. 16B-3 

EXHAUST MANIFOLD ........................................................................... 16B-4 

Diagram of Components (Exhaust System) ................................... 16B-4 

Service ............................................................................................... 16B-5 

EXHAUST PIPE ..................................................................................... 16B-9 

Diagram of Components .................................................................. 16B-9 

Removal and Installation ................................................................ 16B-10 

16B 

Page 2019

16B 

Page 2020

EXHAUST-EXHAUST SYSTEM 

16B-1 


OVERVIEW 

1. Exhaust system consists of the exhaust manifold, muffler and exhaust manifold welding assembly, 

and other related lug bracket, in order to reduce the exhaust noise and exhaust energy. 

2. The exhaust manifold is an important component collecting the exhausts of engine cylinders and 

discharging. 

3. The function of muffler is to reduce the exhaust noise through gradually decreasing the exhaust 

pressure and exhaust pressure pulsation. 

4. The working principle of muffler is that the exhaust gas flows to the expansion chamber and 

resonance chamber through the porous tube, and the exhaust gas continually changes the flow 

direction during this process, gradually decreases and relieves the exhaust pressure and exhaust 

pressure pulsation, consumes the energy and ultimately reduce the exhaust noise. 

16B 

Page 2021

16B-2 


PRECAUTIONS 

1. Safety cautions 

(a). Ensure the parking brake lever is placed on the parking location. 

(b). Fix the wheel with a wedge or corner block, wedge or corner block should be placed in the position 

close to both sides of the tire, it’s preferred to fix on both sides of the rear wheels. 

(c). If operates under the car, the engine should and ignition switch should be turned off.. 


(a). Ensure the engine turned off when repairing the exhaust system, the maintenance work should only 

be conducted after the exhaust system completely cooled. 

(b). The exhaust pipeline should be checked frequently, any leaks should be dealt with immediately, 

tighten the connectors to avoid unnecessary losses. 

(c). After 4,000 ~ 5,000km drive, the exhaust pipe of the vehicle should be checked in the following 

aspects: 

• Whether any bolts and nuts are loosen. To tighten the bolts and nuts of exhaust pipe with uniform 

force, fastening the bolts in diagonal, or it may cause air leaks. 

• Whether there are any exhaust pipe cracks and perforations, and any damage or erosion for 

gasket. 

• The exhaust pipe gasket is suggested to be used once only; in order to ensure the tightness of 

exhaust system, timely replace the damaged gasket. 

16B 

Page 2022


16B-3 


The outside air enters compressor room of turbocharger after being filtered by air filter, and enters intake 

manifold through intake connecting pipe after being compressed by turbocharger, then is distributed to inlet of 

each cylinder by intake manifold. The burned gas drains from exhaust manifold. The formed exhaust gas flow 

will impact turbine of turbocharger so that it can rotate at a high speed. The exhaust gas through turbine 

finally drains to the exterior by rear exhaust pipe. Part of exhaust gas in the exhaust manifold drains from 

EGR valve. Then this exhaust gas enters intake connecting pipe through EGR pipe, and is sent back to 

engine combustor for combustion again to suppress the generation of oxynitride. 

16B 

1 Rear exhaust pipe 

2 EGR pipe 

3 EGR valve 



7 Turbocharger 

8 Intake pipe 

9 Air filter 


Page 2023

16B-4 

EXHAUST-EXHAUST MANIFOLD 


DIAGRAM OF COMPONENTS (EXHAUST SYSTEM) 

16B 

1 Exhaust manifold gasket component 


3 

Hexagon head bolt and flat washer 

assembly 

4 Heat insulation plate assemblyⅡ 

5 Flat washer 


7 Bolt 

8 Booster bracket bolt 

9 Heat insulation plateⅠ 

10 Exhaust manifold bracket 




Page 2024


16B-5 

SERVICE 

1. Remove the turbocharger assembly (Refer to Chapter 21 Booster System - Booster, Service). 

2. Remove the EGR valve assembly (Refer to Chapter 22 EGR System - EGR Valve, Service) 

3. Remove the heat insulation plate assemblyⅡ 

(a). Dismantle 2 fixing bolts of heat insulation plate 

assembly II. 

• Remove the heat insulation assembly II. 

4. Remove the turbocharger bracket 

(a). Dismantle 2 fixing bolts of turbocharger bracket. 

• Remove the turbocharger bracket. 

• Remove the heat insulation plate I. 

5. Remove the exhaust manifold bracket 

(a). Remove the fixing bolts of exhaust manifold bracket. 

• Remove the exhaust manifold bracket. 

16B 

6. Remove the exhaust manifold 

(a). Remove the fixing bolts of exhaust manifold. 

•Remove the exhaust manifold. 

Page 2025

16B-6 


7. Check and clean the exhaust manifold 

(a). Clean the sealing surface that combines exhaust 

manifold and turbocharger with a scraper knife and a 

clean cloth. 

NOTE: 

Please prevent foreign matters from entering into the 

exhaust port 

(b). 

Clean the sealing surface that combines exhaust 

manifold and cylinder head with a scraper knife 

and a clean cloth. 

(c). 

Clean the carbon deposit on the sealing surface of 

exhaust manifold with a crocus cloth. 

16B 

(d). Clean the exhaust manifold with vapor. 

NOTE: 

When cleaning the exhaust manifold with vapor, wear the 

protective goggles, protective masks and protective 

clothing to avoid personnel injury. 

(e). 

Dry the exhaust manifold with compressed air. 

Page 2026


16B-7 

(f). 

Check whether the sealing surface of exhaust manifold 

and turbocharger exists cracks and other damages. If 

severe damages exist, replace the exhaust manifold. 

(g). 

Check whether the sealing surface of exhaust manifold 

and cylinder head exists cracks or other damages. If 

severe damages exist, replace the exhaust manifold. 

(h). 

Check the flatness of exhaust manifold installation 

surface with a precision scale and a feeler gauge. If 

the unevenness exceeds technical scope, the exhaust 

manifold shall be machined or replace it with a new one. 

8. Install the exhaust manifold assembly 

(a). Place the exhaust manifold in the installation position the 

fixing bolts on it and fasten. 

△ Tip: 

The slinger ring and heat insulation plate set with exhaust 

manifold together shall be installed when installing the exhaust 

manifold. 

16B 

(b). Place the exhaust manifold bracket in the 

installation position the fixing bolts on it and fasten. 

Page 2027

16B-8 


(c). 

Place the heat insulation plate Ⅰ and turbocharger 

bracket in the installation position the fixing bolts on it 

and fasten. 

(d). 

Place the heat insulation plate assembly Ⅱ in the 

installation position 2 fixing bolts on it and fasten. 

9. Install the EGR valve assembly (Refer to Chapter 22 EGR System - EGR Valve, Service) 

10. Install the turbocharger assembly (Refer to Chapter 21 Booster System - Booster, Service) 

16B 

Page 2028

EXHAUST PIPE 


EXHAUST-EXHAUST PIPE 

16B-9 

16B 

1 Exhaust pipe gasket assembly 

2 Front exhaust pipe welding 




6 Gasket 


8 Hoop support plate 

9 Middle exhaust pipe assembly 

10 second connection rubber 

11 Muffler front gasket 





16 Muffler assembly 

17 Rear exhaust pipe assembly 

18 Exhaust pipe third bracket 

19 third connection rubber 



22 Hoop 

23 Fourth connection rubber 

Page 2029

16B-10 


REMOVAL AND INSTALLATION 

△ Tip: 

As the exhaust pipe is relatively heavy, certain protective measures should be taken during the disassembly, 

it is preferred to be operated by two persons. 

1. Preparations 

(a). 

Drive the car into the inspection pit or onto the car lift. 

NOTE: 

Turn off the engine after stopping the car, disconnect the battery negative, place the transmission in 

neutral position, and turn on the parking brake system. Operate only after the exhaust system fully 

cooled. 

2. Disassemble the exhaust system assembly 

(a). Remove the connection nuts of front exhaust pipe 

welding and engine. 

• Remove the exhaust pipe gasket assembly. 

(b). 

(c). 

Remove the connecting bolts between front exhaust pipe 

welding and middle exhaust pipe assembly. 

• Remove the gasket. 

Remove the fixing bolts of hoop support plate. 

• Remove the front exhaust pipe welding. 

16B 

(d). Remove the connecting bolts between middle exhaust 

pipe assembly and muffler assembly. 

• Remove the muffler front gasket. 

△ Tip: 

Support the muffler assembly with safety bench to avoid falling; 

otherwise it may cause personal injury. 

Page 2030


16B-11 

(e). 

Remove the second connection rubber between 

middle exhaust pipe assembly and frame. 

• Take out the second connection rubber. 

• Remove the middle exhaust pipe assembly. 

(f). Remove the connecting bolts between muffler 

assembly and rear exhaust pipe assembly. 

• Remove the muffler assembly. 

(g). 

Remove the fixing bolts of exhaust pipe third bracket. 

(h). 

Remove the fourth connection rubber of rear exhaust 

pipe. 

• Remove the rear exhaust pipe assembly. 

16B 

Page 2031

16B-12 


3. Check the exhaust system 

(a). Check whether there are too many gray or carbon 

particles inside the muffler, it should be cleaned if 

any. 

Cleaning method: 

• Purge the muffler assembly with compressed air until 

there is no heavy smoke emitted. 

NOTE: 

Wear masks and goggles before cleaning, to avoid injury. 

(b). Check whether there are too much gray or carbon 

particle inside the front, middle and rear exhaust 

pipe assembly; if any, please remove and clean it. 

△Tip: 

The cleaning method is the same as the previous step 

4. Install the exhaust system assembly 

(a). Place the rear exhaust pipe assembly and fourth 

connection rubber in the installation position, and 

install the connection rubber to the frame. 

(b). 

Install the fixing bolts of the exhaust pipe third bracket. 

16B 

(c). Place the muffler assembly in the installation position; 

connect the bolts between the muffler assembly and 

rear exhaust pipe and fasten. 

△Tip: 

Replace the gasket assembly of exhaust pipe. 

Page 2032


16B-13 

(d). 

Place the middle exhaust pipe assembly and second 

connection rubber in the installation position, and install 

the second connection rubber to the frame. 

(e). Connect the bolts between the middle exhaust pipe 

assembly and muffler assembly and fasten. 

△Tip: 

Replace the front gasket of muffler. 

(f). Place the front exhaust pipe welding in the installation 

position, connect the bolts of hoop support plate and 

fasten. 

(g). Connect the bolts between front exhaust pipe welding 

and middle exhaust pipe assembly and fasten. 

△Tip: 

The gasket shall be replaced. 

(h). Fasten the connection nuts of front exhaust pipe 

welding and engine. 

△Tip: 

The exhaust pipe gasket assembly shall be replaced. 

16B 

Page 2033

-MEMO- 

16B 

Page 2034


COOLING SYSTEM........................................................................... 17B-1 

Overview ............................................................................................. 17B-1 

Precautions ........................................................................................ 17B-2 

Working Principle .............................................................................. 17B-3 

Diagram of Components ................................................................... 17B-4 

THERMOSTAT ................................................................................... 17B-7 

Service ................................................................................................ 17B-7 

TRANSMISSION BELT ................................................................... 17B-11 

Service .............................................................................................. 17B-11 

PULLEY AND FAN .......................................................................... 17B-14 

Service .............................................................................................. 17B-14 

WATER PUMP ................................................................................. 17B-16 

Service .............................................................................................. 17B-16 

OIL COOLER ................................................................................... 17B-19 

Service .............................................................................................. 17B-19 

EXPANSION TANK ......................................................................... 17B-21 

Replacement ..................................................................................... 17B-21 

COOLING PIPELINE ....................................................................... 17B-23 

Replacement ..................................................................................... 17B-23 

RADIATOR ....................................................................................... 17B-25 

Replacement ..................................................................................... 17B-25 

17B 

Page 2035

17B 

Page 2036

COOLING-COOLING SYSTEM 17B-1 


OVERVIEW 

1. The main functions for cooling system are to timely radiate some heat which is absorbed by heated 

parts to ensure that the engine works under the condition of the most appropriate temperature. 

2. The thermostat controls temperature of engine coolant. When coolant temperature is lower than 

engine functioning temperature, the engine coolant reflows the inlet of water pump through the 

bypass to make the coolant temperature is the same with engine functioning temperature. When the 

engine coolant temperature is the same with the functioning temperature, the thermostat opens and 

the bypass is closed, which makes engine coolant flow into the radiator to make the coolant 

temperature is the same with the functioning temperature. 

3. The centrifugal water pump consists of impeller, water pump housing, bearing and water seal. The 

water pump is driven by crank pulley and fan belt. When water seal is damaged and the dripping 

phenomenon is very serious, the water seal shall be replaced. Do not allow to block the outlet when 

water leakage, or else the water will enter the bearing to make the bearing quickly wear down. If there 

is abnormal noise in the bearing during running, then the bearing shall be considered to be replaced. 

4. The fan is induced draught plastic fan. The tensioning degree of fan belt shall be checked regularly 

according to the requirements of “technical maintenance” and the fan belt shall be adjusted. The 

adjustment shall be carried out manually with a force of 70~80N to press the belt between the fan and 

generator pulley. The proper pressing distance is the range of 7~8mm (for new belt is 6~7mm). 

5. Silicon oil fan clutch takes silicon oil as medium and makes use of silicon oil’s high viscosity to 

transmit the torque. The separation and joint of fun clutch are automatically controlled by temperature 

detector when making use of the atmosphere temperature on the back of radiator. 

Temperature-sensing elements are thermometal coiled spring temperature sensors. When the 

temperature of air which is flowing through the radiator increases, thermal deformations of 

thermometal temperature sensors occur and the valve plate shaft is forced to rotate to open the oil 

supply hole on the driven plate. The silicon oil that stored between the driven plate and the front cover 

flows into the operating cavity between the drive plate and driven plate and the clutch engages, fan 

speed increases. The opening of oil supply hole shall be larger with higher air temperature and the 

fan speed is higher; however, when the temperature of air which is flowing through the radiator 

reduces, thermometal temperature sensors shall be reinstated, valve plate close the oil supply hole. 

With the effect of centrifugal force, silicon oil returns to oil chamber from the operating cavity through 

oil return hole. The clutch disengages and fan speed reduces to a very low one. 

6. The drain screw is for the drain of the engine’s coolant in coolant change. 

7. Oil cooler is used for oil cooling in order to maintain the oil temperature in proper rang for better 

engine performance and longer service life of the engine. In the case of oil in engine coolant, carry out 

service for oil cooler immediately. 

8. The radiator is pressure water tank which is the device sending out the coolant heat to the 

atmosphere. The functions of radiator: enlarge radiating area and accelerating the water cooling. 

9. The expansion tank is to reduce the losses of coolant of cooling system. 

10. Two water level scales on the surface of expansion tank express limiting altitude on the liquid surface 

17B 

Page 2037

17B-2 COOLING-COOLING SYSTEM 

PRECAUTIONS 

1. Safety precaution 

(a). Make sure to place the parking brake handle in the parking position. 

(b). Fasten the wheel with corner blocks or wedge and the corner blocks or wedge shall be placed on two 

sides of wheel. And the two sides of rear wheel shall be fixed better. 

(c). The engine shall be shut down and the switch of ignition lock shall be shut down when working at the 

bottom of the car. 


(a). When disconnecting the cooling system pipeline, do not make the coolant overflow. If it cannot be 

continuously used, it shall be abandoned according to the regulations. 

(b). When disconnecting the cooling system pipeline, do not make the chips enter the cooling system 

pipeline, because the chips which enter the cooling system pipeline will damage the cooling system 

and engine. 

(c). The coolant is poisonous and if it cannot be continuously used, dispose of the coolant according to 

the regulations. 

(d). When maintaining the cooling system, pay attention to coolant temperature. If the temperature is too 

high, the operation shall be carried on after the coolant temperature is lower. 

(e). Reasonably use antifreeze solution. The antifreeze solution is poisonous and can irritate to the skin 

and inner organs. Do not suck the antifreeze solution when using it. Clean hands if the hands touch 

the antifreeze solution and timely wash the eyes if the antifreeze solution enters eyes. 

17B 

Page 2038



When the temperature of engine coolant is higher than the nominal temperature of thermostat, coolant flows 

out through engine water outlet and gets into the radiator through open thermostat then it flows through oil 

cooler and gets into the water pump through the water inlet of the pump to complete internal circulation in 

engine body. However, when the temperature of engine coolant is lower than the nominal temperature of 

thermostat, because the thermostat is closed and bypass is open, the coolant flows into the water inlet of 

water pump through bypass pipe to complete internal circulation in engine body. Part of coolant in engine 

body may flow into heater through heater water inlet pipe and then get into water pump water inlet through 

heater water return pipe, finally it shall return to engine body for internal circulation. 

17B 

1 Radiator 

2 Oil cooler 

3 Oil filter 

4 Heater water outlet pipe 

5 Fan heater 

6 Heater water inlet pipe 

7 Expansion tank 

8 Thermostat 

9 Engine water outlet pipe 

10 Bypass pipe 

11 Water pump 

Page 2039



(Thermostat) 

17B 

1 Plug 

2 Copper backing 

3 Screw plug 

4 



5 Water outlet pipe 

6 Thermostat 

7 Water outlet pipe gasket 

8 Housing gasket 


10 Short circle pipe joint 

11 Heating pipe clamp 

12 Bypass hose 

13 Hexagon tapered screw plug 

14 Thermostat housing 

15 Heater water inlet pipe 

16 Heater water pipe 

17 

18 

Water outlet rubber hose at thermostat 

end 

Water return rubber hose at thermostat 

end 

19 Machine cooler steel pipe welding part 

20 



21 Heater opening cap 

Page 2040

(Fan and water pump pulley chamber cover assembly) 


17B 

1 Fan component 

2 Silicon oil clutch component 



5 Flat washer 

6 Stud 

7 Water pump pulley 

8 Fan belt 

9 Water pump O ring 

10 

Water pump pulley chamber cover 

assembly 



13 Bolt 

14 

15 

16 Bolt 

17 Bolt 






Page 2041


(Radiator) 

17B 

1 Radiator assembly 


3 Connecting hose 


5 Engine water inlet hose 

6 Type A worm drive hose clamp 

7 

Hexagon head bolt, Spring washer and 

Flat washer assembly 

8 Engine water outlet hose 

9 




11 Expansion tank assembly 

12 Protective fan housing assembly 

13 



Page 2042

COOLING-THERMOSTAT 

17B-7 

THERMOSTAT 

SERVICE 

1. Thermostat Dismantle 

(a). Dismantle fixing bolts of thermostat cap, take down 

bolts and Harness clamp. 

(b). Take down thermostat cap. 

△ Tip: 

Take down thermostat cap and housing gasket at the same 

time. 

(c). 

Take out the thermostat. 

17B 

2. Checking and Cleaning 

(a). Check the appearance of thermostat for damage. 

• Check for the existence of crack, embedded scrap, 

loss of one-way valve, ball seat damage and other 

damages. 

• In the case of discovery of damage, replace the 

thermostat. 

Page 2043

17B-8 


(b). 

Shovel the remained gasket at the contact surface 

between the thermostat housing and thermostat cap. 

(c). 

Clean the installation surface of thermostat housing. 

(d). 

Check the installation surface of thermostat housing for 

crack and damage. 

• In the case of discovery of crack and scars, 

replace the thermostat housing. 

17B 

3. Measure 

(a). If the thermostat is considered to have fault, measure 

thermostat temperature of turning on the thermostat, 

and place thermostat and a thermometer with 100℃ of 

measuring range into a water container. 

NOTE: 

Do not make thermostat or thermometer contact the 

container. 

Page 2044


17B-9 

(b). Heat the water and check the thermostat according to 

the following steps. 

• Heat the water in the container to the temperature 

which is higher than nominal working temperature 

of thermostat and then the thermostat will 

automatically turn on. 

• If the thermostat cannot automatically turn on 

when the temperature for water in the container is 

higher than the nominal working temperature, it 

indicates that the thermostat is damaged or the 

model is not right and then the thermostat shall be 

replaced. 

NOTE: 

Thermostat is marked with nominal working temperature. 

4. Install thermostat 

(a). Apply sealant on the installation surface of thermostat 

housing. 

(b). Replace with a new gasket. 

Note: 

No matter whether the gasket is damaged, please replace 

the gasket. 

17B 

(c). 

Install thermostat. 

Page 2045

17B-10 


(d). Install the thermostat cap. 

△ Tip: 

Sealant shall be applied on the installation surface of 

thermostat cap. 

(e). 

Screw on fixing bolts and Harness clamps for 

thermostat cap and tighten them. 

17B 

Page 2046

TRANSMISSION BELT 

SERVICE 

COOLING-TRANSMISSION BELT 

17B-11 

1. Dismantle fan and silicon oil clutch 

(a). Dismantle the nuts on the flange of silicon oil clutch. 

(b). Slowly take down fan and silicon oil clutch. 

△ Tip: 

The fan and silicon oil clutch which are not separated can be 

taken down. 

2. Dismantle fan pulley and fan belt 

(a). Loosen the generator bracket and dismantle the fan 

belt pulley and fan belt. 

17B 

3. Check belt appearance 

(a). Carefully check each part of belt. If there are the 

following damages, please replace the pulley. 

• The rubber on the back is ageing and light-reflective, 

in the case of nail scratching, there is no scratch and 

the rubber is inelastic. 

Page 2047

17B-12 


• There is crack of the rubber on the back. 

• There is crack on toothed bottom. 

4. Install fan pulley and fan belt 

(a). Place the fan belt to installation position and install the 

belt. 

△ Tip: 

After belt installation, check the belt tension firstly and then 

adjust the position of generator for proper belt tension. 

17B 

5. Check and adjust belt tension 

(a). Press down the belt between water pump and 

generator pulley with hands to check the belt 

deflection. 

△ Tip: 

Press down the belt with 70~80N of force and the belt 

deflection shall be 7~8mm (the new belt deflection shall be 

6~7mm) 

(b). 

Unscrew fixing bolts of generator bracket; adjust belt 

tension by changing the position of generator. After that, 

check the belt deflection. Tighten fixing bolts of bracket 

until proper belt tension has been reached. 

Page 2048


17B-13 

6. Install fan and silicon oil clutch 

(a). Place the fan and silicon oil clutch in the installation 

position. 

(b). Tighten all nuts for studs. 

△ Tip: 

Rotate the fan and check whether the installation is correct. 

17B 

Page 2049

17B-14 

COOLING-PULLEY AND FAN 

PULLEY AND FAN 

SERVICE 

1. Dismantle the fan and silicon oil clutch (refer to Chapter 17B Cooling-Drive Belt, Dismantle) 

2. Separate the fan and silicon oil clutch 

(a). Dismantle the fixing bolts on the fan. 

(b). 

Push down the silicon oil clutch backward slowly to 

separate the fan and silicon oil clutch. 

17B 

3. Cleaning the pulley 

(a). Clean the pulley with solvent. 

NOTE: 

In cleaning with solvents, acid or alkali materials please 

follow the instructions of the manufacturer. Wear safety 

goggles and protective clothing to avoid personal injury. 

(b). 

Check the bolt hole and its surrounding area of fan 

pulley for crack and check damage in the contact 

surface with drive belt. 

• Fan belt in the case of discovery of pulley damage, 

the fan belt shall be checked, too. 

Page 2050

COOLING-PULLEY AND FAN 

17B-15 

4. Check the fan 

(a). Check whether there is crack or incomplete 

phenomenon in cooling fan. 

• In the case of crack or incomplete phenomenon, 

please replace the fan. 

5. Assemble the fan and silicon oil clutch 

(a). Align the fan bolt holes with corresponding bolt holes of 

the silicon oil clutch and tighten all nuts of the fan. 

17B 

Page 2051

17B-16 

COOLING-WATER PUMP 

WATER PUMP 

SERVICE 

1. Preliminary check 

(a). Clean external water pump of generator with steam or 

hydraulic giant. 

NOTE: 

Wear safety goggles and protective mask and protective 

clothing when using the steam to clean. The hot steam is 

possible to lead to serious personal injury. 

(b). Make the engine run at low idle speed to check 

whether the water pump leaks. 

2. Dismantle the water pump assembly 

(a). Dismantle the fixing bolts of crank position sensor and 

take down the sensor. 

(b). 

Dismantle the fixing bolts of crank pulley and take down 

the pulley. 

17B 

(c). 

Dismantle the fixing bolts of sight hole and take down 

the sight-hole cover. 

Page 2052


17B-17 

(d). Dismantle all remained fixing bolts on water pump 

pulley chamber cover. 

△ Tip: 

There is a fixing bolt on the rear housing of crank pulley. 

(e). 

Take down the water pump pulley chamber cover 

assembly. 

3. Clean and continuously check 

(a). Clean the water pump pulley chamber cover assembly. 

with solvent. 

NOTE: 

Please keep to the manufacturer’s suggestions for use 

when using solvent, acid or basic materials. Wear goggles 

and protective clothing to avoid personal injury. 

(b). Dry the water pump pulley chamber cover assembly. 

with compressed air. 

NOTE: 

Wear proper goggles and protective mask to avoid flying 

chips and dirt to avoid personal injury. 

17B 

(c). 

Check the water pump pulley chamber cover assembly 

for crack. In the case of obvious damage, replace the 

water pump pulley chamber cover assembly. 

Page 2053

17B-18 


(d). 

Check the water pump impeller for pitting and crack. In 

the case of obvious damage, replace the water pump 

pulley chamber cover assembly. 

4. Install the water pump assembly 

(a). Place the water pump pulley chamber cover assembly. 

To installation position, put on bolts and tighten. 

(b). 

Place the sight-hole cover to installation position, put 

on bolts and tighten. 

17B 

(c). 

Place the crank pulley to installation position, put on 

bolts and tighten. 

(d). 

Place the crank position sensor to installation position, 

put on bolts and tighten. 

Page 2054

COOLING-OIL COOLER 

17B-19 

OIL COOLER 

SERVICE 

1. Dismantle the oil cooler. 

(a). Drain the coolant. 

(b). Disconnect the water inlet and outlet pipes of oil cooler. 

(c). 

Dismantle center bolts of oil cooler and take down the 

oil cooler. 

2. Check the oil cooler 

(a). Plug the water outlet pipe of the oil cooler, connect the 

water inlet pipe with inflator and put them into water 

basin with the oil cooler submerged in the water 

completely. 

△ Tip: 

In the case of bubbles appearing in the water basin, replace 

with a new oil cooler. 

17B 

3. Install the oil cooler 

(a). Place the oil cooler to installation position and tighten 

its center bolts. 

Page 2055

17B-20 

COOLING-OIL COOLER 

(b). 

Connect the water inlet and outlet pipes of the oil 

cooler. 

17B 

Page 2056

COOLING-EXPANSION TANK 

17B-21 

EXPANSION TANK 

REPLACEMENT 

1. Dismantle expansion tank 

(a). Disconnect the connection between radiator and 

connecting hose. 

(b). 

Loosen Nylon cable tie and lock iron sheet on the 

connecting hose. 

(c). 

Disconnect the connection between expansion tank 

and connecting hose. 

17B 

(d). 

(e). 

Dismantle the fixing bolts of expansion tank assembly. 

Take down the expansion tank assembly. 

2. Check whether there is crack and leakage phenomenon, if yes, then replace it. 

Page 2057

17B-22 

COOLING-EXPANSION TANK 

3. Install the expansion tank 

(a). Place the expansion tank in the correct installation 

position. 

(b). Install and fasten the fixing bolts of expansion tank. 

(c). 

Correctly connect the connecting hose and expansion 

tank. 

(d). 

Correctly connect the connecting hose and radiator. 

17B 

(e). Fill the antifreeze solution to the suitable height. 

△ Tip: 

In antifreeze solution filling, it is preferable to place a flared 

vessel under the opening of expansion tank. 

NOTE: 

User can choose different marks of antifreeze solution 

according to the local atmosphere temperature. 

(f). Fasten the water outlet hose of expansion tank with 

nylon cable tie and lock iron sheet. 

△ Tip: 

After finishing installation, start the engine, and then observe 

the liquid level height in the expansion tank when the water 

temperature in the engine rises to 80℃. If the coolant is 

insufficient, then add the coolant according to the scale of 

expansion tank. 

Page 2058

COOLING-COOLING PIPELINE 

17B-23 

COOLING PIPELINE 

REPLACEMENT 

1. Open the front cabin cover 

2. Place coolant 

(a). Dismantle the drainage bolt of radiator and drain the 

coolant of cooling pipeline empty and place the 

container under the radiator to storage antifreeze 

coolant. 

△ Tip: 

Do not dismantle cooling pipeline and drain the coolant when 

the engine water temperature is higher than 50℃ to avoid 

scald and engine part damage. 

(b). 

Screw off the cover of radiator and shorten the 

drainage time. 

3. Dismantle cooling hose 

(a). Screw off A-type worm drive hose clamp which 

connects radiator water inlet hose and water inlet or 

water outlet hose and water outlet. 

17B 

(b). 

Screw off A-type worm drive hose clamp which 

connects radiator water inlet hose and engine water 

outlet or water outlet hose and engine water inlet. 

• Take down the radiator water inlet and outlet 

hoses. 

Page 2059

17B-24 

COOLING-COOLING PIPELINE 

4. Check cooling hose 

(a). Check whether the cooling hose has crack or 

expansion, if yes, and then replace the cooling hose 

5. Install cooling pipeline 

(a). Install the radiator water outlet hose in the engine water 

inlet and install the radiator water inlet hose in engine 

water outlet, and fasten the A-type worm drive hose 

clamp. 

(b). 

Install the radiator water outlet hose in the water outlet 

and install the water inlet hose in water inlet, and fasten 

the A-type worm drive hose clamp. 

17B 

(c). 

Install and fasten the drainage bolts and seal washer in 

the drainage hole which is at the bottom of radiator. 

(d). Fill the antifreeze coolant in the proper position and 

screw on the cover of radiator. 

NOTE: 



Page 2060

COOLING-RADIATOR 

17B-25 

RADIATOR 

REPLACEMENT 

1. Dismantle the radiator assembly 

(a). Dismantle the drainage bolts on the radiator and drain 

coolant in the radiator and cooling pipeline. Place a 

container at the bottom of radiator to storage antifreeze 

coolant. 

(b). 

Screw out the cover of radiator and shorten the 

drainage time in order to be conveniently dismantled. 

(c). 

Disconnect the connection between the radiator and 

expansion tank and radiator connecting pipe assembly. 

17B 

(d). 

Screw off A-type worm drive hose clamp which 

connects radiator water inlet hose and water inlet or 

water outlet hose and water outlet. 

Page 2061

17B-26 


(e). 

Dismantle the connecting bolt between radiator and fan 

shroud. 

(f). 

(g). 

Dismantle the fixing bolts of radiator. 

Take down radiator assembly. 

2. Clean and detect radiator 

(a). Block up other water outlets of radiator. Fill certain 

pressure water in the radiator and make sure that each 

part of radiator has no leakage. 

NOTE: 

In the case of leakage for radiator, please timely service or 

replace it. 

17B 

(b). 

If there are foreign matters on the radiator, the heat 

radiating ability for the cooling system will be reduced. 

Check whether the radiating fin is blocked off. If it is 

blocked off, clean the radiator surface with compressed 

air or with not high water pressure. 

(c). 

Thoroughly clean the inner radiator with water. 

Page 2062


17B-27 

3. Install radiator assembly 

(a). Place the radiator in the correct installation position. 

(b). Install and fasten the fixing bolts on both sides of 

radiator. 

(c). 

Install and fasten the connecting bolts between radiator 

and fan shroud. 

(d). 

Install the radiator water outlet hose in the water outlet 

and install the water inlet hose in water inlet, and fasten 

A-type worm drive hose clamp. 

(e). 

Connect the radiator and expansion tank to the radiator 

connecting pipe assembly. 

17B 

(f). 

Install and fasten the drainage bolts and seal washer in 

drainage hole which is at the bottom of radiator. 

Page 2063

17B-28 


(g). Fill the antifreeze coolant in the proper position and 

screw on the cover of radiator. 

NOTE: 



17B 

Page 2064

润滑系统 - 润滑系统 16B-1 


LUBRICATION SYSTEM .......................................................................... 18B-1 

Overview ............................................................................................... 18B-1 

Flow Process Diagram ........................................................................ 18B-3 

Diagram of Components I ................................................................... 18B-4 

Diagram of Components II .................................................................. 18B-5 

Measurement ........................................................................................ 18B-6 

Discharge .............................................................................................. 18B-8 

Checking ............................................................................................... 18B-9 

Injection .............................................................................................. 18B-10 

OIL DIPSTICK ......................................................................................... 18B-12 

Service ................................................................................................ 18B-12 

OIL PAN ................................................................................................... 18B-14 

Service ................................................................................................ 18B-14 

OIL PUMP ................................................................................................ 18B-17 

Service ................................................................................................ 18B-17 

OIL FILTER .............................................................................................. 18B-22 

Service ................................................................................................ 18B-22 

18B 

Page 2065

18B 

Page 2066


18B-1 


OVERVIEW 

1. The lubrication system consists of oil suction filter, oil pump, oil filter, oil dipstick and pipelines. 

2. Because of different operation conditions of engine moving parts, the required lubrication strengths are 

also different, so are the applied lubrication methods. There are three types of lubrication methods: 

pressure lubrication, splash lubrication and gravity lubrication. 

• With the pressure lubrication method, the lubrication oil will be send to each friction surface forcibly 

by oil pump. Generally, the part which is bearing heavy load in operation or with high kinematic 

velocity, such as crankshaft main bearing and wheel bearing etc., shall adopt this pressure 

lubrication method. Moreover, as for the parts such as valve rocker arm shaft and others, the 

pressure lubrication method shall be adopted because the light bearing load and its mounting 

position on the cylinder head. 

• With the splash lubrication method, the lubrication is carried out by oil mist formed by the lubrication 

oil thrown out by rod journal and main journal and the lubrication oil thrown out by special oil jet. 

Generally, the parts which are bearing light load or with low kinematic velocity, such as cam running 

surface, tappet etc., shall adopt the splash lubrication method. In addition, although the working 

load of cylinder wall is heavy, it is not advised to apply excessive lubrication oil in case of oil flowing 

to the combustion chamber and the working deterioration of engine. For this reason, the cylinder 

wall shall be lubricated with splash lubrication method. 

• The gravity lubrication method carries out the lubrication with the gravitational flow of lubrication oil 

itself, for example, the lubrication for air rod and push rod along rocker arm is carried out by swaying 

the rocker arm with the gravity of lubrication oil. 

3. Passing through the oil suction filter, the oil stored in oil pan will be sucked into oil pump by means of oil 

inlet pipe and carried to oil filter after pressurization. The filtered oil can access to the main oil gallery of 

engine block by three ways: 

• One way passing by the main bearing, crankshaft oil hole and reaching the connecting rod bearing. 

• One way passing by the camshaft bush, eccentric oil groove of cam journal and interruptedly 

supplying oil to the rocker arm shaft bush. 

• One way passing by the bearing of correct timing idle gear. 

4. The scientific name of oil is lubrication oil which plays an significant role in normal operation of engine. 

(a). 

(b). 

(c). 

(d). 

(e). 

(f). 

Lubrication action: lubricate the surface of moving part, reduce the frictional resistance and abrasion 

and decrease the power consumption of engine. 

Cleanup action: the oil will constantly circulate in lubrication system, clean the friction surface and take 

away abrasive dust and other foreign matters. 

Cooling action: the oil will constantly circulate in lubrication system, take away the fricative heat of parts 

and carry out the cooling performance. 

Sealing action: there will be an oil film between each two moving parts. This is helpful to increase their 

leak proofness and avoid air leakage or oil leakage. 

Anti-corrosion action: there will be an oil film on the surface of part to protect the part’s surface and 

avoid corrosion and rusting. 

Hydraulic pressure action: the lubrication oil can be used as hydraulic oil, such as hydraulic tappet, to 

carry out the function of hydraulic pressure. 

18B 

Page 2067

18B-2 

(g). 


Damping and buffer action: there will be an oil film on the surface of moving part to absorb the impact, 

reduce small vibration, attenuate the shock and realize the buffer action. 

18B 

Page 2068


18B-3 

FLOW PROCESS DIAGRAM 

18B 

Page 2069

18B-4 


DIAGRAM OF COMPONENTS I 

18B 

1 Spin-on filter element and seal ring 

2 Oil filter seal ring 

3 Oil filter seat component 

4 Flat washer 



7 Oil cooler component 

8 


combination 

9 Connection hose 

10 Oil cooler outlet hose 

11 Oil cooler inlet hose 

12 Oil pump part 

13 


flat washer combination 

14 Seal ring 

15 Oil pump outlet pipe component 

Page 2070


18B-5 

DIAGRAM OF COMPONENTS II 

18B 

1 

Hexagon head bolt, spring washer and flat 

washer combination 

2 Oil drain plug 

3 Sealing gasket 

4 Small oil pan 

5 Oil pan gasket 

6 


and flat washer combination 

7 Aluminum oil pan assembly 

8 


and flat washer combination 

9 Aluminum oil pan rear gasket 

10 Aluminum oil pan front gasket 

Page 2071

18B-6 


MEASUREMENT 

△ Tip: 

Measure the oil level in the oil pan to see whether it is between two scale marks of oil dipstick. 

NOTE: 

• When measuring, the automobile shall be parked at the level position and the engine shall be 

stopped. One shall pull out the oil dipstick when the oil level is static, wipe out the oil on oil dipstick 

with clean cotton cloth, plug the oil dipstick into oil pan again till the end of dipstick and then pull 

out the oil dipstick to check the oil level. 

• When the filled oil of new gasoline engine or the one which is not used for a long time reaches the 

upper scale mark, one shall park the automobile after running for 5-10min at low speed and 

remeasure the oil level with oil dipstick. 

1. Check the oil level 

(a). Park the automobile on the road with level surface and turn 

off the engine. 

NOTE: 

• If the automobile service time is not long, the engine 

shall be started to run for a few minutes. 

• Turn off the engine, wait at least 5min and then check 

the oil level. 

(b). 

Open the automobile engine hood. 

18B 

(c). 

Take out the oil dipstick. 

Page 2072


18B-7 

(d). Check the oil level 

△ Tip: 

There are upper and lower scale marks on oil dipstick in order to 

facilitate checking the oil level. The oil level shall not be lower 

than the lower scale mark in case of that the oil pump cannot 

suck up oil. The oil is also not appropriate to be higher than the 

upper scale mark in case of the impact of crank of crankshaft 

to oil surface leading to excessive oil mist and splash oil drop in 

crank case and serious carbon deposit on the top of piston and 

combustion chamber walls. Meanwhile, there are some faults 

such like that the piston ring is stuck by coking, the diesel engine 

generates smokes and oil seal leakage and the increase of oil 

consumption. For these reasons, besides paying attention to the 

oil pressure, one shall also check the oil level before driving or 

for every 300~500Km running distance of automobile. 

NOTE: 

Besides paying attention to the oil pressure while operation, 

one shall also check the oil level before driving. 

18B 

Page 2073

18B-8 


DISCHARGE 

1. Dismantle the engine assembly. (Refer to Chapter 15A Engine Mechanical Part - Disassembly of 

Engine.) 

2. Dismantle the oil drain bolt 

△ Tip: 

• Do not reuse the disassembled bolt gasket and please 

replace it with a new one. 

NOTE: 

Before discharging the oil, the engine shall continue 

running till the oil temperature reaching approximate 80°C 

to ensure that all oil and suspended dirt are discharged. 

3. Discharge the oil in oil pan 

NOTE: 

• One shall prevent his/her skin from contacting the hot oil 

when discharging oil in order to avoid scalding. 

• One shall properly handle the used oil to protect the 

environment. 

18B 

4. Lubrication oil drain bolt 

△ Tip: 

When placing the lubrication oil drain bolt, the clean oil is 

required. 

5. Install and fasten the oil drain bolt 

NOTE: 

Whenever the oil drain bolt is dissembled, the oil drain bolt 

washer shall be replaced by a new one. 

Page 2074


18B-9 

CHECKING 

1. Check the oil drain bolt on oil pan to see whether it 

is loose. If it is loose, the bolt shall be screwed up. 

2. Check the threads of oil drain bolt to see whether it 

is damaged. If it is damaged, the bolt shall be 

replaced. 

3. Check the threads of oil drain bolt to see whether it 

is damaged. If it is damaged, the bolt shall be tapped 

or the hole shall be expanded and maintained. 

18B 

4. Check the fixing bolt on oil pan to see whether it is 

loose. If it is loose, the bolt shall be screwed up or 

be replaced when necessary. 

Page 2075

18B-10 


INJECTION 

1. Unscrew the oil filler cap 

(a). Take down the oil filler cap. 

△ Tip: 

The oil filler shall be cleaned by wiping prior to taking down the 

oil filler cap to avoid access of foreign matters. 

2. Change oil 

When using for a long time, not only foreign matter or dust will exist in oil, but some unburned fuel oil will also 

mix with oil to reduce the oil density. Moreover, there will be eroded parts due to oil deterioration when bringing 

in part of exhaust gas with acid anhydride etc. For this reason, when used for a period, the oil shall be 

discharged completely and changed with fresh oil. 

△ Tip: 

Replace it every 5,000Km. 

NOTE: 

• Use the diesel oil of grade CF-4 or above that conforms to the Q/SH038.202-1997 specification for 

the Great Wall Oil Company. 

• Select the oil according to ambient temperature when using. 

18B 

Page 2076


18B-11 

3. Fill the oil 

△ Tip: 

If the oil quantity of oil pan is unknown, the filled oil shall reach to 

the minimum volume of oil pan. Then one shall conduct the 

filling several times and fill a certain amount of oil each time till 

the oil level reaching the upper oil level mark on oil dipstick. 

Record the filling amount for knowing the oil volume when the 

next time replacement of oil. 

NOTE: 

• Do not fill till overflow in case of air inflation of oil or the 

loss of oil pressure. 

• The filled oil shall not be mixed with moisture and 

foreign matters. 

• It is prohibited to use the mixture of oils with different 

brands and manufacturers. 

4. Screw up the oil filler cap 

(a). Install the oil filler cap. 

△ Tip: 

As for every time of oil change, the diesel engine shall run with 

no load for a short period to ensure sufficient oil providing to the 

lubrication system and its parts which require the oil supply. 

Meanwhile, one shall also check the oil leakage phenomena of 

oil drain bolt, fuel filter and surrounding parts. 

(b) Check the oil level. 

△ Tip: 

There are upper and lower scale marks on oil dipstick in order to 

facilitate checking the oil level. The oil level shall not be lower 

than the lower scale mark in case of that the oil pump cannot 

suck up oil. The oil is also not appropriate to be higher than the 

upper scale mark in case of the impact of crank of crankshaft 

to oil surface leading to excessive oil mist and splash oil drop in 

crank case and serious carbon deposit on the top of piston and 

combustion chamber walls. Meanwhile, there are some faults 

such like that the piston ring is stuck by coking, the gasoline 

engine generates smokes and oil seal leakage and the increase 

of oil consumption. For these reasons, besides paying attention 

to the oil pressure, one shall also check the oil level before 

driving or for every 300~500Km running distance of automobile. 

NOTE: 

Besides paying attention to the oil pressure while operation, 

one shall also check the oil level before driving. 

18B 

Page 2077

18B-12 

LUBRICATION - OIL DIPSTICK 

OIL DIPSTICK 

SERVICE 

1. Service the oil dipstick 

(a). Clean the ambient dusts of oil dipstick with compressed 

air. 

(b). 

Disengage the connection of oil dipstick pipe and engine 

body. 

(c). 

Dismantle the oil dipstick pipe upper bracket fixing bolt. 

18B 

(d). 

Dismantle the oil dipstick pipe lower bracket fixing bolt. 

Page 2078

LUBRICATION - OIL DIPSTICK 

18B-13 

(e). 

Take out the oil dipstick assembly. 

(f). 

Install the oil dipstick assembly onto the specified 

position. 

(g). 

Install the oil dipstick pipe lower bracket fixing bolt. 

18B 

(h). 

Install the oil dipstick pipe upper bracket fixing bolt. 

(i). 

Connect the connection of oil dipstick pipe and engine 

body. 

Page 2079

18B-14 


OIL PAN 

SERVICE 

△ Tip: 

The oil in oil pan shall be ensured to be discharged completely before dismantling the oil pan. 

1. Dismantle the oil pan 

(a). Turn over the engine body. 

(b). Dismantle the fixing bolt of oil pan. 

(c). 

Take down the oil pan. 

18B 

2. Disassemble the oil pan assembly 

(a). Disassemble the small oil pan fixing bolt. 

(b). Take down the small oil pan and small oil pan gasket. 

△ Tip: 

Do not reuse the removed oil pan gasket and please replace it 

with a new one. 

Page 2080


18B-15 

3. Clean and check the oil pan. 

(a). Scrape all the remaining sealing materials on the oil pan 

and cylinder block, and clean the oil pan with vapor, dry 

the oil pan with compressed air. 

△ Tip: 

No.5 and No.7 machine oil (light spindle oil) can also be used 

when the oil pan is cleaned, and never use gasoline or kerosene 

to clean. 

NOTE: 

• Please wear safety glasses or protective mask and 

protective clothing to avoid serious personal injuries 

caused by hot vapor. 

• When using the compressed air, please wear proper 

safety glasses and protective mask to avoid personal 

injuries caused by splash scraps and dirt. 

(b). Check the oil pan to see whether it can still be used. 

△ Tip: 

• The oil pan is used to store the oil and dissipate the heat of oil. 

Dints and cracks are not allowed on oil pan. 

• When the cracks are not serious, the oil pan can still be 

reused instead of being replaced. 

4. Install the oil pan assembly 

(a). Install the small oil pan and gasket to designated 

position. 

18B 

(b). 

Install and fasten the small oil pan fixing bolt. 

Page 2081

18B-16 


(c). 

Install the oil pan assembly to a designated position. 

(d). 

Install and fasten the fixing bolts of oil pan. 

(e). 

Overturn and adjust the engine block. 

18B 

Page 2082


18B-17 

OIL PUMP 

SERVICE 

1. Dismantle the oil pan assembly. (Refer to Chapter 18B Lubrication-Oil Pan, Service.) 

2. Dismantle the oil pump assembly 

(a). Dismantle 2 fixing bolts of oil pump. 

(b). 

Disconnect the connection of oil pump outlet pipe and oil 

pump. 

(c). 

Take down the oil pump and oil pump outlet pipe. 

18B 


(a). File the rivet point of pinion stopper pin. 

Page 2083

18B-18 


(b). 

Drift the pinion out with a pivot-end drift pin. 

(c). 

Take down the pinion. 

(d). 

Dismantle the fixing bolt of oil pump cover and take 

down the oil pump cover. 

18B 

(e). 

Put the mark on the rotor to confirm the correct direction 

when assembling and dismantle the rotor. 

4. Service for the oil pump 

(a). Check the clearance between rotor and oil pump cover 

with a feeler gauge. If there is severe wear, replace the 

inside and outside rotors or the oil pump assembly. 

Standard value: 0.06 mm 


Page 2084


18B-19 

(b). 

Check the clearance between rotor and oil pump with a 

feeler gauge. If there is severe wear, replace the oil 

pump assembly. 



(c). 

(d). 

Check the clearance of main drive shaft and pump oil. 

• Check the main drive shaft external diameter with 

screw micrometer. 

• Measure the internal diameter of pump body with 

internal dial indicator. 

• The oil pump assembly shall be replaced if the 

clearance between main drive shaft and oil pump 

body exceeds the specified limit value. 



Check whether the oil pump cover and strainer are 

broken or blocked and replace them when necessary. 

18B 

5. Assemble the oil pump 

(a). Install the rotor. 

△ Tip: 

Install the rotor corresponding to the mark put previously. 

Page 2085

18B-20 


(b). 

Install the oil pump cover to designated position, and 

install and fasten the oil pump cover fixing bolt. 

(c). 

Install the pinion to designated position and install the 

pinion drift pin. 

18B 

6. Test the oil pump 

(a). When reassembling the oil pump, the oil pump shall be 

put into the clean oil pan and rotate the pump shaft 

clockwise till the oil flowing out from oil outlet of oil pump. 

One shall block the oil outlet with a hand and continue to 

rotate the pump shaft. If the rotational resistance 

increases, the operation condition is normal. 

The oil pump pressure can be measured with oil 

pressure gauge if necessary. 

7. Install the oil pump assembly 

(a). Install the oil pump and oil pump outlet pipe to 

designated position. 

Page 2086


18B-21 

(b). 

Connect the connection of oil pump outlet pipe and oil 

pump. 

(c). 

Install and fasten 2 fixing bolts of oil pump. 

8. Install the oil pan assembly. (Refer to Chapter 18B Lubrication-Oil Pan, Service.) 

18B 

Page 2087

18B-22 


OIL FILTER 

SERVICE 

1. Dismantle the oil filter assembly 

(a). Disconnect the connection of oil cooler inlet and outlet 

hoses and oil cooler. 

△ Tip: 

One shall place a vessel under the oil filter when disassembling 

to receive the spilled oil. 

(b). 

Dismantle the fixing bolt of oil filter assembly. 

(c). Take down the oil filter assembly and oil filter washer. 

△ Tip: 

Do not reuse the removed oil filler washer. 

18B 

2. Disassemble the oil filter assembly 

(a). Dismantle the oil cooler fixing bolt with special tools and 

take down the oil cooler. 

△ Tip: 

One shall place a clean vessel under the filter to receive the 

spilled oil. 

Page 2088


18B-23 

(b). Dismantle the oil filter element with special tools in the 

counterclockwise direction. 

△ Tip: 

One shall place a clean vessel under the filter when dismantling 

the filter element to receive the spilled oil. 

NOTE: 

Spin-on filter element is a disposable part that can’t be 

reused. 

3. Check the oil filter seat 

(a). Check and clean the oil filter seat and ensure the fitness 

of new oil filter element. 

4. Assemble the oil filter assembly 

(a). Apply a thin layer of oil on the surface of O-ring, and 

screw up the new filter element to the filter seat until the 

resistance is felt. 

18B 

(b). Rotate in the clockwise direction to install the oil filter 

element with special tools. 

△ Tip: 

Rotate it by 3/4 circle clockwise. 

NOTE: 

• Spin-on filter element is a disposable part that can’t be 

reused. 

• When the oil filter is disassembled and installed, it must 

be noticed that do not damage the rubber seal ring to 

prevent impacting the sealing performance and resulting 

in oil leak. 

Page 2089

18B-24 


(c). Install the oil cooler to designated position and install the 

oil cooler fixing nut with special tools. 

△ Tip: 

Apply a thin layer of oil to the surface of O-ring. 

5. Install the oil filter assembly 

(a). Install the oil filler assembly and filter washer to the 

washer in designated position. 

△ Tip: 

Apply clean oil to the new oil filter washer before installing. 

(b). 

Install and fasten the fixing bolt of oil filter assembly. 

18B 

(c). 

Connect the connection of oil cooler inlet and outlet 

hoses and oil cooler. 

Page 2090


IGNITION SYSTEM ................................................................................... 19-1 

Overview ............................................................................................... 19-1 

Precautions .......................................................................................... 19-2 

Check on Board ................................................................................... 19-3 

SPARK PLUG ............................................................................................ 19-4 

Detection .............................................................................................. 19-4 

Service .................................................................................................. 19-5 

HIGH TENSION WIRE .............................................................................. 19-8 

Service .................................................................................................. 19-8 

IGNITION COIL ......................................................................................... 19-9 

Service .................................................................................................. 19-9 

CRANKSHAFT POSITION SENSOR ..................................................... 19-10 

Service ................................................................................................ 19-10 

19 

Page 2091

19 

Page 2092


19-1 


OVERVIEW 

In order to generate high-voltage electric sparks regularly, the gasoline engine is equipped with special 

ignition device, engine ignition system. Making the engine work by igniting combustible gas mixture, the 

ignition system can duly, accurately and reliably generate electric spark in cylinder under any working 

condition or service condition of engine. Generally, the ignition system consists of battery, ignition switch, 

ignition coil, spark plug and fuse. 

19 

Page 2093

19-2 


19 

PRECAUTIONS 

1. When the engine is started and working, do not touch the ignition coil and high tension wire in 

case of high-voltage electric shock. 

2. When conducting the high-voltage trial ignition, it recommends that the high tension wire 

shall be clamped with insulation rubber clamp. Do not directly touch the high tension wire 

with hands in case of electric shock and the damage of ignition system high tension circuit. 

During the trial ignition, one shall firstly plug a high tension wire into a standby spark plug, 

then ground the spark plug and observe the spark-over situation between electrodes of spark 

plug. 

3. When inspecting the service condition of each cylinder with the method of cut-out cylinder by 

cylinder, the high tension wire of cut-out cylinder shall be grounded by short-circuit method 

instead of open-circuit method. 

4. Ignition timing exerts a tremendous influence on engine functioning. For this reason, when 

the engine is in bad service or disassembled, one shall pay attention to check the ignition 

timing. 

5. While the spot welding operation on board, the ground wire of battery shall be disassembled. 

6. If the wire of ignition system (including the disassembly and connection of test instruments) is 

required to be disassembled or connected, the ignition switch shall be shut off primarily. 

7. While cleaning the engine, the ignition switch shall be shut off primarily. 

8. If the high tension wire is required to be unplugged, one shall pull the connecting part (such 

as the connecting sleeve of spark plug) instead of pulling the wire. 

Page 2094


19-3 

CHECK ON BOARD 

1. Check the ignition coil 

(a). Turn off the ignition switch and unplug the terminal 

wiring harness connectors and high tension wires from 

ignition coil kit. 

(b). Respectively measure the resistance between B 

terminal and A & C terminals of 3-terminal- connector 

on the ignition coil kit with ohmmeter (primary coil 

resistance). 

Primary resistance value: 0.52±0.05 Ω 

△ Tip: 

The ignition coil kit shall be replaced if the resistance of ignition 

coil is out of the specified range. 

(c). Measure the resistance between high-voltage output 

terminals of Cylinder 2 & Cylinder 3 and Cylinder 1 & 

Cylinder 4. 

Secondary resistance value: 9840±980 Ω 

△ Tip: 



19 

2. Spark over test. 

If the engine can rotate but not be started, one shall conduct the spark over test for it. The procedure 

is: unplug the high tension wire from the spark plug and assemble an ignition alignment tester onto 

the high tension wire. Connect the clamp of tester onto the bolt or support of engine, rotate the engine 

and observe the spark over situation at the end of tester. If there is no ignition alignment tester, one 

shall hold the high tension wire end with insulating tool, keep the end terminal 6mm distant from the 

proper ground position, revolve the engine and observe the spark over situation at the end of tester. If 

there are continuous and uniform blue sparks, one shall check or replace the spark plug; if no spark or 

the spark is weak or intermittent, one shall check the ignition coil kit (intermediate terminal) to see 

whether it gets sufficient battery voltage and check ignition high tension wire, ignition coil and ignition 

module. 

Page 2095

19-4 

IGNITION - SPARK PLUG 

19 

SPARK PLUG 

DETECTION 

1. Detect the spark plug 

(a). 

(b). 

Method of automobile check 

● Method of touch: Start the engine, make it idling and touch the ceramic insulating part of spark plug. 

If the temperature increases to a very high level and at a fast speed, the spark plug is working 

normally, otherwise, it is abnormal. 

● Method of short circuit: Start the engine, make it idling and short out the spark plug with 

screwdriver cylinder by cylinder and listen to the revolving speed and sound variation of engine. If 

the variation of revolving speed and sound is obvious, the spark plug is working normally, 

otherwise, it is abnormal. 

● Method of spark-over: Screw off the spark plug and put it on the cylinder block. Conduct the trial 

ignition with high tension wire, if no spark or the spark is weak, it means the spark plug has a fault 

of current leakage or it does not work. 

Method of observing color 

● Disassemble the spark plug and observe it, the color of russet or rust means the spark plug is 

normal; if it seems like oil stains, it must be the clearance maladjustment of spark plug, excessive 

gasoline, short circuit or open circuit; if it is smoky black, the selection for soft plug or hard plug 

must be wrong, or there’s a high concentration of gas mixture and the engine oil will go upward; if 

there are deposits between the top and electrode, especially if they are oily deposits, it means the 

oily smoke is unrelated with spark plug, and if they are black deposits, it means spark plug is 

accumulated by carbon deposits and bypassed, and if they are grey deposits, it means the ignition 

miss due to addition agent covering electrode. If the ablation is serious, such as scars on the top, 

black rupture pattern and melt of electrode, it means the spark plug is damaged. 

Page 2096


19-5 

SERVICE 

NOTE: 

The following issues shall be noted for the disassembly or installation of spark plug. 

(a). Before dismantling the spark plug, one shall gently pull out the connector of each cylinder instead of 

pulling the high tension wire with great force to avoid damaging the high tension wire or the 

connection terminals of spark plug which is likely to be damaged. 

(b). As for the disassembly of spark plug, one shall firstly blow off the dirt around spark plug with a thin 

hose in case of dirt falling into the cylinder after screwing off the spark plug. 

(c). One shall disassemble the spark plug when the engine is cooled. One shall not shake the spark plug 

with great force during operation to avoid damaging the sealing property of spark plug. 

(d). During installation, the threads, electrodes and sealing gasket of spark plug shall be cleaned, dried 

and without oil stains in case of current leakage, air leakage, spark weakening and other faults. 

(e). When screwing in the spark plug, the bolt shall be screwed in by 1/2 of its total length with hands and 

then fastened by a jack lever. If the bolt cannot be screwed in smoothly, one shall quit the operation 

and check the spark plug to see whether it is aligned with screw or whether there are foreign matters 

in threads. One shall not aimlessly apply force on it and fasten it to avoid damaging screw hole or 

cylinder head. 

(f). If a flat-seat-type spark plug is selected, it shall be equipped with a sealing gasket, of which the 

quantity shall be adequate. Carbon deposit is likely to exist if the sealing deposit is excessive, while 

for sealing’s sake, no-sealing–gasket is not permitted. If a conical-seat-type spark plug is selected, no 

sealing gasket shall be equipped. 

(g). The spark plug shall be screwed up as required, because loose spark plug will lead to air leakage, 

while the excessively tight spark plug will also lead to air leakage due to elasticity lack. 

19 

1. Disassemble the spark plug 

(a). Disassemble the spark plug with special tools. 

NOTE: 

When the spark plug hole is opened, please prevent foreign matters from entering the combustion 

chamber. 

2. Service the spark plug 

(a). Check the edge of electrodes of spark plug and replace 

the spark plug if it is worn. 

Page 2097

19-6 


(b). Check the gap between central electrode and 

grounding electrode with a spark plug gap gauge to see 

whether it is within the specified range. 

Electrode gap of spark plug: 1.1±0.1 mm 

△ Tip: 

Please use special gauge for spark plug to measure the spark 

plug gap. 

1: Spark plug gap gauge 

2: Grounding electrode 

3: Central electrode 

(c). 

Check the insulator to see whether there are flaws or 

the damages of terminal corrosion or threads. If there 

are, replace the spark plug. 

(d). 

If there are moist carbons, one shall dry it and clean it 

with cleaning agent specially applied to spark plug. 

19 

3. Adjust the spark plug gap 

(a). Put the grounding electrode into the gap part of spark 

plug gap gauge and bend the grounding electrode to 

adjust the gap. 

Electrode gap of spark plug: 1.1±0.1 mm 

NOTE: 

When bending the grounding electrode, the gap gauge of 

spark plug shall not touch the insulator in order to ensure 

the insulator shall not be ruptured. Also, one shall not pull 

or knock the central electrode. 

1: Spark plug gap gauge 

2: Grounding electrode 

3: Central electrode 

4: Insulator 

5: Before adjustment 

Page 2098


19-7 

4. Assemble the spark plug 

(a). Assemble the spark plug with special tools. 


19 

Page 2099

19-8 

IGNITION-HIGH-TENSION WIRE 

HIGH TENSION WIRE 

SERVICE 

1. Disassemble the high tension wire 

NOTE: 

The engine shall be shut off in prior of dismantling the high tension wire. 

2. Detect the high tension wire with multimeter. 

(a). Measure the resistance of high tension wire with an 

multimeter, if it is not within the specified range, replace 

the high tension wire. 

3. Assemble the high tension wire 

(a). Plug the connector of high tension wire and spark plug into the spark plug and ensure its security. 

(b). Insert the connector of high tension wire and ignition coil into the ignition coil and ensure its security. 

19 

Page 2100

IGNITION - CRANKSHAFT POSITION SENSOR 

19-9 

IGNITION COIL 

SERVICE 

1. Check the ignition coil 

(a). Turn off the ignition switch and unplug the terminal wire 

harness connectors and high tension wires from the 

ignition coil kit. 

(b). Disassemble the fixing bolt of ignition coil and take 

down the ignition coil. 

(c). Respectively measure the resistance between B 

terminal and A & C terminals of 3-terminal- connector 

on the ignition coil kit with ohmmeter (primary coil 

resistance). 

Primary resistance value: 0.52±0.05 Ω 

△ Tip: 



(d). Measure the resistance between high-voltage output 

terminals of Cylinder 2 & Cylinder 3 and Cylinder 1 & 

Cylinder 4. 

Secondary resistance value: 9840±980 Ω 

△ Tip: 



19 

2. Assemble the ignition coil 

(a). Assemble the ignition coil to the mounting position and 

tighten the fixing bolt. 


(b). Connect the high tension wires to the ignition coil. 

(c). Assemble the terminal harness connectors of ignition 

coil in place. 

Page 2101

19-10 

IGNITION-HIGH-CRANKSHAFT POSITION SENSOR 

CRANKSHAFT POSITION SENSOR 

SERVICE 

1. Service the crankshaft position sensor 

(a). Detect for the voltage between two terminals. One shall 

test the voltages between each two of terminals A, B, 

and C, 3 terminals of sensor with voltage grade of 

multimeter. When the ignition switch is “ON”, the 

voltage value between A-C terminals is about 8V; the 

voltage value between B-C terminals will vary in the 

range of 0.3-5V when the engine is running. And its 

value varies like pulse: the maximum voltage is 5V, and 

the minimum one is 0.3V. If the actual results are not in 

accordance with the results, the crankshaft position 

sensor shall be replaced. 

A: Signal+ B: Signal- C: Screening Layer 

19 

Page 2102

电器系统 - 发电机 14- 


GENERATOR ......................................................................................... 20B-1 

Overview ............................................................................................ 20B-1 

Diagram of Components .................................................................. 20B-2 

Testing Generator ............................................................................. 20B-3 

Disassembly and Installation of Generator .................................... 20B-6 

STARTER ............................................................................................. 20B-10 

Overview .......................................................................................... 20B-10 

Diagram of Components ................................................................. 20B-11 

Testing Starter ................................................................................. 20B-12 

Disassembly and Installation of Starter ........................................ 20B-15 

BATTERY ASSEMBLY ......................................................................... 20B-17 

Overview .......................................................................................... 20B-17 

Structure .......................................................................................... 20B-18 

Working Principle ........................................................................... 20B-22 

Working Characteristics ................................................................. 20B-23 

Precautions ..................................................................................... 20B-24 

Common Faults and Troubleshooting for Battery ....................... 20B-25 

Diagram of Components ................................................................ 20B-28 

Replacement .................................................................................... 20B-29 

USE OF MAINTENANCE FREE BATTERY ........................................ 20B-32 

Checking of Technical Condition .................................................. 20B-32 

Charge The Maintenance Free Battery ......................................... 20B-33 

20B 

Page 2103

20B 

Page 2104


20B-1 

GENERATOR 

OVERVIEW 

Generator is the main power supply for electric equipment of automobiles. During the period of automobile 

normal operation, generator powers the other electric equipment for starter, and also charges the battery. 

Please pay much attention to the following problems for the use and maintenance of alternator. 

1. The bonding of battery shall be in accordance with the polarity of alternator. The bonding shall be 

negative or else the battery will discharge through diode of silicon rectifier to burn up the diode. 

2. The method of make the output terminal of generator’s grounded (ground) cannot be used to check 

whether the generator generate electricity. 

3. When the generator runs at a high speed, do not dismantle the main electric equipment of battery to 

avoid producing overvoltage and damaging the diode, adjuster or other electric equipment. 

4. Inspect whether the wiring between the generator and battery is fixed and dependable. 

5. Inspect the tension of generator belt to judge whether it is in accordance with the ex-factory 

regulations. If the belt is too loose, the battery will undercharge; if the belt is too tight, the belt and 

generator bearing will be easily damaged. 

6. Once the generator is found out to work abnormally, check it timely, find out and remove the fault. 

7. Maintain the generator regularly. Generally speaking, check and inspect the generator’s electric brush, 

rectifier element, adjuster, bearing and other vulnerable elements one time after the generator runs 

for 750h or after the automobile travels for 30000Km. 

20B 

Page 2105

20B-2 



20B 

1 Belt tension arm 

2 Generator fastening bolt washer 



5 Generator component 

6 Connector bolt 

7 Vacuum pump inlet tube assembly 

8 Copper washer 

9 Vacuum pump return tube 

10 Return tube clip 

11 Nut 



14 

15 


assembly 


assembly 

16 Generator bracket 

17 Generator fastening bolt 


Page 2106


20B-3 

TESTING GENERATOR 

1. Checking generator’s output direct voltage 

(a). Start the generator and make the generator run at idle 

speed. 

(b). Measure the voltages on both terminal s of storage with 

digital multimeter. The voltage registration shall be 

between 13 V and 15V (the detailed registration shall 

be set according to the set value of adjuster). When the 

generator rotate speed rises, the output direct voltage 

of generator basically 

2. AC component test of generator’s output voltage 

Adjust the digital multimeter to the AC voltage and connect it on the positive and negative poles of battery and 

measure the generator’s output AC voltage (normal value shall be ≤0.4V). 

The specific steps are as follows: 

(a). Start the generator and make the generator run at 2000rpm. 

(b). Turn on the headlamp and apply certain load for the generator. 

(c). 

Adjust the digital multimeter to the AC voltage and 

connect it with the positive and negative poles and read 

the AC voltage value. If the voltage is ≤0.4V, it indicates 

that the rectifier of generator works normally. If the 

voltage is not in the range of ≤0.4V, it indicates that the 

rectifier of generator has fault. 

20B 

3. Checking the charging system voltage drop 

The voltage drop test is mainly for checking whether the wiring between generator and battery is in good 

connection. 

The specific methods are as follows: 

(a). Start the generator and make it runs at 2000rpm of the rotate speed. 

(b). Turn on the headlamp and apply certain load for the generator. 

(c). Adjust the digital multimeter to the AC voltage and measure the voltage drop between the generator’s 

output terminal and battery’s positive pole. The normal value is ≤0.4V. If the value is higher than 

0.4V, it indicates that the resistance of the wire connection point is too high. 

△Tip: 

The following is only the schematic diagram. 

Page 2107

20B-4 


20B 

(d). Adjust the digital multimeter to the direct voltage and measure the voltage drop between the 

generator casing and battery’s negative pole. The normal value is ≤0.3V. If the value is higher than 

0.3V, it indicates that the wire connection becomes loose and the resistance of connection point is too 

high. 

△Tip: 

The following is only the schematic diagram 

Page 2108


20B-5 

4. Checking single machine of generator 

(a). Measure whether the generator’s guide terminal is 

conductive with ohmmeter. 

△ Tip: 

Respectively insert ohmmeter hand in two needles of the 

generator’s guide terminal. If the display value on the 

ohmmeter is infinite, it indicates that the wire harness inside 

the generator disconnects, the generator is damaged and shall 

be replaced. If the display value on the ohmmeter is minimum, 

it indicates that the wire harness of generator is in good 

condition. 

(b). No-load test 

△ Tip: 

Disconnect the switch K, rapidly rise generator’s rotate speed, 

make the battery’s positive wire contact the wiring terminal of 

generator of magnetic field for the excitation of generator. 

When the generator voltage is 18V, the rotate speed of 

generator is 1000rpm. 

NOTE: 

The generator shall run flexibly when it is moved by hands 

and there shall be no hysteresis and scraping phenomena. 

1: Magnetic field 2:Armature 3: Neutral point 

(c). Load test 

• Adjust the load resistance of circuit to the maximum. 

• When the alternator voltage is 28 V for the load test, 

the switch shall be switched on to make the 

generator output the current outward. 

• Gradually reduce the load resistance to increase the 

output current and raise the rotate speed to make 

the generator voltage keep 28V. 

20B 

Output current/A Voltage of electric machine/V Generator speed/(rpm) 

5 28

20B-6 


DISASSEMBLY AND INSTALLATION OF GENERATOR 

1. Turn off the ignition switch when the car stops stably. 

2. Disconnect the lead of battery pole 

(a). Disconnect the negative terminal of battery. 

(b). 

Disconnect the vacuum pump inlet and outlet tubes 

behind generator and the generator connector. 

(c). 

Loosen the adjusting bolt above generator. 

20B 

(d). 

Release the whole belt tension and remove the belt. 

Page 2110


20B-7 

(e). Remove the generator fixing bolt. 

△ Tip: 

Remove the generator fixing bolt with two wrenches together. 

(f). 

Remove the adjusting bolt above and the generator. 

3. Disassemble generator assembly 

(a). Remove the vacuum pump fixing bolt. 

20B 

(b). 

Remove the vacuum pump. 

4. Install generator assembly 

(a). Place the vacuum pump to generator installation 

position. 

Page 2111

20B-8 


(b). 

Install and tighten the vacuum pump fixing bolt. 

5. Install generator assembly 

(a). Place the repaired generator to engine bracket. 

(b). Install the upper adjusting bolt. 

△ Tip: 

The upper adjusting bolt is not tightened to install and adjust 

belt. 

(c). 

Install the generator fixing bolt. 


20B 

(d). 

Adjust the generator position, install the generator belt 

and adjust the drive belt tension. 

(e). Install the adjusting bolt above generator. 

△ Tip: 

Do not tighten the adjusting bolt above generator excessively 

to adjust generator belt. 

Page 2112


20B-9 

(f). 

Firmly press the generator belt and check if the belt is 


Reference standard: force of 39 N and deflection of 

approximately 10 ~ 15 mm 

(g). 

Confirm the generator belt is installed in place and 

tighten the generator adjusting bolt. 


(h). 

Connect the vacuum pump inlet and outlet tubes 

behind generator and the generator connector. 

20B 

(i). 

Connect the battery. 

Page 2113

20B-10 


STARTER 

OVERVIEW 

The starter mainly consists of three components: DC series motor, driving mechanism for one -way clutch 

and battery switch. The three components can smoothly finish the start of engine by organic combination and 

cooperative work. 

The detailed working process is as follows: 

Connect the starting ignition → starting relay has electricity → solenoid switch electrifies →produce 

electromagnetic tension → Push off the isolator through shifting fork to mesh it with the flywheel; at the same 

time, transfer the battery’s electric energy to the motor → wheel gear isolator rotates → produce the 

electromagnetic torque to start the engine. 

20B 

Page 2114


20B-11 


1 1 type hexagon nut 


3 Flat washer 

4 Starter motor 


20B 

Page 2115

20B-12 


TESTING STARTER 

1. Testing voltage drop of starting system 

Testing voltage drop is mainly to check the connection condition of lead wire of main circuit for starter. Adjust 

the digital multimeter in the direct voltage, measure it according to the following diagram. Each part’s 

measured voltage value shall be ≤0.2V. if the measured voltage value of one part is >0.2V, it indicates that 

the wiring of the part has problem. 

20B 

2. Testing starter 

Judge the starter’s performance and technical condition by no-load test, brake test and performance test of 

solenoid switch. 

(a). No-load test 

Connect the circuit to observe whether the starter runs normally. Connect the ampere meter in series 

with the circuit. Read the current value and the current value shall not be >90A. 

NOTE: 

Idling time of starter shall not be more than 1 min. 

△Tip: 

The following is only the schematic diagram. 

Page 2116


20B-13 

(b). 

Brake (locked) test 

The brake test shall be performed on the starter’s test station. Check whether the inner circuit of 

starter has fault with the method of measuring torque which is produced when braking and consumed 

current. And also check whether the meshing gear can slip. When performing the brake test, the 

starter shall be proved by no-load test to be in good condition. The test method is as follows. 

• Clamp the starter on the brake fixture of universal 

test stand and clamp three gears of pinion gear with 

clamp splice which is on the brake connecting rod. 

20B 

• Connect the wiring of test stand and starter. 

1: Starter 

Page 2117

20B-14 


• Press down the button SB on the universal test 

stand (press the button tight and then loosen it), the 

starter is braked. Rapidly read the voltage value and 

current value respectively from the voltmeter’s dial 

and ampere meter’s dial and then read the torque 

value from the weight beam. Compare the voltage 

value, current value and torque value with the 

standard value to analysis and judge whether the 

starter has fault. 

NOTE: 

The time of processing circuit shall be not more than 5s. If 

it shall be tested again, the battery shall have a rest for 1~ 

2min to avoid reducing the service life of battery. 

3. Performance test of solenoid switch 

(a). Remove the wiring between M terminal and motor. 

(b). Connect the battery’s negative pole with the starter housing and connect the positive pole with S 

terminal. At this moment, although the coil is kept to be electrified, the electromagnetic force is too 

small and the armature cannot move. 

(c). Connect the negative pole and M terminal to hear that the solenoid switch making pick-up sound and 

the driving gear is pushed out. 

(d). Move away the negative pole from M terminal, the solenoid switch keeps pick-up, and the resistance 

between two electric shocks of solenoid switch is “0” 

20B 

Page 2118


20B-15 

DISASSEMBLY AND INSTALLATION OF STARTER 

1. Disassemble starter assembly 

(a). Disconnect the battery. 

(b). 

Disconnect each lead wire of starter’s wiring terminal 

(c). 

Disassemble the fixing bolts of starter. 

20B 

(d). 

Take down the starter. 

Page 2119

20B-16 


2. Install starter assembly 

(a). Install the starter in the corresponding position 

(b). 

Install and fasten the fixing bolts of starter. 


(c). 

Connect each connecting lead wire of starter’s wiring 

terminal. 

20B 

(d). 

Connect the battery. 

Page 2120

STARTING AND CHARGING - BATTERY ASSEMBLY 

20B-17 

BATTERY ASSEMBLY 

OVERVIEW 

Battery, a device of converting the chemical energy into electric energy, is a reversible direct-current power 

supply with low voltage and is referred as “battery”. The maintenance free battery is a battery which cannot 

be maintained during the service period under the specified service conditions. For lead battery for 

automobile, the maintenance free battery is a battery which cannot be added distilled water during the service 

period. 

Functions of battery: 

1. When start the engine, power the main power supply equipment, such as starter, ignition system and 

so on. 

2. When there is too much electric equipment or when the electricity consumption is more than the 

starter’s capacity of electric power supply, the battery will assist the starter to power the electric 

equipment. 

3. The battery can stabilize the voltage. The battery is considered to be a big capacitor which can absorb 

the momentary overvoltage in the circuit and can protect electric equipment. 

4. When the storage electricity of battery is insufficient and the generator’s load is less, the battery can 

convert the generator’s electric energy as chemical energy to be stored (it means charging) 

5. The battery is considered as a capacitor with big capacity. When the generator speed and load 

change, the battery can keep the system voltage of automobile electric equipment relatively stable. At 

the same time, the battery can absorb momentary overvoltage which is produced by generator to 

protect the automobile electric elements from being damaged. Therefore, the generator cannot be run 

when it is without the battery. 

20B 

Page 2121

20B-18 


STRUCTURE 

△Tip: 

The automobile type of SUP series adopts lead battery. The battery of 12V consists of 6 unit cell battery in 

series. The nominal for each unit cell of battery is 2V, and it is 2.1 V when the battery is filled. 

The lead battery consists of battery plate, battery plate group, and separator, acid electrolyte liquid and 

housing. 

20B 

1 Battery housing 

2 Battery electrolyte liquid 

3 Battery plate and plate group 

4 Battery separator 

Page 2122


20B-19 

1. Plate and plate group 

The battery plate is divided into positive plate and negative plate. The positive plate and negative plate take 

the comb rack which is poured by lead-antimony alloy as the skeleton. Fill the active material on the comb 

rack to manufacture the plate 

The plate frame consists of comb rack which is the attachment 

of active material. 

The active material is filled on the comb rack. The active 

material on the positive plate is nigger-brown lead dioxide 

(PbO 2 ) and the active material on the negative plate is spongy 

caesious pure lead (Pb) 

There are two kinds of comb rack which are adopted by the 

battery: one is the common type as shown in the left diagram. 

20B 

The other is radiative type as shown in the right diagram. 

△Tip: 

The radiative type comb rack, which is characterized by high 

output current, low internal resistance, and is used in the 

new-type battery. 

Page 2123

20B-20 


In order to increase the capacity of battery, each unit cell 

battery has multiple positive and negative plates to form plate 

group, as shown in the left diagram. 

Reason: 

Each positive plate is located between negative plates to 

equally charge and discharge both terminals of positive plate. 

2. Separator 

Functions of separator: 

The insulating separator shall be installed between the 

battery’s positive and negative poles to avoid the short circuit 

of plates. 

△Tip: 

• The separator is characterized by porosity, which is convenient for electrolyte to freely permeate. 

• The separator is made by adopts acid resistance and alkali resistance woodiness, microfoam rubber, 

micropore plastic and impregnated resin paper material. 

• The micropore plastic separator is made in bags and is tightly wrapped on the external of positive plate to 

avoid falling off the active material. 

20B 

3. Acid electrolyte 

The electrolyte is the sulfate water solution which is allocated by certain proportion of sulfate (H 2 SO 4 ) and 

distilled water (H 2 O) . 

The density is 1.24~1.31g/m 3 

△ Tip: 

The electrolyte density has great influence on the capacity and service life of battery. The big density can 

raise the capacity of battery and can reduce the possibility of freeze; when the viscosity increases, the fluidity 

becomes poor to make the capacity of battery reduce and to make the corrosiveness strengthen, as a result, 

the service life of plate and separator is reduced. 

Page 2124


20B-21 

4. Housing 

The housing adopts acid resistance, heat resistance and aseismatic hard rubber or polypropylene plastic to 

make overall structure. The housing is divided into 6 unit cells which are not connected with each other. 

△ Tip: 

The housing bottom has the raised rid which supports the plate group and make the active materials drop in 

the groove from the plate to avoid short circuit of plate. 

20B 

Page 2125

20B-22 



The battery is an electrochemical power source and the charging and discharging process is a kind of 

reversible chemical reaction. 

1. Establish electromotive force 

(a). On the positive plate, PbO 2 and sulfate produce lead 

ion (Pb 4+ ) ascending and descending on the positive 

plate with positive charge to make the positive plate 

has about 2V positive potential. 

(b). On the negative plate, the lead ionization contains lead 

ion(Pb 2+ ) and electron (2e) , the two electrons leave on 

the negative plate to make the negative plate has about 

–0.1V negative potential. 

2. Discharge battery 

The electrolyte can be diluted and water increases when 

chemical reaction with load is processed. 

(a). The positive and negative plates can produce lead 

sulfate (PbSO 4 ) to increase water in the electrolyte. 

(b). When the discharge is processed, the electrolyte 

density will be reduced. 

20B 

3. Charge battery 

The two electrons return the negative pole from the positive 

pole with the function of external power to form the charging 

current flowing from the positive plate to the negative plate. 

(a). The lead sulfate on the plate revert to lead oxide and 

lead and the water in electrolyze reverts to sulfate. 

(b). The sulfate in electrolyze increases and the electrolyze 

density increases when charge is processed. 

Page 2126


20B-23 

WORKING CHARACTERISTICS 

1. Internal resistance of battery 

(a). 

(b). 

(c). 

The internal resistance reflects the load capacity of battery. The lower the battery is, the higher the 

output current is. The internal resistance includes plate resistance, separator resistance and 

electrolyte resistance. 

The plate resistance is very low when it is fully charged. But when the battery’s discharge degree 

increases and the lead sulfate which is covered on the plate surface increases, the plate resistance 

increases too. The separator resistance is determined by the separator’s material, thickness and 

porosity. The micropore plastic separator’s resistance is lower in the common separator. 

The electrolyze resistance is related to electrolyze temperature and density. When the temperature 

falls, the electrolyze viscosity increases and the penetrating power drops, which makes that the 

resistance increases. When the electrolyze density is too high or too low, the resistance will increase. 

2. Discharging characteristic of battery 

(a). The discharging characteristic of battery means that 

the changing law of battery terminal’s voltage Uf and 

electrolyze density P 25 ℃with the discharging time 

changing during constant current discharging. 

3. Charging characteristic of battery 

(a). The charging characteristic of battery means the 

changing law of battery’s charge voltage and 

electrolyze density P 25 ℃ with the charging time 

changing during constant current charging. 

20B 

Page 2127

20B-24 


PRECAUTIONS 

1. The selection of battery shall have the same capacity with that of the automobile. 

2. Keep the vent plug in tightened state to avoid spilling the acid resistance liquor. 

3. When the battery need to charge again, the supplemental current is 11A. When the battery is fully 

charged it has the following phenomena (do not allow being overcharged): 

Phenomenon 1: the voltage and electrolyze density shall not have obvious change within continuous 

2h. 

Phenomenon 2: the inner battery produces strong bubble and electrolyze has “ebullition” 

phenomenon. 

4. The battery is not allowed to be stored for a long time. If the battery shall be stored, then the battery 

shall be charged every three months (the supplement current is 11A and the voltage is 18 V). 

5. Electrolyze of battery contains sulfate which seriously damages the skin, eye and clothes. Prevent 

electrolyze from spilling when moving electrolyze. When the accident happens, the following methods 

can be properly adopted: 

(a). Immediately wash the external which is infected. 

(b). If the electrolyze enters the mouth, immediately rinse the mouth and drink lots of water or milk 

then go to see a doctor. 

20B 

Precautions for maintenance: 

1. Do not make two wiring terminals of battery short circuit, or else the battery will rapidly become hot 

even may burst. In addition, the gas which is dissipated from the battery will be easily to be lighted by 

sparks. Therefore, do not use naked flame near the battery. 

2. When disassembling and installing the electric equipment, first disassemble the ground wire of 

battery in order to avoid short circuit. When replacing bulb, turn off all relevant switches. 

3. When disassembling battery, disassemble the ground wire, then disassemble positive wire and then 

disassemble the battery baffle. Take out the battery from the rack. The installation of battery is in the 

reverse order of disassembly. 

Page 2128


20B-25 

COMMON FAULTS AND TROUBLESHOOTING FOR BATTERY 

Phenomenon 1: Housing broken 

Housing broken is the most serious destructive fault during the use of battery. After the housing is broken, 

electrolyze in the battery will leak and run off. If the housing is interval damage, the adjacent unit cell will be 

short circuit together to make the terminal voltage drop obviously so that the battery cannot properly work. 

Causes: 

1. Improper use and maintenance. For example, the fixed frame is too tight. 

2. Rubber anti-vibration pad is too tight or is not installed. 

3. The automobile fiercely vibrates and impacts during the driving. 

4. The external force hits the battery housing. 

5. Air vent on the plug screw is blocked. 

6. In winter then electrolyze density is too low or the temperature is too low or it freezes. 

Treatment: 

1. After the housing is broken, immediately disassemble the battery from the automobile. The battery 

shall be considered to be repaired or discarded as useless according to the condition. 

Phenomenon 2: Plate vulcanizing 

The battery is undercharge or cannot be charged for a long time after discharging, there is gradually a layer of 

white coarse grain lead sulfate on the plate. This lead sulfate cannot be transferred into lead dioxide in 

normal charge. This phenomenon is called “lead sulfate hardening” which is called “vulcanization” for short. 

The electrical conductivity of this kind of lead sulfate is very bad, which makes the battery’s internal 

resistance increase; when the volume increase, the pore space of active material is blocked and the 

electrolyze is blocked to permeate. Then the effective active material on the plate is reduced, and the 

discharge capacity is reduced, and the battery cannot provide enough start current, as a result, the engine 

cannot be started. 

Causes: 

1. When the battery is undercharge for a long time or is not charged timely after being discharged, some 

lead sulfate on the plate will be dissolved in electrolyze. The higher the temperature is, the bigger the 

solubility is. But when the temperature reduces, the solubility is smaller, and the lead sulfate will 

separate out again and crystallize again on the plate and form vulcanization. 

2. Electrolyze liquid level is not checked for a long time. The liquid level is too low, which makes the 

exposed liquid level on the upper of plate contact with the air and produce strong oxidation. 

3. The battery is overcharged for a long time or the low current is deeply discharged, which makes the 

active material’s long hole in the deep of plate produce lead sulfate so it cannot be easily to recover 

when charging. 

4. The new battery is not thoroughly charged and the active material does not get full recovery. 

5. Electrolyze density is a little higher, the composition is not very pure and external temperature 

changes fiercely. 

Treatment: 

1. When the plate is slightly vulcanization, the low current is used. 

2. Do not use the method of charging for a long time. Eliminate the vulcanization with the method of 

eliminating vulcanization and charge when the vulcanization is serious. 

20B 

Page 2129

20B-26 


20B 

3. When the vulcanization is too serious, please abandon it. 

Phenomenon 3: Internal short circuit 

Internal short circuit means that battery’s positive and negative plates directly contacts or the plates are 

lapped by other electric conduction. 

Causes: 

1. The separator is damaged to make the positive and negative poles directly contact. 

2. The active material deposits a lot and contacts the below of plate group. 

3. The plate group bends. 

4. The conductive material falls off in the battery to make the positive and negative plate group internal 

short circuit. 

Treatment: 

1. Replace the damaged separator, eliminate deposited active material and check or replace the bended 

plate group. 

Phenomenon 4: A lot of active materials come off 

When the battery is used, the active materials on the positive plate will gradually come off. It is because when 

charging or discharging, the volume of active material will continuously change, then it is easily to come off. If 

the battery is improperly used, a large number of active materials will come off, which makes the positive 

plate is prematurely damaged. 

Causes: 

1. The charging current of battery is too high and electrolyze temperature is too high, which makes 

active materials expand, floppy and easy to come off. 

2. The battery usually are overcharged, so a lot of gas emits from plate pore space which builds up 

pressure in the plate pore space, as a result, the active materials come off. 

3. The plate is so bended and deformed. 

4. Electrolyte freezes in winter. 

5. The vibration and bumping for automobile’s driving. 

Treatment: 

1. For lead battery whose plate active materials come off, when there is little deposit, the battery can be 

continuously used after eliminating the deposit. 

2. When there is much deposit, please timely replace the plate and electrolyte. 

Phenomenon 5: Positive plate grid’s corrosion 

The positive plate will be rotted by oxide etch when the battery is used. 

Causes: 

1. The active material lead dioxide on the positive plate is a membrane which cannot compactly and 

completely cover the grid, so the grid will be corroded when charging. 

2. The acids or organic salt which have corrosion function for positive plate grid are mixed in electrolyte. 

3. The battery usually is overcharged. 

4. Electrolyze density and temperature are too high. 

Treatment: 

1. For the battery with lighter corrosion, if there are impurities in electrolyte, pour out the electrolyte, 

clean the inner with distilled water again and again, add standard electrolyte and then the battery can 

be used after charging. 

2. For the battery with serious corrosion, if the electrolyte density is too high, adjust the density to the 

Page 2130


20B-27 

specified value, and then the battery can be continuously used even if it is not charged. 

3. For the battery with serious corrosion, if grid is broken and active materials come off in bulk, and then 

replace the plate. 

Phenomenon 6: Plate bending 

Plate bending appears on the positive plate and seldom appears on the negative plate. If plate bending 

occasionally appears on the negative plate, it is because the positive plate is excessively bended to make the 

negative plate bend. 

Causes: 

1. The plate quality is not good, which is because the filling lead paste is not uneven when 

manufacturing. 

2. The battery usually discharge with large current (for example, usually use the starter), because each 

part’s current density on the plate surface is different, the volumes of active materials change 

differently. 

3. The battery is overcharged. The lead sulfate which is produced in the deep of plate cannot recover 

Treatment: 

when charging to expand the inner plate and to bend the plate. 

1. Take down and correct the bended plate group. 

Phenomenon 7: Polarity reversal of unit cell battery 

The battery with 6 unit cells, if there is one single battery has polarity reversal, and then the voltage is not 12V 

rather than 8V. 

Causes: 

1. The main reason for single battery’s polarity reversal is that the single battery is not found out fault 

Treatment: 

timely (for example, plate’s short circuit, active materials’ falling off). When the battery discharges, the 

single battery will discharge to zero, then when the battery continuously discharges, other single 

batteries’ discharging current will charge it, so polarity reversal happens. 

1. Please replace the plate for single battery with polarity reversal. 

Phenomenon 8: Self-discharge 

The battery which is fully charged will lose electric quantity when it is not used. This phenomenon is called 

“self-discharged”. 

Causes: 

1. The plate materials are not pure and the electrolyte is impure. 

2. There is electrolyte on the cover of battery and the electrolyte can conduct the positive and negative 

piles. 

3. The battery is placed for a long time and sulfate sinks, which make the upper and lower of the plate 

produce potential difference. 

Treatment: 

1. For the battery with little self-discharge, normally discharge the battery, pour out electrolyte, clean it 

with distilled water repeatedly, and then inject the new electrolyte. As a result, the battery can be used 

after it is fully charged. 

2. The battery with serious self-discharge shall be disassembled to be serviced or shall be replaced. 

20B 

Page 2131

20B-28 



20B 

1 Battery 

2 1 type hexagon nut 

3 Pull rod assembly 

4 Battery rack assembly 

5 Hold-down strip assembly 

6 Pull rod assembly 

Page 2132


20B-29 

REPLACEMENT 

1. Stop the automobile on the even pavement, turn off the ignition switch and power supply main 

switch 

2. Disconnect the lead of battery pole 

(a). Open dust cover of lead of battery pole. 

(b). 

Screw off the fixing bolts of lead of battery pole, rock 

the pole around then take out the lead. 

3. Take out the battery 

(a). Screw off the fixed nuts from the battery clamp with 

wrench. 

20B 

(b). Take down the clamping plate of battery and take out 

the battery upward. 

NOTE: 

Check the usability of battery with checking tools. If the 

battery cannot be used, please replace it. 

Page 2133

20B-30 


4. Install the full-charged or the new battery 

5. Install the fixed mount of battery 

(a). Place the battery in the tray of battery. 

△Tip: 

Confirm directions of battery’s positive and negative poles and 

pole to compare the directions with the directions of 

disassembling and to avoid installing the positive and negative 

poles reversed to damage the circuit and components. 

(b). 

Install the fixed pull rod and clamping plate of battery. 

(c). 

Screw up the clamping plate nuts. 

20B 

6. Install the lead wire of pole for battery 

(a). Connect the lead of battery pole on the pole. 

Page 2134


20B-31 

(b). Screw up the fixing bolts of the lead of battery pole and 

fix the dust cover. 

NOTE: 

When installing the lead of battery pole, first install the 

positive terminal and then install the negative terminal. 

20B 

Page 2135

20B-32 

STARTING AND CHARGING - USE OF MAINTENANCE FREE BATTERY 

USE OF MAINTENANCE FREE BATTERY 

CHECKING OF TECHNICAL CONDITION 

1. Usually keep the external clean when using the maintenance free battery. 

2. Usually check the color of electrolyte densimeter indicator inside. 

△Tip: 

If the electrolyte densimeter indicator is black, take down the battery from the automobile for additional 

charge. If the electrolyte densimeter indicator is yellow, check whether the storage housing has crack or is 

damaged and whether electrolyte is leaked. 

3. Before replacing the battery, pay much attention to check whether there is fault for charging 

circuit. 

4. Load test for battery is to inspect the load capacity. 

(a). 

(b). 

(c). 

(d). 

(e). 

Respectively connect two poles for battery on the carbon pole of carbon pile, add 300A of load current 

15s. 

Close the load, stop for 15s to wait for voltage recovery. 

Set the load of carbon pile as the load trial value specified on the label of battery. 

Apply load to test for 15s, read the voltage value of battery and judge whether the battery is good. 

Close the load. 

20B 

Page 2136

STARTING AND CHARGING - USE OF MAINTENANCE FREE BATTERY 

20B-33 

CHARGE THE MAINTENANCE FREE BATTERY 

Additional charging 

1. If the automobile is not used for a long time or there is fault in the charging system, and if the load 

voltage of battery is lower than 10V and the load voltage is lower than 12.4 V, the battery is in need of 

charging. 

2. The charging method for maintenance free battery is the same with that of the common battery. And 

the additional charge adopts constant current charge. 

3. For the first stage of charging, charge the battery with 10% current of battery capacity and the 

charging current is 6A. When each battery voltage is 16A, and then the second stage of charging 

begins. 

4. For the second stage of charging, charge the battery with x0.045 current of battery capacity. When 

each battery voltage is 16V, and then continue charging the battery for about 3~5h. 

5. If the electrolyze temperature is higher than 40℃ when charging, stop charging, reduce the current or 

carry on physical cooling. When the temperature is 45℃, please stop charging. 

6. Keep the battery in good ventilation when charging. Keep away from naked flame and inflammables. 

7. The standard of full charging: the charging indicator is green. 

Quick charging 

1. Quick charging is only used as emergency measure when the automobile cannot start. If the time 

allows, use the common charger. 

2. The current for quick charging is 3/10 of battery capacity. 

3. The time for quick charging is not more than 2h. 

20B 

Page 2137

-MEMO- 

20B 

Page 2138

SUPERCHARGER 

SUPERCHARGING SYSTEM .............................................................. 21-1 

Overview ........................................................................................... 21-1 

Working Principle ............................................................................ 21-2 

Diagram of Components ................................................................. 21-4 

TURBOCHARGER ............................................................................... 21-5 

Service .............................................................................................. 21-5 

21 

Page 2139

14 

21 

Page 2140

SUPERCHARGING SYSTEM-SUPERCHARGING SYSTEM 

21-1 

SUPERCHARGING SYSTEM 

OVERVIEW 

1. This engine is equipped with an exhaust turbocharger. The exhaust turbine of turbocharger is 

assembled on the same shaft with gas compressor, driving by the exhaust gas exhausted by engine 

and driving the gas compressor to compress the air sucked into the air filter to increase the air density 

in cylinder, the air inflow, air supply of fuel for injection pump and the output of engine. 

2. The turbocharger consists of turbine, radial-flow compressor, middle casing, rotor assembly, bypass 

valve etc. The turbine and gas compressor shall be respectively installed on both ends of shaft and 

own their own cast casings. The shaft is installed in the middle casing and supported by the middle 

casing. 

3. The turbine part mainly consists of turbine casing and single stage radial-flow turbine. They form an 

energy converter. When the exhaust gas exhausted from the diesel engine blows to turbine impeller 

in a fixed direction after entering the nozzle through turbine casing, the heat energy and pressure 

energy of exhaust gas will turn to kinetic energy and rotate the turbine at a high speed. 

4. The intermediate is an intermediate support which supports the rotor assembly, fixed turbine casing 

and compressor casing. It is also a lubricating oil tank which can lubricate and cool the floating 

bearing rotor. 

5. The gas compressor mainly consists of centrifugal-flow compressor impeller, diffuser and gas 

compressor casing. Passing by the air filter, the air will be sucked into the compressor impeller 

revolving at a high speed which will increase the air velocity and the pressure. The air will then passes 

diffuser and compressor casing to transform the kinetic energy of air current to pressure energy which 

will enter the cylinder through diesel engine intake pipe after increasing and cause the increase of air 

density in the cylinder of diesel engine. 

6. Air evacuation valve and air release valve are used to ensure the best coordination performance of 

the diesel engine in the range of low and intermediate speed and the turbocharger. This best 

performance can facilitate the diesel engine in terms of gaining sufficient air, being corresponding with 

the increasing of fuel supply amount, enlarging the low speed torque, improving the fuel consumption 

and evacuating or releasing the air in high speed range (a part of exhaust gas can directly enter into 

the exhaust pipe without passing turbine) to avoid the excessive combustion pressure in cylinder due 

to the over speed of turbocharger rotor and the excessive supercharging pressure and mechanical 

load aggravation of diesel engine etc. The open and close of air evacuation and release valve is 

automatically controlled by supercharging pressure. When the supercharging pressure reaches or 

exceeds the specified value, the diaphragm will be against the left spring force, move to the left with 

linkage push rod, and push the rocker arm to rotate around the pin roll, make the air release valve 

open, realize the exhaust bypass deflation and raise the turbocharger speed. 

21 

Page 2141

21-2 



The heat and exhaust gas under a certain pressure exhausted from engine will enter the nozzle diaphragm in 

turbine casing from exhaust manifold. The area of nozzle diaphragm will generally shrink. For the reason, the 

pressure and temperature of exhaust gas will drop, the speed and kinetic energy will increase and the 

exhaust gas flow will impact the turbine in the specified direction to make it rotate at a high speed. Then the 

turbine will drive the centrifugal-flow compressor impeller on same shaft to rotate at the same speed with 

turbine, and the air passed through air filter will be sucked into compressor casing. The compressor impeller 

rotating at a high speed will toss the air to edge of impeller, increase the speed and pressure of air and make 

it entering into diffuser. Because of the form of diffuser: a small inlet and a large outlet, the airflow velocity will 

drop and the pressure will increase. The pressure of air current will continue increasing by passing through 

the ring form compressor casing (with cross sections of all sizes). The compressed air will enter the cylinder 

by passing the intake pipe of engine. By this way, the air inflow of engine will increase, and the output of 

engine will also increase. Passing the turbine, the exhaust gas will finally be injected to the atmosphere. 

21 

Page 2142


21-3 

1 Exhaust pipe 

2 Shaft 

3 Nozzle Diaphragm 

4 Turbine 

5 Turbine casing 

6 Bearing 

7 Diffuser 

8 Compressor impeller 

9 Ring-form gas compressor casing 

10 Intake pipe 

21 

Page 2143

21-4 



21 

1 Tail pipe of turbocharger 

2 Stud 

3 

Nut washer assembly of 

and exhaust pipe 

4 Bracket bolt of turbocharger 


6 Tail pipe bracket 

7 Combination nut 

8 Connecting stud of tail pipe 

9 Tail pipe gasket of turbocharger 

10 Turbocharger components 

11 Connecting bolt of turbocharger 

12 

intake pipe 

Exhaust pipe-connector gasket of 

turbocharger 

13 Exhaust pipe nut 

14 Jointing stud of turbocharger 

15 Flange gasket of oil return pipe 

16 


assembly 

17 Oil return pipe of turbocharger 

18 Heating water pipe clamp 

19 Oil return rubber hose of turbocharger 

20 

Insulation jacketing of turbocharger oil 

return hose 

21 B-type worm drive hose clamp 

22 

23 

Turbocharger intake connecting pipe 

assembly 



24 Oil inlet bolt A 


26 Oil inlet pipe weldment of turbocharger 

27 Oil inlet bolt B 


Page 2144

SUPERCHARGING SYSTEM-TURBOCHARGER 

21-5 

TURBOCHARGER 

SERVICE 

1. Disassemble the turbocharger assembly from the 

engine 

(a). Disassemble the connecting bolt of the EGR pipe and 

the intake connecting pipe assembly of turbocharger. 

(b). 

Disassemble the connecting bolt of the EGR pipe and 

EGR valve. 

(c). 

Take down the EGR pipe. 

21 

(d). 

Disassemble the vent hose clamp of breather. 

● Take down the vent hose of breather. 

Page 2145

21-6 


(e). 

Disassemble the bracket fixing bolt of turbocharger 

intake connecting pipe assembly. 

(f). 

Disassemble the A-type worm drive hose clamp 

connected to turbocharger and its intake connecting 

pipe assembly. 

● Take down the intake connecting pipe assembly of 

turbocharger. 

(g). 

Disassemble the fixing bolt of intake connecting pipe. 

21 

(h). Disassemble the bracket fixing bolt of intake 

connecting pipe. 

(i). 

Disassemble the clamps of intake connecting pipe and 

connecting rubber hose of turbocharger. 

● Take down the intake connecting pipe of engine. 

Page 2146


21-7 

(j). 

Disassemble the oil inlet bolt A of oil inlet pipe 

weldment of turbocharger. 

(k). 

(l). 

Disassemble the oil inlet bolt B of oil inlet pipe 

weldment of turbocharger. 

Take down the oil inlet pipe weldment of turbocharger. 

(m). 

Disassemble the oil return pipe spring hose clamp of 

turbocharger. 

21 

(n). Disassemble the fixing bolt of turbocharger. 

(o). Take down the turbocharger from engine. 

NOTE: 

Disassemble the turbocharger assembly from engine. Do 

not lift the turbocharger with linkage push rod. 

2. Disassemble the turbocharger assembly 

NOTE: 

The turbocharger is a precise machine which will revolve at a high speed. The turbocharger assembly 

shall not be disassembled casually except for necessary situation. 

Page 2147

21-8 


(a). 

Disassemble the connecting bolt of turbocharger oil 

return pipe and turbocharger components and take 

down the oil return pipe. 

(b). 

Disassemble the bolt connecting with turbocharger tail 

pipe and turbocharger components. 

(c). Disassemble the turbocharger tail pipe. 

△ Tip: 

Take down the tail pipe gasket of turbocharger. 

21 

(d). 

Disassemble the bleed-air pipe. 

(e). 

Take out the linkage push rod circlip with pliers. 

Page 2148


21-9 

(f). 

Loosen the fixing bolt of linkage push rod with wrench. 

(g). 

Take down the regulator device of air release valve. 

(h). Take down the fixing bolt connecting the compressor 

casing and intermediate. 

△ Tip: 

Disassemble the fixing bolt connecting the impeller casing and 

intermediate, disassemble the impeller casing and 

intermediate and take out the rotor assembly and two 

impellers. 

NOTE: 

One shall not impact the impeller during disassembly. If 

the impeller is impacted and deformed, it shall not 

continue to be used after alignment. 

21 

3. Clean and check the turbocharger assembly 

(a). Clean the turbine casing with vapor. 

△ Tip: 

Clean the compressor casing and two impellers with vapor. 

NOTE: 

When using the vapor cleaner, one shall ware safety glasses or 

protective mask and protective clothing in case of serious 

personal injuries caused by hot vapor. If the impeller is 

impacted and deformed, it shall not continue to be used after 

alignment. 

Page 2149

21-10 


(b). 

Check the tail pipe gasket of turbocharger to see 

whether it is abraded. If it is, the washer shall be 


(c). Measure the axial clearance of impeller shaft with dial 

indicator. 

Standard Value: 0.06~0.09 mm 

Limiting Value: 0.11 mm 

△ Tip: 

Alternately apply the force of 0.12N on the end of compressor 

impeller and the end of turbine impeller. 

(d). 

Measure the clearance between impeller shaft and 

bearing. 

Standard Value: 0.11~0.18 mm 

Limiting Value: 0.215 mm 

21 

(e). Check the radical clearance of rotor. 

Minimum Clearance: ≥0.1 mm 

△ Tip: 

Depress the compressor impeller with a hand in radical 

direction and measure the minimum clearance between 

compressor impeller and compressor casing. If the measured 

value is smaller than the required minimum clearance value, 

the floating bearing shall be replaced. 

Page 2150


21-11 

(f). Check the axial clearance of rotor. 

Axial clearance value: 0.1 mm 

Limiting value: ≤0.25 mm 

△ Tip: 

One can fix the magnetic base onto the discharge flange facing 

of turbine casing, contact the dial indicator with the end face of 

turbine rotor shaft and push or pull the turbine rotor along axial 

direction. The measured D-value is the axial clearance value. If 

the axial clearance value of compressor is higher than the 

applied limiting value, the assembly shall be disassembled and 

the wore-out parts shall be replaced. Before determining and 

eliminating the causes of turbocharger damage, one shall not 

replace the turbocharger. 

4. Assemble the turbocharger assembly 

(a). Install the impeller and rotor assembly with special 

tools. 

(b). Put the turbine casing and compressor casing on the 

installation position and screw up the fixing bolt. 

(c). 

Put the air release valve regulator device onto the 


21 

(d). 

Install the fixing bolt of linkage push rod. 

Page 2151

21-12 


(e). Install the linkage push rod circlip. 

NOTE: 

One shall not adjust the length of linkage push rod 

installing the air release valve regulator. As for the 

adjustment, one shall refer to the related delivery 

information. 

(f). 

Install the bleed-air pipe. 

21 

(g). Put the turbocharger tail pipe onto the installation 

position of turbocharger components. 

△ Tip: 

Do not forget to install the turbocharger tail pipe gasket when 

installing the turbocharger tail pipe. 

(h). 

Install and fasten the connecting bolt of turbocharger 

tail pipe and turbocharger components. 

5. Install the turbocharger assembly on the engine. 

(a). Put the turbocharger assembly onto the installation 

position and fasten its fixing bolt. 

Page 2152


21-13 

(b). 

Install the oil return pipe spring hose clamp of 

turbocharger. 

(c). 

(d). 

Put the oil inlet pipe weldment of compressor into the 


Install and fasten the oil inlet bolt B of turbocharger oil 

inlet pipe weldment. 

(e). 

Install and fasten the oil inlet bolt A of turbocharger oil 

inlet pipe weldment. 

21 

(f). 

Put the intake connecting pipe of engine on the 


● Fasten the clamps of engine intake connecting pipe 

and turbocharger connecting rubber hose. 

(g). 

Install and fasten the fixing bolt of intake connecting 

pipe bracket. 

Page 2153

21-14 


(h). 

Install and fasten the fixing bolt of intake connecting 

pipe. 

(i). Put the intake connecting pipe assembly of 

turbocharger onto the installation position. 

● Fasten the A-type worm drive hose clamp 

connecting with turbocharger intake connecting pipe 

assembly and turbocharger. 

(j). 

Install and fasten the fixing bolt of turbocharger intake 

connecting pipe assembly bracket. 

21 

(k). 

Fasten the vent hose clamp of breather. 

(l). 

Put the EGR pipe into the installation position 

Page 2154


21-15 

(m). 

Install and fasten the connecting bolt between EGR 

pipe and EGR valve. 

(n). 

Install and fasten the connecting bolt between EGR 

pipe and intake connecting pipe assembly of 

turbocharger. 

21 

Page 2155

-MEMO- 

21 

Page 2156


V O L U M E 4 

11C ENGINE CONTROL SYSTEM 2161 

12C FUEL SYSTEM 2173 

13C EMISSION CONTROL 2195 

14C INTAKE AIR 2201 

15C ENGINE MECHANICAL PART 2209 

16C EXHAUST SYSTEM 2235 

17C COOLING SYSTEM 2243 

18C LUBRICATION SYSTEM 2263 

20C STARTING AND CHARGING 2273 

Page 2157

Page 2158


DIESEL ENGINE CONTROL SYSTEM............................................11C-1 

PRECAUTION............................................................................11C-1 

ENGINE CONTROL MODULE (ECM) .............................................11C-2 

PRINCIPLE ................................................................................11C-2 

REPLACEMENT ........................................................................11C-3 

ACCELEARTOR PEDAL POSITION SENSOR...............................11C-5 

PRINCIPLE ................................................................................11C-5 

INSPECTION ON VEHICLE ......................................................11C-6 

OVERHAUL ...............................................................................11C-7 

VEHICLE SPEED SENSOR.............................................................11C-8 

PRINCIPLE ................................................................................11C-8 

OVERHAUL ...............................................................................11C-9 

11B 

11B 

11B 

11B 

11B 

11B 

11B 

11B 

11B 

11B 

11B 

11B 

11B 

11C 

Page 2159

Page 2160

ENGINE CONTROL SYSTEM - DIESEL ENGINE CONTROL SYSTEM 

DIESEL ENGINE CONTROL SYSTEM 


PRECAUTION 

11C-1 

1. DIESEL ENGINE CONTROL SYSTEM PRECAUTION. 

(a) Power off. 

• The battery negative cable must be disconnected at first before removing or installing any electric 

appliance and when tools or facilities will touch the exposed terminals. It should be connected eventually. 

This will prevent injuring person and vehicle damage. 


WARNING 

The ignition and illumination switches must be shut off before removing or installing the battery negative 

cable (the semiconductor maybe damage without doing that). 

(b) Please do disassembly, assembly and testing in accordance with the provisions introduced in this 

manual during maintenance. 

(c) Clear off the sundries on the mounting surface with a sealant scraper or a wire brush and confirm the 

sealing face is level and smooth and no greasy dirt on it before installation. Don’t forget to remove the 

sealant on the mounting hole, the threaded hole and the thread. 

(d) Paint some sealant evenly on the prescribed diameters to surround the mounting hole. The sealant not 

hardened yet can be scraped away. Install it in place when the sealant is wet (within 15 minutes). Take 

care not to stick the sealant to the place where it's not desired during installation. Wait the sealant to be 

very hardened (1 hour or so) after installation. Don’t apply oil on the painted parts or wet or start the 

engine during this time. 

(e) Tighten the straining bolts with prescribed torque during installing the sensors, actuators or other parts. 

Ensure the diesel engine is always in clean and complete state. Clean or wipe up the parts to ensure 

the clean parts and the assembly quality before removing and assembling the parts. The complicated 

adjustment and maintenance should be taken indoors to avoid the diesel engine being polluted by the 

environment. 

(f) When installing and handling sensors, handle them gently to avoid damage, any impact or falling may 

cause severe damage. 

(g) Don’t test the system electrical signal by use of a fine needle to pierce the harness. 

(h) Take a visual inspection to check if the sensing element at the head of sensor is damaged or color 

changed; Replace it if it's damaged or the color is severe changed. 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

Page 2161

11C-2 

ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM) 


PRINCIPLE 

1. ENGINE CONTROL MODULE DESCRIPTION. 

(a) ECM is the electric control engine control center with the 

micro processor as the core that having sensor signal 

input interface and the executor drive circuit. The ECM 

receives and treats the engine status signal that inputted 

from all sensors, sends control signal to the executor to 

drive the engine running in accordance with the preset 

procedures so as to make the engine run under best 

status, ensure good power capability, fuel economy and 

exhaust capability. 

(b) ECM has self protection function, it may result the 

ignition failure during repair and it will resume normal 

after replacement of ECM, therefore we may deem as 

the ECM trouble. in fact, the ECM doesn’t get damaged 

but just enters into self protection mode. ECM will 

resume normal after flashing programming or “active” on 

factory. 

Page 2162


11C-3 

REPLACEMENT 



NOTE 

When disconnecting or connecting the battery cables, please first turn off the ignition switch and 

lighting switch and completely loosen the cable nut. Do not pry up the cable when peforming these 

operation. 

3. REMOVE ECM MODULE. 

(a) Pull assistant driver seat forward. 

(b) Lift the covering behind assistant driver seat , then 

loosen ECM locking knob . 

(c) Remove the ECM cover. 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

(d) 

Remove 2 ECM electrical connectors. 

11C 

11C 

11C 

11C 

11C 

(e) 

Remove 4 ECM mounting bolts. 

11C 

11C 

11C 

11C 

11C 

11C 

(f) 

Remove ECU. 

11C 

NOTE 

• Disconnect battery negative cable first, wait at least 

1 minute, then remove ECM. 

• Take care not to impact ECM while removing the 

ECM. 

• Keep ECM away water during operation. 

• Be careful of the terminals of ECM. 

11C 

Page 2163

11C-4 


4. INSTALL ECU. 

(a) 

Tighten 4 ECU mounting bolts. 

Torque: 19.6 N•m 

NOTE 

Pay attention to electrostatic protection when installation. 

(b) 

Connect ECU connector. 

NOTE 

Pull ECU connector upward, comfirm that it is installed in 

place properly . 

(c) 

(d) 

Install ECU cover and tighten locking knob. 

Cover the covering and push assistant driver seat back 

to the original position. 


Page 2164

ENGINE CONTROL SYSTEM - ACCELEARTOR PEDAL POSITION SENSOR 

11C-5 

ACCELEARTOR PEDAL POSITION SENSOR 

PRINCIPLE 

1. ACCELERATOR PEDAL POSITION SENSOR. 

(a) The electric accelerator pedal position sensor (APPS) is 

mounted on the pedal bracket. it is 2 three-line types of 

potentiometer sensor. The ECU applies a 5 V reference 

voltage to the sensor. 

(b) The sensor slide indicator connects with the accelerator 

and rotates following the shaft. When the accelerator 

pedal changes, the position of the slide indicator will also 

change on the carbon film resistance, at such moment 

the resistance output will also change, which reflects the 

open extent of the accelerator indirectly. 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

11C 

Page 2165

11C-6 


INSPECTION ON VEHICLE 








APPS 


• Engine turn off 

APPS1 

APPS2 

• Key ON (the throttle is 

closed): 0.899 V 


fully open): 3.548 V 


closed): 0.572 V 


fully open): 1.608 V 

6. IF IT IS NOT OK, CHECK APPS, HARNESS OR ECU. 

Page 2166


11C-7 

OVERHAUL 


2. REMOVE APPS. 

(a) Disconnect APPS connector. 

(b) Loosen 3 APPS mounting nuts. 

11C 

11C 

11C 

11C 

11C 

3. CHECK APPS RESISTANCE. 

(a) Using the analogue multimeter, measure the continuity of 

the APPS resistance. 

(b) The pins of the multimeter connect to terminal 4 and 3 of 

APPS respectively. Turn the shaft of the APPS. The 

value changes linearly varied with the opening of the 

acceperator. When connecting to terminal 2 and 4, the 

value is opposite. 

(c) Check the resistance of the APPS. 

Resistance 

11C 

11C 

11C 

11C 

11C 

11C 


(3) - (4) 

(2) - (4) 

(5) - (6) 

(1) - (6) 

Specified 

Condition 

Turn the shaft of the 

APPS. The value changes 

linearly varied with the 

opening of the accelerator 

11C 

11C 

11C 

11C 

(d) 

(e) 

The resistance value is continuity. 

If the ckeck result is not OK, replace it. 

11C 

11C 

4. INSTALL APPS. 

(a) Tighten 3 APPS retaining bolts. 

(b) Connect APPS connector. 

11C 

11C 

11C 

Page 2167

11C-8 

ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 


PRINCIPLE 

1. VEHICLE SPEED SENSOR DESCRIPTION. 

(a) 

Vehicle speed sensor is the type of hall sensor. It works 

together with signal wheel on output shaft. ECM detects 

digital voltage signal through it and determines the current 

speed of the vehicle. 

Page 2168

ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 

11C-9 

OVERHAUL 



3. REMOVE VEHICLE SPEED SENSOR. 

(a) Disconnect vehicle speed sensor connector. 

(b) Remove vehcle speed sensor retaining bolt. 

11C 

11C 

11C 

11C 

11C 

11C 

(c) 

Pull out vehcle speed sensor straight by slightly turning. 

NOTE 

Clear surface after removing. 

11C 

11C 

11C 

11C 

11C 

4. INSTALL VEHICLE SPEED SENSOR. 

(a) Install vehicle speed sensor and tighten mounting bolt. 

NOTE 

Do not allow any impact tools (such as a hammer, etc.) to 


(b) Connect vehicle speed sensor connector. 

11C 

11C 

11C 

11C 

11C 


6. CHECK AFTER INSTALATION. 

(a) Start the vehicle and check vehicle speed sensor for fluid leakage and confirm that speedometer is 

under normal operation. 

11C 

11C 

11C 

11C 

Page 2169

MEMO 

Page 2170

FUEL SYSTEM 

FUEL SYSTEM.................................................................................12C-1 

PRECAUTION............................................................................12C-1 

FUEL SYSTEM PRESSURE RELEASE PROCESS .................12C-2 

FUEL SYSTEM BLEEDING.......................................................12C-2 

DRAIN FUEL TANK PROCESS.................................................12C-2 

FUEL TUBE CLEAN ..................................................................12C-3 

COMPONENTS .........................................................................12C-4 

FUEL TANK ASSY...........................................................................12C-6 

REPLACEMENT ........................................................................12C-6 

DIESEL FILTER ASSY.....................................................................12C-9 

REPLACEMENT ........................................................................12C-9 

FUEL LEVEL SENSOR AND BRACKET ASSY............................12C-10 

REPLACMENT.........................................................................12C-10 

FUEL FILLER DOOR .....................................................................12C-12 

REPLACEMENT ......................................................................12C-12 

FUEL FILLER DOOR LOCK LATCH ASSY .................................12C-13 

REPLACEMENT ......................................................................12C-13 

FUEL FILLER CAP ........................................................................12C-15 

INSPECTION ...........................................................................12C-15 

FUEL FILLING TUBE AND BREATHER TUBE ASSY .................12C-16 

INSPECTION ...........................................................................12C-16 

ELECTRONIC ACCELERATOR PEDAL......................................12C-20 

REPLACEMENT ......................................................................12C-20 

12B 

12B 

12B 

12B 

12B 

12B 

12B 

12B 

12B 

12B 

12B 

12B 

12B 

12B 

12C 

Page 2171

Page 2172

FUEL SYSTEM 

PRECAUTION 


12C-1 

1. FUEL SYSTEM PRECAUTION. 

(a) Before working on fuel system, disconnect battery negative cable if necessary. 

(b) When removing the fuel hose, use a suitable container to hold the diesel. 

(c) Do not smoke, carry lighted tobacco or work near an open flame when working on fuel system. 

Equipment with ventilator at woking area can avoid personal injury. 

(d) Fuel in the VE dispensing pump and tubes remain under high pressure. In order to avoid personal 

injury, do not loosen tube connector while engine is runing. 

(e) Keep diesel away from rubber and leather parts. 

(f) Diesel injection equipment is designed to very precise tolerances and fine clearances. To prevent fuel 

system damage, it is essential that absolute cleanliness is oberved when working with these 

components. Always install fuel system caps to any open orifices or tubes. 

(g) Before disconncting any of the fuel system tubes or fuel system components, relieve the fuel system 

pressure to prevent accidental spraying of fuel, even when the engine is not running. Failure to follow 

this instruction may result in serious personal injury. 

(h) Check if there is any dirt like mud around the fuel tube connector before this work. And clean dirt away, 

otherwise it can damage fuel system or engine. 

(i) Keep cleaner away from the O-ring of tube connecter. Cleaner can harm seal of fuel system. 

(j) Don’t bend or twist the fuel system tube and pipe by force. 

(k) Before connceting fuel system tube, be sure there is no damage to tube connector. If there is damage, 

crack or dirt on surface. replace it with a new tube assy. 

(l) Wearing eyeshield equipment is needed when working on fuel system compoments. Failure to follow 

this instruction may result in personal injury. 

(m) The metal parts like zn, cu, mn are easily dissolved in diesel. coking may appears in fuel injector which 

reduces the injected diesel to cylinder. So the matal parts above should not be used in high-pressure 

common rail fuel system. 

(n) It is essential to keep fuel system clean. especially it can not contain any impurity, such as corrosion, 

welding spatter. Otherwise, these impurity can block fuel tube, engine shut down suddenly. The 

common rail parts are even damaged. 

12C 

12B 

12C 

Page 2173

12C-2 


FUEL SYSTEM PRESSURE RELEASE PROCESS 


CAUTION 

• Fuel pressure in fuel pump, high pressure fuel pipe and fuel rail is high enough to cause serious 

injury to the skin. 

• Don't loosen any pipe joint when engine is running. waiting for at least 10 minutes after engine 

is off. when oil pressure dropps to a lower level, loosen the high pressure fuel system pipe joint. 

2. BEFORE REPAIRING FUEL SYSTEM, LOOSEN THE 

LOCKING NUT ON FUEL RAIL TO RELEASE FUEL 

PRESSURE. 

3. WHEN REMOVING LOCKING NUT, LEAVE YOU 

HAND FAR AWAY FROM THE CONNECTING JOINT. 

NOTE 

Fuel will spurt from the pipe joint to the engine block side 

along the groove in fuel rail. 

4. TIGHTEN FUEL RAIL LOCKING NUT. 

FUEL SYSTEM BLEEDING 

NOTE 

• When servicing or replacing feed / high-pressure fuel system parts, fuel system will still 

preserve a certain amount of air. Press manual pump to bleed air for fuel system. 

• It is not necessary to bleed air before starting the engine. When cranking engine, mechanical 

fuel pump applies fuel to fuel system. 

1. FUEL SYSTEM BLEEDING. (Refer to CUMMINS ISF 

SERIES ENGINE SERVICE MANUAL ) 

DRAIN FUEL TANK PROCESS 

1. CHECK FUEL LEVEL ON FUEL GAUGE. 

2. DRAIN FUEL TANK. 

(a) Turn ignition switch off. 

(b) Insert hose of less than 22mm in diameter into fuel filler hose through fuel filler port to draw fuel in fuel 

filler hose. 

(c) Disconnect fuel filler hose from fuel tank filler neck. 

(d) Insert the hose into fuel tank to draw fuel through fuel tank filler neck. 

Page 2174


12C-3 

FUEL TUBE CLEAN 

1. USE FUEL TREATMENT THAT FOTON RECOMMENDS TO CLEAN FUEL SYSTEM. 

2. USE FUEL ADDITIVES THAT FOTON RECOMMENDS TO CLEAN FUEL SYSTEM. 

12C 

12B 

12C 

Page 2175

12C-4 


COMPONENTS 

1 Fuel Tank Assy 

2 Fuel Tank Rear Bracket 






Page 2176


12C-5 

12C 




4 Fuel Filler Cap Assy 



7 Guide Pin 

8 Fuel Level Sensor And Bracket Assy 



11 Return Line 

12 Fuel Tank To Diesel Filter Fuel Line 


14 Fuel Filler Hose Assy 

15 Diesel Filter Assy 

16 Diesel Filter To Engine Fuel Line 

17 Diesel Filter Bracket 

18 Guide Pin 

12B 

12C 

Page 2177

12C-6 



REPLACEMENT 

1. RELEASE FUEL PRESSUE. (Refer to “Chapter 12B fuel - fuel system, fuel system pressure 


2. DRAIN FUEL TANK. (Refer to “Chapter 12B fuel - fuel system, drain fuel tank process”) 



5. SUPPORT FUEL TANK WITH A JACK. 

NOTE 

• The tank may have an uneven surface at the bottom so shims or something similar should be 

put on the lower side to keep tank stable when supporting the fuel tank with a jack. 

• Support the position that fuel tank retaining belt never engage 

6. REMOVE FUEL TANK ASSY. 

(a) Remove fuel tank breather pipe clamp. 

(b) Remove fuel tank filler tube clamp. 

(c) Disconnect fuel tank breather pipe and filling tube. 

NOTE 

• Disconnect fuel filler tube, check filler port rubber 

grommet for improper crack, damage or deterioration, 

replace if necessary. 

• Keep the connecting portion clean and avoid 

damage and foreign materials, cover them 

completely with plastic bags or something similar. 

(d) 

(e) 

Remove 4 fuel tank retaining belt mounting bolts. 

Remove 2 fuel tank rear bracket mounting bolts. 

(f) 

Lower the fuel tank to a suitiable position. 

Page 2178


12C-7 

(g) 

(h) 

(i) 

(j) 

Disconnect electric fuel pump assy connector. 

Disconnect feed tube quick connector. 

Disconnect return tube quick connector. 

Disconnect EVAP tube quick connector. 

12C 

NOTE 




damaged. 

• Mark the fuel tube and quick connector to avoid misassembling. 




(k) 

Remove fuel tank assy. 

7. INSTALL FUEL TANK ASSY. 

(a) 

(b) 

(c) 

Support fuel tank to a suitable position with jack. 

Connect electric fuel pump connector. 

Connect feed tube, return tube and EVAP tube quick 

Connectors. 

NOTE 

Connect fuel tube quick connectors until a click is heard, 


are secured. 

12B 

12C 

(d) 

(e) 

Install 2 fuel tank retaining belts and tighten 4 mounting 

bolts. 

Tighten 2 fuel tank rear bracket mounting bolts. 


Page 2179

12C-8 


(f) 

(g) 

Connect fuel tank breather tube, then tighen the clamp. 

Connect fuel tank filling tube, then tighen the clamp. 



10. CHECK FUEL TUBE. 

(a) When Turning ignition switch on, fuel pump will apply fuel pressure to fuel lines. inspect if there is fuel 


(b) Start engine and rev it up and check there is no fuel leakage at the fuel system tube and hose 

connections. 

Page 2180

FUEL - DIESEL FILTER ASSY 

12C-9 

DIESEL FILTER ASSY 

REPLACEMENT 

1. DIESEL FILTER ASSY DESCRIPTION. 

(a) ISF2.8 Engine have a maintainable cylinder-type diesel 

filter which contains a integrated WIF sensor and fuel 

heater. The diesel filter is located between fuel pump and 

tank. 

12C 



3. REPLACE DIESEL FILTER. (Refer to CUMMINS ISF SERIES ENGINE SERVICE MANUAL ) 

NOTE 

• If draining water is required frequently, it means that fuel is not qualified or there is water in fuel 

tank. Please drive the vehicle to service station for repair. 

• In order to ensure fuel clean, in strict accordance with maintenance requirement to operate fuel 

filter sechudle maintenance. Replacement cycle: 15,000 km. 


(a) After installation, turn ignition switch on and check the fuel gauge’s conditions in instrument panel. Start 

engine and check there are no fuel leakage at the diesel system tube and hose connections. 

12B 

12C 

Page 2181

12C-10 

FUEL - FUEL LEVEL SENSOR AND BRACKET ASSY 

FUEL LEVEL SENSOR AND BRACKET ASSY 

REPLACMENT 



2. DRAIN FUEL TANK AS REQUIRED. (Refer to “Chapter 12B fuel - fuel system, drain fuel tank 

process”) 



5. REMOVE FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank, replacment”) 

6. REMOVE FUEL LEVEL SENSOR AND BRACKET 

ASSY. 

(a) Loosen lock ring counterclockwise with special wrench. 

(b) 

Remove fuel level sensor and bracket assy. 

NOTE 

Be careful not to bend float arm during removing fuel level 

sensor and bracket assy. 

7. CHECK SEALING RING OF SEALING COVER. 

(a) Removing sealing ring as possible as early to avoid 

deformation caused by contacting the fuel. 

(b) Check sealing ring for improper crack, damage or deterioration 

and replace if necessary. 

Page 2182

FUEL - FUEL LEVEL SENSOR AND BRACKET ASSY 

12C-11 

8. INSTALL FUEL LEVEL SENSOR AND BRACKET 

ASSY. 

(a) 

(b) 

Place sealing ring into place on the opening of fuel tank. 

Position fuel level sensor and bracket assy into fuel tank. 

12C 

(c) 

(d) 

Press installation surface of fuel level sensor and bracket 

assy into place, then install lock ring and rotate the lock 

ring clockwise. 

Tighten lock ring with special wrench to specific torque. 


NOTE 

When installation, align the mark on the installation surface 

of the fuel pump with the corresponding mark on top surface 

of fuel tank . 

9. INSTALL FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank assy, replacment”) 


(a) 

(b) 

After disconnecting fuel level sensor and bracket connector, connect fuel level sensor and bracket 

connector, turn ignition switch on. Slide fuel level sensor and bracket position manually and then check 

the fuel gauge’s conditions in instrument panel. 


connections and confirm fuel level sensor is functional. 

12B 

12C 

Page 2183

12C-12 

FUEL - FUEL FILLER DOOR 

FUEL FILLER DOOR 

REPLACEMENT 

1. REMOVE FUEL FILLER DOOR. 

(a) Pull fuel filler door handle. 

(b) Open fuel filler door. 

(c) 

(d) 

(e) 

Remove 2 fuel filler door retaining bolts. 

Remove the clip connected to fuel filler cap from fuel filler 

door. 

Remove fuel filler door. 

2. INSTALL FUEL FILLER DOOR. 

(a) Install 2 fuel filler door retaining bolts. 

(b) Install the clip connected to fuel filler cap to fuel filler 

door. 

3. ADJUST FUEL FILLER DOOR. 

NOTE 

Adjust fuel filler door or 2 retaining bolts position manually 

if fuel filler door is not closed completely 

Page 2184


12C-13 

FUEL FILLER DOOR LOCK LATCH ASSY 

REPLACEMENT 

1. REMOVE LEFT B LOWER PANEL. (Refer to “Chapter 88 inner and outer trim panel - left panel, 


12C 

2. REMOVE LEFT FRONT SEAT LOCK ASSY. 

(a) Remvoe 2 left front seat lock assy retaining bolts. 

3. REMOVE FUEL FILLER DOOR LOCK LATCH ASSY. 

(a) Open fuel filler door. 

(b) Remove lock latch retaining nut. 

(c) 

(d) 

Take out lock latch assy. 

Remove fuel filler door cable. 

12B 

12C 

4. INSTALL FUEL FILLER DOOR LOCK LATCH ASSY. 

(a) Install fuel filler door cable to lock latch assy. 

Page 2185

12C-14 


(b) 

Position fuel filler door lock latch assy into place inside B 

pillar, then tighten retaining nut. 

5. CHECK FUEL FILLER DOOR LOCK LATCH ASSY. 

(a) Close fuel filler door, then pull fuel filler door handle. 

(b) Be sure that fuel filler door lock latch assy is operatonal. 

6. INSTALL LEFT FRONT SEAT LOCK ASSY. 

(a) Tighten 2 left front seat lock assy retaining bolts. 

7. INSTALL LEFT FRONT B PILLAR LOWER PANEL. (Refer to “Chapter 88 inner and outer trim 

panel - left panel, replacement”) 

Page 2186

FUEL - FUEL FILLER CAP 

12C-15 


INSPECTION 



12C 




filler cap. 



(a) 

(b) 

Visually inspect fuel filler cap and seal ring. If deformed 


Termly lubricate the rotating part. 




12B 

12C 

Page 2187

12C-16 


FUEL FILLING TUBE AND BREATHER TUBE ASSY 

INSPECTION 


2. REMOVE BATTERY AND BATTERY TRAY. (Refer to “Chapter 20B starting and charging - battery, 


3. OPEN FUEL FILLER DOOR. 


5. DRAIN FUEL TANK AS REQUIRED. (Refer to “Chapter 12B fuel - fuel system, drain fuel tank 

process”) 

6. REMOVE FUEL FILLER AND BREATHER HOSES. 

(a) Remove 3 fuel filler port retaining bolts. 

(b) 

Remove fuel breather hose and fuel filler hose retaining 

bolts that are located below battery tray. 

(c) 

(d) 

(e) 

(f) 


Remove upper fuel breather hose bracket retaining nut. 

Remove the clamp between upper and lower fuel 

breather hoses, then disconnect breather hoses. 

Pull upper fuel breather hose out of the hole on sidewall 

of the battery compartment . 

Page 2188


12C-17 

(g) 

(h) 

Loosen fuel filler hose retaining clamp at the fuel tank 

side, then disconnect fuel filler hose from fuel tank filler 

neck. 

Remove fuel filler hose retaining bolt from vehicle frame. 

12C 

(i) 

(j) 

Remove upper fuel filler hose retaining bolt from vehicle 

frame. 

Remove fuel filler hose and upper fuel breather hose. 

(k) 

Remove retaining bolt on the bracket of lower fuel 

breather, then pull fuel breather hose out of the hole on 


(l) 

(m) 

(n) 

Remove retaining bolt between lower fuel breather hose 

bracket and side member NO.2. 

Remove fuel breather hose clamp at the fuel tank 

breather neck, then disconnect them. 

Pull lower fuel breather hose from the side member 

NO.2, then remove lower fuel breather hose. 

12B 

12C 

7. INSTALL FUEL FILLER AND BREATHER HOSES. 

(a) 

(b) 

Position upper fuel filler hose in place. 

Tighten 3 fuel filler port retaining bolts. 

NOTE 

Engage the groove of seal ring with the lip of fuel filler neck 

first securely when installing fuel filler hose assy. 

Page 2189

12C-18 


(c) 

Tighten fuel filler hose and upper fuel breather hose 

retaining bolt below the battery tray. 

(d) 

(e) 

(f) 


Connect upper and lower breather hoses, then tighten 

the clamp. 

Tighten upper breather hose retaining nut. 

(g) 

(h) 

(i) 

Install fuel filler hose through the hole on side member 

NO.1. 

Connect upper and lower fuel breather hoses, then 


Tighten the retaining bolt securing breather hose bracket 

to side member NO.1. 

(j) 

(k) 

(l) 

Install lower breather hose throuth the hole on side 

member NO.2. 

Tighten retaining bolt securing breather hose bracket to 

side member NO.2. 

Connect breather hose to fuel tank, then tighten the 

clamp. 

Page 2190


12C-19 

(m) 

Tighten retaining bolt securing upper fuel filler hose to 


12C 

(n) 

(o) 

Conncet fuel filler hose to fuel tank filler nect, then 


Tighten 1 fuel filler hose retaining bolt. 

8. INSTALL BATTERY AND BATTERY TRAY. (Refer to “Chapter 20B starting and charging - battery, 



(a) Fill fuel tank if necessary. Check filling is a smooth flow and no fuel leaks. 

10. INSTALL FUEL FILLER CAP, THEN CLOSE THE FUEL FILLER DOOR. 

12B 

12C 

Page 2191

12C-20 

FUEL - ELECTRONIC ACCELERATOR PEDAL 

ELECTRONIC ACCELERATOR PEDAL 

REPLACEMENT 


2. REMOVE ELECTRONIC ACCELERATOR PEDAL. 

(a) 

(b) 

Disconnect electronic accelerator pedal harness connector. 

Remove 3 electronic accelerator pedal retaining nuts. 

3. INSTALL ELECTRONIC ACCELERATOR PEDAL. 

(a) Install 3 electronic accelerator pedal retaining nuts. 

(b) Connect electronic accelerator pedal harness connector. 


(a) After installation, depress accelerator pedal to check that the accelerator pedal operates smoothly 

without stuck phenomenon. 

Page 2192


FUEL FILLER CAP ..........................................................................13C-1 

INSPECTION .............................................................................13C-1 

EGR VALVE .....................................................................................13C-2 

REPLACEMENT ........................................................................13C-2 

DIESEL OXIDATION CATALYST....................................................13C-3 

COMPONENTS .........................................................................13C-3 

REPLACEMENT ........................................................................13C-4 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13B 

13C 

Page 2193

Page 2194

EMISSION CONTROL - FUEL FILLER CAP 

13C-1 



INSPECTION 



13C 




filler cap. 



(a) 

(b) 

Visually inspect fuel filler cap and seal ring. If deformed 


Termly lubricate the rotating part. 


(a) Install the fuel filler cap fixing clip into ring. 


13B 

13C 

Page 2195

13C-2 

EMISSION CONTROL - EGR VALVE 

EGR VALVE 

REPLACEMENT 

1. EGR VALVE DESCRIPTION. 

(a) 

EGR valve is located on the top of exhaust manifold 

which was actuated by the electric motor controlled by 

ECM. EGR valve is an lift valve designed to control EGR 

flow to EGR cooler . 

NOTE 

EGR motor can not be repaired, if damaged, the entire EGR 

valve must be replaced as a unit. 

2. REPLACE EGR VALVE. ( Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL) 

Page 2196

EMISSION CONTROL - DIESEL OXIDATION CATALYST 

DIESEL OXIDATION CATALYST 

COMPONENTS 

13C-3 

13C 

1 Diesel Oxidation Catalyst (DOC) 

2 DOC upper bracket 

3 bolt 

5 bolt 

6 bolt 

7 DOC front grasket 

4 bolt 

13B 

13C 

Page 2197

13C-4 

EMISSION CONTROL - DIESEL OXIDATION CATALYST 

REPLACEMENT 



3. REMOVE FRONT EXHAUST PIPE. (Refer to “Chapter 16B exhaust - exhaust pipe, replacement”) 

4. ISF 2.8 USES DIESEL OXIDATION CATALYST (DOC) 

TO REDUCE HC AND CO2 EMISSION. 

5. REPLACE DIESEL OXIDATION CATALYST. ( Refer to CUMMINS ISF SERIAL ENGINE SERVICE 

MANUAL ) 

NOTE 

Post - processing system of diesel oxidation catalyst core are made by brittle materials. DO not drop 

or impact post-processing system side, because this conditon will result in serious damage for postprocessing 

diesel oxidation catalyst core . 

6. INSTALL DIESEL OXIDATION CATALYST. ( Refer to CUMMINS ISF SERIAL ENGINE SERVICE 

MANUAL ) 

Page 2198

INTAKE AIR 

INTAKE AIR SYSTEM......................................................................14C-1 

PRECAUTION............................................................................14C-1 

COMPONENTS .........................................................................14C-2 

INTAKE AIR PIPE AND HOSE ........................................................14C-4 

REPLACEMENT ........................................................................14C-4 

AIR FILTER ASSY ...........................................................................14C-7 

REPLACEMENT ........................................................................14C-7 

INTERCOOLER INTAKE AIR PIPE...............................................14C-11 

REPLACEMENT ......................................................................14C-11 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14B 

14C 

Page 2199

Page 2200

INTAKE AIR SYSTEM 

AIR 

PRECAUTION 

1. INTAKE AIR SYSTEM PRECAUTION. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 


14C-1 

Intake air must be filtered to avoid debris and dirt entering the engine. loose and damaged pipe or hose 

connection may cause unfiltered air to enter the engine leading to premature engine wear. 

The intake manifold hose connection must be reliable enough to avoid gaps and looseness, etc. 

Each cushion and bracket connection with intake manifold hose must be reliable. There are no cracks 

on the apperance or gaps in the connection portion. 

When using the solvent, acid or alkaline material washing, please follow the manufacturers’ advice to 

wear protective clothing and goggles to avoid personal injury. 

When dealing with corrosive work, use skin and eye protection device to reduce the possibility of 


When using compressed air, wear appropriate goggles and protective mask. Both dust particles and 

dirt will cause injury. 

14C 

14B 

14C 

Page 2201

14C-2 


COMPONENTS 

1 Spring Clamp 

2 Intercooler Intake Air Hose 

3 Intercooler Rear Ripple Hose 

4 Intercooler Rigid Clamp 

5 Intercooler Inlet Rigid Pipe 

6 Intercooler Outlet Rigid Pipe 

7 Intercooler Assy 



10 Nut 


12 Nut 

Page 2202


14C-3 

14C 

1 Band Clamp 

2 Middle Intake Air Pipe 


4 Bending Hose 

5 Mass Air Flow Sensor 

6 Screw 

7 Air Filter Assy 



11 Washer 

12 Band Clamp 

13 Intake Air Duct 

14 Band Clamp 

15 Turbocharger Intake Air Ripple Hose 

8 Air Filter Assy Bracket 

14B 

14C 

Page 2203

14C-4 


INTAKE AIR PIPE AND HOSE 

REPLACEMENT 


(a) 

(b) 



cover. 





(a) Remove 5 engine compartment cover retaining bolts. 

(b) Remove engine compartment cover. 

4. REMOVE TURBOCHARGER INTAKE AIR RIPPLE 

HOSE. 

(a) Remove band clamps on both sides of turbocharger 

intake air ripple hose. 

(b) Remove turbocharger intake air ripple hose. 

Page 2204


14C-5 

5. REMOVE MIDDLE INTAKE AIR PIPE. 

(a) Remove 2 middle intake air pipe retaining bolts. 

(b) Remove retaining clamp on middle intake air pipe side. 

(c) Remove middle intake air pipe. 

14C 

6. REMOVE BENDING HOSE. 

(a) Remove air filter assy. (Refer to “Chapter 14B instake air 

- air filter assy, replacement”) 

(b) 

(c) 

Remove retaining clamp securing bending hose to air 

filter assy. 

Remove bending hose. 

7. INSTALL BENDING HOSE. 

(a) Connect bending hose to air filter assy outlet pipe, then 

tighten the retaining clamp. 

NOTE 

Connect one end of benging hose with triangle mark to air 

filter when installation. 

14B 

14C 

(b) Install air filter assy. (Refer to “Chapter 14B instake air - 

air filter assy, replacement”) 

Page 2205

14C-6 


8. INSTALL MIDDLE INTAKE AIR PIPE. 

(a) 

(b) 

(c) 

Position middle intake air pipe. 

Connect middle intake air pipe to bending hose and 

tighten retaining. 

Tighten 2 retaining bolts securing middle intake air pipe 

to body frame. 

9. INSTALL TURBOCHARGER INTAKE AIR RIPPLE HOSE. 

(a) Position turbocharger intake air ripple hose. 

(b) Tighten band clamps on both sides of turbocharger 

intake air ripple hose. 


(a) After installing air intake pipe and hose, check all parts and parts connection and start the engine to 

make sure engine operates properly. 








Page 2206


14C-7 

AIR FILTER ASSY 

REPLACEMENT 




14C 

3. REMOVE AIR FILTER INTAKE AIR DUCT. 

(a) Remove retaining bolt and clamp for air filter intake air 

duct. 

(b) Remove intake air duct. 

4. REMOVE AIR FILTER ASSY. 

(a) Remove retaining clamp securing bending hose to 

middle intake air pipe. 

14B 

14C 

Page 2207

14C-8 


(b) 

Remove 3 air filter assy retaining bolts. 

(c) 

Disconnect mass air flow sensor connector, then remove 

air filter together with bending hose. 

(d) 

Disconnect air filter and bending hose, remvoe air filter 

assy. 

5. INSTALL AIR FILTER ASSY. 

(a) 

Install bending hose to air filter assy outlet pipe, then 


NOTE 

Connect one end of benging hose with triangle mark to air 

filter when installation. 

(b) Position air filter with bending hose, then connect MAF 

connector. 

Page 2208


14C-9 

(c) 

Tighten clamp securing bending hose to middle intake air 

pipe. 

14C 

(d) 

Tighten 3 air filter assy retaining bolts. 


6. INSTALL INTAKE AIR DUCT. 

(a) Tighten the clamp securing intake air duct to air filter inlet 

pipe. 


14B 

14C 

Page 2209

14C-10 






(a) 

Release 3 retaining clips from air filter lower cover. 

(b) 

Open air filter lower cover and remove air filter element. 

NOTE 

Air filter element is made of paper. If necessary, clear the air 

filter element with high pressure air gun. Do not clean it 

with water. 

(c) 

(d) 

Clean or replace air filter element. 

Install air filter lower cover and lock the retaining clips. 

NOTE 

• The clean intake air has a great effect on diesel engine. Do not operate the engine without 

installing the air filter element. 

• Air filter element blocking will cause oil leakage from turbocharger. Therefore, the maintenance 

or replacement of air filter element must be performed periodically. 

Page 2210

INTAKE AIR - INTERCOOLER INTAKE AIR PIPE 

14C-11 

INTERCOOLER INTAKE AIR PIPE 

REPLACEMENT 




14C 

3. REMOVE INTERCOOLER ASSY. 

(a) Remove retaining spring clamp securing intercooler inlet 

pipe to intercooler intake air hose. 

(b) 

Remove retaining spring clamp securing intercooler outlet 

pipe to intercooler rear ripple hose. 

(c) 

Remove 4 intercooler assy retaining spring bolts. 

(d) 

(e) 

Separate intercooler from intake air hose and rear ripple 

hose. 

Remove intercooler assy. 

14B 

14C 

Page 2211

14C-12 


4. INSTALL INTECOOLER ASSY. 

(a) 

(b) 

Positon intercooler assy and connect intercooler inlet 

and outlet pipe to intake air hose and rear ripple hose, 

then tighten 2 retaining band clamp. 

Tighten 4 intercooler assy retaining bolts. 

5. REMOVE INTERCOOLER INTAKE AIR RIGID PIPE. 

(a) Remove retaining clamp securing intercooler inlet rigid 

pipe to intake air hose. 

(b) 

Remove retaining bolt securing underbody intercooler 

inlet rigid pipe. 

(c) 

Remove spring clamp, disconnect intercooler inlet rigid 

pipe from intake air hose. 

(d) 

Remove 4 intercooler assy retaining bolts. 

Page 2212


14C-13 

(e) 

Remove intercooler inlet rigid pipe. 

14C 

6. INSTALL INTERCOOLER INLET RIGID PIPE. 

(a) 

(b) 

Connect intercooler inlet rigid pipe to intake air hose on 

turbocharger side. 

Tighten retaining clamp. 

(c) 

Tighten intercooler inlet rigid pipe retaining bolt. 

(d) 

Tighten retaining clamp securing intercooler inlet rigid 

pipe to intake air hose. 

14B 

14C 

(e) 

Install intercooler assy. (Refer to “Chapter 14B intake air 

- intercooler intake air pipe, replacement”) 

Page 2213

14C-14 


7. REMOVE INTERCOOLER OUTLET RIGID PIPE. 

(a) 

Remove retaining clamp securing intercooler outlet rigid 

pipe to rear ripple hose. 

(b) 

Remove retaining bolt securing underbody intercooler 

outlet rigid pipe. 

(c) 

(d) 

Loosen retaining bolts on both sides of steering drive 

shaft assy II, then remove the bolt on steering gear side 

as shown in the figure. 

Separate steering drive shaft assy II from steering gear 

assy. 

NOTE 

Before disconnecting steering drive shaft assyII, mark 

steering drive shaft assy and steering gear output shaft for 

easier installation. 

(e) 

Remove retaining clamp, disconnect intercooler outlet 

rigid pipe from rear ripple hose. 

(f) 

Remove 4 intercooler assy retainng bolts.. 

Page 2214


14C-15 

(g) 

Remove intercooler outlet rigid pipe. 

14C 

8. INSTALL INTERCOOLER OUTLET RIGID PIPE. 

(a) 

(b) 

Connect intercooler outlet rigid pipe to rear ripple hose 

on throttle actuator side. 

Tighten retaining clamp. 

(c) 

Tighten intercooler outlet rigid pipe retaining bolt from 

the vehicle beneath. 

(d) 

Connect steering drive shaft assyII to steering gear 

output shaft, then tighten both bolts. 

NOTE 

Align marks when installing steering drive shaft assyII. 

14B 

14C 

Page 2215

14C-16 


(e) 

Connect intercooler outlet rigid pipe to rear ripple hose, 

then tighten retaining clamp. 

(f) 

Install intercooler assy. (Refer to “Chapter 14B intake air 

- intercooler intake air pipe, replacement”) 


(a) After installing intercooler intake air pipe, check all parts and parts connection and start the engine to 

make sure engine operates properly. 




Page 2216


ENGINE MECHANICAL PART ........................................................15C-1 

PRECAUTION............................................................................15C-1 

ENGINE ASSY .................................................................................15C-2 

REPLACEMENT ........................................................................15C-2 

ENGINE ACCESSORY BELT........................................................15C-12 

OVERHAUL .............................................................................15C-12 

15B 

15B 

15B 

15B 

15B 

15B 

15B 

15B 

15B 

15C 

Page 2217

Page 2218

ENGINE MECHANICAL - ENGINE MECHANICAL PART 



PRECAUTION 

15C-1 

1. EMGINE MECHNANICAL PART PRECAUTION. 

(a) Follow the instructions of maintenance methods and regulations to adjust or maintain. 

(b) Before starting the engine, check the coolant level, fill or drain the coolant if necessary. check the 

engine oil level, fill the engine oil if necessary. 

(c) The clearance between ckp sensor and flywheel is 0.5 ~ 1.5 mm. Do not try to adjust it. 

(d) Use the oil as requirement. otherwise exacerbate engine wear. 

(e) Use the original fittings, otherwise it will damage the engine or affect the engine working condition. 

(f) Do not use the high pressure water cannons wash the ecm shell. 

(g) The engine starting time should be less than 5s. Not more than 5 consecutive starting times. The 

interval time to next starting should not be less than 15 seconds. 

(h) Keep the normal coolant temperature 85 ~ 105 ℃ . 

(i) When the engine in high speed or high load, do not turn the ignition switch off. Keep the engine running 

in low speed for 3~5 mins, so that the engine radiates eventually. 

(j) Before opening the radiator cap, ensure the engine is cool. 

(k) Use the sealant scraper to clear the sundrise in seal surface. Confirm seal surface flat and smooth, no 

pollution and foreign bodies. 

(l) Disassembly sequence should be generally from inner to outer, assembly to parts. In order to improve 

the efficiency and ensure the assembly and disassembly correct, pay attention to checking and making 

mark. Removed parts should be cleaned and inspected. The parts can be reused according to the 

classification. Precision parts should be separated with general parts. Put them in clean containers. 

(m) Assembly sequence should be from inside to outside, parts to components, components to assembly. 

Pay attention to the size, location, clearance, torque, etc. When assembling, avoid the missing, 

mistaking, scratching and foreign parts into machine. Assemble bolts, nuts with suitable wrench, 

uniform properly. Use anti-losseness device correctly. According to regulations, appropriately use split 

cotters, spring washer, thrust washers, etc. In addition, in the assembly process, must pay attention to 

the marks to ensure the good position. 

(n) Ensure the diesel engine always in the state of complete cleaness. Before removing or assembling, 

parts should be cleaned to ensure clean and high quality assembly. More complicated adjustment and 

maintenance should be done indoor to prevent diesel engine internal parts from environmental 

pollution. 

(o) Pay attention to the security when repairing or dismantling. Improper tool or engine starting suddenly 

will result in injury. 

15C 

15B 

15C 

Page 2219

15C-2 


ENGINE ASSY 

REPLACEMENT 


2. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioner - refrigerant, 


3. RELEASE FUEL SYSTEM PRESSURE. (Refer to “Chapter 12B fuel - fue system, fuel system 

pressure release process”) 


5. DRAIN COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”) 

6. DRAIN ENGINE OIL. (Refer to “Chapter 18B lubricantion - engine oil, replacement”) 

7. DRAIN TRANSMISSION FLUID. (Refer to “Chapter 41 transmission - transmission assy, replacement”) 





cover. 









Page 2220


15C-3 

13. DISCONNECT GENERATOR POSITIVE CABLE. 

14. DISCONNECT GENERATOR CONNECTOR. 

15C 

15. REMOVE TURBOCHARGER INTAKE AIR RIPPLE HOSE. (Refer to “Chapter 14B intake air - 

intake air pipe and hose, replacement”) 

16. REMOVE MASS AIR FLOW SENSOR CONNECTOR. (Refer to “Chapter 14B intake air - air filter 


17. REMOVE INTERCOOLER OUTLET STEEL PIPE. (Refer to “Chapter 14B intake air - intercooler 

intake air pipe, replacement”) 

18. REMOVE A/C PIPE FROM COMPRESSOR. 

(a) Remove the retaining bolt securing high pressure and 

low pressure pipes to compressor. 

NOTE 

Using clean cloth, block the A/C pipe and A/C compressor 

hole to avoid dust entering. 

19. REMOVE AIR INTAKE PIPE. 

(a) Disconnect ECM wire harness connectors and additonal 

one electrical connector in the ECM compartment. 

(b) Pull engine wire harness and ECM rubber grommet out 

of the hole on the sidewall of ECM compartment. 

20. REMOVE GROUND CABLE MOUNTED ON ENGINE 

THROTTLE ACTUATOR. 

21. DISCONNECT VACUUM BOOSTER HOSE FROM 

INAKE MANIFOLD. 

15B 

15C 

Page 2221

15C-4 


22. DISCONNECT ENGINE WIRE HARNESS CONNEC- 

TORS THROUGH THE HOLE ON THE SIDEWALL OF 

BATTERY COMPARTMENT FROM BATTERY COM- 

PARTMENT FUSE BOX CONNECTOR RECEPTACLE. 

23. DISCONNECT ENGINE WATER OUTLET HOSE. 

24. DISCONNECT ENGINE BLEEDING HOSE. 

25. REMOVE POWER STEERING FLUID RESERVIOR 

FROM THE BRACKET. (Refer to “Chapter 52 power 

steering - power steering pump with fluid reservior, 


26. REMOVE INTERCOOLER INLET STEEL PIPE. (Refer to “Chapter 14B intake air - intercooler 



28. REMOVE FRONT WHEELS. (Refer to “Chapter 33 wheel and tire - wheel, replacement”) 

30. REMOVE RIGHT FRONT SUSPENSION UNIT. 

29. REMOVE LEFT FRONT SUSPENSION UNIT. 

(a) Separate left front shock absorber from lower control 

arm. (Refer to “Chapter 31 front suspension - front shock 


(b) Separate left front stabilizer bar from lower control arm. 



(c) Separate left front stabilizer bar from lower control arm 

ball joint seat. (Refer to “Chapter 31 front suspension - 

lower control arm, replacement”) 

(d) Separate left front steering tie rod from the steering 

knuckle arm. (Refer to “Chapter 52 power steering - 

power steering link assy, replacement”) 

NOTE 


Page 2222


15C-5 

31. REMOVE STEERING DRIVE SHAFT ASSY II. 

(a) Remove retaining bolts on both sides of steering drive 


(b) Remove steering drive shaft assy II. 

15C 

32. DISCONNECT ENGINE WATER INLET HOSE. 

33. DISCONNECT ENGINE FUEL DELIVERY LINE FROM 

DIESEL FILTER ASSY. 

34. DISCONNECT FUEL RETURN TUBE. 

NOTE 

After disconnecting fuel tubes, cover them completely with 

plastic bags or something similar to avoid damage and 

foreign materials. 

35. REMOVE STARTER POSITIVE CABLE. 

36. REMOVE TRANSMISSION FLEXIBLE SHAFT ASSY. (Refer to “Chapter 41 transmission - 


37. REMOVE CLUTCH SLAVE CYLINDER. (Refer to “Chapter 42 clutch - clutch slave cylinder, 


38. REMOVE FRONT EXHAUST PIPE. (Refer to “Chapter 16B exhaust - exhaust pipe, replacement”) 

39. DISCONNECT VSS AND BACK-UP LAMP SWITCH HARNESS CONNECTORS. (Refer to “Chapter 

41 transmission - transmission assy, replacement”) 

40. SUPPORT ENGINE SUB-FRAME AND TRANSMISSION ASSY WITH HYDRAUMATIC JACK. 

NOTE 

Lower the vehicle in suitable position and support bottom of engine sub-frame and transmission assy 

with hydraumatic jack securely. 

15B 

15C 

Page 2223

15C-6 


41. REMOVE SUB-FRAME RETAINING BOLTS. 

(a) 

(b) 

Remove 5 retaining bolts from right side of sub-frame. 

The left is similar as the above, remove 5 retaining bolts 

from left side of sub-frame. 

NOTE 

Before removing sub-frame, mark the sub-frame to ensure 

align the reference line marked on the sub-frame with 

retaining bolts when installing. 

42. SEPARATE PROPELLER SHAFT FROM TRANSMISSION ASSY. (Refer to “Chapter 34 axle and 


43. REMOVE TRANSMISSION MOUNT. 

(a) Remove the retaining nut securing transmission mount to 


(b) 

After supporting the rear of transmission to a suitable 

height with jack, pull the retaining bolt for separating the 

transmission mount from the vehicle frame. 

44. LOWER THE JACK SLOWLY TO SEPARATE ENGINE SUB-FRAME AND TRANSMISSION ASSY 

FROM VEHICLE FRAME. 

NOTE 

• Verify all vacuum hoses, fuel and coolant hoses, electrical connectors between engine/ 

transmission and vehicle are disconnected before lowering engine sub-frame and transmission 

assy. 

• Lower engine about 150 mm slowly. verify all components between the engine/transmission and 

vehicle are disconnected again. 

45. SEPARATE ENGINE ASSY FROM TRANSMISSION ASSY. (Refer to “Chapter 41 transmission - 


46. DISCONNECT HIGH PRESSURE AND LOW PRESSURE FLUID PIPES FROM POWER STEERING 

PUMP. (Refer to “Chapter 52 power steering - power steering link assy, replacement”) 

47. FIT ENGINE HOOK AND HANG ENGINE ASSY WITH A HOIST 

48. REMOVE ENGINE MOUNTS LOCATED ON BOTH SIDES OF ENGINE. 

49. HOIST ENGINE UP AND SEPARATE ENGINE FROM SUB-FRAME. 

50. INSTALL BOTH ENGINE MOUNTS ON ENGINE. 

51. CONNECT HIGH PRESSURE AND LOW PRESSURE FLUID PIPES TO POWER STEERING PUMP. 

(Refer to “Chapter 52 power steering - power steering link assy, replacement”) 

52. INSTALL TRANSMISSION ASSY ONTO ENGINE. (Refer to “Chapter 41 transmission - 


53. PLACE THE HYDRAULIC JACK SUPPORTING ENGINE SUB-FRAME AND TRANSMISSION ASSY 

UNDER THE VEHCLE. 

54. RAISE THE HYDRAULIC JACK UNTIL THE SUB-FRAME RETAINING GUDIES ARE FULLY 

SEATED INTO THE VEHICLE FRAME AND TRANSMISSION MOUNT IS POSITIONED IN PLACE 

PROPERLY. 

Page 2224


15C-7 

NOTE 

• Lift up the hydraulic jack slowly, make sure there is no interference with vehicle during raising 

the engine and transmission assy. 

• During raising slowly, handle lower control arm, steering tie rod and shock absorber related 

position with vehicle avoid interference. 

15C 

55. INSTALL SUB-FRAME RETAINING BOLTS. 

(a) 

(b) 

Install 5 retaining bolts securing sub-frame right side to 


Torque: 150 ~ 170 N.m 

The left is similar as the above, install 5 retaining bolts 

securing sub-frame left side to vehicle frame. 

NOTE 

Align the mark on sub-frame while installation. 

56. INSTALL RETAINING NUT SECURING TRANSMISSION 

MOUNT TO VEHICLE FRAME. 

Torque: 126 ~ 154 N.m 

57. REMOVE GENERATOR RETAINING BOLTS AND 

SEPARATE GENERATOR FROM BRACKET. 

(a) 

(b) 

(c) 

(d) 

58. INSTALL RIGHT FRONT SUSPENSION UNIT. 

Connect left front shock absorber to lower control arm. 

(Refer to “Chapter 31 front suspension - front shock 


Connect left front stabilizer bar to lower control arm. 



Connect left front stabilizer bar to lower control arm ball 

joint seat. (Refer to “Chapter 31 front suspension - lower 

control arm, replacement”) 

Connect left front steering tie rod to the steering knuckle 

arm.(Refer to “Chapter 52 power steering - power 

steering link assy, replacement”) 

15B 

15C 

NOTE 


59. INSTALL FRONT WHEEL. (Refer to “Chapter 33 wheel and tire - wheel, replacement”) 

Page 2225

15C-8 


60. INSTALL STEERING DRIVE SHAFT ASSY II. 

(a) Install steering drive shaft assy II. 

(b) Tighten retaining bolts on both sides of steering drive 


NOTE 

When installing steering drive shaft assy II, make sure 

steering wheel is in the center and front wheel stands 

straight ahead of the vehicle. 

61. INSTALL TRANSMISSION FLEXIBLE SHAFT ASSY. (Refer to “Chapter 41 transmission - 


62. INSTALL CLUTCH SLAVE CYLINDER. (Refer to “Chapter 42 clutch - clutch slave cylinder, 


63. INSTALL FRONT EXHAUST PIPE. (Refer to“Chapter 16B exhaust - exhaust pipe, replacement”) 

64. CONNECT PROPELLER SHAFT TO TRANSMISSION ASSY. (Refer to “Chapter 34 axle and 


65. CONNECT VSS AND BACK-UP LAMP SWITCH HARNESS CONNECTOR. (Refer to “Chapter 41 

transmission - transmission assy, replacement”) 

66. CONNECT ENGINE WATER INLET HOSE. 

67. INSTALL INTERCOOLER INLET STEEL PIPE. (Refer to “Chapter 14B intake air - intercooler 


68. INSTALL INTERCOOLER OUTLET STEEL PIPE. (Refer to “Chapter 14B intake air - intercooler 


69. CONNECT ENGINE FUEL DELIVERY LINE TO DIESEL 

FILTER ASSY. 

70. CONNECT FUEL RUTURN TUBE. 

71. CONNECT STARTER POSITIVE CABLE. 


Page 2226


15C-9 

73. CONNECT ENGINE WATER OUTLET HOSE AND 

TIGHTEN CLAMP. 

74. CONNECT ENGINE BLEEDING HOSE AND TIGHTEN 

CLAMP. 

75. INSTALL POWER STEERING FLUID RESERVIOR TO 

THE BRACKET. (Refer to “Chapter 52 power steering 

- power steering pump with fluid reservior, 


15C 

76. CONNECT WATER INLET AND WATER OUTLET 

HOSE TO FRONT HEATER, THEN TIGHTERN THE 

CLAMPS. 

77. INSTALL A/C PIPES TO COMPRESSOR. 

(a) Install the retaining bolt securing high pressure and low 



NOTE 

Always install O-ring with new one. 

78. INSTALL MASS AIR FLOW SENSOR CONNECTOR. (Refer to “Chapter 14B intake air - air filter 


79. INSTALL TURBOCHARGER INTAKE AIR RIPPLE HOSE. (Refer to “Chapter 14B intake air - intake 

air pipe and hose, replacement”) 

80. CONNECT GERERATOR CONNECTOR AND TIGHTEN 

GENERATOR POSITIVE CABLE RETAINING NUT. 

15B 

15C 

Page 2227

15C-10 


81. INSTALL ENGINE WIRE HARNESS. 

(a) Connect engine ECM harness connectors and additional 

one electrical connector through the hole on the sidewall 

of engine compartment. 

(b) Press the rubber grommet into place. 

82. INSTALL GROUND CABLE TO THE THROTTLE 

ACTUACTOR SIDE. 

83. CONNECT VACUUM BOOSTER HOSE TO INTAKE 

MANIFOLD. 

84. CONNECT ENGINE WIRE HARNESS TO BATTERY COM- 

PARTMENT FUSE BOX CONNECTOR RECEPTACLE. 




(b) Cover front floor covering. 




88. FILL COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”) 

Page 2228


15C-11 

89. FILL ENGINE OIL. (Refer to “Chapter 18B lubricantion - engine oil, replacement”) 

90. ADD POWER STEERING FLUID TO SPECIFIED LEVEL. (Refer to “Chapter 52 power steering - 

steering fluid, replacement”) 

91. FILL TRANSMISSION FLUID. (Refer to “Chapter 41 transmission - transmission assy, replacement”) 

92. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioner - refrigerant, replacement”) 

15C 

15B 

15C 

Page 2229

15C-12 

ENGINE MECHANICAL - ENGINE ACCESSORY BELT 

ENGINE ACCESSORY BELT 

OVERHAUL 

1. Switch off the ignition. 

2. Open the engine hood. 

3. Wait until the engine cools down. 

4. Drain the coolant. (Refer to "Chapter 17B. Cooling - coolant, replacement") 

5. Unscrew the clip screw and pull out the engine water 

outlet hose. 

6. With the toolkit, turn the accessory belt tensioner 

bolt clockwise, until the accessory belt is completely 

loose. 

7. Remove and examine the accessory belt. Replace it in case of any of the following damages: 

CAUTION 

• Water or grease on the belt will quickly reduce its service life. Therefore, after removal, protect the belt, 

the belt pulley and the tensioner from water or grease. Do not wash these parts. In case of heavy 

contamination, replace it with a new one. 

• If any water or grease is found on these parts, check whether there is fluid leakage in the engine. 

(a) Aged and shiny rubber on the back, showing no nail 

scratch. 

Page 2230


15C-13 

(b) 

(c) 

(d) 

(e) 

Cracked or peeled canvas. 

Cracked rubber on the back. 

Cracked belt tooth at the bottom. 

Cracked belt tooth on the side. 

15C 

(f) 



(g) 

(h) 

Unusal tear wear of the belt. 


8. Put the accessory belt around all the belt pulley, 

tensioner and idler, except for the generator belt 

pulley. With the toolkit, turn the tensioner bolts 

clockwise, so that the accessory belt wraps around 

the generator belt pulley. Loose the tensioner. 

CAUTION 

After the installation of the accessory belt, check whether it 

is properly installed around each pulleys. If any malposition 

between the belt and the pulley, turn the tensioner nuts with 

the toolkit and slightely loosen the accessory belt, before 

further adjustment. 

15B 

15C 

Page 2231

15C-14 


9. Install the engine water outlet hose and tighten the 

clip screw.\ 

10. Fill up the coolant. (Refer to "Chapter 17B. Cooling - coolant, replacement") 

11. Restore the engine hood. 

Page 2232


EXHAUST PIPE ...............................................................................16C-1 

COMPONENTS .........................................................................16C-1 

PRECAUTION............................................................................16C-2 

REPLACEMENT ........................................................................16C-3 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16B 

16C 

Page 2233

Page 2234

EXHAUST PIPE 

COMPONENTS 


16C-1 

16C 

1 Rubber Support 

2 Rear Muffler Assy 

3 Nut 

4 Spring Washer 

5 Exhaust Piper Seal Gasket 

6 Bolt 

7 Front Muffler Assy 

8 Front Exhaust Pipe Assy 

9 Front Rubber Support 

10 Nut 

14B 

16C 

Page 2235

16C-2 


PRECAUTION 

1. BEFORE REMOVING MOUNTING RUBBER, ALWAYS APPLY A SMALL AMOUNT OF GREASE TO 

MOUNTING RUBBER FOR REMOVING OR INSTALLING EASILY. 

2. WHEN INSTALLING EXHAUST PIPE, ALWAYS USE NEW RING GASKET OTHERWISE GAS 

LEAKAGE WILL PRESENT. 

3. AFTER A LONG-TIME USED, THE EXHAUST PIPE GASKET WILL BE ADHERED TO EXHAUST 

PIPE. AFTER REMOVING THE MUFFLER, USE THE SCRAPER TO CLEAN THE SURFACE OF 

EXHAUST PIPE AND REPLACE WITH A NEW GASKET TO AVOID EXHAUST LEAKAGE. 

Page 2236


16C-3 

REPLACEMENT 


NOTE 

Exhaust pipe is a high temperature part. Never work around or attempt to service any parts of the 

exhaust system until it cools down. 


16C 

3. REMOVE REAR MUFFLER ASSY.PRECAUTION 

(a) 

Remove 2 rear muffler assy nuts. 

NOTE 



(b) 

(c) 

Remove the rear muffler mounting rubber. 

Remove rear muffler assy. 

4. CHECK REAR MUFFLER ASSY. 

(a) Tap or shake the muffler, check to make sure that broken 



(b) Check the appearance of muffler for corrosion holes that 


replace it. 

NOTE 

After a long-time used, the exhaust pipe gasket will be 

adhered to exhaust pipe. After removing the muffler, use 

the scraper to clean the surface of exhaust pipe and replace 

with a new gasket to avoid exhaust leakage. 

14B 

16C 

5. REMOVE FRONT MUFFLER ASSY. 

(a) Remove front muffler rear mounting rubber 

NOTE 



Page 2237

16C-4 


(b) 

(c) 

(d) 

Remove 2 front muffler retaining nuts. 

Remove 2 support in the front of front muffler. 

Remove front muffler assy. 

6. INSPECT FRONT MUFFLER ASSY. 

(a) 

(b) 

Tap or shake the muffler, check to make sure that broken 



Check the appearance of muffler for corrosion holes that 


replace it. 

7. REMOVE FRONT EXHAUST PIPE ASSY. 

(a) Remove front exhaust pipe mounting rubber. 

(b) Remove 2 retaining bolts securing front exhaust pipe to 

diesel oxidation catalyst. 

8. REMVOE DIESEL OXIDATION CATALYST. (Refer to CUMMINS ISF SERIES ENGINE SERVICE 

MANUAL) 

9. INSTALL DIESEL OXIDATION CATALYST. (Refer to CUMMINS ISF SERIES ENGINE SERVICE 

MANUAL) 

NOTE 

• When reinstalling exhaust pipe each time, always replace ring gasket with new one. 

• When installing heat shield, avoid large gaps or interference between heat shield and each 

exhaust pipes. 

• When installing each mounting rubber, avoid twisting or unusual extension in up/down and left/ 

right directions. 

Page 2238


16C-5 

10. INSTALL FRONT EXHAUST PIPE ASSY. 

(a) Install front exhaust pipe rubber support. 

(b) Tighten 2 retaining bolts securing front exhaust pipe to 

diesel oxidation catalyst. 


16C 

NOTE 



11. INSTALL FRONT MUFFLER ASSY. 

(a) 

Install 1 mounting rubber at the rear side of front muffler 

assy. 

(b) 

(c) 

Install 2 support in the front of front muffler. 

Install 2 front muffler retaining nuts. 


12. INSTALL REAR MUFFLER ASSY. 

(a) Install rear muffler mounting rubber. 

14B 

16C 

(b) 

Tighten 2 retaining bolts in the front of rear muffler. 


Page 2239

16C-6 



(a) Check clearance between exhaust pipe and rear bumper is uniform gap. 

(b) With engine running, check exhaust pipe joints for gas leakage and unusual noises. 

(c) Check to ensure that mounting bracket and mounting rubbers are installed properly stress.improper 

installation could result in excessive noise and vibration. 

Page 2240


COOLING SYSTEM .........................................................................17C-1 

PRECAUTION............................................................................17C-1 

COMPONENTS .........................................................................17C-2 

PROBLEM SYMPTOMS TABLE................................................17C-4 

ON-VEHICLE INSPECT.............................................................17C-5 

COOLANT ........................................................................................17C-7 

REPLACEMENT ........................................................................17C-7 

RESERVIOR.....................................................................................17C-9 

REPLACEMENT ........................................................................17C-9 

COOLING FAN ASSY....................................................................17C-11 

OVERHAUL .............................................................................17C-11 

RADIATOR.....................................................................................17C-14 

REPLACEMENT ......................................................................17C-14 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17B 

17C 

Page 2241

Page 2242


COOLING 

PRECAUTION 


17C-1 

1. COOLING SYSTEM PRECAUTION. 

(a) When disconnecting the cooling hose, use a suitable container to recycle the retains of coolant. If it is 

not to be used, dispose of them according to the regulations. 

(b) When disconnecting the pipes of cooling system, do not let debris go into the pipes of cooling system. It 

may damage the cooling system and engine. 

(c) When disconnecting the cooling system pipes connectors, a special plug must be used to cover the 

nozzle to prevent dirt and impurities. 

(d) Coolant is poisonous, always keep it away from children and pets. If it is not to be used, disposal them 

according to the regulations. 

(e) Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 ℃ 

(120 ℉) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may cause 


(f) Use foton specified coolant, do not use water instead of coolant. Water will damage the engine because 

of corrosion. 

(g) Clean radiator outside regularly, which can prevent mud and dust deposition from damaging radiator. 

17C 

13B 

17C 

Page 2243

17C-2 


COMPONENTS 



3 Fan Cowl 

4 Locking Nut 

5 Cooling Fan Assy 



9 Washer 

10 Nut 

11 Cooling Fan Bracket 


Page 2244


17C-3 

17C 


2 Hose Clamp 

3 Engine Inlet Hose No. 2 

4 Locking Nut 

5 Engine Inlet Pipe 

6 Engine Inlet Hose 

7 Hose Clamp 

8 Engine Outlet Hose No. 2 

9 Engine Outlet Pipe 

10 Engine Outlet Hose 

11 Hose Clamp 

12 Reservoir Refilling Hose 

13 Reservoir Assy 


15 Clamp 

16 Radiator To Reservoir Vent Hose 

17 Hose Clip 


19 Engine Bleeding Hose 


21 Clamp 

22 Hose Clamp 


13B 

17C 

Page 2245

17C-4 






1. Coolant (Lack or leaking) Chapter 17B cooling - coolant, replacement 

2. Coolant (Non-standard) Chapter 17B cooling - coolant, replacement 

3. Thermostat (Damaged) Chapter 17B cooling - thermostat, overhaul 

Engine overheated 

4. Engine (Rough work) - 

5. Radiator (Poor cooling) Chapter 17B cooling - cooling system, precaution 

6. Cooling fan (Damaged) Chapter 17B cooling - cooling fan, overhaul 

7. Cooling system (Blocked) - 

1. Radiator(Damaged) Chapter 17B cooling - radiator, replacement 

Coolant leaking 

2. Cooling system hose(Blocked) - 

3. Coolant pump(Damaged) Chapter 17B cooling - coolant pump, replacement 

4. Coolant reservoir(Damaged) Chapter 17B cooling - coolant, replacement 

Engine room noise 

1. Cooling fan(Damaged) Chapter 17B cooling - cooling fan assy, overhaul 

2. Cooling line - 

Page 2246


17C-5 

ON-VEHICLE INSPECT 

1. CHECK WHETHER COOLANT LEVEL IS NORMAL. 

2. IF COOLANT LACKS ABNORMALLY, CHECK COOLING SYSTEM FOR LEAKAGE. 

CAUTION 


blown out. 

17C 

(a) 

(b) 

(c) 

Fill the reservior with coolant and attach a reservior cap 

tester. 

Warm up the engine. 

Pump it to 110 kPa, and check that the pressure does not 

drop. 

NOTE 

If the pressure drops, check the hoses, reservior, radiator 

or water pump for leakage. If no external leakage is found, 

check the heater core, cylinder block and head. 

3. CHECK ENGINE COOLANT LEVEL IN COOLANT 

RESERVOIR. 

(a) When the engine is cool, the engine coolant level should 

be between the ”LOW” and ”FULL” line. 

(b) 

If the coolant level too low, check for leakage and add 

”FOTON Long-effective coolant” or equivalent up to the 

”FULL” line. 

NOTE 

Do not use water instead of coolant. 

4. CHECK ENGINE COOLANT QUALITY. 

CAUTION 


blown out under pressure. 

(a) Remove the reservior cap. 

(b) Place a container under the radiator to bloom the coolant from the coolant drain hole. 

(c) Loosen the coolant drain plug to drain the coolant and check if there is any excessive deposits of rust or 

scale around the radiator cap and radiator filler hole. The coolant should be free from oil. If excessively 

dirty, replace the coolant. 

(d) Tighten the drain plug and check the coolant level in the coolant reservoir. Fill the coolant if necessary. 

5. INSPECT FINS BLOCKAGE. 

(a) If fins are clogged, wash them with water or a steam cleaner and dry them with compressed air. 

NOTE 

• If the distance between the steam cleaner and core is too close, there is a possibility of 

damaging the fins. So keep the proper injection distance. 

13B 

17C 

Page 2247

17C-6 


• Be careful not to spary water directly onto electronic components. 


(a) Disconnect the cooling fan connector. 

(b) Connect battery and ammeter to the connector. 

(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. 

Temperature: 20°C 

Current: 8.0 ~ 12.0 A 

(d) Connect the cooling fan connector. 

(e) No abnormal noise except fan itself when the fan is rotating at a high speed. 

Page 2248


17C-7 

COOLANT 

REPLACEMENT 

CAUTION 





17C 



NOTE 



the way. 



COOLANT. 

NOTE 








NOTE 












13B 

17C 

Page 2249

17C-8 








NOTE 


Page 2250


17C-9 

RESERVIOR 

REPLACEMENT 

1. DRAIN ENGINE COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”) 

17C 

2. REMOVE RESERVIOR. 

(a) Open reservior cover by turn it slowly to release the 

pressure. 

CAUTION 

Do not open the reservior cap when the engine is hot. 

Coolant temperature should be reduced to 50 ° C (120 ° F) 

below, remove the radiator cap. Otherwise, the cooling 


(b) 

(c) 

Remove reservior vent hose clamp and disconnect vent 

hose. 

Remove reservior retaining bolt. 

(d) 

(e) 

Disconnect coolant fluid level sensor connector. 

Remove reservior refilling hose clamp and disconnect 

reservior refilling hose. 

(f) 

Remove reserivor. 

NOTE 

Do not lose the rubber grommet located on radiator upper 

support when removing reservior. If damaged, replace 

them. 

13B 

17C 

Page 2251

17C-10 


3. INSTALL RESERVIOR. 

(a) 

(b) 

Connect reservior refilling hose and tighten retaining 

clamp. 

Connect coolant fluid sensor connector. 

(c) 

(d) 

(e) 

Locate the lower support of reservior into rubber sleeve 

on upper radiator frame. 

Tighten reservior retaining bolt. 

Connect reservior vent hose. 


(a) Fill the coolant to max level when cold, check coolant fluid level indicator is normal in instrument cluster 

and no coolant leakage is found. 

Page 2252


17C-11 


OVERHAUL 


17C 

2. DISCONNECT COOLING FAN ASSY CONNECTOR. 

3. REMOVE COOLING FAN BRACKET. 

(a) Remove 4 cooling fan bracket retaining bolts and nuts. 

(b) Remove retaining nut securing A/C pipe clamp. 

(c) Move A/C pipes slightly to one aside . 

(d) 

(e) 

Disengage A/C pipes from the dual line clip at the bottom of 


Remove cooling fan bracket carefully. 

13B 

17C 

Page 2253

17C-12 


4. REMOVE COOLING FAN ASSY. 

(a) 

(b) 

Remove 6 cooling fan retaining bolts. 

Remove cooling fan assy from the left side under the 

vehicle. 


(a) Using an ohmmeter, measure the resistance between the terminals. 

Main cooling fan: 



Secondary cooling fan: 


(b) Resistance between white wire and red wire:1.377±15%Ω ; 

(c) Visually inspect cooling fan blade for cracks or unusual bend. 

(d) Rotate cooling fan by hand, the blades should be rotated smoothly. 

6. INSTALL COOLING FAN ASSY. 

(a) Position cooling fan assy into place from under the 

vehicle. 

(b) Tighten 6 cooling fan retaining bolts. 


7. INSTALL COOLING FAN BRACKET. 

(a) Positon cooling fan bracket properly in the original 

positon. 

(b) Tighten 4 bracket retaining bolts and nuts. 


(c) Engage A/C pipes into dual line clip at the bottom of 


Page 2254


17C-13 

(d) 

Tighten A/C pipe clamp retaining nut. 

17C 

8. CONNECT COOLING FAN ASSY CONNECTORS. 


(a) 

Start the vehicle, check cooling fan for normal operation and ensure that no unusual noise is heard 

when engine warms up and A/C switch is on. 

13B 

17C 

Page 2255

17C-14 


RADIATOR 

REPLACEMENT 

WARNING 




1. DRAIN ENGINE COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”) 

2. REMOVE RESERVIOR.(Refer to “Chapter 17B cooling - reservior, replacement”) 

3. REMOVE COOLING FAN ASSY. (Refer to “Chapter 17B cooling- cooling fan assy, replacement”) 

4. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior amd interior trim - front grille, replacement”) 

5. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior amd interior trim - front bumper, 


6. REMOVE ENGINE HOOD LOWER COVER PANEL. 

(a) Remove 4 engine hood lower cover panel retaining bolts. 

(b) 

(c) 

Remove 2 push pins from the back of lower cover panel. 

Remove engine hood lower cover panel. 

7. REMOVE THE FAN COWL. 

(a) Remove 2 retaining bolts in the upper fan cowl. 

(b) Pull out reservior refilling hose from fan cow fixing clip. 

Page 2256


17C-15 

(c) 

(d) 

Push fan cowl upward until 2 lower support disengage 

from radiator lower mounting notch. 

Remove lower fan cowl. 

17C 

8. REMOVE RADIATOR UPPER AND LOWER WATER 

HOSES. 

(a) 

Remove engine water outlet hose to upper radiator. 

NOTE 


necessary. 

(b) 

Remove engine water inlet hose to lower radiator. 

NOTE 


necessary. 

9. REMOVE THE RADIATOR UPPER SUPPORT. 

(a) 

(b) 

Pull out reservior vent hose from fixing clip on radiator 

upper support. 

Disconnect engine hood switch connector and remove 

the wire harness clip from the radiator upper support. 

13B 

17C 

(c) 

(d) 

Disconnect washer motor connector. 

Remove 2 washer assy retaining bolts. 

Page 2257

17C-16 


(e) 

Remove 5 radiator upper support retaining bolts. 

(f) 

Remove radiator upper support and put it aside. 

NOTE 

Do not lose the upper mounting rubber installed on radiator 

upper mounting pin when removing radiator. if damaged, 

replace them. 

10. REMOVE THE RADIATOR. 

(a) 

(b) 

Remove 2 retaining bolts securing upper condenser to 

radiator. 

Remove 2 retaining bolts securing both upper air 


(c) 

(d) 

Remove 2 retaining bolts securing lower condenser to 

radiator. 

Remove 2 retaining bolts securing both lower air 


CAUTION 

Hang and hold condenser with wire after removing the bolts 

securing condenser to radiator to prevent the A/C pipes or 

condenser from damaging. 

(e) 

Lift up and remove the radiator. 

NOTE 

Do not lose lower mounting rubbers of radiator when 

removing radiator and check the mounting rubbers for 

damage, replace them as required. 

Page 2258


17C-17 

11. INSTALL THE RADIATOR. 

NOTE 

Make sure lower mounting rubbers are seated onto raditaor 

lower support before installing radiator. 

17C 

(a) 

(b) 

Tighten 2 retaining bolts securing upper condenser to 

radiator. 

Tighten 2 retaining bolts securing both upper air deflector 

to radiator. 


(c) 

(d) 

Tighten 2 retaining bolts securing lower condenser to 

radiator. 

Tighten 2 retaining bolts securing both lower air deflector 

to radiator. 


12. INSTALL RADIATOR UPPER AND LOWER WATER 

HOSES. 

(a) Connect engine water inlet hose to radiator. 

13B 

17C 

(b) 

Connect engine water outlet hose to radiator. 

Page 2259

17C-18 


13. INSTALL THE FAN COWL. 

(a) Position fan cowl into place from under the vehicle. 

(b) Tighten 2 upper fan cowl retaining bolts. 

14. INSTALL THE RADIATOR UPPER SUPPORT. 

(a) 

Positon the radiator upper support. 

NOTE 

Make sure mounting rubbers are seated onto raditaor upper 

support pin. 

(b) Tighten 5 radiator upper support retaining bolts. 


15. INSTALL ENGINE HOOD LOWER COVER PANEL. 

(a) Position engine hood lower cover panel, then install 2 

push pins. 

(b) 

Tighten 4 lower cover panel retaining bolts. 

16. INSTALL COOLING FAN ASSY. (Refer to “Chapter 17B cooling - cooling fan, overhaul”) 

17. INSTALL RESERVIOR. (Refer to “Chapter 17B cooling - reservior, replacement”) 




20. FILL COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”) 


(a) After installing radiator, let engine be running until cooling fan runs at high speed. check coolant for 

leakage. 

Page 2260


LUBRICATION SYSTEM .................................................................18C-1 

PRECAUTION............................................................................18C-1 

ENGINE OIL .....................................................................................18C-2 

REPLACEMENT ........................................................................18C-2 

OIL FILTER ......................................................................................18C-4 

REPLACEMENT ........................................................................18C-4 

OIL PAN ...........................................................................................18C-6 

REPLACEMENT ........................................................................18C-6 

OIL PUMP ........................................................................................18C-7 

REPLACEMENT ........................................................................18C-7 

18B 

18B 

18B 

18B 

18B 

18B 

18B 

18B 

18B 

18B 

18B 

18B 

18B 

18B 

18C 

Page 2261

Page 2262


PRECAUTION 


18C-1 

CAUTION 

Prolonged and repeated contact with engine oil will cause the skin fat to be removed, resulting in dry 

skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants may 

cause skin cancer. Therefore, the skin must be protected in appropriate methods and with cleaning 

equipment. 

1. LUBRICATION SYSTEM PRECAUTION. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

Avoid contacting with oil for a long time, especially the used engine oil. 

Wear protective clothing, including waterproof work gloves. 

Avoid contaminated clothing, especially underwear containing the oil. 

Never put rags contaminated with oil in pockets. 

Avoid eyes contact with oil, must wear goggles, In addition, equipment must be prepared to clean the 

eyes and wrapping the wound must be dealt with immediately. 

Frequent use of soap and water can clean, especially before meals, and make sure all the oil have 

been removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is 

recommended to replace the natural skin oils cotton suet. 

Do not use gasoline, kerosene, diesel, thinner or solvent to clean skin. 

Before each work, apply cream to help skin cleaning after work. 

If your skin is abnormal, consult a doctor immediately. 

18C 

12B 

18C 

Page 2263

18C-2 


ENGINE OIL 

REPLACEMENT 

1. PARK VEHICLE IN LEVEL ROAD, SLOWLY PULL OUT OIL DIPSTICK, AND CHECK OIL LEVEL, 

OIL LEVEL MUST BE LOCATED WITHIN THE OIL DIPSTICK MARK. 

2. CHECK OIL WITHOUT EXCESSIVE POLLUTION, NO PETROL AND LIQUID MIXED. THERE MUST 

HAVE ENOUGH CONCENTRATIONS AND VISCOSITY. 






CAUTION 

The engine oil maybe hot, be careful, avoid personal injury. 


9. REPLACE A NEW DRAIN PLUG GASKET AND TIGHTEN 

DRAIN PLUG. 




Engine oil: 5 ~ 5.5 L 

NOTE 

The specification of engine oil is CH - 4 level or above (15W-40 in summer and 15W-30 in winter). 


Page 2264


18C-3 


14. CHECK OIL FILTER OR OTHER PART AND ENSURE THERE IS NO OIL LEAKAGE. 





18C 


12B 

18C 

Page 2265

18C-4 


OIL FILTER 

REPLACEMENT 


2. OPEN ENGINE COMPARTMENT COVER AND THEN OPEN OIL FILLER CAP. 


4. REMOVE OIL DRAIN PLUG AND DRAIN ENGINE OIL. 

CAUTION 

Be careful, the engine oil maybe hot. 

NOTE 

Without special circumstances, the oil filter should be 

replaced with engine oil to avoid oil pollution and keep 

engine normal operation. 


6. USING SPECIAL TOOL, REMOVE OIL FILTER. 

7. CLEAN THE SURFACE BETWEEN OIL FILTER AND OIL FILTER BRACKET. 


9. FILL CLEAN OIL INTO OIL FILTER. 

Page 2266


18C-5 


OIL FILTER BRACKET. USING SUITABLE TOOL, TIGHTEN 

OIL FILTER. 

Torqure: 25 ~ 30 N•m 

18C 




13. FILL ENGINE OIL TO SPECIFIED LEVEL. 


15. START ENGINE AND RUN FOR 5 MINUTES WITH THE VEHICLE PARKING ON LEVEL GROUND. 

16. CHECK OIL FILTER AND ENSURE THERE IS NO OIL LEAKAGE. 





12B 

18C 


Page 2267

18C-6 


OIL PAN 

REPLACEMENT 




CAUTION 

Be careful, the engine oil may be hot. 


5. REMOVE OIL PAN. ( Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL ) 

6. CLEAN SURFACE BETWEEN LADDER FRAME AND ENGINE BLOCK. 

7. INSTALL OIL PAN. ( Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL ) 



9. LOWER VEHICLE AND FILL ENGINE OIL TO SPECIFIED LEVEL. 

Page 2268


18C-7 

OIL PUMP 

REPLACEMENT 

1. ISF 2.8 ENGINE USES INNER GEAR TYPE OIL PUMP WHICH IS LOCATED INSIDE FRONT GEAR 

CHAMBER COVER AND DRIVED BY CRANKSHAFT DIRECTLY. 

2. REPLACE OIL PUMP.(Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL ) 

18C 

12B 

18C 

Page 2269

MEMO 

Page 2270


STARTING AND CHARGING SYSTEM ..........................................20C-1 

PRECAUTION............................................................................20C-1 

PROBLEM SYMPTOMS TABLE................................................20C-2 

GENERATOR...................................................................................20C-4 

OVERHAUL ...............................................................................20C-4 

STARTER.......................................................................................20C-10 

COMPONENTS .......................................................................20C-10 

OVERHAUL .............................................................................20C-11 

BATTERY.......................................................................................20C-18 

COMPONENTS .......................................................................20C-18 

USE AND MAINTENANCE......................................................20C-19 

INSPECTION ...........................................................................20C-21 


TROUBLESHOOTING.............................................................20C-22 

REPLACEMENT ......................................................................20C-24 

20B 

20B 

20B 

20B 

20B 

20B 

20B 

20B 

20B 

20B 

20B 

20B 

20B 

20C 

Page 2271

Page 2272


STARTING AND CHARGING SYSTEM 


PRECAUTION 

20C-1 

1. STARTING AND CHARGING SYSTEM PRECAUTION. 

(a) Battery may have escaping explosive gas. in order to avoid personal injury, keep ventilated in engine 

room before maintaining battery. To avoid electric arc, disconnect battery negative cable first and 

connect the negative cable last. 

(b) Battery electrolyte is very dangerous. It can damage the machine and cause serious burns. When 

maintaining battery, prepare neutralizers concentration soda water, wear safety eyepiece and wear 

protective clothing, which can avoid personal injury. 

(c) When using compressed air, wear appropriate goggles and protective mask. Dust particles and dirt can 

cause injury. 

(d) Don't tighten the electrical connectors excessively, which may damage the starter. 

(e) Never short two cables of the battery, it will cause a rapid battery fever even an explosion occur. The 

escaping gas from battery is easily be burned by the spark, so do not use fire near battery. 

(f) After the generator operation, do not try to use spark check whether the generator works. Use bulb or 

multimeter to perform the test. Otherwise it will damage the generator diode. 

(g) Check the generator silicon rectifier devices, it is strictly forbidden to use multimeter or apply 220V 

directly for generator insulation check, otherwise it will make diode breakdown and damaged. 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

Page 2273

20C-2 






1. Starter switch control circuit (Open) Check wire harness 

Starter out of operation 

2. Brush and rectifier (Poor 

connection) 

3. Starter inside circuit (Open or short) 

1. Battery (Low voltage) 

Chapter 20B starting and charging - starter, 

overhaul 


overhaul 



2. Starter wire (Poor connection) Check wire harness 

Starter lacks power, 

can not srart engine 

3. Rectifier (Surface damaged or 

stains) 

4. Brush (Wear) or Brush spring 

(Loss elastic force) 

5. Solenoid switch (Contacts ablation) 


overhaul 


overhaul 


overhaul 

1. Bearing (Wear) Chapter 20B starting and charging - starter, 

overhaul 

Starter keep working 

after engine start. 

2. Starter relay (Copper contacts 

bond) 

3. Starter commutator (Bend or break) 

4. Starter gear tooth surface contact 

(Roughening or stuck) 


overhaul 


overhaul 


overhaul 

1. Generator connect wire Check wire harness 

Generator out of operation 

2. Rotor winding (Open) 

3. Rectifier diode (Damaged) 

4. Brush (Poor connection) 


Chapter 20B starting and charging - generator, 

overhaul 


overhaul 


overhaul 


overhaul 

Page 2274


20C-3 


Generator lacks 

enough electricity 

1. Belt losing tensity 

2. Brush (Poor connection) or Collector 

ring (Smeary) 


Chapter 15B engine mechanical - engine 

accessory belt, overhaul 


overhaul 


overhaul 

20C 

20C 

20C 

4. Battery lose electrolyte or battery 

plate (Damaged) 



20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

Page 2275

20C-4 


GENERATOR 

OVERHAUL 





cover. 


4. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 driver / assistant driver seat - replacement”) 


ASSISTANT DRIVER SEAT . 

(a) Open front surfacing on engine compartment cover. 

(b) Remove 5 engine compartment cover mounting bolts. 

(c) Remove engine compartment cover under assistant 

driver seat. 

6. REMOVE ENGINE BELT. (Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL) 

7. REMOVE GENERATOR. (Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL) 

8. DISASSEMBLE GENERATOR. 

(a) Using pneumatic tools, loosen generator belt pulley retaining 

nut. 

Page 2276


20C-5 

(b) 

Loosen retaining bolts attaching generator front cover to 

stator component. 

20C 

20C 

20C 

(c) 

Insert a screwdriver between front cover and stator then 

separate them. 

20C 

20C 

NOTE 

• If it is difficult to be separated, slap the front cover 

slightly with rubber hammer and pry it with screwdriver. 

• Do not insert screwdriver too deep to prevent stator 

component being damaged. 

20C 

20C 

20C 

(d) 

Using a electric iron (180 ~ 250 w), remove stator. This 

operation should be within 4 seconds to prevent diode 

from heat. 

20C 

20C 

20C 

20C 

(e) 

Loosen 4 retaining bolts from rectifier. 

20C 

20C 

20C 

20C 

20C 

(f) 

Using a electric iron, remove rectifier from regulator. 

20C 

20C 

NOTE 

• Ensure that the heat is not transmitted from electric 

iron to diode for long time. 

• Do not let diode pin bear too much force. 

20C 

Page 2277

20C-6 


(g) 

Remove and inspect rotor. 

• Check the rotor coil is conductive, and confirm that the 

collector rings are conductive. Measure the resistance of 

rotor. If the resistance is less than specified value, it 

means the rotor is short circuit. If it is not conductive or it 

is short circuit, replace the rotor assy. 

Specified value: 3 ~ 5 Ω 

• Check that rotor coil ground. Confirm that it is insulative 

between collector ring and core. If not, replace the rotor 

assy. 

• Using a vernier caliper, measure the slip ring diameter. 



(h) Remove and inspect stator. 

• Check the stator for continuity. Confirm that the coil lead 

is conductive. If not, replace the stator assy. 

• Check the coil ground. Confirm that it is not conductive 

between coil and stator core. Replace the stator assy if 

conductive. 

Page 2278


20C-7 

(i) Inspect stator rectifier. 

• Diode group (three diodes) check: Using an ammeter to 

connect two ends of each diode, check if three diodes 

are conductive. If it is not conductive in both directions, it 

means the diodes are broken, and it is required to 

replace the rectifier assy. 

20C 

20C 

20C 

(j) 

Get rid of welding point of brush lead, then take out the 

brush. 

20C 

20C 

20C 

20C 

20C 

(k) 

If brush is so worn to reach wear limit line, replace brush. 

20C 

20C 

20C 

20C 

20C 

20C 

9. ASSEMBLE GENERATOR. 

(a) When installing new brush, weld brush lead in the 

condition when brush is pressed down to brush bracket 

as shown. 

20C 

20C 

20C 

20C 

(b) 

Tighten 4 retaining bolts of rectifier. 

20C 

20C 

Page 2279

20C-8 


(c) 

Weld rectifiers and stator. 

(d) 

Before mounting rotor on rear cover, insert a steel wire 

into small hole on rear cap, then erect mounted rotor by 

brush, pull out steel wire. 

(e) 

(f) 

Install rotor. 

Tighten the retaining bolts attaching generator front 

cover to stator component. 

10. POSITION GENERATOR BELT PULLY. USING PNEUMATIC TOOLS, INSTALL GENERATOR BELT 

PULLEY RETAINING NUT. 

11. INSTALL GENERATOR.(Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL) 

12. INSTALL GENERATOR BELT.(Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL) 


Page 2280


20C-9 



(a) Place engine compart cover in proper position. 

(b) Tighten 5 engine compartment cover mounting bolts. 

20C 

20C 

20C 

20C 

20C 

20C 

15. INSTALL ASSISTANT DRIVER SEAT.(Refer to “Chapter 84 driver / assistant driver seat - replacement”) 


20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

Page 2281

20C-10 


STARTER 

COMPONENTS 

1 Front Bracket 

2 Spring 

3 Starter Drive Lever 


5 Planetary Gear Bracket 

6 Solenoid Component 


8 Steel Ball 

9 Planetary Gear 

11 Overdrive Clutch 

12 Locating Snap Ring 

13 Magnet Yoke Assy 

14 Commutator 

15 Brush 

16 Brush Bracket 

17 Starter Shell Bolt 


19 Rear Bracket 

10 Internal Gear 

Page 2282


20C-11 

OVERHAUL 




4. REMOVE STARTER. (Refer to 《CUMMINS ENGINE ISF SERIAL SERVICE MANUAL》 ) 

5. INSPECT STARTER 

(a) Pinion gap adjustment. 




terminal. 

NOTE 



• When the 12-volt battery is connected between the S- 

terminal and M-terminal, the pinion will move out. 

• Check the pinion-to-stopper clearance (pinion gap) with 

a feeler gauge. 


20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

• If the pinion gap is out of specification, adjust by adding 

or removing gasket(s) between the magnetic switch and 

front bracket. 

20C 

20C 

20C 

20C 

20C 

(b) Magnetic switch pull-in test. 




terminal. 

20C 

20C 

NOTE 



• When turn ignition switch on, the pinion will move out. If 

the pinion moves out, the pull-in coil is good. If it doesn't, 

replace the magnetic switch. 

Page 2283

20C-12 


(c) 

Magnetic switch hold-in test. 



• Connect a 12-volt battery between the S-terminal and 

body. 

NOTE 



• Manually pull out the pinion as far as the pinion stopper 

position. 

• If the pinion remains out, everything is operating properly. 

If the pinion moves in, the hold-in circuit is open. 

Replace the magnetic switch. 

(d) 

Magnetic switch return test. 



• Connect a 12-volt battery between the M-terminal and 

body. 

NOTE 


to prevent the coil from burning. 

• Pull the pinion out and release. If the pinion quickly 

returns to its original position, everything is operating 

properly. If it doesn't, replace the magnetic switch. 

CAUTION 

Be careful not to get your fingers caught when pulling out 

the pinion. 

6. DISASSEMBLE STARTER. 

(a) Disconnect magnetic coil lead nut from magnetic switch. 

(b) 

Remove magnetic switch retaining bolts. 

Page 2284


20C-13 

(c) 

Remove starter shell retaining bolts. 

20C 

20C 

20C 

(d) 

NOTE 

Disassemble starter as components art shown. 

• When removing armature, do not lose the steel ball 

mounted in the bearing ends. 

• Using a proper control sleeve, push and press the 

locating snap ring to the overdrive clutch side, and 

make it be away from the clip spring. 

20C 

20C 

20C 

20C 

20C 

20C 

• Remove the snap spring with snap ring pliers, then 

remove the locating snap ring and overdrive clutch. 

20C 

20C 

20C 

20C 

20C 

7. CLEAN STARTER PARTS. 

(a) 

(b) 

(c) 

(d) 

Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation winding lead or rotor is 

immerged in detergent, their insulating ability will be damaged. 

Clean starter parts with cloth. 

Drive parts can not be immerged in detergent for cleaning. Before delivering out of factory, the 

overdrive clutch is greased. If clean it by detergent, its grease might be removed. 

Using a brush and dipping with detergent, clean drive parts then dry them with a cloth. 

8. INSPECT COMMUTATOR. 

(a) Support the commutator with a pair of V block and turn it 

to measure the runout of the surface using a dial gauge. 

Standard: ≤ 0.05 mm 

Limit: 0.1 mm 

20C 

20C 

20C 

20C 

20C 

20C 

Page 2285

20C-14 


(b) 

Measure the diameter of the commutator. 



(c) 

Measure the depth of the undercut between segments. 


Limit: 0.2 mm 

9. INSPECT BRUSH AND BRUSH BRACKET. 

(a) Check that it is conductive between brush plate and brush bracket, if not, it is normal. 

(b) Check the commutator contact surface of each brush for abnormal roughness. Also check the height of 

the brush. Replace the brush holder if the height is lower than the limit. 

Limit: 7.0 mm 

(c) When the contact surface of the brush is rectified or the brush holder is replaced, recondition the 

contact surface with sandpaper wrapping around the commutator. 

10. INSPECT OVERDRIVE CLUTCH. 

(a) Make sure that the pinion can not be turned counterclockwise 

and can be turned clockwise freely. 

(b) Check the pinion for abnormal waring and damage. 

11. INSPECT ARMATURE COIL. 

(a) Set the armature in a growler. 

(b) While holding a thin strip of iron against the armature in 

parallel with its axis, turn the armature slowly. The 

armature is normal if the iron strip is not attracted to the 

armature or it does not vibrate. 

NOTE 

Clean the surface of the armature thoroughly before performing 

the test. 

Page 2286


20C-15 

(c) 

Check the insulation between commutator segments and 

armature coils. It is normal if there is not continuity. 

20C 

20C 

20C 

(d) 

Check continuity between a segment and another. It is 

normal if there is continuity. 

20C 

20C 

20C 

20C 

20C 

20C 

12. INSPECT MAGNETIC SWITCH. 

(a) Coil open circuit test. 

• Check that there is continuity between the M terminal 

and body A. 


20C 

20C 

20C 

20C 

20C 

(b) Contact fusion check. 

• Check that there is no continuity between the B terminal 

and M terminal. 

• If there is continuity, replace the magnetic switch. 

20C 

20C 

20C 

20C 

20C 

(c) 

Switch contact check. 

• Push the indicated end of the magnetic switch with a 

strong force to close the internal contacts. Without 

releasing the switch end, check that there is continuity 

between the B terminal and M terminal. 


20C 

Page 2287

20C-16 


13. ASSEMBLE STARTER. 

(a) Using a suitable puller, pull stop ring until it gets over 

snap ring. 

(b) 

Install locating snap ring and overdrive clutch. 

(c) 

(d) 

Assemble starter as components art shown. 

Tighten the starter shell retaining bolts. 


(e) 

Tighten the magnetic switch retaining bolts. 


Page 2288


20C-17 

(f) 

Connect the magnetic coil lead nut to magnetic switch. 


20C 

20C 

20C 

14. INSTALL STARTER. (Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL) 



20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

Page 2289

20C-18 


BATTERY 

COMPONENTS 

1 Battery 

2 Battery Fix Frame 

3 Battery Fix Rod 

4 Mounting Nut 

5 Battery Tray 

6 Bolt And Washer 

Page 2290


20C-19 

USE AND MAINTENANCE 

1. CHARGING DEVICE. 

NOTE 

DC power supply must be used for battery charging, howerever, what is supplied by power plant is AC 

that it must be transformed into DC, After transform, the charging can be performed. 

(a) Rectifier. 

(b) Controllable silicone voltage regulation charger. 

2. CHARGE PRECAUTIONS 

(a) Charging should choose in ventilated dry room, indoor temperature in 5 ℃ ~ 40 ℃ is advisable. 

(b) Battery can not be overlap shelved, also do not put them on the ground directly. It should be put on the 

wooden support, and cannot be set with alkaline battery or other chemicals. 

(c) Charging in field should be far away from fire and heat. 

(d) Liquid temperature should not exceed 45 ℃ and otherwise cooling measures shouldl be taken (by 

reducing filling current or stopping sharge or being cooled down in water tank). 

3. CHARGE CONNECTION. 

(a) The positive pole of charger is to be connected with the positive pole of battery, while the negative pole 

of charger should be connected with the negative pole of battery. Never connect them reversely. 

(b) Charge of most batteries may be determined based on the size of motor power. Connection for charge 

must be firm. 

4. CHARGING MODES. 

(a) Constant current charge. 

(b) Constant voltage charge. 

(c) Quick charge. 

5. AFTER CHARGING, USING THE BELOW METHODS, CHECK THE BATTERY CAPACITY IS 

RESTORED TO STANDARD. 

(a) Voltage method 




below 11.5 v over-discharge or internal failure to be further checked after charging 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

(b) 

Capacity method 

Capacity Tester Display Determination Treatment 





20C 

20C 

Page 2291

20C-20 


6. USING AND MAINTENANCE OF BATTERY IN WINTER 

(a) 

(b) 

Keep the battery is to be maintained under full charge status, avoid the electrolyte from being frozen 

arising from drop in density, which may give rise to breakage of container, curve of pole plats, as well as 

smash and dropout of active substances, and other failures. 

Because the battery capacity reduced in winter, when start the engine in cold status, preheated the 

engine and each time start the engine should not more than 15 seconds, two starting interval 2 ~ 3 

minutes, if can not start the engine in three times, troubleshooting, then restarting. 

Page 2292


20C-21 

INSPECTION 

1. APPEARANCE INSPECTION. 

(a) Observe whether the battery appearance in good condition. Check if fixed terminal and wires are 

connected firmly. 

(b) Observe whether the battery shell and the center partition cracks, and use a wooden beat shell and 

center partitions respectively, listen to the sound without breaking, especially the central baffle and shell 

side of shell wall at the junction of four, prone to crack, should be carefully examined. 

(c) Through mirrors, green for fully charged, red and white says lack of electricity and no electricity. Need 

of the following capacity, voltage detection. 

2. CAPACITY TEST. 

(a) The excel tester is also known as the discharging tongs. 

It consists of a DC voltmeter of three volts and one load 

resistance. 

(b) The tips of the two tongs shall be pressed on the anode 

and the cathode tightly and maintain for five seconds in 

the measurement. Observe the terminal voltage in the 

state of the big load discharging and the discharging 

content and the starting ability can be judged correctly. 

(c) For the excel tester of different brands, the readings of 

the current and the voltage shall be read according to the 

regulations of the factory manual. Generally, the single 

voltage of the battery in good state shall be above 1.5 V 

and keep steady within five seconds. If the voltage drops 

rapidly within five minutes or the voltage of one single 

cell is 0.1 V lower than that of others, it indicates there 

are troubles in the battery and it shall be repaired.Below 

is the use of excel tester of discharge plan detection 

income cross-references. 

Display Zone Determination Treatment 





3. VOLTAGE TEST. 

The following table is derived using the digital multimeter test table. 



20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 


under 112.5 v over-discharge or internal fault to be further checked after charging 

Page 2293

20C-22 



TROUBLESHOOTING 

1. ELECTRICAL QUALITY OF ONE FULL-CHARGED BATTERY REDUCE WITHOUT USE FOR A 

LONG PERIOD. 


The full-charged battery without use will lose its electrical quality gradually and this phenomenon is 

known as “self-discharge”. The important cause of self-discharge is the impure materials. If there are 

impurities in the material of the polar plate or in the electrolyte, there will be a potential difference 

between the impurity and the polar plate and between the impurities. A closed “local current” is formed 

and would make the discharge of the battery. 


For the battery which has discharged seriously, it can be discharged completely or excessively. This will 

enable the impurities on the polar plate into the electrolyte. Then, pour the electrolyte out and clean the 

battery with distilled water. Finally, inject the new electrolyte and re-charge the battery. 

2. BATTERY EXPLODE. 


The water in the electrolyte hydrolyzes into hydrogen or oxygen and a lot of bubbles are generated; 

there are short circuit and vulcanization troubles in the battery; the temperature increases while 

charging and large amount of water are evaporated. Then if the vent holes of the injection hole cover 

are plugged or there are a lot of gases which are unable to escape, the battery will explode when the 

inner pressure comes to a limit (or there are sparks). 


(a) The vent holes of the injection hole cover shall be cleared. 

(b) In order to avoid sparks, the wirings on the polar stud shall be fastened. 

(c) The injection hole cover shall be opened first when check with the excel tester. 

(d) Control the charging amount and do not over-charge in order to reduce the releasing amount of the 

gases. Open flames are prohibited and the ventilation shall be ensured in the charging room. 

3. RAPID DECREASE OF THE LIQUID LEVEL DURING THE USE PROCESS OF THE BATTERY. 


(a) Excessive charging current lead to evaporation of water. 

(b) Battery shell broken. 


(a) Add distilled water. 

(b) Repair shell, add the electrolyte. 

4. A YELLOW OR WHITE PASTE APPEARS ON BATTERY COVER. 


The yellow or white paste surrounding the battery cover and the polar stud is caused by the corrosion of 

the polar studs, wiring clip and the fixed frame by the sulfuric acid sprayed. 


In order to avoid these pastes, clean the electrolyte sprayed on the battery cover and the shell with a 

cloth soaked with the soda solution of 10 percents. Then wipe with water and dry with a clean cloth. 

The paste on the wire ends and the studs shall be wiped with the cloth soaked with soda solution. If 

there are oxides of poor conductivity, scrape them with a little knife and clean them. It would be best to 

smear a coat of Vaseline or butter on the cover after the polar studs and wiring clips are fastened. 

Page 2294


20C-23 

CAUTION 

The vehicle for Foton View CS2 is equipped with maintenance-free battery. If battery is bad, replace the 

battery as a unit. To avoid personal injury, it is strictly prohibited to disassemble the battery. 

Disassembly is limited to find the cause of the problem and provide information through professional 

testing. 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

20C 

Page 2295

20C-24 


REPLACEMENT 



(a) 

(b) 



cover. 

3. REMOVE BATTERY CABLE. 

(a) Open shield and disconnect battery negative cable. 

NOTE 

Disconnect the negative cable first when removal. 

(b) 

Open shield and disconnect battery positive cable. 

4. REMOVE BATTERY FIX FRAME. 

(a) Remove battery fix rod mounting nut. 

(b) Remove battery fix frame. 

5. REMOVE BATTERY. 

NOTE 

Battery should be put up, placing battery upside down is prohibited. 

Page 2296


20C-25 

6. REMOVE BATTERY TRAY. 

(a) Loosen 3 battery tray retaining bolts. 

(b) Remove battery tray. 

20C 

20C 

20C 

7. INSTALL BATTERY TRAY. 

(a) Install 3 battery tray retaining bolts. 


20C 

20C 

20C 

20C 

20C 

20C 

8. INSTALL BATTERY . 

(a) Position battery. 

(b) Place battery fix frame and tighten fix rod mounting nut. 

20C 

20C 

20C 

20C 

20C 

(c) 

(d) 


Connect battery positive cable, tighten mounting nut and 

cover shield. 

Connect battery negative cable, tighten mounting nut 

and cover shield. 

NOTE 

• If terminals has sediments, remove the impurities 

then apply thin layer of grease to terminal. 

• Connect positive battery cable first when installing. 

20C 

20C 

20C 

20C 

20C 

20C 

Page 2297

Page 2298


V O L U M E 5 

31-32 SUSPENSION SYSTEM 2303 

33 TYRE AND WHEEL 2341 

34 AXLE AND PROPELLER SHAFT 2353 

35-36 BRAKING SYSTEMS 2407 

41 TRANSMISSION 2467 

42 CLUTCH 2545 

51 STEERING COLUMN 2567 

52 POWER STEERING 2591 

61 HEATER AND AIR CONDITIONING 2627 

62 SUPPLEMENTAL RESTRAINT SYSTEM 2715 

63 SEAT BELT 2735 

64 LIGHTING 2759 

65 WIPER AND WASHER 2789 

66 AUDIO SYSTEM 2811 

71 WIRING 2827 

81 COMMUNICATION SYSTEM 3221 

82 WINDSHIELDS, MIRRORS & GLASS 3237 

83 INSTRUMENT PANEL 3261 

84 SEATS 3279 

85 DOOR LOCKS 3305 

86 SLIDING ROOF 3327 

87 DOORS AND ENGINE HOOD 3337 

88 EXTERIOR AND INTERIOR TRIM 3359 

91 VEHICLE CONTROL SYSTEM 3397 

Page 2299

Page 2300

SUSPENSION SYSTEM 

FRONT SUSPENSION............................................................. 31-1 

FRONT WHEEL ALIGNMENT ................................................... 31-08 

FRONT SHOCK ABSORBER.................................................... 31-10 

TORSION BAR........................................................................... 31-12 

UPPER CONTROL ARM............................................................ 31-15 

LOWER CONTROL ARM........................................................... 31-18 

STABILIZER BAR...................................................................... 31-20 

STRUT ROD............................................................................... 31-23 

REAR SUSPENSION ............................................................... 32-1 

REAR SHOCK ABSORBER .......................................................... 32-4 

REAR LEAF SPRING ASSY.......................................................... 32-6 

Page 2301

Page 2302


FRONT SUSPENSION....................................................................... 31-1 

PRECAUTION.............................................................................. 31-1 

PROBLEM SYMPTOMS TABLE.................................................. 31-2 

ROAD TEST ................................................................................ 31-4 

COMPONENTS ........................................................................... 31-5 

ON-VEHICLE INSPECTION ........................................................ 31-7 

FRONT WHEEL ALIGNMENT ........................................................... 31-8 

ADJUSTMENT............................................................................. 31-8 

FRONT SHOCK ABSORBER.......................................................... 31-10 

OVERHAUL ............................................................................... 31-10 

TORSION BAR................................................................................. 31-12 

REPLACEMENT ........................................................................ 31-12 

UPPER CONTROL ARM.................................................................. 31-15 

REPLACEMENT ........................................................................ 31-15 

LOWER CONTROL ARM................................................................. 31-18 

REPLACEMENT ........................................................................ 31-18 

STABILIZER BAR............................................................................ 31-20 

REPLACEMENT ........................................................................ 31-20 

STRUT ROD..................................................................................... 31-23 

OVERHAUL ............................................................................... 31-23 

31 

31 

31 

31 

31 

31 

31 

31 

31 

31 

31 

31 

31 

Page 2303

Page 2304


SUSPENSION 

PRECAUTION 

1. FRONT SUSPENSION PRECAUTION 

(a) 

(b) 

(c) 

FRONT SUSPENSION - FRONT SUSPENSION 

31-1 

When installing rubber parts, the tires must be on the ground in no-load condition at final tightening. 

Lubricating oil will shorten the life of rubber liner. Must clean the spilled lubricating oill. 

After installing the suspension parts, check wheel alignment. If necessary, adjust it. 

Lock nut is not reusable. Use new one at every installation. When replacing new parts, do not clean the 

lubrication oil on the lock nut before tightening it. 

31 

20A 

31 

Page 2305

31-2 



Use the table below to help you find the cause of the problem. The numbers indicate the priority of the 

likely cause of the problem. Check each part in order. If necessary, replace these parts 


1. Lubrication oil (Excess) - 

Shock absorber 

oil leakage 

2. Seals (Failure or damaged) - 

3. Shock absorber (Failure) Chapter 31 front suspension - front shock absorber, 

overhaul 

Pulling to one side 

1. Tire (Worn or improperly inflated) 

2. Wheel alignment (Incorrect) 

3. Steering linkage (Loose or worn) 

4. Hub bearing (Worn) 

5. Steering gear (Maladjusted or 

damaged) 

6. Suspension parts (Worn) 

Chapter 33 wheel and tire - wheel and tire assy, onvehicle 

inspection 

Chapter 31 front suspension - front wheel alignment, 

adjustment 

Chapter 51 steering column - steering column assy, 

overhaul 

Chapter 51 steering column - steering propeller 

shaft assy, overhaul 

Chapter 34 axle and propeller shaft - front wheel 

hub, overhaul 

Chapter 52 power steering - steering box, overhaul 

Chapter 31 front suspension - front suspension, onvehicle 

inspection 

1. Vehicle (Overloaded) - 

Bottoming 

Sways/tilt 

2. Shock absorber (Worn or 

damaged) 



3. Stabilizer bar (Bent or broken) 


damaged) 

Chapter 31 front suspension - front shock absorber, 

overhaul 

Chapter 31 Rear suspension - Rear shock absorber, 

overhaul 

Chapter 33 wheel and tire - wheel and tire assy, 

overhaul 


overhaul 



Chapter 31 front suspension - stabilizer bar, 

replacement 


overhaul 

Page 2306


31-3 



2. Wheel (Out of balance) 


damaged) 



overhaul 


overhaul 


overhaul 


adjustment 

31 

Front wheel 

shimmy 

5. Ball joint (Worn or damaged) 

Chapter 31 front suspension - upper control arm, 

replacement 

Chapter 31 front suspension - lower control arm, 

replacement 

6. Hub bearing (Worn) 

Chapter 34 axle and propeller shaft - hub and 

steering knuckle, on-vehicle inspection 



overhaul 



8. Steering gear (Maladjusted or 

damaged) 

Chapter 52 power steering - steering box, overhaul 



adjustment 

Abnomal tire wear 


3. Wheel (Out of balance) 

Chapter 33 wheel and tire - wheel and tire assy, on 

vehicle inspection 


adjustment 

20A 

4. Shock absorber (Worn or damaged) 


overhaul 

31 

Page 2307

31-4 


ROAD TEST 

NOTE 

This is a flow chart for vehicle pull. 

Page 2308


31-5 

COMPONENTS 

31 

1 Front Shock Absorber Assy 

2 Bolt 

3 Flat Washer 

4 Lower Damping Block Assy 

5 Bolt 

6 Lower Control Arm Assy RH 

7 Flat Washer 

8 Bolt 

9 Stabilizer Bar Mounting Bracket RH 

10 Bolt 

11 Sping Washer 

12 M10 Nut M10 

13 Lower Control Arm Camshaft Assy 

14 Nut 

15 Lower Control Arm Cam 

16 Flat Washer 

17 1 Style-Nut 

18 Front Stabilizer Bar Assy 

19 Bolt 

20 Stabilizer Bar Mounting Bracket LH 

21 Nut 

22 Upper Damping Block Assy 

23 Bolt 


25 2 Style-Nut 

26 Strut Rod Assy 

20A 

31 

Page 2309

31-6 


1 Torsion Bar RH 


2 Short Mounting Bolt of Torsion Bar Seat 

3 Long Mounting Bolt of Torsion Bar Seat 

6 Flat Washer 

7 Upper Control Arm Assy 

4 Bolt 

Page 2310


31-7 


1. CHECK TIRES FOR WEAR AND INFLATION PRESSURE. 

For vehicles equipped with 195R15C-106R tires, the front tire pressure is 350 kPa and rear tire pressure is 400 

kPa. The allowable variation is ±5 kPa. The maximum of the same axle tires pressure shall not exceed 10 kPa. 

2. CHECK TIRES FOR RADIAL RUNOUT ERROR. The quantity of wheel sway is less than 1.2 mm. 

3. CHECK FRONT WHEEL BEARING FOR LOOSENESS. 

4. CHECK FRONT SUSPENSION PARTS FOR LOOSENESS AND DAMAGE. 

5. CHECK STEERING ROD FOR LOOSENESS. 

6. CHECK EVERY BALL JOINT FOR TOO LOOSENESS. 

7. PERFORM A STANDARD FLEXIBILITY TEST AND CHECK IF SHOCK ABSORBER WORKS NORMALLY 

8. MEASURE HEIGHT OF UNLOADED VEHICLE. 

(a) Park the vehicle onto an inspection platform and bounce the vehicle to set the suspension system. 

Bounce the front bumper for 5~10 times, then keep the bumper in free state. Measure ground 

clearance at bumper center. Repeat the steps for another time. The difference between two 

measurements should be no more than 10 mm. 

(b) For vehicles equipped with 195R15C-106R tires, measure the ground clearance at front center point of 

lower arm adjusting bolt (also use a self-made measurable tool to measure height in pit). If the 

measured value is not within specified value, adjust the torsion mounting bolt to meet the specified 

requirement. 

31 

20A 

31 

Page 2311

31-8 

FRONT SUSPENSION - FRONT WHEEL ALIGNMENT 

FRONT WHEEL ALIGNMENT 

ADJUSTMENT 

1. INSPECT TIRE. (Refer to “Chapter 33 wheel and tire - wheel and tire assy, on-vehicle 

inspection”) 

2. MEASURE HEIGHT OF WHEELS. 

(a) 

NOTE 

For vehicles equipped with 195R15C-106R tires, measure the ground clearance at front center point of 

lower arm adjusting bolt (also use a self-made measurable tool to measure height in pit). If the 

measured value is not within specified value, adjust the torsion mounting bolt to meet the specified 

requirement. 

• Before inspecting the wheel alignment, adjust the vehicle height to meet the specified value and 

maintain steering wheel center. 

• If the vehicle height is not within the specified value, try to adjust it by pushing down or lifting 

the body. 

3. INSPECT TOE-IN. 

Toe-in (total): 2 ± 2mm (8′ ± 8′) 

If toe-in value is out of the specification, adjust toe-in by the left 

and right tie rods. 

4. ADJUST TOE-IN. 

(a) Loosen tie rod lock nut. 

(b) Turn the outer tie rod RH/LH by an equal amount to 

adjust the toe-in within the specified value. 

NOTE 

Measure the length of the left and right tie rod, and make 

them in the same length. Length difference between the 

right and left tie rod: 3.0 mm or less. 

(c) Tighten the tie rod lock nut. 


5. INSPECT FRONT WHEEL CAMBER, KINGPIN INCLINATION 

AND KINGPIN CASTER. 

Front wheel camber, kingpin inclination and kingpin caster: 

Front Wheel 

Camber 

Kingpin Inclination 

Kingpin Caster 

-0°20′±45′ (Difference between left and 

right < 30′) 

13°05′±45′(Difference between left and 

right < 30′) 

2°35′±45′(Difference between left and 

right < 30′) 

Page 2312

FRONT SUSPENSION - FRONT WHEEL ALIGNMENT 

31-9 

If the kingpin caster is out of the specified value, adjust it by turing 

the strut rod nut. 

NOTE 

The range of adjusting bolt from the initial position can be 

no more than 3 thread. Rotating one revolution is equal to a 

change of approx 30′ in kingpin caster. 

31 

6. ADJUST CAMBER. 

(a) Adjust the front camber by rotating cam. Each scale of 

cam means a 18′ change in camber. It is not allowed to 

rotate cam from the center line over 4.5 scales. 

20A 

31 

Page 2313

31-10 

FRONT SUSPENSION - FRONT SHOCK ABSORBER 

FRONT SHOCK ABSORBER 

OVERHAUL 

1. REMOVE FRONT WHEEL LH ASSY. (Refer to “chapter 33 wheel and tire - front wheel and tire, 


2. REMOVE FRONT SHOCK ABSORBER LH. 

(a) Remove 1 mounting nuts attaching the front shock 

absorber LH to frame. 

(b) Remove the mounting bolt attaching front shock 

absorber LH to the lower control arm. 

(c) Take out the front shock absorber LH. 

3. CHECK SHOCK ABSORBER FOR OIL LEAKAGE. 

(a) Check shock absorber for oil leakage.if the oil leaks from the shock absorber, replace it with a new one. 

4. CHECK SHOCK ABSORBER CONNECTING PARTS. 

(a) Check the shock absorber connecting rod, bushing or other connecting parts for damage. If there is any 

damage, replace it with a new one. 

5. CHECK SHOCK ABSORBER EFFICIENCY. 

(a) Compress and extend the shock absorber rod for 2~3 times and then check that there is no abnormal 

resistance or unusual noise during operation. If there is any abnormality, replace the shock absorber 


Page 2314

FRONT SUSPENSION - FRONT SHOCK ABSORBER 

31-11 

6. INSTALL FRONT SHOCK ABSORBER LH. 

(a) 

Place the shock absorber,tighten the mounting bolt 

attaching the shock absorber to the lower control arm. 

NOTE 

Be sure to use new nut bolt. 

Torque: 80 ~ 100 N•m 

(b) 

Tighten 1 nut attaching front shock absorber LH to frame. 

NOTE 

Be sure to use new nut. 


31 

7. INSPECT AFTER INSTALLATION. 

(a) After the vehicle is assembled, drive it on a bad road for a distance about 10 KM and park it, then touch 

the surfaces of the two shock absorbers with hands. If difference in temperature of the two shock 

absorbers is large, correspondingly, difference in resistance of them is also large and the absorber with 

a low temperature has small resistance. If the temperature of the two shock absorbers doesn’t exceed 

air temperature, it indicates that the shock absorbers have no resistance and disabled. It is necessary 

to replace with a new one. 

(b) When the vehicle is running slowly and given an emergent brake, if the vehicle has an excessive 

vibration, it indicates that there is a fault on shock absorber. Disassemble and erect the shock absorber, 

keep the lower part jointing ring clamping the vise, pull and press the shock absorber rod for several 

times. It should have stable resistance,the pull-up (restoration) resistance should be no less than pulldown 

resistance. If the resistance is unstable or there is no resistance, the shock absorber may lack of 

oil or the valve part is damaged. It is necessary to replace it with a new shock absorber. 

(c) The shock absorber may produce noise during use, this is because the shock absorber is crashed with 

spring, frame or shaft, rubber washer is damaged or fallen off, and dust wrapper is deformed and oil is 

insufficient. It is necessary to find out the root of the fault and replace it. 

(d) If it is impossible to conduct a test, we can take some experiential measures to check it: let an iron bar 

passing through the lower hoisting ring, step the two ends with feet, hold the hoisting ring and pull up 

and down for 2-4 times with hands. If there is large resistance when pulling up and almost no resistance 

when pulling down, stretching resistance is restored compared with resistance before repair, and you 

don’t feel no-running status, it indicates that the shock absorber is in normal condition. 

8. REMOVE AND INSTALL FRONT SHOCK ABSORBER RH. 

NOTE 

Remove and install the Front RH side by the same procedures as the Front LH side. 

20A 

31 

Page 2315

31-12 

FRONT SUSPENSION - TORSION BAR 

TORSION BAR 

REPLACEMENT 

1. REMOVE THE FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank assy, replacement”)or(Refer to 

“Chapter 12B fuel - fuel tank assy, replacement”) 

NOTE 

It is necesary to remove the fuel tank only before removing the torsion bar LH. 

2. REMOVE TORSION BAR ASSY LH. 

(a) 

As the illustration shows, measure the length of the 

extension bolt end A. 

NOTE 

When adjusting the vehicle hight, value A will serve as 

reference. At the end of the torsion bar, there are left and 

right indicator. Do not install it to opposite direction. 

(b) 

Remove the locking nut and adjustment nut of the torsion 

bar LH. 

Page 2316


31-13 

(c) 

Remove 2 mounting bolt attaching the torsion bar to the 

upper control arm. 

31 

(d) 

Pull out the torsion bar backward. 

3. INSTALL TORSION BAR ASSY LH. 

(a) 

Place the torsion bar LH,tighten 2 mounting bolt attaching 

the torsion bar to the upper control arm. 

扭矩 :Torque: 110 ~ 120 N•m 

20A 

(b) 

Tighten the locking nut and adjustment nut of the torsion 

bar LH. 

• Tighten adjustment nut of torsion bar LH. 

• Tighten locking nut .the length of the extension bolt end 

must be the same as the measure value A. 

Torque: 120 ~ 130 N•m 

31 

Page 2317

31-14 


4. INSPECT VEHICLE HEIGHT. IF THE HEIGHT IS OUT OF STANDARD, USE TORSION BAR 

ADJUSTING NUT TO ADJUST. 

5. REMOVE AND INSTALL TORSION BAR ASSY RH. 

NOTE 

Remove and install the RH side by the same procedures as the LH side. 

WARNING 

Be careful not to be scalded by hot exhaust pipe. 

Page 2318

FRONT SUSPENSION - UPPER CONTROL ARM 

31-15 

UPPER CONTROL ARM 

REPLACEMENT 

1. REMOVE FRONT WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire, 


2. REMOVE FRONT DISC BRAKE LH. (Refer to “Chapter 35 brake - front disc brake, overhaul”) 

3. REMOVE TORSION BAR LH. (Refer to Chapter 31 front suspension - torsion bar, replacement”) 

31 

NOTE 

It is not necessary to poll out the torsion bar LH and remove the fuel tank. 

4. REMOVE UPPER CONTROL ARM LH. 

(a) 

Remove mounting bracket mounting bolt of front wheel 

speed sensor cable. 

(b) 

Remove the cotter pin located at slotted nut. 

NOTE 

Removed cotter pin must not be use again. 

(c) 

Removed the slotted nut attaching upper control arm ball 

pin to steering knuckle. 

20A 

31 

(d) 

Remove 3 bolts attaching upper control arm to frame. 

Page 2319

31-16 


(e) 

Take out the upper control arm assy. 

5. INSTALL UPPER CONTROL ARM ASSY LH. 

(a) Place upper control arm,tighten 3 bolts attaching upper 

control arm to frame. 

Torque: 170 ~ 200 N•m 

(b) 

(c) 

Tighten the slotted nut attaching upper control arm ball 

pin to steering knuckle. 

Torque: 105 ~ 125 N•m 

Install the cotter pin located at slotted nut. 

NOTE 

New cotter pin must be used. 

(d) 

Place the mounting bracket of wheel speed sensor 

cable,Tighten mounting bolt. 

6. INSTALL TORSION BAR LH. (Refer to chapter 31 front suspension - torsion bar, replacement”) 

7. INSTALL FRONT DISC BRAKE LH. (Refer to “Chapter 35 brake - front disc brake, overhaul”) 

8. INSTALL FRONT WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire, 


Page 2320


31-17 

9. REMOVE AND INSTALL UPPER CONTROL ARM RH. 

NOTE 


10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension - 

front wheel alignment, adjustment”) 

31 

20A 

31 

Page 2321

31-18 

FRONT SUSPENSION - LOWER CONTROL ARM 

LOWER CONTROL ARM 

REPLACEMENT 



2. REMOVE FRONT DISC BRAKE LH. (Refer to “Chapter 35 brake - front disc brake, overhaul”) 

3. REMOVE LOWER CONTROL ARM ASSY LH. 

(a) Remove bumper block assy. 

(b) Remove the mounting bolt attaching atabilizer bar link LH 

to lower control arm. 

(c) Remove the mounting bolt attaching shock absorber to 

lower contrlo bar. 

(d) 

Remove 4 nuts and bolts attaching ball joint seat to lower 

control arm. 

NOTE 

4 blots including 2 strut rod mounting nuts and bolts. 

(e) Remove the mounting nut attaching lower control arm to 

subframe. 

(f) 

Take out the lower control arm assy LH carefully. 

4. INSTALL LOWER CONTROL ARM ASSY LH. 

(a) Place lower control arm. 

(b) Tighten the mounting nut attaching lower control arm to 

subframe. 

Torque: 180 ~ 220 N•m 

(c) Tighten the mounting bolt attaching strud rod and ball 

joint seat to lower contrlo arm. 

Torque: 100 ~ 120 N•m 

(d) Tighten the mounting bolt attaching ball joint seat to 

lower control arm. 

Torque: 100 ~ 120 N•m 

Page 2322

FRONT SUSPENSION - LOWER CONTROL ARM 

31-19 

(e) 

(f) 

(g) 

Tighten the mounting bolt attaching shock absorber to 


Torque: 80 ~ 100 N•m 

TIghten the mounting bolt attaching stabilizer bar link to 



Place the lower pumper block assy,tighten 2 mounting 

nut at the bottom. 

Totque: 40~ 60 N•m 

31 

5. INSTALL FRONT DISC BRAKE LH. (Refer to “Chapter 35 brake - front disc brake, overhaul”) 



7. REMOVE AND INSTALL LOWER CONTROL ARM RH. 

NOTE 




20A 

31 

Page 2323

31-20 

FRONT SUSPENSION - STABILIZER BAR 

STABILIZER BAR 

REPLACEMENT 

1. REMOVE STABILIZER BAR. 

(a) Remove the mounting bolt attaching stabilizer bar link 

ball joint LH to stabilizer bar. 

(b) Remove the mounting bolt attaching stabilizer bar link 

ball joint RH to stabilizer bar. 

(c) 

(d) 

Remove 2 mounting bolt attaching stabilizer bar bracket 

LH to frame. 

Remove 2 mounting bolt attaching stabilizer bar bracket 

RH to frame. 

Page 2324


31-21 

(e) 

Take down stabilizer bar carefully. 

31 

2. INSPECT STABILIZER BAR BUSHING. 

(a) 

Inspect the stabilizer bar bushing for ageing. If there is any ageing, replace the bushing with new one. 

3. INSTALL STABILIZER BAR. 

(a) Place stabilizer bar. 

(b) Tighten 2 mounting bolt attaching stabilizer bar bracket 

LH to frame. 


(c) Tighten 2 mounting bolt attaching stabilizer bar bracket 

RH to frame. 


20A 

31 

Page 2325

31-22 


(d) 

(e) 

Tighten the mounting bolt attaching stabilizer bar link ball 

joint LH to stabilizer bar. 


Tighten the mounting bolt attaching stabilizer bar link ball 

joint RH to stabilizer bar. 




Page 2326

FRONT SUSPENSION - STRUT ROD 

31-23 

STRUT ROD 

OVERHAUL 

1. REMOVE STRUT ROD LH. 

(a) Remove the nut attaching the strut rod LH to the 

subframe. 

31 

(b) 

Using a wrench, lock the head of bolts attaching the strut 

rod LH to the lower control arm LH. 

(c) 

Remove the mounting nut attaching the strut rod LH to 

the lower control arm LH. 

20A 

31 

(d) 

Take out the the strut rod LH. 

2. CHECK THE RUBBER BUSHING OF THE STRUT ROD FOR DAMAGE. 

Page 2327

31-24 

FRONT SUSPENSION - STRUT ROD 

3. INSTALL STRUT ROD LH. 

(a) Place strut rod,and install rubber bushing and baffle plate 

to strut rod. 

(b) Using a wrench,lock the head of bolts attaching the strut 

rod to the lower contrlo arm. 

(c) 

(d) 

Tighten the nut attaching the strut rod to the lower control 

arm. 

Torque: 100 ~ 120 N•m 

Tighten connecting mounting nut attaching the strut rod 

to the subframe. 

Torque: 115 ~ 135 N•m 

4. REMOVE AND INSTALL STRUT ROD RH. 

NOTE 

Remove the RH side by the procedure as the same procedure as the LH side. 



Page 2328


REAR SUSPENSION ......................................................................... 32-1 


COMPONENTS ........................................................................... 32-2 


REAR SHOCK ABSORBER .............................................................. 32-4 

OVERHAUL ................................................................................. 32-4 

REAR LEAF SPRING ASSY.............................................................. 32-6 

OVERHAUL ................................................................................. 32-6 

32 

32 

32 

32 

32 

32 

32 

32 

32 

32 

32 

32 

Page 2329

Page 2330

REAR SUSPENSION - REAR SUSPENSION 

32-1 




Use the table below to help you find the cause of the problem. The numbers indicate the priority of the 

likely cause of the problem. Check each part in order. If necessary, replace these parts. 

32 


1. Lubrication oil (Excess) - 

Shock absorber oil leakage 

2. Seals (Failure or damaged) - 

3. Shock absorber (Failure) Chapter 32 rear suspension - rear shock 

absorber, overhaul 

1. Shock absorber (Failure) Chapter 32 rear suspension - rear shock 


Suspension noise 

2. Leaf spring (Worn or damaged) Chapter 32 rear suspension - rear leaf 

spring, overhaul 

3. Bushing (Worn or damaged) Chapter 32 rear suspension - rear leaf 


4. Shock absorber and leaf spring 

mounting bolt (Loosen or 

damaged) 

Chapter 32 rear suspension - rear shock 


Sways/tilt 

Abnomal rear tire wear, 

vehicle deviation 

1. Leaf spring pin (Over worn) Chapter 32 rear suspension - rear leaf 


2. U-bolt (Worn or damaged) Chapter 32 rear suspension - rear leaf 


3. Leaf spring (Elastic decline or 

stiffness inconsistent) 

Chapter 32 rear suspension - rear leaf 


4. Leaf spring (Broken) Chapter 32 rear suspension - rear leaf 


1. Tire (Worn or improperly 

inflated) 

Chapter 33 wheel and tire - wheel and tire 

assy, on-vehicle inspection 

2. Wheel (Out of balance) Chapter 33 wheel and tire - wheel and tire 

assy, adjustment 

19 

32 

Page 2331

32-2 


COMPONENTS 

1 Rear Leaf Spring Assy 

2 

Leaf Spring Shackle Outer Plate Welded 

Assy 

3 Leaf Spring Shackle Inner Bushing 

4 Leaf Spring Shackle Inner Plate 


6 Leaf Spring Pin Nut 

7 Rear Damping Block Assy 


10 U-bolt 

11 Leaf Spring Mounting Plate Welded Assy 

12 Rear Shock Absorber Assy 


14 Bolt 

15 Leaf Spring Pin Shaft 


17 Bolt 

9 Bolt 

Page 2332


32-3 


1. ON-VEHICLE INSPECTION 

(a) Check shock absorber for oil leakage. 

(b) Check shock absorber ring rubber bushing for aging, cracking, deforming. Replace it if necessary. 

(c) Leaf spring shackle bushing, every leaf spring pin should be replaced frequently. 

(d) Check U-bolt for cracking, flaw, thread for damage. replace it if necessary. 

(e) U-bolt should be tightened in uniform cross tightened method and step by step tight U-bolt to specified 

value. Tighten the U-bolts again when the leaf spring laminating closely with the car full loaded. In some 

cases that leaf springs can not be compacted because of the bolts and nuts being rusted. Replace it 

with the new U-bolts and nuts if necessary. 

(f) For slide-type leaf spring, a layer of lubricating grease should be applied between the leaf spring and 

shackle bracket to reduce the wear and tear of the slide-type leaf spring. 

32 

19 

32 

Page 2333

32-4 

REAR SUSPENSION - REAR SHOCK ABSORBER 

REAR SHOCK ABSORBER 

OVERHAUL 

1. REMOVE SHOCK ABSORBER RL. 

(a) Remove the lower mounting bolt for the shock absorber 

RL. 

(b) 

(c) 

Remove the upper mounting bolt for the shock absorber 

RL. 

Take out the shock absorber RL with caution. 

2. CHECK SHOCK ABSORBER FOR OIL LEAKAGE. 

(a) Check the shock absorber for oil leakage,If the oil leaks from the shock absorber, replace it with a new 

one. 

3. CHECK SHOCK ABSORBER CONNECTING PARTS. 

(a) Check the shock absorber connecting rod ,rubber bushing or others for damage,replace it with a new 

one if necessary. 

4. CHECK SHOCK ABSORBER EFFICIENCY. 

(a) Compress and extend the shock absorber rod and then check that there is no abnormal resistance or 

unusual noise during operation. If there is any abnormality, replace the shock absorber with a new one. 

5. INSTALL SHOCK ABSORBER RL. 

(a) Place shock absorber RL. 

(b) Tighten the upper mounting bolt for the shock absorber 

RL. 

Torqre: 55 ~ 65 N·m 

Page 2334

REAR SUSPENSION - REAR SHOCK ABSORBER 

32-5 

(c) 

Tighten the lower mounting bolt for the shock absorber 

RL. 

Torqre: 60 ~ 80 N·m 

32 

6. REMOVE AND INSTALL REAR SHOCK ABSORBER RH. 

NOTE 

Remove and install the REAR RH side by the same procedures as the REAR LH side. 

7. INSPECT AFTER INSTALLATION. 

(a) After installation,drive it on a bad road for a distance about 10 KM and park it, then touch the surfaces 

of the two shock absorbers with hands. If difference in temperature of the two shock absorbers is large, 

correspondingly, difference in resistance of them is also large and the absorber with a low temperature 

has small resistance. If the temperature of the two shock absorbers doesn’t exceed air temperature, it 

indicates that the shock absorbers have no resistance and disabled. It is necessary to replace with a 

new one. 

(b) When the vehicle is running slowly and given an emergent brake, if the vehicle has an excessive 

vibration, it indicates that there is a fault on shock absorber. Disassemble and erect the shock absorber, 

keep the lower part jointing ring clamping the vise, pull and press the shock absorber rod for several 

times. It should have stable resistance,the pull-up (restoration) resistance should be no less than pulldown 

resistance. If the resistance is unstable or there is no resistance, the shock absorber may lack of 

oil or the valve part is damaged. It is necessary to replace it with a new shock absorber. 

(c) The shock absorber may produce noise during use, this is because the shock absorber is crashed with 

spring, frame or shaft, rubber washer is damaged or fallen off, and dust wrapper is deformed and oil is 

insufficient. It is necessary to find out the root of the fault and repair it. 

(d) If it is impossible to conduct a test, we can take some experiential measures to check it: let an iron bar 

passing through the lower hoisting ring, step the two ends with feet, hold the hoisting ring and pull up 

and down for 2-4 times with hands. If there is large resistance when pulling up and almost no resistance 

when pulling down, stretching resistance is restored compared with resistance before repair, and you 

don’t feel no-running status, it indicates that the shock absorber is in normal condition. 

19 

32 

Page 2335

32-6 

REAR SUSPENSION - REAR LEAF SPRING ASSY 

REAR LEAF SPRING ASSY 

OVERHAUL 

1. REMOVE REAR SHOCK ABSORBER LH. (Refer to “Chapter 32 rear suspension - rear shock 


2. REMOVE REAR LEAF SPRING ASSY LH. 

(a) 

Using proper jacks, withstand the center of the rear leaf spring. 

(b) 

Remove bolts for the Parking Brake cable fixed shelf. 

(c) 

Remove 4 U-bolts and nuts. 

WARNING 

Before removing the nuts,suport the rear axle with lifting 

jack. 

(d) 

Lowering the jack which holds the leaf spring slowly,remove 

the U-bolts and rear leaf spring anchor plate.Check U- 

bolts,if there are any damaages such as deformation and 

flaw ,replace it in time. 

(e) 

Remove the mounting nut which install the front leaf 

spring axis pin to the frame. 

(f) 

Remove upper mounting nut of leaf spring shackle pin. 

Page 2336


32-7 

(g) 

(h) 

(i) 

Remove lower mounting nut of leaf spring shackle pin. 

Remove shackle inner&outer plates and shackle pin. 

Remove rear leaf spring LH with caution. 

32 

3. CHECK LEAF SPRING FOR AGING, FLAW AND SERIOUS RUSTING. IF THERE IS ANY ONE, 

REPLACE IT WITH A NEW ASSEMBLY. 

4. CHECK SHACKLE BUSHING OF LEAFING SPRING FOR WEARING,AGING ,DAMAGE.IF THERE 

IS ANY ONE ,REPLACE IT WITH A NEW ONE. 

5. CHECK LEAF SPRING ARCH HEIGHT, H = 128 ± 5 mm,Replace new leaf spring if necessary. 

NOTE 

• The defference value of left and right sagitta should not be more than 5 mm, or it will cause 

body sway. 

• The new spring leaf must be as same as the other side (both leaf springs ara “+”or”-”at the 

same time). 

6. INSTALL REAR LEAF SPING ASSY LH. 

(a) 

(b) 

Install shackle inner&outer plates and shackle pin. 

Tighten upper mounting nut of leaf spring shackle pin. 

Torque: 105 ~ 125 N·m 

19 

32 

(c) 

Tighten lower mounting nut of leaf spring shackle pin. 

Torque: 105 ~ 125 N·m 

Page 2337

32-8 


(d) 

Tighten the mounting nut which install the front leaf 

spring axis pin to the frame. 

Torque: 110 ~ 120 N·m 

(e) 

(f) 

Lift the center of rear leaf spring LH with jack 

slowly, make U-bolts cross the rear leaf spring boltholes 

and tighten the nuts with hand. 

Tighten the U-bolt nuts. 

Torque: 85~ 105 N·m 

(g) 

Tighten bolts for the Parking Brake cable fixed shelf. 

(h) 

Move the jack and lifting jack. 

7. INSTALL REAR SHOCK ABSORBER LH. (Refer to “Chapter 32 rear suspension - rear shock 

absorber, overhaul”). 

8. TIGHTEN U-BOLTS NUTS AGAIN AFTER DRIVING 3 ~ 5 KM. 

9. REMOVE AND INATALL REAR LEAF SPRING ASSY RH. 

NOTE 

Remove and install the REAR RH side by the same procedures as the REAR LH side. 

Page 2338

TYRE AND WHEEL 

TIRE AND WHEEL ASSY .................................................................. 33-1 

PRECAUTION.............................................................................. 33-1 

COMPONENTS ........................................................................... 33-2 



ADJUSTMENT............................................................................. 33-7 

FRONT WHEEL AND TIRE................................................................ 33-8 

REPLACEMENT .......................................................................... 33-8 

REAR WHEEL AND TIRE.................................................................. 33-9 

REPLACEMENT .......................................................................... 33-9 

33 

33 

33 

33 

33 

33 

33 

33 

33 

33 

33 

Page 2339

Page 2340

TIRE AND WHEEL ASSY 

WHEEL AND TIRE 

PRECAUTION 

1. TIRE AND WHEEL ASSY PRECAUTION 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

WHEEL AND TIRE - TIRE AND WHEEL ASSY 

Use special tools to remove the tires. Do not remove them by huge hammers or sharp tools. 

33-1 

Do not use tires with different types, sizes, tread patterns, pressure and load index on the same axle. 

Please pay attention to the mark of rolling direction when installing directional tread pattern tires. 

Must swap each tire once after runing 5000 ~ 6000 km, make each tire wear well evenly. 

After swaping tires, reset proper inflation pressure according to the tire position. 

Operate inflation according to this manual’s specification, and measure tire pressure at cold state by 

tire gauge. Before inflating, check the tire valve whether matching valve core flatly and then clean the 

dirt. Inflating air is not allowed to contain water and oil. After inflating, tighten the tire valve core, and 

check the tire leakage. 

Check inflation pressure according to the standard service data. The tire pressure must be within the 

specified value. 

Regularly check front wheel toe-in to avoid unnecessary increased resistance of running, fuel 

consumption and excessive tire wear. 

33 

18A 

33 

Page 2341

33-2 


COMPONENTS 

1 Tire 

2 Wheel Rim 

3 Tubeless Tire Valve 

4 Wheel Hub Nut 

5 Axle Cover 

Page 2342


33-3 




Symptom Suspect Area Suspect Area 

33 

1. Wheel toe-in (Improper value) 

Chapter 31 front suspension - front wheel 

alignment, adjustment 

Abnomal tire wear 

2. Tire ( Improperly inflated) Chapter 33 wheel and tire - wheel and tire 




4. Steering system (Distortion) Chapter 51 steering system - steering box, 

replacement 

1. Front wheel (Different tire 

pressure) 



Front wheel swing or vibration 



3. Shock absorber (Wear or fault) Chapter 31 front suspension - front shock 


4. Steering system (Over Wear) 

Chapter 51 steering system - steering box, 

replacement 

Uncomfortableness when 

running 

1. Tire (Exceed specified pressure) Chapter 33 wheel and tire - wheel and tire 


2. Shock absorber (Failure) 

Chapter 31 front suspension - front shock 


Chapter 32 rear suspension - rear shock 


3. Coil Spring (Failure) Chapter 31 front suspension - torsion bar, 

replacement 

Chapter 32 rear suspension - rear leaf 

spring assy, overhaul 

18A 

33 

Front wheel side slipping 

1. Wheel toe-in (It is not within 

specified value) 

2. Tire (Inflating pressure is not 

within specified value) 





Page 2343

33-4 



1. MEASURE TIRE TREAD DEPTH. 

Depth ≥ 1.6 mm 

If the tire tread depth is less than 1.6 mm, replace it with a new one. 

NOTE 

Replace a pair of tires at the both wheel side. 

2. CHECK TIRES ABNORMAL WEAR. 

(a) Visually inspect the tires shoulder wear. If the tire wears, 

measure the inflation pressure. Inflate and swap the 

wheel if tire pressure is lower or overload. 

(b) 

Visually inspect the wear tires at center. If the tire wears, 

release extra pressure and swap the wheel assy. 

Page 2344


33-5 

(c) 

Visually inspect the tire inner edge (shoulder) wear. The 

inner Edge (shoulder) wear is usually caused by excessive 

toe-out and/or excessive negative camber, suspension 

parts loose. Avoid turning at high speed. Swap the wheel 

assy after adjustment. 

33 

(d) 

Visually inspect the tire outer edge (shoulder ) wear. The 

outer edge (shoulder) wear is usually caused by excessive 

toe-in and/or excessive positive camber, suspension parts 

loose. Avoid turning at high spped. Swap the wheel assy 

after adjustment. 

18A 

33 

(e) 

Visually inspect the tire feathering wear that occurs along 

both inside and outside shoulder ribs. This kind of wear 

is usually caused by abnomal toe-in. Check/adjust the 

wheel alignment and Swap the wheel assy. 

Page 2345

33-6 


(f) 

Visually inspect the tire corrugate wear. This kind of wear 

is caused by improper inflation pressure, wheel out of 

balance, hub bearing loose or worn and rim deformation. 

Swap the wheel assy after adjustment. 

3. MEASURE COLD TIRE INFLATION PRESSURE. 

Tire Specification Front wheel Rear wheel Spare tire 

195R15C-106R 350 kPa 400 kPa 420 kPa 

If tire size or inflation pressure doesn’t match standard service data, adjust or replace it with a new wheel as 

necessary. 

4. INSPECT TIRE CROWN, TIRE SHOULDER, TIRE EDGE. 

Replace the tire with a new one, if bent, cut, cracked, dented, deformation and abrasion exists. 

5. INSPECT TIRE VALVE. 

If air leaks from tire valve, replace it with a new one. 

6. INSPECT RIM. 

Replace the rim with a new one If it is found deformation, corrosion and crack. 

7. INSPECT WHELL NUTS. 

Check the tightening torque one by one according to the standard service data. 

Page 2346


33-7 

ADJUSTMENT 

1. TIRE SWAP. 

NOTE 

Illustration arrow shows the driving direction o. 

(a) 

(a) 

Illustration A is cross swap every tire with spare tire. 

Illustration B is cross swap every tire without spare tire. 

33 

2. WHEEL ASSEMBLY OF THE DYNAMIC BALANCE. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

(j) 

(k) 

Clean dirt, stones and used balance weights from measured 

wheel. 

Measure tire pressure and inflate as recommended. 

Select the match cone based on size of rim center hole 

to tighten by fast nut. 

Turn on the balance tester power. 

Measure rim width. 

Measure tire diameter. 

Measure the distance between the rim edge and the 

balance tester. 

Pull off wheel protect cover and then start test. 

After test completed, fix balance weights based on 

measurement result. 

Repeat aforementioned procedure, adjust till the data to 

match specification. 

Demount wheel assy. 

18A 

33 

3. FRONT WHEEL TOE-IN. (Refer to Chapter 31 front suspention - front wheel alignment , 

adjustment ) 

4. TIRE REPAIR SHOULD BE PERFORMED IN COMPLIANCE WITH LOCAL REGULATIONS. 

Page 2347

33-8 

WHEEL AND TIRE - FRONT WHEEL AND TIRE 

FRONT WHEEL AND TIRE 

REPLACEMENT 

1. LIFT VEHICLE. 

2. REMOVE LH FRONT WHEEL. 

(a) 

Remove 6 hub nuts of LH front wheel. 

NOTE 

Undo all front hub nuts diagonally. 

(b) 

Remove LH front wheel. 

3. INSTALL LH FRONT WHEEL. 

(a) 

Replace LH front wheel. 

(b) 

Tighten 6 hub nuts of LH front wheel. 

Toque: 100 ~ 120 N·m 

NOTE 

Tighten all front hub nuts diagonally. 

4. REMOVE AND INSTALL RH FRONT WHEEL. 

NOTE 

Remove and install the wheel FRONT RH by the same procedures as the LH front wheel. 


Page 2348

WHEEL AND TIRE - REAR WHEEL AND TIRE 

33-9 

REAR WHEEL AND TIRE 

REPLACEMENT 


2. APPLY PARKING BRAKE. 

33 

3. REMOVE LH REAR WHEEL. 

(a) Remove 6 hub nuts of LH rear wheel. 

NOTE 

Loosen all front wheel nuts diagonally. 

(b) 

Remove LH rear wheel. 

18A 

4. INSTALL LH REAR WHEEL. 

(a) 

Replace LH rear wheel. 

33 

(b) 

Tighten 6 hub nuts of LH rear wheel. 

Torque: 100 ~ 120 N·m 

NOTE 

Tighten all front hub nuts diagonally. 

5. REMOVE AND INSTALL RH REAR WHEEL. 

NOTE 

Remove and install the RH rear wheel by the same procedures as the LH rear wheel. 


Page 2349

MEMO 

Page 2350


PROPELLER SHAFT ASSY .............................................................. 34-1 

PRECAUTION.............................................................................. 34-1 


COMPONENTS ........................................................................... 34-3 

INSPECTION ............................................................................... 34-4 

OVERHAUL ................................................................................. 34-5 

U-JOINT ............................................................................................. 34-8 

OVERHAUL ................................................................................. 34-8 

CENTER SUPPORT BEARING ....................................................... 34-12 

OVERHAUL ............................................................................... 34-12 

AXLE HUB AND STEERING KNUCKLE......................................... 34-16 


ON-VEHICLE INSPECTION ...................................................... 34-18 

FRONT HUB..................................................................................... 34-20 

OVERHAUL ............................................................................... 34-20 

REAR AXLE HUB ............................................................................ 34-24 

OVERHAUL ............................................................................... 34-24 

STEERING KNUCKLE..................................................................... 34-28 

OVERHAUL ............................................................................... 34-28 

REAR AXLE ..................................................................................... 34-34 

PRECAUTION............................................................................ 34-34 



FINAL DRIVE OIL ............................................................................ 34-40 

REPLACEMENT ........................................................................ 34-40 

AXLE SHAFT ASSY......................................................................... 34-43 

OVERHAUL ............................................................................... 34-43 

REAR AXLE HOUSING WELDING ASSY....................................... 34-44 

OVERHAUL ............................................................................... 34-44 

DRIVE PINION ................................................................................. 34-50 

INSPECTION ............................................................................. 34-50 

34 

34 

34 

34 

34 

34 

34 

34 

34 

34 

Page 2351

Page 2352

AXLE AND PROPELLER SHAFT - PROPELLER SHAFT ASSY 

PROPELLER SHAFT ASSY 

PRECAUTION 


34-1 

1. PROPELLER SHAFT ASSY PRECAUTION 

(a) Do not disassemble the propeller shaft assy unless absolutely necessary. 

(b) If disassembly of propeller shaft assy is required, be sure to clean all separated parts before assembly. 

(c) After disassembling of propeller shaft assy, be sure to check all separated parts one by one and 

perform repairing or replacing when necessary. 

34 

17A 

34 

Page 2353

34-2 






1. Propeller shaft assy (Loose) 

Chapter 34 axle and propeller shaft - propeller 


2. Lubrication (Insufficient) - 

Abnormal noise of 

propeller shaft assy 

Propeller shaft assy 

vibration 

3. U-joint (Worn or damaged) 

4. Center support bearing (Worn or 

damaged) 

5. Slip spline (Worn) 

1. Propeller shaft assy (Loose) 

2. U-joint yoke (Incorrect installation) 

3. Propeller shaft assy (Bent or 

twisted) 

4. Propeller shaft assy (Unbalanced) 

5. Center support bearing rubber 

grommet (Aging or damaged) 

6. Center suppor bearing (Worn or 

damaged) 

Chapter 34 axle and propeller shaft - U-joint, 

overhaul 

Chapter 34 axle and propeller shaft - center 

support bearing, overhaul 


shaft assy, inspection 













Center support 

bearing overheat 

1. Center support with rubber 

grommet (Incorrect installation) 

2. Lubrication (Insufficient) - 

3. Oil seal (Too tight) 





Page 2354


34-3 

COMPONENTS 

34 

17A 

34 

1 Propeller Shaft Assy 


2 

Bolt , Spring Washer and Flat Washer 

Set 

5 Propeller Shaft Nut 

3 Propeller Shaft Bolt 

Page 2355

34-4 


INSPECTION 

1. INSPECT VIBRATION OF POWERTRAIN. 

(a) Check front wheels for dynamic balance. (Refer to “Chapter 33 wheel and tire - wheel and tire assy, 

adjustment”) 

(b) Check rear wheels for dynamic balance. (Refer to “Chapter 33 wheel and tire - wheel and tire assy, 


(c) Perform the road test. Check the powertrain for vibration when vehicle is moving or stops. 

2. INSPECT PROPELLER SHAFT ASSY DIAMETER RUNOUT. 

(a) Using V-block and dial indicator, measure the diameter 

runout of propeller shaft assy. 

Limit: ≤ 0.5 mm 

If the diameter runout is out of the specification, correct the 

propeller shaft assy using press machine. If the diameter runout 

is still out of the specification after correction, replace with a new 

propeller shaft assy. (Chapter 34 axle and propeller shaft - 

propeller shaft assy, overhaul) 

3. INSPECT PROPELLER SHAFT ASSY DYNAMIC BALANCE. 

(a) Using dynamic balancer, check the propeller shaft assy. 

Dynamic unbalance: ≤ 20 g.cm ( 3200 r/min) 

If the dynamic unbalance is out of the specification, weld balance 

weight at the corresponding position on the both ends of propeller 

shaft assy. 

NOTE 

• It is no more than 3 balance weight at each end if welding. 

• Perform step (a) again to check whether dynamic 

unbalance is within the specification. 

4. INSPECT SLIP SPLINE CLEARANCE. 

(a) Using feeler gauge, measure the tangential clearance 

between sleeve yoke and spline on transmission output 

shaft. 


Limit: 0.3 mm 

If the clearance is out of the specification, replace with a new 

propeller shaft assy. (Refer to “Chapter 34 axle and propeller 

shaft - propeller shaft assy, overhaul”) 

Page 2356


34-5 

OVERHAUL 

1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - propeller shaft assy, precaution”) 

2. REMOVE PROPELLER SHAFT ASSY. 

(a) Mark on the front propeller shaft U-joint and transmission 

dust-proof cover. 

34 

NOTE 

Make sure the marks are clear. 

(b) 

Mark on the rear propeller shaft U-joint and final drive 

flange. 

NOTE 


(c) 

Remove the 4 sets of nuts and bolts attaching propeller 

shaft to final drive flange. 

NOTE 

Discard the removed nuts and bolts. 

17A 

34 

(d) 

Lower the propeller shaft and set it aside. 

NOTE 

When performing this operation, another operator who holds the 

propeller shaft up is required. 

Page 2357

34-6 


(e) 

Remove the 2 bolts fixing center suport bearing bracket. 

NOTE 

• Discard the removed bolts. 

• When performing this operation, another operator who 

holds the propeller shaft up is required. 

(f) 

Lower the center support with rubber grommet. 

NOTE 



(g) 

Pull out the sleeve yoke from transmission dust-proof 

cover and remove the propeller shaft assy. 

NOTE 

Be sure to save the propeller assy carefully. 

3. INSPECT PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller 

shaft assy, inspection”) 

4. INSPECT U-JOINT. (Refer to “Chapter 34 axle and propeller shaft - U-joint, overhaul”) 

5. INSTALL PROPELLER SHAFT ASSY. 

(a) Insert the sleeve yoke into transmission dust-proof cover 

according to the marks. 

NOTE 

• Before assembly, internal and external spline should 

be applied with car general lithium grease. 

• Be sure to perform this operation according to the 

marks. 



Page 2358


34-7 

(b) 

Position the center support with rubber grommet properly 

NOTE 



34 

(c) 

Tighten the 2 bolts fixing center suport bearing bracket. 

Torque: 60 ~ 70 N•m. 

NOTE 

• Be sure to use new bolts. 



(d) 

Position the propeller shaft properly according to the marks. 

NOTE 


marks. 

• Align the marks by rotating the pinion flange when 

necessary. 

17A 

34 

(e) 

Install the 4 sets of nuts and bolts attaching propeller 

shaft to final drive flange. 


NOTE 

Be sure to use new nuts and bolts. 

Page 2359

34-8 

AXLE AND PROPELLER SHAFT - U-JOINT 

U-JOINT 

OVERHAUL 


2. REMOVE PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller 

shaft assy, overhaul”) 

3. DISASSEMBLE MIDDLE U-JOINT OF PROPELLER 

SHAFT ASSY. 

(a) Mark on the end yoke, cross spider and tube yoke. 

NOTE 


(b) 

Using snap ring pliers, remove the 4 snap rings. 

NOTE 

Discard the removed snap rings. 

(c) 

Using copper rod and hammer, remove the round 

bearing. 

NOTE 

Do not hammer the round bearing and do not clamp the 

propeller shaft with vice directly. 

Page 2360


34-9 

(d) 

Remove the 4 round bearings and the 4 dust-proof 

covers. 

NOTE 

Discard the removed dust-proof cover. 

(e) Remove the cross spider. 

(f) Separate the end yoke from tube yoke. 

34 

4. DISASSEMBLE FRONT U-JOINT OF PROPELLER SHAFT ASSY. 

NOTE 

Disassemble the front U-joint by the same procedures as the middle U-joint. 

5. DISASSEMBLE REAR U-JOINT OF PROPELLER SHAFT ASSY. 

NOTE 

Disassemble the rear U-joint by the same procedures as the middle U-joint. 

6. INSPECT CROSS SPIDER. 

(a) Check the cross spider for wear and tear. 

NOTE 

Cross spider doesn’t need maintenance, has no grease mouth, and should be rotated flexibly. 

(b) Using the micrometer caliper, measure the cross spider 

journal. 



If the cross spider is excessively worn, replace with a new part. 

17A 

34 

(c) Using the dial indicator, measure the clearance between 

round bearing and yoke. 

Clearance: 0 mm (Interference fit) 

If clearance exits, replace with new round bearing and yoke. 

NOTE 

Insert the round bearing into yoke. Measure the clearance 

by shaking bearing along radial direction lightly. 

Page 2361

34-10 


(d) Using the vice and the dial indicator, measure the radial 

clearance between round bearing and cross spider. 

Radial clearance: 0.01 ~ 0.055 mm 

If the radial clearance is out of the specification, replace with 

new round bearing and cross spider. 

CAUTION 

Wrap the cross spider with rag to prevent the spider that is 

clamped by vice from being damaged. 

NOTE 

Hitch the cross spider with round bearing. Measure the 

radial clearance by shaking bearing along radial direction 

lightly. 

(e) Using dial indicator, measure the axial clearance 

between round bearing and cross spider. 

Axial clearance: 0.01 ~ 0.055 mm 

If the axial clearance is out of the specification, replace with new 

round bearing and cross spider. 

NOTE 

Hitch the cross spider with round bearing. Measure the 

axialclearance by shaking bearing along axial direction 

lightly. 

7. ASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. 

(a) Apply the grease on the mating surfaces of cross spider and round bearing. 

Grease: lithium base grease No.2 

NOTE 

• Only apply the grease on the mating surface of cross spider and round bearing. 

• If the applying grease is excessive, it will cause problem for further operations. 

(b) Position the end yoke and tube yoke properly according 

to the marks. 

(c) Install the 4 round bearings and the 4 dust-proof covers 

at ouside of yoke. 

(d) Install the cross spider at inside of yoke. 

(e) Using the copper rod and the hammer, install the 4 round 

bearings and the 4 dust-proof covers properly. 

NOTE 

• Be sure to use new dust-proof covers. 


marks. 

Page 2362


34-11 

(f) 

Using snap ring pliers, install the 4 snap rings. 

NOTE 

Be sure to use new snap rings. 

34 

8. ASSEMBLE FRONT U-JOINT OF PROPELLER SHAFT ASSY. 

NOTE 

Reassemble the front U-joint by the same procedures as the middle U-joint. 

9. ASSEMBLE REAR U-JOINT OF PROPELLER SHAFT ASSY. 

NOTE 

Reassemble the rear U-joint by the same procedures as the middle U-joint. 

10. INSTALL PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller 


17A 

34 

Page 2363

34-12 

AXLE AND PROPELLER SHAFT - CENTER SUPPORT BEARING 


OVERHAUL 


2. REMOVE PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller 


3. DISASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and 

propeller shaft - U-joint, overhaul”) 

4. REMOVE END YOKE. 

(a) Remove the nut. 

NOTE 

Discard the removed nut. 

(b) 

Remove the flat washer. 

(c) 

Mark on the end yoke and spline. 

NOTE 

• Make sure the marks are clear. 

• Make sure the yoke direction of U-joint is consistent. 

(d) 

Using a puller, remove the end yoke. 

Page 2364


34-13 

5. REMOVE CENTER SUPPORT WITH RUBBER GROMMET 

ASSY. 

CAUTION 

Do not damage the rubber grommet. 

34 

6. REMOVE CENTER SUPPORT BEARING. 

(a) Using a puller, remove the center support bearing assy. 

(b) 

Remove the 2 oil seals on both side. 

NOTE 

Discard the removed oil seals. 

17A 

34 

(c) 

Using hammer and copper rod, remove the center 

support bearing from bearing cup. 

7. INSPECT CENTER SUPPORT BEARING. 

(a) Check whether the center support bearing can be rotated freely. 

(b) Check whether the center support bearing is worn excessively. 

(c) If any fault is found, replace with a new part. 

8. INSTALL CENTER SUPPORT BEARING ASSY. 

(a) Apply the grease on the center support bearing and bearing cup. 


Page 2365

34-14 


(b) 

(c) 

Using hammer and copper rod, install the center support 

bearing to bearing cup. 

Apply the grease on the oil seal lip. 


NOTE 

Be sure to use new oil seals. 

(d) 

Install the 2 oil seals on both side. 

(e) 

Install the center support bearing assy with hammer and 

copper rod. 

9. INSTALL CENTER SUPPORT WITH RUBBER GROMMET 

ASSY. 

CAUTION 

Do not damage the rubber grommet during operation. 

10. INSTALL END YOKE. 

(a) Position the end yoke properly according to the marks. 

NOTE 


marks. 

• Make sure the yoke direction of U-joint is consistent. 

Page 2366


34-15 

(b) 

Install the flat washer. 

34 

(c) 

Tighten the nut. 

NOTE 

Be sure to use a new nut. 

11. INSPECT CENTER SUPPORT BEARING. 

(a) Check whether the center support with rubber grommet can be rotated freely without deviation when 

rotating it by hands. 

(b) Replace with new center support bearing, bearing cup and support with rubber grommet assy if 

necessary. 

12. ASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and 

propeller shaft - U-joint, overhaul”) 

13. INSTALL PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller 


17A 

34 

Page 2367

34-16 

AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE 

AXLE HUB AND STEERING KNUCKLE 


See the table below to help you find the cause of the problem. The numbers indicate the priority of the likely 



Wandering / Pulling 

1. Tire type (Incorrect) 

2. Tire (Worn) 

3. Tire pressure (Incorrect) 


5. Axle hub bearing (Worn) 

6. Front shock absorber 

(Damaged) 

7. Suspension (Loose or 

damaged) 


inspection 


inspection 


inspection 



Chapter 34 axle and propeller shaft - axle hub and 



overhaul 

- 

8. Steering tie rod (Loose or worn) Chapter 52 power steering - steering box, overhaul 

Wheel vibration 

9. Stabilizer bar (Bent or fractured) 

1. Wheel (Unbalanced or worn 

excessively) 

2. Axle hub bearing (Worn) 


damaged) 

4. B-joint (Worn) 

Chapter 31 front suspension - stabilizer bar, 

replacement 


inspection 


adjustment 

Chapter 34 axle and propeller shaft - axle hub and 



overhaul 

Chapter 32 rear suspension - rear shock absorber, 

overhaul 

Chapter 34 axle and propeller shaft - steering 

knuckle, overhaul 

Chapter 31 front suspension - upper control arm, 

replacement 

Chapter 31 front suspension - lower control arm, 

replacement 

5. Steering tie rod (Loose or worn) Chapter 52 power steering - steering box, overhaul 

6. Steering box (Damaged) Chapter 52 power steering - steering box, overhaul 

Page 2368


34-17 


1. Power steering fluid level (Low) 

2. Steering knuckle (Worn) 

Chapter 52 power steering - power steering system, 

on-vehicle inspection 

Chapter 52 power steering - steering 

fluid,replacement 



34 

Abnormal noise 

3. Steering propeller shaft (Worn) 

4. Power steering pump (Worn or 

damaged) 



Chapter 52 power steering - power steering system, 


Chapter 52 power steering - power steering pump 


5. Steering box (Damaged) Chapter 52 power steering - steering box, overhaul 

17A 

34 

Page 2369

34-18 



1. INSPECT FRONT AXLE HUB BEARING. 

(a) 

(b) 

Remove the front wheel assy. (Refer to “Chapter 33 wheel and tire - front wheel and tire, replacement”) 

Remove the front disk brake caliper assy. (Refer to “Chapter 35 brake - front brake, overhaul”) 

(c) 

Open the lock-edge, loosen retaining snap ring. 

CAUTION 

Be sure to take care to operate,don’t destroy retaining snap 

ring. 

NOTE 

Use special tool to loosen retaining snap ring. 

(d) Remove oil seal. 

NOTE 

Discard the removed oil seal. 

(e) Using dial indicator, measure the back lash around the 

center of front axle hub. 

Back lash: ≤ 0.2 mm 

If the back lash is out of the specification, replace with new front 

axle hub bearings. 

NOTE 

• Measure the back lash by shaking the front axle hub 

along the axial direction lightly. 

• When performing the measurment, make the dial 

indicator be close to the center of axle hub. 

(f) Using dial indicator, measure the deviation at the edge of 

front axle hub. 

Deviation: ≤ 0.2 mm 

If the deviation is out of the specification, replace with a new 

front axle hub. 

NOTE 

• Measure the deviation by rotating the front axle hub 

slowly. 

• When performing the measurement, make the dial 

indicator be close to the edge of axle hub. 

Page 2370


34-19 

(g) 

Install oil seal. 

NOTE 

Be sure to use new oil seal. 

(h) Tighten retaining snap ring of hub bearing,lock the retaining 

snap ring. 

34 

CAUTION 

Don’t destroy the retaining snap ring 

(i) Install the front disk brake.. (Refer to “Chapter 35 brake - 

front brake, overhaul”) 

(j) Install the front wheel assy. (Refer to “Chapter 33 wheel 

and tire - front wheel and tire, replacement”) 

2. INSPECT REAR AXLE HUB BEARING. 

NOTE 

Check rear axle hub bearing when removed. 

17A 

34 

Page 2371

34-20 

AXLE AND PROPELLER SHAFT - FRONT HUB 

FRONT HUB 

OVERHAUL 

1. REMOVE THE FRONT WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - front wheel and 

tire, replacement”) 

2. REMOVE THE FRONT DISK BRAKE CALIPER ASSY LH. (Refer to “Chapter 35 brake - front 

brake, overhaul”) 

3. REMOVE FRONT HUB LH. 

(a) Open the lock-edge, loosen retaining snap ring. 

CAUTION 

Be sure to take care to operate, don’t destroy retaining 

snap ring. 

NOTE 

Use special tool to loosen retaining snap ring. 

(b) 

Remove tone wheel. 

Page 2372


34-21 

(c) 

Remove internal hub bearing and oil seal of front hub, 

wash and inspect internal hub bearing, if necessary, 

replace it. 

NOTE 

Discard the removed internal bearing oil seal. 

(d) Remove retaining plate. 

(e) Remove external hub bearing, wash and inspect it, if 

necessary, replace it. 

34 

NOTE 

Rear axle hub LH and axle shaft is an assy. 

4. INSTALL FRONT HUB LH. 

(a) Apply grease on steering knuckle LH. 

NOTE 

• Be sure to use Alvania - RL3 grease. 

• Apply the grease to the entire surface of steering knuckle LH. 

(b) 

Install external bearing. 

NOTE 

Fill the grease into the bearings for more than 1/2. 

(c) Install retaining plate. 

(d) Apply grease to inside of retaining plate. 

17A 

34 

NOTE 

• Be sure to use Alvania - RL3 grease. 

• The total amount of grease is 14 ~ 16 gram. 

(e) Install external bearing. 

NOTE 

Fill the grease into the bearings for more than 1/2. 

Page 2373

34-22 


(f) Fill the grease into the bearings for more than 1/2. 


If the back lash is out of the specification, replace with new front 


NOTE 

• Measure the back lash by shaking the front axle hub 

LH along the axial direction lightly. 

• When performing the measurment, make the dial 

indicator be close the center of axle hub. 

(g) 

Install oil seal. 

NOTE 

Be sure to use new oil seal. 

(h) Install tone wheel. 

(i) 

Tighten retaining snap ring of hub bearing. 

CAUTION 

Don’t destroy retaining snap ring. 

(j) 

Install the front disk brake caliper assy LH. (Refer to 

“Chapter 35 brake - front brake, overhaul”) 

Page 2374


34-23 

(k) Using dial indicator, measure the deviation at the edge of 

front axle hub LH. 




NOTE 

• Measure the deviation by rotating the front axle hub 

LH slowly. 


indicator close to the edge of axle hub. 

34 

(l) Rotate the front axle hub LH by 2 ~ 3 turns. 

(m) Using spring scale, measure the primal rotating force of 


Primal rotating force: 5 N·m 

If the primal rotating force is out of the specification, adjust the 

front axle hub nut. 

5. Install the front wheel assy LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire, 


6. REMOVE AND INSTALL FRONT AXLE HUB RH. 

NOTE 


17A 

34 

Page 2375

34-24 

AXLE AND PROPELLER SHAFT - REAR AXLE HUB 

REAR AXLE HUB 

OVERHAUL 

1. Remove the rear wheel and tire assy LH. (Refer to “Chapter 33 wheel and tire - rear wheel and 

tire, replacement”) 

2. REMOVE REAR BARE LH.(Refer to “Chapter 35 brake - rear brake, overhaul”) 

3. REMOVE REAR HUB WITH AXLE SHAFT ASSY LH. 

(a) Remove 2 mounting bolts attaching cable of parking 

brake operation rear assy LH to brake backing plate. 

NOTE 

Remove bolts from the front of the brake backing plate. 

(b) 

Remove tubing joint nut of rear brake LH, take out oil 

tube of rear brake LH. 

(c) 

Undo bolt, remove wheel speed sensor. 

(d) 

Remove 4 nuts. 

Page 2376


34-25 

(e) 

Remove rear axle hub with axle shaft LH and rear brake 

backing plateLH. 

34 

4. INSTALL REAR AXLE HUB WITH AXLE SHAFT ASSY 

LH. 

(a) Using dial indicator, measure the back lash around the 

center of rear axle hub LH. 


If the back lash is out of the specification, replace with new rear 


NOTE 

• Measure the back lash by shaking the rear axle hub 

LH along the axial direction lightly. 


indicator be close to the center of axle hub. 

(b) 

Insert the rear wheel hub and axle shaft into the rear axle 

housing. 

NOTE 

Apply No. 2 lithium base grease on six convex platform 

plane of brake backing plate, don’t pollute working surface 

of brake drum and brake shoes. 

(c) 

Tighten 4 mounting nuts. 

Toque: 65 ~ 80 N·m6 

17A 

34 

(d) Using dial indicator, measure the deviation at the edge of 

rear axle hub LH. 




NOTE 

• Measure the deviation by rotating the rear axle hub 

LH slowly. 


indicator be close to the edge of axle hub. 

Page 2377

34-26 


(e) 

Position rear wheel speed sensor LH, tighten mounting 

bolt. 

(f) 

Connect rear brake fluid tube to rear wheel brake cylinder 

LH, tighten the tubing joint nut. 

Torque:21 ~ 24 N·m 

(g) 

Position the cable of parking brake operation rear assy 

LH to brake backing plate,tighten 2 mounting bolts. 

NOTE 

Install bolts from the front of the brake backing plate. 

5. INSTALL REAR BRAKE LH. (Refer to “Chapter 35 brake - rear brake, overhaul”) 

6. MEASURE THE PRIMAL ROTATING FORCE. 

(a) Rotate the rear axle hub LH by 2 ~ 3 turns. 

(b) Using spring scale, measure the primal rotating force of 


Primal rotating force: 5 N·m 

7. INSTALL THE REAR WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire, 


Page 2378


34-27 

8. BRAKE SYSTEM REFILLING AND BLEEDING. (Refet to “Chapter 35 braking system - brake fluid, 

bleeding”) 

9. REMOVE AND INSTALL REAR AXLE HUB RH. 

NOTE 


34 

17A 

34 

Page 2379

34-28 

AXLE AND PROPELLER SHAFT - STEERING KNUCKLE 


OVERHAUL 



2. REMOVE THE FRONT BRAKE DISK WITH AXLE HUB ASSY LH. (Refer to “Chapter 35 brake - 

front brake, overhaul”) 

3. REMOE FRONT WHEEL SPEED SENSOR LH AND 

BRACKET. 

4. REMOVE STEERING KNUCKLE LH. 

(a) Separate the steering tie rod B-joint LH from the steering 

knuckle arm LH. 

• Remove the cotter pin. 

NOTE 

Discard the removed cotter pin. 

• Remove the slotted nut. 

NOTE 

Discard the removed slotted nut. 

• Set the steering tie rod LH aside. 

(b) Remove the lower control arm B-joint LH. 


NOTE 


Page 2380


34-29 

• Remove the slotted nut. 

NOTE 


34 

• Loosen the 4 sets of bolts and nuts. 

NOTE 

Discard the removed bolts and nuts. 

17A 

34 

• Using hammer and copper rod, remove the lower control 

arm B-joint LH. 

Page 2381

34-30 


(c) 

Separate the steering knuckle LH from the upper control 

arm B-joint LH. 


NOTE 


• Loosen the slotted nut. 

NOTE 


• Using hammer and copper rod, remove the steering 

knuckle LH. 

5. INSPECT B-JOINT. 

(a) Check the contact area between steering tie rod B-joint 

and steering knuckle arm. 

• Apply red lead evenly to the steering tie rod B-joint shaft 

and hole of steering knuckle arm. 

• Insert the steering tie rod B-joint shaft into the hole of 

steering knuckle arm, then pull it out again. Check the 

contact area. 

Standard: red area ≤ 3/4 shaft length,evenly 

Page 2382


34-31 

If any problem is found, replace with a new steering box and 

steering knuckle arm. (Refer to “Chapter 52 power steering - 

steering box, overhaul”) 

(b) Check the contact area between lower control arm B- 

joint and steering knuckle. 

• Apply red lead evenly to the lower control arm B-joint 

shaft and hole of steering knuckle. 

• Insert the lower control arm B-joint shaft into the hole of 

steering knuckle, then pull it out again. Check the contact 

area. 


If any problem is found, replace with a new lower control arm B- 

joint and steering knuckle. (Refer to “Chapter 31 front 

suspension - lower control arm, replacement”) 

(c) Check the contact area between upper control arm B- 

joint and steering knuckle. 

• Apply red lead evenly to the upper control arm B-joint 

shaft and hole of steering knuckle. 

• Insert the upper control arm B-joint shaft into the hole of 

steering knuckle, then pull it out again. Check the contact 

area. 


If any problem is found, replace with a new lower control arm B - 

joint and steering knuckle. (Refer to “Chapter 31 front 

suspension - upper control arm, replacement”) 

34 

17A 

34 

6. INSTALL STEERING KNUCKLE LH. 

(a) Install the upper control arm B-joint LH. 

• Using hammer and copper rod, position the steering 

knuckle LH properly. 

• Tighten the slotted nut. 

Torque: 110 ~ 115 N·m 

NOTE 

Be sure to use a new slotted nut. 

Page 2383

34-32 


• Install the cotter pin. 

NOTE 

Be sure to use a new cotter pin. 

(b) Install the lower control arm B-joint LH. 

• Using hammer and cooper rod, position the lower control 

arm B-joint LH properly. 

NOTE 

Align the holes of B-joint and lower control arm LH. 

• Tighten the 2 sets of bolts and nuts fixing lower B-joint 

with lower control arm . 

Torque: 110 ~ 120 N·m 

NOTE 

Be sure to use new bolts and nuts. 

• Tighten the 2 sets of bolts and nuts fixing lower B-joint 

and lower control arm and strut rod. 

Torque: 110 ~ 120 N·m 

NOTE 

Be sure to use new bolts and nuts. 

• Tighten the slotted nut fixing lower B-joint and steering 

knuckle. 

Torque: 110 ~ 115 N·m 

NOTE 


Page 2384


34-33 


NOTE 


34 

(c) 

Connect the steering tie rod LH to the steering knuckle 

arm LH. 

• Insert the steering tie rod B-joint LH into the hole in 

steering knuckle arm LH. 

• Tighten the slotted nut. 

Torque: 84 ~ 100 N·m 

NOTE 



NOTE 


17A 

34 

7. INSTALL FRONT WHEEL SPEED SENSOR LH AND 

BRACKET. 





10. REMOVE AND INSTALL STEERING KNUCKLE RH. 

NOTE 


11. INSPECT FRONT WHEEL ANGLE. (Refer to “Chapter 31 front suspension - front wheel 

alignment, adjustment”) 

Page 2385

34-34 

REAR AXLE 

PRECAUTION 

AXLE AND PROPELLER SHAFT - REAR AXLE 

1. PRECAUTION ON MAITAINING FINAL DRIVE OIL. 

(a) Be sure to use the specified final drive oil. 

Final drive oil: 

Type Grade Viscosity Capacity 

Gear oil for weight-load 

motor 

GL - 5 SAE 80W/90 2.5 L 

(b) Be sure to replace the final drive oil regularly. (Refer to “Chapter 34 axle and propeller shaft - final drive 

oil, replacement”) 

• Replace with new final drive oil during the primal Level 2 maintenance. 

• Replace with new final drive oil in the primal 40000 Km or 24 months. 

• Replace with new final drive oil in the primal 80000 Km or 48 months. Then repeat this operation in 

each following 50000 Km. 

(c) Check regularly, at least every 4 times for Level 2 maitenance: 

• Check the final drive oil for discolouration, thinning, etc. 

If any fault is found, replace with new final drive oil. (Refer to “Chapter 34 axle and propeller shaft - final 

drive oil, replacement”) 

2. PRECAUTION ON MAINTAINING FINAL DRIVE ASSY. 

(a) Be sure to check the vent plug regularly. Clean it when 

necessary. 

NOTE 

• Remove and clean the vent plug during each level1 

maintenance. 

• The stuck vent plug may raise the oil pressure inside 

the final drive assy, even cause leakage. 

• Wash vent plug, check the final drive oil level 

simultaneously. 

(b) Disassemble and clean the final drive assy during the 

Level 3 maintenance. Then assemble the final drive assy 

according to the specification. 

(c) Check the rear brake shoe and brake drum regularly for 

wear and tear. (Refer to “Chapter 35 brake - rear brake, 

on-vehilce inspection”) 

3. SERVICING PRECAUTION ON FINAL DRIVE ASSY. 

(a) Be sure to replace the mating parts as a set. 

Page 2386


34-35 

(b) Discard all removed rubber parts (O-rings, oil seal, grommet, etc. ). 

(c) With the method of visual check, red lead, etc., check all parts carefully for faults below: 

Uneven wear Eccentric wear Scratch Crack 

Deformation Bend Bend Rusting 

34 

Discolouration 

Invalidation or weakness 

(Spring) 

Abnormal noise (Bearing) 

Deterioration (Brake 

shoes) 

(d) 

When assembling the final drive assy, make sure all parts are clean without oil fouling and metal scrap. 

Without special introduction, apply the final drive oil on the parts for lubrication before performing 

operations. 


Type Type Viscosity Capacity 


motor 

GL - 5 SAE 80W/90 2.5 L 

4. PRECAUTION ON VEHICLE DRIVING. 

(a) Never overload when driving vehicle. 

(b) Never release the clutch pedal too quickly when vehicle driving. 

CAUTION 

Releasing the clutch pedal too quickly will strick the gear and cause damage. 

17A 

34 

Page 2387

34-36 





Symptom Suspect area Reference 

Continuous 

knocking 

(Turning) 

Continuous 

knocking 

(At high speed) 

Continuous 

knocking 

(Accelerating) 

Intermittent 

knocking 

(Running) 

Leakage 

(Final drive) 

主减速器过热 

Overheat 

(Final drive) 

1. Side pinion thrust washer (Worn) 

2. Side pinion (Worn) 

1. Drive pinion, crown gear 

(Excessive back lash or worn) 


(Undersize back lash) 





1. Axle shaft spline (Excessive back 

lash or worn) 



3. Final drive assy (Impurity entry) 

1. Vent plug (Jam) 

2. Final drive oil level (High) 

3. Bolts (Loose or worn) 

4. Final drive housing (Crack or 

fracture) 

1. Final drive oil level (Low) 



3. Differential bearing (Too tight) 


assy, overhaul 




assy, inspection and adjustment 







Chapter 34 axle and propeller shaft - axle shaft 


Chapter 34 axle and propeller shaft - axle shaft 


Chapter 34 axle and propeller shaft - final drive oil, 

replacement 

Chapter 34 axle and propeller shaft - rear axle, 

precaution 

Chapter 34 axle and propeller shaft - final drive, onvehicle 

inspection 



Chapter 34 axle and propeller shaft - final drive, onvehicle 

inspection 

Chapter 34 axle and propeller shaft - final drive oil, 

replacement 



Chapter 34 axle and propeller shaft - drive pinion, 

overhaul 

4. Rear brake (Stuck) Chapter 35 brake - rear brake, overhaull 

Page 2388


34-37 


1. INSPECT DRIVE AXLE BASH LASH. 

(a) Park the vehicle on level road with parking brake applied. 

(b) Move transmission to neutral position and fully apply the parking brake. 

(c) Lift rear wheels off the ground with jack or lift. 

34 

(d) Separate the propeller shaft assy from pinion flange. 

• Mark on the rear propeller shaft U-joint and pinion flange. 

NOTE 

Make the marks are clear. 

• Remove the 4 sets of nuts and bolts. 

NOTE 


17A 

34 

• Lower the propeller shaft and set it aside. 

NOTE 

Support the propeller shaft with a bracket. 

(e) Measure the drive axle back lash. 

• Rotate counterclockwise the pinion flange by hand until it 

becomes hard to rotate. 

• Mark on the final drive housing and pinion flange. 

NOTE 


Page 2389

34-38 


• Rotate clockwise the pinion flange by hand until it 

becomes hard to rotate. 

• The distance between the 2 marks is the drive axle back 

lash. 

(f) Connect the propeller shaft to pinion flange. 

• Position the propeller shaft properly according to the 

marks. 

NOTE 


marks. 

• Align the marks by rotating the pinion flange when 

necessary. 

• Tighten the 4 sets of nuts and bolts. 


NOTE 


2. CHECK FINAL DRIVE OIL LEVEL. 

(a) Using a wrench, remove the filler plug. 

(b) 

Check the distance between the filler hole of final drive 

and final drive oil level. 

CAUTION 

• Higher and lower final drive oil level can cause 

problem. 

• Fill or drain the final drive oil when necessary. (Refer 

to “Chapter 34 axle and propeller shaft - final drive 


Page 2390


34-39 

(c) 

Using a wrench, install the filler plug. 


34 

3. CHECK FINAL DRIVE HOUSING. 

(a) Check the final drive housing for crack, leakage, etc. Replace it when necessary. 

17A 

34 

Page 2391

34-40 

AXLE AND PROPELLER SHAFT - FINAL DRIVE OIL 

FINAL DRIVE OIL 

REPLACEMENT 


2. DRAIN FINAL DRIVE OIL. 

(a) Remove the vent plug. 

(b) 

(c) 

Using a wrench, remove the drain plug. 

Drain the final drive oil completely. 

NOTE 

Use a container to collect final drive oil when performing 

this operation. 

(d) 

Using a wrench, install the drain plug. 

Toque: 50 ~ 55 N·m 

Page 2392


34-41 

3. FILL FINAL DRIVE OIL. 

(a) Using a wrench, remove the filler plug. 

34 

(b) 

Fill the final drive oil. 


Type Grade Viscosity Capacity 


motor 

GL - 5 SAE 80W/90 2.5 L 

(c) 

Check final drive oil level. 

Check the distance between the filler hole of final drive 

and final drive oil level. 

CAUTION 

• Higher and lower gear oil level can cause problem. 

• Fill or drain the final drive oil when necessary. (Refer 

to “Chapter 34 axle and propeller shaft - final drive 


17A 

34 

(d) 

Using a wrench, install the filler plug. 

Toque: 15 ~ 25 N·m 

Page 2393

34-42 


(e) 

Install the vent plug. 

Page 2394

AXLE SHAFT ASSY 

OVERHAUL 

AXLE AND PROPELLER SHAFT - AXLE SHAFT ASSY 

34-43 

1. REMOVE AXLE SHAFT ASSY LH. 

(a) Remove the rear wheel assy LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire, 


(b) Remove the rear brake LH. (Refer to “Chapter 35 brake - rear brake, overhaul”) 

(c) Remove rear axle hub LH.(Refer to “Chapter 34 axle and propeller shaft - rear axle hub, 

overhaul”) 

NOTE 

Rear axle hub LH and axle shaft is a assy. 

34 

2. INSPECTION AXLE SHAFT ASSY. 

(a) Using V-block and dial indicator, measure the diameter 

runout of the axle shaft assy and flange end face runout. 

Diameter runout: ≤ 0.3 mm 

End face runout: ≤ 0.1 mm 

If the diameter runout and end face runout are out of the 

specification,correct the axle shaft assy. Replace the new one if 

necessary. 

(b) Using magnetic testing method, inspect axle shaft 

whether there is crack. 

(c) Check the axle shaft splines for fracture, worn an 

deformation. 

If any fault is detected, replace with a new axle shaft assy. 

3. INSTALL REAR AXLE HUB LH.(Refer to “Chapter 34 axle and propeller shaft - rear axle hub, 

overhaul”) 

NOTE 

Rear axle hub LH and axle shaft is a assy. 

4. REMOVE AND INSTALL AXLE SHAFT ASSY RH. 

NOTE 


5. BRAKE FLUID REFILL AND BLEEDING. (Refer to “Chapter 35 brake system - brake fluid, 

bleeding”) 

17A 

34 

Page 2395

34-44 

AXLE AND PROPELLER SHAFT - REAR AXLE HOUSING WELDING ASSY 

REAR AXLE HOUSING WELDING ASSY 

OVERHAUL 



3. REMOVE REAR WHEEL ASSYS. (Refer to “Chapter 33 wheel and tire - rear wheel and tire, 


4. REMOVE REAR BRAKES. (Refer to “Chapter 35 brake - rear brake, overhaul”) 

5. DRAIN FINAL DRIVE OIL. (Rrefer to “Chapter 34 axle propeller shaft - final drive oil, 


6. REMOVE REAR BRAKE TUBES ,PARKING CABLE 

AND WHEEL SPEED SENSOR. 

NOTE 

Before removing rear brake tubes, operate brake bleeding 

firstly. 

(a) Remove 2 bolts attaching cable of parking brake rear 

assy LH to brake backing plate, remove cable bracket 

mounting bolts and set the cable aside. 

NOTE 


(b) 

Remove 2 bolts attaching cable of parking brake rear 

assy RH to brake backing plate, remove cable bracket 

mounting bolts and set the cable aside. 

NOTE 


(c) 

Remove brake tubing joint nut LH of rear axle, wheel 

speed sensor mounting bolt and mounting bracket LH of 

brake tube and wheel speed sensor. 

Page 2396


34-45 

(d) 

Remove brake tubing joint nut RH of rear axle, wheel 

speed sensor mounting bolt and mounting bracket LH of 

brake tube and wheel speed sensor. 

34 

(e) 

Remove mounting bolt of upper brake tube and tubing 

joint nuts LH . 

(f) 

Remove mounting bolts of brake tubes and wheel speed 

sensor cable brackets that are located at the top and 

center(LH and RH) of rear axle. 

17A 

34 

(g) 

Take down and place brake tubes, wheel speed sensors 

and brackets aside. 

NOTE 

Make sure to prevent the brake tubes from deformation. 

7. REMOVE AXLE HUB ASSYS LH AND RH. (Refer to “Chapter 34 axle and propeller shaft - rear 

axle hub, overhaul”) 

8. REMOVE AXLE SHAFT ASSY LH AND RH.(Refer to “Chapter 34 axle and propeller shaft - axle 


9. REMOVE MAIN DIFFERENTIAL. 

(a) Separate the propeller shaft assy from pinion flange. 

• Mark on the rear propeller shaft U-joint and pinion flange. 

NOTE 


Page 2397

34-46 


• Remove the 4 sets of nuts and bolts. 

NOTE 


• Lower the propeller shaft and set it aside. 

NOTE 


(b) 

Remove nuts and the final drive assy. 

NOTE 


10. REMOVE REAR SUSPENSION. (Refer to “Chapter 32 rear suspension - rear leaf spring assy, 

overhaul”) 

NOTE 

Support the propeller shaft with a bracket before removing. 

11. REMOVE THE REAR AXLE WELDING HOUSING 

ASSY. 

12. INSPECT THE REAR HOUSING ASSY. 

(a) Check rear axle welding housing for surface crack and oil leakage, replace it if nessary. 

Page 2398


34-47 

13. INSTALL REAR AXLE WELDING HOUSING ASSY. 

(a) Support the housing to correct position with a bracket. 

34 

14. INSTALL REAR SUSPENSION. (Refer to “Chapter 32 rear suspension - rear leaf spring assy, 

overhaul”) 

15. INSTALL MAIN DIFFERENTIAL. 

(a) Position the final drive assy, tighten 10 mounting nuts. 

Toque: 27 ~ 32 N•m 

NOTE 


(b) 

Install the propeller shaft properly according to the 

marks. 

NOTE 


17A 

34 

(c) 

Tighten the 4 set of nuts and bolts. 

Toque: 70 ~ 79 N•m 

NOTE 


(d) 

Remove lifting and supporting devices. 

16. INSTALL AXLE SHAFT ASSY LH AND RH.(Refer to “Chapter 34 axle and propeller shaft - axle 


17. INSTALL AXLE HUB ASSYS LH AND RH. (Refer to “Chapter 34 axle and propeller shaft - rear 


Page 2399

34-48 


18. INSTALL REAR BRAKE TUBES ,PARKING CABLE 

AND WHEEL SPEED SENSOR. 

(a) 

Position brake tubes, wheel speed sensor cables and 

brackets.Tighten mounting bolts of brake tubes and 

wheel speed sensor cable brackets that are located at 

the top and center(LH and RH) of rear axle. 

(b) 

Tighten mounting bolt of upper brake tube and tubing 

joint nuts LH. 

(c) 

Tighten brake tubing joint nut RH of rear axle, wheel 

speed sensor mounting bolt and install mounting bracket 

LH of brake tube and wheel speed sensor. 


(d) 

Tighten brake tubing joint nut LH of rear axle, wheel 

speed sensor mounting bolt and install mounting bracket 

LH of brake tube and wheel speed sensor. 


(e) 

Tighten 2 bolts attaching cable of parking brake rear assy 

RH to brake backing plate.Tighten cable bracket mounting 

bolts. 

NOTE 


Page 2400


34-49 

(f) Tighten 2 bolts attaching cable of parking brake rear 

assy LH to brake backing plate.Tighten cable bracket 

mounting bolts. 

NOTE 


34 

19. INTALL THE REAR BRAKE. (Refer to “Chapter 35 brake - rear brake, overhaul”) 

20. INSTALL REAR WHEEL ASSYS. (Refer to “Chapter 33 wheel and tire - rear wheel and tire, 


21. FILL THE FINAL DRIVE OIL. (refer to “Chapter 34 axle and propeller shaft - final drive oil, 


22. FILL BRAKE FLUID. (Refer to “Chapter 35 brake system - brake fluid, bleeding”) 


17A 

34 

Page 2401

34-50 

DRIVE PINION 

INSPECTION 

AXLE AND PROPELLER SHAFT - DRIVE PINION 

1. INSPECT PINION FLANGE. 

(a) Using dial indicator, measure the pinion flange back lash. 


If the back lash is out of the specification, replace with new 

pinion inner and outer bearing and collapsible spacer. (Refer to 

“Chapter 34 axle and propeller shaft - drive pinion, overhaul”) 

(b) Using dial indicator, measure the pinion flange deviation. 



pinion flange. (Refer to “Chapter 34 axle and propeller shaft - 

drive pinion, overhaul”) 

2. INSPECT PRELOAD. 

(a) Open the lock plate. 

(b) Loosen the pinion nut. 

Page 2402


34-51 

(c) 

Tighten the pinion nut. 


34 

(d) 

Using a torque wrench, measure the primal rotating force 

of drive pinion. 

Primal rotating force: 1.3 ~ 2.2 N·m 

WARNING 

Never loosen the pinion nut to reduce the primal rotating 

force of drive pinion. 

NOTE 

• If the primal rotating force is more than the specification, 

replace with a new collapsible spacer. (Refer to “Chapter 

34 axle and propeller shaft - drive pinion, overhaul”) 

• If the primal rotating force is less than the specification, 

perform the following operations. 

(e) 

Tighten the pinion nut further. 

Torque (Increment): 13 N·m 

Torque (Maximum): 343 N·m 

17A 

34 

(f) 

Using a torque wrench, measure the primal rotating force 

of drive pinion again. 

Primal rotating force: 1.3 ~ 2.2 N·m 

NOTE 

• If the primal rotating force is still less than the 

specification, repeat step (e) ~ (f) until the primal 

rotating force is within the specification. 

• If the primal rotating force is still less than the 

specification when the pinion nut retaining torque 

exceeds the maximum, replace with a new collapsible 

spacer. (Refer to “Chapter 34 axle and propeller shaft 

- drive pinion, overhaul”) 

Page 2403

34-52 


(g) 

Fold the lock plate up. 

Page 2404

BRAKING SYSTEMS 

BRAKE SYSTEM ....................................................................... 35-1 

PROBLEM SYMPTOMS TABLE ................................................ 35-02 

BRAKE FLUID............................................................................. 35-04 

BRAKE PEDAL........................................................................... 35-06 

CYLINDER ASSY........................................................................ 35-14 

VACUUM BOOSTER LINE ......................................................... 35-18 

FRONT BRAKE........................................................................... 35-20 

REAR BRAKE............................................................................. 35-26 

ABS ACTUATOR ........................................................................ 35-37 

WHEEL SPEED SENSOR........................................................... 35-40 

PARKING BRAKE...................................................................... 36-1 

PROBLEM SYMPTOMS TABLE................................................... 36-1 

FRONT PARKING BRAKE OPERATION ASSY........................... 36-4 

REAR PARKING BRAKE OPERATION ASSY ............................. 36-8 

Page 2405

Page 2406

BRAKE 

BRAKE SYSTEM ............................................................................... 35-1 

PRECAUTION.............................................................................. 35-1 

PROBLEM SYMPTOMS TABLE ....................................................... 35-2 

BRAKE FLUID.................................................................................... 35-4 

BLEEDING................................................................................... 35-4 

BRAKE PEDAL.................................................................................. 35-6 

COMPONENTS ........................................................................... 35-6 

ADJUSTMENT............................................................................. 35-7 

REPLACEMENT .......................................................................... 35-9 

VACUUM BOOSTER WITH BRAKE MASTER 

CYLINDER ASSY............................................................................. 35-14 

OVERHAUL ............................................................................... 35-14 

VACUUM BOOSTER LINE .............................................................. 35-18 

REPLACEMENT ........................................................................ 35-18 

FRONT BRAKE................................................................................ 35-20 

OVERHAUL ............................................................................... 35-20 

REAR BRAKE.................................................................................. 35-26 


OVERHAUL ............................................................................... 35-27 

ABS ACTUATOR ............................................................................. 35-37 

REPLACEMENT ........................................................................ 35-37 

WHEEL SPEED SENSOR................................................................ 35-40 

REPLACEMENT ........................................................................ 35-40 

35 

35 

35 

35 

35 

35 

35 

35 

35 

Page 2407

Page 2408

BRAKE SYSTEM 

PRECAUTION 

BRAKE - BRAKE SYSTEM 

35-1 

1. BRAKE PRECAUTION 

(a) Care must be taken to replace each part properly, because it could affect the performance of the brake 

system and result in a driving hazard, replace with the parts which have the same part number or 

equivalent. 

(b) It is very important to keep parts and the area clean when repairing the brake system. 

(c) To avoid spreading brake dust, do not clean any brake components with sand paper, dry brush and 

compressed air. Only use a water dampende towel to clean brake components. 

(d) When removing or installing brake lines, use the pipeline nut wrench. 

(e) Always tighten brake lines when installing. 

35 

16A 

35 

Page 2409

35-2 

BRAKE - PROBLEM SYMPTOMS TABLE 





1. Brake fluid (Lacking) Chapter 35 brake - brake fluid, bleeding 

2. Brake system (Leaking) - 

Low pedal or spongy 

pedal 

3. Brake pad (Worn) Chapter 35 brake - front brake, overhaul 

4. Brake master cylinder assy 

(Failure) 

Chapter 35 brake - vacuum booster with brake 

master cylinder assy, overhaul 

5. Brake system (Air in system) Chapter 35 brake - brake fluid, bleeding 

6. Brake caliper (Failure) Chapter 35 brake - front brake, overhaul 

1. Brake tube(Block) - 

2. Brake cylinder (Sticking) Chapter 35 brake - rear brake, overhaul 

Brake drag 

3. Brake caliper (Sticking) Chapter 35 brake - front brake, overhaul 

4. Axle hub bearing (Loose) 

Chapter 34 axle and propeller shaft - axle hub 

and steering knuckle, on vehicle inspection 

5. Brake pedal free play (Out of 

adjustment) 

1. Tire (Improperly inflated) 

Chapter 35 brake - brake pedal, adjustment 


on vehicle inspection 

2. Brake shoe (Oily) - 

3. Brake shoe (Worn) Chapter 35 brake - rear brake, overhaul 

4. Brake pad (Oily) - 

Pull to one side 


6. Brake disk (Warped) Chapter 35 brake - front brake, overhaul 

7. Brake drum (Warped) Chapter 35 brake - rear brake, overhaul 

8. Brake caliper (Brake force 

unequal) 

9. Brake cylinder (Brake force 

unequal) 

Chapter 35 brake - front brake, overhaul 

Chapter 35 brake - rear brake, overhaul 


2. Brake caliper (Bolt loose) Chapter 35 brake - front brake, overhaul 

Braking instability 

3. Brake caliper mounting (Bolt 

loose) 

Chapter 35 brake - front brake, overhaul 

4. Brake caliper (Sticking) Chapter 35 brake - front brake, overhaul 

5. Brake cylinder (Sticking) Chapter 35 brake - rear brake, overhaul 

Page 2410

BRAKE - PROBLEM SYMPTOMS TABLE 

35-3 


Lack of braking force 


2. Brake shoe (Worn) Chapter 35 brake - rear brake, overhaul 

3. Brake lines (Air in system) Chapter 35 brake - brake fluid, bleeding 

35 

16A 

35 

Page 2411

35-4 

BRAKE - BRAKE FLUID 

BRAKE FLUID 

BLEEDING 

NOTE 

If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the 

system. 

WARNING 




Brake fluid: DOT3 or DOT4 brake fluid 

WARNING 

Brake fluid damages painted surfaces and irritates skin. If 

brake fluid is spilled on any painted surfaces or skin, wash 


2. BLEED BRAKE MASTER CYLINDER ASSY. 

(a) Tighten tubing joint nut fitting brake tube to brake master 

cylinder. 

NOTE 

If the brake cylinder has been removed or if the brake fluid 

reservoir assy becomes empty, bleed the air from the 


(b) 

Rapidly depress the brake pedal and hold it. 

(c) 

(d) 

Loosen tubing joint nut separately, bleed the air and 

fluid,then tighten tubing joint nut immediately. 

Repeat steps (b) and (c) 3 or 4 times until all the air in the 


Page 2412

BRAKE - BRAKE FLUID 

35-5 

3. BLEED BRAKE LINE. 

(a) Connect the hose to the bleeder plug of rear wheel brake 

cylinder. 

(b) Rapidly depress the brake pedal several times, then 


(c) When brake fluid stops flowing, tighten the bleeder plug, 



(d) Repeat steps (b) and (c) 3 or 4 times until all the air in the 


35 

(e) 

(f) 

(g) 

(h) 

(i) 

Connect the hose to the bleeder plug of front disk brake 

caliper. 

Rapidly depress the brake pedal several times, then 


When brake fluid stops flowing, tighten the bleeder plug, 



Repeat steps (f) and (g) 3 or 4 times until all the air in the 


Repeat the above procedures to bleed the air out of the 

brake line for each wheel. 

16A 

35 

NOTE 

Sequence Of Brake Line Bleeding(sit in driver seat): Rear 

RH - Rear LH - Front RH - Front LH 


(a) Check the fluid level and fill the fluid reservoir with brake 


Brake fluid: DOT3 or DOT4 brake fluid 

Page 2413

35-6 

BRAKE PEDAL 

COMPONENTS 

BRAKE - BRAKE PEDAL 

1 Flat Pin 

2 Cotter Pin 

4 Bolt 

5 Nut 

3 Brake Pedal Assy 

Page 2414


35-7 

ADJUSTMENT 

1. INSPECT BRAKE PEDAL HEIGHT. 

(a) Inspect the height between brake pedal and floor. 

Specification: 148 mm 

35 

2. ADJUST BRAKE PEDAL HEIGHT. 

(a) Remove the stop lamp switch. (Refer to “Chapter 35 brake - brake pedal, replacement”) 

(b) Disconnect the push rod from the brake pedal. (Refer to “Chapter 35 brake - brake pedal, 


16A 

(c) 

Loosen the lock nut, then adjust the brake pedal by 

truning the push rod clevis. Tighten the lock nut after 

adjusting. 

35 

(d) Connect the push rod to the brake pedal. (Refer to 

“Chapter 35 brake - brake pedal, replacement”) 

(e) Install stop lamp switch. (Refer to “Chapter 35 brake - 

brake pedal, replacement”) 

(f) Push the brake pedal down about 5 ~ 10 mm and turn 

the stop lamp switch in the position where the stop lamp 

goes off, then tighten the lock nut. 

(g) After installation, check that stop lamp comes on when 

depressing the brake pedal about 5 ~ 10 mm. 

Page 2415

35-8 


3. INSPECT BRAKE PEDAL FREE PLAY. 

(a) Stop the engine and depress the brake pedal several 

times until there is no more vacuum left in the vacuum 

booster. 

(b) Depress the brake pedal until the pedal resistance 

begins to be felt, then inspect the brake pedal free play L. 

(c) Measure the brake pedal free play. 

Specification: 5 ~ 10 mm 

Page 2416


35-9 

REPLACEMENT 


2. REMOVE THE DASHBOARD(Refer to “Chapter 83 instrument panel - dashboard, replacement”) 

3. REMOVE STOP LAMP SWITCH. 

(a) Disconnect the connector from stop lamp switch. 

(b) Loosen the lock nut from stop lamp switch. 

(c) Remove the stop lamp switch. 

35 

16A 

35 

4. DISCONNECT THE CONNECTION BETWEEN PUSH 

ROD CLEVIS AND BRAKE PEDAL. 

(a) 

Remove the cotter pin and flat pin, then disconnect the 

push rod clevis from brake pedal. 

NOTE 


Page 2417

35-10 


5. REMOVE BRAKE PEDAL AND BRACKET. 

(a) Remove 4 mounting bolts of bracket and 4 lock nuts of 

bracket. 

(b) Tack down the brake pedal and bracket. 

6. REMOVE BRAKE PEDAL. 

(a) Loosen the return spring. 

WARNING 

The return spring is under great pressure. To avoid injury, 

use caution when removing the return spring. 

(b) Remove the lower mounting bolt attaching pedal to 

bracket. 

(c) Remove the upper mounting bolt attaching pedal to 

bracket. 

Page 2418


35-11 

(d) 

Remove the brake pedal. 

35 

7. INSTALL BRAKE PEDAL. 

(a) 

(b) 

(c) 

Position the brake pedal. 

Tighten mounting bolts attaching the pedal to bracket. 


Install return spring and shaft sleeve, tighten return 

spring bolts. 


WARNING 

The return spring is under great pressure. To avoid injury, 

use caution when removing the return spring. 

16A 

35 

Page 2419

35-12 


8. INSTALL BRAKE PEDAL AND BRACKET. 

(a) Position brake pedal and bracket. 

(b) Tighten 4 mounting bolts of bracket. 

NOTE 

Diagonally tighten 4 bolts. 

(c) Tighten 4 lock nuts of bracket. 

9. CONNECT PUSH ROD CLEVIS TO BRAKE PEDAL. 

(a) Install the cotter pin roll and flat pin. 

NOTE 

Make sure to use new cotter pin. 

Page 2420


35-13 

10. INSTALL STOP LAMP SWITCH. 

(a) Install the stop lamp switch and tighten the lock nut of 

stop lamp switch. 

(b) Connect the connector to stop lamp switch. 

35 

(c) 

Adjust the distance between stop lamp switch and brake 

pedal. (Refer to “Chapter 35 brake - brake pedal, 


11. INSPECT AND ADJUST BRAKE PEDAL HEIGHT. (Refer to “Chapter 35 brake - brake pedal, 


12. INSPECT BRAKE PEDAL FREE PLAY. (Refer to “Chapter 35 brake - brake pedal, adjustment”) 


16A 

35 

Page 2421

35-14 

BRAKE - VACUUM BOOSTER WITH BRAKE MASTER CYLINDER ASSY 

VACUUM BOOSTER WITH BRAKE MASTER CYLINDER 

ASSY 

OVERHAUL 


2. DRAIN BRAKE FLUID COMPLETELY. 

WARNING 



3. REMOVE WASHER ASSY.(Refer to “Chapter 65 wiper and washer - wssher assy, replacement”) 

4. REMOVE VACUUM BOOSTER WITH BRAKE 

MASTER CYLINDER ASSY. 

(a) Disconnect the connector of Brake liquid level sensor, 

and remove the sensor wire from bracket. 

(b) Remove the brake fluid hosepipe from clutch master 

cylinder. 

(c) Remove brake tubing joint nuts,and remove brake tubes. 

(d) Pull out the vaccum booster pipe. 

(e) 

(f) 

Remove the cotter pin and flat pin, then disconnect the 

push rod clevis from brake pedal. 

Remoe 4 mounting lock nuts of vaccum booster and 

brake master sylinder assy. 

Page 2422


35-15 

(g) 

Remove vaccum booster with brake master sylinder assy 

and fluid reservior. 

35 

5. DISASSEMBLE VACCUM BOOSTER WITH BRAKE 

MASTER SYLINDER ASSY AND FLUID RESERVIOR. 

(a) 

Remove 2 mounting nuts of brake master sylinder. 

(b) 

Disassemble vaccum booster and brake master cylinder. 

16A 

35 

(c) 

Pull out mounting clip of brake fluid reservior. 

(d) 

Separate brake fluid reservior and brake master cylinder. 

NOTE 

Brake masrer cylinder and fluid reservior can be removed 

independently when brake fluid is drained completly. 

Page 2423

35-16 


6. CHECK BRAKE MASTER CYLINDER. 

(a) Check the cylinder and seal ring for damage. 

7. ASSEMBLE VACCUM BOOSTER WITH BRAKE 

MASTER SYLINDER ASSY AND FLUID RESERVIOR. 

(a) Position brake fluid reservior. 

(b) Insert the mountiong clip. 

(c) 

(d) 

Connect vaccum booster and brake master cylinder. 



8. INSTALL VACCUM BOOSTER WITH BRAKE MASTER 

SYLINDER ASSY. 

(a) Position vaccum booster with brake master cylinder 

assy. 

(b) Tighten 4 lock nuts of vaccum booster with brake master 

cylinder assy. 


(c) Install the cotter pin and flat pin, then connect the push 

rod clevis to brake pedal. 

Page 2424


35-17 

(d) 

(e) 

(f) 

(g) 

Connect vaccum booster pipe. 

Position brake tubes and tighten tubing joint nuts. 


Connect the brake fluid hosepipe which connect to clutch 

master cylinder and tighten the clamp. 

Connect the connector of Brake liquid level sensor,and 

fix the sensor wire to bracket. 

35 

9. INSTALL WASHER ASSY. (Refer to “Chapter 65 wiper and washer - wssher assy, replacement”) 


WARNING 



11. BLEED BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake fluid, bleeding”) 

12. BLEED BRAKE LINES. (Refer to “Chapter 35 brake - brake fluid, bleeding”) 

13. INSPECT AND ADJUST BRAKE PEDAL HEIGHT. (Refer to “Chapter 35 brake - brake pedal, 


14. INSPECT AND ADJUST BRAKE PEDAL FREE PLAY. (Refer to “Chapter 35 brake - brake pedal, 



16. CHECK BRAKE FLUID FOR LEAKING. 


16A 

35 

Page 2425

35-18 

BRAKE - VACUUM BOOSTER LINE 

VACUUM BOOSTER LINE 

REPLACEMENT 

1. REMOVE WASHER ASSY.(Refer to “Chapter 65 wiper and washer - wssher assy, replacement”) 

2. REMOVE VACCUM BOOSTER PIPE. 

(a) Pull out the vaccum booster pipe from brake vaccum 

booster. 

(b) Loosen clamp,disconnect vaccum booster from clutch 

vaccum booster. 

(c) 

Loosen clamp,disconnect vaccum booster from intake 

mainfold of engine. 

(d) 

(e) 

Along the pipeline end, loosen all fixed clamp. 

Remove vaccum booster pipe. 

NOTE 

Vaccum booster pipe is made up of two pipes,each one can 

be replaced independently. 

Page 2426

BRAKE - VACUUM BOOSTER LINE 

35-19 

3. INSTLL VACCUM BOOSTER PIPE. 

(a) Position vaccum booster pipe. 

(b) Connect vaccum booster pipe to brake vaccum booster. 

(c) Connect vaccum booster pipe to clutch vaccum 

booster,and tighten clamp screw. 

35 

(d) 

Connect vaccum booster pipe to intake mainfold of 

engine,and tighten clamp screw. 

(e) Along the pipeline end, fix all clamp. 

4. INSTALL WASHER ASSY. (Refer to “Chapter 65 wiper and washer - wssher assy, replacement”) 

16A 

35 

Page 2427

35-20 

BRAKE - FRONT BRAKE 

FRONT BRAKE 

OVERHAUL 

1. REMOVE FRONT WHEEL LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire, 



WARNING 



3. REMOVE FRONT DISK BRAKE CALIPER ASSY LH. 

(a) Remove screw and disconnect brake tube from front disk 

brake caliper assy LH. 

(b) Remove the 2 mounting bolts and front disk brake caliper 

assy LH. 

4. CHECK FRONT DISK BRAKE CALIPER ASSY FOR LEAKING,RUSTING AND SCORING, 

REPLACE IF NECESSARY. 

5. REMOVE FRONT BRAKE PAD ASSY LH. 

(a) Remove outer brake pad assy LH. 

Page 2428


35-21 

(b) 

Remove inner brake pad assy LH. 

35 

6. INSPECT BRAKE PAD THICKNESS. 

(a) Measure the brake pad thickness. 

Specification: 16 mm ~ 16.1 mm 

Limit: 8 mm 

16A 

35 

7. REMOVE FRONT DISK BRAKE CALIPER MOUNTING 

LH. 

(a) Remove the 2 bolts and front disk brake caliper mounting. 

Page 2429

35-22 


8. INSPCTE DISK THICKNESS. 

(a) Measure the disk thickness. 

Specification: 28 ± 0.1 mm 

(b) Measure the disk thickness difference. 

The thickness difference of the plane in the same 

circle ≤ 0.01mm 

9. INSPECT FRONT DISK RUNOUT. 

(a) Temporarily fasten the front disk with knuckle bolts. 

(b) Measure the disk runout at the position where is 10 mm 

away from the outer edge of the disk. 

Ultimate value: 0.03 mm 

(c) If the disk runout is the maximum value or is outside the 

maximum value, inspect the clearance of axle hub and 

axle hub runout. If the clearance of axle hub and axle 

hub runout is nomal, adjust the disk runout or grind it on 

a “On-vehical” brake lathe. 

10. REMOVE FRONT DISK LH. 

(a) Remove 4 mounting bolts. 

(b) Remove front disk with front axle hub. 

Page 2430


35-23 

(c) 

Remove 6 mounting bolts. 

35 

(d) 

Remove disk. 

11. INSTALL FRONT DISK LH. 

NOTE 

Select the installation position which the front disk has the 

minimum runout. 

(a) Install front disk to front axle hub,tighten 6 bolts. 


16A 

35 

NOTE 

Checked the inner bearing, replace with a new axle hub if 

necessary. (Refer to “Chapter 34 axle and propeller shaft - 


(b) 

Postion front disk with front axle hub and hub bearing,Tighten 

4 mounting bolts. 

Torque: 85 ~ 120 N•m 

Page 2431

35-24 


12. INSTALL FRONT DISK BRAKE CALIPER MOUNTING 

LH. 

(a) Install front disk brake caliper mounting and tighten 2 

mounting bolts. 


13. INSTALL FRONT BRAKE PAD ASSY. 

(a) 

NOTE 

Install inner brake pad assy. 

• Replace the anti-squeal shim when replacing the 

brake pad. 

• Keep the friction surface of brake pad and front disk 

away from oil and grease. 

(b) 

Install outer brake pad assy LH. 

NOTE 

• Replace the anti-squeal shim when replacing the 

brake pad. 

• Keep the friction surface of brake pad and front disk 

away from oil and grease. 

Page 2432


35-25 

14. INSTALL FRONT DISK BRAKE CALIPER LH. 

(a) 

(b) 

(c) 

Using a suitable tool, push the brake cylinder piston back. 

Install the front disk brake caliper assy LH and tighten 

the 2 nuts. 

Torque: 90 ~ 110 N•m 

Install brake tube and tighten plug. 


35 

15. REMOVE AND INSTALL FRONT BRAKE RH. 

NOTE 



WARNING 




18. BLEED BRAKE LINES. (Refer to “Chapter 35 brake - brake fluid, bleeding”) 



21. INSATLL FRONT WHEEL LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire, 


16A 

35 

Page 2433

35-26 

BRAKE - REAR BRAKE 

REAR BRAKE 


1. CHECK BRAKE SHOE THICKNESS. 

(a) Remove the brake lining inspection hole plug and check 

the brake shoe thickness through the brake lining 

inspection hole. 

Page 2434


35-27 

OVERHAUL 

1. RELEASE PARKING BRAKE. 

2. REMOVE REAR WHEEL LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire, 



35 

WARNING 



4. REMOVE REAR BRAKE DRUM AND WASHER LH. 

5. REMOVE ADJUSTMENT SHEET AND TENSION 

SPRING FOR PARKING BRAKE . 

(a) Loosen tension spring of parking brake adjustment 

sheet. 

16A 

35 

(b) 

Remove adjustment sheet and tension spring for parking 

brake. 

6. LOOSEN BRAKE SHOE TENSION SPRING FROM 

LEADING SHOE . 

WARNING 

The parking brake tension spring is under great pressure. 

To avoid injury, use caution when removing the parking 

brake tension spring. 

Page 2435

35-28 


7. REMOVE LOWER TENSION SPRING ,RETAINING 

PLATE AND RETURN SPRING. 

(a) 

(b) 

Loosen lower tension spring from RH side. 

Loosen lower tension spring and retaining plate from LH 

side. 

(c) 

Remove lower tension spring and retaining plate. 

(d) 

Remove return spring. 

8. REMOVE LEADING SHOE. 

(a) Remove the leading shoe hold spring. 

WARNING 

The leading shoe hold spring is under great pressure. To 

avoid injury, use caution when removing the leading shoe 

hold spring. 

Page 2436


35-29 

(b) 

Remove the leading shoe. 

35 

9. INSPECT BRAKE SHOE THICKNESS. 



CAUTION 

If the thickness is at the ultimate thickness or less, or if it 

appears severe uneven wear, replace with a new brake 

shoe. 

16A 

35 

10. REMOVE TRAILING SHOE. 

(a) Remove the trailing shoe hold spring. 

WARNING 

The trailing shoe hold spring is under great pressure. To 

avoid injury, use caution when removing the trailing shoe 

hold spring. 

(b) 

Remove the parking brake cable. 

Page 2437

35-30 


(c) 

Remove the trailing shoe. 

(d) 

Remove parking brake shoe strut set and tension spring. 

11. REMOVE REAR BRAKE AUTOMATIC ADJUSTING 

LEVER AND PARKING BRAKE SHOE LEVER. 

(a) 

Remove the C-washer. 

(b) 

(c) 

Remove the rear brake automatic adjusting lever. 

Remove parking brake shoe lever. 

Page 2438


35-31 

12. INSPECT BRAKE SHOE THICKNESS. 



CAUTION 

If the thickness is at the ultimate thickness or less, or if it 

appears severe uneven wear, replace with a new brake 

shoe. 

35 

13. INSPECT REAR BRAKE DRUM INSIDE DIAMETER. 

Ultimate value: 254 ~ 254.2 mm 

CAUTION 

If the inside diameter is outside ultimate value, replace with 

a new rear brake drum. 

14. INSPECT REAR BRAKE DRUM AND BRAKE SHOE 

FOR PROPER CONTACT. 

(a) 

Apply chalk to the inside of the rear brake drum, then 

grind brake shoe on the surface of the drum. If the 

contact between the rear brake drum and the brake shoe 

is improper, repair brake shoe by a brake shoe grinder or 

replace the rear brake drum. 

16A 

35 

15. REMOVE REAR WHEEL BRAKE CYLINDER ASSY 

LH. 

(a) Loosen tubing joint nut and disconnect the brake fluid 

tube from rear wheel brake cylinder. 

(b) 

Remove the bleeder plug. 

Page 2439

35-32 


(c) 

Remove the 2 bolts from rear wheel brake cylinder. 

(d) 

Remove rear wheel brake cylinder. 

16. INSTALL REAR WHEEL BRAKE CYLINDER ASSY LH. 

(a) Install the 2 bolts to rear wheel brake cylinder. 


(b) 

Install the bleeder plug. 


(c) 

Connect the brake fluid tube to rear wheel brake cylinder 

and tighten the tubing joint nut. 


Page 2440


35-33 

17. INSTALL REAR BRAKE AUTOMATIC ADJUSTING 

LEVER AND PARKING BRAKE SHOE LEVER. 

(a) 

(b) 

(c) 

Install the rear brake automatic adjusting lever. 

Install the parking brake shoe lever. 

Install the C-washer. 

35 

18. INSTALL TRAILING SHOE. 

(a) Install parking brake shoe strut set and tension spring to 

trailing shoes. 

(b) Connect the parking brake cable to parking brake shoe 

lever. 

(c) Position the trailing shoe, install the trailing shoe hold 

spring. 

NOTE 

Apply No. 2 lithium base grease on contact surface of 

trailing shoe and wheel brake cylinder when installing 

trailing shoe,Don’t pollut the working surface of brake drum 

and shoe . 

16A 

35 

WARNING 

The trailing shoe hold spring is under great pressure. To 

avoid injury, use caution when installing the trailing shoe 

hold spring. 

19. INSTALL LEADING SHOE. 

(a) Install parking brake tension spring to leading shoe. 

WARNING 

The parking brake tension spring is under great pressure. 

To avoid injury, use caution when installing the parking 

brake tension spring. 

(b) Install leading shoe to wheel brake cylinder,and install 

parking brake shoe strut set to leading by rotating 

leading shoe. 

(c) Position the leading shoe,Install the leading shoe hold 

spring. 

NOTE 

Apply No. 2 lithium base grease on contact surface of 

leading shoe and wheel brake cylinder when installling 

leading shoe,Don’t pollut the working surface of brake 

drum and shoe . 

Page 2441

35-34 


WARNING 

The leading shoe hold spring is under great pressure. To 

avoid injury, use caution when installing the leading shoe 

hold spring. 

20. INSTALL RETURN SPRING AND LOWER TENSION 

SPRING , RETAINING PLATE . 

(a) Install return spring. 

WARNING 

The brake shoe return spring is under great pressure. To 

avoid injury, use caution when installing the leading shoe 

hold spring. 

(b) 

Install retaining plate and lower tension spring. 

WARNING 

The lower tension spring is under pressure. To avoid injury, 

use caution when installing the leading shoe hold spring. 

21. INSTALL ADJUSTMENT SHEET AND TENSION SPRING 

FOR PARKING BRAKE. 

(a) Install adjustment sheet for parking brake. 

(b) Install tension spring of adjustment sheet. 

WARNING 

The tension spring of adjustment sheet is under pressure. 

To avoid injury, use caution when installing the leading 

shoe hold spring. 

Page 2442


35-35 

22. INSPECT BRAKE SHOES AND REAR BRAKE DRUM 

INSTALLATION. 

(a) 

(b) 

Check that each part is installed properly. 

Measure the inside diameter of rear brake drum and the 

diameter of brake shoes. Inspect the clearance between 

rear brake drum and brake shoes. 

Specification: 0.5 mm 

35 

NOTE 

There should be no oil or grease adhering to the friction 

surface between brake shoe and rear brake drum. 

23. ADJUST CLEARANCE BETWEEN REAR BRAKE 

DRUM AND BRAKE SHOES. 

(a) 

(b) 

Remove the hole plug behind brake backing plate. 

Adjust the clearance between brake shoes and rear 

brake drum. 

16A 

35 

24. INSTALL REAR BRAKE DRUM AND WASHER LH. 

Page 2443

35-36 


25. FILL BRAKE FLUID INTO RESERVIOR. 

WARNING 




27. BLEED BRAKE LINE. (Refer to “Chapter 35 brake - brake fluid, bleeding”) 

28. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 35 brake - brake fluid, 

bleeding”) 


30. INSTALL REAR WHEEL LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire, 


31. REMOVE AND INSTALL REAR BRAKE DRUM RH. 

NOTE 


Page 2444

BRAKE - ABS ACTUATOR 

35-37 

ABS ACTUATOR 

REPLACEMENT 



35 

WARNING 



3. REMOVE FRONT BUMPER ASSY.(Refer to “Chapter 88 exterior and interior trim - front bumper, 


4. REMOVE ABS ACTUATOR ASSY. 

(a) Disconnect the connect from ABS actuator. 

16A 

35 

(b) 

Remove 6 brake tubes from ABS actuator. 

NOTE 

Make marks on the ABS actuator connecting fluid tube assy 

in order to install them properly. 

(c) Remove 2 mounting bolts of ABS actuator. 

Page 2445

35-38 


(d) 

Remove ABS actuator. 

NOTE 

Don’t destroy rubber washer of core pin at the bottom of 

actuator and mounting nuts. 

5. INSTALL ABS ACTUATOR. 

(a) Position ABS actuator. 

(b) Tighten 2 mounting nuts of ABS actuator. 

(c) Connect the ABS connecting fluid tubes to ABS actuator 

as the marks show, and tighten tubing joint nuts. 


(d) 

Connect the connector to ABS actuator. 

6. INSTALL FRONT BUMPER ASSY.(Refer to “Chapter 88 exterior and interior trim - front bumper, 


7. CONNECT BATTERY NEGATIVE CABLE 


WARNING 




10. BLEED BRAKE LINE. (Refer to “Chapter 35 brake - brake fluid, bleeding”) 

Page 2446


35-39 

11. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 35 brake - brake fluid, 

bleeding”) 

12. CHECK BRAKE FLUID FOR LEAKAGE. 

13. INSPECT ABS ACTUATOT BY SCAN TOOL. (Refer to “Chapter 04 diagnostics - anti-lock brake 

system, pre-check”) 

35 

16A 

35 

Page 2447

35-40 

BRAKE - WHEEL SPEED SENSOR 

WHEEL SPEED SENSOR 

REPLACEMENT 


2. REMOVE FRONT WHEEL SPEED SENSOR LH. 

(a) Remove mounting bolts of front wheel speed sensor LH. 

(b) Disconnect the connector of wheel speed sensor LH. 

(c) Remove the clamp of front wheel speed sensor wire LH. 

(d) Remove front wheel speed sensor LH. 

3. REMOVE REAR WHEEL SPEED SENSOR LH. 

(a) Remove mounting bolts of rear wheel speed sensor LH. 

(b) 

Disconnect the connector of rear wheel speed sensor 

LH. 

(c) 

(d) 

Remove the clamp of rear wheel speed sensor wire LH. 

Remove rear wheel speed sensor LH. 

Page 2448

BRAKE - WHEEL SPEED SENSOR 

35-41 

4. INSTALL REAR WHEEL SPEED SENSOR LH. 

(a) 

Install rear wheel speed sensor LH and tighten mounting 

bolt. 

35 

(b) 

Connect the connector of rear wheel speed sensor LH. 

(c) 

Install the clamp and wire of rear wheel speed sensor 

LH. 

16A 

5. INSTALL FRONT WHEEL SPEED SENSOR LH. 

(a) 

(b) 

(c) 

Install front wheel speed sensor LH,tighten mounting 

bolt. 

Connect the connector of front wheel speed sensor LH. 

Install the clamp and wire of front wheel speed sensor 

LH. 

35 

6. REMOVE AND INSTALL FRONT WHEEL SPEED SENSOR RH. 

NOTE 

Remove and Install the RH side by the same procedures as the LH side. 

7. REMOVE AND INSTALL REAR WHEEL SPEED SENSOR RH. 

NOTE 

Remove and Install the RH side by the same procedures as the LH side. 


9. INSPECT WHEEL SPEED SENSOR SIGNAL. 

Page 2449

MEMO 

Page 2450

PARKING BRAKE 

PARKING BRAKE SYSTEM.............................................................. 36-1 


ADJUSTMENT............................................................................. 36-2 

COMPONENTS ........................................................................... 36-3 

FRONT PARKING BRAKE OPERATION ASSY............................... 36-4 

REPLACEMENT .......................................................................... 36-4 

REAR PARKING BRAKE OPERATION ASSY ................................. 36-8 

REPLACEMENT .......................................................................... 36-8 

36 

36 

36 

36 

36 

36 

36 

36 

Page 2451

Page 2452

PARKING BRAKE - PARKING BRAKE SYSTEM 

36-1 

PARKING BRAKE SYSTEM 

BRAKE 




36 


1. Parking Brake cable(Sticking) - 

Brake drag 

2. Brake shoe clearance (Out of 

adjustment) 

3. Return spring (Damaged) 

4. Parking brake tension spring 

(Damaged) 


Chapter 36 parking brake - parking brake system,adjustment 

Chapter 36 parking brake - front parking brake 

operation assy, replacement 


5. Parking brake return spring 

(Damaged) 


36 

36 

Page 2453

36-2 


ADJUSTMENT 



2. INSPECT BRAKE SHOES AND REAR BRAKE DRUM INSTALLATION. (Refer to “Chapter 35 brake 

- rear brake, overhaul”) 

3. ADJUST SINGLE CLEARANCE BETWEEN REAR BRAKE DRUM AND BRAKE SHOES. (Refer to 

“Chapter 35 brake - rear brake, overhaul”) 



5. ADJUST BOTH CLEARANCE BETWEEN REAR 

BRAKE DRUM AND BRAKE SHOES. 

(a) Adjust both clearance between rear brake drum and 

brake shoes at the same time by adjustment screw at the 

parking brake rocker arm with bracket assy,until both 

clearance pass muster. 

Page 2454


36-3 

COMPONENTS 

36 

1 

2 Bolt 

3 Nut 

4 Bolt 

Parking Brake Operation Handle With 

Cable Assy 

5 Bolt 

6 Clamp 

7 Cable Bracket 

8 

Parking Brake Rocker Arm With Bracket 

Assy 

36 

36 

Page 2455

36-4 

PARKING BRAKE - FRONT PARKING BRAKE OPERATION ASSY 

FRONT PARKING BRAKE OPERATION ASSY 

REPLACEMENT 


2. REMOVE PARKING BRAKE SHIELD ASSY. (Refer to “Chapter 83 instrument panel - dashboard, 


3. REMOVE PARKING BRAKE SWITCH. 

(a) Disconnect the connector from parking brake switch. 

(b) Remove the parking brake switch. 

4. REMOVE PARKING BRAKE OPERATION HANDLE 

WITH CABLE ASSY. 

(a) 

Remove 2 upper mounting bolts. 

(b) 

Remove 2 lower mounting nuts 

(c) 

Remove 2 lower mounting bolts LH. 

Page 2456


36-5 

(d) 

Disconnect cable of parking brake operation handle 

with cable assy from parking brake rocker arm with 

bracket assy. 

36 

(e) 

(f) 

Along the end of front parking brake operation assy, 

remove all clamps, remove the clamp between front 

parking brake cable and frame and the clamp between 

front parking brake and the other cables. 

Remove parking brake operation handle with cable 

assy. 

5. REMOVE PARKING BRAKE ROCKER ARM WITH 

BRACKET ASSY. 

(a) Disconnect cable of parking brake operation handle 

with cable assy from parking brake rocker arm with 

bracket assy. 

(b) Remove return spring. 

36 

36 

(c) 

(d) 

(e) 

Disconnect cable of rear parking brake operation assy 

LH/RH from parking brake rocker arm with bracket 

assy. 

Remove 2 mounting bolts fitting parking brake rocker 

arm with bracket assy to frame. 

Remove parking brake rocker arm with bracket assy. 

6. INSTALL PARKING BRAKE ROCKER ARM WITH 

BRACKET ASSY. 

(a) 

(b) 

Position parking brake rocker arm with bracket assy, 

tighten 2 mounting bolts. 

Connect cable of rear parking brake operation assy LH 

to parking brake rocker arm with bracket assy. 

Page 2457

36-6 


(c) 

(d) 

Install return spring. 

Connect cable of parking brake operation handle with 

cable assy to parking brake rocker arm with bracket 

assy. 

7. INSTALL ARKING BRAKE OPERATION HANDLE WITH 

CABLE ASSY. 

(a) Position parking brake operation handle with cable assy 

and tighten 2 lower mounting bolts LH. 

(b) 

Tighten 2 lower mounting nuts. 

(c) Tighten 2 upper mounting bolts. 

(d) 

Connect cable of parking brake operation handle with 

cable assy to parking brake rocker arm with bracket 

assy. 

Page 2458


36-7 

(e) 

Along the end of front parking brake operation assy, 

install the clamp between front parking brake cable and 

frame and the clamp between front parking brake and 

the other cables. 

36 

8. INSTALL PARKING BRAKE SWITCH. 

(a) Install parking brake switch. 

(b) Connect the connector to parking brake switch. 

9. INSTALL PARKING BRAKE SHIELD ASSY. (Refer to “Chapter 83 instrument panel - dashboard, 



36 

36 

Page 2459

36-8 

PARKING BRAKE - REAR PARKING BRAKE OPERATION ASSY 

REAR PARKING BRAKE OPERATION ASSY 

REPLACEMENT 



2. REMOVE REAR BRAKE LH. (Refer to “Chapter 35 barake - rear brake, overhaul”) 

3. REMOVE REAR PARKING BRAKE OPERATION ASSY LH. 

(a) 

Disconnect the connecting between rear parking brake operation assy LH and rear brake actuator 

lever. (Refer to” Chapter 35 brake - rear brake, overhaul”) 

(b) 

Remove 2 bolts fitting rear parking brake operation assy 

LH to brake backing plate. 

NOTE 

Remove bolts from the front of brake backing plate. 

(c) 

Disconnect rear parking brake operation assy LH from 

parking brake rocker arm with bracket assy. 

(d) 

(e) 

Disconnect rear parking brake operation assy LH from 

all brackets. 

Remove rear parking brake operation assy LH. 

4. INSTALL REAR PARKING BRAKE OPERATION ASSY 

LH. 

(a) Install 2 mounting bolts fitting rear parking brake operation 

assy LH to brake backing plate. 

NOTE 

Install bolts from the front of brake backing plate. 

Page 2460

PARKING BRAKE - REAR PARKING BRAKE OPERATION ASSY 

36-9 

(b) 

Connect rear parking brake operation assy LH to parking 

brake rocker arm with bracket assy. 

36 

(c) 

(d) 

Connect rear parking brake operation assy LH to all 

brackets. 

Connect rear parking brake operation assy LH to rear 

brake actuator lever. (Refer to” Chapter 35 brake - rear 

brake, overhaul”) 

5. INSTALL REAR BRAKE LH. (Refer to “Chapter 35 barake - rear brake, overhaul”) 



7. REMOVE AND INSTALL REAR PARKING BRAKE OPERATION ASSY RH. 

NOTE 


36 

36 

Page 2461

INDEX 


A 

ABS ACTUATOR .........................................................................35-37 

ADJUSTMENT(BRAKE PEDAL)....................................................35-7 

ADJUSTMENT(FRONT WHEEL ALIGNMENT) ............................31-8 

ADJUSTMENT(PARKING BRAKE SYSTEM) ...............................36-2 

AIR FILTER ASSY ...................................................................... 14C-7 

AXLE SHAFT ASSY.....................................................................34-43 

B 

BATTERY.................................................................................. 20C-18 

BLEEDING(BRAKE FLUID) ...........................................................35-4 

BRAKE FLUID................................................................................35-4 

BRAKE PEDAL ..............................................................................35-6 

BRAKE SYSTEM ...........................................................................35-1 

C 

CENTER SUPPORT BEARING...................................................34-12 

COMPONENTS(BRAKE PEDAL) ..................................................35-6 

COMPONENTS(COOLING SYSTEM)........................................ 17C-2 

COMPONENTS(EXHAUST PIPE).............................................. 16C-1 

COMPONENTS(FUEL SYSTEM) ............................................... 12C-4 

COMPONENTS(INTAKE AIR SYSTEM) .................................... 14C-2 

COMPONENTS(REAR SUSPENSION) ........................................32-2 

COMPONENTS(STARTER) ..................................................... 20C-10 

COMPOSITION(BATTERY)...................................................... 20C-18 

COOLANT................................................................................... 17C-7 

COOLING SYSTEM.................................................................... 17C-1 

D 

DIESEL ENGINE CONTROL SYSTEM ...................................... 11C-1 

DRIVE PINION.............................................................................34-50 

E 

ELECTRONIC ACCELERATOR PEDAL .................................. 12C-20 

ENGINE ACCESSORY BELT................................................... 15C-12 

ENGINE CONTROL MODULE (ECM) ........................................ 11C-2 

ENGINE MECHANICAL PART ................................................... 15C-1 

ENGINE OIL................................................................................ 18C-2 

F 

FRONT BRAKE............................................................................35-20 

FRONT PARKING BRAKE OPERATION ASSY............................36-4 

FRONT SUSPENSION ..................................................................31-1 

FRONT WHEEL ALIGNMENT .......................................................31-8 

FRONT WHEEL AND TIRE ...........................................................33-8 

FUEL FILLER CAP ....................................................... 12C-15, 13C-1 

FUEL FILLER DOOR ................................................................ 12C-12 

FUEL FILLER DOOR LOCK LATCH ASSY.............................. 12C-13 

FUEL FILLING TUBE AND BREATHER TUBE ASSY ............. 12C-16 

FUEL LEVEL SENSOR AND BRACKET ASSY ....................... 12C-10 

FUEL SYSTEM ........................................................................... 12C-1 

G 

GENERATOR..............................................................................20C-4 

J 

INSPECTION(BATTERY)..........................................................20C-21 

INSPECTION(DRIVE PINION).................................................... 34-50 

INSPECTION(FUEL FILLER CAP) ...............................12C-15, 13C-1 

INSPECTION(FUEL FILLING TUBE AND BREATHER 

TUBE ASSY) .............................................................................12C-16 

INSPECTION(PROPELLER SHAFT ASSY) ................................. 34-4 

INTAKE AIR PIPE AND HOSE....................................................14C-4 

INTAKE AIR SYSTEM.................................................................14C-1 

INTERCOOLER INTAKE AIR PIPE ..........................................14C-11 

L 

LUBRICATION SYSTEM.............................................................18C-1 

O 

OIL FILTER .................................................................................18C-4 

OIL PAN ......................................................................................18C-6 

OIL PUMP ...................................................................................18C-7 

ON VEHICLE INSPECT(COOLING SYSTEM) ...........................17C-5 

ON-VEHICLE INSPECTION(FRONT SUSPENSION) .................. 31-7 

ON-VEHICLE INSPECTION(REAR BRAKE) .............................. 35-26 

ON-VEHICLE INSPECTION(REAR SUSPENSION)..................... 32-3 

ON-VEHICLE INSPECTION(TIRE AND WHEEL ASSY) .............. 33-4 

OVERHAUL(AXLE SHAFT ASSY).............................................. 34-43 

OVERHAUL(CENTER SUPPORT BEARING) ............................ 34-12 

OVERHAUL(ENGINE ACCESSORY BELT) .............................15C-12 

OVERHAUL(FRONT BRAKE)..................................................... 35-20 

OVERHAUL(GENERATOR)........................................................20C-4 

OVERHAUL(OIL PUMP) .............................................................18C-7 

OVERHAUL(REAR BRAKE) ....................................................... 35-27 

OVERHAUL(REAR LEAF SPRING ASSY) ................................... 32-6 

OVERHAUL(REAR SHOCK ABSORBER).................................... 32-4 

OVERHAUL(STARTER)............................................................20C-11 

OVERHAUL(VACUUM BOOSTER WITH BRAKE MASTER CYLIN- 

DER ASSY) ................................................................................. 35-14 

P 

PARKING BRAKE SYSTEM ......................................................... 36-1 

PRECAUTION(BRAKE SYSTEM)................................................. 35-1 

PRECAUTION(COOLING SYSTEM) ..........................................17C-1 

PRECAUTION(DIESEL ENGINE CONTROL SYSTEM).............11C-1 

PRECAUTION(ENGINE MECHANICAL PART)..........................15C-1 

PRECAUTION(FRONT SUSPENSION)........................................ 31-1 

PRECAUTION(FUEL SYSTEM)..................................................12C-1 

PRECAUTION(INTAKE AIR SYSTEM).......................................14C-1 

PRECAUTION(LUBRICATION SYSTEM)...................................18C-1 

PRECAUTION(PROPELLER SHAFT ASSY)................................ 34-1 

PRECAUTION(STARTING AND CHARGING SYSTEM)............20C-1 

PRINCIPLE(VEHICLE SPEED SENSOR) ..................................11C-8 

PROBLEM SYMPTOMS TABLE ................................................... 35-2 

PROBLEM SYMPTOMS TABLE(PARKING BRAKE SYSTEM) ... 36-1 

PROBLEM SYMPTOMS TABLE(REAR SUSPENSION) .............. 32-1 

Page 2462

PROBLEM SYMPTOMS TABLE(STARTING AND CHARGING SYS- 

TEM)............................................................................................20C-2 

PROBLEM SYMPTOMS TABLE(TIRE AND WHEEL ASSY) ....... 33-3 

PROPELLER SHAFT ASSY.......................................................... 34-1 

R 

RADIATOR ................................................................................17C-14 

REAR BRAKE ............................................................................. 35-26 

REAR LEAF SPRING ASSY ......................................................... 32-6 

REAR SHOCK ABSORBER.......................................................... 32-4 

REAR SUSPENSION .................................................................... 32-1 

REPLACEMENT(ABS ACTUATOR) ........................................... 35-37 

REPLACEMENT(AIR FILTER ASSY) .........................................14C-7 

REPLACEMENT(BATTERY).....................................................20C-24 

REPLACEMENT(BRAKE PEDAL) ................................................ 35-9 

REPLACEMENT(COOLANT)......................................................17C-7 

REPLACEMENT(ELECTRONIC ACCELERATOR PEDAL) .....12C-20 

REPLACEMENT(ENGINE ASSY)...............................................15C-2 

REPLACEMENT(ENGINE OIL)...................................................18C-2 

REPLACEMENT(EXHAUST PIPE) .................................16C-2, 16C-3 

REPLACEMENT(FRONT PARKING BRAKE 

OPERATION ASSY)...................................................................... 36-4 

REPLACEMENT(FRONT WHEEL AND TIRE) ............................. 33-8 

REPLACEMENT(FUEL FILLER DOOR LOCK 

LATCH ASSY) ...........................................................................12C-13 

REPLACEMENT(FUEL FILLING DOOR)..................................12C-12 

REPLACEMENT(FUEL LEVEL SENSOR AND BRACKET 

ASSY)........................................................................................12C-10 

REPLACEMENT(INTAKE AIR PIPE AND HOSE) ......................14C-4 

REPLACEMENT(INTERCOOLER INTAKE AIR PIPE) .............14C-11 

REPLACEMENT(OIL FILTER) ....................................................18C-4 

REPLACEMENT(OIL PAN) .........................................................18C-6 

REPLACEMENT(RADIATOR)...................................................17C-14 

REPLACEMENT(RESERVIOR) ..................................................17C-9 

REPLACEMENT(VACUUM BOOSTER LINE) ............................ 35-18 

REPLACEMENT(WHEEL SPEED SENSOR) ............................. 35-40 

RESERVIOR ...............................................................................17C-9 

S 

STARTER..................................................................................20C-10 

STARTING AND CHARGING SYSTEM......................................20C-1 

T 

TIRE AND WHEEL ASSY ............................................................. 33-1 

W 

VACUUM BOOSTER LINE ......................................................... 35-18 

VACUUM BOOSTER WITH BRAKE MASTER CYLINDER 

ASSY........................................................................................... 35-14 

VEHICLE SPEED SENSOR........................................................11C-8 

WHEEL SPEED SENSOR .......................................................... 35-40 

USE AND MAINTENANCE(BATTERY) ....................................20C-19 

Page 2463

Page 2464

TRANSMISSION 

TRANSMISSION OPERATION MECHANISM ASSY ........................ 41-1 

COMPONENTS ........................................................................... 41-1 

REPLACEMENT .......................................................................... 41-3 

TRANSMISSION ASSY(YANCHENGZHONGMA ZM001)................ 41-8 

DIAGRAM OF COMPONENTS.................................................... 41-8 

REPLACEMENT ........................................................................ 41-10 

DISASSEMBLY AND ASSEMBLY............................................. 41-15 

CLUTCH CASE ................................................................................ 41-39 

DIAGRAM OF COMPONENTS.................................................. 41-39 

SERVICE ................................................................................... 41-40 

REAR PART ASSEMBLY................................................................ 41-43 


SERVICE ................................................................................... 41-44 

FORK SHAFT ASSEMBLY.............................................................. 41-48 


SERVICE ................................................................................... 41-49 

INPUT SHAFT ASSEMBLY ............................................................. 41-51 


SERVICE ................................................................................... 41-52 

OUTPUT SHAFT ASSEMBLY ......................................................... 41-54 


SERVICE ................................................................................... 41-55 

COUNTER SHAFT ASSEMBLY ...................................................... 41-62 


SERVICE ................................................................................... 41-63 

REVERSE SHAFT ASSEMBLY....................................................... 41-67 


SERVICE ................................................................................... 41-68 

SERVICE FOR OTHER IMPORTANT COMPONENTS OF TRANS- 

MISSION.................................................................................... 41-70 

TRANSMISSION ASSY(TANGSHANAIXIN) ................................... 41-73 

REPLACEMENT ........................................................................ 41-73 

41 

41 

41 

41 

41 

41 

41 

Page 2465

Page 2466

TRANSMISSION - TRANSMISSION OPERATION MECHANISM ASSY 

TRANSMISSION OPERATION MECHANISM ASSY 

COMPONENTS 

41-1 

41 

14A 

41 

1 Shifting Control Lever Ball Assy 

2 Dust Cover 

3 Big Washer 

4 Bolt And Spring Washer Set 

5 Operation Mechanism Assy 

Page 2467

41-2 


1 Flexible Shaft Assy 

2 Flexible Shaft Bracket Assy No.1 

3 Nut 

4 

Bolt,spring Washer And Flat Washer 

Set 

5 Bolt 



Page 2468


41-3 

REPLACEMENT 

1. STOP THE ENGINE AND PARK THE VEHICLE ON LEVEL GROUND WITH PARKING BRAKE. 

2. REMOVE TRANSMISSION SHIFTING CONTROL LEVER 

BALL ASSY AND DUST COVER. 

(a) 

Using plastic ripping bar,pry off retaining trim frame of 

transmission Shifting Control Lever dust cover. 

41 

NOTE 

Don’t destroy dust cover. 

(b) 

Remove shifting control lever ball assy by turning it 

counterclockwise, and remove dust cover. 

14A 

41 

3. REMOVE DASHBOAD. (Refer to “Chapter 83 instrument panel - darshboad, replacement”) 

4. REMOVE TRANSMISSION OPERATION MECHANISM 

ASSY AND CABLES. 

(a) 

(b) 

Disconnect flexible shaft of gear shifting cable from 

transmission operation mechanism assy, then remove 

cable clamp from transmission operation mechanism 

assy. 

Disconnect flexible shaft gear selecting cable from 

transmission operation mechanism assy, then remove 

cable clamp from transmission operation mechanism 

assy. 

Page 2469

41-4 


(c) 

Remove 4 mounting bolts of transmission operation 

mechanism assy. 

(d) 

Remove transmission operation mechanism assy. 

(e) 

Remove 2 bolts fitting cables to lower body. 

Page 2470


41-5 

(f) 

Remove cotter pin,disconnect flexible shaft of gear 

shifting cable and flexible shaft of gear selecting cable 

from transmission assy. 

NOTE 


(g) Remove cables from brackets located at transmission 

assy. 

41 

(h) 

(i) 

Along the end of cables,remove 1 cable clamp located at 

the bottom of body and 2 clamps located at subframe. 

Remove gear shifting cable and gear selecting cable 

assy. 

14A 

41 

5. INSTALL TRANSMISSION OPERATION MECHANISM 

ASSY AND CABLES. 

(a) Position cables. 

(b) Connect flexible shaft of gear shifting cable and flexible 

shaft of gear selecting cable to transmission assy. 

NOTE 


(c) Install cables to bracket located at transmission assy. 

(d) 

Tighten 2 bolts fitting cables to lower body. 

Page 2471

41-6 


(e) 

(f) 

(g) 

Along the end of cables, install 1 cable clamp located at 

the bottom of body and 2 clamps located at subframe. 

Position transmission operation mechanism assy. 

Tighten 4 mounting bolts. 

(h) Install gear selecting cable clamp to transmission 

operation mechanism assy,then connect flexible shaft of 

gear selecting cable to transmission operation 

mechanism assy. 

NOTE 

• Make sure that the transmission operation mechanism 

is in neutral position before connecting the flexible 

shaft to it, or adjust it. 

• Apply lithium base grease NO.3 to joint of transmission 

operation michanism assy and flexible shaft of cable. 

(i) Install gear shifting cable clamp to transmission 

operation mechanism assy,then connect flexible shaft of 

gear shifting cable to transmission operation mechanism 

assy. 

NOTE 

• Make sure that the transmission operation mechanism 

is in neutral position before connecting the flexible 

shaft to it,or adjust it. 

• Apply lithium base grease NO.3 to joint of transmission 

operation michanism assy and flexible shaft of cable. 

6. INSTALL DASHBOAD. (Refer to “Chapter 83 instrument panel - darshboad, replacement”) 

Page 2472


41-7 

7. INSTALL TRANSMISSION SHIFTING CONTROL LEVER 

BALL ASSY AND DUST COVER. 

(a) 

(b) 

Install dust cover, turn shifting control lever ball clockwise 

in order to install it. 

Install retaining trim frame of dust cover. 

41 

NOTE 

Don’t detroy dust cover. 

8. INSPECT TRANSMISSION OPERATION MECHANIZE ASSY FOR SMOOTH SHIFTING, NO 

STICKING AND LOOSENING. 

14A 

41 

Page 2473

41-8 

TRANSMISSION - TRANSMISSION ASSY(YANCHENGZHONGMA ZM001) 

TRANSMISSION ASSY(YANCHENGZHONGMA ZM001) 


Page 2474


41-9 

1 Ball head washer 

2 Control lever cover assembly 

3 Locating pin 

4 Breather plug 

5 Shift extension bar assembly 

6 Dust cover 

7 Shift lever spring cover 

8 Shift lever spring 

9 Sealing washer 

10 Positioning mechanism assembly 

11 Odometer driven gear assembly 

12 Oil guiding groove 

13 Shift block 

14 Locating bolt of shift block 

15 Steel ball 

16 Self-locking spring 

17 Plug 

18 Oil storage box 

19 Stopper pin 

20 Shift shaft 

21 Shift fork, lock and pin assembly 

22 Shift lever 

23 Odometer drive pinion retainer ring 

24 Odometer drive pinion 

25 Stopper 

26 Stopper spring 

27 Stopper shaft 

28 Intermediate plate assembly 

29 Case 

30 Hexagon head plug 


32 Reverse switch assembly 

33 Hexagon head screw plug 

34 Front cover oil seal 

35 Front cover 

36 Bowl-shaped expansion plug 

37 Clutch release fork assembly 

38 Clutch release fork shield 

39 Clutch case 

40 Clutch release fork stud 

41 Release bearing assembly 

41 

14A 

41 

Page 2475

41-10 


REPLACEMENT 

1. STOP THE ENGINE. PARK VEHICLE ON LEVELGROUND WITH PARKING BRAKE AND SHIFT IN 

NEUTRAL POSITION. 



4. REMOVE DRAIN PLUG BY DOWNSIDE AND DRAIN 

TRANSMISSION FLUID COMPLETELY. TIGHTEN DRAIN 

PLUG. 


NOTE 





draining. 

5. DISCONNECT TRANSMISSION ASSY FROM OTHER 

PARTS,THEN REMOVE TRANSMISSION ASSY. 

(a) Remove crankshaft position sensor located at the top of 

transimission. 

WARNING 

Be careful not to be scalded by exhaust pipe. 

(b) 

Remove vehicle speed sensor located at the left of 

transmission. 

Page 2476


41-11 

(c) 

Remove the back-up lamp switch located at the right of 

transmission. 

41 

(d) 

(e) 

(f) 

Remove the clutch slave cylinder assy. (Refer to “Chapter 

42 clutch - clutch slave cylinder assy, replacement”) 

Remove back nuts,disconnect flexible shaft of gear 

shifting cable and flexible shaft of gear selecting cable 

from transmission assy. 

Remove 2 mounting bolts of cable bracket and cable 

bracket located at transmission case. 

14A 

41 

(g) 

Remove 2 mounting bolts and 2 nut bolts of transmission 

front cover and transmission front cover. 

WARNING 


(h) 

(i) 

Remove starter. (Refer to “Chapter 20A starting and 

charging - starter, overhaul”) 

Remove propeller shaft assy. (Refer to “Chapter 34 axle 

and propeller shaft - propeller shaft assy, overhaul”) 

Page 2477

41-12 


(j) 

Remove 4 nuts and disconnect the transmission from 

lifting lug. 

WARNING 

• Use jack to support transmission assy and engine 

before operation. 

• Be careful not to be scalded by exhaust pipe. 

(k) 

Remove 5 bolts and disconnect transmission assy from 

engine. Remove the transmission assy. 

NOTE 

There are five bolts,one is used for retaining air condition 

pipe, another one which isn’t installed temporarily is used 

for retaining gear shifting cable bracket. 

6. INSTALL TRANSMISSION ASSY, AND CONNECT OTHER 

PARTS TO TRANSMISSION ASSY. 

(a) 

Support the transmission assy by jack and shift in one of 

forward gears. Rotate the input shaft and align with the 

spline of clutch disk at the same time. Then insert the 

input shaft completely and shift in neutral position. 

WARNING 

Adopt protective measures to prevent from injuring when 

supporting by jack. 

(b) Install bolts with hand to connect transmission to engine. 

NOTE 

There are five bolts,one is used for retaining air condition 

pipe, another one which isn’t installed temporarily is used 

for retaining gear shifting cable bracket. 

(c) 

Support the transmission assy by jack and connect the 

transmission assy to lifting lug. Install 4 bolts with hand. 

WARNING 



(d) Tighten 4 nuts of lifting lug. 

Torque:41 ~ 51N•m 

Page 2478


41-13 

(e) 

Tighten bolts to connect transmission assy to engine. 

Torque: 42.2 ~ 53.9 N•m 

NOTE 

Diagonally tighten all bolts in order to install closely. 

(f) 

(g) 

Install propeller shaft assy. (Refer to “Chapter 34 axle 


Install starter. (Refer to “Chapter 20A starting and 


41 

(h) 

Position transmission font cover,tighten 2 mounting bolts 

and 2 nut bolts. 

Torque: 7.8 ~ 9.8 N•m 

14A 

(i) 

Position cable bracket located at transmission case and 


41 

NOTE 

Tighten the through bolt which is used to connect transmission 

to engine to 42.2 ~ 53.9 N•m. 

(j) Position flexible shaft of gear shifting cable and flexible 

shaft of gear selecting cable,then tighten mounting nuts. 

NOTE 

Make sure the shift rocker arm in neutral before installation. 


(k) 

(l) 

(m) 

Remove jack. 

Install the clutch slave cylinder assy. (Refer to “Chapter 

42 clutch - clutch slave cylinder assy,replacement”) 

Install the back-up lamp switch located at the right of 

transmission. 

Page 2479

41-14 


(n) 

Install vehicle speed sensor located at the left of 

transmission. 

(o) 

Install vehicle speed sensor located at the top of 

transmission. 

7. REMOVE FILLER PLUG AND FILL TRANSMISSION 

FLUID. THEN TIGHTEN FILLER PLUG. 


CAUTION 


75W/90 for 2.0 L. 


• Parking the vehicle on the levelground when 

checking fluid level. The fluid level must be flush 

with lower edge of oil filler. 



10. TRANSMISSION RUNNING - IN TEST. 

(a) Keep the rotate speed around 1500 r/min; keep the fluid temperature upper 15 centidegree; without 

load; keep transmission run more than 15 min in neutral position; keep transmission run more than 20 

min in other positions. 

(b) Inspect the transmission for smooth shifting. 

(c) Check there is no fricative and clash during running-in test. 

(d) Check there is no leakage around trasmission. 

(e) Drain out transmission fluid and clean inside of transmission after running-in test. Fill transmission fluid. 

TRANSMISSION 

Page 2480


41-15 

DISASSEMBLY AND ASSEMBLY 

1. Place the transmission assembly on the 

disassembling table, and shift the transmission in 

neutral 

41 

NOTE: 

Before disassembling the transmission assembly, drain the 

lubricating oil inside, and disassemble the transmission after 

cleaning the surface. 

2. Dismantle the clutch case assembly 

(a) Pull out the clutch release fork outward slightly, make the 

clutch release fork leave the release bearing locating 

snap spring. 

(b) Push the clutch release fork outward for a certain 

distance, which makes it released from the clutch 

release fork spherical support pillar. 

(c) Remove the clutch release fork and fork dustproof cover; 

remove the separate bearing from input shaft gland. 

14A 

41 

(d) 

Dismantle the fixing bolts connecting the clutch case and 

transmission case. 

Tip: 

When dismantling, evenly loose the fixing bolts along the 

diagonal direction, and avoid omitted dismantlement. 

(e) 

Remove the clutch case assembly. 

Tip: 

If the clutch case tightly connects with the transmission case, 

knock the proper part of clutch case with rubber hammer, so as 

to remove the clutch case. 

Page 2481

41-16 


3. Dismantle the front cover assembly 

(a) Dismantle the fixing bolts on the transmission front cover. 

(b) 

Remove the front cover assembly. 

Tip: 

If the front cover assembly tightly connects with the transmission 

case, knock the proper part of front cover with rubber hammer, 

so as to remove the clutch case. 

4. Dismantle the variable speed control cover assembly 

(a) Dismantle the locating mechanism components of gear 

selecting lever and gear shifting lever, and remove the 

sealing washer. 

Tip: 

The locating mechanism components of gear selecting lever and 

gear shifting lever should be two symmetrical components, 

dismantle the two simultaneously as much as possible to 

facilitate the dismantling of the following components. 

(b) 

Dismantle the fixing bolts of variable speed control cover 

and rear part assembly.。 

Page 2482


41-17 

(c) 

Remove the variable speed control cover assembly. 

41 

5. Dismantle the transmission rear part assembly 

(a) 

Dismantle the locating bolts of shift lever. 

14A 

41 

(b) 

Dismantle the stopper spring plug, remove the stopper 

spring and steel balls of fifth gear fork shaft with the bar 

magnet. 

(c) 

Dismantle the fixing bolts of odometer driven gear 

assembly. 

Page 2483

41-18 


(d) 

Remove the odometer driven gear assembly. 

(e) 

Dismantle the fixing bolts of rear case assembly 

Tip: 


diagonal direction, and avoid deforming the case. 

(f) 

Remove the transmission rear case assembly. 

Tip: 

Firstly, slowly remove a certain distance until the rear case 

assembly released from the locating pin and the shift lever could 

be seen, reverse the rear case assembly, make the shift lever 

leave the groove of shift fork shaft, and then remove the rear 

case assembly.。 

6. Dismantle the transmission front case assembly 

(a) Remove the input shaft and counter shaft front bearing 

stop ringwith calipers. 

Page 2484


41-19 

(b) 

Remove the transmission case assembly towards the 

direction of input shaft end. 

Tip: 

Slightly knock the transmission case with rubber hammer if 

necessary, so as to separate the bearing from the case.。 

41 

7. Dismantle the odometer drive pinion 

(a) Dismantle the outer retainer ring of odometer drive pinion 

with calipers. 

14A 

41 

(b) 

Remove the odometer drive pinion; dismantle the inner 

retainer ring of odometer drive pinion. 

8. Dismantle the control part of the intermediate plate 

assembly 

(a) Dismantle each locating bolt of fork shaft with Allen 

wrench, remove the spring and steel ball with magnet 

one by one. 

Page 2485

41-20 


(b) 

Dismantle each fork, lock and pin assembly, elastic 

cylindrical pin, locating screws of first and second shift 

fork, clamping retainer ring. 

Tip: 

When dismantling the shift fork, lock, pin and elastic cylindrical 

pin, the available punch could be less than Φ5 (such as Φ4. 5), 

the pin should be struck out from the other side of the figure. 

When dismantling the fork shaft retainer ring or elastic cylindrical 

pin assembly, avoid vigorous knocking, which may cause the 

fork shaft bent or damaged. 

(c) Rotate the fifth gear shift shaft and pull out it, and remove 

the fifth gear shift fork, interlocking ball of fifth reverse 

fork shaft. 

(d) 

Pull out fifth reverse lead block fork shaft and remove the 

fifth reverse shift lead block. 

(e) 

Remove the interlock ball inside the intermediate plate 

assembly with the bar magnet, dismantle the reverse 

shift shaft and reverse shift block rocker assembly, and 

after dismantling the reverse shift shaft, remove the 

interlock pin. 

Page 2486


41-21 

(f) 

Remove the interlock pin, dismantle the shift shafts of 

first and second gears, remove the interlock pin inside 

the intermediate plate assembly with the bar magnet. 

41 

(g) 

Pull out the short interlock pin; dismantle the shift shafts 

of third and fourth gears. 

14A 

41 

(h) 

Remove the shift forks of first and second gears, and 

shift forks of third and fourth gears upward. 

9. Dismantle the moving part of intermediate plate 

assembly 

(a) Dismantle the retainer ring of fifth gear synchronous 

bevel on the rear end of fifth counter shaft with calipers. 

Page 2487

41-22 


(b) 

Remove the fifth gear synchronous bevel gear of the 

counter shaft. 

(c) 

Dismantle the fifth gear synchronizer and fifth gear input 

gear assembly of the counter shaft. 

(d) 

Remove the fifth gear needle bearing, fifth gear thrust 

washer and locking ball (Φ6. 35) of the counter shaft. 

(e) 

Dismantle the retainer ring of output shaft fifth gear, and 

remove the fifth gear. Dismantle the fixing bolts of output 

shaft rear bearing backing plate with Allen wrench and 

remove the output shaft rear bearing backing plate. 

Page 2488


41-23 

(f) 

Dismantle the fixing bolts of the reverse gear rocker arm 

bracket group. 

41 

(g) 

Remove the reverse gear rocker arm bracket group. 

14A 

41 

(h) 

Dismantle the fixing bolts of reverse gear idler shaft 

pressing plate with wrench and remove the reverse gear 

idler shaft pressing plate. 

(i) 

Pull out the reverse gear idler assembly and the reverse 

gear idler shaft. 

Page 2489

41-24 


(j) 

Dismantle the rear bearing stop rings of the output shaft 

and counter shaft with calipers. 

(k) 

Dismantle the rear bearing of counter shaft with bearing 

puller. 

(l) Dismantle the counter shaft assembly from the 

intermediate plate assembly. 

(m) 

Pull out the input shaft assembly (the roller pin inside the 

shaft should not missed), and the gear ring of third and 

fourth gears synchronizer. 

Page 2490


41-25 

(n) 

Pull out the output shaft assembly, finish part of the 

assembly disassembly. 

41 

10. Install the moving part of the intermediate plate 

assembly 

(a) 

Vertically fix the intermediate plate assembly on the 

working table, hold one end of the output shaft assembly, 

knock the intermediate plate assembly with rubber 

hammer at the same time, and install the output shaft 

assembly into intermediate plate assembly. 

14A 

41 

(b) 

Install the output shaft rear bearing stop ringwith snap 

ring plier. 

Tip: 

The stop ringshould be stuck with the intermediate plate 

assembly, and avoid the excessive axial clearance of output 

shaft. 

(c) 

Press mount the input shaft bearing onto the input shaft; 

install the input shaft retainer ring with snap ring plier. 

Page 2491

41-26 


(d) 

Coat the lithium base grease in the input shaft needle 

bearing hole, install the needle into the input shaft needle 

bearing hole, install the third and fourth gear 

synchronizer gear ring onto the input shaft. 

Tip: 

The input shaft has totally 13 needle bearings, avoid any 

omission. 

(e) 

Install input shaft onto the output shaft, and install the 

three grooves of synchronizer ring corresponding with 

the three slide blocks on the synchronizer. 

Tip: 

Rotate the input shaft for several circles after installation, and 

check whether it smooth and with proper clearance, if any 

abnormal, pull out the input shaft and check whether the needle 

bearings are working well. 

(f) 

Install the counter shaft into the intermediate plate 

assembly and hold the counter shaft, install the counter 

shaft rear bearing. 

Tip: 

The bearing ring groove should be installed outward and avoid 

reversely installing. 

(g) 

Install the count shaft rear bearing stop ringwith snap 

ring plier. 

Tip: 

The stop ringshould be stuck with the intermediate plate 

assembly, and avoid the excessive clearance damaging other 

parts. 

Page 2492


41-27 

(h) 

Install the reverse gear idler assembly and the reverse 


41 

(i) 

Rotate the idler shaft and make the pressing plate 

corresponding with the idler shaft groove, and make the 

pressing plate holes corresponding with the fixing bolt 

holes of intermediate plate assembly, install the 

connecting bolts of screw locking glue smeared idler 

shaft locking tab and fasten to specified torque. 


14A 

41 

(j) 

Install the two hollow locating pins to the intermediate 

plate assembly, and install the upper rocker arm bracket. 

(k) 

Smear appropriate screw locking glue on the fixing bolts 

of rocker arm bracket assembly, install the intermediate 

plate assembly from the other side and fasten. 


Page 2493

41-28 


(l) 

(m) 

Smear the screw locking glue on the connecting bolts of 

output shaft rear bearing, install the rear bearing 

pressing plate with torque socket wrench and fasten the 

screws. 

Torque: 17~22 N· 

Install fifth gear shaft retainer ring and output shaft fifth 

gear. 

(n) 

Install the locking ball and fifth gear thrust washer. 

(o) 

After smearing the gear oil on counter shaft fifth gear 

needle bearing, install in onto counter shaft. 

(p) 

Install counter shaft fifth gear input gear and fifth gear 

synchronizer assembly. 

Tip: 

Because the input gear needle bearing of counter shaft fifth gear 

is semicircle bearing, avoid falling and omission when installing 

the gear. 

Page 2494


41-29 

(q) 

Cover the conical surface of fifth gear coupling gear with 

synchronizer gear ring, install the fifth gear coupling gear, 

align the synchronizer ring groove with the synchronizer 

slide block and install. 

41 

(r) 

Select a fifth gear synchronizer retainer ring which may 

minimizes the axial clearance, install the fifth gear 

synchronizer retainer ring with calipers. 

14A 

41 

(s) 

Measure the axial clearance of counter shaft fifth gear 

with feeler. 

Standard clearance: 0. 1~0. 3 mm 

Maximum clearance: 0. 3 mm 

11. Install the control part of the intermediate plate 

assembly 

(a) Install the shift fork of first and second gears, and third 

and fourth gears. 

(b) Install the intermediate plate assembly and shift fork into 

the shift shaft of third and fourth gears. 

Page 2495

41-30 


(c) 

Knock the elastic cylindrical pin assembly into the third 

and fourth gear shift fork with punch and hammer (the 

opening direction of elastic cylindrical pin should be 

towards the fork shaft axis). 

Tip: 

Avoid vigorous knocking when installing the fork shaft retainer 

ring or elastic cylindrical pin assembly, so as to prevent fork 

shaft bent or damaged, and the fork shaft retainer ring or elastic 

cylindrical pin assembly could also be installed in place by pliers. 

(d) 

Smear the interlock pin with grease, and install it on the 

first and second gear shift shaft. 

(e) 

Install the short interlock pin into the intermediate plate 

with the bar magnet, install the first and second gear shift 

shaft into first and second gear shift fork and 

intermediate plate assembly. 

(f) 

Install the fixing bolts of first and second gear shift, fasten 

the bolts. 


Tip: 

Smear the screw locking glue on the fixing bolts. 

Page 2496


41-31 

(g) 

(h) 

(i) 

Install the reverse block, reverse lever and two E-rings 

on the reverse gear rocker arm, the reverse arm open 

end should be installed on the reverse gear rocker arm 

bracket. 

Smear the grease on the interlock pin, and install it on 

reverse shift shaft. 

Install the interlock pin into intermediate plate assembly 

with the bar magnet, and install the reverse shift shaft 

into reverse lever and intermediate plate assembly. 

41 

(j) 

Knock the elastic cylindrical pin assembly into the 

reverse shift fork with punch and hammer (the opening 

direction of elastic cylindrical pin should be towards the 

fork shaft axis). 

Tip: 




cylindrical pin assembly could also be installed in place by 

pliers.。 

14A 

41 

(k) 

Install the lock ball into the fifth reverse gear lead block 

with the bar magnet, and install the fifth gear shift shaft. 

(l) 

Install the interlock ball into the intermediate plate 

assembly with the bar magnet, install the fifth gear shift 

shaft into the intermediate plate assembly. 

Page 2497

41-32 


(m) 

Install fifth gear shift fork. 

(n) 

Knock the elastic cylindrical pin assembly into the fifth 

gear shift fork one by one with punch and hammer (the 

opening direction of elastic cylindrical pin should be 

towards the fork shaft axis). 

Tip: 





(o) 

Install the fifth reverse shift shaft into the fifth reverse 

shift block and intermediate plate assembly. 

(p) 

Knock the elastic cylindrical pin assembly into the fifth 

reverse shift block with punch and hammer (the opening 

direction of elastic cylindrical pin should be towards the 

fork shaft axis). 

Tip: 





Page 2498


41-33 

(q) 

Knock the shift shaft retainer ring with steel bar or 

hammer. 

41 

(r) Install the gear locating ball and spring (4 balls and 4 

springs) into the intermediate plate assembly. 

Tip: 

Install the short spring (fifth gear) into the bottom of intermediate 

plate assembly, smear the screw locking glue on each hexagon 

socket head bolts, fasten the plug to specified torque with Allen 

wrench. 


14A 

41 

12. Install the odometer drive pinion 

(a) Install the retainer ring in odometer drive pinion in place 

with calipers, put in the locking ball of odometer drive 

pinion, and install the odometer drive pinion.。 

(b) 

Install the retainer ring in odometer drive pinion in place 


Page 2499

41-34 


13. Install transmission case 

(a) Evenly smear the antioxidant sealant on the contacting 

surface of transmission front case and intermediate plate 

assembly. 

(b) 

Install the transmission case on the intermediate plate 

assembly, and ensure the shift fork shaft aligning with the 

object lead hole. Knock the hard part of the front case 

with rubber hammer if necessary, which could make it 

install in place. 

(c) 

Install 2 stop rings on the input shaft bearing and counter 

shaft front bearing with snap ring plier. 

14. Install the case assembly, shift shaft and shift block 

(a) Install the components inside the rear case before the 

assembly, such as limiting mechanism, oil guiding 

groove, and evenly smear antioxidant sealant on the 

contacting surface of rear case and intermediate plate 

assembly. 

Tip: 

When installing the rear case, align the select and shift lever with 

select and shift lever shaft with hands and install in place, do not 

fasten the fixing bolts of select and shift gear right now. Insert 

the select and shift lever arm into the third and fourth gear fork 

shaft groove, align the fifth reverse shift shaft with the rear case 

installation hole, and push the rear case. 

Page 2500


41-35 

(b) 

Install and fasten the fixing bolts on rear case. 


41 

(c) 

Vertically install the driven gear assembly of odometer. 

14A 

41 

(d) 

nstall the fixing bolt of odometer driven gear assembly 

and fasten to specified torque. 


(e) 

Install the fifth reverse guide block locating ball, self 

locking spring and smear appropriate screw locking glue 

on the threads of the hexagon socket head bolts and 

fasten. 


Page 2501

41-36 


(f) 

Smear appropriate screw locking glue on the threads of 

shift block locating bolt, install and fasten the shift block 

fixing bolt. 


15. After assembling the transmission front and rear housing, the followings should be checked. 

(a) Check whether the input shaft and output shaft could rotate flexibly. 

(b) Check whether each gear is clear and reliable, and whether there is reverse lock function. 

16. Install the left locating mechanism components. 

(a) Install the seal washer on the locating mechanism 

components. 

NOTE: 

Distinguish the left one and right one when installing, the left 

locating mechanism components have smaller elastic force 

(look the input shaft from the transmission output shaft). 

(b) Fasten the locating mechanism components. 

Torque: 30~50 N· 

17. Install the transmission control lever cover 

(a) Smear appropriate antioxidant sealant on the contacting 

surface of transmission control lever cover and rear 

case. 

(b) 

Install the fixing bolts of transmission control lever cover 

and fasten to specified torque. 


Page 2502


41-37 

18. Install the transmission front bearing cover 

assembly 

(a) 

(b) 

(c) 

Install the oil seal into the front bearing cover. 

Evenly smear the antioxidant sealant on the contacting 

surface of transmission front bearing cover and front 

case, and install the front bearing cover. 

Smear appropriate sealant on the threads of hexagon 

head bolt. 

41 

(d) 

Install the bolts and fasten to specified torque. 


14A 

41 

19. Install the clutch cover 

(a) Align and install the clutch case location hole to the 


(b) 

Install the fixing bolt of clutch case and fasten to 



Tip: 

When fastening the bolts, diagonally fasten the bolts in several 

times as much as possible, and avoid the case deformation or 

case damage caused by unevenly forced bolts. 

(c) Install the studof clutch release fork and fasten to 



Page 2503

41-38 


(d) 

Install the clutch release fork, fork housing and release 

bearing. 

20. Install the reverse switch, filling plug, drain plug 


21. Finish the disassembly and assembly of transmission assembly 

Page 2504

CLUTCH CASE 


TRANSMISSION - CLUTCH CASE 

41-39 

41 

14A 

41 

1 Clutch release fork housing 

2 Clutch release fork assembly 

4 Clutch release fork stud 

5 Release bearing subassembly 

3 Clutch case 

Page 2505

41-40 

SERVICE 


1. Dismantle the clutch case assembly 

(a) Unlock the spring fastener connecting the clutch release 

bearing and the clutch release fork. 

(b) Push the clutch release fork outward for a certain 

distance, which makes it released from the clutch 

release fork support pillar. 

(c) Remove the clutch release bearing; remove the clutch 

release fork from the clutch case. This could avoid 

dismantling the dust cover of clutch release fork. 

(d) 

Dismantle the coupling bolts connecting the clutch case 

and the transmission case. 

Tip: 


diagonal direction, and avoid deforming the case. 

(e) 

Remove the clutch case assembly. 

Tip: 

If the clutch case is tightly connected with the transmission case, 

the rubber hammer could be used for knocking the clutch case, 

so as to remove the clutch case. 

(f) 

Dismantle the clutch release fork support pillar. 

Page 2506


41-41 

(g) 

Dismantle the clutch release fork housing 

Tip: 

The clutch housing is soft gelatinous material, avoid using sharp 

knives when dismantling 

41 

2. Install the clutch case assembly 

(a) Install the clutch release fork housing. 

14A 

41 

(b) 

Install the clutch release fork stud and fasten to specified 

torque. 


(c) 

Align and install the location hole of clutch case to 


Page 2507

41-42 


(d) 

Install the clutch case fixing bolt and fasten to specified 

torque. 


Tip: 

When installing, fasten the bolts evenly along the diagonal 

direction for several times, and avoid housing deformation 

during fastening. 

(e) 

Install the clutch release fork, fork housing and release 

bearing. 

3. Finish the service of clutch case 

Page 2508

REAR PART ASSEMBLY 


TRANSMISSION - REAR PART ASSEMBLY 

41-43 

41 

14A 

41 

1 Ball head washer 

2 Control lever cover assembly 

3 Locating pin 

4 Breather plug 


6 Locating mechanism components 

7 Odometer driven gear assembly 

8 Steel ball 

9 Self-locking spring 

10 Plug 

12 Oil guiding groove 

13 Shift block 

14 Locating bolt of shift block 

15 Stopper pin 

16 Shift shaft 


18 Shift lever 

19 Stopper block 


21 Stopper shaft 

11 Oil storage box 

Page 2509

41-44 

SERVICE 


1. Dismantle the transmission rear part assembly. 

(a) Pull out the gear selecting shaft and gear shifting shaft, 

and remove the gear shifting block assembly. 

(b) 

Dismantle the fixing bolt of oil guiding groove. 

(c) 

Remove the oil guiding groove. 

(d) 

Dismantle the fixing bolts of oil storage box and remove 

the oil storage box. 

Page 2510


41-45 

(e) 

Dismantle the plug cover bolts of elastic cylindrical pin 

with Allen wrench, and dismantle the elastic cylindrical 

pin with proper drift pin. 

41 

(f) 

Pull out the reverse limit assembly. 

14A 

41 

(g) 

Strike out the shift fork, lock and pin assembly with 

hammer and drift pin, dismantle the shift shaft and shift 

lever. 

(h) 

Strike out the reverse limit pin with hammer and drift pin, 

and dismantle the stopper block, stopper spring and 

stopper shaft. 

Page 2511

41-46 


(i) 

Check the wearing value of shift block; replace it if the 

requirements are not satisfied. 

(j) 

Check the wearing of shift lever head; replace it if the 

requirements are not satisfied. 

2. Assemble the transmission rear part assembly 

(a) Assemble the stopper block, stopper spring and stopper 

shaft, install the stopper pin in place with copper bar. 

(b) Install the reverse limit assembly in place. 

(c) 

Install the plug cover bolts of elastic cylindrical pin in 

place with Allen wrench. 

Page 2512


41-47 

(d) 

Smear appropriate screw locking glue on the fixing bolts 

of oil storage box, install the oil storage box and fasten 

the fixing bolts to specified torque. 


41 

(e) 

Smear appropriate screw locking glue oil on the bolts of 

guiding groove, install the oil guiding groove, and fasten 

the fixing bolt to specified torque. 


14A 

41 

3. After assembling the rear case or transmission case, the followings should be checked 

(a) Check whether the rotations of input shaft and output shaft are flexible. 

(b) Check whether each gear is clear and reliable, and whether there is reverse lock function. 

4. Finish the service of transmission rear part assembly 

Page 2513

41-48 

FORK SHAFT ASSEMBLY 


TRANSMISSION - FORK SHAFT ASSEMBLY 

1 Elastic cylindrical pin 

2 Fifth gear shift fork 


4 Fifth reverse gear shift guide block 

5 Clamping ring 

6 Short interlock pin 

7 First and second gear shift shaft 

8 Interlock guide pillar 

9 Fifth reverse shift shaft 

10 Third and fourth gear shift shaft 

11 Interlock pin 

12 Reverse gear shift fork shaft 

13 Steel ball 

14 Fifth gear shift fork shaft 

15 Stopper spring screw plug 


17 Intermediate plate 

18 First and second gear shift fork 

19 Third and fourth gear shift fork 

20 Reverse gear shift lever 

21 

Locating screw of first and second gear 

shift fork 

22 Reverse gear shift block 

23 

Reverse gear rocker arm bracket 

assembly 

24 Reverse gear rocker arm 

25 Split washer 

Page 2514


41-49 

SERVICE 

Tip: 

During the motion, the car jump to neutral, different to engage a gear, out of gear etc. it may be caused by: 

• The fork axis circular groove excessively worn, the interlock pin excessively worn, the spring generated 

elastic deformation. 

• The fork working surface is excessively worn. 

Due to these reasons, the following checks should be performed to the components of fork shaft assembly. 

1. Check the free length of the self locking spring 

Standard value: 31. 6 mm 

Limitation value: 30. 1 mm 

41 

14A 

2. Check the wearing of locking ball. 

41 

3. Check the fork head thickness of fork 

Standard value: 10. 00 mm 

Limitation value: 9. 00 mm 

4. Check the wearing of the connection between 

moving shaft and intermediate plate assembly 

Page 2515

41-50 


5. Replace the damaged parts in time after checking. 

6. Finish the service of fork shaft assembly 

Page 2516

INPUT SHAFT ASSEMBLY 


TRANSMISSION - INPUT SHAFT ASSEMBLY 

41-51 

41 

14A 

41 

1 Bearing shaft retainer ring 

2 Bearing stop ring 

4 Input shaft assembly 

5 Needle bearing 

3 Bearing 

Page 2517

41-52 

SERVICE 


1. Dissemble the input shaft assembly 

(a) Remove the needle bearings inside the input shaft one 

by one, and place them in the proper places to avoid 

missing. 

(b) 

Disassemble the snap ring inside the input shaft bearing 


(c) 

Pull out the input shaft bearing with bearing extractor. 

2. Check the radial runout of input shaft bearing 

Reference value of limitation: 0. 2 mm 

Page 2518


41-53 

3. Check the input shaft 

(a) Check whether the shaft diameter of input shaft end worn 

with vernier caliper; please replace the input shaft if 

worn. 

(b) Check whether the input shaft spline damaged; please 

replace the input shaft if damaged. 

41 

4. Assemble the input shaft assembly 

(a) Punch the input shaft bearing onto the input shaft, install 

the input shaft retainer ring with snap ring plier. 

14A 

41 

(b) 

Smear appropriate lithium base grease in the input shaft 

needle bearing, install the needle into the input shaft, and 

then install the third and fourth gear synchronizer gear 

ring. 

(c) Install the input shaft into output shaft, align the 

synchronizer ring trislot with the synchronizer block 

andinstall. 

5. Ensure the flexible rotation after installation. 

6. Finish the service of input shaft assembly 

Page 2519

41-54 

OUTPUT SHAFT ASSEMBLY 


TRANSMISSION - OUTPUT SHAFT ASSEMBLY 

1 Fifth gear shaft retainer ring 

2 Fifth gear 

3 Output shaft rear bearing baffle plate 

4 Output shaft rear bearing stop ring 

5 Output shaft rear bearing 


7 Steel ball 

8 Output shaft 

9 First gear 

10 First gear bushing 

11 First gear needle bearing 

12 First-second gear synchronizer ring 

13 

14 

First-second gear synchronizer spring 

spreader ring 

First-second gear synchronizer gear 

hub 

15 

16 

First-second gear synchronizer slide 

block 

First-second gear synchronizer gear 

sleeve 

17 Second gear needle bearing 

18 Second gear assembly 

19 Third gear needle bearing 

20 Third gear assembly 

21 

22 

23 

24 

25 

Third-fourth gear synchronizer gear 

ring 

Third-fourth-fifth gear synchronizer 

spring spreader ring 


hub 

Third-fourth gear synchronizer slide 

block 


sleeve 

26 Third-fourth gear hub retainer ring 

Page 2520


41-55 

SERVICE 

1. Take out output shaft assembly from connecting 

plate 

Tip: 

Take out the shaft and avoid damage of gears. 

41 

2. Disassembling output shaft assembly 

(a) Fix the output shaft on the connecting plate. 

(b) Disassemble the third-fourth gear hub retainer ring with 

circlip pliers. 

14A 

41 

(c) 

Take out third-fourth gear synchronizer. 

(d) 

Take out third gear assembly. 

Page 2521

41-56 


(e) 

Take out third gear needle bearing. 

(f) 

(g) 

Fix the output shaft upside down on the connecting plate. 

Take out first speed gear. 

(h) 

Take out first speed gear needle bearing and first speed 

gear bushing. 

(i) 

Take out first-second gear synchronizer assembly. 

Page 2522


41-57 

(j) 

Take out second gear and second gear needle bearing. 

41 

3. Check on critical components on output shaft 

Tip: 

According to Table of Fault Phenomena and analysis of possible damaged part, it needs to service certain part 

as below: 

(a) 

Use dial indicator to check radial runout of second shaft. 

Maximum: 0.1mm 

14A 

41 

(b) 

Note: 

Check the diameter of gear hole by bore dial indicator. 

Reference wear maximum: 0.12mm 

Other gears need to be checked with same way. 

Page 2523

41-58 


(c) 

Check the gears and replace new one if there’s 

excessive wear or snaggletooth. 

(d) 

Use thickness gauge to check the space between 

synchronizer hub and synchronizer stopping plate. 

Reference Maximum: 0.09~0.31 mm 

(e) 

Check the space between synchronizer geared teeth and 

engaging teeth. 

Standard value: 1. 0~1. 6 mm 

Limit value: 0. 8 mm 

(f) 

Check the radial runout of output shaft rear bearing. 

Reference Maximum: 0. 2mm 

Page 2524


41-59 

4. Assemble the output shaft assembly 

Note: 

When assembling, it’s necessary to dip lubrication oil on each 

part in order to protect and assemble the parts easily. 

(a) Fix the output shaft upside on the connecting plate and 

assemble second gear assembly and second gear 

needle bearing 

41 

(b) 

Note: 

Assemble first-second gear synchronizer according to 

pictures. 

The direction of first-second gear synchronizer is opposite to the 

direction of output shaft. The side with fork groove should toward 

to connecting plate. Two spring spreader ring should be 

staggered to each other. 

14A 

41 

(c) 

Fix first-second gear synchronizer assembly and firstsecond 

gear synchronizer geared ring. 

(d) 

Dip lubrication oil on first speed gear bearing bush and 

locking ball (Φ6.35) and assemble them on output shaft, 

then assemble first speed needle bearing. 

Page 2525

41-60 


(e) 

Install first speed gear. 

(f) 

Assemble third gear needle bearing. 

(g) 

Assemble third gear assembly. 

(h) 

Note: 

Assemble third-fourth gear synchronizer and third-fourth 


The side with 45° terrace of third -fourth gear synchronizer gear 

hub should toward to input shaft. The side with big chamfer of 

third -fourth gear synchronizer sleeve should toward to input 

shaft. Two spring spreader rings should be staggered to each 

other. 

Page 2526


41-61 

(i) 

Assemble third-fourth gear synchronizer and third-fourth 


41 

(j) 

Fix third -fourth gear hub retainer ring with pliers. 

14A 

41 

(k) 

Check axial clearance of each gears to see if it’s within 

standard. 

Axial clearance: 0. 1~0. 25 mm 

5. Check the flexibility of input shaft and output shaft 

6. Accomplish the process of servicing on output shaft 

Page 2527

41-62 

TRANSMISSION - COUNTER SHAFT ASSEMBLY 

COUNTER SHAFT ASSEMBLY 


1 

Fifth gear synchronizer gear hub 

retainer ring 

2 Fifth gear connection gear 

3 

4 

5 

Third, fourth and fifth gear synchronizer 

gear ring 

Fifth gear synchronizer meshing gear 

sleeve 

Third, fourth and fifth gear synchronizer 

spring spreader ring 

6 Counter shaft fifth gear assembly 

7 Fifth gear synchronizer slide block 

8 Middle fifth gear needle bearing 

10 Counter shaft rear shaft retainer ring 

11 Counter shaft rear bearing 


13 Steel ball 

14 Counter shaft 

15 Counter shaft connecting gear 

16 Counter shaft front bearing 

17 Counter shaft front bearing stop ring 

18 

Counter shaft front bearing shaft 

retainer ring 

9 Fifth gear thrust washer 

Page 2528


41-63 

SERVICE 

1. Dismantle the counter shaft assembly 

(a) 

Dismantle the counter shaft front bearing snap ring with 

calipers. 

41 

(b) 

Press out the counter shaft front bearing with pressure 

bracket. 

Tip: 

Bearing extractor could be used for dismantling the bearing. 

14A 

41 

(c) 

Check the counter shaft front bearing radial runout. 

Reference value of limitation: 0. 2 mm 

Page 2529

41-64 


(d) Press out the counter shaft connecting gear with 

pressure bracket. 

2. Check on critical components on counter shaft 

Tip: 

According to Table of Fault Phenomena and analysis of possible damaged part, it needs to service certain part 

as below: 

(a) 

Use dial indicator to check radial runout of counter shaft. 

Maximum: 0. 1mm 

(b) 

Note: 

Check the diameter of gear hole by bore dial indicator. 

Reference wear maximum: 0. 12mm 

Other gears need to be checked with same way 

Page 2530


41-65 

(c) 

Check the gears and replace new one if there’s 

excessive wear or snaggletooth 

41 

(d) 

Use thickness gauge to check the space between 

synchronizer hub and synchronizer stopping plate. 

Reference Maximum: 0. 09~0. 31 mm 

14A 

41 

(e) 

Check the space between synchronizer geared teeth and 

engaging teeth. 

Standard value: 1. 0~1. 6 mm 

Limit value: 0. 8 mm 

3. Assemble the counter shaft assembly 

(a) Press the counter shaft connecting gear in place with 


Page 2531

41-66 


(b) 

Press the counter shaft front bearing in place with 


(c) 

Install the counter shaft front bearing snap ring in place 


4. Check whether the counter shaft operate flexibly after installation. 

5. Finish the service for counter shaft assembly 

Page 2532

REVERSE SHAFT ASSEMBLY 


TRANSMISSION - REVERSE SHAFT ASSEMBLY 

41-67 

41 

14A 

41 

1 Reverse gear idler shaft pressing plate 

2 Reverse gear idler shaft 

3 Reverse idler assembly 


Page 2533

41-68 

SERVICE 


1. Dismantle the reverse shaft assembly 

(a) Dismantle the fixing bolts of reverse gear idler shaft 

pressing plate and remove the pressing plate of reverse 


(b) 

Rotate and pull out the reverse gear idler assembly and 

the reverse gear idler shaft. 

2. Check the parts of reverse shaft 

Tip: 

According to Table of Fault Phenomena and analysis of possible damaged part, it need to service certain part 

as below: 

(a) 

Use vernier caliper to check whether the gear bushing 

bore worn, replace the gear bushing if any worn. 

(b) 

Check whether there is gear tooth worn, fatigue and 

spalling, corrosion and spots, broken and etc. , please 

replace the reverse gear if any. 

Page 2534


41-69 

(c) 

Check whether the reverse shaft parts worn, replace it if 

seriously worn. 

41 

3. Install the reverse gear idler shaft 

(a) Install the reverse gear idler shaft assembly and the 

reverse gear idler shaft. 

14A 

41 

(b) Rotate the idler shaft to make the pressing plate 

corresponding with the idler shaft groove, and make the 

pressing plate holes align with the intermediate plate 

assembly fixing bolt hole. Install the idler shaft locking 

plate smeared screw locking glue and fasten to specified 

torque. 


4. Finish the service for reverse shaft 

Page 2535

41-70 


SERVICE FOR OTHER IMPORTANT COMPONENTS OF TRANSMIS- 

SION 

Tip: 

According to Table of Fault Phenomena and analysis of possible damaged part, it’s needed to service certain 

part as below: 

1. Service for the front case 

(a) Check the flatness of front case and intermediate plate 

assembly contacting surface with steel ruler or feeler, 

replace timely if could not meet the requirements, so as 

to prevent transmission oil leakage. 

Tip: 

When checking, please check with the steel ruler or feeler at 

different directions and measure for several times, in order to 

obtain an accurate value. 

2. Service for the front cover 

(a) Check the flatness of front cover and front case 

contacting surface with steel ruler or feeler, replace 

timely if could not meet the requirements, so as to 

prevent transmission oil leakage. 

Tip: 




(b) 

Check the wearing extent of the front cover core 

diameter with the vernier caliper, repair or replace timely 

if could not meet the requirements. 

Page 2536


41-71 

3. Service for the rear case 

(a) Check the flatness of rear case and transmission control 

lever cover with steel ruler or feeler, replace timely if 

could not meet the requirements, so as to prevent 

transmission oil leakage. 

41 

Tip: 




(b) Check the flatness of check rear case and 

intermediateplate assembly with steel ruler or feeler, 

replace timely if could not meet the requirements, so as 

to prevent transmission oil leakage. 

14A 

41 

Tip: 




4. Service for the intermediate plate assembly 

(a) Check the flatness of intermediate plate assembly with 

steel ruler or feeler, replace timely if could not meet the 

requirements, so as to prevent transmission oil leakage. 

Tip: 




Page 2537

41-72 


(b) 

Check the wearing extent of the connecting holes on 

intermediate plate assembly shafts with the vernier 

caliper, repair or replace timely if could not meet the 

requirements. 

5. Service for the variable speed control cover 

(a) Check the wearing extent of the core diameter of variable 

speed control cover with the vernier caliper, repair or 

replace timely if could not meet the requirements. 

6. Service for the clutch case 

(a) Check the flatness of clutch case and front case 

contacting surface with steel ruler or feeler, replace 

timely if could not meet the requirements, so as to 

prevent transmission oil leakage. 

Tip: 




Page 2538

TRANSMISSION - TRANSMISSION ASSY(TANGSHANAIXIN) 

41-73 

TRANSMISSION ASSY(TANGSHANAIXIN) 

REPLACEMENT 

1. STOP THE ENGINE. PARK VEHICLE ON LEVELGROUND WITH PARKING BRAKE AND SHIFT IN 

NEUTRAL POSITION. 



41 

4. REMOVE LOWER DRAIN PLUG RH AND DRAIN 

TRANSMISSION FLUID COMPLETELY. TIGHTEN 

DRAIN PLUG. 

Torque: 29.8 ~ 44.6 N•m 

NOTE 





draining. 

5. DISCONNECT TRANSMISSION ASSY FROM OTHER 

PARTS,THEN REMOVE TRANSMISSION ASSY. 

(a) Remove vehicle speed sensor located at the right of 

transmission. 

14A 

41 

WARNING 


(b) Remove the back-up lamp switch located at the upper of 

transmission RH. 

WARNING 


(c) 

Remove nuts,disconnect flexible shaft of gear shifting 

cable and flexible shaft of gear selecting cable from 

transmission assy. 

WARNING 


(d) Remove 2 mounting bolts of cable bracket and cable 

bracket located at transmission case. 

WARNING 


(e) 

(f) 

Remove the clutch slave cylinder assy. (Refer to 

“Chapter 42 clutch - clutch slave cylinder assy, 


Remove starter.(Refer to “Chapter 20B starting and 


Page 2539

41-74 


(g) 

(h) 

Remove propeller shaft assy. (Refer to “Chapter 34 axle 


Remove 4 nuts and disconnect the transmission from 

lifting lug. 

WARNING 

• Use jack to support transmission assy and engine 

before operation. 

• Be careful not to be scalded by exhaust pipe. 

(i) 

Remove 10 bolts and disconnect transmission assy from 

engine. Remove the transmission assy. 

NOTE 

2 bolts that is used for retaining starter include in these 10 

removed bolts. 

6. INSTALL TRANSMISSION ASSY, AND CONNECT 

OTHER PARTS TO TRANSMISSION ASSY. 

(a) 

Support the transmission assy by jack and shift in one of 

forward gears. Rotate the input shaft and align with the 

spline of clutch disk at the same time. Then insert the 

input shaft completely and shift in neutral position. 

WARNING 



(b) Install 10 bolts with hand to connect transmission and 

engine. 

NOTE 

Two bolts that are used for retaining starter are not installed 

temporarily. 

Page 2540


41-75 

(c) 

Support the transmission assy by jack and connect the 

transmission assy to lifting lug. Install 4 bolts with hand. 

WARNING 



(d) Tighten 4 nuts of lifting lug. 


41 

(e) 

Tighten bolts to connect transmission assy to engine. 

Model 

M6 X 1.25 

M10 X 1.25 

Torque 

78 ~ 96 N•m 

45 ~ 55 N•m 

NOTE 

Diagonally tighten all bolts in order to install closely. 

(f) Install propeller shaft assy. (Refer to “Chapter 34 axle 


(g) Install starter. (Refer to “Chapter 20B starting and 


(h) Remove jack. 

(i) Install the clutch slave cylinder assy. (Refer to “Chapter 

42 clutch - clutch slave cylinder assy, replacement”) 

14A 

41 

(j) 

(k) 

Position cable bracket located at transmission case and 


Position flexible shaft of gear shifting cable and flexible 

shaft of gear selecting cable,then tighten mounting nuts. 


Page 2541

41-76 


(l) 

(m) 

Install the back-up lamp switch located at the upper of 

transmission RH. 

Remove vehicle speed sensor located at the right of 

transmission. 

7. FILL TRANSMISSION FLUID AND TIGNTEN FILLER 

PLUG. 

Torque: 29.8 ~ 44.6 N•m 

CAUTION 


75W/90 for 2.4 L. 


• Parking the vehicle on the levelground when checking 

fluid level. The fluid level must be with in 5 mm from 

the lowest position of the filler plug. 



10. TRANSMISSION RUNNING - IN TEST. 

(a) Keep the rotate speed around 1500 r/min; keep the fluid temperature upper 15 centidegree; without 

load; keep transmission run more than 15 min in neutral position; keep transmission run more than 20 

min in other positions. 

(b) Inspect the transmission for smooth shifting. 

(c) Check there is no fricative and clash during running-in test. 

(d) Check there is no leakage around trasmission. 

(e) Drain out transmission fluid and clean inside of transmission after running-in test. Fill transmission fluid. 

Page 2542

CLUTCH 

CLUTCH SYSTEM ............................................................................. 42-1 

PRECAUTION.............................................................................. 42-1 


CLUTCH FLUID.................................................................................. 42-3 

BLEEDING................................................................................... 42-3 

CLUTCH PEDAL................................................................................ 42-4 

COMPONENTS ........................................................................... 42-4 

ADJUSTMENT............................................................................. 42-5 

REPLACEMENT .......................................................................... 42-6 

VACUUM BOOSTER WITH CLUTCH MASTER 

CYLINDER ASSY............................................................................... 42-8 

REPLACEMENT .......................................................................... 42-8 

CLUTCH SLAVE CYLINDER........................................................... 42-11 

REPLACEMENT ........................................................................ 42-11 

CLUTCH SUB - ASSY...................................................................... 42-13 

COMPONENTS ......................................................................... 42-13 

OVERHAUL ............................................................................... 42-14 

42 

42 

42 

42 

42 

42 

Page 2543

Page 2544

CLUTCH - CLUTCH SYSTEM 

42-1 

CLUTCH SYSTEM 

PRECAUTION 

1. CLUTCH SYSTEM PRECAUTION. 

(a) To avoid spreading clutch dust, do not clean any clutch components with sand paper, dry brush or 

compressed air. Only use a water dampened towel to clean clutch components. 

42 

13A 

42 

Page 2545

42-2 

CLUTCH - CLUTCH SYSTEM 





1. Clutch pedal free play(Out of 

adjustment) 

Chapter 42 clutch - clutch pedal, adjustment 

2. clutch driven disk (Worn) Chapter 42 clutch - clutch subassy, overhaul 

Clutch slips 

3. Flywheel ( Warped) Chapter 42 clutch - clutch subassy, overhaul 

4. Clutch pressure plate with 

cover assy (Warped) 

Chapter 42 clutch - clutch subassy, overhaul 

5. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul 

1. Clutch pedal free play (Out of 

adjustment) 

Chapter 42 clutch - clutch pedal, adjustment 

2. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul 

3. Clutch master cylinder 

(Leaking) 

Chapter 42 clutch - vacuum booster with 

clutch master cylinder assy, replacement 

Clutch does not disengage 

4. Clutch slave cylinder (Leaking) 

Chapter 42 clutch - clutch slave cylinder assy, 

replacement 

5. Clutch line (Air in line) Chapter 42 clutch - clutch fluid, bleeding 

6. clutch driven disk (Worn) Chapter 42 clutch - clutch subassy, overhaul 


cover assy (Warped) 


8. Clutch release bearing (Worn) Chapter 42 clutch - clutch subassy, overhaul 

9. Clutch release fork (Worn) Chapter 42 clutch - clutch subassy, overhaul 

1. Torsion spring (Fracture) Chapter 42 clutch - clutch subassy, overhaul 

Clutch noisy 

2. Clutch driven disk(Worn) Chapter 42 clutch - clutch subassy, overhaul 

3. Clutch release bearing (Loose) Chapter 42 clutch - clutch subassy, overhaul 

4. Clutch pedal (Warped) Chapter 42 clutch - clutch pedal, replaecment 

1. Clutch driven disk (Worn or 

warped) 


2. Flywheel (Worn) Chapter 42 clutch - clutch subassy, overhaul 

Clutch chatters 


cover assy(Worn) 

4. Torsion spring (Fracture or 

warped) 



5. Diaphragm spring (Warped) Chapter 42 clutch - clutch subassy, overhaul 

6. Engine mount (Loose) - 

Page 2546

CLUTCH - CLUTCH FLUID 

42-3 

CLUTCH FLUID 

BLEEDING 

1. FILL THE FLUID RESERVOIR WITH CLUTCH FLUID. 

Clutch fluid: DOT3 or DOT4 brake fluid 

WARNING 

Clutch fluid will damage painted surfaces and irritate skin. If 

clutch fluid is spilled on any painted surfaces or skin, wash 


42 

2. BLEED CLUTCH SLAVE CYLINDER ASSY. 

(a) Connect a hose to the bleeder plug. 

(b) Depress the clutch pedal several times, then loosen the 

bleeder plug with the pedal held down. 

(c) When clutch fluid stops flowing, tighten the bleeder plug, 

then release the clutch pedal. 

(d) Repeat steps (b) and (c) until all the air in the system has 

been bled out. 

13A 

42 

3. CHECK FLUID LEVEL IN FLUID RESERVOIR. 

(a) Check the fluid level and fill the fluid reservoir with clutch 


Clutch fluid: DOT3 or DOT4 brake fluid 

Page 2547

42-4 

CLUTCH PEDAL 

COMPONENTS 

CLUTCH - CLUTCH PEDAL 

1 Clutch Pedal Assy 

2 Flat Pin 

3 Cotter Pin 

4 

Bolt,spring Washer And Flat Washer 

Set 

Page 2548


42-5 

ADJUSTMENT 

1. INSPECT CLUTCH PEDAL HEIGHT. 

(a) Inspect the height H between the clutch pedal and floor. 


2. ADJUST CLUTCH PEDAL HEIGHT. 

(a) Loosen the lock nut and turn the stop bolt until the height 

is correct. Tighten the lock nut. 


42 

13A 

42 

3. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH 

ROD PLAY. 

(a) Depress the clutch pedal until the pedal resistance 

begins to be felt. Inspect the clutch pedal free play L1. 

(b) Gently depress the pedal until the pedal resistance 

begins to increase a little. Inspect push rod play L2. 

4. ADJUST CLUTCH PEDAL FREE PLAY AND PUSH 

ROD PLAY. 

(a) Loosen the lock nut and turn the push rod until the clutch 

pedal free play and push rod play are correct, and then 

tighten the lock nut. 

(b) After adjusting the pedal free play, inspect the clutch 

pedal height. 

Page 2549

42-6 


REPLACEMENT 


2. REMOVE SREERING LOWER COVER. (Refer to “Chapter 83 instrument panel - darshboad, 


3. REMOVE ALARM CONTROLLER. (Refer to “Chapter 85 door locks - alarm controller, 


4. REMOVE FLAT PIN OF CLUTCH MASTER CYLINDER 

PUSH ROD. 

(a) Remove cotter pin of clutch master cylinder push rod. 

NOTE 

Discard removed cotter pin. 

(b) Remove flat pin of clutch master cylinder push rod. 

5. REMOVE CLUTCH SWITCH. 

(a) Disconnect the connector of clutch switch. 

(b) Loosen nut,and remove clutch switch. 

6. REMOVE CLUTCH PEDAL AND BRACKET. 

(a) Remove 2 nuts of bracket in cab. 

(b) Remove mounting bolt of bracket located at the top of 

cab. 

(c) Remove clutch pedal and bracket. 

Page 2550


42-7 

7. INSTALL CLUTCH PEDAL AND BRACKET. 

(a) Position clutch pedal and bracket, tighten 2 mounting 

nuts of bracket in cab. 


(b) Tighten mounting bolt of bracker located at the top of the 

cab. 


42 

8. INSTALL CLUTCH SWITCH. 

(a) Position clutch switch. 

(b) Tighten lower mounting nut. 

(c) Connect the connector. 

13A 

42 

9. INSTALL FLAT PIN OF CLUTCH MASTER CYLINDER 

PUSH ROD. 

(a) 

(b) 

Install flat pin of clutch master cylinder push rod. 

Install cotter pin of clutch master cylinder push rod. 

NOTE 


10. INSTALL ALARM CONTROLLER. (Refer to “Chapter 85 door locks - alarm controller, 


11. INSTALL SREERING LOWER COVER. (Refer to “Chapter 83 instrument panel - darshboad, 


12. INSPECT AND ADJUST THE CLUTCH PEDAL HEIGHT. (Refer to “Chapter 42 clutch - clutch 

pedal, adjustment”) 

13. INSPECT AND ADJUST THE CLUTCH PEDAL FREE PLAY AND PUSH ROD PLAY. (Refer to 

“Chapter 42 clutch - clutch pedal, adjustment”) 


Page 2551

42-8 

CLUTCH - VACUUM BOOSTER WITH CLUTCH MASTER CYLINDER ASSY 

VACUUM BOOSTER WITH CLUTCH MASTER CYLINDER 

ASSY 

REPLACEMENT 


2. REMOVE SREERING LOWER COVER. (Refer to “Chapter 83 instrument panel - darshboad, 


3. REMOVE ALARM CONTROLLER. (Refer to “Chapter 85 door locks - alarm controller, 


4. REMOVE WASHER ASSY. (Refer to “Chapter 65 wiper and washer - washer assy, replacement”) 

5. DRAIN CLUTCH FLUID COMPLETELY. 

WARNING 

Clutch fluid will damage painted surfaces and irritate skin. If clutch fluid is spilled on any painted 

surfaces or skin, wash it off immediately with water. 

6. REMOVE VACUUM BOOSTER WITH CLUTCH MASTER 

CYLINDER ASSY. 

(a) Loosen the clamp,then disconnect the hose from vacuum 

booster. 

(b) Loosen the clamp,then disconnect the hose from fluid 

reservoir. 

WARNING 

Clutch fluid will damage painted surfaces and irritate skin. If 

clutch fluid is spilled on any painted surfaces or skin, wash 


(c) 

Loosen the tube joint nut and disconnect the tube from 

the clutch master cylinder. 

(d) 

Remove the cotter pin and flat pin of vacuum booster 

with clutch master cylinder assy push rod. 

NOTE 

Discard removed cotter pin. 

(e) Remove 2 mounting nuts of vacuum booster with clutch 


Page 2552


42-9 

(f) 

Remove vacuum booster with clutch master cylinder 

assy. 

42 

7. DISASSEMBLE VACCUM BOOSTER WITH CLUTCH 

MASTER SYLINDER ASSY. 

(a) 

Loosen the 2 retaining nut connect vacuum booster and 

clutch master cylinder. 

13A 

42 

(b) 

Disassemble vaccum booster and clutch master cylinder. 

NOTE 

Clutch master cylinder can be replaced independently. 

8. ASSEMBLE VACCUM BOOSTER WITH CLUTCH 

MASTER SYLINDER ASSY 

(a) 

(b) 

Assemble vaccum booster and clutch master sylinder. 



9. INSTALL VACUUM BOOSTER WITH CLUTCH MASTER 

CYLINDER ASSY. 

(a) 

(b) 

Position vacuum booster with clutch master cylinder assy 

and tighten 2 mounting nuts. 


Install the cotter pin and flat pin of vacuum booster with 

clutch master cylinder assy push rod. 

Page 2553

42-10 


NOTE 


(c) 

Install the clutch master cylinder tube and tighten the 

tube joint nut. 


(d) 

(e) 

Install hose to fluid reservoir, and install clamp. 

Install hose to vacuum booster,and install clamp. 

10. FILL THE FLUID RESERVOIR WITH CLUTCH FLUID,THEN BLEED AIR FROM CLUTCH SYSTEM. 

(Refer to “Chapter 42 clutch - clutch fluid, bleeding”) 

11. INSPECT AND ADJUST THE CLUTCH PEDAL HEIGHT. (Refer to “Chapter 42 clutch - clutch 

pedal, adjustment”) 

12. CHECK FLUID LEVEL IN CLUTCH FLUID RESERVOIR. (Refer to “Chapter 42 clutch - clutch fluid, 

bleeding”) 

13. INSTALL WASHER ASSY. (Refer to “Chapter 65 wiper and washer - washer assy, replacement”) 

14. INSTALL ALARM CONTROLLER. (Refer to “Chapter 85 door locks - alarm controller, 


15. INSTALL SREERING LOWER COVER. (Refer to “Chapter 83 instrument panel - darshboad, 



Page 2554

CLUTCH - CLUTCH SLAVE CYLINDER 

42-11 

CLUTCH SLAVE CYLINDER 

REPLACEMENT 

1. DRAIN CLUTCH FLUID COMPLETELY. 

WARNING 

Clutch fluid will damage painted surfaces and irritate skin. If clutch fluid is spilled on any painted 

surfaces or skin, wash it off immediately with water. 

42 

2. REMOVE CLUTCH SLAVE CYLINDER ASSY. 

(a) Loosen the screw, then disconnect the hose from clutch 

slave cylinder. 

13A 

42 

(b) 

Remove 2 bolts from the clutch slave cylinder. 

(c) 

Remove the clutch slave cylinder. 

3. INSTALL CLUTCH SLAVE CYLINDER ASSY. 

(a) Install clutch slave cylinder and tighten 2 bolts . 

Page 2555

42-12 

CLUTCH - CLUTCH SLAVE CYLINDER 

(b) 

Connect the hose to the clutch slave cylinder and tighten 

the screw. 


NOTE 

Be sure to use a new washer. 

4. FILL THE FLUID RESERVOIR WITH CLUTCH FLUID,THEN BLEED AIR FROM CLUTCH SYSTEM. 

(Refer to “Chapter 42 clutch - clutch fluid, bleeding”) 

5. CHECK FLUID LEVEL IN CLUTCH FLUID RESERVOIR. (Refer to “Chapter 42 clutch - clutch fluid, 

bleeding”) 

Page 2556

CLUTCH SUB - ASSY 

COMPONENTS 

CLUTCH - CLUTCH SUB - ASSY 

42-13 

42 

13A 

42 

1 Bolt 


3 Flat Washer 

4 

Clutch Pressure Plate With Cover 

Assy 

5 Driven Disk Assy 

6 Locating Pin 

Page 2557

42-14 


OVERHAUL 

1. REMOVE TRANSMISSION ASSY. (Refer to “Chapter 41 transmission (YANCHENGZHONGMA 

ZM001) - transmission assy, replacement”,“Chapter 41 transmission (TANGSHANAIXIN) - 


2. REMOVE CLUTCH RELEASE BEARING AND CLUTCH 

RELEASE FORK. 

(a) 

Remove clutch release bearing hub clip. 

(b) 

Remove clutch release bearing. 

(c) 

Remove clutch release fork. 

3. REMOVE CLUTCH RELEASE FORK DUST BOOT. 

Page 2558


42-15 

4. REMOVE CLUTCH PRESSURE PLATE WITH COVER 

ASSY. 

(a) 

(b) 

Make sure the marks on the clutch pressure plate with 

cover assy align with the one on the flywheel. 

Diagonally loosen each bolt one turn at a time until 

spring tension is released. Then remove 6 bolts. 

42 

(c) 

Remove clutch pressure plate with cover assy. 

13A 

NOTE 

Do not drop the clutch driven disk assy. 

42 

5. REMOVE CLUTCH DRIVEN DISK ASSY. 

NOTE 

Keep the clutch driven disk away from oil and grease. 

6. INSPECT CLUTCH DREVEN DISK ASSY. 

(a) Measure the rivet head depth with a vernier caliper. 

Replace the clutch dreven disk assy if necessary. 

Page 2559

42-16 


(b) 

Measure the runout of the clutch dreven disk assy with a 

dial indicator. 

(c) 

(d) 

Check the surface of the disk for loose rivets, uneven 

contact or adhesion of oil or grease. Replace with a new 

part if necessary. 

Check the torsion spring for clearance and wear. Replace 

with a new part if necessary. 

7. INSPECT CLUTCH PRESSURE PLATE WITH COVER 

ASSY. 

(a) 

(b) 

Measure the depth and width of diaphragm spring for 

wear with a vernier caliper. 

Measure the height of the diaphragm spring. Replace the 

clutch pressure plate with cover assy if necessary. 

(c) 

(d) 

Inspect the surface of the clutch pressure plate with 

cover assy for wear and cracks. Replace clutch pressure 

plate with cover assy if necessary. 

Inspect the strap plate rivets for looseness. Replace the 

clutch pressure plate with cover assy if necessary. 

8. INSPECT FLYWHEEL. 

(a) Measure the runout of flywheel with a dial indicator. 

Replace with a new part if necessary. 

Page 2560


42-17 

9. INSPECT CLUTCH RELEASE BEARING. 

(a) Inspect the clutch release bearing for wear, noise or 

improper rotation. Inspect the friction surface between 

the clutch release bearing and the diaphragm spring for 

wear. 

42 

NOTE 

The bearing is permanently lubricated and requires no 

cleaning or lubrication. 

CAUTION 

• Inspect the inside and outside surface for wear or 

damage. Replace with new part if necessary. 

• Inspect the friction surface of clutch release bearing 

and release fork for wear. Replace with new part if 

necessary. 

10. INSPECT CLUTCH RELEASE FORK. 

(a) Inspect the position of the clutch release fork as shown 

by arrows for wear and shape change. Replace if 

necessary. 

13A 

42 

11. INSTALL CLUTCH DRIVEN DISK ASSY. 

(a) Install the clutch driven disk assy with a special tool. 

NOTE 

Take care not to install the clutch driven disk assy in the 

wrong direction. 

(b) Apply 2 lithium grease to spline of cltch driven disk, don’t 

pollute other parts of driven disk and pressure plate . 

Page 2561

42-18 


12. INSTALL CLUTCH PRESSURE PLATE WITH COVER 

ASSY. 

(a) 

(b) 

Make sure the marks on the clutch pressure plate with 

cover assy align with the one on the flywheel. 

Install the clutch pressure plate with cover assy with a 

special tool. 

(c) 

Diagonally tighten all 6 bolts of clutch ressure plate with 

cover assy. 


13. INSPECT AND ADJUST CLUTCH PRESSURE PLATE WITH COVER ASSY. 

(a) Inspect the height of the diaphragm spring after installation. Adjust the tip of the diaphragm spring if 

necessary. 

14. INSTALL CLUTCH RELEASE FORK DUST BOOT. 

Page 2562


42-19 

15. INSTALL CLUTCH RELEASE BEARING AND CLUTCH 

RELEASE FORK. 

(a) 

Apply grease to the release fork in the areas indicated by 

the arrows. 

Lubricating grease: Mitsubishi pure lubricating 

grease NO. 0101011 or same product. 

42 

(b) 

Install clutch release fork. 

CAUTION 

Install the clutch release fork to the release fork support. 

(c) Install clutch release bearing. 

NOTE 

Apply grease to the friction surface between the clutch 

release bearing and the release fork before installation. 

Lubricating grease: Mitsubishi pure lubricating 

grease NO. 0101011 or same product. 

(d) Install clutch release bearing hub clip. 

13A 

42 

16. INSTALL TRANSMISSION ASSY. (Refer to “Chapter 41 transmission (YANCHENGZHONGMA 

ZM001) - transmission assy, replacement”,“Chapter 41 transmission (TANGSHANAIXIN)- 


Page 2563

MEMO 

Page 2564


STEERING SYSTEM.......................................................................... 51-1 

PRECAUTION.............................................................................. 51-1 


COMPONENTS ........................................................................... 51-5 


STEERING WHEEL ASSY................................................................. 51-7 

ADJUSTMENT............................................................................. 51-7 

OVERHAUL ................................................................................. 51-8 

COMBINATION SWITCH ASSY ...................................................... 51-12 

COMPONENTS ......................................................................... 51-12 

REPLACEMENT ........................................................................ 51-13 

STEERING COLUMN ASSY............................................................ 51-16 

OVERHAUL ............................................................................... 51-16 

STEERING PROPELLER SHAFT ASSY......................................... 51-19 

REPLACEMENT ........................................................................ 51-19 

51 

51 

51 

51 

51 

Page 2565

Page 2566

STEERING SYSTEM 

COLUMN 

PRECAUTION 

STEERING COLUMN - STEERING SYSTEM 

51-1 

1. STEERING SYSTEM PRECAUTION. 

(a) Take care when replacing parts, always comply with the instructions of this manual. 

(b) Incorret replacement may affect the performance of the steering system and result in traffic accident. 

2. PRECAUTIONS ON SRS SYSTEM. 

(a) Some vehicles are equipped with SRS (Supplemental Restraint Sysem) such as the driver airbag. 

(b) Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly 

deploy during servicing, even a serious accident. 

(c) Before servicing (including removal or installation of parts, inspection or replacement), be sure 

to read the precaution for the supplemental restraint system. (Refer to “Chapter 62 supplemental 

restraint system - supplemental restraint system, precaution”) 

51 

51 

51 

Page 2567

51-2 






1. Front axle (Overloaded) - 

2. Tire (Insufficient pressure) 

3. Power steering fluid (Low) 

Chapter 33 tire and wheel - tire and wheel, onvehicle 

inspection 

Chapter 52 power steering - steering fluid, 

replacement 

4. Steering fluid reservior (Filter jammed) - 

Steering heavily 

5. Hydraulic circuit (Leaking) 

6. Steering pump belt (Loose or skid) 

7. Front wheel alignment (Incorrect) 


9. Steering knuckle arm (Worn) 

10. Ball joint (Worn) 

11.Steering column (Bent) 

12.Steering propeller shaft (Deformed) 

13.Power steering pump (Worn or 

damaged) 

14.Steering box (Damaged) 

15.Power steering line assy (Jammed) 

Chapter 52 power steering - steering box,overhaul 

Chapter 52 power steering - power steering 

system, on-vehicle inspection 









Chapter 51 steering column - steering column 



shaft assy, overhual 


pump, replacement 

Chapter 52 power steering - steering box, 

overhual 


line assy, replacement 

Page 2568


51-3 



2. Tire (Different pressure) 

3. Steering knuckle (Loose or worn) 


replacement 


inspection 



51 

Steering 

instability 

4. Steering knuckle arm (Loose or worn) 



5. Steering column (Loose or worn) 

6. Steering propeller shaft (U-joint loose or 

worn) 

7. Steering box (Loose or damaged) 



3. Hydraulic circuit (Invading air) 

4. Return hose (Curving or jammed) 


assy, overhual 


shaft assy, overhual 


overhual 


inspection 




bleeding 



51 

51 

Poor return 


6. Steering column (Bent) 

7. Steering propeller shaft (Deformed) 


damaged) 

9. Steering box (Damaged) 










overhaul 

Page 2569

51-4 



Excessive 

steering wheel 

free play 

1. Steering wheel (Worn) 

2. Steering propeller shaft (loose or worn) 


4. Ball joint (Worn) 

5. Front hub bearing (Worn) 

6. Steering box (Loose or damaged) 


Chapter 51 steering column - steering wheel 








Chapter 34 axle and propeller shaft - axle hub, 

overhaul 


overhaul 


replacement 

2. Steering fluid reservior (Filter jam) - 


Steering not 

smooth 





damaged) 

7. Steering Box (Damaged) 

8. Power steering line assy (Jam) 



3. Steering column (Worn) 


5. Steering box (Worn or damaged) 


bleeding 








overhaul 




replacement 


bleeding 






overhaul 

Page 2570


51-5 

COMPONENTS 

51 

51 

51 

1 Nut 

2 Steering Wheel Assy 

3 Steering Column Assy 

4 Bolt 

5 Bolt 

6 Steering Propeller Shaft Assy I 

8 Screw 

9 Cloumn Base Frame Assy 

10 Bolt, Spring Washer 

11 Bolt 

12 Steering Propeller Shaft Assy II 

13 Steering Retarder Assy 

7 Steering Propeller Shaft Protection Cover 

Page 2571

51-6 



1. CHECK STEERING WHEEL FREE PLAY. 

(a) Stop the vehicle. 

(b) Turn the steering wheel to its straight position and face the 

tires straight ahead. 

(c) Turn the steering wheel gently left and right, check the 

steering wheel free play. 

Free play: ± 10 ° 

If the free play is out of the specification, then: 

• Inspect interrelated parts. (Refer to ”Chapter 51 steering 

column - steering system, problem symptoms table”) 

• Inspect the maximum front wheel steering angle, adjust it if 

necessary. (Refer to “Chapter 31 front suspension - front 

wheel alignment, adjustment”) 

2. CHECK THE VEHICLE DEVIATION. 

(a) Drive straightly the vehicle and along the center line of the road at 50Km/h speed. 

(b) Release the steering wheel and continue traveling straightly for 100 m. 

(c) Measure the offset. 

Offset LH: < Half Car Body 

Offset RH: < Half Car Body 

If the checking value is out of specification, there is fault on the off track for this vehicle. 

Page 2572

STEERING COLUMN - STEERING WHEEL ASSY 

51-7 

STEERING WHEEL ASSY 

ADJUSTMENT 

1. STEERING WHEEL UP-DOWN ADJUSTMENT. 

(a) Pull the handle down to position as shown. 

51 

(b) 

Adjust the steering wheel up and down. 

Adjustable distance: 27 mm 

WARNING 

• Be sure to adjust the steering wheel towards your 

chest, instead of the head or neck. 

• Simultaneously adjust the driver seat. make sure the 

distance between steering wheel and your chest. 

(Refer to “Chapter 84 seat - Driver / assistant driver 

seat, adjustment”) 

• Do not perform this operation when the vehicle is 

running. 

(c) Release the handle. 

51 

51 

WARNING 

Make sure the steering wheel is locked completely without 

clearance. 

Page 2573

51-8 


OVERHAUL 

1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”) 

2. DISCONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - 

battery, replacement”) 

3. DISCONNECT BATTERY POSITIVE CABLE. (Refer to “Chapter 20 starting and charging - battery, 


4. REMOVE DRIVER AIRBAG ASSY. 

(a) Turn the steering wheel to its straight position and face the 


(b) 

Using a inner hex spanner, loosen 2 bolts at the bottom 

of steering wheel. 

(c) 

(d) 

Turn the driver airbag assy over. 

Disconnect the driver airbag connector. 

CAUTION 

• Do not drag the clock spring wire harness. 

• Do not disassemble the driver airbag assy. 

• Driver airbag assy should be stored with the top 

surface upward. Also, do not put any things on top 

surface of driver airbag assy. 

Page 2574


51-9 

51 

5. REMOVE STEERING WHEEL ASSY. 

(a) Disconnect the driver airbag connector. 

(b) Loosen the nut. 

NOTE 

Store it carefully to prevent it from being missing. 

51 

51 

(c) 

Mark on the steering wheel and steering column assy. 

WARNING 


(d) Pull out the steering wheel from the steering column. 

6. INSPECT STEERING WHEEL ASSY. 

(a) Check the steering wheel for warp, micro-cracks or fracture. 

(b) Check the spline for deformation or damaged above 2 teeth. If any fault is detected, replace it with a 

new steering wheel. 

7. INSTALL STEERING WHEEL ASSY. 

(a) Align the marks on the steering wheel assy and steering 

column assy. 

(b) Install the steering wheel to steering column. 

WARNING 

• Be sure to perform this procedure according to the 

marks. 

• Make sure the tires face ahead straightly. 

Page 2575

51-10 


(c) Tighten the nut. 


(d) Connect the clock spring wire harness connector. 

8. INSPECT STEERING WHEEL TURNING FORCE. 

(a) Using a spring scales, pull the steering wheel rim tangentially, 

measure the steering wheel turning force (engine stopped). 

Steering wheel turning force (engine stopped): < 300 N 

If steering wheel turning force exceeds the maximum, inspect 

interrelated parts. (Refer to “Chapter 51 steering column - 

steering system, problem symptoms table”) 

NOTE 

For measurment, turn the steering wheel to both sides in 

the range of 80°. 

9. INSTALL DRIVER AIRBAG ASSY. 

(a) Connect the driver airbag connector. 

WANING 

• Never use the airbag parts removed from another 

vehicle. When replacing, use a new one. 

• If the driver airbag assy has been dropped, or there 

are cracks, dents or any faults in the case or connector, 

replace the driver airbag assy with a new one. 

• Do not drag the clock spring wire harness. Make 

sure the wire harness does not interfere with parts 

around. 

NOTE 

If hear a “click”, the connector is connected completely. 

(b) 

Install the driver airbag assy to steering wheel. 

Page 2576


51-11 

WARNING 

• There should be no interference between the driver 

airbag assy and steering wheel. 

• The clearance should be uniform all the way around 

when the driver airbag assy is installed on the 

steering wheel. 

51 

(c) 

Using a inner hex spanner, tighten 2 bolts at the bottom 

of steering wheel. 

51 

51 

10. CONNECT BATTERY POSITIVE CABLE.(Refer to “Chapter 20 starting and charging - battery, 


11. CONNECT BATTERY NEGETIVE CABLE. (Refer to “Chapter 20 starting and charging - battery, 


12. INSPECT SRS WARNING LIGHT. 

Page 2577

51-12 

STEERING COLUMN - COMBINATION SWITCH ASSY 

COMBINATION SWITCH ASSY 

COMPONENTS 

1 Light Switch Assy 

2 Wiper Switch Assy 

3 Combination Switch Upper Cover 

5 Ignition Switch Assy 

6 Combination Switch Lower Cover 

7 Screw 

4 Ignition Switch Keyring Assy 

Page 2578


51-13 

REPLACEMENT 






4. REMOVE DRIVER AIRBAG ASSY. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 

5. REMOVE STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 

6. REMOVE COMBINATION SWITCH ASSY. 

(a) Loosen 2 screws. 

51 

51 

51 

(b) 

Remove combination switch upper and lower cover. 

(c) 

(d) 

Disconnect the front combination lamp switch connector. 

Remove the front combination lamp switch. 

Page 2579

51-14 


(e) 

(f) 

Disconnect the wiper and washer switch connector. 

Remove the wiper and washer switch. 

7. INSTALL COMBINATION SWITCH ASSY. 

(a) Install the wiper and washer switch. 

(b) Connect the wiper and washer switch connector. 

(c) 

(d) 

Install the front combination lamp switch. 

Connect the front combination lamp switch connector. 

(e) 

Install combination switch upper and lower cover. 

NOTE 

Make sure the covers are positioned properly. 

(f) 

Tighten 2 screws. 

Page 2580


51-15 

8. INSTALL STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 

9. INSTALL DRIVER AIRBAG ASSY. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 

10. CONNECT BATTERY POSITIVE CABLE. (Refer to “Chapter 20 starting and charging - battery, 


11. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery, 


12. INSPECT COMBINATION SWITCH ASSY FUNCTION. 

51 

51 

51 

Page 2581

51-16 

STEERING COLUMN - STEERING COLUMN ASSY 

STEERING COLUMN ASSY 

OVERHAUL 




3. DISCONNECT BATTERY POSITIVE CABLE. 

4. REMOVE DRIVER AIRBAG ASSY. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 


overhaul”) 

6. REMOVE CLOCK SPRING. (Refer to “Chapter 62 supplemental restraint system - clock spring, 


7. REMOVE COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination 

switch assy, replacement”) 

8. REMOVE STEERING COLUMN LOWER COVER. 

(a) Remove store content box. 

(b) Remove the steering column lower cover. 

(c) Remove the steering shaft cover. 

9. REMOVE IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - removal&installation and 

disassembly&reassembly”) 

10. REMOVE STEERING COLUMN ASSY. 

(a) Mark on the steering column and steering propeller shaft 

I. 

WARNING 


(b) 

Remove the bolt. 

Page 2582


51-17 

(c) 

Pull the steering propeller shaft I down from the steering 

column. 

51 

(d) 

(e) 

(f) 

NOTE 

Remove 3 bolts. 

Remove 2 harness clips. 

Remove the steering column assy. 

• When storage, cover the splines with gum cap or soft cloth 

on the both sides to prevent damage. 

51 

51 

WARNING 

• Be sure to store the steering column carefully, especially 

the splines. 

11. INSPECT STEERING COLUMN ASSY. 

(a) Check the spline shaft. 

• Check for rusting, crack and fracture. 

• Check for deformation or damage for more than 2 teeth. 

• If any fault is detected, replace with a new steering column assy. 

12. INSTALL STEERING COLUMN ASSY. 

(a) Positon the steering column assy properly. 

(b) Tighten 3 nuts. 


(c) Install 2 harness clips. 

(d) 

Install the steering propeller shaft to the steering column 

assy according to the marks. 

WARNING 

Be sure to perform this operation according to the marks. 

Page 2583

51-18 


(e) Tighten the bolt. 


13. INSTALL IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - removal&installation 

and disassembly&reassembly”) 

14. INSTALL STEERING COLUMN LOWER COVER. 

(a) Install the steering column lower cover. 

(b) Install the steering propeller shaft cover. 

15. INSTALL CLOCK SPRING. (Refer to “Chapter 62 supplemental restraint system - clock spring, 



overhaul”) 

17. INSTALL DRIVER AIRBAG ASSY. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 






Page 2584

STEERING COLUMN - STEERING PROPELLER SHAFT ASSY 

51-19 

STEERING PROPELLER SHAFT ASSY 

REPLACEMENT 

1. REMOVE THE STEERING COLUMN ASSY.(Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 

2. REMOVE STEERING PROPELLER SHAFT I ASSY. 

(a) 

(b) 

Mark on the steering propeller shaft I and the steering 

retarder. 

Remove the bolt. 

51 

WARNING 


(c) 

(d) 

Pull the steering propeller shaft I up. 

Disconnect from the steering retarder. 

51 

51 

WARNING 

Be sure to store the steering propeller shaft carefully to 

prevent damage, expecially the splines. 

3. REMOVE STEERING PROPELLER SHAFT COVER ASSY. 

(a) Loosen 4 mounting nuts. 

(b) Remove steering propeller shaft cover assy. 

4. REMOVE STEERING RETARD ASSY. 

(a) Loosen 3 mounting bolts. 

(b) Remove steering retard support. 

Page 2585

51-20 


(c) 

Remove steering retard assy mounting bolts. 

2 

(d) 

(e) 

Loosn the steering propeller shaft II upper bolt. 

Remove the steering retard assy. 

NOTE 

Be sure to store the steering propeller shaft carefully to 

prevent damage, expecially the splines, do not turn the 

steering drive shaft. 

5. REMOVE STEERING PROPELLER SHAFT II ASSY. 

(a) Remove the bolt. 

(b) Disconnect the steering propeller shaft II and steering 

gear assy. 

(c) Mark on the steering column and the steering propeller 

shaft. 

NOTE 


6. INSPECT THE STEERING COLUMN ASSY. 

(a) Check the steering column assy for bend. 

Replace with a new steering propeller shaft if necessary. 

(b) Inspect the splines, splined sleeves and U-joint yoke. 

• Check for warp, micro-cracks or fracture. 

• Check for deformation or damage for more than 2 teeth. 

If any fault is detected, replace with a new steering propeller shaft assy. 

(c) Inspect the steering propeller shaft U-joint. 

• Check whether the U-joint rolls smoothly. 

• Check bearing seals and cover failure. 

• Check universal joint cross shaft journal indentation, flaking, eccentric wear and cracks. 

• Check universal joint smooth rotation. 

Replace with a new steering propeller shaft when necessary. 

• Measure the clearance between the cross shaft necks and bearings. 

Clearance: ≤ 0.2 mm 

If the clearance exceeds the manximum, replace with a new steering propeller shaft. 

Page 2586


51-21 

7. INSTALL THE SEERING PROPELLER SHAFT II ASSY. 

(a) 

(b) 

Install the steering propeller shaft II to the steering gear 

assy to the marks. 

Tighten the bolt. 


51 

8. INSTALL STEERING RETARD ASSY. 

(a) Install the steering propeller shaft II to the steering retard 

assy to the marks. 

(b) Tighten 1 bolt. 


51 

51 

(c) 

Tighen 2 steering retard assy mounting bolts. 


(d) 

Tighten 3 steering retard assy cover bolts. 

9. INSTALL STEERING PROPELLER SHAFT COVER ASSY. 

(a) Tighten 4 steering propeller shaft mounting bolts. 

Page 2587

51-22 


10. INSTALL STEERING PROPELLER SHAFT I. 

(a) 

(b) 

Install the steering propeller shaft to the steering column 

and the steering retard according to the marks. 



WARNING 


11. INSTALL THE STEERING COLUMN ASSY.(Refer to “Chapter 51 steering column - steering wheel 

assy, overhaul”) 

Page 2588


POWER STEERING SYSTEM ........................................................... 52-1 

PRECAUTION.............................................................................. 52-1 


COMPONENTS ........................................................................... 52-5 


STEERING FLUID............................................................................ 52-13 

REPLACEMENT ........................................................................ 52-13 

BLEEDING AND PURIFYING.................................................... 52-15 

POWER STEERING PUMP WITH FLUID RESERVIOR ASSY....... 52-17 

REPLACEMENT ........................................................................ 52-17 

POWER STEERING LINE ASSY..................................................... 52-22 

REPLACEMENT ........................................................................ 52-22 

STEERING GEAR ASSY ................................................................. 52-28 

OVERHAUL ............................................................................... 52-28 

STEERING FLUID RESERVIOR...................................................... 52-33 

REPLACEMENT ........................................................................ 52-33 

52 

52 

52 

52 

Page 2589

Page 2590

POWER STEERING - 

POWER STEERING SYSTEM 

STEERING 

PRECAUTION 


52-1 

1. PRECAUTION ON POWER STEERING SYSTEM. 

(a) Take care when replacing parts, always comply with the instructions of this manual. 

(b) Incorrect replacement may affect the performance of the steering system and result in driving 

dangerously. 

2. PRECAUTION ON MAINTAINING THE POWER STEERING SYSTEM. 

(a) Be sure to use the specified steering fluid. 

Steering fluid: ATF- Ⅲ 

(b) Replace the steering fluid and clean the fluid reservior filter in the primal 2500 Km for a new steering 

gear assy. Then repeat these two operations in each following 5000 Km or 1 year. (Refer to “Chapter 52 

power steering - steering fluid, replacement”) 

(c) Check the steering fluid level and whether the fluid goes bad or exist excessive impurities every month. 

(Refer to “Chapter 52 power steering - power steering system, on-vehicle inspection”) 

(d) Regularly check at least each 5000 Km. 

• Check for loose. 

• Check steering system operation. 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

Page 2591

52-2 POWER STEERING - POWER STEERING SYSTEM 





1. Overloaded - 


3. Power steering fluid level (Low) 


inspection 


replacement 


Steering heavily 

5. Hydraulic Circuit (Leaking) 

6. Steering Pump (Loose or skid) 



9. Steering knuckle arm (Worn) 





damaged) 

14. Steering gear assy (Damaged) 

15. Power steering line assy (Jammed) 

Chapter 52 power steering - steering gear 










Chapter 31 front suspension - lower control 

arm, replacement 



Chapter 51 steering column - steering 

propeller shaft assy, overhaul 







Page 2592



52-3 


Steering instability(Can 

not keep 

straight lane) 

steering gear assy 

overheat 

(It exceeds the 

enviromental 

temperature more 

than 65 ℃ ) 


2. Tire (Different pressure) 

3. Steering knuckle (Loosen or worn) 

4. Steering knuckle arm (Loosen or worn) 

5. Steering column (Loose or worn) 

6. Steering propeller shaft (U-joint loose 

or worn) 

7. steering gear assy (Loose or 

damaged) 

1. Overload - 

2. Operation (Incorrect) 

(Residence more than 4 seconds at the 

limit position on both sides) 

3. Power steering pump (Exsessive flow) 

4. Power steering line assy (Deformed or 

jammed) 



3. Hydraulic cicuit (Invading air) 


replacement 


inspection 











- 



- 


inspection 




bleeding and purifying 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

4. Return hose (Curving or jammed) 



52 

Poor return 







assy, inspection 



52 

52 

52 


damaged) 



9. steering gear assy (Damaged) 



Page 2593



Excessive 

steering wheel 

free play 

1. Steering wheel (Worn) 

2. Steering propeller shaft (U-joint loose 

or worn) 



5. Front hub bearing (Worn) 

6. steering gear assy (Loose or 

damaged) 










Chapter 34 axle and propeller shaft - axle hub, 

overhaul 




replacement 







damaged) 

7. steering gear assy (Damaged) 

8. Power steering line assy (Jammed) 









pump, overhaul 






replacement 

2. Hydraulic circuit (Invading air) Chapter 52 power steering - steering fluid, 


Steering irregularity 

3. Steering column (Worn) Chapter 51 steering column - steering column 


4. Steering propeller shaft (Worn) Chapter 51 steering column - steering 


5. steering gear assy (Worn or damaged) 



Page 2594



52-5 

COMPONENTS 

GASOLINE VEHICLES(4G69) 

52 

1 Split Pin 

2 Slotted Nut 

3 Steering Gear Assy 

4 Flat Washer 


6 Bolt 


8 Bolt 

9 Tensioner With Bracket Assy. 

11 Clamp 

12 Flat Washer 

13 Bolt 

14 Washer 

15 Bolt 

16 Ribbed Belt 

17 High-pressure Line Assy 

18 Low-pressure Line Assy 

19 Steering Propeller Shaft Assy 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

10 

Power Steering Pump With Fluid Reservior 

Assy 

20 Engine Crankshaft Belt Pulley 

Page 2595


DIESEL VEHICLES (ISF2.8) 


2 

High-pressure And Low-pressure Line 

Assy 

3 Ribbed Belt 

4 Nut 

5 Copper Washer 

6 Copper Washer 

7 Bolt 

8 Bolt 

9 Fluid Reservior 


11 Clip 

13 Pipeline 

14 Clip 

15 Socket 


17 Nut 


19 Steering Pump Bracket Assy 

20 Bolt 

21 Belt Pulley 

22 Tensioner With Bracket Assy 


12 Power Steering Pump 

Page 2596




52-7 

2. CHECK STEERING FLUID LEVEL. 

(a) Park the vehicle on a flat road. 

1. INSPECT DRIVE BELT. 

(a) Visual check for exsessive wear, etc. 

If any fault is found, replace the drive belt. 

NOTE 

Cracks on the rib side of a belt are considered acceptable. If 

the missing chunks from the ribs are found on the belt, it 

should be replaced. 

(b) Check the deflection. 

• Apply a force of 98 N to push the middle of the drive belt 

and adjust deflection if necessary. 

Deflection (Gasoline vehicle) : 5.5 ~ 8.5 mm 

Deflection (Diesel vehicle) : 5.5 ~ 8.5 mm 

WARNING 

Make sure the engine is stopped before performing this 

operation. 

(b) Check the steering fluid level. 

• Fill the steering fluid if necessary. (Refer to “Chapter 52 

power steering - steering fluid, replacement”) 

Steering fluid: ATF - Ⅲ 

NOTE 

• Make sure the egnine is stopped. 

• Check that the fluid level is within the COLD range, if 

the fluid is cold. 

• Check that the fluid level is within the HOT range, if 

the fluid is hot. 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

(c) 

(d) 

Start the engine and run it at idle. 

Turn the steering wheel fully to the right and left several 

times to get fluid temperature high. 

Fluid temperature: - 40 ~ 120 ℃ 

Page 2597


CAUTION 

Make sure the time when steering wheel stays at full lock 

position will not exceed 4 seconds, otherwise it will damage 

the power steering pump. 

(e) 

Check fluid for foam and emulsification. 

If foam or emulsification is identified, bleed the power 

steering sysytem. (Refer to “Chapter 52 power steering - 

steering fluid, bleeding”) 

(f) 

With the engine idling, check the steering fluid level in 

the fluid reservior. 

NOTE 

Check that the fluid level is within the HOT range, if the fluid 

is hot. 

(g) Stop the engine. 

(h) Wait a few minutes, check the steering fluid level in the 

fluid reservior again. 

NOTE 





(i) Then check steering fluid level . 

Steering fluid level difference: ≤ 5 mm 

If the difference is out of the specification, bleed the power 

steering system. (Refer to “Chapter 52 power steering - steering 

fluid, bleeding and purifying”) 

(j) 

Check the steering fluid level finally and fill the steering 



Page 2598



52-9 

3. CHECK STEERING FLUID PRESSURE. 

Gasoline vehicles (4G69) 

(a) Separate the high-pressure tube from power steering pump. 

CAUTION 

Be sure to keep it clean and prevent dirt entry 

52 

52 

52 

Diesel vehicles (ISF2.8) 

(a) 

Separate the high-pressure tube from power steering pump. 

CAUTION 

Be sure to keep tube clean and prevent dirt entry. 

52 

52 

52 

52 

Gasoline vehicles. 

Diesel vehicles. 

(b) Connect the special tool as shown in the illustration.. 

SPECIAL TOOL: 

CAUTION 

• Be sure to keep it clean and prevent dirt entry. 

• Check that the valve of the SST is in “OPEN” position. 

NOTE 

Connect the SST by the same procedures as the gasoline 

vehicles, although look different. 

(c) Bleed the power steering system. (Refer to “Chapter 52 

power steering - steering fluid, bleed and purifying”) 

(d) Start the engine and run it at idle. 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

Page 2599


(e) 


times to get fluid temperature high. 

Fluid temperature: - 40 ~ 120 ℃ 

NOTE 




NOTE 

Lift front wheels off the ground with jack or lift. 

(f) With the engine idling, close the valve of the special tool. 

(g) Observe the reading on the special tool. 

(h) The max pressure of steering system is (10±0.5)MPa. 

CAUTION 

• Do not close the valve for more than 4 seconds. 

• Do not let the fluid temperature become too high. 

(i) 

(j) 

With the engine idling, open the valve of the SST. 

Measure the fluid pressure when engine is running at 

1000 rpm and 3000 rpm. 

CAUTION 

Do not turn the steering wheel. 

(k) 

(l) 

(m) 

With the engine idling and the valve fully opened, turn 

the steering wheel to full lock position. 

Observe the reading on the SST. 

The max pressure of steering system is (10±0.5)MPa. 

CAUTION 

• Do not close the valve for more than 4 seconds. 

• Do not let the fluid temperature become too high. 

(n) 

Disconnect the SST 

CAUTION 

Be sure to keep tube clean and prevent dirt entry. 

Page 2600



52-11 

Gasoline vehicles (4G69) 

(o) Connect the high-pressure tube to power steering pump. 


CAUTION 

Be sure to keep it clean and prevent dirt entry. 

52 

52 

52 

52 

Diesel vehicles. (ISF2.8) 

(p) 

Connect the high-pressure tube to power steering pump 

52 

52 

52 

52 

52 

(q) Bleed the power steering system. (Refer to “Chapter 52 

power steering - steering fluid, bleeding and purifying”)。 

4. INSPECT STEERING WHEEL TURNING FORCE. 

(a) 

Turn the steering wheel to its straight position and face the 


52 

52 

52 

52 

52 

52 

(b) 

(c) 

(d) 

Remove the driver airbag assy. (Refer to “Chapter 51 steering 

column - steering wheel assy, overhaul”) 


Using a torque wrench, measure the steering wheel turning 

force (engine idling) 

Steering wheel turning force (engine stop): < 300 N 

52 

52 

52 

52 

52 

NOTE 

Take the tire type, pressure and contact surface into your 

consideration before diagnosis. 

Page 2601


(e) 

Tighten the steering wheel lock nut. 


(f) 

Install the driver airbag assy. (Refer to “Chapter 51 steering 

column - steering wheel assy, overhaul”) 

5. CHECK THE OFF TRACK. 

(a) Driving straightly (50Km/h) along the center line of the road. 

(b) Release the steering wheel and continue traveling straightly for 100 m. 

(c) Measure the offset in 100 m distance. 

Offset LH: < Half car body 

Offset RH: < Half car body 

If the measurement value is out of the specification, there is fault on the off track for this vehicle. 

Page 2602



52-13 


REPLACEMENT 

1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system, precaution”) 

2. DRAIN STEERING FLUID. 

(a) Lift front wheels off the ground with jack or lift. 

(b) Remove the steering fluid reservior cap when turning it 

counterclockwise. 

NOTE 


52 

52 

52 

52 

52 

52 

(c) 

Loosen the clamp and separate the low- pressure hose 

from steering gear assy. 

NOTE 


52 

52 

52 

52 

52 

(d) 

(e) 

(f) 


Drain the steering fluid. 


times until steering fluid is drained fully. 

CAUTION 

• Do not perform this operation for more than 10 seconds. 

• Make sure the time when steering wheel stays at full 

lock position will not exceed 4 seconds, otherwise it 

will damage the power steering pump. 

(g) Stop the engine. 

3. FILL STEERING FLUID. 

(a) Connect the low-pressure hose to steering gear assy 

and tighten the clamp. 


CAUTION 


52 

52 

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52 

52 

52 

52 

Page 2603

52-14 POWER STEERING - STEERING FLUID 

(b) 

(c) 

(d) 

Fill the steering fluid. 


Volumn: 1.2 L 



times until the fluid will not be emulsifiable and the level 

will no longer drop down. 

CAUTION 




(e) 

Check the steering fluid level and fill the steering fluid if 

necessary. (Refer to “Chapter 52 power steering - power 

steering system, on-vehicle inspection”) 


NOTE 





(f) 

Install and turn clockwise the reservior cap.. 

NOTE 


(g) 

(h) 

Stop the engine. 

Lower the vehicle. 

Page 2604



52-15 

BLEEDING AND PURIFYING 

1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system”) 

2. BLEED POWER STEERING SYSTEM. 


(b) 

Turn counterclockwise and remove the steering fluid 

reservior cap. 

NOTE 


52 

52 

52 

52 

52 

52 

(c) Turn the steering wheel fully to the right and left several 

times. 

(d) Start the engine and run it at idle. 

(e) Turn the steering wheel. 

• Turn the steering wheel to left full lock position for 2 ~ 3 

seconds, then turn to the opposite full lock position for 2 

~ 3 seconds. 

• Repeat the previous procedure several times. 

CAUTION 




(f) Stop the engine. 

52 

52 

52 

52 

52 

52 

52 

52 

(g) 

Check for foam or emulcification.If foam or emulsification 

is identified, Turn the steering wheel fully to the right and 

left several times until the fluid will not be emulsifiable 

and the level will no longer drop down. 

52 

52 

NOTE 

If the system has to be bled twice becauce of foam or 

emulcification, check for fluid leakage in the system. 

52 

52 

52 

52 

Page 2605

52-16 POWER STEERING - STEERING FLUID 

(h) 

Check the steering fluid level and fill the steering fluid if 

necessary. (Refer to “Chapter 52 power steering - power 

steering system, on-vehicle inspection”) 


NOTE 





(i) 

Install and turn clockwise the reservior cap. 

NOTE 


(j) Stop the engine. 

(k) Lower the vehicle. 

3. PURIFY POWER STEERING SYSTEM. 


(b) Start the engine and run it at idle. 

(c) Turn the steering wheel fully to the right and left several times. 

CAUTION 

Make sure the time when steering wheel stays at full lock position will not exceed 4 seconds, otherwise it will 

damage the power steering pump. 

(d) Check for abnormal noise. 

If abnormal noise is identified, bleed the power steering system. (Refer to “Chapter 52 power steering - 

steering fluid, bleeding and purifying”) 

(e) Turn the steering wheel fully to the right and left several times until the noise disappears. 

(f) Stop the engine. 

(g) Lower the vehicle. 

(h) Check for jam and dirt in the steering fluid reservior filter. 

Clean or replace the filter if necessary. 

Page 2606


POWER STEERING PUMP WITH FLUID 

RESERVIOR ASSY 

POWER STEERING PUMP WITH FLUID RESERVIOR ASSY 

REPLACEMENT 

GASOLINE VEHICLE (4G69) 

52-17 

CAUTION 

• Generally, treat the power steering pump with fluid reservior assy as a whole. Do not separate 

the fluid reservior from the power steering pump unless absolutely necessary. 

• Do not disassemble the power steering pump because of its high precision. 

• If damaged, replace the new steering oil pump assy. 


2. DRAIN FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”) 

3. SEPARATE POWER STEERING LINE ASSY. 

(a) Separate the high-pressure tube from the power steering 

pump. 

NOTE 


(b) Separate the low-pressure hose from the steering fluid 

reservior. 

NOTE 


4. REMOVE DRIVE BELT. 

(a) Loosen the retaining bolt from the tensioner. 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

(b) 

Adjust the tensioner adjusting bolt to loosen the drive 

belt. 

52 

52 

52 

52 

52 

Page 2607

52-18 POWER STEERING - 



(c) Remove the drive belt (ribbed belt). 

5. REMOVE POWER STEERING PUMP WITH FLUID 

RESERVIOR ASSY. 

(a) 

Remove the pulley nut. 

(b) 

Remove the power steering pump pulley. 

(c) 

Remove 2 bolts and 1 nut. 

(d) 

Remove the power steering pump with fluid reservior 

assy. 

Page 2608




52-19 

6. INSTALL POWER STEERING PUMP WITH FLUID 

RESERVIOR ASSY. 

(a) Position the power steering pump with fluid reservior 

assy properly. 

NOTE 

Install the power steering pump pulley temporarily, check 

whether the pump pulley is on the same plane with the 

engine crankshaft pulley and tensioner . 

52 

52 

52 

(b) 

Tighten 2 bolts and 1 nut. 

52 

52 

52 

52 

52 

52 

(c) 

Install the power steering pump pulley. 

WARNING 

Make sure the power steering pump pulley is on the same 

plane with the engine crankshaft pulley and tensioner. 

52 

52 

52 

52 

(d) 

Install the pulley nut. 

52 

52 

52 

52 

52 

52 

7. INSTALL DRIVE BELT. 

(a) Install the drive belt (ribbed belt). 

52 

Page 2609

52-20 POWER STEERING - 



(b) Tighten the adjusting bolt, tension steering oil pump belt. 

(c) Apply a force of 98 N to middle of the drive belt and 

check the deflection. Adjust the tensioner adjusting bolt if 

necessary. 

Deflection : ≤ 5 mm 

WARNING 

Be sure to make sure the egnine is stopped before 

performing this operation 

(d) 

Tighten the retaining nut to the tensioner. 

8. CONNECT THE HIGH-PRESSURE TUBE. 

(a) Connect the high-pressure tube to power steering pump. 


NOTE 


(b) Connect the low-pressure hose to fluid reservior and 

tighten the clamp. 

NOTE 


9. FILL FLUID. (Refer to “Chapter 52 power steering - steering fluid,replacement”) 

Page 2610





52-21 

1. REMOVE DIESEL VEHICLES THE POWER STEERING BUMP WITH FLUID RESERVIOR ASSY. 

(Refer to 《COMMINS ISF SERVICES ENGINE MANUAL,SECTION 9- drive) 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

Page 2611

52-22 POWER STEERING - POWER STEERING LINE ASSY 

POWER STEERING LINE ASSY 

REPLACEMENT 

GASOLINE VEHICLE (4G69) 



3. REMOVE POWER STEERING LINE ASSY. 

(a) Loosen 2 power steering line assy retaining bolts. 

(b) 

Separate the power steering line assy:Steering pump 

side. 

• Separate the high-pressure tube from the power 

steering pump. 

NOTE 


• Loosen the clamp and separate the low-pressure 

hose from the steering fluid reservior. 

NOTE 


(c) Separate the power steering line assy from the steering 

gear assy. 

• Separate the high-pressure tube from the steering 

gear assy. 

NOTE 



hose from the steering gear assy. 

NOTE 


(d) 

(e) 

Remove the power steering line assy. 

Loosen 3 bolts to separate the high-pressure line assy 

from the low-pressure line assy. 

Page 2612



52-23 

4. INSTALL POWER STEERING LINE ASSY. 

(a) Tighten 3 bolts attaching the hig-pressure line assy to the 

low-pressure line assy. 

(b) Position the power steering line assy properly. 

52 

52 

52 

(c) 

Connect the power steering line assy to the power 

steering pump and the steering fluid reservior. 

• Connect the high-pressure tube to power steering 

pump. 


NOTE 


52 

52 

52 

52 

52 

52 

• Connect the low-pressure hose to fluid reservior and 

tighten the clamp. 

NOTE 


52 

52 

52 

52 

52 

(d) 

Connect the power steering line assy to the steering gear 

assy. 

• Connect the hig-pressure tube to the steering gear 

assy. 


NOTE 


• Connect the low-pressure hose to the steering gear 

assy and tighten the clamp. 


NOTE 


52 

52 

52 

52 

52 

52 

Page 2613


(e) 

Tighten 1 bolts attaching power steering line assy to 

power steering line assy. 

5. FILL FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”) 

Page 2614



52-25 




3. REMOVE POWER STEERING LINE ASSY. 

(a) Loosen 1 power steering line assy retaining bolts. 

52 

52 

52 

52 

52 

52 

(b) 

(c) 

Disconnect the power steering line from power steering 

pump side. 

Separate the high-pressure tube from the power steering 

pump. 

NOTE 


52 

52 

52 

52 

52 

(d) 

Loosen the clamp and separate the low-pressure hose 

from the steering fluid reservior. 

NOTE 


52 

52 

52 

52 

52 

(e) 

Separate the power steering line assy from the steering 

gear assy. 

• Separate the high-pressure tube from the steering 

gear assy. 

NOTE 



hose from the steering gear assy. 

52 

52 

52 

52 

NOTE 


Page 2615


(f) 

Loosen 3 bolts to separate the high-pressure line assy 

from the low-pressure line assy. 

4. INSTALL POWER STEERING LINE ASSY. 

(a) Tighten 3 bolts attaching the hig-pressure line assy to the 

low-pressure line assy. 

(b) Position the power steering line assy properly. 

(c) 

Connect the power steering line assy:Steering pump 

side. 

• Connect the high-pressure tube to power steering 

pump. 

NOTE 


(d) 

Tighten the clamp and connect the low-pressure hose 


NOTE 


(e) 

Connect the power steering line assy to the steering gear 

assy. 

• Connect the hig-pressure tube to the steering gear 

assy. 


NOTE 


Page 2616



52-27 

(f) 

Tighten 1 bolt attaching power steering line assy to 

power steering line assy. 

52 

52 

52 


6. BLEED POWER STEERING SYSTEM.(Refer to “Chapter 52 power steering - steering fluid, bleeding 

and purifying”) 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

Page 2617

52-28 POWER STEERING - STEERING GEAR ASSY 

STEERING GEAR ASSY 

OVERHAUL 

CAUTION 

• Do not disassemble the power steering pump because of its high precision. 



3. TURN STEERING WHEEL STRAIGHTLY. 

(a) 

Turn the steering wheel to its straight position and face the 

tires to straight ahead. 

4. SEPARATE STEERING TIE ROD FROM STEERING 

KNUCKLE. 

(a) 

(b) 

(c) 

Separate the steering tie rod LH from the steering knuckle 

arm LH. 

Remove the split pin. 

Loosen the slotted nut. 

NOTE 

Do not reuse the removed split pin. 

(d) 

Remove the left side steering gear rod ball and socket 

joints from the knuckle arm. 

(e) 

Separate the steering tie rod RH from the steering knuckle 

RH. 

NOTE 

Separate the RH side by the same procedures as the LH 

side. 

Page 2618



52-29 

5. SEPARATE POWER STEERING LINE ASSY FROM 

STEERING GEAR ASSY. 

(a) Separate the high-pressure tube from the steering gear 

assy. 

NOTE 


(b) Loosen the clamp and separate the low- pressure hose 

from the steering gear assy.. 

NOTE 


(c) 

Loosen 1 retaining bolt from power steering line assy. 

52 

52 

52 

52 

52 

52 

52 

52 

52 

6. SEPARATE STEERING PROPELLER SHAFT FROM 

STEERING GEAR ASSY. 

(a) Mark on the steering propeller shaft and the steering 

gear assy. 

(b) Loosen the bolt. 

(c) Pull the steering propeller shaft up from the steering gear 

assy. 

NOTE 


7. REMOVE STEERING GEAR ASSY. 

(a) Remove 4 bolts. 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

Page 2619


(b) 

Remove the steering gear assy. 

WARNING 

Take care because the steering gear assy is quite heavy. 

8. INSPECT STEERING GEAR ASSY. 

(a) Check the steering gear assy for crack by magnetic testing. 

If any fault is detected, replace with a new steering gear assy. 

(b) Check the contact area between steering tie rod B-joint 

and steering knuckle arm. 

• Apply red lead evenly to the steering tie rod B-joint shaft 

and hole of steering knuckle arm. 

• Insert the steering tie rod B-joint shaft into the hole of 

steeering knuckle arm, then pull it out again. Check the 

contact area. 

Standard: red area ≤ 3/4 shaft length 

The red area is out of specification, replace with a new steering 

gear assy and steering knuckle arm. (Refer to “Chapter 52 power 

steering - steering gear assy, overhaul”, “Chapter 34 axle and 

propeller shaft - steering knuckle, overhaul”) 

9. INSTALL STEERING GEAR ASSY. 

(a) Position the steering gear assy properly. 

WARNING 

Take care because the steering gear assy is quite heavy. 

(b) 

Tighten 4 bolts. 

Torque: 108 ~ 125 N•m 

Page 2620



52-31 

10. CONNECT STEERING PROPELLER SHAFT TO STEERING 

GEAR ASSY. 

(a) Install the steering propeller shaft to the steering gear 

assy according to the marks. 

(b) Tighten the bolt. 


WARNING 


52 

52 

52 

52 

11. CONNECT POWER STEERING LINE ASSY TO STEERING GEAR ASSY. 

(a) 

Connect the high-pressure tube to steering gear assy 



NOTE 


(b) Connect the low-pressure hose to steering gear assy 



NOTE 


(c) Tighten 1 bolt attaching power steering line assy to the 

steering gear assy. 

NOTE 

Make sure the line assy does not be bended. 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

52 

12. CONNECT STEERING TIE ROD TO STEERING KNUCKLE. 

(a) Connect the steering tie rod LH to the steering knuckle LH. 

(b) Insert the steering tie rod LH B-joint shaft into the 

steering knuckle arm LH hole. 

52 

52 

52 

52 

52 

Page 2621


(c) 

(d) 

Tighten the slotted nut. 

Install the cotter pin. 

NOTE 


Torque: 84 ~ 100 N•m 

(e) 

Connect the steering gear trolley ball and socket joints 

LH. 

NOTE 

Connect the RH side by the same procedures as the LH 

side. 

13. FILL FLUID. (Refer to “Chapter 52 power steering - power steering system, replacement”) 



Page 2622


STEERING FLUID RESERVIOR 

52-33 

STEERING FLUID RESERVIOR 

REPLACEMENT 




3. REMOVE STEERING FLUID RESERVIOR. 

(a) Loosen clip and separate the steering low pressure hose 


(b) Remove the steering fluid reservior from the support. 

52 

52 

52 

52 

52 

52 

52 

4. INSTALL STEERING FLUID RESERVIOR. 

(a) Position the steering fluid reservior to the support. 

(b) Connect the steering low- pressure hose. 

(c) Tighten 2 clips. 

52 

52 

52 

52 

52 


6. BLEED THE POWER STEERING SYSTEM. (Refer To “chapter 52 Power Steering - Steering Fluid, 

Bleeding and purifying”) 


52 

52 

52 

52 

52 

52 

52 

52 

Page 2623

MEMO 

Page 2624


HEATER AND AIR CONDITIONING SYSTEM................................. 61-1 

PRECAUTION.............................................................................. 61-1 



REFRIGERANT.................................................................................. 61-8 


REPLACEMENT ........................................................................ 61-14 

COMPRESSOR OIL......................................................................... 61-17 

INSPECTION ............................................................................. 61-17 

REPLACEMENT ........................................................................ 61-18 

MULTI-MEDIA AND A/C CONTROLLER ASSY ............................. 61-19 

REPLACEMENT ........................................................................ 61-19 

REAR HEATER BLOWER CONTROL SWITCH............................. 61-21 

REPLACEMENT ........................................................................ 61-21 

REAR A/C BLOWER SWITCH ........................................................ 61-23 

REPLACEMENT ........................................................................ 61-23 

FRONT HEATER CORE .................................................................. 61-25 

REPLACEMENT ........................................................................ 61-25 

REAR HEATER CORE..................................................................... 61-35 

REPLACEMENT ........................................................................ 61-35 

FRONT EVAPORATOR CORE....................................................... 61-39 

REPLACEMENT ........................................................................ 61-39 

TOP EVAPORATOR CORE............................................................. 61-42 

REPLACEMENT ........................................................................ 61-42 

FRONT EVAPORATOR THERMISTOR .......................................... 61-46 

REPLACEMENT ........................................................................ 61-46 

TOP EVAPORATOR TEMPERATURE SENSOR............................ 61-47 

REPLACEMENT ........................................................................ 61-47 

FRONT EXPANSION VALVE .......................................................... 61-49 

REPLACEMENT ........................................................................ 61-49 

REAR EXPANSION VALVE............................................................. 61-50 

REPLACEMENT ........................................................................ 61-50 

FRONT A/C BLOWER ..................................................................... 61-52 

OVERHAUL ............................................................................... 61-52 

REAR A/C BLOWER........................................................................ 61-53 

OVERHAUL ............................................................................... 61-53 

REAR HEATER BLOWER............................................................... 61-55 

OVERHAUL ............................................................................... 61-55 

FRONT BLOWER CONTROL MODULE ......................................... 61-56 

REPLACEMENT ........................................................................ 61-56 

REAR HEATER BLOWER RESISTOR............................................ 61-57 

REPLACEMENT ........................................................................ 61-57 

TOP EVAPORATOR BLOWER RESISTOR.................................... 61-59 

REPLACEMENT ........................................................................ 61-59 

FRONT A/C VENT DUCT................................................................. 61-60 

REPLACEMENT ........................................................................ 61-60 

REAR A/C VENT DUCT................................................................... 61-62 

REPLACEMENT ........................................................................ 61-62 

RECIRCULATION DOOR MOTOR.................................................. 61-63 

REPLACEMENT ........................................................................ 61-63 

61 

61 

61 

61 

61 

Page 2625

BLEND DOOR MOTOR ................................................................... 61-65 

REPLACEMENT ........................................................................ 61-65 

MODE DOOR MOTOR ..................................................................... 61-67 

REPLACEMENT ........................................................................ 61-67 

FRONT A/C FILTER......................................................................... 61-69 

REPLACEMENT ........................................................................ 61-69 

REAR A/C FILTER SCREEN ........................................................... 61-71 

REPLACEMENT ........................................................................ 61-71 

A/C PRESSURE SWITCH................................................................ 61-72 

REPLACEMENT ........................................................................ 61-72 

REAR A/C SHUT-OFF SOLENOID VALVE..................................... 61-73 

REPLACEMENT ........................................................................ 61-73 

REAR HEATER SOLENOID VALVE ............................................... 61-75 

REPLACEMENT ........................................................................ 61-75 

COOLING FAN ASSY ...................................................................... 61-77 

REPLACEMENT ........................................................................ 61-77 

COMPRESSOR(4G69)..................................................................... 61-78 

OVERHAUL ............................................................................... 61-78 

COMPRESSOR(ISF2.8) ................................................................... 61-80 

OVERHAUL ............................................................................... 61-80 

CONDENSER ................................................................................... 61-83 

OVERHAUL ............................................................................... 61-83 

A/C RECEIVER DRIER FILTER ELEMENT .................................... 61-85 

REPLACEMENT ........................................................................ 61-85 

Page 2626

HEATER AND AIR CONDITIONING - 


SYSTEM 


AND AIR CONDITIONING 

PRECAUTION 

1. HEATER AND AIR CONDITIONING PRECAUTION. 

(a) Expressions of ignition switch. 

Expression 






61-1 

(b) Power off. 

• Before removing or installing any electrical devices, please disconnect the negative cable to prevent 


NOTE 

For the vehicle equipped with the power door locks, before disconnecting the negative battery cable, 

do not leave the key in the vehicle and avoid the door to be locked. 

• Make sure ignition switch is OFF if no specific instructions. 

(c) When disconnecting negative battery cable, memory of the audio system will be erased. 

NOTE 

When work is finished, reset the audio systems as they were before. ( Refer to “Audio system owner 

manual”) 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

(d) 

Do not handle refrigerant in an enclosed area or near 

the flame. 

61 

61 

61 

61 

61 

(e) 

(f) 

Do not do welding operation to the parts filled with 

refrigerant. 

Always wear eye protection glasses. 

(g) Be careful not to get liquid refrigerant in your eyes or on 

your skin. 

If liquid refrigerant gets in your eyes or on your skin: 

• Wash the area with cool water. 

NOTE 

Do not rub your eyes or skin. 

• Apply clean petroleum jelly to the skin. 

• Go to a physician or hospital immediately for professional 

treatment. 

61 

61 

61 

Page 2627

61-2 HEATER AND AIR CONDITIONING - 


SYSTEM 

(h) 

(i) 

(j) 

(k) 

Never heat container or expose it to naked flame. 

Be careful not to drop container and not to apply physical 

shocks to it. 

Do not operate compressor without enough refrigerant in 

refrigerant system. 

If there is no enough refrigerant in the refrigerant system, 

oil lubrication will be insufficient and compressor will be 

burned out. So take care to avoid this condition. 

Do not open high pressure manifold valve while 

compressor is operating. 

If the high pressure valves opened, refrigerant flows in 

the reverse direction and could cause the charging 

cylinder to rupture. So only open and close the lower 

pressure valve. 

(l) Be careful not to overcharge system with refrigerant. 

If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine 

overheating, etc. 

(m) When removing refrigerant components from a vehicle, immediately cap (seal) the component to 

minimize the entry of moisture from the atmosphere. 

(n) When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before 

connecting the components. Connect all refrigerant loop components as quickly as possible to 

minimize the entry of moisture into the system. 

(o) Only use the specified compressor oil from a sealed container. Immediatedly reseal containers of 

compressor oil. Without proper sealing, compressor oil will become moisture saturated and should not 

be used. 

(p) Avoid breathing A/C refrigerant and compressor oil vapor or mist. Exposure may irritate eyes, nose and 

throat. Remove R-134a from the A/C system using certified service equipment meeting requirements of 

R-134a recycling equipment. If accidental system discharge occurs, ventilate work area before 

resuming service. Additional health and safety information may be available from refrigerant and 

compressor oil manufacturers. 

(q) Do not allow compressor oil to contact with styrofoam parts. Otherwise, damage may occurr. 

(r) Do not store or heat refrigerant containers above 52 ℃ . 

(s) Do not intentionally drop, puncture, or incinerate refrigerant containers. 

(t) Do not do pressure test or leakage test R-134a service equipment and/or vehicle air conditioning 

systems with compressed air during repairing. Some mixtures of air and R-134a have been proved to 

be combustible at high pressure. These mixtures, if ignited, may cause injury or property damage. 

Additional health and safety information may be available from refrigerant manufacturers. 

Page 2628



SYSTEM 

61-3 




1. COOLING SYSTEM DOES NOT FUNCTION. 


1. Fuse (Burned) - 

2. Belt (Loose) - 

3. A/C clutch (Damaged) - 

4. A/C cut relay (Damaged) - 

61 

61 

61 

61 

61 

Air flow normal, 

compressor not 

work 

5. Multi-media and A/C controller 

assy (Damaged) 

6. A/C pressure switch (Damaged) 


(Damaged) 

8. A/C clutch relay (Damaged) - 

9. A/C relay (Damaged) - 

10.ECM (Damaged) - 

11.Harness (Open or short) - 

Chapter 61 heater and air conditioning - multi-media 

and A/C controller assy, replacement 

Chapter 61 heater and air conditioning - A/C 

pressure switch, replacement 

Chapter 61 heater and air conditioning - front 

evaporator thermistor, replacement 

61 

61 

61 

61 

61 

61 

61 

12.Compressor (Damaged) 

Chapter 61 heater and air conditioning -compressor, 

replacement 

61 

Front blower inoperative 

Top blower inoperative 

1. Fuse (Damaged) - 

2. Harness (Open or short) - 




(Damaged) 

5. Front blower motor (Damaged) 



Chapter 61 heater and air conditioning - front blower 

control module, replacement 

Chapter 61 heater and air conditioning - front A/C 

blower, replacement 

1. Top evaporator blower resistor Chapter 61 heater and air conditioning - top 

evaporator blower resistor, replacement 

2. Rear A/C blower 

Chapter 61 heater and air conditioning - rear A/C 


61 

61 

61 

61 

61 

61 

61 

Cooling insufficient 

(air flow normal, 

compressor work) 


1. Refrigerant (Leaking) 

2. Compressor (Damaged) 


blower switch, replacement 

Chapter 61 heater and air conditioning - refrigerant, 



overhaul 

Page 2629



SYSTEM 

2. COOLING SPORADIC. 


1. Harness (Poor contact) - 

2. Relay (Poor contact) - 

Air flow sporadic 


(Damaged) 


assy 


(Damaged) 

6. Vent duct (Blocked) 


blower switch, replacemrnt 





Chapter 61 heater and air conditioning - vent duct, 

replacement 

1. Belt (Slipping) Chapter 61 heater and air conditioning -compressor, 

replacement 

Compressor work 

sporadic 

2. A/C clutch (Slipping) 



4. A/C pressure switch (Damaged) 



replacement 



Chapter 61 heater and air conditioning - A/C 

pressure switch, replacement 


replacement 


Blower and 

compressor 

normal, but cooling 

sporadic 


(Loose) 

2. System block intermittently - 


evaporator thermistor, replacement 

3. COOLING INSUFFICIENT. 



2. Relay (Poor contact) - 

Air abnormal 









Chapter 61 heater and air conditioning - front A/C 


Page 2630



SYSTEM 

61-5 


Air flow normal, 

compressor 

abnormal 

Pressure low on 

both low and high 

pressure sides 

1. A/C clutch (Slipping) Chapter 61 heater and air conditioning -compressor, 

overhaul 

2. Belt (Slipping) 



1. Refrigerant (Leaking) 

2. Evaporator (Frosting) 


overhaul 


overhaul 





61 

61 

61 

61 

61 

61 

Pressure high on 

both low and high 

pressure sides 

1. Refrigerant (Redundancy) 

2. Air mixed in refrigerant system 

3. Condenser (Surface filth 

blocked) 

4. Expansion valve (filth blocked) 





Chapter 61 heater and air conditioning - condenser, 

replacement 


expansion valve, replacement 

61 

61 

61 

61 

61 

Pressure too high 

on low pressure 

side, 

Pressure too low 

on high pressure 

side. 

Others 


2. Condenser (Blocked) 

3. Pipeline between compressor 

and reciever tank (Blocked) 

1. Temperature control knob 

(Damaged) 

2. Blend door motor (Damaged) 


replacement 

Chapter 61 heater and air conditioning - condenser, 

replacement 

- 





61 

61 

61 

61 

61 

61 

4. COOLING SYSTEM BIG NOISE. 


1. Belt (Loose) Chapter 61 heater and air conditioning -compressor, 

overhaul 

2. Compressor bracket (Damaged) - 

61 

61 

61 

System outer noise 


4. Compressor oil (Less than 

specification) 

5. A/C clutch (Slipping) 


replacement 

Chapter 61 heater and air conditioning -compressor 

oil, replacement 


replacement 

Page 2631



SYSTEM 


System inner noise 

1. Refrigerant (Incorrect) 

2. Air mixed in refrigerant system 

(Slipping) 







overhaul 

5. NO HEATING OR HEATING INSUFFICIENT. 


1. Rear heater motor (Damaged) 

Chapter 61 heater and air conditioning - rear heater 

blower, overhaul 

2. Blower relay (Damaged) - 

No heating 



assy 


(Damage) 

Chapter 61 heater and air conditioning - blend door 

motor, replacement 


and A/C controller assyr, replacemrnt 



1. Coolant (Insufficient) - 

Heating insufficient 

2. Front heater core (Deformation) 

3. Rear heater core (Deformation) 

4. Heater hose (Fouling or air in 

hose) 

5. Rear heater solenoid 

valve(Damage) 


Chapter 61 heater and air conditioning - front heater 

core, replacemrnt 


core, replacemrnt 

- 



Chapter 61 heater and air conditioning - blend door 

motor, replacement 

Page 2632




SYSTEM 

61-7 

1. COMPRESSOR ASSY WITH CLUTCH. 

(a) Connect the positive pole from the battery to cable and negative lead to the body ground. 

(b) Check the clutch energized or not. 

If operation is not as specified, replace the compressor assy. 

2. HEATER CORE. 

Add coolant to heater core and then check for leakage. 

3. A/C PIPE. 

Water immersion: With dry nitrogen pipe inside, high-pressure pipe is 3.5 MPa and low-pressure is 1.67 MPa. 

Immerse them in the water for 5 minutes to see whether there is bubble on the surface. 

4. EVAPORATOR. 

Water immersion: Pump 1.67 MPa pressure into the evaporator, then immerse it in the water for 5 minutes to 

see whether there is bubble on the surface. 

5. CONDENSER. 

Water immersion: Pump 3.5 MPa pressure into the condenser, then immerse it in the water for 3 minutes to 

see whether there is bubble on the surface. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2633

61-8 HEATER AND AIR CONDITIONING - REFRIGERANT 

REFRIGERANT 


1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET. 

(a) This is a method in which the trouble is located by using a manifold gauge set. Read the manifold 

gauge pressure when these conditions are established. 

Test conditions: 

• Temperature at the air inlet is 30 ~ 35 ℃ . 

• Engine running at 1500 RPM. 

• Blower switch at “HI” position. 

• Temperature control switch at “COOL” position 

• A/C switch ON. 

• Full open doors. 

NOTE 

These gauge indications are shown when the refrigerant system has been opened and the refrigerant 

charged without vacuum purging. 

• Normally function refrigerant system. 

Gauge reading: 

Low pressure side: 0.15 ~ 0.25 MPa 

High pressure side: 1.37 ~ 2.37 MPa 

• Moisture present in refrigerant system (Condition: Periodically cools and then fails to cool) 

Symptom Probable Cause Diagnosis Remedy 

During operation, 

pressure on low pressure 

side sometimes becomes 

a vacuum and sometimes 

normal. 

Moisture in refrigerating 

system freezes at 

expansion valve orifice 

causing a temporary stop 

of cycle. However, when it 

melts, normal state is 

restored. 

1. Reciever tank in 

oversaturated state 

2. Moisture in 

refrigerating system 

freezes at expansion 

valve orifice and 

blocks circulation of 

refrigerant. 

1. Replace condenser 

2. Remove moisture in 

cycle by repeatedly 

evacuating air 

3. Supply proper amount 

of new refrigerant 

Page 2634


REFRIGERANT 

61-9 

• Insufficient cooling (Condition: Cooling system does not function effectively.) 

61 

61 

61 

61 


Pressure low on both low 

and high pressure sides 

Insufficient cooling 

performance 

Gas leakage in 

refrigeration system 

Insufficient refrigerant 

Refrigerant leakage 

• Poor circulation of refrigerant (Condition: Cooling system does not function effectively.) 

1. Check for gas leakage 

and repair if necessary 

2. Supply proper amount 

of new refrigerant 

3. If indicated pressure 

value is closed to 0 

when connecting to 

gauge, create the 

vacuum after 

inspecting and 

repairing location of 

leak 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 


Pressure low on both low 

and high pressure sides 

Frost on pipe from 

condenser to unit 

Refrigerant flow 

obstructed by dirt in 

reciever tank 

Reciever tank clogged 

Replace reciever tank 

61 

61 

61 

61 

Page 2635


• Refrigerant does not circulate (Condition: Cooling functions intermittently.) 


Vacuum indicated on low 

pressure side, very low 

pressure indicated on 

high pressure side 

Frost or dew seen on pipe 

before and after reciever 

tank or expansion valve 

1. Refrigerant flow 

obstructed by moisture 

or dirt in refrigerant 

system 

2. Refrigerant flow 

obstructed by gas 

leaked from expansion 

valve 

Refrigerant not circulate 

1. Check expansion 

valve 

2. Clean out dirt in 

expansion valve by air 

blowing 

3. Replace condenser 

4. Evacuate air and 

supply proper amount 

of new refrigerants 

5. For gas leakage from 

expansion valve, 

replace expansion 

valve 

• Refrigerant overcharged or insufficient cooling of condenser (Condition: Cooling system does not 

function effectively.) 


Pressure too high on both 

low and high pressure 

sides 

1. Unable to develop 

sufficient performance 

due to excessive use 

of refrigeration system 

2. Insufficient cooling of 

condenser 

1. Excessive refrigerant 

in cycle 

2. Condnser cooling 

insufficient condenser 

fins 

3. Clogged at cooling fan 

1. Clean condenser 

2. Check cooling fan with 

cooling fan 

dooroperation 

3. If 1 and 2 are in normal 

state, check refrigerant 

and supply proper 

amount of refrigerant. 

Page 2636


REFRIGERANT 

61-11 

• Air present in refrigeration system (Condition: Cooling system does not function.) 

61 

61 

61 

61 




sides 

The low pressure pipe 

overheated 

Air entered in refrigeration 

system 

1. Air present in 

refrigeration system 

2. Insufficient vacuum 

purging 

• Expansion valve trouble (Condition: Refrigerant functions insufficient.) 

1. Check compressor oil 

to see if it is dirty or 

insufficient 

2. Vacuumize and supply 

new refrigerant 

61 

61 

61 

61 

61 

61 

61 

61 

61 




sides 

Frost or large amount of 

dew on pipe of low 

pressure side 

Trouble in expansion 

valve 

1. Excessive refrigerant 

in low pressure pipe 

2. Expansion valve 

opened too wide 

Check and replace 

expansion valve 

61 

61 

61 

61 

61 

61 

61 

Page 2637


• Compressor failure (Condition: Refrigerant is not effective.) 


Pressure too high on low 

pressure side 

Pressure too low on high 

pressure side 

Internal leakage in 

compressor 

1. Compressor failure 

2. Leakage from 

damaged valve or 

broken sliding parts 


compressor 

Gauge reading (Reference) 

1 Blower LO Zone 2 Blower HI Zone 

2. LEAKAGE DETECTION WITH SOAP SOLUTION. 

(a) 

For a large amount of leakage on refrigerant pipe connection, leakage can be detected by spraying 

soap liquid around the connection with a sprayer to check whether any bubble appears. This is a simple 

and convenient method for leakage detection, but it is unable to detect minor leakage. 

3. LEAKAGE DETECTION WITH NON-SELECTIVE DETECTOR. 

(a) 

This detector can detect leakage of all kinds of liquid and gas regardless of chemical composition of the 

detected material. It has advantages of easy using, stable performance and low cost, etc., but it cannot 

be used for area detection of leakage. 

Page 2638


REFRIGERANT 

61-13 

4. LEAKAGE DETECTION WITH HALOGEN LEAKAGE DETECTOR. 

(a) It equipped with special sensor which can detect air compounds containing a small amount of fluorine, 

chlorine, bromine and iodine without interference of other materials. The great advantage of this 

instrument is its high sensitivity which can reduce error. Its minimum detection limit is less than 5g per 

year for area detection of leakage and 1.5g per year for leak-point detection (for leak-point, which leaks 

1.5g per year). 

5. LEAKAGE DETECTION WITH SPECIAL ELECTRONIC LEAKAGE DETECTOR. 

(a) This instrument is complicated and expensive which can detect certain compounds without interference 

of other materials. R-134a, a kind of special electronic leakage detector with high sensitivity and 

selectivity, can not only detect leak-point correctly, but also can identify whether refrigerant is R-134a 

type. Because it has high sensitivity, pay attention to pollution around the instrument when using it, 

otherwise, it may cause error report. 

6. LEAKAGE DETECTION WITH FLUORESCENT DYE. 

(a) Fluorescent dye can produce fluorescence under the irradiation of ultraviolet light. Therefore, if add this 

kind of dye to compressor oil or refrigerant, the leak-point can be detected through irradiating outer part 

of the system when the system has a leakage. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2639


REPLACEMENT 

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM. 

(a) Turn the A/C switch ON. 

(b) Operate the compressor at the engine RPM 1000 for 5 to 6 minutes to circulate the refrigerant and 

collect compressor oil remaining in each component into the compressor as many as possible. 

(c) Stop the engine. 

(d) 

Recover the refrigerant. 

NOTE 

Do not release the refrigerant into the air. 

2. PUMP VACUUM. 

(a) 

(b) 

Connect high pressure and low pressure gauge hoses to 

maintenance valve on compressor, and connect central 

hose to vacuum pump. 

Open high and low pressure valves of manifold pressure 

gauge, and then open the vacuum pump valve. 

(c) Start the vacuum pump. Keep vacuumizing for at least 20 

minutes to make vacuum value below -760 mmHg. Shut 

manual valves at both high and low pressure sides and 

stop vacuumizing to detect leakage. 

3. INSPECT LEAKAGE OF REFRIGERANT. 

(a) Shut valves, the gauge value shall not increase within 5 minutes. If the value increases, repair where 

leaks, then pump vacuum again. 

4. SUPPLY REFRIGERANT. 

(a) If there is no leakage, connect central filling hose of manifold pressure gauge with refrigerant tank. 

(b) Loosen the nut of manifold pressure gauge central hose, and retighten it until white gas refrigerant 

flows out and a “fizz” sound is heard, which indicates that air in central hose is exhausted. 

(c) 

Open high pressure manual valve, and turn refrigerant tank 

upside down to SUPPLYliquid refrigerant into refrigeration 

system. Do not start air conditioning system at this moment 

to avoid back flow. Add at least 200g of refrigerant each 

time. 

Page 2640


REFRIGERANT 

61-15 

(d) 

Shut high pressure manual valve and open low pressure 

manual valve to allow gas refrigerant to enter refrigeration 

system. Start the engine. The refrigerant entering from low 

pressure manual valve must be gasified because liquid 

refrigerant will cause liquid impact in compressor and 

damage the unit. 

61 

61 

61 

(e) Add refrigerant according to the specified amount of the 

A/C system. If there is no specified amount, observe the 

high and low pressure gauges and the peephole of the 

refrigerant flow state (clear, sparkling, turbidity) to 

estimate the adding time. 

Specified value: 

Front and rear A/C:850 + 0/- 25 g 

Front A/C:700 ± 25 g 

When estimating refrigerant adding amount, set the 

basic conditions: 

• Radiator water temperature: maintain stable state 

• A/C switch: ON 

• Temperature regulator: adjust inner circulation air 

temperature to 25 ~ 30 ℃ 

• Fan swtich: HI position 

• Change inner and outer air: Inner circulation 

• Door: full open 

• Window: full open 

• Estimate the adding amount 

(f) After finishing the adding process, turn the HVAC switch 

to OFF and wait to balance pressure condition, reopen 

the A/C switch to ON and begin to judge. 

Sparkling condition: gas and liquid refrigerant mixed 

state with bubble. 

Clear conditon: it is clear condition when all refrigerant is 

liquid. 

Turbidity condition: when the oil and refrigerant separae 

with each other, it shows thin ivory. 

Sparkling and turbidity condition: gas refrigerant and 

separated oil mixing state, it shows thin ivory and 

sparkling 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2641


Refrigerant Adding Amount 

Peephole Condition (After Turn 

On The HVAC Switch About 1 

Minute ) 

High Side Pressure 

Suitable 

1.8 ~ 2.5 MPa 

Excessive 

> 2.5 MPa 

Insufficient 

1.2 MPa 

(g) 

(h) 

(i) 

Above peephole conditions are visible general condition. When it is hard to judge the peephole 

condition due to the reasons such as external condition, it must be confirmed to inspect the pressure 

variation of the high pressure side (excessive adding when pressure sharply up). 

When adding refrigerant, pay attention to refrigerant condition variation in peephole and high side 

pressure variation in the pressure gauge. 

Shut low pressure manual valve and remove maintenance valve, then cap the valve quickly to avoid 

gas leakage. 

5. WARM UP ENGINE. 

6. CHECK REFRIGERANT FOR LEAKAGE. (Refer to “Chapter 61 heater and air conditioning - 

refrigerant, on-vehicle inspection”) 

Page 2642


COMPRESSOR OIL 

61-17 

COMPRESSOR OIL 

INSPECTION 

1. CORRELATION METHOD: 

Take fresh compressor oil into test tube as the standard oil and also take old compressor oil into test 

tube, then compare the two tubes. If the color of the old compressor oil is light yellow or orange, it can 

be used. If it turns to bronzing turbid liquid, it can not be used. 

2. PAPER METHOD: 

Drip a drop of compressor oil on a clean white paper. After a while, check the color of the oil. If the color 

is light and uniform, which shows it is no impurity and can be used. If the center of the oil has black 

spot, which shows the oil is metamorphous and can not be used. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2643

61-18 HEATER AND AIR CONDITIONING - COMPRESSOR OIL 

REPLACEMENT 

1. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, 


2. DRAIN OUT COMPRESSOR OIL. 

(a) Remove the compressor. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”) 

(b) Pour out the oil from the compressor. 

3. SUPPLYCOMPRESSOR OIL. 

(a) Install the compressor. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”) 

(b) SUPPLYthe oil into the compressor as the specified value. 

Specified value: 180 mL 

• Generally, it is no need to add oil to new A/C system, because new compressor has the whole amount 

of the oil for the system (14% ~ 18% amount of the refrigerant ). If the A/C system has more than two 

times repairment or other causes the lack of compressor oil, it is need to add compressor oil. After 

replacing the A/C system, add compressor oil as necessary. 

Part Name 

Amount of oil 

Compressor - 

Evaporator 

Reciever tank 

10 ml 

5 ~ 10 ml 

Condenser 

No leakage 

Leakage 

5 ml 

10 ml 

Pipe 

Gas leakage 

Replace all pipes 

No leakage - 

Leakage 

5 ml 

No leakage - 

Leakage 

80 ml 

40 ~ 60 ml 

4. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”) 




Page 2644


MULTI-MEDIA AND A/C CONTROLLER 

ASSY 

MULTI-MEDIA AND A/C CONTROLLER ASSY 

REPLACEMENT 


61-19 

61 

2. REMOVE FRAME BEZEL OF MULTI-MEDIA AND A/C 

CONTROLLER ASSY. 

NOTE 

Pry frame bezel out with prying tool, be careful not to 

scratch frame bezel and dashboard. 

61 

61 

61 

61 

61 

61 

61 

61 

3. REMOVE MULTI-MEDIA AND A/C CONTROLLER 

ASSY. 

(a) 

Remove 4 mounting screws securing multi-media and A/C 

controller assy into the centre opening of dashboard. 

61 

61 

61 

61 

(b) 

(c) 

Pull multi-media and A/C controller assy out far enough 

to disconnect antenna cable, multi-media wire harness 

connectors and A/C controller wire harness connectors. 

Remove GPS antenna attached to the top of multi-media 

and A/C controller assy. 

61 

61 

61 

61 

61 

(d) 

Remove multi-media and A/C controller assy. 

61 

61 

Page 2645


MULTI-MEDIA AND A/C CONTROLLER 

ASSY 

4. INSTALL MULTI-MEDIA AND A/C CONTROLLER ASSY. 

(a) Attach GPS antenna to the top surface of multi-media 

and A/C controller assy and fit the GPS connector into 

corresponding socket. 

(b) Place multi-media and A/C controller assy to the centre 

opening of dashboard and connect wire harness 

connectors to multi-media and A/C controller connector 

receptacle. 

(c) 

Install multi-media and A/C controller assy into place, 

then tighten 4 mounting screws. 

(d) 

Install the frame bezel and press it into place. 


6. INSPECT MULTI-MEDIA AND A/C CONTROLLER ASSY AND RESET RADIO STATIONS. 

7. CHECK TO ENSURE THAT MULTI-MEDIA AND A/C CONTROLLER ASSY WORKS PROPERLY. 

Page 2646


REAR HEATER BLOWER CONTROL 

SWITCH 

REAR HEATER BLOWER CONTROL SWITCH 

REPLACEMENT 

61-21 


2. REMOVE FRONT SIDE WALL GUARD BOARD. (Refer to “Chapter 88 inner/outer trim panel - left 

panel, replacement”) 

3. REMOVE REAR HEATER BLOWER SWITCH. 

(a) Pull out rear heater blower switch cap. 

61 

61 

61 

61 

61 

61 

(b) 

(c) 

Disconnect rear heater blower switch connector. 

Remove 2 rear heater blower switch bracket retaining 

screws from the back of front side wall guard board. 

61 

61 

61 

61 

61 

61 

61 

61 

(d) 

(e) 

Seperate rear heater blower switch from rear heater 

blower switch bracket. 

Remove rear heater blower switch. 

61 

61 

61 

61 

61 

61 

Page 2647


REAR HEATER BLOWER CONTROL 

SWITCH 

4. INSTALL REAR HEATER BLOWER SWITCH. 

(a) Install rear heater blower switch until it snaps into 

bracket, then position them on rear of front side wall 

guard board. 

(b) Tighten 2 retaining screws. 

(c) Connect rear heater blower switch connector. 

(d) 

Install rear heater blower switch cap. 

5. INSTALL FRONT SIDE WALL GUARD BOARD. (Refer to “Chapter 88 inner/outer trim panel - left 

panel, replacement”) 


(a) Turn rear heater blower switch on, confirm blower switch is functional in all positons. 

Page 2648


REAR A/C BLOWER SWITCH 

61-23 

REAR A/C BLOWER SWITCH 

REPLACEMENT 


2. REMOVE REAR A/C BLOWER SWITCH. 

(a) Pry up rear A/C blower switch control panel along its 

edge. 

(b) Disconnect rear A/C blower switch connector from the 

back of rear A/C blower switch control panel. 

61 

61 

61 

61 

61 

(c) 

Pull rear A/C blower switch cap out, then seperate rear 

A/C blower switch from rear A/C blower switch control 

panel. 

61 

61 

61 

61 

61 

61 

3. INSTALL REAR A/C BLOWER SWITCH. 

(a) Position rear A/C blower switch on rear A/C blower 

switch control panel, and snap it into place. 

61 

61 

61 

61 

61 

(b) 

Connect the wire harness connector which extends from 

the mounting opening of roof panel to connector 

receptacle of the rear A/C blower switch integrated on 

rear of A/C blower switch control panel. 

61 

61 

61 

61 

Page 2649

61-24 HEATER AND AIR CONDITIONING - REAR A/C BLOWER SWITCH 

(c) 

Position rear A/C blower switch control panel onto the 

opening of the roof panel and press it into place, then 

plug the blower switch cap. 


(a) Turn rear heater blower switch on, confirm blower switch is functional in all positons. 

Page 2650


FRONT HEATER CORE 

61-25 


REPLACEMENT 





4. REMOVE DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”) 

5. REMOVE FRONT DASHBOARD BEAM ASSY AND 

INSTRUMENT PANEL WIRE HARNESS. 

(a) Remove 5 dashboard stay retaining bolts. 

61 

61 

61 

61 

61 

61 

61 

61 

(b) 

Remove 2 retaining bolts securing hand brake bracket to 

dashboard assy. 

61 

61 

61 

61 

61 

(c) 

(d) 

Disconnect 5 electrical connectors from the left and 

lower side of the driver side junction box. 

Loosen power connecting nut in driver side junction box. 

61 

61 

61 

61 

61 

(e) 

(f) 

Release the tab on top of driver side junction box to 

remove it from the dashboard beam assy. 

Disconnect 5 electrical connectors from the rear and 

right side of driver side junction box. 

61 

61 

Page 2651

61-26 HEATER AND AIR CONDITIONING - FRONT HEATER CORE 

(g) 

Remove 3 retaining bolts mounting steering column to 

dashboard beam assy. 

(h) 

Remove 1 retaining bolt securing clutch pedal bracket to 


(i) 

Remove 2 retaining bolts securing A/C unit assy to dashboardb 

beam assy. 

(j) 

(k) 

Remove 1 retaining bolt securing A/C unit assy to dashboard 

beam assy. 

Disconnect recirculation door motor connector. 

(l) 

Remove 2 electrical wire harness ties at the bottom of 

the A/C unit assy. 

Page 2652



61-27 

(m) 

(n) 

(o) 

(p) 

Remove 1 electrical harness tie on one side of the ac 

assy. 

Disconnect evaporator temperature sensor connector. 

Disconnect blend door motor connector. 

Disconnect blower control module connector. 

61 

61 

61 

(q) 

Disconnect mode door connector. 

61 

61 

61 

61 

61 

(r) 

Loosen 2 retaining bolts securing dashboard beam assy 

to left A pillar. 

61 

61 

61 

61 

61 

61 

61 

61 

(s) 

Loosen 2 retaining bolts securing dashboard beam assy 

to right A pillar. 

61 

61 

61 

61 

Page 2653


(t) 

(u) 

Remove front windshield lower trim cover and front wiper 

motor assy. (Refer to “Chapter 65 wiper and washer 

system - wiper link with motor assy, replacement”) 

Remove 2 bolts located in dedicated holes below the 

wiper motor that secure dashboard beam assy to front 

dash panel. 

(v) 

Remove dashboard beam and wire harness. 

NOTE 

Remove dashboard beam out of the vehicle carefully, do 

not scratch the trim panel and relevant component inside 

the vehicle. 

6. REMOVE A/C ASSY. 

(a) Remove the bolt securing high and low pressure pipes to 

evaporator core, then separate them 

(b) Remove clamps and separate inlet and outlet hoses from 

front heater core. 

(c) 

Disconnect drain hose from A/C unit assy. 

Page 2654



61-29 

(d) 

Remove 2 retaining bolts mounting the bottom of A/C 

unit assy to the body. 

61 

61 

61 

(e) Remove A/C unit assy. 

NOTE 

Do not drag or damage relevant component while removing 

the A/C unit assy from the inside of the vehicle. 

61 

61 

61 

61 

61 

61 

7. REMOVE HEATER CORE. 

(a) Remove 3 heater core cover retaining screws. 

(b) Slide heater core. 

61 

61 

61 

61 

61 

8. CHECK HEATER CORE. 

NOTE 

Check heater core for dust contamination and coolant 

leaks, if necessary, clean or replace it. 

61 

61 

61 

61 

61 

9. INSTALL HEATER CORE. 

(a) Insert heater core into heater unit assy carefully. 

(b) Position heater core cover and tightern 3 retaining 

screws. 

61 

Page 2655


10. INSTALL A/C UNIT ASSY. 

(a) Position A/C unit assy in vehicle until it is located in place 

(b) Tighten 2 retaining bolts at the bottom of A/C unit assy. 

(c) 

Connect drain hose to the A/C unit assy. 

(d) 

Position high and low pressure pipes in place, then 

tighten 1 mounting bolt. 

NOTE 

Always use a new O-ring for high-pressure and low-pressure 

pipes before installing A/C pipes. 

(e) 

Attach inlet and outlet hoses to the front heater core, 

then tighten 2 clamps. 

11. INSTALL DASHBOARD BEAM ASSY AND WIRE HARNESS. 

(a) Position dashboard into vehicle. 

NOTE 

Position dashboard beam in vehicle, do not scratch interior trim panel and related part or drag wire 

harness hard. 

Page 2656



61-31 

(b) 

Tighten 2 retaining bolts mounting dashboard beam assy 

to left A pillar. 

(c) 

(d) 

(e) 


to right A pillar. 


to front dash panel in the holes on dash panel. 

Tighten 2 retaining bolts mounting A/C unit assy to dashboard 

beam assy. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2657


(f) 

Tighten 3 retaining bolts mounting steering column to 


(g) 

Tighten 1 retaining bolt securing clutch pedal bracket to 


(h) 

Tighten 3 retaining bolts securing steering column to 


(i) 

(j) 

(k) 

(l) 

Connect evaporator temperature sensor connector. 

Connect blend door motor connector. 

Connect blower and blower control module connectors. 

Fasten 1 electrical wiring harness tie to one side of the A/C 

assy. 

(m) 

Fasten 2 electrical wire harness ties to the bottom of A/C 

assy. 

Page 2658


(n) 


Connect recirculation door motor connector. 

61-33 

61 

61 

61 

(o) 

Connect 5 electrical wire harness connectors to the back 

and right side of the driver side junction box. 

61 

61 

61 

61 

61 

(p) 

(q) 

(r) 

Fix the driver side junction box in place. 

Connect 5 electrical wire harness connectors on one 

side and bottom of the driver side junction box. 

Tighten power connecting nut located on lower driver 

side junction box. 

61 

61 

61 

61 

61 

(s) 

Tighten 2 retaining bolts mounting hand brake bracket to 


61 

61 

61 

61 

61 

(t) 

Tighten 5 dashboard stay retaining bolts. 

61 

61 

Page 2659


12. INSTALL DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”) 

13. INSTALL FRONT WINDSHIELD LOWER TRIM COVER AND FRONT WIPER MOTOR ASSY. (Refer 

to “Chapter 65 wiper and washer system - wiper link with motor assy, replacement”) 

Page 2660


REAR HEATER CORE 

61-35 


REPLACEMENT 




4. REMOVE REAR HEATER ASSY. 

(a) Loosen water inlet and outlet hoses clamps. 

(b) Separate inlet and outlet hoses from rear heater pipes 

extending to the vehicle beneath through the floor. 

61 

61 

61 

61 

61 

61 

(c) 

(d) 

Disconnect rear heater assy connector. 

Remove 1 retaining screw in the front of rear heater assy. 

61 

61 

61 

61 

61 

61 

(e) 

(f) 

Remove 2 retaining screws on the back of rear heater 

assy. 

Remove rear heater assy. 

61 

61 

61 

61 

61 

5. REMOVE REAR HEATER CORE. 

(a) Remove 2 heater core upper cover retaining screws. 

61 

61 

61 

Page 2661

61-36 HEATER AND AIR CONDITIONING - REAR HEATER CORE 

(b) 

(c) 

Remove 3 blower cover retaining screws and 1 inlet and 

outlet pipes retaining screw on one side of heater assy. 

Remove blower upper cover. 

(d) 

(e) 

Disconnect blower connector. 

Remove 3 blower retaining screws. 

(f) 

Remove blower. 

(g) 

Slide rear heater core. 

Page 2662



61-37 

6. CHECK REAR HEATER CORE. 

NOTE 

Check rear heater core for dust contamination and coolant 

leakage, if necessary ,clean or replace it. 

61 

61 

61 

7. ASSEMBLE REAR HEATER ASSY. 

(a) Place rear heater core into rear heater assy. 

61 

61 

61 

61 

61 

(b) 

(c) 

Position blower and then tighten 3 retaining screws. 

Connect blower connector. 

61 

61 

61 

61 

61 

(d) 

(e) 

Install blower cover. 

Tighten 3 blower cover retaining screws and 1 screw on 

one side of the inlet and outlet pipes. 

61 

61 

61 

61 

61 

61 

61 

Page 2663

61-38 HEATER AND AIR CONDITIONING - REAR HEATER CORE 

(f) 

Install 2 blower upper cover retaining screws. 

8. INSTALL REAR HEATER ASSY. 

(a) Position rear heater assy under the passenger seat. 

(b) Tighten 2 retaining screws on the back of rear heater 

assy. 

(c) Tighten 1 retaing screw in the front of rear heater assy . 

(d) Connect rear heater assy connector. 

(e) 

Attach inlet and outlet hoses to rear heater core under 

the vehicle. 



(a) Start the engine until it is warm, confirm rear heater is functional and no coolant leaks. 

Page 2664


FRONT EVAPORATOR CORE 

61-39 


REPLACEMENT 



3. RECOVER REFERGRIATANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, 



5. REMOVE DASHBOARD BEAM ASSY AND DASHBOARD WIRE HARNESS. (Refer to “Chapter 61 

heater and air conditioning - front heater core, replacement”) 

6. REMOVE A/C UNIT ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater core, 


7. REMOVE FRONT HEATER CORE. (Refer to “Chapter 61 heater and air conditioning - front heater 

core, replacement”) 

8. REMOVE BLOWER ASSY. 

(a) Remove 3 blower assy retaining screws. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

(b) 

(c) 

Remove 2 blower assy retaining screws. 

Remove blower assy. 

61 

61 

61 

61 

61 

61 

9. REMOVE HEATER ASSY. 

(a) Remove 5 heater assy retaining screws. 

(b) Remove heater assy. 

61 

61 

61 

Page 2665

61-40 HEATER AND AIR CONDITIONING - FRONT EVAPORATOR CORE 

10. REMOVE EVAPORATOR CORE. 

(a) Remove 9 evaporator core retaining screws. 

(b) Remove Front Evaporator Thermistor. (refer to “Chapter 

61 heater and air conditioning - front evaporator thermistor, 

replacement “) 

(c) Remove evaporator core. 

11. CHECK EVAPORATOR CORE. 

NOTE 

Check evaporator core for dust contamination and 

refrigerant leakage, if necessary, clean or replace it. 

12. INSTALL EVAPORATOR CORE. 

(a) Position evaporator core into evaporator assy . 


13. INSTALL FRONT EVAPORATOR THERMISTOR. (Refer to “Chapter 61 heater and air conditioning - 

front evaporator thermistor, replacement”) 

14. INSTALL HEATER ASSY. 

(a) Position heater assy into place. 

(b) Tighten 5 heater assy retaining screws 

Page 2666



61-41 

15. INSTALL BLOWER ASSY. 

(a) Position blower assy. 

(b) Tighten 3 blower assy retaining screws. 

61 

61 

61 

(c) 

Tighten 2 blower assy retaining screw. 

61 

61 

61 

61 

61 

61 

16. INSTALL A/C ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater core, 


17. INSTALL DASHBOARD BEAM ASSY. (Refer to “Chapter 61 heater and air conditioning - front 

heater core, replacement”) 



20. SUPPLY REFERGENANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, 



(a) 

Start the vehicle and turn A/C switch on, check that A/C system is functional and no refrigerant leaks. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2667

61-42 HEATER AND AIR CONDITIONING - TOP EVAPORATOR CORE 

TOP EVAPORATOR CORE 

REPLACEMENT 


2. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”) 

3. REMOVE ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”) 

4. REMOVE TOP EVAPORATOR ASSY. 

(a) 

(b) 

Remove high-pressure and low-pressure pipes on top 

evaporator. 

Disconnect right drain hose. 

(c) 

(d) 

Disconnect top evaporator assy connector. 

Disconnect left drain hose. 

(e) 

(f) 

(g) 

Remove 2 retaining bolts in the front of top evaporator 

assy. 

Remove 3 retaining bolts in the back of top evaporator 

assy. 

Remove top evaporator assy. 

Page 2668



61-43 

5. REMOVE TOP EVAPORATOR CORE. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

(a) 

(b) 

(c) 

(d) 

(e) 

Disconnect evaporator temperature sensor connector. 

Remove 19 top evaporator assy housing retaining screws. 

Remove top evaporator assy upper housing. 

Remove 1 retaining screw from the clamp securing highpressure 

and low-pressure pipes to lower housing. 

Remove top evaporator core. 

61 

61 

61 

61 

61 

61 

61 

6. REMOVE TOP EVAPORATOR TEMPERATURE SENSOR AND FILTER SCREEN. 

7. CHECK TOP EVAPORATOR CORE. 

NOTE 

Check evaporator core for dust contamination and 

refrigerant leakage, if necessary, clean or replace it. 

61 

61 

61 

61 

8. INSTALL TOP EVAPORATOR TEMPERATURE SENSOR. (Refer to “Chapter 61 heater and air 

conditioning - top evaporator temperature sensor, replacement”) 

Page 2669

61-44 HEATER AND AIR CONDITIONING - TOP EVAPORATOR CORE 

9. INSTALL TOP EVAPORATOR CORE. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

Position top evaporator core into top evaporator housing 

properly. 

Tighten retaining screws on clamp securing high-pressue 

and low-pressure pipes to lower housing. 

Install top evaporator assy upper housing, then tighten 

19 retaining screws. 

Connect evaporator temperature sensor connector. 

Position top evaporator on mounting bracket of roof. 

Tighten 5 top evaporator assy retaining bolts. 

Page 2670



61-45 

(g) 

(h) 

Replace O-ring for top evaporator high-pressure and 

lower-pressure pipes, then tighten high-pressure and 

low-pressure pipes nut. 

Connect right drain hose. 

61 

61 

61 

61 

61 

(i) 

(j) 

Connect top evaporator assy wire harness connector. 

Connect left drain hose. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

10. SUPPLY REFRIGERRANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”) 

11. INSTALL ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”) 


(a) Start the vehicle and turn A/C switch on, check that A/C system is functional and no refrigerant leaks. 

61 

61 

61 

61 

61 

61 

Page 2671

61-46 HEATER AND AIR CONDITIONING - FRONT EVAPORATOR THERMISTOR 

FRONT EVAPORATOR THERMISTOR 

REPLACEMENT 

1. DISCONNECT BATTERY NEGATIVE CABLE . 


3. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”) 

4. REMOVE FRONT A/C ASSY.(Refer to “Chapter 61 heater and air conditioning - front heater core, 


5. REMOVE FRONT EVAPORATOR THERMISTOR. 

(a) Remove blower assy and heater assy.(refer to ) 

(b) 

Remove front evaporator thermistor carefully. 

6. INSTALL FRONT EVAPORATOR THERMISTOR. 

(a) 

Position front evaporator thermistor on original position, 

and run out thermistor wire along the slot on evaporator 

housing. 

NOTE 

Install front evaporator thermistor carefully to avoid 

damage to the thermistor. 

7. ASSEMBLE A/C ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater core, 


8. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, 



Page 2672


TOP EVAPORATOR TEMPERATURE 

SENSOR 

TOP EVAPORATOR TEMPERATURE SENSOR 

REPLACEMENT 

61-47 



2. REMOVE TOP EVAPORATOR CORE. (Refer to “Chapter 61 heater and air conditioning - top 

evaporator core, replacement”) 

3. REMOVE TOP EVAPORATOR TEMPERATURE SENSOR. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

(a) 

(b) 

(c) 

(d) 

Remove 19 top evaporator assy housing retaining screws. 

Disconnect top evaporator temperature sensor connector. 

Remove top evaporator assy upper housing. 

Pry out top evaporator temperature sensor clamp. 

61 

61 

61 

61 

61 

61 

61 

Page 2673


TOP EVAPORATOR TEMPERATURE 

SENSOR 

(e) 

Remove top evaporator temperature sensor. 

4. INSTALL TOP EVAPORATOR TEMPERATURE SENSOR. 

(a) Position front evaporator temperature sensor on original 

position and remove sensor wire along the slot on evaporator 

housing. 

NOTE 

Install evaporator temperature sensor carefully and avoid 

damage to sensor element. 

5. INSTALL TOP EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - top evaporator 




Page 2674


FRONT EXPANSION VALVE 

61-49 

FRONT EXPANSION VALVE 

REPLACEMENT 


2. OPEN ENGINE HOOD. 



4. REMOVE FRONT EXPANSION VALVE. 

(a) Remove 1 retaining bolt securing front A/C high-pressure 

and low-pressure pipes to expansion valve. 

61 

61 

61 

61 

61 

61 

61 

(b) 

(c) 

Remove 2 bolts securing expansion valve to evaporator 

core 

Remove expansion valve. 

61 

61 

61 

61 

61 

61 

5. INSTALL EXPANSION VALVE. 

(a) Install expansion valve to evaporator core. 

(b) Tighten 2 retaining bolts. 

NOTE 

Always use new O-ring and lubricate it with compressor oil. 

61 

61 

61 

61 

61 

(c) 

Install high-pressure and low-pressure pipes to expansion 

valve, then tighten retaining bolt. 

NOTE 

Always use new O-ring and lubricate it with compressor oil. 

61 

61 



Page 2675

61-50 HEATER AND AIR CONDITIONING - REAR EXPANSION VALVE 

REAR EXPANSION VALVE 

REPLACEMENT 





4. REMOVE REAR EXPANSION VALVE. 

(a) Disconnect rear A/C shut off solenoid. 

(b) Remove retaining bolt securing rear A/C high-pressure 

and low-pressure pipes to expansion valve. 

(c) 

(d) 

Remove 2 bolts securing expansion valve to evaporator 

core 

Remove high-pressure and low-pressure pipes and shut 

off solenoid valve. 

(e) 

(f) 

Remove 2 rear expansion valve retaining bolts. 

Remove rear expansion valve. 

5. INSTALL REAR A/C EXPANSION VALVE. 

(a) 

Install rear A/C expansion valve to rear A/C pipes. 

NOTE 

Always use new O-ring and lubricate it with compressor oil 

(b) 

Tighten 2 retaining bolts. 

Page 2676


REAR EXPANSION VALVE 

61-51 

(c) 

(d) 

Install rear A/C high-pressure and low-pressure pipes 

below rear A/C expansion valve, then tighten retaining 

bolt. 

Connect rear A/C shut off solenoid valve connector. 

61 

61 

61 

(e) 

Connect high-pressure and low-pressure pipes to rear A/C 

pipes assy, then tighten nut to standard torque. 



61 

61 

61 

61 

61 

61 



61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2677

61-52 HEATER AND AIR CONDITIONING - FRONT A/C BLOWER 

FRONT A/C BLOWER 

OVERHAUL 


2. REMOVE FRONT A/C BLOWER. 

(a) 

(b) 

(c) 

Disconnect front A/C blower connector from behind the 

glove box. 

Remove 3 blower retaining screws. 

Remove blower. 

3. CHECK BLOWER. 

(a) Rotate the blade of the blower by hand, no stuck phenomenon 

is found. 

(b) Visually inspect blade of the blower, no abnormal wear 

is present. 

4. INSTALL FRONT A/C BLOWER.. 

(a) Place front A/C blower into blower unit and tighten 3 

retaining screws. 

(b) Connect blower connector. 


(a) Turn front A/C switch on, confirm that blower works normally and no noise is heard. 

Page 2678


REAR A/C BLOWER 

61-53 

REAR A/C BLOWER 

OVERHAUL 



3. REMOVE LEFT TOP BLOWER. 

(a) Remove 3 blower cover retaining screws. 

(b) Remove blower cover. 

61 

61 

61 

61 

61 

61 

(c) 

(d) 

Remove 3 blower retaining screws in top evaporator 

housing. 

Remove blower and disconncet blower connector. 

61 

61 

61 

61 

61 

61 

4. REMOVE RIGHT TOP BLOWER. 

NOTE 

The precedure to remove right top blower is similar to the precedure above. 



is found. 

(b) Visually inspect blade of the blower, no abnormal wear is 

present. 

61 

61 

61 

61 

61 

61 

61 

6. INSTALL LEFT BLOWER. 

(a) Position blower into top evaporator housing in place. 


(c) Connect blower connector to the back of blower. 

61 

Page 2679

61-54 HEATER AND AIR CONDITIONING - REAR A/C BLOWER 

(d) 

Install blower cover and tighten 3 retaining screws. 

7. INSTALL RIGHT BLOWER. 

NOTE 

The precedure to install right blower is similar to the precedure above. 


(a) Turn top evaporator blower switch on, check blower works normally and no abnormal noise is heard. 


Page 2680


REAR HEATER BLOWER 

61-55 

REAR HEATER BLOWER 

OVERHAUL 


2. REMOVE REAR HEATER CORE. (Refer to “Chapter 61 heater and air conditioning - rear heater 


3. REMOVE REAR HEATER BLOWER. (Refer to “Chapter 61 heater and air conditioning - rear 




is found. 

(b) Visually inspect blade of the blower, no abnormal wear is 

present. 

61 

61 

61 

61 

61 

61 

61 

61 

5. INSTALL REAR HEATER BLOWER. (Refer to “Chapter 61 heater and air conditioning - rear 


6. INSTALL REAR HEATER CORE (Refer to “Chapter 61 heater and air conditioning - rear heater 



(a) Turn rear heater blower switch on, check blower works normally and no abnormal noise is heard. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2681

61-56 HEATER AND AIR CONDITIONING - FRONT BLOWER CONTROL MODULE 

FRONT BLOWER CONTROL MODULE 

REPLACEMENT 


2. REMOVE FRONT BLOWER CONTROL MODULE. 

(a) 

(b) 

Disconnect front blower control module connector under 

the glove box. 

Remove 2 front blower control module retaining screws. 

(c) 

Remove front blower control module. 

3. INSTALL FRONT BLOWER CONTROL MODULE. 

(a) Insert front blower control module into blower housing. 

(b) Tighten front blower control module retaining screws. 

(c) Connect front blower control module connector. 


(a) Turn front blower switch on, check front blower is operational in all positions. 

Page 2682


REAR HEATER BLOWER RESISTOR 

61-57 

REAR HEATER BLOWER RESISTOR 

REPLACEMENT 


2. REMOVE REAR HEATER BLOWER RESISTOR. 

(a) Remove 3 rear heater blower resistor upper cover 


61 

61 

61 

61 

61 

(b) 

(c) 

Disconnect rear heater blower resistor connector. 

Remove 2 rear heater blower resistor retaining screws. 

61 

61 

61 

61 

61 

(d) 

Remove rear heater blower resistor. 

61 

61 

61 

61 

61 

61 

3. INSTALL REAR HEATER BLOWER RESISTOR. 

(a) Install rear heater blower resistor. 


61 

61 

61 

61 

Page 2683

61-58 HEATER AND AIR CONDITIONING - REAR HEATER BLOWER RESISTOR 

(c) 

(d) 

Install blower resistor upper cover. 

Tighten 3 retaining screws. 


(a) Turn rear heater blower switch on, check rear heater blower is operational in all positions. 

Page 2684


TOP EVAPORATOR BLOWER 

RESISTOR 

TOP EVAPORATOR BLOWER RESISTOR 

REPLACEMENT 



61-59 

3. REMOVE TOP EVAPORATOR BLOWER RESISTOR. 

(a) Disconnect blower resistor connector. 

(b) Remove blower resistor retaining screw. 

61 

61 

61 

61 

61 

61 

(c) 

Remove blower resistor. 

61 

61 

61 

61 

61 

61 

4. INSTALL TOP EVAPORATOR BLOWER RESISTOR. 

(a) Insert blower resistor into top evaporator housing. 

(b) Tighten 1 retaining screw. 

(c) Connect blower resistor connector. 

61 

61 

61 

61 

61 


(a) Turn top evaporator blower switch on, check top evaporator blower is operational in all positions. 


61 

61 

61 

Page 2685

61-60 HEATER AND AIR CONDITIONING - FRONT A/C VENT DUCT 

FRONT A/C VENT DUCT 

REPLACEMENT 

1. INSTRUMENT PANEL VENT DUCT. 

(a) Remove instrument panel. (Refer to “Chapter 83 

instrument panel - dashboard, replacement”) 

NOTE 

A/C front and side vent duct are an integral part of 

instrument panel and can not be serviced or replaced 

separately. 

2. INSTALL DASHBOARD VENT DUCT. (Refer to “Chapter 83 instrument panel - dashboard, 


3. REMOVE LEFT FOOT DUCT. 

(a) Remove dashboard. (Refer to “Chapter 83 instrument panel - dashboard, replacement”) 

(b) Remove 4 transmission operation mechanism retaining bolts. (Refer to “Chapter 41 transmission - transmission 

operation mechanism assy, replacement”) 

(c) 

(d) 

Remove 3 left foot duct mounting bolts and disengage 

the pawls. 

Remove left foot duct. 

4. INSTALL LEFT FOOT DUCT. 

(a) Position left foot duct to front A/C assy and engage the 

pawls. 


(c) 

(d) 

Install 4 transmission operation mechanism retaining 

bolts. (Refer to “Chapter 41 transmission - transmission 

operation mechanism assy, replacement”) 

Install dashboard. (Refer to “Chapter 83 instrument panel 

- dashboard, replacement”)l 

Page 2686


FRONT A/C VENT DUCT 

61-61 

5. REMOVE RIGHT FOOT DUCT. 

(a) Remove glove box to get access to right foot duct. 

(b) Disengage the pawl. 

(c) Remove right foot duct. 

61 

61 

61 

61 

61 

61 

6. INSTALL RIGHT VENT DUCT. 

(a) Engage right vent duct with front A/C assy. 

(b) Install glove box. 

61 

61 

61 

61 

61 

61 

61 

61 


(a) Turn front blower switch on, check rear heater blower is operational in all positions. 

61 

61 

61 

61 

61 

61 

Page 2687

61-62 HEATER AND AIR CONDITIONING - REAR A/C VENT DUCT 

REAR A/C VENT DUCT 

REPLACEMENT 

1. REMOVE REAR A/C VENT DUCT. 

(a) Remove roof panel. (Refer to “Chapter 88 exterior and 

interior - roof panel, replacement”) 

NOTE 

Rear A/C vent duct is an integral part of roof panel and can 

not be serviced separately. 

2. INSTALL REAR A/C VENT DUCT. 

(a) Install roof panel. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”) 

Page 2688


RECIRCULATION DOOR MOTOR 

61-63 

RECIRCULATION DOOR MOTOR 

REPLACEMENT 


2. REMOVE GLOVE BOX. 

(a) Pull glove box upward to disengage the pawl on its lower 

side from the latch on dashboard. 

(b) Remove glove box. 

61 

61 

61 

61 

61 

61 

3. REMOVE REVERSE RADAR CONTROL UNIT. 

(a) Disconnect reverse radar control unit connector and 

remove retaining bolt. 

(b) Remove reverse radar control unit. 

61 

61 

61 

61 

61 

4. REMOVE RECIRCULATION DOOR MOTOR. 

(a) Disconnect recirculation door motor connector and 

remove 3 retaining screws. 

61 

61 

61 

61 

61 

(b) 

Remove recirculation door motor. 

61 

61 

61 

61 

Page 2689

61-64 HEATER AND AIR CONDITIONING - RECIRCULATION DOOR MOTOR 

5. INSTALL RECIRCULATION DOOR MOTOR. 

(a) Position recirculation door motor. 

(b) Tighten 3 recirculation door motor retaining screws and 

connect the connector. 

6. INSTALL REVERSE RADAR CONTROL UNIT. 

(a) Tighten 1 reverse radar control unit retaining bolt. 

(b) Connect reverse radar control unit connector. 

7. INSTALL GLOVE BOX. 

(a) Position glove box with its pawl and latch on dashboard 

aligned. 

(a) Install glove box into place. 


(a) Turn A/C switch on, confirm that recirculation door motor works normally. 

Page 2690


BLEND DOOR MOTOR 

61-65 

BLEND DOOR MOTOR 

REPLACEMENT 







6. REMOVE FRONT A/C ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater 


7. REMOVE BLEND DOOR MOTOR. 

(a) Disassemble front A/C assy. (Refer to “Chapter 61 heater 

and air conditioning - front evaporator core, replacement”) 

(b) Remove 3 blend door motor retaining screws. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

(c) 

Remove blend door motor. 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2691

61-66 HEATER AND AIR CONDITIONING - BLEND DOOR MOTOR 

8. INSTALL BLNED DOOR MOTOR. 

(a) 

(b) 

Tighten 3 blend door motor retaining screws. 

Assemble front A/C assy. (Refer to “Chapter 61 heater 

and air conditioning - front evaporator core, replacement”) 

9. INSTALL A/C ASSY. (REFER TO “CHAPTER 61 HEATER AND AIR CONDITIONING - FRONT 

HEATER CORE, REPLACEMENT”) 







(a) Turn A/C switch on, confirm blend door motor works normally. 

Page 2692


MODE DOOR MOTOR 

61-67 

MODE DOOR MOTOR 

REPLACEMENT 




NOTE 

BEFORE REMOVING DASHBOARD, ENSURE THE VENT BUTTON ON A/C CONTROLLER IS SELECTED 

AND AIR COMES OUT FROM THE CENTER ONLY. 

4. REMOVE MODE DOOR MOTOR. 

(a) Remove 3 mode door motor retaining screws. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

(b) 

Remove mode door motor. 

61 

61 

61 

61 

61 

61 

5. INSTALL MODE DOOR MOTOR. 

(a) Tighten 3 mode door motor retainng screws. 

NOTE 

When installation, ensure the upper ventilator door in A/C 

assy is in a position where air comes out only from the 

center. 

61 

61 

61 

Page 2693

61-68 HEATER AND AIR CONDITIONING - MODE DOOR MOTOR 




(a) Turn A/C switch on, confirm that mode door motor works normally. 

Page 2694


FRONT A/C FILTER 

61-69 

FRONT A/C FILTER 

REPLACEMENT 

1. REMOVE GLOVE BOX. 

61 

61 

61 

61 

61 

2. REMOVE A/C FILTER COVER. 

(a) Release locking tab on both sides of filter cover, then 

remove cover. 

61 

61 

61 

61 

61 

3. SLIDE A/C FILTER. 

61 

61 

61 

61 

61 

4. INSTALL A/C FILTER. 

NOTE 

Install A/C filter according to arrow direction marked on one 

side. 

61 

61 

61 

61 

61 

Page 2695

61-70 HEATER AND AIR CONDITIONING - FRONT A/C FILTER 

5. INSTALL A/C FILTER COVER AND SNAP IT INTO 

PLACE. 

6. INSTALL GLOVE BOX. 

Page 2696


REAR A/C FILTER SCREEN 

61-71 

REAR A/C FILTER SCREEN 

REPLACEMENT 




3. REMOVE TOP EVAPORATOR. (Refer to “Chapter 61 heater and air conditioning - top evaporator 


4. REMOVE REAR A/C FILTER SCREEN. 

(a) Remove top evaporator. (Refer to “Chapter 61 heater 

and air conditioning - top evaporator core, replacement”) 

(b) Remove adhesive tape, then remove filter screen. 

NOTE 

Replace filter screen or clean filter screen with water, then 

dry it with compressor air. 

5. INSTALL REAR A/C FILTER SCREEN. 

(a) Secure filter screen to the top A/C evaporator with adhesive tape. 

6. INSTALL TOP EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - top evaporator 





61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

Page 2697

61-72 HEATER AND AIR CONDITIONING - A/C PRESSURE SWITCH 

A/C PRESSURE SWITCH 

REPLACEMENT 





4. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior amd interior trim - front bumper assy, 


5. REMOVE A/C PRESSURE SWITCH . 

(a) Disconnect A/C pressure switch connector. 

(b) 

Remove A/C pressure switch with suitable wrench. 

6. INSTALL A/C PRESSURE SWITCH. 

NOTE 

Always use new O-ring and apply compressor oil to it. 

(a) 

Tighten A/C pressure switch to specified torque. 





(a) Turn A/C switch on, check that electronic fan speed is varied with the pressure in A/C line, then comfirm 

A/C pressure switch is functional. 

9. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior amd interior trim - front bumper assy, 


10. INSTALL FRONT GRILLE.(Refer to “Chapter 88 exterior amd interior trim - front grille, replacement”) 

Page 2698


REAR A/C SHUT-OFF SOLENOID 

VALVE 

REAR A/C SHUT-OFF SOLENOID VALVE 

REPLACEMENT 

61-73 




3. REMOVE REAR A/C SHUT OFF SOLENOID VALVE. 

(a) Open engine ECM compartment cover behind assistant 

driver seat. 

(b) Disconnect rear A/C shut off solenoid valve connector. 

61 

61 

61 

61 

61 

61 

(c) 

(d) 

(e) 

Remove high pressure pipe above the rear A/C shut off 

solenoid valve. 

Remove A/C pipe locking nut under the vehicle. 

Remove rear A/C pipe and rear A/C shut off solenoid 

valve. 

61 

61 

61 

61 

61 

61 

(f) 

(g) 

Separate rear A/C shut off solenoid valve from high 

pressure pipe. 

Remove shut off solenoid valve. 

61 

61 

61 

61 

61 

4. INSTALL REAR A/C SHUT OFF SOLENOID VALVE. 

(a) Connect rear A/C shut off solenoid valve to upper highpressure 

pipe. then tighten the union nut to standard 

torque. 

(b) Connect rear A/C pipes assy to lower high-pressure 

pipe, then tighten the connection nut to standard torque. 


61 

61 

61 

NOTE 

Install the rear A/C shut off solenoid valve according to the 

arrow direction marked on it. 

Page 2699


REAR A/C SHUT-OFF SOLENOID 

VALVE 

(c) 

Connect rear A/C shut off solenoid connector. 




(a) Start the vehicle and turn A/C switch on, check that rear A/C system is functional and no refrigerant 

leakage was present. 

Page 2700


REAR HEATER SOLENOID VALVE 

61-75 

REAR HEATER SOLENOID VALVE 

REPLACEMENT 



3. REMOVE REAR HEATER SOLENOID VALVE. 

(a) Disconnect rear heater solenoid valve connector. 

61 

61 

61 

61 

61 

61 

(b) 

Remove 2 clamps on both sides of heater hose, then 

separate them from rear heater solenoid valve. 

61 

61 

61 

61 

61 

(c) 

Remove 2 rear heater solenoid valve retaining screws. 

61 

61 

61 

61 

61 

(d) 

Remove rear heater solenoid valve. 

61 

61 

61 

61 

Page 2701

61-76 HEATER AND AIR CONDITIONING - REAR HEATER SOLENOID VALVE 

4. INSTALL REAR HEATER SOLENOID VALVE. 

(a) Position rear heater solenoid valve, then tighten 2 


NOTE 

Note the water flow direction and do not reverse direction 

when installation. 

(b) 

Attach heater hoses to solenoid valve, then tighten 

clamps. 

(c) 

Connect rear heater solenoid valve connector. 


(a) Fill coolant, start engine until it is warm, check both sides of solenoid valve for coolant leaks. 

(b) Turn rear blower switch on, confirm that rear heater is functional. 

Page 2702



61-77 


REPLACEMENT 

1. REMOVE COOLING FAN ASSY. (Refer to “Chapter 17 cooling - cooling fan assy, replacement”) 

2. DISASSEMBLE COOLING FAN ASSY. 

(a) Remove 3 cooling fan locking nuts. 

61 

61 

61 

61 

61 

(b) 

Remove retaining nut mounting fan blade to fan motor. 

61 

61 

61 

61 

61 

61 

3. ASSEMBLE COOLING FAN ASSY. 

(a) Tighten retaining nut mounting fan blade to fan motor. 

61 

61 

61 

61 

61 

(b) 

Tighten 3 cooling fan locking nuts. 

61 

61 

61 

61 

4. INSTALL COOLING FAN ASSY. (Refer to “Chapter 17 cooling - cooling fan assy, replacement”) 

Page 2703

61-78 HEATER AND AIR CONDITIONING - COMPRESSOR(4G69) 

COMPRESSOR(4G69) 

OVERHAUL 





4. REMOVE COMPRESSORE BELT. 

(a) Loosen idler locking nut. 

(b) loosen idler adjustment bolt by turning it counterclockwise. 

(c) Remove compressor belt. 

5. REMOVE COMPRESSOR ASSY. 

(a) 

(b) 

(c) 

Disconnect compressor connector. 

Loosen 2 retaining nuts mounting high-pressure and lowpressure 

pipes to compressor. 

Separate high-pressure and low-pressure pipes from 

compressor. 

(d) 

(e) 

Remove 4 compressor retaining bolts. 

Reomve compressor assy. 

6. CHECK COMPRESSOR OIL. 

(a) If replace the compressor with a new one, remove the refrigerant gas from the service valve, drain the 

following amount of oil from the new compressor before installing. 


Oil capacity inside new compressor - remaining oil amount in the removed compressor = oil 

amount to be drained out when replacing. 

Page 2704


COMPRESSOR(4G69) 

61-79 

NOTE 

• When checking the compressor oil level, observe the precautions on the compressor removal/ 

installation. 

• Compressor oil will remain in the pipes of the vehicle. If a new compressor is installed without 

draining out some oil inside, too much oil will affect heat exchange in the refrigerant cycle and 

cause refrigerant failure. 

• If the remaining oil in the removed compressor is too little in volume, oil leakage checking is 

necessary. 

• Be sure to use the right compressor oil. 

7. INSTALL COMPRESSOR ASSY. 

(a) Position the compressor properly, then tighten 4 retaining 

bolts. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

(b) Install high-pressure and low-pressure pipes, then 

tighten 2 retaining nuts. 

NOTE 

• Check compressor for specified oil level. 

• Always use new O-rings and sufficiently apply 

compressor oil to them. 

(c) Connect compressor connector. 

61 

61 

61 

61 

61 

8. Connect the connector. 

(a) Install compressor belt. 

(b) Rotate adjustment bolt clockwise to keep compressor 

belt in proper tensiton. 

(c) Tighten idler locking nut. 

61 

61 

61 

61 

61 

61 




(a) Start engine until it is warm, then turn A/C switch on, check compressor works normally and no refrigerant 

leaks. 

Page 2705

61-80 HEATER AND AIR CONDITIONING - COMPRESSOR(ISF2.8) 

COMPRESSOR(ISF2.8) 

OVERHAUL 






(b) Turn over driver seat and open engine compartment 

cover. 


NOTE 

It is recommended that the battery negative cable must be disconnected, prior to compressor 

removing, to avoid touching generator positive retaining nut. 

5. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - drive / assistant driver seat, 


6. OPEN ENGINE COMPARTMENT COVER UNDER 


(a) Open front floor covering. 

(b) Remove 5 retaining bolts. 

(c) Remove engine compartment cover under assistant 

driver seat. 

7. REMOVE INTAKE CORRUGATED HOSE TO TURBO 

CHARGER. 

(a) Remove band clamps from both sides of intake ripple 

hose. 

(b) Remove intake ripple hose. 

8. DISCONNECT COMPRESSOR CONNECTOR. 

Page 2706


COMPRESSOR(ISF2.8) 

61-81 

9. REMOVE HIGH PRESSURE AND LOW PRESSURE 

PIPES ON COMPRESSOR SIDE. 

(a) Remove retaining bolt mounting high pressure and low 


NOTE 

Cover the inlet and outlet holes on compressor and the 

opening of high pressure and low pressure pipes with a 

clean cloth to avoid dust entering. 

61 

61 

61 

61 

10. REMOVE ENGINE BELT. (Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL) 

11. REMOVE COMPRESSOR ASSY. (Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL) 

12. CHECK COMPRESSOR OIL. 

(a) If replace the compressor with a new one, remove the refrigerant gas from the service valve, drain the 

following amount of oil from the new compressor before installing. 


Oil capacity inside new compressor - remaining oil amount in the removed compressor = oil 

amount to be drained out when replacing. 

NOTE 

• When checking the compressor oil level, observe the precautions on the compressor removal/ 

installation. 

• Compressor oil will remain in the pipes of the vehicle. If a new compressor is installed without 

draining out some oil inside, too much oil will affect heat exchange in the refrigerant cycle and 

cause refrigerant failure. 

• If the remaining oil in the removed compressor is too little in volume, oil leakage checking is 

necessary. 

• Be sure to use the right compressor oil. 

13. INSTALL COMPRESSOR ASSY. (Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL) 

14. INSTALL COMPRESSOR ASSY. 

(a) Install high pressure and low pressure pipes to compressor. 


NOTE 

Always use a new O - ring to A/C pipes. 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

61 

15. CONNECT COMPRESSOR CONNECTOR. 

61 

Page 2707

61-82 HEATER AND AIR CONDITIONING - COMPRESSOR(ISF2.8) 

16. INSTALL INTAKE RIPPLE HOSE TO TURBOCHARGER. 

(a) 

(b) 

Position intake ripple hose to turbocharger. 

Tighten the band clamp on both sides of intake ripple 

hose. 

17. INSTALL ENGINE BELT. (Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL) 

18. INSTALL BATTERY NEGATIVE CABLE. 

19. SUPPLYREFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, 






(a) 

(b) 

Tighten 5 engine compartment cover retaining bolts. 

Cover surfacing to front floor. 

22. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - drive / assistant driver seat, 



Page 2708


CONDENSER 

61-83 

CONDENSER 

OVERHAUL 


2. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior amd interior trim - front bumper assy, 




4. REMOVE CONDENSER. 

(a) Loosen A/C high pressure and low pressure pipes retaining 

bolts. 

(b) Disconnect high pressure and low pressure pipes from 

condenser. 

61 

61 

61 

61 

61 

61 

61 

61 

(c) 

Loosen 4 retaining bolts mounting condenser to radiator. 

61 

61 

61 

61 

61 

61 

(d) 

Remove the condenser with caution. 

NOTE 

The condenser is a heat exchanger. It has many vulnerable 

parts (especially the heat sink) in structure and material. 

When removing and installing, pay attention not to 

dropping, colliding or scraping. 

61 

61 

61 

61 

61 

5. INSTALL CONDENSER. 

(a) Position condenser on radiator. 

(b) Tighten 4 retaining bolts securing condenser to radiator. 

61 

NOTE 

Add 20 ml compressor oil to condenser when replacing 

with a new condenser. 

Page 2709

61-84 HEATER AND AIR CONDITIONING - CONDENSER 

(c) 

(d) 

Install high pressure pipe to condensser, then tighten the 

retaining bolt. 

Install low pressure pipe to condensser, then tighten the 

retaining bolt. 

NOTE 

Always use new O - rings and apply compressor oil to them 

before installing high pressure and low pressure pipes. 





Page 2710


A/C RECEIVER DRIER FILTER 

ELEMENT 

A/C RECEIVER DRIER FILTER ELEMENT 

REPLACEMENT 

61-85 




3. REMOVE CONDENSER. (Refer to “Chapter 61 heater and air conditioning - condenser, replacement”) 

4. REMOVE A/C RECEIVER DRIER FILTER ELEMENT. 

(a) Remove locking bolt from the bottom of A/C receiver 

drier with special wrench. 

61 

61 

61 

61 

61 

61 

61 

61 

(b) 

Remove filter element, filter screen and locking bolt. 

61 

NOTE 

Always use new O - ring and apply compressor oil to it 

before installing filter element and filter screen. 

61 

61 

61 

61 

5. INSTALL A/C RECEIVER DRIER FILTER ELEMENT. 

(a) Install new filter element and filter screen. 

(a) Tighten locking bolt. 

Torque: 30 - 35 N.m 

61 

61 

61 

61 

61 

61 

6. INSTALL CONDENSER.(Refer to “Chapter 61 heater and air conditioning - condenser, 



8. CHECK AFTER INSTALLATION . 

(a) Turn A/C switch on, check that A/C system works normally and no refrigerant leaks. 

61 

Page 2711

MEMO 

Page 2712


SUPPLEMENTAL RESTRAINT SYSTEM ......................................... 62-1 

PRECAUTION.............................................................................. 62-1 

SYSTEM PRINCIPLES................................................................ 62-2 

SYSTEM PERFORMANCE ......................................................... 62-3 


HORN SWITCH ASSY ....................................................................... 62-6 

REPLACEMENT .......................................................................... 62-6 

DISPOSAL ................................................................................... 62-9 

CLOCK SPRING .............................................................................. 62-13 

REPLACEMENT ........................................................................ 62-13 

RCM.................................................................................................. 62-16 

REPLACEMENT ........................................................................ 62-16 

62 

62 

62 

62 

Page 2713

Page 2714

SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM 

62-1 


RESTRAINT SYSTEM 

PRECAUTION 

WARNING 

• Some vehicles are equipped with SRS (Supplemental Restraint System), which contains a driver 

airbag. Failure to carry out service operations in the correct sequence could cause the SRS to 

unexpectedly deploy during servicing. It may lead to a serious accident. Furthermore, if a 

mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when 

required. Before servicing (including removal or installation of parts, inspection or 

replacement), be sure to read the following items carefully, then follow the correct procedures 

described in the service manual. 

• Operation must be started 90 seconds after the ignition switch is turned to the “LOCK” position 

and the negative (-) cable and positive (+) cable are disconnected from the battery. (The SRS is 

equipped with a back-up power source. If operation is started within 90 seconds after 

disconnecting the battery negative (-) cable and positive (+) cable, the SRS may deploy.) 

• Do not expose the horn switch assy (with driver airbag) directly to hot air or flames. 

WARNING 

• Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most 

important source of information when troubleshooting. When troubleshooting the SRS, always 

inspect the DTCs before disconnecting the battery. 

• Even in case of a minor collision that the SRS does not deploy, the horn switch assy should be 

inspected. (Refer to “Chapter 62 supplemental restraint system - horn switch assy, replacement”, 

“Chapter 62 supplemental restraint system - RCM, replacement”) 

• Before repairing, remove the RCM first if shocks may be applied to it during repairs. 

• Never use SRS related parts from another vehicle. Be sure to replace them with new parts when 

necessary. 

• Do not disassemble and repair the horn switch assy. 

• If the horn switch assy has been dropped, or there are cracks, dents or other faults, replace it 


• Use a multimeter with high impedance (10 kΩ/V minimum) for troubleshooting of the SRS electrical 

circuits. 

• Information labels are attached to the SRS components. Be sure to follow the instructions on 

the labels when performing operations. 

• After repairing on the SRS system, perform the inspection of airbag warning light. (Refer to 

“Chapter 04 diagnostics - supplemental restraint system, precheck”, “Chapter 04 diagnostics - 

supplemental restraint system, SRS warning light is always on”, “Chapter 04 diagnostics - 

supplemental restraint system, SRS warning light is inoperative”) 

• When the negative (-) cable is disconnected from the battery, the memory of the clock and audio 

system will be cleared. So before repairing, record the necessary data of the clock and audio 

system. After repairing, reset the clock and audio system. Never use a back-up power supply 

from another battery to avoid erasing the memory in each memory system. The back-up power 

supply will supply power to the SRS system. It could cause the SRS to unexpectedly deploy 

during servicing. 

62 

62 

62 

Page 2715

62-2 


SYSTEM PRINCIPLES 

1. SYSTEM STRUCTURE. 

(a) The SRS system contains steering wheel assy, driver airbag, airbag wire harness, clock spring and 

RCM. 

2. SYSTEM SELF-CHECK. 

(a) After turning the ignition switch to the “ON” position to start the SRS, the RCM will perform self-check 

by the preset programme. 

• If the airbag warning light goes out 4 seconds after lighting up, it means that the system is normal and 

has passed the self-check. then the RCM enters monitoring status. 

• If the airbag warning light does not light up,flashes or stays on, it means that the system is abnormal 

and fail to pass the self-check. 

System temperature: - 35 ~ 85 ℃ 

System volt: 12 ± 3 V 

3. SYSTEM PRINCIPLES. 

(a) When driving normally (including all kinds of road condition and interference), the RCM will not output 

the ignition signal. The drive airbag is nonoperative. 

(b) When the vehicle is involved in a serious frontal impact, the RCM will output the ignition signal timely to 

deploy the driver airbag. 

(c) The deployed airbag absorbs the driver’s part energy in the collision to reduce the possible injuries. 

WARNING 

• The SRS airbag just provides a further protection besides the seat belt. 

• To achieve the perfect protection, the driver must fasten the seat belt correctly and keep a good 

posture. 

• The technical parameters of airbag and RCM is matched each other. Never use airbag or RCM 

components of other brands with this product together. 

CAUTION 

• It’s forbidden to maintenance in unauthorized dealer or by non-professional operators. 

• Never use a multimeter to measure the resistance of airbag. to prevent airbag deployed unexpectedlly. 

Page 2716


62-3 

SYSTEM PERFORMANCE 

1. AIRBAG. 

(a) Fuzzy state (or critical condition) 

• If the vehicle frontal collision strength, lower than the vehicle 23 ± 1 Km/h speed driving straight frontal 

walls can not be moved and will not be deformed collision strength (perpendicular to the vehicle direction), 

the airbag will be operative timely. 

• If the vehicle frontal collision strength, more than the vehicle 23 ± 1 Km/h speed driving straight frontal 

walls can not be moved and will not be deformed collision strength (perpendicular to the vehicle direction), 

the airbag will be operative timely. 

• If the strength of the frontal impact is within the strength of impact against unmovable and underformable 

walls (perpendicular to the driving direction) when driving in straight line at the speed between 13± 

1 Km/h and 23 ± 1 Km/h, the system will be in fuzzy control state, which is normal weather or not the 

airbags are deployed. 

(b) When a collision described below, the airbag must be deployed timely to protect the driver. In addition, 

the relevant laws and regulations should be complied with. 

(c) If the vehicle by the impact from the side or the rear, or vehicles overturning, or not by the positive 

impact from, the airbag will not expand in the design. 

(d) If the vehicle suffers a serious collision which is from the bottom, the airbag will be deployed possibly. 

62 

62 

62 

Page 2717

62-4 



1. INSPECT HORN SWITCH ASSY (VEHICLE DOES NOT SUFFER A COLLISION). 

(a) Check the diagnostic system. (Refer to “Chapter 04 diagnostics - supplemental restraint system, 

precheck”) 

(b) Visual check. 

• Check for cuts, micro-cracks or marked discoloration on the horn switch assy surface and in 

the grooved portion. 

CAUTION 

• Make sure there is no interference between the horn switch assy and steering wheel. 

• Make sure the clearance between the horn switch assy and steering wheel is uniform. 

• If any fault is found, replace with a new part if necessary. (Refer to “Chapter 62 supplemental 

restraint system, horn switch assy, replacement”, “Chapter 51 steering column - steering wheel 


2. INSPECT HORN SWITCH ASSY (VEHICLE SUFFERS A COLLISION BUT AIRBAG IS NOT 

DEPLOYED). 

(a) Check the diagnostic system. 

(b) Remove the horn switch assy. (Refer to “Chapter 62 supplemental restraint system, horn switch assy, 


(c) Visual check. 

• Check for cuts, micro-cracks or marked discoloration on 

the horn switch assy surface and in the grooved portion. 

• Check for cuts and cracks in wire harness and chipping 

in connectors. 

• Check for deformation on the steering wheel assy. 

• Check whether the clock spring is damaged. 

If any fault is found, replace with a new part if necessary. (Refer 

to “Chapter 62 supplemental restraint system, horn switch assy, 

replacement”, ”Chapter 62 supplemental restraint system - clock 

spring, replacement”, “Chapter 51 steering column - steering 

wheel assy, replacement”) 

(d) Install the horn switch assy. (Refer to “Chapter 62 

supplemental restraint system - horn switch assy, 


CAUTION 

• Make sure there is no interference between the horn 

switch assy and steering wheel. 

• Make sure the clearance between the horn switch 

assy and steering wheel is uniform. 

Page 2718


62-5 

If any fault is found, replace with a new part for necessary. 

(Refer to “Chapter 62 supplemental restraint system, horn 

switch assy, replacement”, “Chapter 51 steering column - 

steering wheel assy, replacement”) 

3. INSPECT HORN SWITCH ASSY. (VEHICLE SUFFERS A COLLISION AND AIRBAG IS NOT DEPLOYED) 

(a) Check the diagnostic system. (Refer to “Chapter 04 diagnostics - supplemental restraint system, 

precheck”) 

(b) Replace the horn switch assy, clock spring, SRS wire harness and RCM with new parts. (Refer to 

“Chapter 62 supplemental restraint system - horn switch assy, replacement”, “ Chapter 62 

supplemental restraint system - clock spring, replacement”, “Chapter 62 supplemental restraint system 

- RCM, replacement”) 

CAUTION 

If the airbag is deployed, be sure to replace all of the horn switch assy, clock spring, SRS wire harness 

and RCM together. 

4. INSPECT RCM .(VEHICLE DOES NOT SUFFER A COLLISION) 


5. INSPECT RCM. (VEHICLE SUFFERS A COLLISION BUT AIRBAG IS NOT DEPLOYED) 


6. INSPECT RCM .(VEHICLE SUFFERS A COLLISION AND AIRBAG IS DEPLOYED) 


(b) Replace the horn switch assy, clock spring, SRS wire harness and RCM with new parts. (Refer to 

“Chapter 62 supplemental restraint system - horn switch assy, replacement”, “Chapter 62 supplemental 

restraint system - clock spring, replacement”, “Chapter 62 supplemental restraint system - RCM, 


62 

62 

62 

Page 2719

62-6 

SUPPLEMENTAL RESTRAINT SYSTEM - HORN SWITCH ASSY 

HORN SWITCH ASSY 

REPLACEMENT 

1. PRECAUTION. (Refer to “Chapter 62 supplemental restraint system - supplemental restraint 

system, precaution”) 





4. REMOVE HORN SWITCH ASSY. 

(a) Turn the steering wheel to its straight position and face 

the tires straight ahead. 

(b) 

Using a hex spanner, loosen 2 inner hex bolts at the 

bottom of the steering wheel. 

(c) 

(d) 

Turn the horn switch assy over. 

Disconnect the horn switch wire harness connector. 

(e) 

Remove the horn switch assy. 

Page 2720


62-7 

CAUTION 

• Do not drag the clock spring wire harness. 

• Do not disassemble the horn switch assy. 

• When removing the horn switch assy or handling a 

new horn switch assy, it should be placed with the 

pad top surface upward. Placing it with the pad top 

surface downward may lead to a serious accident if 

the airbag accidently inflates. Also, do not place 

horn switch assy on top of one another. 

62 

62 

62 

5. INSPECT HORN SWITCH ASSY. 

(a) Visually check for cuts, micro-cracks and marked discolouration on the horn switch assy top surface 

and in the grooved portion. 

Page 2721

62-8 


6. INSTALL HORN SWITCH ASSY. 

(a) Connect the horn switch wire harness connector. 

CAUTION 

• Never use SRS parts from another vehicle. Be sure to 

replace them with new parts when replacing. 

• If the horn switch assy has been dropped, or there 

are cracks, dents or other faults, be sure to replace it 


• Do not drag the clock spring wire harness and make 

sure there is no interference between wire harness 

and parts around. 

NOTE 

If you hear a clicking sound, the connector is connected 

completely. 

(b) Position the horn switch assy properly. 

CAUTION 

• Make sure there is no interference between the horn 

switch assy and steering wheel. 

• Make sure the clearance between the horn switch 

assy and steering wheel is uniform. 

(c) 

Using a hex spanner, tighten 2 inner hex bolts at the 

bottom of the steering wheel. 


7. CONNECT BATTERY POSITIVE CABLE.(Refer to “Chapter 20 starting and charging - battery,replacement”) 

8. CONNECT BATTERY NEGATIVE CABLE.(Refer to “Chapter 20 starting and charging - battery,replacement”) 

9. INSPECT SRS WARNING LIGHT 

Page 2722


62-9 

DISPOSAL 

WARNING 

• Never dispose of the horn switch assy with an undeployed airbag. 

• The airbag produces a sizable exploding sound when being deployed. So be sure to perform the 

operations outdoor where it will not create a nuisance to nearby residents. 

• When deploying the airbag, be sure to use the 

specified SST (SRS Airbag Deployment Tool) and 

perform the operations in a place away from 

electrical noise. 

62 

62 

62 

• When deploying a airbag, be sure to perform the 

operation at least 10 m away from horn switch assy. 

• The horn switch assy is very hot when the airbag is 

depoyed. So leave it at least 30 minutes after 

deployment. 

• Use gloves and goggles when handling a horn 

switch assy with the deployed airbag. 

• Do not apply water, etc. to a horn switch assy with 

the deployed airbag. 

• Be sure to wash your hands with water after 

completing the operation. 

CAUTION 

When disposing of the horn switch assy, be sure to follow the correct procedures described below to 

deploy the airbag. 

Page 2723

62-10 


1. CHECK FUNCTION OF SST. 

(a) Prepare a battery for the power supply to deploy the 

airbag. 

(b) Connect the SST to the battery. 

NOTE 

Do not connect the yellow connector which will be 

connected to the airbag. 

(c) 

Press the SST activation switch, check whether the 

illumination lights up. 

Standard: Light up 

CAUTION 

If the illumination lights up when the activation switch is 

not pressed, SST malfunction is probable. Never use this 

SST. 

(d) 

Disconnect the SST from the battery. 

2. DISPOSE OF HORN SWITCH ASSY. 

CAUTION 

• When disposing of the horn switch assy (with airbag), never use the customers’ vehicle to 

deploy the airbag. 

• Be sure to follow the procedures described below when deploying the airbag. 

(a) Prepare a battery for the power supply to deploy the airbag. 

(b) Remove the horn switch assy. (Refer to “Chapter 62 supplemental restraint system - horn switch assy, 


(c) 

Tighten 2 bolts to the 2 bolt holes of the horn switch assy. 

CAUTION 

• Tighten the bolts by hands until the bolts become 

hard to turn. 

• Do not tighten the bolts too much. 

• The bolts should be long enough. 

(d) 

Connect the SST to the horn switch assy. 

Page 2724


62-11 

(e) 

(f) 

Prepare a steel rim with tire and place it level. 

Separately tie the left and right sides of the horn switch 

assy to the steel rim through the hub nut holes. 

WARNING 

• Be sure to tie down the horn switch assy with the 

pad surface upward. 

• Make sure the horn switch assy is tied down tightly. 

NOTE 

• To avoid damaging the SST connector and wire 

harness, secure some slack for the SST wire harness 

inside the steel rim. 

62 

62 

62 

(g) 

(h) 

Connect the SST to the battery. 

Move the SST at least 10 m away from the horn switch 

assy. 

(i) 

Cover the horn switch assy with a carton or tires. 

CAUTION 

• Make sure the horn switch assy is covered 

completely. 

• Weight the carton down with at least 20 Kg. 

• Place at least 3 tires. In addition, always use the 

redundant tires which may be marked by the airbag 

deployment. 

(j) 

Press the activation switch to deploy the airbag. 

WARNING 

Make sure nobody is within 10 m away from the horn switch 

assy. 

NOTE 

The airbag is deployed simultaneously when the LED of the 

SST activation switch lights up. 

Page 2725

62-12 


(k) 

(l) 

Remove the horn switch assy from the steel rim. 

Put the horn switch assy in a plastic bag and tie the end 

tightly. Dispose of it in the same way as other general 

parts disposal. 

WARNING 

• The horn switch assy is very hot when the airbag is 

depoyed. So leave it at least 30 minutes after 

deployment. 

• Use gloves and goggles when handling a horn 

switch assy with the deployed airbag. 

• Do not apply water, etc. to a horn switch assy with 

the deployed airbag. 

• Be sure to wash your hands with water after 

completing the operation. 

Page 2726

SUPPLEMENTAL RESTRAINT SYSTEM - CLOCK SPRING 

62-13 

CLOCK SPRING 

REPLACEMENT 






4. REMOVE HORN SWITCH ASSY. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 


overhaul”) 

6. REMOVE COMBINATION SWITCH COVER. (Refer to “Chapter 51 steering column - combination 


62 

62 

62 

7. REMOVE CLOCK SPRING. 

(a) Disconnect 2 connectors: 

(b) 

Remove the clock spring with 3 clips. 

8. INSTALL CLOCK SPRING. 

(a) Install the clock spring with 3 clips. 

Page 2727

62-14 


(b) 

Connect 2 connectors: 

9. CENTER CLOCK SPRING. 

(a) Make sure the ignition switch is in the “LOCK” position. 

(b) Make sure the battery positive and negative cables are 

disconnected. 

CAUTION 

Do not start the operation within 90 seconds after 

diconnecting the cables. 

NOTE 

There is an information label on the clock spring. Follow 

the instructions on the label. 

(c) Rotate the cable counterclockwise by hands until it 

becomes hard to turn. 

(d) 

Rotate the cable clockwise about 3 turns to align the 

marks. 

NOTE 

The cable will rotate above 3 turns to either left or right off 

the center. 

NOTE 

For a new clock spring: 

• It is located at the center position by clip. 

• Do not forget to remove the clip after installing a new 

clock spring. 

Page 2728


62-15 

10. INSTALL COMBINATION SWITCH UPPER COVER. (Refer to “Chapter 51 steering column - combination 



overhaul”) 

12. INSTALL HORN SWITCH ASSY. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 

13. CONNECT BATTERY POSITIVE CABLE. (If airbag is equipped, refer to “Chapter 20 starting and 

charging - battery, replacement”) 




62 

62 

62 

Page 2729

62-16 

SUPPLEMENTAL RESTRAINT SYSTEM - RCM 

RCM 

REPLACEMENT 






4. REMOVE INSTRUMENT CENTER COVER. 

(a) Loosen 3 screws and 2 bolts to remove the instrument 

center cover. 

NOTE 

The instrument cover is on the front carpet assy which is in 

front of the middle platform assy and under the dashboard 

ashtray assy. 

5. REMOVE RCM. 


(b) Make sure the battery positive and negative cables are disconnected. 

CAUTION 

• Do not start the operation within 90 seconds after diconnecting the cables. 

• Never strike the RCM when it is energized. 

(c) 

Disconnect the RCM wire harness connector. 

(d) 

Loosen 3 bolts and remove the RCM. 

6. INSTALL RCM. 


(b) Make sure the battery positive and negative cables are disconnected. 

Page 2730

SUPPLEMENTAL RESTRAINT SYSTEM - RCM 

62-17 

CAUTION 

• Do not start the operation within 90 seconds after diconnecting the cables. 

• Never strike the RCM when it is energized. 

(c) Position the RCM properly. 

(d) Tighten 3 bolts by the sequence shown in the illustration. 


NOTE 

Position the RCM along the direction shown in the 

information label. 

62 

62 

62 

(e) 

Connect the RCM wire harness connector. 

7. INSTALL INSTRUMENT CENTER COVER. 

(a) 

Tighten 3 screws and 2 bolts to install the instrument 

center cover. 






Page 2731

MEMO 

Page 2732

SEAT BELT 

SEAT BELT SYSTEM ........................................................................ 63-1 

PRECAUTION.............................................................................. 63-1 

SEAT BELT WARNING SYSTEM...................................................... 63-2 


INSPECTION ............................................................................... 63-3 

DRIVER / ASSISTANT DRIVER SEAT BELT ................................... 63-4 

COMPONENTS ........................................................................... 63-4 

PASSENGER SEAT BELT ................................................................ 63-5 

COMPONENTS ........................................................................... 63-5 

SEAT BELT CATCH ASSY................................................................ 63-9 

REPLACEMENT .......................................................................... 63-9 

RETRACTOR ASSY......................................................................... 63-15 

OVERHAUL ............................................................................... 63-15 

63 

63 

63 

Page 2733

Page 2734

SEAT BELT - SEAT BELT SYSTEM 

63-1 

SEAT BELT SYSTEM 

BELT 

PRECAUTION 

WARNING 

• Once any fault is found in the system, be sure to replace the parts (including belt, retractor, lock 

catch & latch, bolt and nut). 

• The seat belt which is not used in a collision should also be inspected and replaced if found any 

damage or working improperly. 

63 

63 

Page 2735

63-2 

SEAT BELT - SEAT BELT WARNING SYSTEM 

SEAT BELT WARNING SYSTEM 


Use the table below to help you find the cause of the problem. The numbers indicate the prioity of the likely 



1. Fuse (Burnt) - 

Seat belt warning light does not 

light up 

2.Intument cluster (Damaged) 

3.Electric lock catch assy (Damaged) 

Chapter 83 instrument panel-instrument 

cluster, replacement 

Chapter 63 seat belt - seat belt 

warning system, inspection 

4. Wire harness (Open or short) - 

Page 2736

SEAT BELT - SEAT BELT WARNING SYSTEM 

63-3 

INSPECTION 

1. INSPECT ELECTRIC LOCK CATCH ASSY. 

(a) Check the resistance. 

Standard: 

Driver seat belt 

latch plate 

Terminal 

Specified 

condition 

Pull out 1-2 < 2Ω 

63 

63 

Insert 1-2 > 1MΩ 

Page 2737

63-4 

SEAT BELT - DRIVER / ASSISTANT DRIVER SEAT BELT 

DRIVER / ASSISTANT DRIVER SEAT BELT 

COMPONENTS 

1 Driver Seat Belt With Retractor Assy 

2 Webbing Lock Catch Assy 

3 Electric Lock Catch Assy 

4 

5 Bolt 

Assistant Driver Seat Belt With Retractor 

Assy 

Page 2738

SEAT BELT - PASSENGER SEAT BELT 

63-5 

PASSENGER SEAT BELT 

COMPONENTS 

LEFT PASSENGER SEATS (2+2+2+2) 

63 

63 

1 Belt With Latch Plate Assy 

2 Dual Webbing Catch Assy 

3 

Belt With Latch Plate And Webbing Catch 

Assy 

Page 2739

63-6 


RIGHT PASSENGER SEATS (1+1+1) 

1 Seat Belt With Retractor 2 Webbing Catch Assy 

Page 2740


63-7 

LEFT PASSENGER SEATS (3+3) 

63 

63 

1 Belt With Latch Plate Assy 2 Dual Lock Catch Assy 

Page 2741

63-8 


RIGHT PASSENGER SEATS (1+1+2) 

1 Belt With retractor Assy 

2 Webbing Catch Assy 

3 Dual Lock Catch Assy 

4 

Belt With Latch Plate And Lock Catch 

Assy 

Page 2742

SEAT BELT - SEAT BELT CATCH ASSY 

63-9 

SEAT BELT CATCH ASSY 

REPLACEMENT 

1. REMOVE ELECTRIC LOCK CATCH ASSY. 

(a) 

Remove the driver seat assy. (Refer to “ Chapter 84 seat - driver / assistant driver seat, removal & 

installation and disassembly & reassembly”) 

63 

(b) 

Loosen the screw of the seat side tirm cover. 

63 

(c) 

Remove the reclining adjuster trim cover electric lock 

catch side by the sequence shown in the illustration. 

NOTE 

• Move the trim cover backward to separate 2 slots. 

• Pull outward and remove the trim cover. 

(d) 

Loosen completely the bolt attaching the electric lock 

catch to the driver seat reclining adjuster. 

Page 2743

63-10 


(e) 

Remove the electric lock catch assy. 

(f) 

Pull out the electric lock catch wire harness through the 

aperture between cushion pad and reclining adjuster. 

NOTE 

Be careful. Do not damage the electric lock catch wire harness 

connector. 

2. REMOVE LOCK CATCH ASSY. 

NOTE 

• Remove the lock catch assy by the same procedures as the electric lock catch assy. 

• Remove the lock catch assy in step (e). 

• Skip step (f). 

3. REMOVE LEFT REAR PASSENGER SEAT WEBBING 

CATCH ASSY. 

(a) Turn over the left coner of the middle seat cushion. 

(b) Loosen the bolt. 

(c) Remove the webbing catch assy. 

Page 2744


63-11 

4. REMOVE THE MIDDLE REAR SEAT WEBBING CATCH. 

(a) 

Remove seat cushion regulating handle. 

63 

63 

(b) 

Loosen retaining screw. 

(c) 

Remove the reclining adjuster trim cover. 

(d) 

(e) 

Loosen webbing catch retaining bolt. 

Remove webbing catch assy. 

5. REMOVE RIGHT REAR SEAT WEBBING CATCH ASSY. 

NOTE 

Remove the right rear seat webbing catch assy by the same procedures as the middle rear seat 

webbing catch assy 

Page 2745

63-12 


6. INSTALL ELECTRIC LOCK CATCH ASSY. 

(a) 

Put the electric lock catch wire harness connector 

through the aperture between cushion pad and reclining 

adjuster. 

CAUTION 

Be careful. Do not damage the electric lock catch wire harness 

connector. 

(b) 

(c) 

Position the electric lock catch assy properly. 



(d) 

Install the reclining adjuster trim cover electric lock catch 

sie by the sequence shown in the illustration. 

NOTE 

• Push the trim cover inward to align the slots. 

• Move the trim cover forward to position it properly. 

(e) 

Tighten the screw. 

7. INSTALL LOCK CATCH ASSY. 

NOTE 

• Install the lock catch assy by the same procedures as the electric lock catch assy. 

• Position the lock catch assy properly in step (b). 

Page 2746


63-13 

• Skip step (a). 

8. INSTALL THE LEFT REAR PASSENGER SEAT WEBBING 

CATCH. 

(a) 

(b) 

(c) 

Position the webbing catch assy. 


Position the seat cushion. 


63 

63 

9. INSTALL THE MIDDLE REAR PASSENGER SEAT 

WEBBING CATCH. 

(a) Position the webbing catch assy. 



(c) 

Install the webbing catch side trim. 

(d) 


Page 2747

63-14 


(e) 

Insert seat cushion regulating handle. 

10. INSTALL RIGHT REAR SEAT WEBBING CATCH ASSY. 

NOTE 

Install the right rear seat webbing catch assy by the same procedures as the middle rear seat webbing 

catch assy. 

Page 2748

SEAT BELT - RETRACTOR ASSY 

63-15 

RETRACTOR ASSY 

OVERHAUL 

1. REMOVE DRIVER SEAT BELT WITH RETRACTOR 

ASSY. 

(a) 

Turn up the trim cover, loosen the bolt. 

63 

63 

(b) 

Remove the lower belt retaining bolt. 

(c) Remove front quarter panel guard board.(Refer to “Chapter 88 

exterior and interior trim - quarter panel guard board, 


(d) 

(e) 

Loosen the bolt. 

Remove the driver seat belt retractor assy. 

CAUTION 

Never disassemble the retractor. 

2. REMOVE ASSISTANT DRIVER SEAT BELT WITH RETRACTOR ASSY. 

NOTE 

Remove the assistant driver seat belt with retractor by the same procedures as the driver seat belt with 

retractor assy. 

Page 2749

63-16 


3. INSPECT RETRACTOR. 

(a) Check whether the seat belt is locked when tilting the 

retractor. 

• Within 15° of tilt in all the directions, check that the 

seat belt should not be locked. 

• Over 45° of tilt in all the directions, check that the 

seat belt should be locked. 

If the operation is out of the specification, replace with a new 

driver / assistant driver seat belt with retractor assy. (Refer to 

“Chapter 63 seat belt - retractor assy, overhaul”) 

4. REMOVE LEFT REAR PASSENGER SEAT BELT WITH RETRACTOR ASSY. 

(a) Remove left rear passenger seat assy. (Refer to “Chapter 84 seat - driver / assistant driver seat, 

remove & installion and disassembly & reassemlby”) 

(b) 

(c) 

(d) 

Remove seat belt with retractor assy trim cover. 

Loosen retractor retaining bolt, remove retractor assy. 

Loosen belt lower retaining bolt. 

NOTE 

Be careful not to lose gasket. 

(e) 

Remove the belt upper retaining bolt. 

(f) 

Remove seat belt with retractor assy. 

Page 2750


63-17 

5. REMOVE MIDDLE REAR PASSENGER SEAT BELT 

WITH RETRACTOR ASSY. 

(a) 

Remove retractor housing. 

63 

63 

(b) 

Remove the retractor retaining bolt. 

(c) 

Remove 4 belt retaining screws. 

Page 2751

63-18 


(d) 

(e) 

(f) 

Turn over the middle rear seat cushion. 

Loosen belt bolt. 

Remove seat belt with retractor assy. 

6. REMOVE RIGHT REAR ASSISTANT DRIVER SEAT BELT WITH RETRACTOR ASSY. 

NOTE 

Remove the right rear assistant driver seat belt with retractor by the same procedures as the left rear 

assistant driver seat belt with retractor assy. 

7. INSTALL DRIVER SEAT BELT RETRACTOR ASSY. 

(a) Position the driver seat belt retractor assy. 


(c) Install front quarter panel guard board.(Refer to “Chapter 88 

exterior and interior trim - quarter panelquarter panel guard 

board, replacement”) 


NOTE 

Make sure the seat belt is flat, do not kink or winding. 

(d) 

Install belt lower retaining bolt. 


Page 2752


63-19 

(e) 

(f) 



Install the trim cover. 

CAUTION 

Make sure the seat belt is flat, do not kink or winding. 

63 

63 

8. INSTALL ASSISTANT DRIVER SEAT BELT WITH RETRACTOR ASSY. 

NOTE 

Install the assistant driver seat belt with retractor by the same procedures as the driver seat belt with 

retractor assy. 

9. INSTALL LEFT REAR PASSENGER SEAT BELT WITH 

RETRACTOR ASSY. 

(a) Position the belt upper retaining bolt. 

(b) Tighten the belt upper retaining bolt 


(c) Install the trim cover. 

(d) 

(e) 

(f) 

(g) 

Tighten belt lower retaining bolt. 

Position the retractor. 

Tighten the retractor retaining bolt. 


Install belt retractor trim cover. 

Page 2753

63-20 


10. INSTALL MIDDLE REAR SEAT RETRACTOR. 

(a) Turn over the middle rear seat cushion. 

(b) Tighten the belt bottom retaining bolt. 


(c) 

(d) 

Install seat cushion. 

Tighten 4 belt retaining screws. 

(e) 

(f) 

Position the seat belt with retractor. 

Tighten seat belt with retractor retaining bolt. 


Page 2754


63-21 

(g) 

(h) 

Position the belt retractor housing. 

Install the belt retractor housing. 

63 

63 

11. INSTALL RIGHT REAR SEAT BELT WITH RETRACTOR ASSY. 

NOTE 

Install the right rear passenger belt with retractor by the same procedures as the left rear passenger 

belt with retractor assy. 

12. Inspect driver / assistant driver seat belt with retractor assy. 

(a) Check belt locking operation. 

• The belt should be locked when being dragged quickly. 

(b) Check children protection operation. 

• After extracting the belt out of the retractor completely, the retractor enters LOCK mode. In this mode, 

the belt only can be contracted. 

• When the belt contracts fully, the retractor will recover to NORMAL mode from LOCK mode. 

NOTE 

This function is used for the children protector applied to the vehicle. 

If the operation is out of the specification, replace with a new driver / assistant driver seat belt with retractor 

assy. (Refer to “Chapter 63 seat belt - retractor assy, overhaul”) 

Page 2755

MEMO 

Page 2756

LIGHTING 

LIGHTING SYSTEM........................................................................... 64-1 

PRECAUTION.............................................................................. 64-1 

FRONT COMBINATION LAMP ASSY............................................... 64-2 

COMPONENTS ........................................................................... 64-2 

REPLACEMENT .......................................................................... 64-3 

ADJUSTMENT............................................................................. 64-7 

FRONT FOG LAMP ASSY................................................................. 64-8 

REPLACEMENT .......................................................................... 64-8 

REAR COMBINATION LAMP ASSY............................................... 64-10 

COMPONENTS ......................................................................... 64-10 

REPLACEMENT ........................................................................ 64-11 

LICENCE LAMP ASSY .................................................................... 64-14 

REPLACEMENT ........................................................................ 64-14 

HIGH-MOUNTED STOP LAMP ASSY............................................. 64-16 

REPLACEMENT ........................................................................ 64-16 

FRONT DOME LIGHT ASSY ........................................................... 64-17 

REPLACEMENT ........................................................................ 64-17 

MIDDLE DOME LIGHT ASSY.......................................................... 64-19 

REPLACEMENT ........................................................................ 64-19 

REAR DOME LIGHT ASSY ............................................................. 64-22 

REPLACEMENT ........................................................................ 64-22 

STEP LAMP ASSY........................................................................... 64-25 

REPLACEMENT ........................................................................ 64-25 

COMBINATION SWITCH ASSY ...................................................... 64-27 

REPLACEMENT ........................................................................ 64-27 

64 

64 

64 

Page 2757

Page 2758


PRECAUTION 

1. LIGHTING SYSTEM PRECAUTION. 

(a) 

(b) 

(c) 

(d) 

LIGHTING - LIGHTING SYSTEM 

64-1 

Even if a thin film of oil is left on the surface of the halogen lamp, its service life will be shortened because 

the lamp will be burned at a higher temperature. 

Handle any halogen lamp with great care. Dropping, hitting or damaging the bulb in any way may result 

in exploding and scattering because the internal pressure is high. 

Always use a bulb of the same wattage for replacement. Be sure not to touch the bulb immediately. 

Reinstall the socket firmly after bulb replacement. The lens may become cloudy or the light cavity may 

be filled with water through the gaps around the socket. 

64 

64 

19A 

Page 2759

64-2 

LIGHTING - FRONT COMBINATION LAMP ASSY 

FRONT COMBINATION LAMP ASSY 

COMPONENTS 





5 Bolt 

6 Support Holder 


8 Bolt 

Page 2760


64-3 

REPLACEMENT 


2. REMOVE FRONT COMBINATION LAMP ASSY LH. 

(a) Remove the front grille. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”) 

(b) Remove the front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy, 


64 

64 

(c) 

Loosen 3 screws. 

(d) 

Disconnect the 3 connectors and remove front combination 

lamp assy LH. 

19A 

3. REMOVE FRONT COMBINATION LAMP ASSY RH. 

NOTE 

Remove the RH side by the same procedures as the LH side. 

4. REMOVE HEADLAMP BULB LH. 

(a) Remove the cap . 

Page 2761

64-4 


(b) 

Remove the steel wire. 

(c) 

Remove the headlamp bulb. 

5. REMOVE HEADLAMP BULB RH. 

NOTE 


6. REMOVE LAMPLET BULB LH. 

(a) 

Remove the lamp socket. 

(b) 

Remove the lamplet bulb. 

7. REMOVE LAMPLET BULB RH. 

NOTE 

Remove the RH side by the same procedures as the LH side 

Page 2762


64-5 

8. REMOVE SIDE TURN SIGNAL LAMP BULB. 

NOTE 

Side turn signal lamp bulb is LED (Light emitting diode) it can not be replaced without the lamp socket. 

9. INSTALL HEADLAMP BULB LH 

(a) 

Install the headlamp bulb, Tighten the steel wire. 

64 

64 

(b) 

Install the cap. 

19A 

10. INSTALL HEADLAMP BULB RH. 

NOTE 

Install the RH side by the same procedures as the LH side 

11. INSTALL LAMPLET BULB LH. 

(a) 

(b) 

Install the lamplet bulb. 

Install the lamp socket. 

12. INSTALL LAMPLET BULB RH. 

NOTE 

Install the RH side by the same procedures as the LH side 

Page 2763

64-6 


13. INSTALL FRONT COMBINATION LAMP ASSY LH. 

(a) Connect the 3 connectors to front combination lamp assy 

LH. 

(b) Install the front combination lamp LH and tighten the 3 

screws. 

(c) Install the front bumper assy. (Refer to “Chapter 88 

exterior and interior trim - front bumper assy, 


(d) Install the front grille. (Refer to “Chapter 88 exterior and 

interior trim - front grille, replacement”) 

14. INSTALL FRONT COMBINATION LAMP ASSY RH. 

NOTE 

Install the RH side by the same procedures as the LH side. 


Page 2764


64-7 

ADJUSTMENT 

1. ADJUST THE HEADLAMP AIMING. 

(a) Park the vehicle in the following conditions. 

• The area around the headlight is not deformed. 

• The vehicle is parked on a level surface. 

• Tire inflation pressure is in the specified value. (Refer to “Chapter 33 tire and wheel - tire and wheel 

system, on-vehicle inspection,”) 

• A driver is in the driver’s seat or let something weighs 73 Kg on the seat of the vehicle; the vehicle is 

ready for driving. (with a tank full) 

64 

64 

(b) Check the headlamp aiming. 

• Park the vehicle at the flat field and make the lens surface 

of the headlamps be 10m away from the screen.The 

curtain or flat wall can be used as the screen. 


• Turn the headlamps on. 

• Check that the headlamps properly strike the position 

shown in the illustration. 

NOTE 

A and B shows the position of the headlamps; H shows the 

height of the headlamps; L1 and L2 shows the distance 

between the center of headlamps and the center of the 

vehicle. 

• Adjust the headlamps if necessary. 

(c) 

Adjust the adjusting screws to adjust the headlamp aiming 

to be within the specified range. 

19A 

Page 2765

64-8 

LIGHTING - FRONT FOG LAMP ASSY 

FRONT FOG LAMP ASSY 

REPLACEMENT 


2. REMOVE FRONT FOG LAMP ASSY LH. 

(a) Remove the front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy, 


(b) 

Disconnect the connectors from the front fog lamp assy. 

(c) 

Loosen 3 nuts and remove the front fog lamp assy LH. 

3. REMOVE FRONT FOG LAMP BULB LH. 

(a) Remove the cap. 

(b) Remove the steel wire. 

(c) Remove the front fog lamp bulb 

4. REMOVE FRONT FOG LAMP ASSY RH. 

NOTE 


Page 2766

LIGHTING - FRONT FOG LAMP ASSY 

64-9 

5. INSTALL FRONT FOG LAMP BULB LH. 

(a) Install the front fog lamp bulb. 

(b) Install the steel wire. 

(c) Install the cap. 

64 

64 

6. INSTALL FRONT FOG LAMP ASSY LH. 

(a) Install the front fog lamp assy and tighten 3 nuts. 

(b) 

Connect the connectors to front fog lamp assy. 

19A 

(c) 

Install the front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy, 


7. INSTALL FRONT FOG LAMP ASSY RH. 

NOTE 



Page 2767

64-10 

LIGHTING - REAR COMBINATION LAMP ASSY 

REAR COMBINATION LAMP ASSY 

COMPONENTS 



3 Bolt 


5 High-mounted Stop Lamp Assy 

7 License Plate Lamp Assy 

8 Bolt 


10 Sealing Gasket LH 

11 Sealing Gasket RH 

6 Nut 

Page 2768


64-11 

REPLACEMENT 


2. REMOVE REAR COMBINATION LAMP ASSY LH. 

(a) Remove the 3 bolts. 

64 

64 

(b) 

Disconnect the connector and remove rear combination 

lamp assy LH. 

3. REMOVE BULBS OF REAR COMBINATION LAMP ASSY 

LH. 

(a) Remove the lamp sockets. 

19A 

(b) 

Remove the bulbs. 

Page 2769

64-12 


4. REMOVE REAR COMBINATION LAMP ASSY RH. 

NOTE 


5. INSTALL BULBS OF REAR COMBINATION LAMP 

ASSY LH. 

(a) 

Install the bulbs. 

(b) 

Install lamp sockets. 

6. INSTALLE REAR COMBINATION LAMP ASSY LH. 

(a) Connect the connector to rear combination lamp assy 

LH. 

(b) 

Install the rear combination lamp assy LH and tighten the 

3 bolts. 

Page 2770


64-13 

7. INSTALL REAR COMBINATION LAMP ASSY RH. 

NOTE 



64 

64 

19A 

Page 2771

64-14 

LIGHTING - LICENCE LAMP ASSY 

LICENCE LAMP ASSY 

REPLACEMENT 


2. REMOVE LICENCE LAMP ASSY LH. 

(a) Remove 2 screws of licence lamp assy LH. 

(b) 

(c) 

Remove the lampshade. 

Disconnect the connector. 

(d) 

Remove the bulb of licence lamp. 

3. REMOVE LICENCE LAMP ASSY RH. 

NOTE 


4. INSTALL LICENCE LAMP ASSY LH. 

(a) Install the bulb of licence lamp. 

Page 2772

LIGHTING - LICENCE LAMP ASSY 

64-15 

(b) 

(c) 

Install the lampshade. 

Connect the connector. 

64 

64 

(d) 


5. INSTALL LICENCE LAMP ASSY RH. 

NOTE 



19A 

Page 2773

64-16 

LIGHTING - HIGH-MOUNTED STOP LAMP ASSY 

HIGH-MOUNTED STOP LAMP ASSY 

REPLACEMENT 


2. REMOVE HIGH-MOUNTED STOP LAMP ASSY. 

(a) 

(b) 

Remove the rear hatch upper guard board. (Refer to 

“Chapter 88 exterior and interior trim - vehicle door inner 

guard board, replacement”) 


(c) 

(d) 

Loosen 2 screws. 

Remove the high-mounted stop lamp assy. 

3. INSTALL HIGH-MOUNTED STOP LAMP ASSY. 

(a) 


(b) Connect the connector . 

4. CONNECT THE BATTERY NEGATIVE GABLE. 

(c) 




Page 2774

LIGHTING - FRONT DOME LIGHT ASSY 

64-17 

FRONT DOME LIGHT ASSY 

REPLACEMENT 


2. REMOVE FRONT DOME LIGHT BULB. 

(a) 


NOTE 

Be carefully, do not damage interior trim. 

64 

64 

(b) 

(c) 


Remove the front dome light. 

(d) 

Remove the front dome light bulb. 

NOTE 


19A 

3. INSTALL FRONT DOME LIGHT. 

(a) Position the front dome light bulb. 

Page 2775

64-18 

LIGHTING - FRONT DOME LIGHT ASSY 

(b) 


(c) 



Page 2776

LIGHTING - MIDDLE DOME LIGHT ASSY 

64-19 

MIDDLE DOME LIGHT ASSY 

REPLACEMENT 


2. REMOVE MIDDLE DOME LIGHT ASSY. 

(a) 


NOTE 


64 

64 

(b) 

Loosen 2 screws 

(c) 

(d) 


Remove the middle dome light assy. 

19A 

3. INSTALL MIDDLE DOME LIGHT ASSY. 

(a) Connect the connector. 

Page 2777

64-20 


(b) 

Tighten 2 screws 

(c) 


4. REMOVE MIDDLE DOME LIGHT BULB. 

(a) 


NOTE 


(b) 

(c) 

Turn up the leaf spring. 

Remove the dome light. 

NOTE 

Be carefully, do not damage the light. 

5. INSTALL MIDDLE DOME LIGHT BULB. 

(a) Turn up the leaf spring. 

(b) Install the dome light. 

Page 2778


64-21 

(c) 


64 

64 

19A 

Page 2779

64-22 

LIGHTING - REAR DOME LIGHT ASSY 

REAR DOME LIGHT ASSY 

REPLACEMENT 


2. REMOVE REAR DOME LIGHT ASSY. 

(a) 

Hold on both side, remove the cover of air purifier. 

(b) 

(c) 

Loosen 8 screws and 2 bolts. 

Disconnect 3 connectors. 

(d) 

Remove rear dome light socket. 

Page 2780


64-23 

(e) 

Remove rear dome light bulb. 

64 

64 

3. INSTALL REAR DOME LIGHT BULB. 

(a) 

Position the rear dome light bulb. 

(b) 

(c) 

Connect 3 connectors 

Tighten 8 screws and 2 bolts. 

19A 

Page 2781

64-24 


(d) 

Install the cover of air purifier. 


Page 2782

LIGHTING - STEP LAMP ASSY 

64-25 

STEP LAMP ASSY 

REPLACEMENT 


2. REMOVE STEP LAMP ASSY. 

(a) 

Use a screwdriver to remove step lamp assy. 

64 

64 

(b) 

(c) 


Remove the step lamp assy. 

3. INSTALL STEP LAMP ASSY. 


19A 

(b) 

Install step lamp assy. 

Page 2783

64-26 

LIGHTING - STEP LAMP ASSY 

4. REMOVE STEP LAMP BULB. 

(a) 

(b) 

Remove the step lamp lampshade. 

Remove the step lamp bulb. 

NOTE 

Be careful do not damage the step lamp. 

5. INSTALL STEP LAMP BULB. 

(a) Install the step lamp bulb. 

(b) Install the step lamp lampshade. 


Page 2784

LIGHTING - COMBINATION SWITCH ASSY 

64-27 

COMBINATION SWITCH ASSY 

REPLACEMENT 


2. REMOVE COMBINATION SWITCH ASSY. 

(a) Remove the steering wheel assy. (Refer to “Chapter 51 steering column - steering wheel assy, 

overhaul”) 

64 

64 

(b) 

(c) 

Loosen the 2 screws. 

Remove the upper and lower cover. 

(d) 

(e) 

Disconnect combination switch connector. 

Remove combination switch assy. 

19A 

3. INSTALL COMBINATION SWITCH ASSY. 

(a) Position the combination switch. 

(b) Connect the combination switch connector. 

(c) 

(d) 

Install the upper and lower cover. 

Tighten the 2 screws. 

(e) Install the steering wheel assy. (Refer to “Chapter 51 

steering column - steering wheel assy, overhaul”) 

Page 2785

64-28 

LIGHTING - COMBINATION SWITCH ASSY 


Page 2786


WIPER AND WASHER SYSTEM....................................................... 65-1 

PRECAUTION.............................................................................. 65-1 


COMPONENTS ........................................................................... 65-4 

WIPER ASSY ..................................................................................... 65-5 

REPLACEMENT .......................................................................... 65-5 

WIPER LINK WITH MOTOR ASSY ................................................... 65-9 

REPLACEMENT .......................................................................... 65-9 

WIPER BLADE WITH BRACKET ASSY ......................................... 65-13 

REPLACEMENT ........................................................................ 65-13 

WASHER NOZZLE........................................................................... 65-15 

INSPECTION ............................................................................. 65-15 

ADJUSTMENT........................................................................... 65-16 

WASHER ASSY ............................................................................... 65-17 

REPLACEMENT ........................................................................ 65-17 

WASHER PUMP ASSY.................................................................... 65-19 

REPLACEMENT ........................................................................ 65-19 

65 

65 

Page 2787

Page 2788

WIPER AND WASHER - WIPER AND WASHER SYSTEM 

WIPER AND WASHER SYSTEM 

AND WASHER 

PRECAUTION 

1. PRECAUTION ON WASHER FLUID. 

(a) Usually use ordinary washer fluid for window glass. 

(b) Sometimes use water instead of the washer fluid temporarily. 

(c) Be sure to fill correct washer fluid in low temperature area. 

(d) Never use the coolant for engine or other substitutes to prevent damage on body paint. 

65-1 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

Page 2789

65-2 






1. Fuse (Damaged) - 

Wipers do not operate 

2. Wiper switches (Damaged) 

3. Wiper motor (Damaged) 


combination switch assy, 

replacement 


wiper motor assy, replacement 


Front wipers do not operate in LO 

or HI 

1. Front wiper switch (Damaged) 

2. Front wiper motor (Damaged) 



replacement 







replacement 

Front wipers do not operate in 

INT 

2. Solid state timer (Damaged) - 

3. Front wiper motor (Damaged) 




Rear wiper does not operate 

1. Rear wiper and washer switch 

(Damaged) 



replacement 


Wiper arms do not stop automatically 

or not in correct position 

(Wiper switch turned off) 

1. Wiper arms (Installed incorrectly) 

2. Wiper motor (Damaged) 


wiper assy, replacement 





1. Worm (Rusty or unlubricated) 

2. Wiper link (Worn or deformed) 

3. Wiper blade assy (Aging or 

cracked) 




wiper link assy, replacement 


wiper blade with bracket assy, 

replacement 

Page 2790


65-3 


Wiper less effective 

1. Front and rear windshield (Be 

soiled by oil or wax) 

2. Washer fluid (Poor quality) - 

3. Wiper blade assy (Incorrect type) - 

4. Wiper blade assy (Aging or 

cracked) 

- 


wiper blade with bracket assy, 

replacement 

65 

65 

65 

65 

5. Wiper arms (Deformed or 

damaged) 



65 

Washers do not operate 

6. Wiper arms (Spring force 

declined) 


2. Rear wiper and washer switch 

(Damaged) 

3. Washer motor with pump assy 

(Damaged) 


1. Washer fluid (Low) - 

2. Washer fluid (Frozen) - 





replacement 



replacement 

- 

65 

65 

65 

65 

65 

65 

65 

65 

Washer fluid does not spray or 

spray powerlessly 

Incorrect point where washer fluid 

spray on front / rear windshield 

3. Washer fluid hose (Curving or 

jam) 

4. Washer nozzle (Blocking) 

5. Washer motor with pump assy 

(Damaged) 

1. Washer nozzle (Adjustment 

required) 

- 


washer nozzle, inspection 

- 


washer nozzle, adjustment 

65 

65 

65 

65 

65 

65 

65 

Page 2791

65-4 


COMPONENTS 

VEHICLE WITH REAR WIPER ASSY 

1 Front Wiper Assy RH 

2 Front Wiper Assy LH 

3 Bolt 

4 Washer 

5 Front Link With Motor Assy 

6 Front Washer Assy 

8 Washer 

9 Rear Washer Assy 

10 Rear Wiper Assy 

11 Nut 

12 Rear Link With Motor Assy 

13 Bolt 

7 Bolt 

Page 2792

WIPER AND WASHER - WIPER ASSY 

65-5 

WIPER ASSY 

REPLACEMENT 

1. REMOVE FRONT WIPER ASSY LH. 

(a) Remove the front wiper arm cap. 

CAUTION 

Do not perform this operation when the windshield is dry to prevent 

scoring. 

65 

65 

65 

65 

65 

65 

65 

65 

(b) 

Loosen the nut and remove the spring washer. 

65 

65 

65 

65 

(c) 

Remove the front wiper assy LH. 

65 

65 

NOTE 

Upturn the front wiper arm LH before performing this operation. 

65 

65 

65 

65 

65 

65 

2. REMOVE FRONT WIPER ASSY RH. 

NOTE 


Page 2793

65-6 


3. REMOVE REAR WIPER ASSY. 

(a) Remove the rear wiper arm cap. 

(b) 

(c) 

Loosen the nut 

Remove the rear wiper assy. 

NOTE 

Upturn the rear wiper arm before performing this procedure. 

4. INSTALL FRONT WIPER ASSY LH. 

(a) Scrape off the spline part of the wiper arm with a round 

file or equivalent. 

(b) Clean the wiper pivot spline with the wire brush. 

(c) 

(d) 

Position the front wiper assy LH properly. 

Install the spring washer and tighten the nut. 


NOTE 

• The front wiper blade assy LH should be located 

along lower edge of the windshield. 

• Upturn the front wiper arm LH before performing this 

procedure. 

Page 2794


65-7 

(e) 

Install the front wiper arm cap. 

NOTE 

• Turn the front wiper arm LH down after performing 

this procedure. 

• Make sure the front wiper blade assy LH is located 

along lower edge of the rear windshield. 

65 

65 

65 

65 

65 

65 

(f) Check the automatic stop position of front wiper assy LH. 

• Set the front wiper switch to the “INT / LO / HI” position to 

activate the front wiper assy. 

CAUTION 

Do not perform this operation when the windshield is dry to 

prevent scoring. 

• Set the front wiper switch to the “OFF” position to stop 

the front wiper assy at the automatic stop position. 

• Check whether the front wiper blade assy LH is located 

along lower edge of the windshield. 

65 

65 

65 

65 

65 

65 

5. INSTALL FRONT WIPER ASSY RH. 

NOTE 


6. INSTALL REAR WIPER ASSY. 

(a) Scrape off the serration part of the wiper arm with a 

round file or equivalent. 

(b) Clean the wiper pivot serration with the wire brush. 

65 

65 

65 

65 

65 

65 

(c) 

(d) 

Position the rear wiper assy properly. 


65 

65 

NOTE 

• The rear wiper blade assy should be located along 

the lower edge of the rear window. 

• Turn the rear wiper arm up before performing this 

procedure. 

Page 2795

65-8 


(e) 

Install the rear wiper arm cap. 

NOTE 

• Turn the rear wiper arm down after performing this 

procedure. 

• Make sure the rear wiper blade assy is located along 

lower edge of the rear window. 

(f) 

Check the automatic position of rear wiper assy. 

• Set the rear wiper switch to the “INT/ON” position to 

activate the rear wiper assy. 

CAUTION 

Do not perform this operation when the rear window is dry 

to prevent scoring. 

• Set the rear wiper switch to the “OFF” position to 

stop the rear wiper assy at the automatic stop 

position. 

• Check whether the rear wiper blade assy is located 

along lower edge of the rear window. 

Page 2796

WIPER AND WASHER - WIPER LINK WITH MOTOR ASSY 

WIPER LINK WITH MOTOR ASSY 

REPLACEMENT 

1. STOP WIPER ASSY AT AUTOMATIC STOP POSITION. 

(a) Stop the front wiper assy at the automatic stop position. 

• Set the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy. 

65-9 

CAUTION 

Do not perform this operation when the windshield is dry in order to prevent the windshield from 

scoring. 

• Set the front wiper switch to the “OFF” position to stop the front wiper assy at the automatic stop 

position. 

(b) Stop the rear wiper assy at the automatic stop position. 

• Set the rear wiper switch to the “INT / ON” position to activate the rear wiper assy. 

CAUTION 

Do not perform this operation when the rear window is dry in order to prevent the windshield from 

scoring. 

• Set the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop 

position. 



3. REMOVE FRONT WIPER LINK WITH MOTOR ASSY. 

(a) Open the engine hood and support it with the hood rod. 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

(b) 

(c) 

(d) 

Remove windshield lower trim cover side rubber strip. 

Loosen retaining buckles. 

Remove windshield lower trim cover. 

65 

65 

65 

65 

65 

65 

65 

65 

Page 2797

65-10 


(e) 

Disconnect front wiper motor connector. 

(f) 

(g) 

Loosen 2 wiper link bolts. 

Remove front wiper link with motor assy. 

4. REMOVE REAR WIPER MOTOR WITH LINK ASSY. 

(a) Remove the rear wiper assy. (Refer to “Chapter 65 wiper and washer - wiper assy, replacement”) 

(b) 

(c) 

Remove the rear wiper arm shaft seal. 

Remove the nut. 

(d) 

(e) 




Disconnect the rear wiper motor with link assy connector. 

Page 2798


65-11 

(f) 

(g) 

Loosen 3 bolts. 

Remove rear wiper motor with link assy. 

NOTE 

Store the rear wiper motor with link assy carefully. Do not 

rotate the rocker arm of rear wiper motor with link assy. 

65 

65 

65 

5. INSTALL FRONT WIPER LINK WITH MOTOR ASSY. 

(a) Tighten front wiper link with motor 2 bolts. 


(b) Connect motor connector. 

65 

65 

65 

65 

65 

65 

(c) 

(d) 

(e) 

Position the windshield lower trim cover. 

Install clips and windshield lower trim cover. 

Install windshield lower trim side rubber strip. 

NOTE 

Be sure change new clips. 

65 

65 

65 

65 

65 

6. INSTALL REAR WIPER MOTOR WITH LINK ASSY. 

(a) Position the rear wiper motor with link assy properly. 

(b) Tighten 3 bolts. 


65 

65 

65 

65 

(c) 

Connect the rear wiper motor with link assy connector. 

65 

65 

Page 2799

65-12 


(d) 

(e) 

(f) 

Install the rear hatch upper guard board. (Refer to 




Install the rear wiper arm shaft seal. 

(g) 

Install the rear wiper assy. (Refer to “Chapter 65 wiper 

and washer - wiper assy, replacement”) 


replacement”). 

8. CHECK AUTOMATIC STOP POSITION OF WIPER ASSY. 

(a) Check automatic stop position of the front wiper assy LH. 

• Set the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy. 

CAUTION 

Do not perform this operation when the windshield is dry in order to prevent the windshield from 

scoring. 

• Set the front wiper switch to the “OFF” position to stop the front wiper assy at the automatic stop 

position. 

• Check whether the front wiper blade assy LH is located along lower edge of the windshield. 

(b) Check the automatic position of rear wiper assy. 

• Set the rear wiper switch to the “INT / ON” position to activate the rear wiper assy. 

CAUTION 

Do not perform this operation when the rear window is dry in order to prevent the windshield from 

scoring. 

• Set the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop 

position. 

• Check whether the rear wiper blade assy is located along lower edge of the rear window. 

Page 2800

WIPER AND WASHER - WIPER BLADE WITH BRACKET ASSY 

65-13 

WIPER BLADE WITH BRACKET ASSY 

REPLACEMENT 

1. REMOVE FRONT WIPER BLADE WITH BRACKET ASSY LH. 

(a) Upturn the front wiper blade bracket assy LH. 

(b) 

Press the latch plate. 

65 

65 

65 

65 

65 

65 

(c) Remove the front wiper blade with bracket assy LH. 

65 

65 

65 

65 

65 

65 

2. REMOVE FRONT WIPER BLADE WITH BRACKET ASSY RH. 

NOTE 


3. REMOVE REAR WIPER BLADE WITH BRACKET ASSY. 

NOTE 

Remove the rear side by the same procedures as the front side. 

4. INSTALL FRONT WIPER BLADE WITH BRACKET 

ASSY LH. 

(a) Position the front wiper blade with bracket assy LH. 

(b) Turn the front wiper blade bracket assy LH down. 

65 

65 

65 

65 

65 

65 

65 

65 

Page 2801

65-14 

WIPER AND WASHER - WIPER BLADE WITH BRACKET ASSY 

(c) 

Install the front wiper blade with bracket assy LH. 

NOTE 

If hear a “click”, the front wiper blade assy is connected to 

the front wiper link assy completely. 

(d) 

Turn the front wiper blade with brackte assy LH down. 

5. INSTALL FRONT WIPER BLADE WITH BRACKET ASSY RH. 

NOTE 


6. INSTALL REAR WIPER BLADE WITH BRACKET ASSY. 

NOTE 

Install the rear side by the same procedures as the front side. 

Page 2802

WIPER AND WASHER - WASHER NOZZLE 

65-15 

WASHER NOZZLE 

INSPECTION 

1. INSPECT WASHER NOZZLE. 

(a) Set the front washer switch to the “ON” position. Check the point which the washer fluid sprays on 

windshield is in the range shown in the illustration. 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

65 

(b) 

Set the rear wiper and washer switch and check the point which the washer fluid spray on rear window 

is in the range shown in the illustration. 

65 

65 

65 

65 

65 

65 

65 

65 

65 

Page 2803

65-16 

WIPER AND WASHER - WASHER NOZZLE 

ADJUSTMENT 

1. ADJUST WASHER NOZZLE. 

(a) Check the point which the washer fluid sprays on windshield and rear window. (Refer to “Chapter 65 

wiper and washer - washer nozzle, inspection”) 

(b) Insert a needle or equivalent into the nozzle to adjust until the point which the washer fluid sprays on 

windshield and rear window is within the range specified. 

Page 2804

WIPER AND WASHER - WASHER ASSY 

65-17 

WASHER ASSY 

REPLACEMENT 

1. REMOVE WASHER ASSY. 

(a) Loosen 2 screws. 

65 

65 

65 

65 

(b) Disconnect washer pump connector and water pipe. 

65 

65 

65 

65 

65 

65 

(c) 

Remove the washer assy. 

65 

65 

65 

65 

65 

2. INSTALL WASHER ASSY. 

(a) 

Position the washer assy. 

65 

65 

65 

65 

65 

Page 2805

65-18 

WIPER AND WASHER - WASHER ASSY 

(b) 

Connect washer pump connector and water pipe. 

(c) 

Tighten 2 screws, install the washer assy. 

Page 2806

WIPER AND WASHER - WASHER PUMP ASSY 

65-19 

WASHER PUMP ASSY 

REPLACEMENT 

1. REMOVE WASHER PUMP ASSY. 

(a) Disconnect washer pump connector. 

65 

65 

65 

65 

(b) Remove washer assy.(Refer to “Chapter 65 wiper and 

washer - washer assy, replacement”) 

(c) Disconnect washer pump pipe. 

(d) Remove washer pump. 

NOTE 

Do not reuse the seal ring again. 

65 

65 

65 

65 

65 

65 

65 

2. INSTALL WASHER PUMP ASSY. 

(a) Replacement the seal ring. 

(b) Position the washer pump. 

65 

65 

65 

65 

65 

(c) 

Connect washer pump pipe. 

65 

65 

65 

65 

(d) 

Install washer assy.(Refer to “Chapter 65 wiper and 

washer - washer assy, replacement”) 

Page 2807

65-20 

WIPER AND WASHER - WASHER PUMP ASSY 

(e) 

Connect the washer pump connector. 

Page 2808

AUDIO SYSTEM 

AUDIO SYSTEM................................................................................. 66-1 

COMPONENTS ........................................................................... 66-1 

MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY ........... 66-2 

REPLACEMENT .......................................................................... 66-2 

FRONT SPEAKER ASSY .................................................................. 66-4 

REPLACEMENT .......................................................................... 66-4 

MIDDLE SPEAKER ASSY................................................................. 66-6 

REPLACEMENT .......................................................................... 66-6 

REAR SPERKER ASSY..................................................................... 66-8 

REPLACEMENT .......................................................................... 66-8 

TELESCOPIC ANTENNA ASSY...................................................... 66-10 

REPLACEMENT ........................................................................ 66-10 

ELECTRIC DEVICE ACCESSORIES .............................................. 66-12 

REPLACEMENT ........................................................................ 66-12 

02 

66 

02 

Page 2809

Page 2810

AUDIO SYSTEM 

SYSTEM 

COMPONENTS 

AUDIO SYSTEM - AUDIO SYSTEM 

66-1 

66 

66 

19A 

1 Telescopic Antenna Mounting Bolt 

2 Telescopic Antenna Assy 

3 Telescopic Antenna Clamp 

4 Water Pipe Inner Rubber Block 

5 

Multi-media and Air-condition Controller 

Assy 

6 Screw 


8 Flat Washer 

9 Screw and Big Washer Set 

10 Front Speaker Assy 

11 Screw and Flat Washer Set 

12 Plastic Nut 

13 Speaker Assy RR 

14 Speaker Assy RL 

Page 2811

66-2 

AUDIO SYSTEM - MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY 

MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY 

REPLACEMENT 


2. REMOVE EXTERIOR FRAME OF MULTI-MEDIA AND 

AIR-CONDITION CONTROLLER ASSY. 

NOTE 

Pry out the frame with plastic trim stick, be careful not damage 

exterior frame and panel. 

3. REMOVE MULTI-MEDIA AND AIR-CONDITION CON- 

TROLLER ASSY. 

(a) 

Remove 4 mounting screws of Multi-media and aircondition 

controller assy. 

(b) 

(c) 

Take out Multi-media and air-condition assy,disconnect 

connector of Multi-media and air-condition controller assy 

with telescopic antenna,power supply,signal wire,aircondition 

wire. 

Remove GPS antenna. 

(d) 

Remove Multi-media and air-condition controller assy. 

Page 2812

AUDIO SYSTEM - MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY 

66-3 

4. INSTALL MULTI-MEDIA AND AIR-CONDITION CONTROLLER 

ASSY. 

(a) 

(b) 

Install GPS antenna. 

Reconnect connector of multi-media and air-condition 

controller assy with telescopic antenna, power supply, 

signal wire, air-condition wire. 

66 

66 

(c) 

Replace multi-media and air-condition controller assy, tighten 

4 mounting screws of multi-media and air-condition controller 

assy. 

5. INSTALL EXTER-FRAME OF MULTI-MEDIA AND AIR- 

CONDITION CONTROLLER ASSY. 

19A 

6. RECONNECT BATTERY NEGATIVE CABLE. 

7. INSPECT MULTI-MEDIA AND AIR-CONDITION CONTROLLER ASSY, RESET THE STATIONS. 

8. INSPECT MULTI-MEDIA AND AIR-CONDITION CONTROLLER ASSY FOR ITS PROPER 

OPERATION. 

Page 2813

66-4 

AUDIO SYSTEM - FRONT SPEAKER ASSY 

FRONT SPEAKER ASSY 

REPLACEMENT 


2. REMOVE FRONT DOOR INNER GUARD PLATE ASSY LH. (Refer to “Chapter 88 exterior and 

interior trim - vehicle door inner guard board, replacement”) 

3. REMOVE FRONT SPEAKER ASSY LH. 

(a) Remove the 3 screws from front speaker assy LH. 

(b) 

Take down the front speaker assy LH and disconnect the 

connector. 

(c) 

Remove the front speaker assy LH. 

4. INSTALL FRONT SPEAKER ASSY LH. 

(a) Reconnect conector of front speaker LH. 

Page 2814

AUDIO SYSTEM - FRONT SPEAKER ASSY 

66-5 

(b) 

Position front sperker LH, tighten 3 mounting screws. 

66 

66 

5. INSTALL FRONT DOOR INNER GUARD PLATE ASSY LH. (Refer to “Chapter 88 exterior and 

interior trim - vehicle door inner guard board, replacement”) 


7. INSPECT FRONT SPEAKER ASSY LH FOR ITS PROPER OPERATION. 

8. REMOVE AND INSTALL FRONT SPEAKER ASSY RH. 

NOTE 


19A 

Page 2815

66-6 

AUDIO SYSTEM - MIDDLE SPEAKER ASSY 

MIDDLE SPEAKER ASSY 

REPLACEMENT 


2. REMOVE ROOF GUARD BOARD.(Refer to “Chapter 88 exterior and interior trim - roof guard 

board inner trim, replacement”) 

3. Remove middle speaker assy LH. 

(a) Remove 2 mounting screws of middle speaker LH. 

(b) 

Take down middle speaker assy LH, disconnect connector 

of middle speaker LH. 

(c) 

Remove the middle speaker assy LH. 

4. INSTALL MIDDLE SPEAKER ASSY LH. 

(a) reconnect the connector of middle speaker assy LH. 

Page 2816

AUDIO SYSTEM - MIDDLE SPEAKER ASSY 

66-7 

(b) 

Position middle speaker assy LH, tighten 2 mounting 

screws. 

66 

66 

5. INSTALL ROOF GUARD BOARD.(Refer to “Chapter 88 exterior and interior trim - roof guard 

board inner trim, replacement”) 


7. INSPECT MIDDLE SPEAKER ASSY LH FOR ITS PROPER OPERATION. 

8. REMOVE AND INSTALL MIDDLE SPEAKER ASSY RH. 

NOTE 


19A 

Page 2817

66-8 

AUDIO SYSTEM - REAR SPERKER ASSY 

REAR SPERKER ASSY 

REPLACEMENT 


2. REMOVE SIDE WALL REAR LOWER GUARD BOARD LH. (Refer to “Chapter 88 exterior and 

interior trim - side wall guard board, replacement”) 

3. REMOVE REAR SPEAKER ASSY LH. 

(a) Remove 3 screws from rear speaker assy LH. 

(b) 

Take down rear speaker assy LH, disconnect the 

connector of rear speaker assy LH. 

(c) 

Remove the rear speaker assy LH. 

4. NSTALL REAR SPEAKER ASSY LH. 

(a) Reconnect the connector of the rear speaker assy LH. 

Page 2818

AUDIO SYSTEM - REAR SPERKER ASSY 

66-9 

(b) 

Position the rear speaker assy LH,Tighten 3 mounting 

screws. 

66 

66 

5. INSTALL SIDE WALL REAR LOWER GUARD BOARD LH. (Refer to “Chapter 88 exterior and 

interior trim - side wall guard board, replacement”) 


7. INSPECT REAR SPEAKER ASSY LH FOR ITS PROPER OPERATION. 

8. REMOVE AND INSTALL REAR SPEAKER RH. 

NOTE 


19A 

Page 2819

66-10 

AUDIO SYSTEM - TELESCOPIC ANTENNA ASSY 

TELESCOPIC ANTENNA ASSY 

REPLACEMENT 


2. REMOVE MULTI-MEDIA AND AIR-CONDITION CONTROLLER ASSY.(Refer to “Chapter 66 audio 

system - Multi-media and Air-condition controller assy, replacement”) 

3. REMOVE DASHBOARD. (Refer to“Chapter 88 instrument panel-dashboard,replacement) 

4. REMOVE TELESCOPIC ANTENNA ASSY. 

(a) Release 7 retaining clips of telescopic antenna. 

(b) 

Remove 2 mounting bolts of telescopic antenna, pull out 

the telescopic antenna. 

NOTE 

Telescopic antenna should prevent from break when you 

pull out it. 

5. INSTALL TELESCOPIC ANTENNA ASSY. 

(a) Insert telescopic antenna from outside, replace it, tighten 

2 mounting bolt of external telescopic antenna. 

Page 2820

AUDIO SYSTEM - TELESCOPIC ANTENNA ASSY 

66-11 

(b) 

Engage 7 retaining clips of telescopic antenna. 

66 

66 

6. INSTALL DASHBOARD. (Refer to“Chapter 88 instrument panel-dashboard,replacement) 

7. INSTALL MULTI-MEDIA AND AIR-CONDITION CONTROLLER ASSY. (Refer to “Chapter 66 audio 

system - Multi-media and Air-condition controller assy, replacement”) 


19A 

Page 2821

66-12 

AUDIO SYSTEM - ELECTRIC DEVICE ACCESSORIES 

ELECTRIC DEVICE ACCESSORIES 

REPLACEMENT 


2. REMOVE CIGARETTE LIGHTER ASSY. 

(a) Pull out cigarette lighter connector. 

(b) 

Pull out cigarette lighter body from dash board by using 

special tool. 

(c) 

Disconnect cigarette lighter connector. 

(d) 

Remove cigarette lighter assy. 

Page 2822


66-13 

3. REMOVE 12 V POWER SOCKET ASSY. 

(a) 

Loosen rear retaining ring. 

66 

66 

(b) 

Disconnect connector of power suply line. 

(c) 

Remove 12V power socket assy. 

19A 

4. INSTALL 12 V POWER SOCKET ASSY. 

(a) 

Reconnect connector of power suply line. 

(b) 

Position12V power socket assy, tighten rear retaining 

ring. 

Page 2823

66-14 


5. INSTALL CIGARETTE LIGHTER ASSY. 

(a) 


(b) 

Make sure that conduction aperture has already install to 

the dash board. 

(c) 

Install cigarette lighter to conduction aperture. 

(d) 

Install the cigarette lighter. 

6. INSTALL CIGARETTE LIGHTER. 

7. INSPECT ELECTRIC DEVICE ACCESSORIES FOR ITS PROPER OPERATION. 

Page 2824

WIRING 


INTRODUCTION.......................................................................... 71-1 

SYSTEM WIRING DIAGRAM SECTION EXAMPLE ................... 71-2 

POWER SOURCE SECTION EXAMPLE .................................... 71-5 

CONNECTOR VIEWS SECTION EXAMPLE .............................. 71-6 

GLOSSARY OF TERMS AND SYMBOLS................................... 71-7 

FUSE AND RELAY LOCATIONS ................................................ 71-9 

WIRING DIAGRAM .......................................................................... 71-18 

POWER SOURCE ..................................................................... 71-18 

ENGINE CONTROL SYSTEM................................................... 71-24 

STARTING SYSTEM ................................................................. 71-37 

CHARGING SYSTEM................................................................ 71-39 

ANTI-LOCK BRAKE CONTROL SYSTEM ................................ 71-41 

HEATER AND CONDITIONING CONTROL SYSTEM.............. 71-44 

LIGHT SYSTEM......................................................................... 71-52 

WIPER AND WASHER.............................................................. 71-77 

MULTIMEDIA SYSTEM ............................................................. 71-80 

POWER SOCKET...................................................................... 71-83 

COMMUNICATION SYSTEM .................................................... 71-85 

POWER MIRROR...................................................................... 71-90 

WINDOW DEFROSTER ............................................................ 71-93 

INSTRUMENT CLUSTER.......................................................... 71-96 

ANTI-THEIF SYSTEM.............................................................. 71-103 

SLIDING ROOF ....................................................................... 71-108 

RESTRAINT CONTROL SYSTEM .......................................... 71-110 

CONNECTOR VIEWS .................................................................... 71-112 

A - CHASSIS & FRAME WIRE HARNESS ............................ 71-112 

B - BATTERY WIRE HARNESS .............................................. 71-125 

C - FRONT BUMPER WIRE HARNESS.................................. 71-126 

D - FRONT DOOR LH WIRE HARNESS................................. 71-127 

E - ENGINE WIRE HARNESS................................................. 71-130 

F - ROOF WIRE HARNESS 1.................................................. 71-142 

G - ROOF WIRE HARNESS 2................................................. 71-146 

H - FRONT DOOR RH WIRE HARNESS ................................ 71-148 

I - INSTRUMENT PANEL WIRE HARNESS............................ 71-150 

J - REAR HATCH WIRE HARNESS........................................ 71-166 

K - REAR HATCH TRANSITION WIRE HARNESS................. 71-168 

L - REAR EVAPORATOR WIRE HARNESS ........................... 71-169 

M - DIAGNOSIS WIRE HARNESS .......................................... 71-170 

N - STEP LAMP WIRE HARNESS .......................................... 71-171 

O - DRIVER SEAT BELT WIRE HARNESS ............................ 71-172 

P - REAR HEATER WIRE HARNESS ..................................... 71-173 

Q - REAR BUMPER TRANSITION WIRE HARNESS ............. 71-174 

R - REAR BUMPER WIRE HARNESS .................................... 71-175 

S - REAR DEFROST RH WIRE HARNESS ............................ 71-176 

T - REAR DEFROST LH WIRE HARNESS ............................. 71-177 

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS........... 71-178 

V - FRONT WIRE HARNESS................................................. 71-179 

X - PREHEATING WIRE HARNESS ....................................... 71-185 

71 

71 

71 

Page 2825

WIRE HARNESS & CONNECTOR LOCATION VIEWS................ 71-186 


V - FRONT WIRE HARNESS .................................................. 71-186 



A - CHASSIS & FRAME WIRE HARNESS .............................. 71-190 

E - ENGINE WIRE HARNESS ................................................. 71-193 

I - INSTRUMENT PANEL WIRE HARNESS............................ 71-196 



O - DRIVER SEAT BELT WIRE HARNESS ............................ 71-199 




L - REAR EVAPORATOR WIRE HARNESS ........................... 71-202 

N - STEP LAMP WIRE HARNESS .......................................... 71-203 

G - ROOF WIRE HARNESS 2 ................................................. 71-204 

J - REAR HATCH WIRE HARNESS ........................................ 71-204 




S - REAR DEFROST RH WIRE HARNESS ............................ 71-204 

T - REAR DEFROST LH WIRE HARNESS ............................. 71-204 

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS............. 71-204 

Page 2826

WIRING - HOW TO USE THIS MANUAL 

71-1 


WIRING 

INTRODUCTION 

This manual provides information on the electrical circuits installed on vehicles by dividing them into electrical 

systems. The actual wiring of each system wiring diagram is shown from the point where the power source is 

received from the battery to each ground point. (All wiring diagrams are shown with the switches in the OFF 

position.) 

When troubleshooting any problem, firstly, make sure you understand the operation of the circuit where the 

problem was detected (see System Wiring Diagram Section). Secondly, understand the power source supplying 

to that circuit (see Power Source Section). Finally, understand the direction of current flow (see System 

Description). 

When the circuit operation is understood, begin troubleshooting of the suspected circuit to find out the cause. 

(Based on relays, controllers, accessory, inlines, sensors, actuators, switches, ground points, connection location 

of each system wiring diagram and wire harness location.) 

71 

71 

Page 2827

71-2 


SYSTEM WIRING DIAGRAM SECTION EXAMPLE 

*The system wiring diagram shown here is an EXAMPLE ONLY. It is different to the actual circuit 

shown in the SYSTEM WIRING DIAGRAM SECTION. 

Page 2828


71-3 

Note 

No. Name Description 

1 System Title Distinguish between different systems and functions, easy to query. 

2 

Indicates the 

wire color 

Wire colors are indicated by an alphabetical code,easy to query. 

The first letter indicates the basic wire color and the second letter indicates 

the color of the stripe. 

Example: 

R (Red) 

L-B (Blue and Black) 

71 

71 

3 

4 

Indicates the 

component name 

Indicates the 

component number 

Name of electrical component, easy to query. 

An electrical component can only have one name. 

Number of electrical component, easy to query. 

An electrical component has one or more numbers. 

Female and male connectors have different numbering rules. 

The two examples below are viewed from terminal side when connectors are 

unplugged. 

Female - Numbered in order from upper right to lower left. 

5 

Indicates the pin number 

of 

connector 

Male - Numbered in order from upper left to lower right. 

This rules also applied to inline connector number. 

6 Indicates a ground point 

The first letter of the code for each ground point(s) indicates the component’s 

location. 

7 

8 

Indicates related 

system 

Indicates inline 

connector number 

Indicate that other system(s) associated with this system. 

A group of inline has two connector numbers, one is the female and the other 

is the male. 

Male: 

9 


gender 

Female: 

Page 2829

71-4 




Note 


10 System Description Describe the current flows and how the system works. 

11 Service Hints Describe the component's value and principle. Refer in the service process. 

12 Parts Location Indicate the wire harness showing the parts location on the vehicle. 

13 Inline Indicate the inline two parts gender and the connected wire harness types. 

14 Ground Points Indicate the ground location of each wire harness. 

Page 2830


71-5 

POWER SOURCE SECTION EXAMPLE 

The “POWER SOURCE” section describes how the current flows and each part power feed conditions. In the 

POWER SOURCE wiring diagram, the conditions when battery power is supplied to each system are explained. 

Since all system wiring diagrams start from the power source, the power source system must be fully 

understood. 

71 

71 



Page 2831

71-6 


CONNECTOR VIEWS SECTION EXAMPLE 

*The connector views shown here is an EXAMPLE ONLY. It is different to the actual connector views 

shown in the CONNECTOR VIEWS SECTION. 

Note 


1 Connector Face Indicate connector face and pin order. 

2 Component Name 

3 Component Number 





4 Connector Information Indicate pin number, wire color and function. 

Page 2832


71-7 

GLOSSARY OF TERMS AND SYMBOLS 

BATTERY 

Stores chemical energy and converts it into electrical energy. 

Provides DC current for the auto’s various electrical circuits. 

GROUND 

The point at which wiring attaches to the body, thereby providing a 

return path for an electrical circuit. Without a ground, current cannot 

flow. 

71 

71 

FUSIBLE LINK 

FUSE 

FUSIBLE LINK 

In high amperage circuits, a heavy gauge wire burns when it is overloaded 

to protect the connected components. 

FUSE 

A thin metal strip burns when too much current flows through it, 

thereby it can stop current flow and protect a circuit from damage. 

COIL 

When the magnetic field engenders fluctuations, the coil circuit is 

induced electromotive force. 

SOLENOID 

An electromagnetic coil which forms a magnetic field when current 

flows, to move a plunger, etc. 

SINGLE FILAMENT 

LAMPS 

Current flow causes a headlight filament to heat up and emit light. A 

headlight may have either a single filament or double filaments. 

DOUBLE FILAMENT 

MOTOR 

MOTOR 

A power unit which converts electrical energy into mechanical 

energy, especially rotary motion. 

SPEED MOTOR 

INLINE 

Indicate the connector joining wire harness and wire harness. 

DIODE 

A semiconductor which allows current flow in only one direction. 

LED (LIGHT EMITTING DIODE) 

Upon current flow, these diodes emit light without producing the 

heat of a comparable light. 

Page 2833

71-8 


HORN 

An electric device which sounds a loud audible signal. 

THERMISTOR SENSOR 

A resistor which varies its resistance with temperature. 

RESISTOR 

TAPPED RESISTOR 

SLIDE RHEOSTAT 

RESISTOR 

An electrical component with a fixed resistance, placed in a circuit to 

reduce voltage to a specific value. 


A resistor which supplies two or more different non-adjustable 

resistance values. 


A controllable resistor with a variable rate of resistance. Also called 

a potentiometer or rheostat. 

POWER SOCKET (CIGARETTE LIGHTER) 

An electric resistance heating element. 

MANUAL SWITCH 

Opens and closes circuits, stops or allows current flow. 

IGNITION SWITCH 

A key operated switch with several positions which allows various 

circuits. 

HEATER 


RELAY(4Pin) 

RELAY 

Basically, an electrically operated switch which may be normally 

closed or open. Current flow through a small coil to create a magnetic 

field which either opens or closes an attached switch. 

RELAY(5Pin) 

Page 2834


71-9 

FUSE AND RELAY LOCATIONS 

POSITIVE JUNCTION BOX 

71 

71 

FUSIBLE LINK 

No. Amps Function 

F1 60A Instrument Panel Fusible Link 

F2 120A Charge Fusible Link 


F4 60A Battery Fusible Link 

F5 50A Engine Room Fusible Link 

F3 120A Pre-heat Fusible Link 

Page 2835

71-10 


BATTERY COMPARTMENT JUNCTION BOX LOCATION 

FUSIBLE LINK 



F9 30A AM2 Fusible Link F10 40A ABS Pump Fusible Link 

Page 2836


71-11 

FUSE 

71 


F2 7.5A Start Fuse 

F3 5A ABS IG Fuse 

F4 15A Accessory Fuse 

F5 15A Fuel Pump/Diesel Filter Fuse 


F6 30A ECM Main Fuse 

F7 10A Diagnosis Fuse 

F8 25A ABS Valve Fuse 

71 

RELAY 

No. 

R1 

R2 

Function 

Fuel Pump/Diesel Filter Heating Relay 

Starter Relay 

Page 2837

71-12 


ENGINE ROOM JUNCTION BOX LOCATION 

FUSIBLE LINK 



F1 30A Low-speed Fan Fusible Link F2 30A High-speed Fan Fusible Link 

Page 2838


71-13 

FUSE 

71 


F7 15A Stop Lamp Fuse 

F11 15A Injector Fuse 


F12 15A Ignition Coil Fuse 

71 

\\\RELAY 

No. 

Function 

No. 

Function 

R1 

Low-speed Fan 1 Relay 

R5 

High-speed Fan 2 Relay 

R3 


R6 

Main Relay 

R4 


Page 2839

71-14 


CO - PILOT SIDE JUNCTION BOX LOCATION 

FUSIBLE LINK 



F6 30A Rear A/C Fusible Link F13 30A Front Blower Fusible Link 

Page 2840


71-15 

FUSE 

71 


F8 15A Rear Heater Fuse 

F9 10A Airbag Fuse 


F10 7.5A Outside Mirror Defrost Fuse 

F11 25A Rear Defroster Fuse 

71 

RELAY 

No. 

Function 

No. 

Function 

R1 

Compressor Relay 

R7 

Water Valve Relay 

R4 

Rear A/C Relay 

R8 

A/C Cut Off Relay 

R5 

Outside Mirror Defrost Relay 

R9 

Front Blower Relay 

R6 

Rear Heater Relay 

R10 

Rear Defroster Relay 

Page 2841

71-16 


DRIVER SIDE JUNCTION BOX LOCATION 

FUSIBLE LINK 


F28 20A AM1 Fusible Link 


F30 40A IG2 Fusible Link 

F29 20A Power Window Fusible Link 

Page 2842


71-17 

FUSE 

71 


F1 15A A/C Fuse 

F2 5A ECU IG Fuse 

F3 15A Power Fuse 

F4 10A Back-up Lamp Fuse 

F7 15A Sliding Roof Fuse 

F8 10A Rear Wiper Fuse 

F9 10A Turn Signal Fuse 

F10 15A Cigarette Lighter Fuse 

F11 15A Front Wiper Fuse 

F14 7.5A Lo-beam RH Fuse 

F15 7.5A Lo-beam LH Fuse 

F16 7.5A Radio ACC Fuse 

F17 7.5A Instrument IG Fuse 

F18 7.5A Lamplet Fuse 


F19 7.5A Switch Lighting Fuse 

F20 10A Hi-beam RH Fuse 

F21 10A Hi-beam LH Fuse 

F22 20A Headlamp Fuse 

F23 10A Rear Fog Lamp Fuse 

F24 10A Central Locking Fuse 

F25 7.5A A/C Controller Fuse 

F26 15A Front Fog Lamp Fuse 

F27 15A Horn Fuse 

F32 10A Radio/Outside Mirror Fuse 

F33 10A Instrument Cluster Fuse 

F34 10A Dome Light Fuse 

F35 15A Hazard Warning Fuse 

71 

RELAY 

No. 

Function 

No. 

Function 

R1 

Rear Wiper Relay 

R7 

Front Fog Lamp Relay 

R4 

IG2 Relay 

R8 

Horn Relay 

R5 

Hi-beam Relay 

R9 

Rear Fog Lamp Relay 

R6 

Lo-beam Relay 

R10 

Lamplet Relay 

Page 2843

71-18 


POWER SOURCE 

WIRING - WIRING DIAGRAM 

Page 2844


71-19 

71 

71 

Page 2845

71-20 


Page 2846


71-21 

71 

71 

Page 2847

71-22 


Page 2848


71-23 

Service Hints 

• I009 Ignition Switch 

AM1 - ACC: Closed with the ignition switch at ACC/ON position. 

AM1 - IG1: Closed with the ignition switch at ON/ST position. 


AM2 - ST2: Closed with the ignition switch at ST position. 

71 

Parts Location 

71 

Code Wire Harness Code Wire Harness 

A017 Chassis & Frame Wire Harness I009 Instrument Panel Wire Harness 

B001 

Battery Wire Harness 

Connector Joining Wire Harness and Wire Harness 

Code Code Wire Harness (Connector Location) 

A101 

A102 

A104 

A106 

A111 

I110 

I104 

I106 

I111 

E101 

I109 

M101 

Chassis & Frame Wire Harness & Instrument Panel Wire Harness 

(Under the Driver Side Junction Box) 




(Right Side of the Driver Side Junction Box) 

Chassis & Frame Wire Harness & Engine Wire Harness 

(Manhole After the Co-pilot Seat) 


(Under the Right Side of the Instrument Panel) 

Instrument Panel Wire Harness & Diagnosis Wire Harness 

(Under the Left Side of the Central Instrument Panel) 

Ground Points 

Code Ground Points Location Code Ground Points Location 

B201 Engine Block Side B202 Car Body Side of the Battery Compartment 

Page 2849

71-24 



ENGINE CONTROL SYSTEM - WITH 4G69 ENGINE 

Page 2850


71-25 

71 

71 

Page 2851

71-26 


Page 2852


71-27 

71 

71 

Page 2853

71-28 


System Description 

Engine control system of 4G69 engine is based on Engine Control Module (ECM) of Delphi MT20U2 as the 

center system. The engine control system mainly consists of sensor signal input, engine control module (ECM) 

and executive control. 

• Sensor Signal Input 

Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor 

Manifold absolute pressure/intake air temperature (MAP/IAT) sensor integrates functions of manifold absolute 

pressure sensor with those of intake air temperature sensor, while achieving the functions of feedback 

manifold absolute pressure and intake air temperature. 

Manifold absolute pressure sensor measures engine inhaled air volume, which is a critical element that forms 

method of speed-density type air flow measurement. The sensor directly senses manifold absolute pressure 

state inside the engine intake manifold. The engine control module (ECM) takes this reference signal as the 

basis to adjust the basic fuel supply sprayed into the engine. 

Intake air temperature sensor uses NTC (negative temperature coefficient) thermistor sensor, with which the 

engine control module (ECM) measures the air temperature in the engine cylinder and modifies the engine 

fuel supply. 

Engine Coolant Temperature Sensor 

Engine coolant temperature sensor is used for detecting engine operating temperature. The engine control 

module (ECM) provides the optimum control solution for the engine according to different temperatures. 

Engine coolant temperature sensor uses NTC thermistor sensor, with engine coolant temperature rising and 

resistance value decreasing. 

Crankshaft Position Sensor 

As magnetoelectric sensor, crankshaft position sensor works with gear ring of crankshaft. The sensor detects 

the change of reluctance while the crankshaft rotates and alternating reluctance generates alternating output 

signal. The notch positions on the gear ring correspond to top dead center (TDC) in the engine. The engine 

control module (ECM) uses this signal to determine the rotation position and speed of the crankshaft. 

Knock Sensor 

Knock sensor is a vibration acceleration sensor, equipped at the engine knock induction-sensitive parts and 

used for sensing the knock generated by the engine. The engine control module (ECM) uses knock intensity 

detected by the knock sensor to modify ignition advance angle and achieve the effective control of the knock, 

so as to optimize engine power performance, fuel economy and reduce emissions. 


Throttle position sensor consists of carbon film resistor and sliding pointer driven by throttle shaft. When the 

throttle opening changes, the signal that the sensor feeds back to the engine control module (ECM) also 

varies. The control module determines real-time engine load and dynamic change condition based on the 

sensor signal value and its rate of change. 

Upstream (Downstream) Oxygen Sensor 

Oxygen sensor is an important symbolic component of closed loop fuel control system. With its adjustment 

and keeping the desired air-fuel ratio, the three-way catalytic converter can 

achieve the best conversion efficiency. The zirconium oxide in oxygen sensor is heated (> 300 ℃ ) for 

activation. The sensor changes the output voltage according to the presence or absence of oxygen in the 

exhaust and determines the oxygen content in the exhaust. If the oxygen content in the exhaust is increased, 

output voltage of oxygen sensor will be decreased; on the other hand, the output voltage will be increased, 

thus providing feedback of the actual air-fuel ratio conditions for the engine control module (ECM). Usually, 

when the sensor has the theoretical air-fuel ratio (14.6:1), it will result in dramatic change of voltage amplitude, 

helping the engine control module (ECM) to accurately determine the air-fuel ratio. 

Odometer Sensor 

Odometer sensor is Hall effect sensor, working with signal wheel on the transmission output shaft. The engine 

control module (ECM) measures digital voltage signal through the sensor. In order to determine the current 

vehicle speed. 

Page 2854


71-29 

• Executive Control 

Fuel injection Control 

The system uses the speed density method to make multi-point sequential injection, i.e., each engine cycle 

implements accurate fuel supply through main pulse width and amended pulse width, which has closed-loop 

control and self-learning function. 

Oil pump is single-stage electric turbine pump, and its operation is controlled by the engine control module 

(ECM) through the pump relay. When ignition switch is turned on, the pump will run for 1.5 seconds. If the 

crankshaft position signal is not received, the pump will stop running. If the crankshaft position signal is 

detected, the oil pump starts to work. Upon loss of crankshaft position signal, the pump will stop running. 

Mounting Position: in the fuel tank. 

Fuel injector is a ball valve device with solenoid switch. The coil in injector is controlled grounded by the 

engine control module (ECM) to produce magnetic force and pull up spool. The fuel is ejected from the pilot 

hole in the form of mist. The main factors affecting changes in fuel injection pulse width include air-fuel ratio, 

manifold absolute pressure, intake air temperature, closed loop feedback correction, acceleration 

concentration, deceleration cutoff, self-learning and correction. 

71 

71 

Ignition Control 

The system uses grouping ignition. Ignition coil is divided into two groups, each group providing the ignition 

energy for two cylinder spark plugs with 360-degree crankshaft angle difference. 

Idle Control 

The system uses the idle air control, achieving high-precision idle speed control. 

The idle stepping motor controls circulation area of throttle body bypass air duct to adjust control volume in the 

engine. The engine control module (ECM) controls the amount of movement (forward / backward) for the 

stepping motor through the digital square wave signal. 

Canister Solenoid Valve Control 

The engine control module (ECM) controls volume of gasoline vapor in intake manifold flowing from canister 

through the canister solenoid valve control. The opening of canister solenoid valve is determined by the 

engine control module (ECM) according to the duty cycle signal based on the state of engine. 

Fan Control 

The engine control module (ECM) monitors the level of coolant temperature and whether the air-conditioning 

works properly to determine the operating state of each fan. 

• Malfunciton Diagnosis Function 

When the system comes into operation, the engine control module (ECM) controls the operation of all parts of 

the system and conducts detection in real time. Once the system or parts have faults, the system will switch on 

the malfunction indicator light (MIL) to remind drivers of repair in time. When the system is in failure, the 

engine control module (ECM) will start backup emergency control program. 

Service Hints 

• E010 Engine Coolant Temperature Sensor 

1 - Ground: Approx. 5 volts 

1 - 2: Approx. 29 KΩ (-20 ℃ ) 

Approx. 9 KΩ (0 ℃ ) 

Approx. 3 KΩ (20 ℃ ) 

Approx. 0.3 KΩ (80 ℃ ) 

• E015 Idle Speed Control Valve 

1 - 2: Approx. 53 Ω 

3 - 4: Approx. 53 Ω 

• E002 Fuel Injector 1, E003 Fuel Injector 2, E004 Fuel Injector 3, E005 Fuel Injector 4 


• E009 Throttle Position Sensor 


Page 2855

71-30 


• E007 Upstream Oxygen Sensor, A019 Downstream Oxygen Sensor 


• E006 Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor 




A001 Chassis & Frame Wire Harness E006 Engine Wire Harness 









E001 Engine Wire Harness I003 Instrument Panel Wire Harness 



E004 Engine Wire Harness M002 Data Link Connector 

E005 Engine Wire Harness V107 Front Wire Harness 



A101 

A102 

A104 

A106 

A107 

I102 

I104 

I106 

I111 

E101 

E102 

V102 






(Right Side of the Driver side Junction Box) 





Instrument Panel Wire Harness & Front Wire Harness 

(Left Side of the Driver side Junction Box) 

Page 2856


71-31 

I110 

M101 

Instrument Panel Wire Harness & Data Link Connector 

(Under the Left Side of the CentralInstrument Panel) 

Ground Points 

71 


A202 

Left Front Wheel Cover Plate Side 

Plates 

I201 

Left Side of the Instrument Panel 

71 

A203 

Right Front Wheel Cover Plate Side 

Plates 

I205 

Central of the Instrument Panel 

Page 2857

71-32 


ENGINE CONTROL SYSTEM - WITH ISF2.8 ENGINE 

Page 2858


71-33 

71 

71 

Page 2859

71-34 


Page 2860


71-35 


Engine control system of ISF2.8 engine is based on Engine Control Module (ECM) of Bosch CM2220 as the 









71 

71 






Mounting Position: on the flywheel housing perpendicular to the crankshaft position. 
























Page 2861

71-36 








E022 Engine Wire Harness V017 Front Wire Harness 

E023 Engine Wire Harness X001 Pre-heater Wire Harness 





A101 

A102 

A104 

A113 

I102 

I110 

I104 

I106 

I111 

B003 

V102 

M101 







Chassis & Frame Wire Harness & Battery Wire Harness 

(Battery Compartment) 


(Left Side of the Driver side Junction Box) 

Instrument Panel Wire Harness & Data Link Connector 

(Under the Left Side of the CentralInstrument Panel) 

Ground Points 


A202 

Left Front Wheel Cover Plate Side 

Plates 

B202 

Car Body Side of the Battery 

Compartment 

A203 

Right Front Wheel Cover Plate Side 

Plates 

I201 


Page 2862


71-37 

STARTING SYSTEM 

71 

71 

Page 2863

71-38 



• Starting System 

a. When ignition switch is turned to ST, the current flows through battery fusible link positive in junction box, to 

AM2 fusible link in battery compartment junction box, through the AM2 fusible box. The current flows from pin 

ST2 of ignition switch through starter fuse and accessory fuse in battery compartment junction box to pin 85 of 

starter relay, and through coil to ground at pin 86 of starter relay. Coil then creates a magnetic field, and switch 

is activated. 

b. The current flows through AM2 fusible link, through starter relay, to solenoid switch of starter. Solenoid 

switch creates a magnetic field, and starter is activated. 

c. The current flows through the terminal of starter, to starter motor, and to crank the engine. 

Service Hints 

• I009 Ignition Switch 

AM2 – IG2: Closed with the ignition switch at ON/ST position. 

AM2 – ST2: Closed with the ignition switch at ST position. 



B001 Battery Wire Harness E014 Engine Wire Harness 

B002 Battery Wire Harness I009 Instrument Panel Wire Harness 



A101 

A102 

A106 

A113 

I104 

I106 

E101 

B101 







Chassis & Frame Wire Harness & Battery Wire Harness 

(Battery Compartment) 

Ground Points 

Code 

A202 

Ground Points Location 

Left Front Wheel Cover Plate Side Plates 

Page 2864


71-39 

CHARGING SYSTEM 

71 

71 

Page 2865

71-40 



• Charging System 

a. 4G69 engine: When ignition switch is turned to ON/ST, the current flows output from ignition switch to ignition 

fuse in engine room junction box, through the fuse, to IG terminal of generator connector A018. 

b. When ignition switch is ON/ST, the current flows output from ignition switch, to instrument panel fuse in 

driver side junction box, through the fuse, to pin A20 of instrument cluster. The current flows through charging 

warning light of instrument cluster, from pin B25 of instrument cluster, to pin L of generator connector A018, to 

field winding of generator. Field winding creates a magnetic field. Rotation of the excited field coil generates 

AC voltage in the stator. The alternation current is rectified through diodes to DC voltage, to pin 1 of generator 

connector A017, to charge fusible link and charge a battery, at the same time, supply electrical energy to other 

electrical devices. 

Service Hints 

• A018 Generator 

1 - Ground:12 volts with the ignition switch at ON position and engine not running. 





A018 

Chassis & Frame Wire Harness 



A101 

A102 

I104 

I106 





Page 2866


71-41 

ANTI-LOCK BRAKE CONTROL SYSTEM 

71 

71 

Page 2867

71-42 



ABS control system uses vehicle speed sensor to detect vehicle speed and transmits the speed signal to the 

control module. The control module controls wheel slipping rate by repeatedly increasing or decreasing the 

wheel brake pressure according to the input vehicle speed, keep the wheels rotating. The system enables the 

vehicle in braking state to prevent the wheels locking and have the steering capability, guaranteeing stability in 

the braking direction and preventing side-slipping and deviation. 

• Power Input 

The current flows through battery fusible link in positive junction box to ABS valve fuse and ABS pump fusible 

link in battery compartment junction box, to pin 1 and 25 of ABS module. System is then powered. 

• Ignition signal 

When ignition switch is ON/ST, current flows through ABS IG fuse in driver side junction box, to pin 20 of ABS 

module and ABS system getss ignition signal. 

• Speed Signal 

Speed sensor provide the alternating signal to the ABS module. The signal from 4 sensors: front wheel speed 

sensor LH, front wheel speed sensor RH, rear wheel speed sensor LH and rear wheel speed sensor RH. 

• Brake Signal 

a. 4G69 engine: The current flows through battery fusible link in positive junction box, to ECM main fuse in battery 

compartment junction box, to stop lamp fuse in engine room junction box, to pin 2 of stop lamp switch. 

When the brake pedal is depressed, the current flows from pin 1 of stop lamp switch, to pin 30 of ABS module, 

and provide the brake signal to the ABS module. 

b. ISF2.8 engine: The current flows through engine room fusible link in positive junction box, to stop lamp fuse 

in engine room junction box, to pin 2 of stop lamp switch. When the brake pedal is depressed, the current 

flows from pin 1 of stop lamp switch, to pin 30 of ABS module, and provide the brake signal to the ABS 

module. 

• Malfunction Diagnosis Function 

When the system comes into operation, ABS module detects the operation of all parts of the system. Once the 

system or parts have faults, the system will switch on the ABS warning light to remind drivers of repair in time. 

Service Hints 

• A025 Stop Lamp Switch 

1 - 2:Closed when the brake pedal depressed. 



A009 Chassis & Frame Wire Harness A025 Chassis & Frame Wire Harness 



A012 Chassis & Frame Wire Harness M002 Diagnosis Wire Harness 

A013 

Chassis & Frame Wire Harness 



A101 

A102 

I104 

I106 





Page 2868


71-43 

I110 

M101 

Instrument Panel Wire Harness & Diagnosis Wire Harness 

(Under the Left Side of the Central Instrument Panel) 

Ground Points 

71 

Code 

A201 


Left Front Wheel Cover Plate Side Plates 

71 

Page 2869

71-44 


HEATER AND CONDITIONING CONTROL SYSTEM 

FRONT AND REAR AIR CONDITIONING CONTROL SYSTEM 

Page 2870


71-45 

71 

71 

Page 2871

71-46 


Page 2872


71-47 


• Ignition Switch At On/st, A/C System Power Supply 

a. When ignition switch is turned to ON/ST, current flows through A/C fuse in driver side junction box, to pin 30 

of A/C cut off relay, through the relay, battery output from the pin 87a of cut off relay, to pin 10 of A/C controller, 

pin 85 of front blower relay, pin 30 and 85 of compressor relay (ISF2,8 engine) and pin 2 of rear blower forward 

switch, then A/C system getss the operation power. 

b. When ignition switch is turned to ON/ST, current flows through ignition fuse in engine room junction box, to 

pin 86 of main relay, pass the the pin 85 of main relay, to pin 10 of the ECM module, the ECM module control 

the main relay working. When the pin 85 of main relay is controlled by ECM to connect the ground, coil then 

creates a magnetic field, and switch is activated. The current flows through battery fusible link in positive junction 

box, to main fuse in battery cmpartment junction box, to main relay, through the relay, to injector fuse, pass 

the fuse and connect the pin 85 of compressor relay (4G69 engine). 

• Ignition Switch At St, A/C System Power Supply 

When ignition switch is turned to ST, current flows through starter fuse in battery compartment junction box, to 

pin 85 of A/C cut off relay, through the coil to pin 86 and connect the groud. Coil then creates a magnetic field, 

and switch is open, cut off the power of A/C system to sure the starter motor have more power to crank the 

engine. 

• Front A/C Control 

a. blower control: current flows from the pin 87a of A/C relay, to pin 86 of front blower relay, through coil of 

relay, output from the pin 86 of relay to pin 8 of A/C control panel; A/C control panel make the coil of relay to 

connect the ground, coil creates a magnetic field, and switch is closed. Current outputs from the pin 30 of A/C 

relay, to pin 1 of the front blower, through the pin 2 of the blower, to pin 4 of blower control module. A/C control 

panel control the front blower by controlling the blower control module. 

b. A/C clutch control: Working inquire signal of the front A/C system outputs from pin 9 of A/C control 

panel, to pin 1 of triple pressure switch, the signal through switch and connect to engine ECM. If the 

pressure of refrigerant in A/C pipe meet the specification as design, ECM will control the A/C relay 

coil to connect the ground.Coil then creates a magnetic field, and switch is activated. Current flows into A/C 

clutch solenoid and A/C compressor clutch engage and front A/C system begin to work 

c. servo motor (internal & external circulation) control: Current flows from pin 6 of A/C control panel, to pin 6 

of circulation motor, outputs from pin 5 of circulation motor, to pin 7 of A/C control panel. Motor is working, the 

front A/C system is internal circulation mode, on the contrary, system is external circulation mode. 

d. servo motor (temperature) control: Current flows from pin 5 and 4 of A/C control panel, to pin 5 and 6 of 

servo motor to control the motor operation. The current flows through the potentiometer in servo motor and 

return to A/C control panel from pin 3 and 1 of servo motor to pin 26 and 27 of A/C control panel. The signal 

current outputs from pin 2 of motor, to pin 23 of A/C control panel, feedback the position signal of servo 

motor(step motor). 

e. servo motor (mode) control: Current flows from pin 1 and 3 of A/C control panel, to pin 5 and 6 of servo 

motor to control the motor operation. The current flows through the potentiometer in servo motor and return to 

A/C control panel from pin 3 and 1 of servo motor to pin 26 and 27 of A/C control panel. The signal current outputs 

from pin 2 of motor, to pin 24 of A/C control panel, feedback the position signal of servo motor(step 

motor). 

f. Current flows from pin 29 of A/C control panel, to pin 1 of evaporator thermistor, through thermister, outputs 

from pin 2 of thermister, to pin 33 of A/C control panel. The A/C sustem getsss the temperature Info of evaporator. 

• Rear A/C Blower Control 

Press the switch of rear blower, current flows pin 2 of switch and outputs from pin 5 of switch, through pin 85 of 

rear A/C relay; Coil then creates a magnetic field, and switch is activated. Current flows from A/C cut off relay 

and outputs from pin 30 of rear A/C relay, to pin 1 of rear left blower and pin 1 of rear right blower, through the 

blowers, to pin1 of blower resistor and outputs: 

a. blower at lower speed: Current flows from pin 2 of right and left blower, to pin 1 of blower resistor, through 

resistor, outputs from pin 3 of blower resistor, to pin 4 of top evaporator blower switch, through switch, connect 

the ground at pin 3 of switch. 

b. blower at middle speed: Current flows from pin 2 of right and left blower, to pin 1 of blower resistor, through 



c. blower at higher speed: Current flows from pin 2 of right and left blower, to pin 1 of blower resistor, through 



71 

71 

Page 2873

71-48 


• Rear A/C Solenoid Control 

Press the button of rear A/C in A/C control panel, switch on the rear blower forward switch and top evaporator 

blower switch. The signal of rear A/C request outputs from pin 2 of top evaporator blower switch, to pin 36 of 

A/C control panel; Rear A/C relay coil creates a magnetic field, and switch is activated, blowers are working; 

The power of rear A/C solenoid outputs from pin 87 of A/C control panel, to pin 1 of rear A/C solenoid, through 

solenoid, to pin 1 of A/C control panel and conrtol panel control the operation of rear A/C soleniod. 

Service Hints 

• A/C Cut Off Relay 

30 - 87a:Open with the ignition switch at ST position. 

• Rear A/C Relay 

30 - 87:Closed when rear A/C system is working. 

• compressor Relay 

30 - 87:Closed when fron A/C system is working. 





E001 Engine Wire Harness L001 Rear Evaporator Wire Harness 

E013 Engine Wire Harness L002 Rear Evaporator Wire Harness 

I020 Instrument Panel Wire Harness L003 Rear Evaporator Wire Harness 



I023 Instrument Panel Wire Harness N003 Step Lamp Wire Harness 

I024 Instrument Panel Wire Harness V017 Front Wire Harness 

I025 

Instrument Panel Wire Harness 



A101 

A102 

A104 

A106 

A107 

A108 

I104 

I106 

I111 

E101 

E102 

N101 











Chassis & Frame Wire Harness & Step Lamp Wire Harness 

(Under the B-Pillar RH) 

Page 2874


71-49 


A111 

A112 

I109 

E103 





71 

F101 

I107 

Roof Wire Harness 1 & Instrument Panel Wire Harness 

(Above the Left Side of the Instrument Panel) 

71 

F106 

L101 

Roof Wire Harness 1 & Rear Evaporator Wire Harness 

(in Front Roof) 

I102 

V102 


(Left Side of the Driver Side Junction Box) 

Ground Points 


A202 Left Front Wheel Cover Plate Side Plate I204 Central of the Instrument Panel 

I201 


Page 2875

71-50 


REAR HEATER CONTROL 

Page 2876


71-51 


• Rear Blower Forward Switch control 

When ignition switch is turned to ON/ST, current flows through pin 30 of A/C cut off relay in co-pilot side junction 

box, through the relay, to pin 87a of cut off relay and outputs: 

a. to pin 30 of water valve relay. 

b. to pin 2 of rear blower forward switch, press the switch, the current flows from pin 5 of switch to 85 pin of 

water valve relay and pin 85 of rear heater relay. 

• Rear Heater Blower Operation 

When switch on the rear blower forward switch and rear heater blower switch, the rear heater relay is at operating 

status; Current flows through charge fusible link and instrument panel fusible link in positive junction box, 

to rear heater fuse in co-pilot side junction box, to rear heater relay, coil then creates magnetic field, and switch 

is activated, current flows through relay to pin 2 of rear heater blower, the speed of blower is controlled by 

resistor: 

a. Current outputs from pin 4 of rear heater blower, to pin 4 of rear heater blower switch, through the switch, 

connect to the ground at the pin 1 of switch. Blower is at higher speed. 

b. Current outputs from pin 1 of rear heater blower, to pin 5 of rear heater blower switch, through the switch, 

connect to the ground at the pin 1 of switch. Blower is at middle speed. 

c. Current outputs from pin 3 of rear heater blower, to pin 6 of rear heater blower switch, through the switch, 


• Water valve operation 

When switch on the rear blower forward switch and rear heater blower switch, water valve is at operating status; 

Current flows through coil and creates magnetic field, and switch is activated, current flows through relay 

to pin 1 of rear heater water valve and connect to ground at pin 2 of valve, water valve is working. 

71 

71 



A007 Chassis & Frame Wire Harness P001 Rear Heater Wire Harness 

I023 Instrument Panel Wire Harness P002 Rear Heater Wire Harness 



A102 

A104 

A109 

A111 

I106 

I111 

P101 

I109 





Chassis & Frame Wire Harness & Rear Heater Wire Harness 

(At the Left Side of the Chassis) 



Ground Points 


A202 Left Front Wheel Cover Plate Side Plates I201 Left Side of the Instrument Panel 

A204 Right Front Wheel Cover Plate Side Plates I203 Left Side of the Instrument Panel 

Page 2877

71-52 


LIGHT SYSTEM 

HEADLAMP 

Page 2878


71-53 


• Headlamp (Low Beam) 

The current flows through charge and instrument panel fusible link, to pin 85 of lo-beam relay, through coil of 

relay, and then to pin 8 of combination switch. When the combination switch is set headlamp (Low Beam) 

position, the current output from pin 11 of combination switch to connect the ground. The coil of relay creates a 

magnetic field, and switch is activated. The current flows through switch of relay, to lo-beam fuse (LH) and lobeam 

fuse (RH) in dirver side junction box, and pass then to pin 3 of left lamp and pin 3 of right headlamp and 

through light of headlamp (Low Beam). The power is ground at pin 1 of left and right headlamp. This enables 

headlamp (Low Beam) to operate. 

• Headlamp (High Beam) 

The current flows through charge and instrument panel fusible link, to headlamp fuse in driver side junction 

box, to pin 85 and pin 30 of hi-beam relay, through coil of relay, and then to pin 9 of combination switch. When 

the combination switch is set headlamp (High Beam) position, the current output from pin 11 of combination 

switch to connect the ground. The coil of relay creates a magnetic field, and switch is activated. The current 

flows through switch of relay, to hi-beam fuse (LH) and hi-beam fuse (RH) in driver side junction box, and pass 

then to pin 2 of headlamp LH and pin2 of headlamp RH, and through light of headlamp (High Beam). The 

power is ground at pin 1 of left and right headlamp. This enables headlamp (High Beam) to operate. 

• High Beam Indicator 

When the combination switch is set headlamp (High Beam) position, the current flows through hi-beam (LH), 

to instrument cluster, and through high beam indicator. This enables high beam indicator to operate. 

• Flash to Pass 

The current flows through charge and instrument panel fusible link, to headlamp fuse in driver side junction 


the combination switch is set flash to pass position, the current output from pin 11 of combination switch to 

connect the ground. The coil of relay creates a magnetic field, and switch is activated. The current flows 

through switch of relay, to hi-beam fuse (LH) and hi-beam fuse (RH) in driver side junction box, and pass then 

to pin 2 of headlamp LH and pin2 of headlamp RH, and through light of headlamp (High Beam). The power is 

ground at pin 1 of left and right headlamp. This enables flash to pass to operate. 

• Headlamp Adjusting 

When low beam lamp is under working condition, current through right low beam lamp fuse, to pin 1 of front 

left/right adjusting motor, to supply power for adjusting motor. Pin 2 of front left/right adjusting motor connect to 

the pin 4 and pin 5 of the adjusting switch, adjusting motor control the adjusting motor. 

71 

71 

Service Hints 

• I012 Combination Switch (Light Control) 

8 - 9:Closed with the combination switch at Headlamp position ( Low Beam). 

9 - 11:Closed with the combination switch at Headlamp position (High Beam and Flash to Pass). 

9 - 11:Closed with the combination switch at Flash to Pass position. 





V001 Front Wire Harness V006 Front Wire Harness 



A104 

I111 



Page 2879

71-54 



I102 

V102 



Page 2880


71-55 

Ground Points 


I201 Left Side of the Instrument Panel V201 Left Side of the Longitudinal Beam Flank 

71 

I202 Left Side of the Instrument Panel V203 Right Side of the Longitudinal Beam 

71 

Page 2881

71-56 


LAMPLET 

Page 2882


71-57 


• Width Light 

The current flows through charge and instrument panel fusible link in positive junction box, to pin 85 of lamplet 

relay in driver side junction box, pass the coil of relay and then to pin 13 of combination switch. When the 

combination switch is set lamplet light or headlamp (Low Beam/High Beam) position, the current flows output 

pin 10 of combination switch to connect the ground. The coil of lamplet relay creates a magnetic field, and 

switch is activated. The current flows through switch of relay, and through the lamplet fuse in driver side 

junction box, to pin 2 of front position lamp LH and pin 2 of front position lamp RH. The power is ground at pin 

1 of front position lamp LH and pin 1 of front position lamp RH. This enables width light to operate. 

• Tail Light 






junction box, to pin 1 of front combination lamp LH and pin 1 of front combination lamp RH. The power is 

ground at pin 2 of front combination lamp LH and pin 2 of front combination lamp RH. This enables tail light to 

operate. 

• License Light 






junction box, to pin 1 of license light. The power is ground at pin 2 of license light. This enables license light to 

operate. 

71 

71 

Service Hints 


13 - 10:Closed with the combination switch at Headlamp and lamplet position. 



F006 Roof Wire Harness 1 J004 Rear Hatch Wire Harness 

G001 Roof Wire Harness 2 V002 Front Wire Harness 




A104 

F101 

F103 

G103 

I111 

I107 

G101 

K101 





Roof Wire Harness 1 & Roof Wire Harness 2 

(Left Side of the Top Cap Rear Beam) 

Roof Wire Harness 2 & Rear Hatch Transition Wire Harness 

(Right Side of the Top Cap Rear Beam) 

Page 2883

71-58 



J101 

I102 

K102 

V102 

Rear Hatch Wire Harness & Rear Hatch Transition Wire Harness 

(Under the Right Side of the Rear Hatch) 



Ground Points 


F201 Rear Inner Panel of the Left Gusset J201 Under the Right Side of the Right Door 

G201 Rear Inner Panel of the Right Gusset V201 Left Side of the Longitudinal Beam Flank 

I201 Left Side of the Instrument Panel V203 Right Side of the Longitudinal Beam 

Page 2884


71-59 

STOP LAMP 

71 

71 

Page 2885

71-60 



• 4G69 Engine 

The current flows through battery fusible link in positive junction box, to ECM main fuse in battery compartment 

junction box, to stop lamp fuse in engine room junction box, to pin 2 of stop lamp switch. The stop lamp 

switch is closed with the brake pedal depressed. The current then flows from pin 1 of stop lamp switch to pin 3 

of rear combination lamp LH, pin 3 of rear combination lamp RH and pin 2 of high-mounted stop lamp. The 

power is ground at pin 2 of rear combination lamp LH, pin 2 of rear combination lamp RH and pin 1 of highmounted 

stop lamp. This enables stop lamp and high-mounted stop lamp to operate. 

• ISF 2.8 Engine 

The current flows through engine room fusible link in positive junction box, to stop lamp fuse in engine room 

junction box, to pin 2 of stop lamp switch. The stop lamp switch is closed with the brake pedal depressed. The 

current then flows from pin 1 of stop lamp switch to pin 3 of rear combination lamp LH, pin 3 of rear 

combination lamp RH and pin 2 of high-mounted stop lamp. The power is ground at pin 2 of rear combination 

lamp LH, pin 2 of rear combination lamp RH and pin 1 of high-mounted stop lamp. This enables stop lamp and 

high-mounted stop lamp to operate. 

Service Hints 

• A025 Stop Lamp Switch 

1 - 2:Closed with the brake pedal depressed. 



A025 Chassis & Frame Wire Harness G001 Roof Wire Harness 2 

F006 Roof Wire Harness 1 U002 High-mounted Stop Lamp Wire Harness 



A102 

F101 

F103 

F105 

I106 

I107 

G101 

U101 







Roof Wire Harness 1 & High-mounted Stop Lamp Wire Harness 


Ground Points 


F201 Rear Inner Panel of the Left Gusset G201 Rear Inner Panel of the Right Gusset 

Page 2886


71-61 

BACK-UP LAMP 

71 

71 

Page 2887

71-62 



When ignition switch is ON/ST, the current flows throug back-up lamp fuse in driver side junction box, to pin 1 

of back-up lamp switch. The current flows from pin 2 of back-up lamp switch, and then to the circuit as follows: 

a. The current pass through pin 6 of rear combination lamp LH, and ground at pin 2 of rear combination lamp 

LH. This enables rear back-up lamp LH to operate. 

b. The current pass through pin 6 of rear combination lamp RH, and ground at pin 2 of rear combination lamp 

RH. This enables rear back-up lamp RH to operate. 

c. The current pass through the reverse radar control unit. Reverse radar control unit is then powered. 

d. The current pass through the multimedia system. Multimedia system is then powered. 

Service Hints 

• A021 Back-up Lamp Switch 

1 – 2: Closed with the shift lever in “R” position. 



A021 Chassis & Frame Wire Harness F006 Roof Wire Harness 1 

G001 Roof Wire Harness 2 



A102 

A104 

F101 

F103 

I106 

I111 

I107 

G101 









Ground Points 


F201 Rear Inner Panel of the Left Gusset I201 Left Side of the Instrument Panel 

G201 

Rear Inner Panel of the Right Gusset 

Page 2888


71-63 

TURN SIGNAL AND HAZARD WARNING LAMPS 

71 

71 

Page 2889

71-64 



• Turn Signal Lamp Working Condition 

Current flows through hazard waring fuse in driver side junction box, to pin 1 of flasher, to supply power for 

flasher. 

When ignition switch is ON/ST, the current flows through turn signal fuse in driver side junction box, to pin 6 of 

combination switch. When operating the combination switch, the current flow output from pin 7 and pin 5 of 

combination switch, to pin 12 and pin 5 of flasher, vehicle turning lamp is under working condition. 

• Turn Signal Lamp LH 

When the combination switch is in Left Turn position, the current flows output from pin 9 and pin 4 of flasher, 

the circuit as follows: 

a. The current flows through pin 2 of front turn signal lamp LH, and ground at pin 1 of front turn signal lamp LH. 

This enables front turn signal lamp LH to operate. 

b. The current flows through pin 4 of rear combination lamp LH, and ground at pin 2 of rear combination lamp 

LH. This enables rear turn signal lamp LH to operate. 

c. The current flows to pin A32 of instrument cluster and ground at pin B30 of instrument cluster. This enables 

left turn signal/hazard indicator to operate. 

• Turn Signal Lamp RH 

When the combination switch is in Right Turn position, the current flows output from pin 10 and pin 2 of flasher, 


a. The current flows to pin 2 of front turn signal lamp RH, and ground at pin 1 of front turn signal lamp RH. This 

enables front turn signal lamp RH to operate. 

b. The current flows through pin 4 of rear combination lamp RH, and ground at pin 2 of rear combination lamp 

RH. This enables rear turn signal lamp RH to operate. 

c. The current flows to pin B32 of instrument cluster and ground at pin B30 of instrument cluster. This enables 

right turn signal/hazard indicator to operate. 

• Hazard Warning Lamp 

When hazard warning switch is pressed, the signal flows from pin 8 of hazard warning switch, to pin 7 of 

flasher. Flasher is working condition; The current flows output from pin 4 , 2, 9, 10 of flasher. 

Power from pin 9 and pin 4 of flasher: 














Service Hints 

• I006 Hazard Warning Switch 

7 - 10:Closed with the hazard warning switch released. 

7 - 8:Closed with the hazard warning switch pressed. 

4 - 5 - 6:Closed with the hazard warning switch pressed. 

• I012 Combination Switch 

5 - 6:Closed with the combination switch at Left Turn position. 

6 - 7:Closed with the combination switch at Right Turn position. 



Page 2890


71-65 

F006 Roof Wire Harness 1 I012 Instrument Panel Wire Harness 

G001 Roof Wire Harness 2 I034 Instrument Panel Wire Harness 

I002 Instrument Panel Wire Harness I039 Instrument Panel Wire Harness 

71 



I006 


71 



A104 

F101 

F103 

I102 

I111 

I107 

G101 

V102 









Ground Points 


F201 Rear Inner Panel of the Left Gusset V201 Left Side of the Longitudinal Beam Flank 

G201 Rear Inner Panel of the Right Gusset V203 Right Side of the Longitudinal Beam 

I201 


Page 2891

71-66 


FOG LAMP 

Page 2892


71-67 


• Front Fog Lamp 

Operation requirement: Always turn on lamplet or headlamp. 


relay, pass the coil of relay and then to pin 13 of combination switch. When the combination switch is set lamplet 

or headlamp (Low Beam/High Beam) position, the current flows output pin 10 of combination switch to 

connect the ground. The coil of relay creates a magnetic field, and switch is activated. The current flows 

through switch of relay, from the pin 87 of relay to front fog relay coil, to pin 2 of ombination switch. When front 

fog lamp switch is closed, the current flows output from pin 4 of combination switch to connect the ground. The 

coil of front fog lamp relay creates a magnetic field, and switch is activated. The current flows through fog lamp 

fuse in driver side junction box, to front fog lamp relay, and through switch of front fog lamp relay, to pin 1 of 

front fog lamp LH and pin 1 of front fog lamp RH, the power is ground at pin 2 of front fog lamp LH and pin 2 of 

front fog lamp RH. This enables front fog lamp LH and front fog lamp RH to operate. 

• Rear Fog Lamp 

The current flows through charge and instrument panel fusible link in positive junction box, to rear fog lamp 

fuse in driver side junction box, to rear fog lamp relay. When front low beam lamp work and rear fog lamp 

switch is closed, the current flows output from pin 4 of combination switch to connect the ground. The coil of 

rear fog lamp relay creates a magnetic field, and switch is activated. The current flows through rear lamp fuse 

in driver side junction box, to rear fog lamp relay, and through switch of rear fog lamp relay, to pin 5 of rear 

combination lamp LH and pin 5 of rear combination lamp RH, the power is ground at pin 2 of rear combination 

lamp LH and pin 2 of rear combination lamp RH. This enables rear fog lamp LH and rear fog lamp RH to operate. 

• Fog Lamp indicator 

a. Front fog lamp indicator: When front fog lamp is woring, the current flows to pin A7 of instrument cluster and 

ground at pin B30 of instrument cluster. This enables front fog lamp indicator to operate. 

b. Rear fog lamp indicator: When rear fog lamp is working, the current flows to pin B21 of instrument cluster 

and ground at pin B30 of instrument cluster. This enables rear fog lamp indicator to operate. 

71 

71 

Service Hints 


10 - 13:Closed with the combination switch at Lamplet and Headlamp position 



C001 Front Bumper Wire Harness I002 Instrument Panel Wire Harness 

C002 Front Bumper Wire Harness I003 Instrument Panel Wire Harness 


G001 Roof Wire Harness 2 



A104 

C101 

F103 

I111 

V110 

G101 



Front Bumper Wire Harness & Front Wire Harness 

(Left Front Combination Lamps Positioning Plate Side) 



Page 2893

71-68 



I102 

I107 

V102 

F101 



Instrument Panel Wire Harness & Roof Wire Harness 1 


Ground Points 



G201 Rear Inner Panel of the Right Gusset V202 Left Side of the Longitudinal Beam 

Page 2894


71-69 

INTERIOR LAMPS 

71 

71 

Page 2895

71-70 


Page 2896


71-71 


• Front Dome Light 

The current flows through charge and instrument panel fusible link in positive junction box, to dome light fuse 

in driver side junction box, to pin 1 and 2 of front dome light. Front dome light is working condition. 

a. Press front dome light switch, and the power is ground by the switch. This enables front dome light to 

operate. 

b. Dome light switch is at DOOR postion; If any front door is not closed, the front door ajar switch will turn to 

ON. The current flows from pin 4 of front dome lamp, to front door ajar switch. The power is ground by ajar the 

switch. This enables front dome light to operate. 

• central dome Light 


in driver side junction box, to pin 1 of central dome light. central dome light is working condition. 

a. When central dome light is at ON position; The current flows from pin 3 (high equipped) or 2 (low equipped) 

of central dome light, to pin 5 of central dome light switch, press the switch, and the power is ground by the pin 

2 of switch. This enables central dome light to operate. 

b. When central dome light is at DOOR position (high equipped); If sliding door is not closed, the door ajar 

switch will turn to ON. The current flows from pin 2 of central dome lamp, to door ajar switch. The power is 

ground by ajar the switch. This enables central dome light to operate. 

• Step lamp 


in driver side junction box, to pin 1 of step light and output from pin 2 of step light; If sliding door is not closed, 

the door ajar switch will turn to ON. The current flows from pin 2 of step light, to door ajar switch. The power is 

ground by ajar the switch. This enables step light to operate. 

• Ignition Switch Illumination 


in driver side junction box, to pin 1 of ignition switch illumination; The current outputs from the pin 2 of ignition 

switch illumination, to pin B1 of central locking controller, the central locking controller control the ignition 

switch illumination to operation. 

• Trunk lamp 


in driver side junction box, to pin 1 of trunk lamp and output from pin 2 of trunk lamp; If rear hatch door is not 

closed, the door ajar switch will turn to ON. The current flows from pin 2 of trunk lamp, to door ajar switch. The 

power is ground by ajar the switch. This enables trunk lamp to operate. 

• Door open Indicatior 

If any door is not closed, the door ajar switch will turn to ON. The ground signal input pin A15 and A30 of 

instrument cluster and this enables indicatior to operate. 

71 

71 








F007 Roof Wire Harness 1 J001 Rear Hatch Wire Harness 

G003 Roof Wire Harness 2 J003 Rear Hatch Wire Harness 

I002 Instrument Panel Wire Harness N002 Step Lamp Wire Harness 

Page 2897

71-72 




A102 

A104 

A108 

F101 

F103 

G103 

J101 

I106 

I111 

N101 

I107 

G101 

K101 

K102 















Ground Points 


F201 Rear Inner Panel of the Left Gusset J201 Under the Right Side of the Right Door 

I203 


Page 2898


71-73 

ILLUMINATION 

71 

71 

Page 2899

71-74 


Page 2900


71-75 



The current flows from charge and instrument panel fusible link, to pin 85 of lamplet relay, through the coil of 

tail light relay, and then to pin 13 of combination switch. When the combination switch is set lampet or 

headlamp (Low Beam/High Beam) position, the current flows output pin 10 of combination switch to connect 

the ground. The coil of lamplet relay creates a magnetic field, and switch is activated. The current flows 

through switch of relay and through the lamplet and switch light fuse in driver side junction box and the system 

getsss the power to operation. 

• Instrument Cluster Illumination 

When the combination switch is set lamplet or headlamp position, the current flows output lamplet fuse in 

driver side junction box, to pin A6 of instrument cluster. This enables instrument cluster illumination to operate. 

• Hazard Warning Switch Illumination 

When the combination switch is set lamplet or headlamp position, the current flows output lamplet fuse in 

driver side junction box, to pin 2 of hazard warning switch, to pin 3 of hazard warning switch, the power is 

ground at pin 3 of hazard warning switch. This enables hazard warning switch illumination to operate. 

• Headlamp Dimmer Switch Illumination 

When the combination switch is set lamplet or headlamp position, the current flows output switch light fuse in 

driver side junction box, to pin 3 of headlamp dimmer switch illumination, to pin 6 of headlamp dimmer switch 

illumination, the power is ground at pin 6 of headlamp dimmer switch illumination. This enables headlamp 

dimmer switch illumination to operate. 

• Instrument Dimmer Switch Illumination 


driver side junction box, to pin 3 of instrument dimmer switch illumination, to pin 6 of instrument dimmer 

switch illumination, the power is ground at pin 6 of instrument dimmer switch illumination. This enables 

instrument dimmer switch illumination to operate. 

• Rear Window Defroster Switch Illumination 


driver side junction box, to pin 3 of rear window defroster switch illumination, to pin 1 of rear window defroster 

switch illumination, the power is ground at pin 1 of rear window defroster switch illumination. This enables 

rear window defroster switch illumination to operate. 

• Outside Mirror Defroster Switch Illumination 


driver side junction box, to pin 3 of outside mirror defroster switch illumination, to pin 1 of outside mirror 

defroster switch illumination, the power is ground at pin 1 of outside mirror defroster switch illumination. 

This enables outside mirror defroster switch illumination to operate. 

• Rear Blower Forward Switch Illumination 


driver side junction box, to pin 3 of rear blower forward switch illumination, to pin 1 of rear blower forward 

switch illumination, the power is ground at pin 1 of rear blower forward switch illumination. This enables 

rear blower forward switch illumination to operate. 

• Dome Light Switch Illumination 


driver side junction box, to pin 3 of dome light switch illumination, to pin 1 of dome light switch illumination, 

the power is ground at pin 1 of dome light switch illumination. This enables dome light switch illumination 

to operate. 

• Cigarette Lighter Illumination 


driver side junction box, to pin 3 of cigarette lighter illumination, to pin 1 of cigarette lighter illumination, 

the power is ground at pin 1 of cigarette lighter illumination. This enables cigarette lighter illumination to 

operate. 

• Radio Illumination 


driver side junction box, to pin A3 of radio illumination, to pin A8 of radio illumination, the power is ground 

at pin A8 of radio illumination. This enables radio illumination to operate. 

71 

71 

Page 2901

71-76 


• A/C Control Panel llumination 


driver side junction box, to pin 32 of A/C control panel llumination, to pin 20 of A/C control panel 

llumination, the power is ground at pin 20 of A/C control panel llumination. This enables A/C control 

panel llumination to operate. 

• Diagnosis Switch llumination 


driver side junction box, to pin 3 of diagnosis switch llumination, to pin 1 of diagnosis switch llumination, 

the power is ground at pin 1 of diagnosis switch llumination. This enables diagnosis switch llumination to 

operate. 

Service Hints 


10 - 13:Closed with the combination switch at Lamplet or Headlamp position. 












A104 

I111 



Ground Points 


I201 Left Side of the Instrument Panel I204 Central of the Instrument Panel 


I203 


Page 2902


71-77 


71 

71 

Page 2903

71-78 



When ignition switch is ON/ST, the current flows through front wiper fuse and rear wiper fuse in driver side 

junction box. System is then powered. 

• Front Wiper Switch LO 

When the front wiper switch of combination switch is in LO position, the current flows from front wiper fuse, to 

pin 8 of combination switch, and output from pin 7 of combination switch, to pin 1 of front wiper motor, and 

through wiper motor to ground. This enables front wiper to operate at low speed. 

• Front Wiper Switch MIST 




• Front Wiper Switch HI 

When the front wiper switch of combination switch is in HI position, the current flows from front wiper fuse, to 


through wiper motor to ground. This enables front wiper to operate at high speed. 

• Front Wiper Switch INT 

When the front wiper switch of combination switch is set INT, The intermittent current flows from pin 7 of 

combination switch, to front wiper motor. This enables front wiper to operate in the intermittent mode. 

• Front Washer switch ON 

When the front washer switch is in ON position, the current flows output from pin 2 of front washer pump, and 

through the front washer pump, output from pin 1 of front washer pump, to pin 4 of combination switch, and 

ground at pin 5 of combination switch. This enables front washer to function. 

• Rear Wiper Switch ON 

The current flows output from rear wiper fuse, to pin 85 and 87 of rear wiper relay, and then output from pin 30 

of rear wiper relay. When the rear wiper switch is in ON position, the current flows into pin 2 of combination 

switch, and then to ground at pin 5 of combination switch; The current flows into coil of rear wiper relay. The 

coil of relay creates a magnetic field, and switch is activated. The current flows through switch of relay, from 

the pin 30 of relay, to pin 4 of rear wiper motor, and through the rear wiper motor, to ground at pin 3 of rear 

wiper motor. This enables rear wiper to operation. 

• Rear Washer Switch ON 

When the rear wiper switch is in ON position, the current flows from rear wiper fuse, to pin 2 of rear washer 

pump, and output from pin 1 of rear washer pump, to pin 3 of combination switch, and ground at pin 5 of 

combination switch. This enables rear washer to operation. 




U001 High-mounted Stop Lamp Wire Harness V011 Front Wire Harness 

V009 

Front Wire Harness 



A104 

F102 

F105 

I111 

I108 

U101 







Page 2904


71-79 


I101 

I102 

V101 

V102 





71 

Ground Points 

71 



I201 Left Side of the Instrument Panel V202 Left Side of the Longitudinal Beam 

Page 2905

71-80 



Page 2906


71-81 

Service Hints 

• I031 Radio 

A4 - Ground Points:Approx.12 V with the ignition switch at ACC/ON position. 

A7 - Ground Points:Approx. 12 V 

• D001 Front Speaker LH 

1 - 2:Approx. 4 Ω 

• H001 Front Speaker RH 

1 - 2:Approx. 4 Ω 

• F005 Rear Speaker LH 

1 - 2:Approx. 4 Ω 

• G002 Rear Speaker RH 

1 - 2:Approx. 4 Ω 

71 

71 




D001 Front Door LH Wire Harness I030 Instrument Panel Wire Harness 


G002 Roof Wire Harness 2 I032 Instrument Panel Wire Harness 

H001 Front Door RH Wire Harness J005 Rear Hatch Wire Harness 



A101 

A104 

D103 

F101 

F102 

F103 

F104 

G103 

H103 

I101 

I104 

I111 

V106 

I107 

I108 

G101 

G102 

K101 

V109 

V101 





Front Door LH Wire Harness & Front Wire Harness 

(Under the Left Side of the Door Flame) 











Front Door RH Wire Harness & Front Wire Harness 

(Under the Right Side of the Door Flame) 



Page 2907

71-82 



J101 

K102 



Ground Points 


G201 Rear Inner Panel of the Right Gusset I205 Central of the Instrument Panel 

Page 2908


71-83 

POWER SOCKET 

71 

71 

Page 2909

71-84 



• Cigarette Lighter 

When ignition switch is ACC/ON, the current flows through cigarette lighter fuse in driver side junction box, pin 

2 of cigarette lighter. When pressing the cigarette lighter, the current flows output from pin 1 of cigarette lighter, 

and ground at pin 1 of cigarette lighter. This enables cigarette lighter to operate. 

• 12V Power Output Socket 

When ignition switch is ON/ST, the current flows through cigarette lighter fuse in driver side junction box, pin 2 

of power output socket. When pressing the power output socket, the current flows output from pin 1 of power 

output socket, and ground at pin 1 of power output socket. This enables power output socket to operate. 






A104 

I111 



Ground Points 


I201 Left Side of the Instrument Panel I203 Left Side of the Instrument Panel 

Page 2910


71-85 

COMMUNICATION SYSTEM 

HORN 

71 

71 

Page 2911

71-86 



• horn control 

The current flows through charge and instrument panel fusible link in positive junction box, to horn fuse in 

driver side junction box, to pin 85 of horn relay, and through the coil of horn relay, and then to the circuit as 

follows: 

a. High equipped: Current flows from 2 pin of clock spring, to horn switch, when pressing the horn switch, the 

power is ground by switch. The coil of horn relay creates a magnetic field, and switch is activated. The current 

then flows through switch of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables horn to 

operate. 

b. low equipped: Current flows to horn switch, when pressing the horn switch, the power is ground by switch. 

The coil of horn relay creates a magnetic field, and switch is activated. The current then flows through switch 

of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables horn to operate. 

• Horn of Anti-thief System 

Pin 86 of horn relay is controlled by pin B4 of central locking controller to coonect the ground; When pin 86 of 

relay to connect the ground, The coil of horn relay creates a magnetic field, and switch is activated. The 

current then flows through switch of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables 

horn to operate. 





I038 




A104 

I102 

I111 

V102 





Ground Points 

Code 

V202 


Left Side of the Longitudinal Beam 

Page 2912


71-87 


71 

71 

Page 2913

71-88 



When ignition switch is ON/ST, the current flows through back-up lamp fuse in driver side junction box, to pin 2 

of back-up lamp switch. When shift lever in “R” position, the current flows from pin 1 of back-up lamp switch to 

pin 1 of reverse radar control unit. The reverse radar control system is then powered. 

• Reverse Radar Sensor LH 

The current outputs from pin 7 of reverse radar control unit, to pin 1 of reverse radar sensor LH, and through 

the sensor, output from pin 2 of reverse radar sensor LH, to pin 11 of reverse radar control unit, this detects the 

obstacle in rear left side. 

• Reverse Radar Central Sensor LH 

The current outputs from pin 8 of reverse radar control unit, to pin 1 of reverse radar central sensor LH, and 

through the sensor, output from pin 2 of reverse radar central sensor LH, to pin 11 of reverse radar control unit, 

this detects the obstacle in rear left central side. 

• Reverse Radar Central Sensor RH 

The current outputs from pin 4 of reverse radar control unit, to pin 1 of reverse radar central sensor RH, and 

through the sensor, output from pin 2 of reverse radar central sensor RH, to pin 11 of reverse radar control 

unit, this detects the obstacle in rear right central side. 

• Reverse Radar Sensor RH 

The current outputs from pin 15 of reverse radar control unit, to pin 1 of reverse radar sensor RH, and through 

the sensor, output from pin 2 of reverse radar sensor RH, to pin 11 of reverse radar control unit, this detects 

the obstacle in rear right side. 

Service Hints 

• A021 Back-up Lamp Switch 

1 - 2:Closed with the shift lever in “R” position. 



A021 Chassis & Frame Wire Harness R001 Rear Bumper Wire Harness 

A026 Chassis & Frame Wire Harness R002 Rear Bumper Wire Harness 

I002 Instrument Panel Wire Harness R003 Rear Bumper Wire Harness 

I028 Instrument Panel Wire Harness R004 Rear Bumper Wire Harness 



A101 

A102 

A103 

A104 

A110 

I104 

I106 

I105 

I111 

Q102 









Chassis & Frame Wire Harness & Rear Bumper Transition Wire Harness 

(Left Rear Side of the Car Body) 

Page 2914


71-89 


Q101 

R101 

Rear Bumper Transition Wire Harness & Rear Bumper Wire Harness 

(Left Side of the Rear Bumper) 

71 

Ground Points 



71 

Page 2915

71-90 


POWER MIRROR 

Page 2916


71-91 


When ignition switch is ACC/ON, the current flows through radio ACC fuse in driver side junction box, to pin 4 

of outside mirror switch. System is then powered. 

• Outside Mirror LH (Up/Down) 

The current flows from pin 4 of electric outside mirror switch and output from pin 7 of electric outside mirror 

switch, to pin 6 of outside mirror LH, through motor, the current flows from pin 4 of outside mirror LH, to pin 5 

of electric outside mirror switch, and ground at pin 6 of electric outside mirror switch. This enables outside 

mirror LH to go up. 




mirror LH to go down. 

• Outside Mirror RH (Up/Down) 


switch, to pin 6 of outside mirror RH, through motor, the current flows from pin 4 of outside mirror RH, to pin 5 


mirror RH to go up. 




mirror RH to go down. 

• Outside Mirror LH (Left/Right) 

TThe current flows from pin 4 of electric outside mirror switch and output from pin 5 of electric outside mirror 



mirror LH to turn to left. 




mirror LH to turn to right. 

• Outside Mirror RH (Left/Right) 




mirror RH to turn to left. 




mirror RH to turn to right. 

71 

71 



D003 Front Door LH Wire Harness H003 Front Door RH Wire Harness 

D004 

Front Door LH Wire Harness 



D101 

D102 

V104 

V105 





Page 2917

71-92 



I101 

V107 

V101 

H101 



Front Wire Harness & Front Door RH Wire Harness 


Ground Points 

Code 

V202 


Left Side of the Longitudinal Beam 

Page 2918


71-93 

WINDOW DEFROSTER 

71 

71 

Page 2919

71-94 



• Rear Window Defrost 

When ignition switch is ON/ST, the current flows through outside mirror defrost fuse in co-pilot side junction 

box, to pin 2 of rear window defroster switch, when press the switch, pin 5 and pin 2 of rear window defroster 

switch connected, the current flows to pin 85 of rear defroster relay, through the coil in rear defroster relay, and 

output from pin 86 of rear defroster relay. The coil of rear defroster relay creates a magnetic field, and switch is 

activated. The current flows through switch of rear defroster relay, to pin 1 of rear window defrost grid and 

ground. This enables rear window defroster to operate. 

• Outside Mirror Defrost 


box, to pin 2 of outside mirror defroster switch, when press the switch, pin 5 and pin 2 of outside mirror 

defroster switch connected, the current flows to pin 85 of outside mirror defroster relay, through the coil in outside 

mirror defroster relay, and output from pin 86 of outside mirror defroster relay. The coil of outside mirror 

defroster relay creates a magnetic field, and switch is activated. The current flows from outside mirror defrost 

fuse, through switch of outside mirror defroster relay, to pin 1 of outside mirror defrost grid and ground at pin 2 

of grid. This enables outside mirror defroster to operate. 

Service Hints 

• I016 Rear Window Defrost Switch 

2 - 5:Closed with the rear window defrost switch in operation. 

• I017 Outside mirror Defrost Switch 

2 - 5:Closed with the outside mirror defrost switch in operation. 




H003 Front Door RH Wire Harness S001 Rear Defrost RH Wire Harness 

I016 Instrument Panel Wire Harness T001 Rear Defrost LH Wire Harness 



A102 

A103 

D102 

D103 

F102 

F105 

H101 

I106 

I105 

V105 

V106 

I108 

U101 

V107 















Page 2920


71-95 


H103 

I101 

V109 

V101 





71 

S101 

U103 

Rear Defrost RH Wire Harness & High-mounted Stop Lamp Wire Harness 

(Above the Right Side of the Rear Hatch) 

71 

T101 

U102 

Rear Defrost LH Wire Harness & High-mounted Stop Lamp Wire Harness 

(Above the Left Side of the Rear Hatch) 

Ground Points 


A201 Left Front Wheel Cover Plate Side Plates V202 Left Side of the Longitudinal Beam 

I203 


Page 2921

71-96 



Page 2922


71-97 

71 

71 

Page 2923

71-98 


Page 2924


71-99 

71 

71 

Page 2925

71-100 



• instrument cluster power 

a. ISF 2.8 engine: When ignition switch is ON/ST, the current flows through instrument IG fuse in driver side 

junction box, to pin A1 and A20 of instrument cluster. System is then powered. 

b. 4G69 engine: The instrument cluster IG power of circuit as follows: When ignition switch is ON/ST, the current 

flows through instrument IG fuse in driver side junction box, to pin A20 of instrument cluster. System is 

then powered. When ignition switch is ON/ST, current flows through main relay and output from pin 87 of relay, 

to pin A1 of intrument cluster. System is then powered. 

• Engine Coolant Fluid Level Warning Light 

The current flows through engine coolant fluid level warning light in instrument cluster, and output from pin B7 

of instrument cluster, to pin 2 of engine coolant level sensor, and ground at pin 1 of engine coolant level 

sensor. This enables engine coolant fluid level warning light to operate. 

• Engine Coolant Temperature Indicator 

The current flows from pin B16 of instrument cluster, to pin 1 of engine coolant temperature sensor, and 

ground at pin 2 of engine coolant temperature sensor (ISF2.8) or itself (4G69). This enables engine coolant 

fluid temperature indicator to operate. 

• Engine Oil Pressure Warning Light 

The current flows through engine oil pressure warning light in instrument cluster, and output from pin B22 of 

instrument cluster, to pin 1 of engine oil pressure switch, and then to ground. This enables engine oil pressure 

warning light to operate. 

• Low Fuel Indicator and Warning Light 

The current flows through low fuel warning light in instrument cluster, and output from pin A23 of instrument 

cluster, to pin 3 of fuel level sensor, and then ground at pin 2 of level sensor. This checks the fuel leveland 

shows the fuel level in instrument cluster, if the fuel is less, the warning light will be activated. 

• ABS Warning Light 

The current flows into pin A20 of instrument cluster, through ABS warning light in instrument cluster, and 

output from pin B20 of instrument cluster, to 15 of ABS module. If ABS system is fault, this enables ABS 


• EBD Warning Light 

The current flows into pin A20 of instrument cluster, through EBD warning light in instrument cluster, and 

output from pin B24 of instrument cluster, to 14 of ABS module. If ABS system is fault, this enables EBD 


• Charging Warning Light 

The current flows into pin A20 of instrument cluster, through charging warning light in instrument cluster, and 

output from pin B25 of instrument cluster, to pin 1 of generator. This identifies if the generator operates or not. 

• Safe Belt Indicator 

The current flows into pin A20 of instrument cluster, through safe belt indicator in instrument cluster, and 

output from pin A31of instrument cluster, to pin 1 of driver seat belt warning switch. If driver do not fasten the 

safe belt, switch will close, this enables safe belt indicator to operate. 

• Buzzer of Safe Belt 

The current flows through buzzer in instrument cluster, and output from pin B9 of instrument cluster, to pin 1 of 

driver seat belt warning switch. If driver do not fasten the safe belt, switch will close, this enables buzzer to 

operate. 

• Air Bag System Warning Light 

The current flows into pin A20 of instrument cluster, through warning light in instrument cluster, and output 

from pin B27 of instrument cluster, to pin 7 of RCM. If Air bag system is fault, this enables air bag system 

warning light to operate 

• Parking Indicator 

The current flows into pin A20 of instrument cluster, through indicator in instrument cluster, and output from pin 

B6 of instrument cluster, to pin 1 of parking brake switch. Through switch to ground, this enables parking indicator 

to operate 

• Brake Warning Light 

The current flows into pin A20 of instrument cluster, through brake warning light in instrument cluster, and 

output pin B28 of instrument cluster, to pin 1 of brake fluid level sensor, and ground at pin 2 of brake fluid level 

sensor. This checks the brake fluid level. 

Page 2926


71-101 

• Lamplet indicator 

The current flows into pin A6 of instrument cluster, through indicator in instrument cluster, and output pin B30 

of instrument cluster to ground. If lamplet or interior lamp work, the indicator will be activated. 

• Enging Pre-heating indicator 

ISF2.8 engine: The current flows into pin A1 of instrument cluster, through indicator in instrument cluster, and 

output pin A27 of instrument cluster, to pin 35 of ECM. If pre-heating system is working, the indicator will be 

activated. 

• Malfunction Indicator 

The current flows into pin A1 of instrument cluster, through malfunction indicator in instrument cluster, and 

output from pin B23 of instrument cluster, to pin 19 of ECM (4G69) or 22 of ECM (ISF2.8). If engine control 

system fault exist, this enables malfunction indicator to operate. 

• Maintenance Indicator 


A28 of instrument cluster, to pin 12 of ECM (4G69) or 36 of ECM (ISF2.8). If engine need to service, this 

enables indicator to operate. 

• Engine Stop Indicator 

ISF 2.8 engine: The current flows into pin A20 of instrument cluster, through indicator in instrument cluster, 

and output from pin A24 of instrument cluster, to pin 49 of ECM. ECM control the stop indicator. 

• Vacuum Warning Light 

ISF 2.8 engine: The current flows from pin A26 of instrument cluster, through indicator in instrument cluster, to 

pin 1 of vacuum warning switch. Through the switch to connect ground, this enables the warning light to operate. 

71 

71 









A027 Chassis & Frame Wire Harness O001 Driver Seat Belt Wire Harness 

A032 Chassis & Frame Wire Harness V012 Front Wire Harness 

A036 Chassis & Frame Wire Harness V016 Front Wire Harness 

E001 

Engine Wire Harness 



A101 

A102 

A103 

I104 

I106 

I105 







Page 2927

71-102 



A104 

A105 

A106 

A107 

A112 

I102 

I111 

O101 

E101 

E102 

E103 

V102 



Chassis & Frame Wire Harness & Driver Seat Belt Wire Harness 

(Above the B-Pillar LH) 









Ground Points 


A202 Left Front Wheel Cover Plate Side Plates I203 Left Side of the Instrument Panel 

A204 Right Front Wheel Cover Plate Side Plates V202 Left Side of the Longitudinal Beam 

I201 


Page 2928


71-103 

ANTI-THEIF SYSTEM 

71 

71 

Page 2929

71-104 


Page 2930


71-105 


The current flows through charge and instrument panel fusible link in positive junction box, to driver side junction 

box and circuit as follows: 

a. Through the central locking fuse, to pin B3 of central locking controller, system getsss the power of central 

locking. 

b. Through power window fusible link, to pin A8 of central locking controller, system getsss the power of electrical 

window. 

c. Through power window fusible link, to pin 12 of door control switch, switch is then powered. 

• Key Lock Signal 

a. When key lock switch is LOCK position, the current flows output from pin A6 of central locking controller, to 

pin 9 of front door lock actuator assembly LH and through the key lock switch, to ground at pin 7 of front door 

lock actuator assembly LH. This enables closed with door of all with mechanical operate. 

b. When key lock switch is OPEN position, the current flows output from pin A7 of central locking controller, to 

pin 10 of front door lock actuator assembly LH, and through the key lock switch, to ground at pin 7 of front door 

lock actuator assembly LH. This enables opened with door of all with mechanical operate. 

• Status of Front Door LH 

Current flows from pin B2 of central locking controller, to pin 1 of front door LH switch, through switch to 

ground, system getss the signal of front door status. 

• Status of Hood 

Current flows from pin B6 of central locking controller, to pin 1 of hood switch, through 2 pin of switch to 

ground, system getss the signal of hood status. 

• Collision Signal 

Signal is from pin 30 of restraint control module, to pin A11 of central locking controller. System getssgetss the 

Info of collision. 

• vehicle speed signal 

Signal is from pin A9 of instrumen cluster, to pin A17 of central locking controller. When the vehicle speed 

attach the value as design, system will lock all door that unlocked before. 

• Key Insert signal 

Current flows from pin B8 of central locking controller, to pin 3 of key insert switch, through the switch and 

ground at pin 4 of switch. System getss the key insert signal. 

• Door control switch 

Pin 1 and 2 of door control switch connect the pin A15 and A16 of central locking controller, through this 

connection, the controller getsss the signal that control the door window and lock from door control swith. 

• Door Actuator Control 

a. Front door LH unlock: The current flows output from pin A3 of central locking controller, to pin 1 of front door 

lock actuator assembly LH, and through the motor in front door lock actuator assembly LH, output from pin 4 of 

front door lock actuator assembly LH, to pin A2 of central locking controller. This enables front door LH open. 

On the contrary, the front door LH is closed. 

b. Front door RH unlock: The current flows output from pin A3 of central locking controller, to pin 1 of front door 

lock actuator assembly RH, and through the motor in front door lock actuator assembly RH, output from pin 4 

of front door lock actuator assembly RH, to pin A2 of central locking controller. This enables front door RH 

open. On the contrary, the front door RH is closed. 

c. Sliding door unlock: The current flows output from pin A3 of central locking controller, to pin 2 of sliding door 

lock actuator assembly, and through the motor in sliding door lock actuator assembly, output from pin 4 of sliding 

door lock actuator assembly, to pin A2 of central locking controller. This enables sliding door open. On the 

contrary, the sliding door is closed. 

d. Rear hatch unlock: The current flows output from pin A3 of central locking controller, to pin 2 of rear hatch 

lock actuator assembly, and through the motor in door lock actuator assembly, output from pin 4 of lock 

actuator assembly, to pin A2 of central locking controller. This enables rear hatch open. On the contrary, the 

rear hatch is closed. 

• Power Window Control 

a. Power window LH up: The current flows output from pin A5 of central locking controller, to pin 1 of power 

window LH, and through the motor, output from pin 2 of power window LH, to pin A4 of central locking 

controller. This enables power window LH up. On the contrary, power window LH is down. 

b. Power window RH up: The current flows output from pin A7 of central locking controller, to pin 1 of power 

window RH, and through the motor, output from pin 2 of power window RH, to pin A6 of central locking 

controller. This enables power window RH up. On the contrary, power window RH is down. 

71 

71 

Page 2931

71-106 









H002 Front Door RH Wire Harness J002 Rear Hatch Wire Harness 

H004 Front Door RH Wire Harness N001 Step Lamp Wire Harness 

H005 Front Door RH Wire Harness V015 Front Wire Harness 



A102 

A103 

A104 

A108 

D101 

D102 

D103 

F101 

F103 

G103 

H101 

H102 

H103 

I101 

I106 

I105 

I111 

N101 

V104 

V105 

V106 

I107 

G101 

K101 

V107 

V108 

V109 

V101 





























Page 2932


71-107 


I103 

J101 

V103 

K102 





71 

Ground Points 

71 


I202 Left Side of the Instrument Panel V202 Left Side of the Longitudinal Beam 

Page 2933

71-108 


SLIDING ROOF 

Page 2934


71-109 


• System power 

a. When ignition switch is ACC: The current flows through cigarette lighter fuse in driver side junction box, pin 

4 of sliding roof ECU and pin 2 of sliding roof switch. Then system is powered. 

b. When ignition switch is ON/ST: The current flows through sliding roof fuse in driver side junction box, pin 1 

of sliding roof ECU and pin 3 of sliding roof switch. Then system is powered. 

• System Control 

ECU getss the operation signal from the switch and control the motor to operate. All operation is accordance 

with user want. 

71 

71 



F002 Roof Wire Harness 1 F003 Roof Wire Harness 1 



A104 

I111 



Ground Points 



Page 2935

71-110 


RESTRAINT CONTROL SYSTEM 

Page 2936


71-111 


When a car collides with an obstacle, it will quickly open an airbag filled with air, so that the occupants can 

throw themselves on the airbag when moving due to inertia, thereby easing the impact on occupants and 

absorbing collision energy to reduce personal injuries. 

When ignition switch is ON/ST, the current flows through airbag fuse in co-pilot side junction box, to pin 5 of 

restraint control module. System is then powered 

• Deployment of Airbag 

When vehicle is in a frontal collision exceeding a specified level, the current flows from pin 10 of restraint 

control module, to pin 3 of clock spring, to driver airbag. Current then flows from driver airbag, to pin 4 of clock 

spring, and back to pin 11 of restraint control module. Driver airbag is then activated. 


control module, to pin 1 of passenger airbag. Current then flows from pin 2 of passenger airbag, and back to 

pin 14 of restraint control module. Passenger airbag is then activated. 

• All Door Unlock 


control module, to pin A11 of central locking controller. Central locking controller getss the sginal of collision 

and unlock the all door. 


When the system comes into operation, restraint control module detects the operation of all parts of the 

system. Once the system or parts have faults, the system will switch on the SRS warning light to remind 

drivers of repair in time. 

71 

71 





I003 Instrument Panel Wire Harness M002 Diagnosis Wire Harness 

I007 




A102 

A103 

I106 

I105 





Ground Points 

Code 

A205 


Left Side of the Airbag Module 

Page 2937

71-112 

WIRING - CONNECTOR VIEWS 

CONNECTOR VIEWS 

A - CHASSIS & FRAME WIRE HARNESS 

A004 to Positive Junction Box A 

Code Color Function Qualifier 

1 W 

2 W-G 

Battery Compartment 

Junction Box Power 

Input 

Engine Room 


Input 

A007 Rear Heater Blower Switch 


1 W-B 

2 P 

3 W-B 

Rear Heater Air Flow 

Switch Ground 


Switch Input 


Switch Ground 

4 B Rear Heater Motor H 

A005 to Positive Junction Box C 

5 W Rear Heater Motor M 

6 L Rear Heater Motor L 


1 R-B Generator Output B+ 

A008 Front Door Lamp Switch LH 


A006 to Positive Junction Box D 

1 W-L Switch Input 


1 R 

to Positive Junction 

Box D Power Input 

Page 2938


71-113 

71 

71 

A009 ABS Module 

Code Color Function Qualifier Code Color Function Qualifier 

1 R 

ABS Motor Power 

Input 

20 - - 

2 - - 21 - - 

3 Y-R 

4 L 

EBD Warning Lamp 

Signal Output 

Front Right Wheel 

Speed Sensor- 

22 - - 

23 - - 

5 - - 24 - - 

6 R-L Data Link Connector k 25 R-W 

ABS Solenoid Valve 

Power Input 

7 - - 26 - - 

8 W 

Front Left Wheel 

Speed Sensor- 

27 Y-G 

ABS Fault Light 

Signal Output 

9 - - 28 R-W ABS-IG Input 

10 - - 29 LG 

Rear Right Wheel 

Speed Sensor- 

11 - - 30 G-W Brake Signal Input 

12 - - 31 Y-W 

Rear Left Wheel 

Speed Sensor+ 

13 W-B Ground 32 - - 

14 - - 33 - - 

15 - - 34 - - 

16 G 

17 P 

18 L-G 

19 B 


Speed Sensor+ 


Speed Sensor+ 


Speed Sensor- 


Speed Sensor+ 

35 - - 

36 - - 

37 - - 

38 W-B Ground 

Page 2939

71-114 


A010 Front Wheel Speed Sensor LH 


1 W 

2 B 


Speed Sensor- 


Speed Sensor+ 

A013 Rear Wheel Speed Sensor RH 


1 LG 

2 P 


Speed Sensor- 


Speed Sensor+ 

A011 Front Wheel Speed Sensor RH 


1 L 

2 G 


Speed Sensor- 


Speed Sensor+ 

A014 Acceleration Sensor 


1 Br-R 

2 Br-G 

3 SB 

Acceleration Sensor 

Signal- 


Signal+ 


Power+ 

A012 Rear Wheel Speed Sensor LH 


1 L-G 

2 Y-W 


Speed Sensor- 


Speed Sensor+ 

A015 Secondary Fan Motor 


1 W Secondary Fan+ 

2 Y 

3 W-B 

Secondary Fan Low 

Speed+ 

Secondary Fan 

Ground 

Page 2940


71-115 

71 

A016 Main Fan Motor 


1 R-W Fan High Speed+ 

2 R-B Fan Low Speed+ 

3 W-B Main Fan Ground 

A019 Downstream Oxygen Sensor 


1 B 

2 O 

Downstream Oxygen 

Signal- 


Signal+ 

71 

3 Y-B 

4 G 


Heating 


Sensor+ 

A017 Generator B+ 



A020 Odometer Sensor 


1 R-B Sensor Power 

A018 Generator Excitation (Gasoline) 


1 P-L Generator Excitation 

2 L IG End 

2 W-B 

3 W-G 


Ground 

Vehicle Speed Signal 

Output 

A021 Back-up Lamp Switch (Gasoline) 


A018 Generator (Diesel) 


1 - - 


1 W-L 

2 B-Y 

Back-up Lamp Power 

Input 

Reverse Power 

Output 

Page 2941

71-116 


A021 Back-up Lamp Switch (Diesel) 


1 W-L 


Input 

A024 Front Door Lamp Switch RH 


1 R-W Front Door Lamp+ 

2 B-Y 


Output 

A025 Stop Lamp Switch 


A022 Fuel Sensor/Fuel Pump 


1 Br 

2 W-B 

Fuel Pump Relay Pin 

30 

Fuel Pump,Fuel 

Sensor Ground 

1 G-W Brake Power Output 

2 W-R 

3 L-Y 

Stop Lamp Power 

Input 

Engine ECM Brake 

Switch Output 

4 W-B SW RET 

3 V Fuel Sensor+ Input 

4 W-B Ground 

A026 Parking Brake Switch 


A023 Engine Oil Pressure Sensor 

1 Y Parking Brake Switch 


1 L-Y 

Engine Oil Pressure 

Warning Light 

Page 2942


71-117 

71 

71 

A027 Restraint control module (RCM) 


1 - - 16 - - 

2 - - 17 - - 

3 - - 18 - - 

4 - - 19 - - 

5 B-O Airbag Power Input 20 - - 

6 W-B Airbag Ground 21 - - 

7 B-Y 

Airbag Warning Lamp 

Signal Output 

22 - - 

8 - - 23 - - 

9 R-L Airbag K 24 - - 

10 Y 

11 Y-B 

Airbag Drive Low-side 

Interface ACU 

Airbag Drive Highside 

Interface ACU 

25 - - 

26 - - 

12 - - 27 - - 

13 G-B 

14 G-R 


Interface ACU 

High-side 


Interface ACU 

Low-side 

28 - - 

29 - - 

15 - - 30 Y 

Collision Signal 

Output 

Page 2943

71-118 


A028 Front Blower 


1 R-W Front Blower+ 

A032 Vacuum Level Alarm Switch (Diesel) 


1 B - 

2 G-W Front Blower- 

A029 Front Door Lamp Diode LH 


1 R-W Front Door Lamp+ 

2 W-L Diode- 

A033 Data Link Connector 120 Resistance 

(Diesel) 


1 G-B - 

2 G-O - 

3 - - 

A030 Diesel Filter Heater (Diesel) 


1 Br - 

2 W-B - 

A034 Clutch Switch (Diesel) 


1 - - 

2 - - 

3 W-B - 

4 L-B - 

A031 Preheating Relay Coil (Diesel) 


1 L-Y - 

2 L-B - 

Page 2944


71-119 

A035 Electronic Throttle (Diesel) 


3 W - 

71 

A035 Electronic Throttle (Diesel) 


1 B - 

2 L-G - 

4 Y - 

5 W-R - 

6 Y-G - 

71 

A036 ECM (Diesel) 


E1 

W-R 

Engine ECU Power 

Input 

E30 - - 

E2 W-B Engine ECU Ground E31 - - 

E3 

W-R 


Input 

E32 - - 

E4 W-B Engine ECU Ground E33 W-B 

High-speed Fan 

Control Input Pin 86 

E5 

W-R 


Input 

E34 

B-W 

Low-speed Fan 

Control Feedback Pin 

86 

E6 W-B Engine ECU Ground E35 G-Y 

Preheat Indication 

Output 

E7 - - E36 Br Engine Maintenance 

E8 - - E37 - - 

E9 V-W Speed Output E38 - - 

E10 

B-Y 

Diagnosis Switch 

Output 

E39 L-B Clutch Control Output 

Page 2945

71-120 


A036 ECM (Diesel) 


E11 

R-W 

Medium Pressure 

Switch + Output 

E40 - - 

E12 - - E41 B-G ECU-IG 

E13 - - E42 Y-G Throttle Sensor 2+ 

E14 G-B CAN-H E43 W-R Throttle Sensor 2 

E15 G-O CAN-L E44 L-G Throttle Sensor 1 

E16 - - E45 - - 

E17 - - E46 L-B 

Preheating Relay Coil 

Output 

E18 - - E47 R-Y Fan Low-speed Diode 

E19 - - E48 L 

A/C Low Level 

Approval Output 

E20 - - E49 Y-W Engine Stop Light 

E21 

L-Y 


Input 

E50 - - 

E22 L-W MILL Light E51 - - 

E23 - - E52 L-Y 

Engine ECU Brake 

Switch Output 

E24 - - E53 - - 

E25 - - E54 - - 

E26 - - E55 Y Throttle Sensor 2- 

E27 Y-B A/C Request Input E56 B Throttle Sensor 1- 

E28 L Vehicle Speed Input E57 W Throttle Sensor 1+ 

E29 W-B SW RET E58 - - 

A101 to Instrument Panel Wire Harness A 


4 - - 

5 L - 



1 B-W - 

2 B - 

3 - - 

6 Y - 

7 V - 

8 Y-B - 

9 Y-R - 

10 Y-G - 

11 W-G - 

Page 2946


71-121 



12 V-W - 

13 P-L - 

14 R-W - 

15 L-W - 

16 Y-W - 

17 L-Y - 

18 Y-G - 

19 Br - 

20 G-Y - 

A102 to Instrument Panel Wire Harness B 


11 G-W - 

12 - - 

13 W-L - 

14 R-Y - 

15 W-L - 

16 B-Y - 

17 R - 

18 G - 

19 - - 

71 

71 

21 W-L - 

21 R-B - 

22 R-B - 

23 - - 

24 - - 

4G69 Left 

hand 

ISF2.8 

Left Hand 

20 - - 

A103 to Instrument Panel Wire Harness C 


1 Y-B - 

2 Y - 

A102 to Instrument Panel Wire Harness B 


1 R-B 

2 B-G 

3 R-W 

4 R 

5 G-B - 

6 R - 

7 W-B - 

8 - - 

9 W-L - 

10 R-L - 

3 G-L - 

4 Br-L - 

5 B-Y - 

6 Y - 

7 Y-L - 

8 B - 

9 G-B - 

10 G-R - 

11 - - 

12 B - 

13 - - 

14 B - 

15 R-G - 

Page 2947

71-122 


A103 to Instrument Panel Wire Harness C 


16 R-B - 

17 R-W - 

18 R-L - 

19 - - 

A106 to Engine Wire Harness 1 (Gasoline) 


6 R-W - 

7 Y - 

8 W-B - 

9 L - 

10 R - 

11 L - 

12 W-L - 

A104 to Instrument Panel Wire Harness D 


1 R - 

13 G-B - 

14 - - 

15 V-W - 

16 L - 

A105 to Driver Seat Belt Warning Wire 

Harness Assy 


1 B-W - 

2 W-B - 



1 - - 

2 Br-R - 

3 Br-G - 

4 SB - 

5 G - 

6 - - 

7 - - 



1 Br - 

2 L-W - 

3 Y-G - 

4 - - 

5 Y-B - 

8 - - 

9 R-L - 

10 B - 

11 Y-B - 

12 O - 

13 - - 

14 B-G - 

Page 2948


71-123 



15 G-W - 

16 G - 

A108 to Step Lamp Wire Harness 


1 G - 

2 L - 

3 R - 

4 - - 

5 R - 

6 Gr - 

7 R-Y - 

8 - - 

A110 to Rear Bumper Transition Wire 

Harness 


1 R-G - 

2 R-B - 

3 R-L - 

4 R-W - 

5 B - 

6 - - 

7 - - 

8 - - 

71 

71 

A109 to Rear Heater Wire Harness 


1 W - 

2 L-B - 

3 L - 

4 B - 

5 W-B - 

6 W-L - 

7 - - 

8 - - 

Page 2949

71-124 


A112 to Engine Wire Harness A (Diesel) 

A111 to Instrument Panel Wire Harness E 


1 R - 

2 Gr - 

3 - - 

4 - - 

5 R-B - 

6 Gr-R - 

7 G-W - 


1 - - 

2 G-B - 

3 Y-G - 

4 - - 

5 - - 

6 L-Y - 

7 W-B - 

8 - - 

8 - - 

9 - - 

10 G - 

11 LG - 

12 L - 

13 - - 

14 - - 

A113 to Battery Wire Harness B (Diesel) 


1 W-B - 

2 R - 

Page 2950


71-125 

B - BATTERY WIRE HARNESS 

71 

B001 Starter 


B R - 

B101 to Chassis & Frame Wire Harness B 


1 W-B - 

2 R - 

71 

B002 Starter Excitation 


B R - 

Page 2951

71-126 


C - FRONT BUMPER WIRE HARNESS 

C001 Front Fog Lamp LH 


1 LG Fog Lamp Power 

2 W-B Ground 

C101 to Front Wire Harness 


1 - - 

2 - - 

3 - - 

C002 Front Fog Lamp RH 



4 LG - 

5 W-B - 

6 LG - 

2 W-B Ground 

Page 2952


71-127 

D - FRONT DOOR LH WIRE HARNESS 

71 

D001 Front Speaker LH 


1 V 

Front Left Speaker 

Power Input 

2 P Front Left Speaker- 

D004 Electric Outside Mirror Switch 


1 L-R 

Left Outside Mirror 

Left And Right Adjust 

Input 

2 - - 

71 

3 L-Y 

Right Outside Mirror 

Left and Right Adjust 

Output 

D002 Power Window Motor LH 


4 G-R 

Outside Mirror Switch 

Power Input 

5 R-Y Outside Mirror- 

6 W-B Ground 

1 R 

2 G 

Driver Side Window 

Up Input 


Down Input 

7 R 

8 R-L 

Left Outside Mirror Up 

And Down Adjust 

Input 


Up And Down Adjust 

output 

D003 Outside Mirror Assy LH 


1 - - 

2 W-B 

3 B 

Outside Mirror Assy 

LH Ground 


Defroster Power Input 

4 R-Y Left Outside Mirror- 

5 L-R 

6 R 



Input 



Input 

D005 Door Control Switch 


1 L-B 

2 L 

3 L-Y 

4 P-L 

5 L-G 

Left Side Door Assy 

Control Switch Input 

Left Side Door Assy 


Right Side Window 

Control Switch Output 





Page 2953

71-128 




6 W-B 

Door Control Switch 

Ground 

7 - - 

8 - - 

9 G-R 


Lamplet Control 

10 - - 

11 - - 

12 W-L 


Power Input 

D101 to Front Wire Harness A 


1 R - 

2 L-R - 

3 L-Y - 

4 G-R - 

5 G - 

6 L-O - 

7 R-Y - 

8 R-L - 

D006 Front Door Lock Assy LH 


1 G 

Front Left Door Lock 

Unlock Input 

2 - - 

3 - - 

4 R 

Front Left Door Lock 

Latch Input 

5 - - 

6 - - 

7 W-B 

Front Door Lock Assy 

LH Ground 

8 - - 

9 L-O Key Lock Output 

10 L-R Key Unlock Output 

D102 to Front Wire Harness B 


1 L-B - 

2 L-Y - 

3 P-L - 

4 W-L - 

5 W-B - 

6 L - 

7 G-R - 

8 L-G - 

Page 2954


71-129 

71 

D103 to Front Wire Harness C 


71 

1 - - 

2 P - 

3 R - 

4 B - 

5 V - 

6 G - 

Page 2955

71-130 


E - ENGINE WIRE HARNESS 

E001 ECM 


1 L Ignition Coil 42 Br-Y 

Idle Speed Control B 

Low 

2 B Ground 43 - - 

3 B Ground 44 G-W Main Relay Control 

4 G Ignition Coil 45 - - 

5 - - 46 - - 

6 L-W Injector A- 47 W 

7 L-P Injector C- 48 O 

8 L-V Injector B- 49 W-R 

Upstream Oxygen 

Sensor Signal+ 



Coolant Temperature 

Sensor+ 

9 G 

10 L 

Fuel Pump Relay 

ECU Control 

Air Conditioning Low 

Level Approval Output 

50 - - 

51 L Vehicle Speed Input 

11 P 


Sensor- 

52 W-B 


Sensor- 

12 Br Engine Maintenance 53 - - 

13 - - 54 L-Y Air Pressure MAP 

14 - - 55 - - 

15 - - 56 - - 

16 - - 57 - - 

17 W-B 


Control 

58 B-W Knock Sensor 

18 V-W Vehicle Speed 59 Br-G Acceleration Sensor+ 

19 L-W MIL 60 - - 

20 G-Br 

Idle Speed Control A 

High 

61 - - 

Page 2956


71-131 

E001 ECM 


21 G-Y 


Low 

62 - - 

71 

22 - - 63 - - 

23 Y-B 


Sensor Heating- 

64 W-Y 

Canister Solenoid 

Valve- 

71 

24 L-R 



65 Y 

Starter Excitation 

Power Output 

25 L-O Injector D- 66 SB 

Intake Air 

Temperature 


Power 2 

26 R-W 

27 V-G 



Switch 


67 W-L ECU Power 

68 B-G ECU-IG 

28 - - 69 - - 

29 - - 70 SB 


Power 

30 O 


Sensor+ 

71 L-W Air Temperature 

31 - - 72 - - 

32 - - 73 B 

33 - - 74 Br-R 

Upstream And 



Throttle Position Sen- 

sor- 

34 - - 75 R-L ECU-K Line 

35 - - 76 Br-R 



Signal- 

36 - - 77 - - 

37 O-V Knock Sensor 78 - - 

38 - - 79 Y-B AC Request 

39 - - 80 - - 

40 - - 81 - - 

41 Y-P 


High 

Page 2957

71-132 


E002 Injector A 


1 G Injector+ 

2 L-W Injector A- 

E006 Mainfold Absolute Pressure/Intake Air 

Temperature Sensor 


1 L-Y Air Pressure MAP 

2 SB 



Power 2 


E003 Injector B 


1 G Injector+ 

2 L-V Injector B- 

4 Br-R 

Intake Air 

Temperature 


Signal- 

E007 Upstream Oxygen Sensor 


E004 Injector C 


1 G Injector+ 

2 L-P Injector C- 

1 B 

2 W 

3 L-R 

4 G 


Sensor Signal- 






Sensor+ 

E005 Injector D 


1 G Injector+ 

2 L-O Injector D- 

E008 Crankshaft Position Sensor 


1 O 


Sensor+ 

Page 2958


71-133 



2 P 


Sensor- 

3 - Ground 

E012 Engine Coolant Temperature Sense 

Plug 


71 

71 

1 Y-G 

Water Temperature 

Gauge Sensor 

E009 Throttle Position Sensor 


1 SB 

2 Br-R 

3 V-G 


Power 

Throttle Position 

Sensor- 


E013 Compressor 


1 G-B 

Compressor Excitation 

E010 Engine Coolant Temperature Sensor 


1 W-B 


Sensor- 

E014 Starter Coil 


1 R 

Starter Excitation Output 

2 W-R 


Sensor+ 

E015 Idle Air Control Valve 

E011 Knock Sensor 


1 O-V Knock Sensor 



1 Br-Y 

2 Y-P 


Low 


High 

Page 2959

71-134 




3 G-Y 

4 G-Br 


Low 


High 

E017 Ignition Coil 


1 G Ignition Coil 

2 L Ignition coil+ 

3 L Ignition Coil 

E016 Canister Solenoid Valve 


1 W-Y Canister Valve- 

2 G Canister Valve+ 

E018 Engine Electronic Control Module 


1 P 

Cylinder 3 Fuel 

Injector Solenoid 

Valve Drive Signal 

49 B 



Valve Drive Circuit 

2 P 




50 P 




3 - - 51 - - 

4 - - 52 - - 

5 P EGR Valve Motor+ 53 P 

Intake Throttle 

Actuator Motor- 

6 - - 54 - - 

7 - - 55 - - 

Page 2960


71-135 



8 - - 56 - - 

71 

9 - - 57 - - 

10 - - 58 - - 

11 - - 59 - - 

71 

12 - - 60 - - 

13 R 

Engine Crankshaft 

Position 5V power 

61 - - 

14 B 


Position Circuit 

62 L 

Engine Camshaft 

Position Signal 

15 G 

SAE J1939 Data 

Communication 

Interface+ 

63 B 



Circuit 

16 G 

SAE J1939 Data 

Communication 

Interface- 

64 B 

Atmospheric Pressure 

Circuit 

17 - - 65 B 

18 - - 66 B 

19 - - 67 B 

20 - - 68 B 

21 - - 69 L 

22 - - 70 L 

Intake Manifold 

Pressure/ 

Temperature Circuit 

EGR Valve Position 

Circuit 


Actuator Position 

Circuit 

Fuel Rail Pressure 

Circuit 


Signal 


Pressure Signal 

23 L 


Temperature Signal 

71 - - 

24 - - 72 L 


Signal 

25 B 




73 B 




26 B 




74 P 




27 - - 75 - - 

28 - - 76 - - 

Page 2961

71-136 




29 P EGR Valve Motor- 77 P 


Actuator Motor+ 

30 - - 78 - - 

31 B 

Fuel Pump Actuator 

Circuit 

79 - - 

32 P 


Signal 

80 R 

Air Mass Flow 12V 

Power 

33 - - 81 - - 

34 - - 82 - - 

35 - - 83 - - 

36 - - 84 - - 

37 L 

38 L 


Switch 



Signal 

85 - - 

86 L Air Mass Flow Signal 

39 - - 87 R 

40 B Air Mass Flow Circuit 88 R 

41 - - 89 R 

42 - - 90 R 


Position Sensor 5V 

power 


5V Power 

Intake manifold 

Pressure/ 

Temperature 5V 

power 


5V Power 

43 B 

Engine Coolant 

Temperature Circuit 

91 R 


Actuator Position 5V 

Power 

44 B 

Fuel Moisture Content 

Circuit 

92 R 

Fuel Rail Pressure 5V 

Power 

45 - - 93 - - 

46 L 



94 - - 

47 L 


Signal 

95 L 



Signal 

48 - - 96 L 


Signal 

Page 2962


71-137 

71 



1 R 5V Signal 

2 B Circuit 

3 L Signal 

E022 Intake manifold Pressure/ 



1 L Pressure Signal 

2 R 5V Power 

3 L Temperature Signal 

4 B Circuit 

71 

E020 Camshaft Position Sensor 


1 R 5V Power 

2 B Circuit 

3 L Signal 

E023 Atmospheric Pressure Sensor 


1 R 5V Power 

2 B Circuit 

3 L Signal 

E021 Fuel Rail Pressure Sensor 


1 B Circuit 

2 L Signal 

3 R 5V Power 



1 B Circuit 

2 L Signal 

Page 2963

71-138 


E025 Fuel Moisture Content Sensor 


1 L Sensor Signal 

2 B Sensor Circuit 

E028 SAE J1939 Data Communication 

Interface 


1 G 

Data Communication 

Circuit 

2 G 

Data Communication 

Signal 

3 - - 

E026 Engine Oil Pressure Switch 


1 L Sensor Signal 

2 - - 

E029 Injector 1 


1 B Drive Circuit 

2 P Drive Signal 

E027 Fuel Pump Actuator 


1 P Signal 

2 B Circuit 





Page 2964


71-139 

71 





E034 Intake Throttle Actuator 


1 P 

2 L 





Signal 

71 





3 B 

4 R 

5 P 



Circuit 


Actuator Position 5V 

Power 



E035 EGR Valve 

E033 Air Mass Flow Sensor 


1 L Signal 

2 B 12V Power 

3 R Circuit 

4 - - 


1 P EGR Valve Motor- 

2 P EGR Valve Motor+ 

3 L 

4 B 

5 R 


Circuit 


Circuit 


5V Power 

Page 2965

71-140 


E101 to Chassis Wire Harness 1 


E036 Engine Oil Pressure Switch (IC) 


1 L-Y Signal 

8 W-B 

9 L 

10 R 


Control 




Output 

11 L Ignition Coil+ 


13 G-B 

Compressor 

Excitation 

14 - - 


(IC) 

15 V-W Vehicle Speed 



1 Y-G Signal Input 

2 W-B Signal Output 



1 - - 



1 Br Engine Maintenance 

2 L-W MILL 

3 Y-G 


Gauge Sensor 

4 - - 

5 Y-B AC Request 

6 R-W 



Switch 

2 Br-R 


Sensor- 

3 Br-G Acceleration Sensor+ 

4 SB 

5 G 


Sensor Power 

Injector,Oxygen 

Sensor,Canister 

Solenoid Valve+ 

6 - - 

7 - - 

8 - - 

9 R-L ECU-K Line 

7 Y 


Power Input 

10 B 

Upstream And 



Page 2966


71-141 



11 Y-B 

12 O 





13 - - 

14 B-G ECU-IG 

15 G-W Main Relay Control 

16 G 


ECU Control 

E103 to Chassis Wire Harness A (Diesel) 


1 - - 

2 G-B - 

3 Y-G - 

4 - - 

5 - - 

6 L-Y - 

7 W-B - 

8 - - 

71 

71 

Page 2967

71-142 


F - ROOF WIRE HARNESS 1 

F003 Sliding Roof Control Switch 


F001 Front Dome Light 


1 R 

2 R 

Front Dome Light 

Power Input 

Central Dome Light 

Power Input 

3 W-B Ground 

2 R-B 

3 R 

Sliding Roof ACC 

Input 

Sliding Roof Switch 

Power Input 

4 G Sliding Roof Switch 

5 W-B 

Sliding Roof Switch 

Ground 

6 - - 

4 R-W Front Dome Light- 

F004 Central Dome Light (High Equipped) 

F002 Sliding Roof ECU 


1 R 

Sliding Roof ECU 

Power Input 

2 G Sliding Roof Switch 


1 R 

Trunk Lighting Power 

Input 

2 R-Y Central Dome Light- 

3 Y 

Dome Light Power 

Output 

3 W-B 

4 R-B 

to Power Sliding Roof 

ECU- 

Sliding Roof ECU- 

ACC Input 

5 Y 

Sliding Roof Control 

Switch 

6 - - 

F004 Central Dome Light (Low Equipped) 


1 R Lighting Power Input 

2 Y Power Output 

F003 Sliding Roof Control Switch 


1 Y Sliding Roof Switch 

Page 2968


71-143 

F005 Rear Speaker LH 


1 Y 

Rear Left Speaker 

Power Input 

2 B Rear Left Speaker- 

3 Y 

F007 Air Purifier 



Output 

71 

71 

F006 Rear Combination Lamp LH 


1 V-W Rear Left Lamplet+ 

2 W-B 

Rear Left Combination 

Lamp Ground 

3 G-W Rear Left Stop Lamp+ 

4 G-Y 

5 R-Y 

6 B-Y 

Rear Left Turn Signal 

Power Input 

Rear Left FogLamp 

Power Input 

Rear Left Back-up 

Lamp+ 



F101 to Instrument Panel Wire Harness A 


1 V-W - 

2 G-W - 

3 Br - 

4 Y-W - 

5 B-Y - 

6 Y - 

7 L - 

8 W-B - 

9 R - 

10 R-W - 

11 LG - 

12 R-Y - 

13 R-B - 

14 R-Y - 

15 G-B - 

16 G-Y - 

17 R - 

18 G - 

1 R 

Illumination Power 

Input 

2 R-Y Dome Light- 

Page 2969

71-144 


F103 to Roof Wire Harness 2A 


9 R-Y - 

F102 to Instrument Panel Wire Harness B 


1 Y - 

10 V-W - 

11 R - 

12 G - 

2 B - 

3 - - 

4 R-B - 

5 R - 

6 W - 

7 R - 

8 G-W - 

9 G-O - 

10 G-R - 

11 Br - 

12 G-Y - 

13 B - 

F104 to Roof Wire Harness 2B 


1 - - 

2 G-O - 

3 - - 

4 R - 

5 W - 

6 G-W - 



1 G-W - 

2 R-B - 

3 R - 

4 G-B - 

5 - - 

6 R-Y - 

7 - - 

8 B-Y - 

F105 to High-mounted Stop Lamp Wire 

Harness 


1 G-W - 

2 B - 

3 G-Y - 

4 B - 

5 W-B - 

6 - - 

7 G-R - 

8 Br - 

Page 2970


71-145 

71 

F106 to Rear Evaporator Wire Harness 


71 

1 W-B - 

2 L - 

3 Y-W - 

4 Br - 

5 L - 

6 LG - 

Page 2971

71-146 


G - ROOF WIRE HARNESS 2 

G001 Rear Combination Lamp RH 


1 V-W Rear Right Lamplet+ 

G101 to Roof Wire Harness 1A 


1 G-W - 

2 W-B 

3 G-W 

4 G-B 

5 R-Y 

6 B-Y 

Rear Right 

Combination Lamp 

Ground 

Rear Right Stop 

Lamp+ 

Rear Right Turn 

Signal Power Input 

Rear Right Fog Lamp 

Power Input 

Rear Right Back-up 

Lamp+ 

2 R-B - 

3 R - 

4 G-B - 

5 - - 

6 R-Y - 

7 - - 

8 B-Y - 

9 R-Y - 

10 V-W - 

11 R - 

12 G - 

G002 Rear Speaker RH 


1 W 

Rear Right Speaker 

Power Input 

2 R Rear Right Speaker- 

G102 to Roof Wire Harness 1B 


1 - - 

2 G-O - 

3 - - 

4 R - 

G003 Sliding Door Ajar Switch RH 


5 W - 

6 G-W - 

1 R-Y 

Right Middle Door 

Lamp Power Input 

Page 2972


71-147 

71 

G103 to Rear Hatch Transition Wire 

Harness 

71 


1 - - 

2 V-W - 

3 R - 

4 B-Y - 

5 - - 

6 R-B - 

7 G - 

8 R - 

9 G-O - 

10 G-W - 

Page 2973

71-148 


H - FRONT DOOR RH WIRE HARNESS 

H001 Front Speaker RH 


H004 Window Control Switch RH 


1 L 

Front Right Speaker 

Power Input 

1 L-G 



2 L-G Front Right Speaker- 

2 - - 

3 P-L 

4 L-Y 





H002 Power Window Motor RH 

5 - - 


1 G-R 

2 R-L 

Co-pilot Side Window 

Up Input 


Down Input 

H005 Front Door Lock Assy RH 


1 G 

Front Right Door Lock 

Unlock Input 

2 - - 

H003 Outside Mirror Assy RH 


1 - - 

2 W-B 

3 B 


Ground 



4 R-Y Right Outside Mirror- 

5 L-Y 



Input 

3 - - 

4 R 

Front Right Door Lock 

Latch Input 

5 - - 

6 - - 

7 - - 

8 - - 

9 - - 

10 - - 

6 R-L 



Input 

Page 2974


71-149 

71 

H101 to Front Wire Harness A 


1 R - 

2 - - 

3 L-Y - 

4 R-L - 

5 G - 

6 - - 

7 R-Y - 

8 B - 

H103 to Front Wire Harness C 


1 W-B - 

2 L - 

3 G-R - 

4 - - 

5 L-G - 

6 R-L - 

71 

H102 to Front Wire Harness B 


1 - - 

2 - - 

3 L-Y - 

4 P-Y - 

5 - - 

6 - - 

7 - - 

8 L-G - 

Page 2975

71-150 


I - INSTRUMENT PANEL WIRE HARNESS 

I002 Instrument Cluster A 


A26 

B 

Vacuum Level Alarm 

+ Input 

I002 Instrument Cluster A 


A1 W-L Instrument Power 

A2 - - 


A4 - - 

A27 G-Y Preheat Indicator 

A28 Br Engine Maintenance 

A29 - - 

A30 

R-W 

Front Door Open 

Indicator 

A31 B-W Seat Belt Warning 

A32 G-Y Left Turn Indicator 

A5 - - 

A6 V-W Lamplet Signal Input 

A7 

LG 

Front Fog Lamp 

Indicator 


A9 W-L Vehicle Speed Output 

A10 L-B Vehicle Speed Output 

A11 - - 

A12 - - 

A13 

W-G 


Input 

A14 B Lighting PWM Signal 

A15 W-R Door Open Indicator 

A16 

R 

Instrument Power 

Input 

A17 - - 

A18 - - 

A19 W-B Instrument A Ground 

A20 R-B Instrument IG Ground 

A21 - - 

A22 - - 


A24 Y-W Engine Stop Light 

A25 - - 

I003 Instrument Cluster B 


B1 - - 

B2 - - 

B3 - - 

B4 - - 

B5 - - 

B6 

Y 

B7 V-W 

Instrument Parking 

Brake Light 

Coolant Level Sensor 

+ Output 

B8 - - 

B9 

B-W 

Seat Belt Alarm + 

Output 

B10 V-W Speed Input 

B11 - - 

B12 - - 

B13 - - 

B14 - - 

Page 2976


71-151 

B15 - - 

B16 

Y-G 


Gauge Sensor 

B17 - - 

B18 - - 

B19 - - 

B20 

B21 

I003 Instrument Cluster B 


Y-G 

R-Y 


Signal Input 

Rear Fog Lamp 

Indicator 

I004 Headlamp Dimmer Switch 


3 G 

4 LG 

5 Br 

6 W-B 

Headlamp Dimmer 

Lighting 

to Front Left 

Headlamp Adjustment 

Motor 

to Front Right 


Motor 


Switch Ground 

71 

71 

B22 

L-Y 


Warning Light 

B23 

B24 

B25 

L-W 

Y-R 

P-L 

Engine Failure 

Warning Input 

EBD Warning Light 

Signal Input 

Instrument Charging 

Indicator Input 

B26 - - 

B27 

B-Y 

B28 R-W 


Signal Input 

Brake Fluid Sensor + 

Output 

B29 - - 

B30 W-B Instrument B Ground 

B31 R-G High Beam Indicator 

I005 Instrument Dimmer Switch 


1 - - 

2 - - 

3 G 

Instrument Dimmer 

Switch Lamplet 

4 - - 

5 B Lighting PWM Signal 

6 W-B 


Switch Ground 

B32 G-B Right Turn Indicator 

I006 Hazard Warning Switch 

I004 Headlamp Dimmer Switch 


1 G-B 

2 W-B 

to Front Right Low 

Beam Fuse 


Switch Ground 


1 - - 

2 G 

3 W-B 

Hazard Warning 

Switch Lighting 

Instructions 


Switch Ground 

Page 2977

71-152 


I006 Hazard Warning Switch 


4 - - 

5 - - 

6 - - 

7 W-B Ground 

A16 

I007 Central Locking Controller Assy A 


L 

Left Door Assy 

Switch(Clock) Output 

A17 W-L Vehicle Speed Signal 

A18 R-B Ignition Switch 

8 G-R Switch Signal Output 

9 - - 

10 - - 

I008 Central Locking Controller Assy B 

I007 Central Locking Controller Assy A 


A1 W-B Ground 

A2 R Lock Output 

A3 G Unlock Output 

A4 

A5 

G 

R 


Down Output 


Up Output 


B1 

B2 

B3 

W-R 

W-L 

R 

Ignition Switch 

Illumination Control 

Front Left Door Open 

Signal Output 

Central Locking Spare 

Power 

B4 G-R Horn 

B5 - - 

B6 

O-L 

to Engine Hood 

Switch Output 

A6 

R-L 


Down Output 

B7 

V-W 

Lamplet Forget to 

Turn Off Hints 

A7 

A8 

G-R 

W-L 


Up Output 

Window Control 

Power Input 

A9 L-O Key Lock Input 

A10 L-R Key Unlock Input 

B8 O-B Key Detection Switch 

B9 - - 

B10 W-B Ground 

B11 - - 

B12 - - 

A11 Y Collision Signal Input 

A12 G-Y Left Turn Light Signal 

A13 

G-B 

Right Turn Light 

Signal 


A15 

L-B 

Left Door Assy 

Switch(Data) Output 

Page 2978


71-153 

I009 Ignition Switch 


1 W 

Ignition Switch AM1 

Power Input 

2 R IG1 Power Output 

3 R ACC Output 

4 G-B 

5 R-B 

Start Control Power 

Output 


Power Input 

6 L Ignition Switch IG2 

I010 Ignition Switch Illumination 


I012 Combination Switch (Light) 


1 - - 

2 B-W 

3 L 


Switch 

Rear Fog Lamp 

Switch 

4 W-B Light Switch Ground 

5 G-V Left Turn Switch 

6 Y-B Turn Signal Switch 

7 G-W Right Turn Switch 

8 W-R to Low Beam Relay 

9 L-R to High Beam Relay 



12 - - 

13 G-R 

Lamplet Relay Control 

Input 

71 

71 

1 R 



Input 

2 W-R to Central Lock Unit 

I013 Combination Switch (Wiper) 


1 - - 

I011 Key Insert Switch 


1 - - 

2 - - 

3 O-B Switch Input 

4 W-B Switch Ground 

2 W Rear Wiper 

3 P 

Rear Washing Motor 

Input 

4 Y-W Front Washing Motor- 

5 W-B Wiper Switch Ground 

6 Y 

Wiper Intermittent 

Output 

Page 2979

71-154 


I013 Combination Switch (Wiper) 


7 L-W 

8 G-R 

9 L-R 

Wiper Low Speed 

Output 

Wiper Switch Power 

Input 

Wiper High Speed 

Output 

10 - - 

I016 Rear Window Defroster Switch 


1 W-B 

2 Y-L 

Rear Window 

Defroster Switch 

Ground 

Rear Window 


Power Input 

3 G 

Rear Window 


Lighting 

I014 Clock Spring 


1 - - 

2 G-R Horn Switch 

3 Y 


Interface ACU 

4 - - 

5 Br-L 

6 W-B 

Rear Window 


Power Output 

Rear Window 


Ground 

4 Y-B 


Interface ACU 

I017 Outside Mirror Defroster Switch 


I015 12V Power Output Socket 


1 W-B Ground 

2 R-Y 12V Power Output 

3 - - 

1 W-B 

2 Y-L 

3 G 



Ground 



Power Input 



Lighting 

4 - - 

5 G-L 


Defroster Control 

Output 

Page 2980


71-155 

I017 Outside Mirror Defroster Switch 


6 W-B 



Ground 

71 

71 

I020 A/C Control Panel A 


I018 Dome Light Switch 


1 W-B Ground 

2 W-B Ground 

3 G 

Dome Light Switch 

Illumination 

4 - - 

5 Y 


Input 

6 R Indicator Power Input 

1 Gr 

2 L-B 

3 L-Y 

4 L 

Rear AC Solenoid 

Valve-Input 

Servo Motor (Mode) 

Defrost 


Blowing Face 

Warm Damper 

Control 

5 L-R Cold Damper Control 

6 G-W Internal Circulation 

7 G External Circulation 

8 G 

Blower Relay Control 

Power Input 

9 G-B AC Request Output 

10 R-B AC IG Power 

11 - - 

I019 Diagnosis Switch 



2 W-B Switch - 

3 G Illumination Power 

4 - - 

5 B-Y Switch Input 

6 R-B Switch Power 

12 - - 

13 - - 

14 - - 

15 - - 

16 - - 

17 - - 

18 W-B Ground 

19 R-G 

Front Air Conditioning 

Controller Battery 

Power Input 

20 W-B Ground 

Page 2981

71-156 


I022 Servo Motor (Temperature) 

I021 A/C Control Panel B 


21 Y-W 

Rear Temperature 

Sensor- 

22 - - 

23 L-O 

24 L-G 

Mix Damper 

Feedback 


Mode Feedback 

25 - - 

26 B 

Servo Motor 

(Mode)/ 

(Temperature) 5V 

Output 


1 W-B 

2 L-O 

3 B 

Servo Motor 

(Temperature) 

Internal Temperature 

Mix Damper 

Feedback 

Servo Motor 


Output 

4 - - 


6 L 

Warm Damper 

Control 

27 W-B 

Servo Motor 

(Mode)/ 

(Temperature) 


28 Y-G Front Blower- 

29 V 

Front Evaporator 

Temperature Sensor+ 

30 - - 

31 - - 

32 G 


Controller Back 

Lighting 

33 Br Temperature Sensor- 

34 - - 

35 Y Blower Feedback 

I023 Rear Blower Forward Switch 


1 W-B 

2 R-B 

3 G 

Rear Blower Forward 

Switch Ground 


Switch Power Input 



4 - - 

5 Gr-R 

Solenoid Valve Power 

Output 

36 LG 

Rear AC Switch 

Request Output 

6 W-B 


Switch Ground 

Page 2982


71-157 

71 

I024 Servo Motor (Mode) 


1 W-B 

2 L-G 

Servo Motor 

(Temperature) 



Mode Feedback 

I026 Front Evaporator Thermistor 


1 V 




71 

3 B 


5V Output 

4 - - 

5 L-B 

6 L-Y 


Defrost 


Blowing Face 

I027 Servo Motor (Internal & External 

Circulation) 


1 - - 

2 - - 

3 - - 

4 - - 

I025 Blower Control Module 




1 W-B Ground 


3 Y-G Blower Control 


I028 Reverse Radar Control Unit 


1 B-R Reverse Power Input 

2 G-R 

3 W-L 

Front Right Reverse 

Radar Sensor Output 

Reverse Radar 

Sensor Power Input 

Page 2983

71-158 


I028 Reverse Radar Control Unit 


4 R-W 

Reverse Radar 

Central Right Sensor 

Output 

5 - - 

6 L-B Vehicle Speed Signal 

7 R-G 

8 R-B 

Reverse Radar 

Sensor LH Output 

Reverse Radar 

Central Left Sensor 

Output 

9 Y Parking Signal 

10 G-O 

Front Left Reverse 


I030 CD Player-C2 


1 B-Y Reverse Detection 


3 - - 

4 - - 

5 - - 

6 - - 

11 B 

Reverse Radar 

Sensor Ground 

12 - - 

13 - - 

14 - - 

15 R-L 

Reverse Radar 

Sensor RH Output 

16 W-B Ground 

I031 Radio A 


A1 - - 

A2 - - 

A3 G Radio illumination 

A4 G-R Radio ACC Input 

I029 CD Player-C1 


1 G-W VIDEO GND Input 

2 G-O VIDEO+ Output 

A5 - - 

A6 - - 

A7 R Radio Power Input 

A8 W-B Ground 

3 - - 

4 - - 

5 - - 

6 - - 

Page 2984


71-159 

71 

I032 Radio B 


B1 

W 


Power Output 

B2 R Rear Right Speaker- 

B3 

L 


Power Output 

B4 L-G Front Right Speaker- 

B5 

V 


Power Output 

B6 P Front Left Speaker- 

B7 

Y 


Power Output 

B8 B Rear Left Speaker- 

I034 Flasher 


1 B-Y Power 

2 G-B 

Rear Right Turning 

Lamp Power 

3 - - 

4 R-Y 

5 G-V 

Front Left Turning 

Lamp Power 

Left Turning Signal 

Input 

6 - - 

7 G-R 

Hazard Warning/Turn 

Signal 

8 W-B Ground 

9 G-Y 

Rear Left Turning 

Lamp Power 

71 

10 R-L 

Front Right Turning 

Lamp Power 

11 - - 

12 G-W 

Right Turning Signal 

Input 

I033 Cigarette Lighter 


1 W-B Ground 

2 R-B 

3 G 

Cigarette Lighter 

Power Input 


Illumination 

I035 Passenger Airbag Assy 


1 G-B 


Interface ACU 

High-side 

Page 2985

71-160 


I035 Passenger Airbag Assy 


2 G-R 


Interface ACU 

Low-side 

I039 Right Turn Signal Lamp Diode 


I036 Right Side Sliding Door Lamp Diode 


1 G-B 

2 R-L 


Lamp Power 


Lamp Power 

1 W-R 

2 R-Y 

Diode - Door Open 



Indicator Output 

I040 Left Turn Signal Lamp Diode 


I037 Rear Hatch Lamp Switch Diode 


1 G-Y 

2 R-Y 


Lamp Power 


Lamp Power 

1 W-R 

2 R-B 



Rear Hatch Lamp 

Indicate Output 

I101 to Front Wire Harness A 


I038 Horn Switch 


1 G-R Signal Output 

1 - - 

2 - - 

3 - - 

4 - - 

5 P - 

6 G-Y - 

7 G-O - 

Page 2986


71-161 

I101 to Front Wire Harness A 


8 G-R - 

9 B - 

10 O-L - 

11 - - 

12 - - 

13 - - 

14 - - 

15 - - 

16 - - 

17 G-R - 

18 B - 

19 - - 

20 G-R - 

21 W-L - 

22 L-O - 

23 L-R - 

24 L - 

25 L-B - 

26 G - 

27 R - 

I102 to Front Wire Harness B 


5 P - 

6 L - 

7 L-G - 

8 V-W - 

9 R-W - 

10 R-W - 

11 G-B - 

12 V-W - 

13 - - 

14 LG - 

15 W-B - 

16 Y-B - 

17 R-L - 

18 R-Y - 

19 R-B - 

20 R-G - 

21 G-B - 

22 L-B - 

23 G-R - 

24 L-W - 

25 L-R - 

26 Y - 

27 Y-W - 

71 

71 

I102 to Front Wire Harness B 


1 LG - 

2 Br - 

3 B - 

4 B - 

I103 to Front Wire Harness C 


1 - - 

2 - - 

Page 2987

71-162 


I103 to Front Wire Harness C 


I104 to Chassis & Frame Wire Harness A 


3 - - 

4 R-L - 

5 G-R - 

6 G - 

7 R - 

21 W-L - 

21 R-B 

22 R-B - 

23 - - 

24 - - 

4G69 

(LH) 

ISF2.8 

(LH) 

I104 to Chassis & Frame Wire Harness A 


1 B-W - 

2 B - 

3 - - 

4 - - 

5 L - 

6 Y - 

7 V - 

8 Y-B - 

9 Y-R - 

10 Y-G - 

11 W-G - 

12 V-W - 

13 P-L - 

14 R-W - 

15 L-W - 

16 Y-W - 

17 L-Y - 

18 Y-G - 

19 Br - 

20 G-Y - 

I105 to Chassis & Frame Wire Harness C 


1 Y-B - 

2 Y - 

3 G-L - 

4 Br-L - 

5 B-Y - 

6 Y - 

7 Y-L - 

8 B - 

9 G-B - 

10 G-R - 

11 - - 

12 B - 

13 - - 

14 B - 

15 R-G - 

16 R-B - 

17 R-W - 

18 R-L - 

19 - - 

Page 2988


71-163 

71 

I106 to Chassis & Frame Wire Harness B 


1 R-B - 

2 B-G - 

3 R-W - 

4 R - 

5 G-B - 

6 R - 

7 W-B - 

8 B-Y - 

9 W-L - 

10 R-L - 

11 G-W - 

12 - - 

13 W-L - 

14 R-Y - 

15 W-L - 

16 B-Y - 

17 R - 

18 G - 

19 G-O - 

20 G-B - 

I107 to Roof Wire Harness Assy 1A 


1 V-W - 

2 G-W - 

3 Br - 

4 Y-W - 

5 B-Y - 

6 Y - 

7 L - 

8 W-B - 

9 R - 

10 R-W - 

11 LG - 

12 R-Y - 

13 R-B - 

14 R-Y - 

15 G-B - 

16 G-Y - 

17 R - 

18 G - 

71 

I108 to Roof Wire Harness Assy 1B 


1 Y - 

2 B - 

3 - - 

Page 2989

71-164 


I108 to Roof Wire Harness Assy 1B 


4 R-B - 

5 R - 

6 W - 

7 R - 

8 G-W - 

9 G-O - 

10 G-R - 

11 Br - 

12 G-Y - 

13 B - 

I110 to Data Link Connector 


1 - - 

2 W-B - 

3 - - 

4 W-L - 

5 R-L - 

6 G-O - 

7 G-B - 

8 W-B - 

I109 to Chassis & Frame Wire Harness E 


1 R - 

2 Gr - 

3 - - 

4 - - 

5 R-B - 

6 Gr-R - 

7 G-W - 

8 - - 

9 - - 

10 G - 

11 LG - 

12 L - 

13 - - 

14 - - 

Page 2990


71-165 

71 

I111 to Chassis & Frame Wire Harness D 


1 R - 

71 

Page 2991

71-166 


J - REAR HATCH WIRE HARNESS 

J001 Rear Hatch Lock Assy-Switch 


J004 License Lamp 


1 R-B 

2 W-B 

Rear Hatch/Trunk 

Lights Power Input 

Rear Hatch Lock 

Ground 

1 V-W Power 

2 W-B Ground 

J005 Camera 

J002 Rear Hatch Lock Assy-Motor 


1 R 

2 G 

Rear Hatch Latch 

Input 

Rear Hatch Unlocking 

Input 


1 W-B Camera Ground 

2 B-Y Camera Power Input 

3 G-W Video Output 

4 G-O Video Input 

J003 Trunk Lamp 


1 R 

2 R-B 

Trunk Lamp Power 

Input 


Output 

Page 2992


71-167 

71 

J101 to Rear Hatch Transition Wire Harness 


71 

1 B-Y - 

2 R - 

3 V-W - 

4 - - 

5 G-W - 

6 G-O - 

7 R - 

8 G - 

9 R-B - 

10 W-B - 

Page 2993

71-168 


K - REAR HATCH TRANSITION WIRE HARNESS 

K101 to Roof Wire Harness 2 


1 - - 

2 V-W - 

3 R - 

4 B-Y - 

5 - - 

6 R-B - 

7 G - 

8 R - 

9 G-O - 

10 G-W - 

K102 to Rear Hatch Wire Harness 


1 B-Y - 

2 R - 

3 V-W - 

4 - - 

5 G-W - 

6 G-O - 

7 R - 

8 G - 

9 R-B - 

10 - - 

Page 2994


71-169 

L - REAR EVAPORATOR WIRE HARNESS 

71 

L001 Left Blower 


1 R + 

2 L-W - 

L004 Temperature Sensor 


1 B-W Ground 

2 W Sensor+ 

71 

L002 Right Blower 


1 L + 

2 L-W - 

L005 Top Evaporator Blower Switch 


1 B Ground 

2 R-B A/C signal 

3 B Ground 

4 L-G L Position 

5 L-R M Position 

6 R-B H Position 

L003 Blower Resistor 


1 L-W to Blower- 

2 L-R M Position 

3 L-G L Position 

4 R-B H Position 

L101 to Roof Wire Harness 1 


1 B - 

2 L - 

3 W - 

4 B-W - 

5 R - 

6 R-B - 

Page 2995

71-170 


M - DIAGNOSIS WIRE HARNESS 

M001 Data Link Connector Resistance 


1 G-B CAN-H 

2 G-O CAN-L 

3 - - 

M101 to Instrument Panel Wire Harness 


1 - - 

2 W-B - 

3 - - 

4 W-L - 

5 R-L - 

6 G-O - 

7 G-B - 

M002 Data Link Connector 

8 W-B - 


1 - - 

2 - - 

3 - - 

4 W-B Ground 

5 W-B Ground 

6 G-B CAN-H 

7 R-L 

Data Link Connector 

K 

8 - - 

9 - - 

10 - - 

11 - - 

12 - - 

13 - - 

14 G-O CAN-L 

15 - - 

16 W-L Power Input 

Page 2996


71-171 

N - STEP LAMP WIRE HARNESS 

71 

N001 Right Side Sliding Door Lock Assy 


1 - - 

2 G 

Right Side Sliding 

Door Unlocking Input 

3 - - 

4 R 

Right Side Sliding 

Door Locking Input 

N101 to Chassis & Frame Wire Harness 


1 G - 

2 L - 

3 R - 

4 - - 

5 R - 

6 Gr - 

7 R-Y - 

8 - - 

71 

N002 Step Lamp 


1 R 

2 R-Y 

Step Lamp Power 

Input 

Right Sliding Door 

Light Switch Output 

N003 Rear A/C Solenoid Valve 


1 L 

2 Gr 

Rear A/C Solenoid 

Valve Power Input 


Valve Output 

Page 2997

71-172 


O - DRIVER SEAT BELT WIRE HARNESS 

O001 Driver Seat Belt Warning Switch 


1 B-W - 

2 W-B - 

O101 to Chassis & Frame Wire Harness 


1 B-W - 

2 W-B - 

Page 2998


71-173 

P - REAR HEATER WIRE HARNESS 

71 

P001 Rear Heater Solenoid Valve 


1 W-L 


Power Input 

2 W-B Ground 

P002 Rear Heater Motor 



P101 to Chassis & Frame Wire Harness 


1 W - 

2 L-B - 

3 L - 

4 B - 

5 W-B - 

6 W-L - 

7 - - 

8 - - 

71 

2 L-B 

Rear Heater Motor+ 

Input 



Page 2999

71-174 


Q - REAR BUMPER TRANSITION WIRE HARNESS 

Q101 to Rear Bumper Wire Harness 


1 R-W - 

2 R-L - 

3 R-B - 

4 R-G - 

5 - - 

6 - - 

7 - - 

8 B - 

Q102 to Chassis & Frame Wire Harness 


1 R-G - 

2 R-B - 

3 R-L - 

4 R-W - 

5 B - 

6 - - 

7 - - 

8 - - 

Page 3000


71-175 

R - REAR BUMPER WIRE HARNESS 

71 

R001 Reverse Radar Sensor LH 


R004 Reverse Radar Sensor RH 


71 

1 R-G 

Reverse Radar Sensor 

LH Input 

1 R-L 

Reverse Radar 

Sensor RH Input 

2 B 


LH Ground 

2 B 

Reverse Radar 

Sensor RH Ground 

3 - - 

3 - - 

R002 Reverse Radar Central Sensor LH 


1 R-B 

2 B 

Reverse Radar Central 

Left Sensor Input 

Reverse Radar 


Ground 

3 - - 

R101 to Rear Bumper Transition Wire 

Harness 


1 R-W - 

2 R-L - 

3 R-B - 

4 R-G - 

5 - - 

6 - - 

7 - - 

8 B - 

R003 Reverse Radar Central Sensor RH 


1 R-W 

2 B 


Right Sensor 

Input 

Reverse Radar 


Ground 

3 - - 

Page 3001

71-176 


S - REAR DEFROST RH WIRE HARNESS 

S001 Rear Defrost Heating Wire RH 


1 B 

Rear Right Defrost 

Power Input 

S101 to High-mounted Stop Lamp Wire 

Harness 


1 - - 

2 B - 

Page 3002


71-177 

T - REAR DEFROST LH WIRE HARNESS 

71 

T001 Rear Defrost Heating Wire LH 


1 B Ground 

T101 to High-mounted Stop Lamp Wire 

Harness 


1 - - 

2 B - 

71 

Page 3003

71-178 


U - HIGH-MOUNTED STOP LAMP WIRE HARNESS 

U101 to Roof Wire Harness 1 


6 - - 

U001 Rear Wiper 

7 G-R - 

8 Br - 


1 Br Rear Wiper Return 

2 G-Y 

Rear Wiper Power 

Input 

3 W-B Ground 

4 G-R 

Relay to The Rear 

Wiper Power Output 

U102 to Rear Defrost LH Wire Harness 


1 - - 

2 B - 

U002 High-mounted Stop Lamp 


1 W-B 

2 G-W 

High-mounted Stop 

Lamp- 


Lamp+ 

U103 to Rear Defrost RH Wire Harness 


1 - - 

2 B - 



1 G-W - 

2 B - 

3 G-Y - 

4 B - 

5 W-B - 

Page 3004


71-179 

V - FRONT WIRE HARNESS 

71 

V001 Left Headlight Dimming Motor 


V004 Front Turn Signal Lamp LH 


71 

1 G-B Motor Power 

2 LG 

3 W-B 

Left Headlamp 

Adjusting Signal 

Left Headlamp 

Dimming Motor 

Ground 

1 W-B 

2 R-Y 

Front Turn Signal 

Lamp LH Ground 


Lamp LH Power Input 

V005 Right Headlight Dimming Motor 

V002 Front Position Lamp LH 


1 W-B Ground 



2 Br 

Right Headlamp 


2 V-W 

Front Left Position 

Lamp+ 

3 W-B 

Right headlamp 

Dimming Motor 

Ground 

V003 Headlamp LH 


1 W-B 

Left Headlamp 

Ground 

2 R-G Front Left High Beam 

3 R-B Front Left Low Beam 

V006 Headlamp RH 


1 W-B 

2 L-B 


Ground 

Front Right High 

Beam 

3 G-B 

Front Right Low 

Beam 

Page 3005

71-180 


V007 Front Position Lamp RH 


1 W-B Ground 

V010 Front Washing Reservoir Motor 



2 V-W Front Position Lamp+ 

2 G-R 

Front Washing 

Motor+ 

V008 Front Turn Signal Lamp RH 


V011 Windshield Wiper Assy 

1 W-B 

2 R-L 


Lamp RH Ground 


Lamp RH Power Input 


1 L-W 

Front Wiper Lowspeed 

Input 

2 G-R Front Wiper+ 

V009 Rear Washing Reservoir Motor 


3 Y 

4 L-R 

5 W-B 

Front Wiper 

Intermittent Input 

Front Wiper Highspeed 

Input 

Windshield Wiper 

Assy Ground 

1 P 

2 G-Y 


Output 


Power Input 

V012 Brake Fluid Level Sensor 


1 R-W 

Brake Fluid Level 

Sensor + Input 

2 W-B Ground 

Page 3006


71-181 

71 

V013 Bass Horn 


1 B Horn+ 

V016 Coolant Level Sensor 


1 W-B Ground 

71 

2 W-B Ground 

2 V-B 

Coolant Level Sensor 

+ Input 

V014 Alt Horn 


1 B Horn+ 

2 W-B Ground 

V017 Triple Pressure Switch 


1 G-B AV Request Input 

2 W-B 


Switch- 

3 R-W 


Switch+ Input 

4 Y-B AV Request Output 

V015 Engine Hood Switch 


1 O-L 

2 W-B 

Engine Hood Switch 

Input 


Ground 

V101 to Instrument Panel Wire Harness 

assy A 


1 - - 

2 - - 

3 - - 

4 - - 

5 P - 

Page 3007

71-182 



assy A 


6 G-Y - 

7 G-O - 

8 G-R - 

9 B - 

10 O-L - 

11 - - 

12 - - 

13 - - 

14 - - 

15 - - 

16 - - 

17 G-R - 

18 B - 

19 - - 

20 G-R - 

21 W-L - 

22 L-O - 

23 L-R - 

24 L - 

25 L-B - 

26 G - 

27 R - 


assy B 


3 B - 

4 V - 

5 P - 

6 L - 

7 L-G - 

8 V-W - 

9 R-W - 

10 R-W - 

11 G-B - 

12 V-W - 

13 - - 

14 LG - 

15 W-B - 

16 Y-B - 

17 R-L - 

18 R-Y - 

19 R-B - 

20 R-G - 

21 G-B - 

22 L-B - 

23 G-R - 

24 L-W - 

25 L-R - 

26 Y - 

27 Y-W - 


assy B 


1 LG - 

2 Br - 

Page 3008


71-183 

71 


assy C 


1 - - 

2 - - 

3 - - 

4 R-L - 

5 G-R - 

6 G - 

7 R - 

V105 to Driver Door Wire Harness Assy B 


1 L-B - 

2 L-Y - 

3 P-L - 

4 W-L - 

5 W-B - 

6 L - 

7 G-R - 

8 L-G - 

71 

V104 to Driver Door Wire Harness Assy A 


1 R - 

2 L-R - 

3 L-Y - 

4 G-R - 

5 G - 

6 L-O - 

7 R-Y - 

8 R-L - 

V106 to Driver Door Wire Harness Assy C 


1 - - 

2 P - 

3 R - 

4 B - 

5 V - 

6 G - 

Page 3009

71-184 


V107 to Co-Driver Door Wire Harness Assy 

A 


1 R - 

2 - - 

3 L-Y - 

4 R-L - 

5 G - 

6 - - 


C 


1 W-B - 

2 L - 

3 G-R - 

4 - - 

5 L-G - 

6 R-L - 

7 R-Y - 

8 B - 

V110 to Front Bumper Wire Harness Assy 


B 


1 - - 

2 - - 

3 L-Y - 

4 P-L - 


1 B - 

2 G-R - 

3 G-O - 

4 - - 

5 W-B - 

6 LG - 

5 - - 

6 - - 

7 - - 

8 L-G - 

Page 3010


71-185 

X - PREHEATING WIRE HARNESS 

71 

X001 Pre-heater 


1 B Pre-heater+ 

X003 Pre-heater Relay B 


1 R Pre-heater Relay B 

71 

X002 Pre-heater Relay L 


1 B Pre-heater Relay L 

Page 3011

71-186 

WIRING - WIRE HARNESS & CONNECTOR LOCATION VIEWS 

WIRE HARNESS & CONNECTOR LOCATION VIEWS 



C Front Bumper Wire Harness - Connector 

C001 Front Fog Lamp LH C002 Front Fog Lamp RH 

C Front Bumper Wire Harness- Inline 


Page 3012


71-187 

V Front Wire Harness - Connector 

00 

V001 

Left Headlight Dimming Motor 

V010 

Front Washing Reservoir Motor 

V002 

V003 

Front Position Lamp LH 

Headlamp LH 

V011 

V012 

Windshield Wiper Assy 

Brake Fluid Level Sensor 

71 

V004 

V005 

Front Turn Signal Lamp LH 

Right Headlight Dimming Motor 

V013 

V014 

Bass Horn 

Alt Horn 

71 


V015 


V007 

Front Position Lamp RH 

V016 

Coolant level Sensor 

V008 

Front Turn Signal Lamp RH 

V017 

Triple Pressure Switch 

V009 

Rear Washing Reservoir Motor 

V Front Wire Harness - Inline 

V101 

to Instrument Panel Wire Harness assy A 

V106 

to Driver Door Wire Harness Assy C 

V102 

to Instrument Panel Wire Harness assy B 

V107 

to Co-Driver Door Wire Harness Assy A 

V103 

to Instrument Panel Wire Harness assy C 

V108 

to Co-Driver Door Wire Harness Assy B 

V104 

to Driver Door Wire Harness Assy A 

V109 

to Co-Driver Door Wire Harness Assy C 

V105 

to Driver Door Wire Harness Assy B 

V110 

to Front Bumper Wire Harness Assy 

V Front Wire Harness - Ground 

V201 

Front Wire Harness Left Side Ground 

V203 

Front Wire Harness Right Side Ground 

V202 

Front Wire Harness Central Ground 

Page 3013

71-188 



D Front Door LH Wire Harness - Connector 

D001 

Front Speaker LH 

D004 

Electric Outside Mirror Switch 

D002 

Power Window Motor LH 

D005 


D003 

Outside Mirror Assy LH 

D006 

Front Door Lock Assy LH 

D Front Door LH Wire Harness - Inline 

D101 

to Front Wire Harness A 

D103 

to Front Wire Harness C 

D102 

to Front Wire Harness B 

Page 3014


71-189 


71 

71 

H Front Door RH Wire Harness - Connector 

H001 

Front Speaker RH 

H004 

Window Control Switch RH 

H002 

Power Window Motor RH 

H005 

Front Door Lock Assy RH 

H003 

Outside Mirror Assy RH 

H Front Door RH Wire Harness - Inline 

H101 


H103 


H102 


Page 3015

71-190 


A - CHASSIS & FRAME WIRE HARNESS 

A Chassis & Frame Wire Harness - Connector 

A004 

to Positive Junction Box A 

A025 

Stop Lamp Switch 

A005 

to Positive Junction Box C 

A026 

Parking Brake Switch 

A006 

to Positive Junction Box D 

A027 

Restraint control module (RCM) 

A010 

Front Wheel Speed Sensor LH 

A028 

Front Blower 

A011 

Front Wheel Speed Sensor RH 

A029 

Front Door Lamp Diode LH 

A014 


A031 

Preheating Relay Coil (Diesel) 

A015 

Secondary Fan Motor 

A032 

Vacuum Level Alarm Switch (Diesel) 

A016 

Main Fan Motor 

A034 

Clutch Switch 

A018 

Generator Excitation 

A035 

Electronic Throttle 

A023 

Engine Oil Pressure Sensor 

Page 3016


71-191 

A Chassis & Frame Wire Harness - Inline 

A102 

to Instrument Panel Wire Harness B 

A109 

to Rear Heater Wire Harness 

A103 

A104 

to Instrument Panel Wire Harness C 

to Instrument Panel Wire Harness D 

A111 

A112 

to Instrument Panel Wire Harness D 

to Engine Wire Harness A (Diesel) 

71 

A105 

A106 

to Driver Seat Belt Warning Wire Harness 

Assy 

to Engine Wire Harness 1 (Gasoline) 

A113 

to Battery Wire Harness B (Diesel) 

71 

A Chassis & Frame Wire Harness - Ground 

A205 

Airbag Ground 

Page 3017

71-192 


A Chassis & Frame Wire Harness - Connector 

A007 

Rear Heater Blower Switch 

A008 

Front Door Lamp Switch LH 

A009 

ABS Module 

A012 Rear Wheel Speed Sensor LH 

A013 Rear Wheel Speed Sensor RH 

A017 Generator B+ 

A019 Downstream Oxygen Sensor 

A021 

A022 

A024 

A030 

A033 

A036 

Back-up Lamp Switch 

Fuel Sensor/Fuel Pump 

Front Door Lamp Switch RH 

Diesel Filter Heater (Diesel) 

Data Link Connector 120 Resistance 

(Diesel) 

ECM (Diesel) 

A020 


A Chassis & Frame Wire Harness - Inline 

A101 

to Instrument Panel Wire Harness A 

A108 

to Step Lamp Wire Harness 

A107 

to Engine Wire Harness 2 (Gasoline) 

A110 

to Rear Bumper Transition Wire Harness 

A Chassis & Frame Wire Harness - Ground 

A201 

Engine Room Left Side/ABS Ground 

A204 

Engine Room Right Side Ground 

A202 

Engine Room Left Side Ground 

A203 

Electronic Fan Ground 

Page 3018


71-193 


ENGINE 4G69 

71 

71 

E Engine Wire Harness - Connector 

E001 

ECM 

E010 


E002 

Injector A 

E011 

Knock Sensor 

E003 

Injector B 

E012 

Engine Coolant Temperature Sense Plug 

E004 

Injector C 

E013 

Compressor 

E005 

Injector D 

E014 

Starter Coil 

E006 

E007 

E008 

Mainfold Absolute Pressure/Intake Air 


Upstream Oxygen Sensor 


E015 

E016 

E017 

Idle Air Control Valve 

Canister Solenoid Valve 

Ignition Coil 

E009 


E Engine Wire Harness - Inline 

E101 to Chassis Wire Harness 1 E102 to Chassis Wire Harness 2 

Page 3019

71-194 


E Engine Wire Harness - Ground 

E201 Ground (Near the Thermostat) 

Page 3020


71-195 

ENGINE ISF2.8 

71 

71 


E013 

E018 

E019 

E020 

E021 

E022 

E023 

E024 

E025 

Compressor 

Engine Electronic Control Module 



Fuel Rail Pressure Sensor 

Intake manifold Pressure/Temperature 

Sensor 

Atmospheric Pressure Sensor 


Fuel Moisture Content Sensor 

E028 

SAE J1939 Data Communication 

Interface 





E033 

E034 

E035 

E036 

Air Mass Flow Sensor 

Intake Throttle Actuator 

EGR Valve 

Engine Oil Pressure Switch (IC) 

E026 

E027 



E037 


(IC) 


E103 

to Chassis Wire Harness A (Diesel) 

Page 3021

71-196 


I - INSTRUMENT PANEL WIRE HARNESS 


I Instrument Panel Wire Harness - Connector 

I002 

Instrument Cluster A 

I019 


I003 

Instrument Cluster B 

I020 

A/C Control Panel A 

I004 

Headlamp Dimmer Switch 

I021 

A/C Control Panel B 

I005 

Instrument Dimmer Switch 

I022 

Servo Motor (Temperature) 

I006 

Hazard Warning Switch 

I023 

Rear Blower Forward Switch 

I007 

Central Locking Controller Assy A 

I024 


I008 

Central Locking Controller Assy B 

I025 

Blower Control Module 

I012 

Combination Switch (Light) 

I026 

Front Evaporator Thermistor 

I013 

I014 

I015 

I016 

I017 

I018 

Combination Switch (Wiper) 

Clock Spring 

12V Power Output Socket 

Rear Window Defroster Switch 

Outside Mirror Defroster Switch 


I027 

I028 

I029 

I030 

I031 

Servo Motor (Internal & External 

Circulation) 

Reverse Radar Control Unit 

CD Player-C1 

CD Player-C2 

Radio A 

Page 3022


71-197 

I032 

Radio B 

I035 

Passenger Airbag Assy 

I033 


I038 

Horn Switch 

I Instrument Panel Wire Harness - Inline 

71 

I107 

to Roof Wire Harness Assy 1A 

I109 

to Chassis & Frame Wire Harness E 

I108 

to Roof Wire Harness Assy 1B 

71 

M Diagnosis Wire Harness - Connector 

M001 Data Link Connector Resistance M002 Data Link Connector 

M Diagnosis Wire Harness - Inline 

M101 

to Instrument Panel Wire Harness 

69 

Page 3023

71-198 


I Instrument Panel Wire Harness - Connector 

I009 


I036 

Right Side Sliding Door Lamp Diode 

I010 

Ignition Switch Illumination 

I037 

Rear Hatch Lamp Switch Diode 

I011 

Key Insert Switch 

I039 

Right Turn Signal Lamp Diode 

I034 

Flasher 

I040 

Left Turn Signal Lamp Diode 

I Instrument Panel Wire Harness - Inline 

I101 


I105 

to Chassis & Frame Wire Harness C 

I102 


I106 

to Chassis & Frame Wire Harness B 

I103 


I110 

to Data Link Connector 

I104 

to Chassis & Frame Wire Harness A 

I111 

to Chassis & Frame Wire Harness D 

I Instrument Panel Wire Harness - Ground 

I201 Instrument Panel Signal Ground 

I202 Instrument Panel Power Ground 

I203 

I204 

I205 

Instrument Panel Power Ground 

A/C System Ground 

Radio/Data Link Connector Ground 

Page 3024


71-199 


O - DRIVER SEAT BELT WIRE HARNESS 



71 

71 

B Battery Wire Harness - Connector 

B001 Starter B002 Starter Excitation 

B Battery Wire Harness - Inline 

B101 

to Chassis & Frame Wire Harness B 

B Battery Wire Harness - Ground 

B201 Engine Ground in Engine Room B202 Body Ground (Battery Side) 

O Driver Seat Belt Wire Harness - Connector 

O001 

Driver Seat Belt Warning Switch 

Page 3025

71-200 


O Driver Seat Belt Wire Harness - Inline 

O101 

to Chassis & Frame Wire Harness 

P Rear Heater Wire Harness - Connector 

P001 Rear Heater Solenoid Valve P002 Rear Heater Motor 

P Rear Heater Wire Harness - Inline 

P101 


X Preheating Wire Harness - Connector 

X001 

Pre-heater 

X003 

Pre-heater Relay B 

X002 

Pre-heater Relay L 

Page 3026


71-201 


71 

71 

F Roof Wire Harness 1 - Connector 

F001 


F004 

Central Dome light (Low Equipped) 

F002 

Sliding Roof ECU 

F005 

Rear Speaker LH 

F003 

Sliding Roof Control Switch 

F006 

Rear Combination Lamp LH 

F004 

Central Dome light (High Equipped) 

F007 

Air Purifier 

F Roof Wire Harness 1 - Inline 

F101 

F102 

F103 

to Instrument Panel Wire Harness A 

to Instrument Panel Wire Harness B 

to Roof Wire Harness 2A 

F105 

F106 

to High-mounted Stop Lamp Wire 

Harness 

to Rear Evaporator Wire Harness 

F104 

to Roof Wire Harness 2B 

F Roof Wire Harness 1 - Ground 

F201 

Roof Wire Harness Rear Left Department 

Ground 

Page 3027

71-202 


L - REAR EVAPORATOR WIRE HARNESS 

L Rear Evaporator Wire Harness - Connector 

L001 

Left Blower 

L004 


L002 

Right Blower 

L005 

Top Evaporator Blower Switch 

L003 

Blower Resistor 

L Rear Evaporator Wire Harness - Inline 

L101 to Roof Wire Harness 1 

Page 3028


71-203 

N - STEP LAMP WIRE HARNESS 

71 

71 

N Step Lamp Wire Harness - Connector 

N001 

Right Side Sliding Door Lock Assy 

N003 

Rear A/C Solenoid Valve 

N002 

Step Lamp 

N Step Lamp Wire Harness - Inline 

N101 


Page 3029

71-204 







S - REAR DEFROST RH WIRE HARNESS 

T - REAR DEFROST LH WIRE HARNESS 


G Roof Wire Harness 2 - Connector 

G001 

Rear Combination Lamp RH 

G003 

Sliding Door Ajar Switch RH 

G002 

Rear Speaker RH 

G Roof Wire Harness 2 - Inline 

G101 


G103 

to Rear Hatch Transition Wire Harness 

G102 


Page 3030


71-205 

G Roof Wire Harness 2 - Ground 

G201 

Roof Rear Right Department Ground 

71 

J Rear Hatch Wire Harness - Connector 

J001 

J002 

Rear Hatch Lock Assy-Switch 

Rear Hatch Lock Assy-Motor 

J004 

J005 

License Lamp 

Camera 

71 

J003 

Trunk Lamp 

J Rear Hatch Wire Harness - Inline 

J101 


J Rear Hatch Wire Harness - Ground 

J201 

Rear Hatch Internal Ground 

Q Rear Bumper Transition Wire Harness - Inline 

Q101 to Rear Bumper Wire Harness Q102 to Chassis & Frame Wire Harness 

R Rear Bumper Wire Harness - Connector 

R001 

Reverse Radar Sensor LH 

R003 

Reverse Radar Central Sensor RH 

R002 

Reverse Radar Central Sensor LH 

R004 

Reverse Radar Sensor RH 

R Rear Bumper Wire Harness - Inline 

R101 


S Rear Defrost RH Wire Harness - Connector 

S001 

Rear Defrost Heating Wire RH 

S Rear Defrost RH Wire Harness - Inline 

S101 

to High-mounted Stop Lamp Wire Harness 

T Rear Defrost LH Wire Harness - Connector 

T001 

Rear Defrost Heating Wire LH 

Page 3031

71-206 


T Rear Defrost LH Wire Harness - Inline 

T101 

to High-mounted Stop Lamp Wire Harness 

U High-mounted Stop Lamp Wire Harness - Connector 

U001 Rear Wiper U002 High-mounted Stop Lamp 

U High-mounted Stop Lamp Wire Harness - Inline 


U103 

to Rear Defrost RH Wire Harness 

U102 

to Rear Defrost LH Wire Harness 

Page 3032

WIRING(RHD) 


INTRODUCTION.......................................................................... 71-1 

SYSTEM WIRING DIAGRAM SECTION EXAMPLE ................... 71-2 

POWER SOURCE SECTION EXAMPLE .................................... 71-5 

CONNECTOR VIEWS SECTION EXAMPLE .............................. 71-6 

GLOSSARY OF TERMS AND SYMBOLS................................... 71-7 

FUSE AND RELAY LOCATIONS ................................................ 71-9 

WIRING DIAGRAM .......................................................................... 71-19 

POWER SOURCE ..................................................................... 71-19 

ENGINE CONTROL SYSTEM................................................... 71-23 

STARTING SYSTEM ................................................................. 71-35 

CHARGING SYSTEM................................................................ 71-37 

ANTI-LOCK BRAKE CONTROL SYSTEM ................................ 71-39 

HEATER AND CONDITIONING CONTROL SYSTEM.............. 71-42 

LIGHT SYSTEM......................................................................... 71-49 

WIPER AND WASHER.............................................................. 71-73 

MULTIMEDIA SYSTEM ............................................................. 71-76 

POWER SOCKET...................................................................... 71-79 

COMMUNICATION SYSTEM .................................................... 71-81 

POWER MIRROR...................................................................... 71-85 

WINDOW DEFROSTER ............................................................ 71-88 

INSTRUMENT CLUSTER.......................................................... 71-90 

ANTI-THEIF SYSTEM................................................................ 71-97 

RESTRAINT CONTROL SYSTEM .......................................... 71-102 

CONNECTOR VIEWS .................................................................... 71-104 






G - ROOF WIRE HARNESS 2................................................. 71-122 


J - REAR HATCH WIRE HARNESS........................................ 71-127 






U - HIGH-MOUNTED STOP LAMP WIRE HARNESS........... 71-134 

V - FRONT WIRE HARNESS................................................. 71-135 


Z - Main Wire Harness ............................................................. 71-142 

WIRE HARNESS & CONNECTOR LOCATION VIEWS................ 71-166 


V - FRONT WIRE HARNESS .................................................. 71-166 



Z - MAIN WIRE HARNESS(CHASSIS & FRAME SECTION) 71-170 


71 

71 

71 

Page 3033

Z - MAIN WIRE HARNESS(INSTRUMENT PANEL 

SECTION) ............................................ 71-175 






G - ROOF WIRE HARNESS 2 ................................................. 71-182 

J - REAR HATCH WIRE HARNESS ........................................ 71-182 




U - HIGH-MOUNTED STOP LAMP WIRE HARNESS............. 71-182 

Page 3034

WIRING(RHD) - HOW TO USE THIS MANUAL 

71-1 


WIRING(RHD) 

INTRODUCTION 

This manual provides information on the electrical circuits installed on vehicles by dividing them into electrical 

systems. The actual wiring of each system wiring diagram is shown from the point where the power source is 

received from the battery to each ground point. (All wiring diagrams are shown with the switches in the OFF 

position.) 

When troubleshooting any problem, firstly, make sure you understand the operation of the circuit where the 

problem was detected (see System Wiring Diagram Section). Secondly, understand the power source supplying 

to that circuit (see Power Source Section). Finally, understand the direction of current flow (see System 

Description). 

When the circuit operation is understood, begin troubleshooting of the suspected circuit to find out the cause. 

(Based on relays, controllers, accessory, inlines, sensors, actuators, switches, ground points, connection location 

of each system wiring diagram and wire harness location.) 

71 

71 

Page 3035

71-2 


SYSTEM WIRING DIAGRAM SECTION EXAMPLE 



Page 3036


71-3 

Note 


1 System Title Distinguish between different systems and functions, easy to query. 

2 

Indicates the 

wire color 

Wire colors are indicated by an alphabetical code,easy to query. 

The first letter indicates the basic wire color and the second letter indicates 

the color of the stripe. 

Example: 

R (Red) 

L-B (Blue and Black) 

71 

71 

3 

4 

Indicates the 

component name 

Indicates the 

component number 





Female and male connectors have different numbering rules. 

The two examples below are viewed from terminal side when connectors are 

unplugged. 

Female - Numbered in order from upper right to lower left. 

5 

Indicates the pin number 

of 

connector 

Male - Numbered in order from upper left to lower right. 

This rules also applied to inline connector number. 

6 Indicates a ground point 

The first letter of the code for each ground point(s) indicates the component’s 

location. 

7 

8 

Indicates related 

system 


connector number 

Indicate that other system(s) associated with this system. 

A group of inline has two connector numbers, one is the female and the other 

is the male. 

Male: 

9 


gender 

Female: 

Page 3037

71-4 




Note 


10 System Description Describe the current flows and how the system works. 

11 Service Hints Describe the component's value and principle. Refer in the service process. 

12 Parts Location Indicate the wire harness showing the parts location on the vehicle. 

13 Inline Indicate the inline two parts gender and the connected wire harness types. 

14 Ground Points Indicate the ground location of each wire harness. 

Page 3038


71-5 

POWER SOURCE SECTION EXAMPLE 

The “POWER SOURCE” section describes how the current flows and each part power feed conditions. In the 

POWER SOURCE wiring diagram, the conditions when battery power is supplied to each system are explained. 

Since all system wiring diagrams start from the power source, the power source system must be fully 

understood. 

71 

71 



Page 3039

71-6 



*The connector views shown here is an EXAMPLE ONLY. It is different to the actual connector views 

shown in the CONNECTOR VIEWS SECTION. 

Note 


1 Connector Face Indicate connector face and pin order. 

2 Component Name 

3 Component Number 





4 Connector Information Indicate pin number, wire color and function. 

Page 3040


71-7 

GLOSSARY OF TERMS AND SYMBOLS 

BATTERY 

Stores chemical energy and converts it into electrical energy. 

Provides DC current for the auto’s various electrical circuits. 

GROUND 

The point at which wiring attaches to the body, thereby providing a 

return path for an electrical circuit. Without a ground, current cannot 

flow. 

71 

71 

FUSIBLE LINK 

FUSE 

FUSIBLE LINK 

In high amperage circuits, a heavy gauge wire burns when it is overloaded 

to protect the connected components. 

FUSE 

A thin metal strip burns when too much current flows through it, 

thereby it can stop current flow and protect a circuit from damage. 

COIL 

When the magnetic field engenders fluctuations, the coil circuit is 

induced electromotive force. 

SOLENOID 

An electromagnetic coil which forms a magnetic field when current 

flows, to move a plunger, etc. 

SINGLE FILAMENT 

LAMPS 

Current flow causes a headlight filament to heat up and emit light. A 

headlight may have either a single filament or double filaments. 

DOUBLE FILAMENT 

MOTOR 

MOTOR 

A power unit which converts electrical energy into mechanical 

energy, especially rotary motion. 

SPEED MOTOR 

INLINE 

Indicate the connector joining wire harness and wire harness. 

DIODE 

A semiconductor which allows current flow in only one direction. 

LED (LIGHT EMITTING DIODE) 

Upon current flow, these diodes emit light without producing the 

heat of a comparable light. 

Page 3041

71-8 


HORN 

An electric device which sounds a loud audible signal. 

THERMISTOR SENSOR 

A resistor which varies its resistance with temperature. 

RESISTOR 



RESISTOR 

An electrical component with a fixed resistance, placed in a circuit to 

reduce voltage to a specific value. 


A resistor which supplies two or more different non-adjustable 

resistance values. 


A controllable resistor with a variable rate of resistance. Also called 

a potentiometer or rheostat. 

POWER SOCKET (CIGARETTE LIGHTER) 


MANUAL SWITCH 

Opens and closes circuits, stops or allows current flow. 

IGNITION SWITCH 

A key operated switch with several positions which allows various 

circuits. 

HEATER 


RELAY(4Pin) 

RELAY 

Basically, an electrically operated switch which may be normally 

closed or open. Current flow through a small coil to create a magnetic 

field which either opens or closes an attached switch. 

RELAY(5Pin) 

Page 3042


71-9 

FUSE AND RELAY LOCATIONS 

POSITIVE JUNCTION BOX 

71 

71 

FUSIBLE LINK 


F1 60A Instrument Panel Fusible Link 

F2 120A Charge Fusible Link 


F4 60A Battery Fusible Link 

F5 50A Engine Room Fusible Link 

F3 120A Pre-heat Fusible Link 

Page 3043

71-10 


BATTERY COMPARTMENT JUNCTION BOX LOCATION 

FUSIBLE LINK 



F9 30A AM2 Fusible Link F10 40A ABS Pump Fusible Link 

Page 3044


71-11 

FUSE 

71 


F2 7.5A Start Fuse 

F3 5A ABS IG Fuse 

F4 15A Accessory Fuse 

F5 15A Fuel Pump/Diesel Filter Fuse 


F6 30A ECU Main Fuse 

F7 10A Diagnosis Fuse 

F8 25A ABS Valve Fuse 

71 

RELAY 

No. 

R1 

R2 

Function 

Fuel Pump/Diesel Filter Heating Relay 

Starter Relay 

Page 3045

71-12 


ENGINE ROOM JUNCTION BOX LOCATION 

FUSIBLE LINK 



F1 30A Low-speed Fan Fusible Link F2 30A High-speed Fan Fusible Link 

Page 3046


71-13 

FUSE 

71 


F7 15A Stop Lamp Fuse 

F11 15A Injector Fuse 


F12 15A Ignition Coil Fuse 

71 

\\\RELAY 

No. 

Function 

No. 

Function 

R1 


R5 


R3 


R6 

Main Relay 

R4 


Page 3047

71-14 


CO - PILOT SIDE JUNCTION BOX LOCATION 

Page 3048


71-15 

71 

71 

Page 3049

71-16 


Page 3050


71-17 

FUSIBLE LINK 

71 


F19 40A IG2 Fusible Link 

F20 20A Power Window Fusible Link 

F21 20A AM1 Fusible Link 


F25 30A Rear A/C Fusible Link 

F27 30A Front Blower Fusible Link 

71 

FUSE 


F2 7.5A Radio Fuse 

F3 7.5A A/C Controller Fuse 

F5 10A Instrument Cluster Fuse 

F7 10A Rear Fog Lamp Fuse 

F9 15A Horn Fuse 

F11 15A Front Fog Lamp Fuse 

F12 15A Hazard Warning Fuse 

F13 10A Dome Light Fuse 

F14 20A Headlamp Fuse 

F15 20A Central Locking Fuse 

F17 15A Rear Heater Fuse 

F28 7.5A Small Lamp Fuse 

F29 7.5A Switch Lighting Fuse 

F30 10A Left High Beam Fuse 

F31 10A Right High Beam Fuse 


F32 7.5A left Low Beam Fuse 

F33 7.5A Right Low Beam Fuse 

F34 10A Radio/Outside Mirror Fuse 

F35 15A Cigarette Lighter Fuse 

F36 7.5A Instrument IG Fuse 

F37 15A Front Wiper Fuse 

F43 10A Turn Signal Fuse 

F44 10A Rear Wiper Fuse 

F46 10A Airbag Fuse 

F48 10A Back-up Lamp Fuse 

F49 15A Power Fuse 

F50 5A ECU IG Fuse 

F51 15A A/C Fuse 

F52 7.5A Outside Mirror Defrost Fuse 

Page 3051

71-18 


RELAY 

No. 

Function 

No. 

Function 

R1 

Lamplet Relay 

R14 


R2 

Low Beam Relay 

R16 

Rear Wiper Relay 

R5 

Rear Heater Relay 

R18 

Rear A/C Relay 

R6 

Rear Fog Lamp Relay 

R19 

A/C Cut Off Relay 

R7 

Horn Relay 

R20 

Front Blower Relay 

R8 

Front Fog Lamp Relay 

R21 

High Beam Relay 

R9 

Outside Mirror Defrost Relay 

R22 

IG2 Relay 

R11 

Compressor Relay 

Page 3052


POWER SOURCE 

WIRING(RHD) - WIRING DIAGRAM 

71-19 

71 

71 

Page 3053

71-20 


Page 3054


71-21 

71 

71 

Page 3055

71-22 


Service Hints 

• Z015 Ignition Switch 

AM1 - ACC: Closed with the ignition switch at ACC/ON position. 



AM2 - ST2: Closed with the ignition switch at ST position. 



B001 Battery Wire Harness Z050 Main Wire Harness 

Z015 Main Wire Harness Z051 Main Wire Harness 




Z111 

Z113 

E101 

M101 

Main Wire Harness & Engine Wire Harness 

(Manhole After the Driver Seat) 

Main Wire Harness & Diagnosis Wire Harness 

(Under the Right Bottom Side of the Instrument Panel) 

Ground Points 



Z203 

Instrument Panel Signal Ground 

Page 3056


71-23 


ENGINE CONTROL SYSTEM - WITH 4G69 ENGINE 

71 

71 

Page 3057

71-24 


Page 3058


71-25 

71 

71 

Page 3059

71-26 


Page 3060


71-27 


Engine control system of 4G69 engine is based on Engine Control Module (ECM) of Delphi MT20U2 as the 




Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor 

Manifold absolute pressure/intake air temperature (MAP/IAT) sensor integrates functions of manifold absolute 

pressure sensor with those of intake air temperature sensor, while achieving the functions of feedback 

manifold absolute pressure and intake air temperature. 

Manifold absolute pressure sensor measures engine inhaled air volume, which is a critical element that forms 

method of speed-density type air flow measurement. The sensor directly senses manifold absolute pressure 

state inside the engine intake manifold. The engine control module (ECM) takes this reference signal as the 

basis to adjust the basic fuel supply sprayed into the engine. 

Intake air temperature sensor uses NTC (negative temperature coefficient) thermistor sensor, with which the 

engine control module (ECM) measures the air temperature in the engine cylinder and modifies the engine 

fuel supply. 

71 

71 











Knock Sensor 

Knock sensor is a vibration acceleration sensor, equipped at the engine knock induction-sensitive parts and 

used for sensing the knock generated by the engine. The engine control module (ECM) uses knock intensity 

detected by the knock sensor to modify ignition advance angle and achieve the effective control of the knock, 

so as to optimize engine power performance, fuel economy and reduce emissions. 


Throttle position sensor consists of carbon film resistor and sliding pointer driven by throttle shaft. When the 

throttle opening changes, the signal that the sensor feeds back to the engine control module (ECM) also 

varies. The control module determines real-time engine load and dynamic change condition based on the 

sensor signal value and its rate of change. 

Upstream (Downstream) Oxygen Sensor 

Oxygen sensor is an important symbolic component of closed loop fuel control system. With its adjustment 

and keeping the desired air-fuel ratio, the three-way catalytic converter can 

achieve the best conversion efficiency. The zirconium oxide in oxygen sensor is heated (> 300 ℃ ) for 

activation. The sensor changes the output voltage according to the presence or absence of oxygen in the 

exhaust and determines the oxygen content in the exhaust. If the oxygen content in the exhaust is increased, 

output voltage of oxygen sensor will be decreased; on the other hand, the output voltage will be increased, 

thus providing feedback of the actual air-fuel ratio conditions for the engine control module (ECM). Usually, 

when the sensor has the theoretical air-fuel ratio (14.6:1), it will result in dramatic change of voltage amplitude, 

helping the engine control module (ECM) to accurately determine the air-fuel ratio. 





Page 3061

71-28 


• Executive Control 

Fuel injection Control 

The system uses the speed density method to make multi-point sequential injection, i.e., each engine cycle 

implements accurate fuel supply through main pulse width and amended pulse width, which has closed-loop 

control and self-learning function. 

Oil pump is single-stage electric turbine pump, and its operation is controlled by the engine control module 

(ECM) through the pump relay. When ignition switch is turned on, the pump will run for 1.5 seconds. If the 

crankshaft position signal is not received, the pump will stop running. If the crankshaft position signal is 

detected, the oil pump starts to work. Upon loss of crankshaft position signal, the pump will stop running. 

Mounting Position: in the fuel tank. 

Fuel injector is a ball valve device with solenoid switch. The coil in injector is controlled grounded by the 

engine control module (ECM) to produce magnetic force and pull up spool. The fuel is ejected from the pilot 

hole in the form of mist. The main factors affecting changes in fuel injection pulse width include air-fuel ratio, 

manifold absolute pressure, intake air temperature, closed loop feedback correction, acceleration 

concentration, deceleration cutoff, self-learning and correction. 

Ignition Control 

The system uses grouping ignition. Ignition coil is divided into two groups, each group providing the ignition 

energy for two cylinder spark plugs with 360-degree crankshaft angle difference. 

Idle Control 

The system uses the idle air control, achieving high-precision idle speed control. 

The idle stepping motor controls circulation area of throttle body bypass air duct to adjust control volume in the 

engine. The engine control module (ECM) controls the amount of movement (forward / backward) for the 

stepping motor through the digital square wave signal. 

Canister Solenoid Valve Control 

The engine control module (ECM) controls volume of gasoline vapor in intake manifold flowing from canister 

through the canister solenoid valve control. The opening of canister solenoid valve is determined by the 

engine control module (ECM) according to the duty cycle signal based on the state of engine. 

Fan Control 

The engine control module (ECM) monitors the level of coolant temperature and whether the air-conditioning 

works properly to determine the operating state of each fan. 








E001 Engine Wire Harness E002 Engine Wire Harness 







M002 Diagnosis Wire Harness V031 Front Wire Harness 

Page 3062


71-29 








Z077 

Main Wire Harness 

71 

71 



E101 

E102 

M101 

Z101 

Z111 

Z112 

Z113 

V112 

Engine Wire Harness & Main Wire Harness 




Diagnosis Wire Harness & Main Wire Harness 


Main Wire Harness & Front Wire Harness 

(Right Side of the Instrument Panel) 

Ground Points 


E201 Ground (Near the Thermostat) Z203 Instrument Panel Signal Ground 

Z204 Radio/Data Link Connector Ground Z208 Vehicle Frame Left Side Ground 

Z209 


Page 3063

71-30 


ENGINE CONTROL SYSTEM - WITH ISF2.8 ENGINE 

Page 3064


71-31 

71 

71 

Page 3065

71-32 


Page 3066


71-33 


Engine control system of ISF2.8 engine is based on Engine Control Module (ECM) of Bosch CM2220 as the 









71 

71 






Mounting Position: on the flywheel housing perpendicular to the crankshaft position. 





















E056 Engine Wire Harness M001 Diagnosis Wire Harness 

M002 Diagnosis Wire Harness V031 Front Wire Harness 

X001 Preheating Wire Harness X002 Preheating Wire Harness 

Page 3067

71-34 



X003 Preheating Wire Harness Z001 Main Wire Harness 











B101 

M101 

Z101 

Z107 

Z113 

V112 

Battery Wire Harness & Main Wire Harness 

(Car Body Side of the Battery Compartment) 





Ground Points 


B201 Engine Ground in Engine Room Z208 Vehicle Frame Left Side Ground 

Z209 


Page 3068


71-35 

STARTING SYSTEM 

71 

71 

Page 3069

71-36 



• Starting System 

a. When ignition switch is turned to ST, the current flows through battery fusible link positive in junction box, to 

AM2 fusible link in battery compartment junction box, through the AM2 fusible box. The current flows from pin 

ST2 of ignition switch through starter fuse and accessory fuse in battery compartment junction box to pin 85 of 

starter relay, and through coil to ground at pin 86 of starter relay. Coil then creates a magnetic field, and switch 

is activated. 

b. The current flows through AM2 fusible link, through starter relay, to solenoid switch of starter. Solenoid 

switch creates a magnetic field, and starter is activated. 

c. The current flows through the terminal of starter, to starter motor, and to crank the engine. 

Service Hints 

• Z015 Ignition Switch 

AM2 – IG2: Closed with the ignition switch at ON/ST position. 

AM2 – ST2: Closed with the ignition switch at ST position. 



B001 Battery Wire Harness B002 Battery Wire Harness 

E014 Engine Wire Harness Z015 Main Wire Harness 




Z107 

Z111 

B101 

E101 

Main Wire Harness & Battery Wire Harness 

(Car Body Side of the Battery Compartment) 

Main Wire Harness & Engine Wire Harness 


Ground Points 

Code 

Z208 


Vehicle Frame Left Side Ground 

Page 3070


71-37 

CHARGING SYSTEM 

71 

71 

Page 3071

71-38 



• Charging System 

a. 4G69 engine: When ignition switch is turned to ON/ST, the current flows output from ignition switch to ignition 

fuse in engine room junction box, through the fuse, to IG terminal of generator connector A018. 

b. When ignition switch is ON/ST, the current flows output from ignition switch, to instrument panel fuse in copilot 

side junction box, through the fuse, to pin A20 of instrument cluster. The current flows through charging 

warning light of instrument cluster, from pin B25 of instrument cluster, to pin L of generator connector Z066, to 

field winding of generator. Field winding creates a magnetic field. Rotation of the excited field coil generates 

AC voltage in the stator. The alternation current is rectified through diodes to DC voltage, to pin 1 of generator 

connector Z074, to charge fusible link and charge a battery, at the same time, supply electrical energy to other 

electrical devices. 

Service Hints 

• Z066,Z074 Generator 

1 - Ground:12 volts with the ignition switch at ON position and engine not running. 






Z074 


Page 3072


71-39 

ANTI-LOCK BRAKE CONTROL SYSTEM 

71 

71 

Page 3073

71-40 



ABS control system uses vehicle speed sensor to detect vehicle speed and transmits the speed signal to the 

control module. The control module controls wheel slipping rate by repeatedly increasing or decreasing the 

wheel brake pressure according to the input vehicle speed, keep the wheels rotating. The system enables the 

vehicle in braking state to prevent the wheels locking and have the steering capability, guaranteeing stability in 

the braking direction and preventing side-slipping and deviation. 

• Power Input 

The current flows through battery fusible link in positive junction box to ABS valve fuse and ABS pump fusible 

link in battery compartment junction box, to pin 1 and 25 of ABS module. System is then powered. 

• Ignition Signal 

When ignition switch is ON/ST, current flows through ABS IG fuse in co-pilot side junction box, to pin 28 of 

ABS module and ABS system getss ignition signal. 

• Speed Signal 

Speed sensor provide the alternating signal to the ABS module. The signal from 4 sensors: front wheel speed 

sensor LH, front wheel speed sensor RH, rear wheel speed sensor LH and rear wheel speed sensor RH. 

• Brake Signal 

a. 4G69 engine: The current flows through battery fusible link in positive junction box, to ECM main fuse in battery 

compartment junction box, to stop lamp fuse in engine room junction box, to pin 2 of stop lamp switch. 

When the brake pedal is depressed, the current flows from pin 1 of stop lamp switch, to pin 30 of ABS module, 

and provide the brake signal to the ABS module. 

b. ISF2.8 engine: The current flows through engine room fusible link in positive junction box, to stop lamp fuse 

in engine room junction box, to pin 2 of stop lamp switch. When the brake pedal is depressed, the current 

flows from pin 1 of stop lamp switch, to pin 30 of ABS module, and provide the brake signal to the ABS 

module. 


When the system comes into operation, ABS module detects the operation of all parts of the system. Once the 

system or parts have faults, the system will switch on the ABS warning light and the EBD warning light to 

remind drivers of repair in time. 

Service Hints 

• Z006 Stop Lamp Switch 

1 - 2:Closed when the brake pedal depressed. 



M002 Diagnosis Wire Harness Z002 Main Wire Harness 






Z063 


Page 3074


71-41 



Z113 

M101 

Ground Points 

Main Wire Harness & Diagnosis Wire Harness 

(Under the Right Bottom Side of the Instrument Panel 

71 

71 

Code 

Z207 


ABS Ground 

Page 3075

71-42 



FRONT AND REAR AIR CONDITIONING CONTROL SYSTEM 

Page 3076


71-43 

71 

71 

Page 3077

71-44 


Page 3078


71-45 


• Ignition Switch At On/St, A/C System Power Supply 

a. When ignition switch is turned to ON/ST, current flows through A/C fuse in co-pilot side junction box, to pin 

30 of A/C cut off relay, through the relay, battery output from the pin 87a of cut off relay, to pin 10 of A/C controller, 

pin 85 of front blower relay, pin 30 and 85 of compressor relay and pin 2 of rear blower forward switch, 

then A/C system getss the operation power. 

• Ignition Switch At St, A/C System Power Supply 

When ignition switch is turned to ST, current flows through starter fuse in battery compartment junction box, to 

pin 85 of A/C cut off relay, through the coil to pin 86 and connect the groud. Coil then creates a magnetic field, 

and switch is open, cut off the power of A/C system to sure the starter motor have more power to crank the 

engine. 

• Front A/C Control 

a. blower control: current flows from the pin 87a of A/C relay, to pin 85 of front blower relay, through coil of 

relay, output from the pin 86 of relay to pin 8 of A/C control panel A; A/C control panel make the coil of relay to 

connect the ground, coil creates a magnetic field, and switch is closed. Current outputs from the pin 30 of A/C 

relay, to pin 1 of the front blower, through the pin 2 of the blower, to pin 4 of blower control module. A/C control 

panel control the front blower by controlling the blower control module. 

b. A/C clutch control: Working inquire signal of the front A/C system outputs from pin 9 of A/C control panel, to 

pin 1 of triple pressure switch, the signal through switch and connect to engine ECM. If the pressure of refrigerant 

in A/C pipe meet the specification as design, ECM will control the A/C relay coil to connect the 

ground.Coil then creates a magnetic field, and switch is activated. Current flows into A/C clutch solenoid and 

A/C compressor clutch engage and front A/C system begin to work. 

c. servo motor (internal & external circulation) control: Current flows from pin 6 of A/C control panel A, to pin 

5 of circulation motor, outputs from pin 6 of circulation motor, to pin 7 of A/C control panel A. Motor is working, 

the front A/C system is internal circulation mode, on the contrary, system is external circulation mode. 

d. servo motor (temperature) control: Current flows from pin 5 and 4 of A/C control panel A, to pin 5 and 6 of 

servo motor to control the motor operation. The current flows through the potentiometer in servo motor and 

return to A/C control panel from pin 3 and 1 of servo motor to pin 26 and 27 of A/C control panel B. The signal 

current outputs from pin 2 of motor, to pin 23 of A/C control panel B, feedback the position signal of servo 

motor(step motor). 

e. servo motor (mode) control: Current flows from pin 2 and 3 of A/C control panel, to pin 5 and 6 of servo 

motor to control the motor operation. The current flows through the potentiometer in servo motor and return to 

A/C control panel from pin 3 and 1 of servo motor to pin 26 and 27 of A/C control panel B. The signal current 

outputs from pin 2 of motor, to pin 24 of A/C control panel B, feedback the position signal of servo motor(step 

motor). 

f. Current flows from pin 29 of A/C control panel B, to pin 1 of evaporator thermistor, through thermister, outputs 

from pin 2 of thermister, to pin 33 of A/C control panel B. The A/C sustem getsss the temperature Info of 

evaporator. 

71 

71 

Service Hints 

• A/C Cut Off Relay 

30 - 87a:Open with the ignition switch at ST position. 

• Rear A/C Relay 

30 - 87:Closed when rear A/C system is working. 

• Compressor Relay 

30 - 87:Closed when fron A/C system is working. 




F008 Roof Wire Harness 1 V031 Front Wire Harness 



Page 3079

71-46 








Z072 




E101 

E103 

F107 

Z101 

Z111 

Z108 

Z103 

V112 

Engine Wire Harnes & Main Wire Harness 


Engine Wire Harnes & Main Wire Harness 


Roof Wire Harness 1 & Main Wire Harness 

(Left Side of the Instrument Panel) 



Ground Points 


Z203 Instrument Panel Signal Ground Z204 Radio/Data Link Connector Ground 

Z205 


Page 3080


71-47 

REAR HEATER CONTROL 

71 

71 

Page 3081

71-48 



• Rear Blower Forward Switch control 

When ignition switch is turned to ON/ST, current flows through pin 30 of A/C cut off relay in co-pilot side junction 

box, through the relay, to pin 87a of cut off relay and outputs: 

a. to pin 30 of water valve relay. 

b. to pin 2 of rear blower forward switch, press the switch, the current flows from pin 5 of switch to 85 pin of 

water valve relay and pin 85 of rear heater relay. 

• Rear Heater Blower Operation 

When switch on the rear blower forward switch and rear heater blower switch, the rear heater relay is at operating 

status; Current flows through charge fusible link and instrument panel fusible link in positive junction box, 

to rear heater fuse in co-pilot side junction box, to rear heater relay, coil then creates magnetic field, and switch 

is activated, current flows through relay to pin 2 of rear heater blower, the speed of blower is controlled by 

resistor: 

a. Current outputs from pin 4 of rear heater blower, to pin 4 of rear heater blower switch, through the switch, 

connect to the ground at the pin 1 of switch. Blower is at higher speed. 

b. Current outputs from pin 1 of rear heater blower, to pin 5 of rear heater blower switch, through the switch, 


c. Current outputs from pin 3 of rear heater blower, to pin 6 of rear heater blower switch, through the switch, 


• Water valve operation 

When switch on the rear blower forward switch and rear heater blower switch, water valve is at operating status; 

Current flows through coil and creates magnetic field, and switch is activated, current flows through relay 

to pin 1 of rear heater water valve and connect to ground at pin 2 of valve, water valve is working. 



P001 Rear Heater Wire Harness P002 Rear Heater Wire Harness 



Z051 Main Wire Harness Main Wire Harness 



Z109 

P101 

Main Wire Harness & Rear Heater Wire Harnesss 

(Left Side of the Chassis) 

Ground Points 


Z202 Instrument Panel Power Ground Z204 Radio/Data Link Connector Ground 

Z205 A/C System Ground Z210 Engine Room Right Side Ground 

Page 3082


71-49 

LIGHT SYSTEM 

HEADLAMP 

71 

71 

Page 3083

71-50 



• Headlamp (Low Beam) 

The current flows through charge and instrument panel fusible link, to pin 86 and 87 of lo-beam relay in copilot 

side junction box, through coil of relay, and then to pin 10 of combination switch. When the combination 

switch is set headlamp (Low Beam) position, the current output from pin 7 of combination switch to connect 

the ground. The coil of relay creates a magnetic field, and switch is activated. The current flows through switch 

of relay, to lo-beam fuse (LH) and lo-beam fuse (RH) in dirver side junction box, and pass then to pin 3 of left 

lamp and pin 3 of right headlamp and through light of headlamp (Low Beam). The power is ground at pin 1 of 

left and right headlamp. This enables headlamp (Low Beam) to operate. 

• Headlamp (High Beam) 

The current flows through charge and instrument panel fusible link, to headlamp fuse in co-pilot side junction 


the combination switch is set headlamp (High Beam) position, the current output from pin 7 of combination 

switch to connect the ground. The coil of relay creates a magnetic field, and switch is activated. The current 

flows through switch of relay, to hi-beam fuse (LH) and hi-beam fuse (RH) in co-pilot side junction box, and 

pass then to pin 2 of headlamp LH and pin2 of headlamp RH, and through light of headlamp (High Beam). 

The power is ground at pin 1 of left and right headlamp. This enables headlamp (High Beam) to operate. 

• High Beam Indicator 

When the combination switch is set headlamp (High Beam) position, the current flows through hi-beam (LH), 

to instrument cluster, and through high beam indicator. This enables high beam indicator to operate. 

• Flash to Pass 

The current flows through charge and instrument panel fusible link, to headlamp fuse in co-pilot side junction 


the combination switch is set flash to pass position, the current output from pin 7 of combination switch to connect 

the ground. The coil of relay creates a magnetic field, and switch is activated. The current flows through 

switch of relay, to hi-beam fuse (LH) and hi-beam fuse (RH) in co-pilot side junction box, and pass then to pin 

2 of headlamp LH and pin2 of headlamp RH, and through light of headlamp (High Beam). The power is 

ground at pin 1 of left and right headlamp. This enables flash to pass to operate. 

• Headlamp Adjusting 

When low beam lamp is under working condition, current through right low beam lamp fuse, to pin 1 of front 

left/right adjusting motor, to supply power for adjusting motor. Pin 2 of front left/right adjusting motor connect to 

the pin 4 and pin 5 of the adjusting switch, adjusting motor control the adjusting motor. 

Service Hints 

• Z011 Combination Switch (Light Control) 

10 - 7:Closed with the combination switch at Headlamp position ( Low Beam). 

9 - 7:Closed with the combination switch at Headlamp position (High Beam and Flash to Pass). 




V023 Front Wire Harness Z011 Main Wire Harness 


Z051 




Z105 

V111 



Page 3084


71-51 

Ground Points 


V205 Front Wire Harness Left Side Ground V206 Front Wire Harness Right Side Ground 

71 

Z201 Instrument Panel Power Ground Z203 Instrument Panel Signal Ground 

71 

Page 3085

71-52 


LAMPLET 

Page 3086


71-53 


• Width Light 

The current flows through charge and instrument panel fusible link in positive junction box, to pin 85 and 87 of 

lamplet relay in co-pilot side junction box, pass the coil of relay and then to pin 5 of combination switch. When 

the combination switch is set lamplet light or headlamp (Low Beam/High Beam) position, the current flows 

output pin 8 of combination switch to connect the ground. The coil of lamplet relay creates a magnetic field, 

and switch is activated. The current flows through switch of relay, and through the lamplet fuse in co-pilot side 

junction box, to pin 2 of front position lamp LH and pin 2 of front position lamp RH. The power is ground at pin 

1 of front position lamp LH and pin 1 of front position lamp RH. This enables width light to operate. 

• Tail Light 






junction box, to pin 1 of front combination lamp LH and pin 1 of front combination lamp RH. The power is 

ground at pin 2 of front combination lamp LH and pin 2 of front combination lamp RH. This enables tail light to 

operate. 

• License Light 






junction box, to pin 1 of license light. The power is ground at pin 2 of license light. This enables license light to 

operate. 

71 

71 

Service Hints 


5 - 8:Closed with the combination switch at Headlamp and lamplet position. 



F012 Roof Wire Harness 1 G004 Roof Wire Harness 2 

J004 Rear Hatch Wire Harness V019 Front Wire Harness 

V024 Front Wire Harness Z011 Main Wire Harness 




G104 

G105 

Z103 

Z105 

F109 

K101 

F107 

V111 


(Top Cap of the Rear Beam Left Side) 


(Top Cap of the Rear Beam Right Side) 

Main Wire Harness & Roof Wire Harness 1 




Page 3087

71-54 


Ground Points 


F202 


Ground 

G202 

Roof Wire Harness Rear Right Department 

Ground 

J201 Rear Hatch Internal Ground V205 Front Wire Harness Left Side Ground 

V206 Front Wire Harness Right Side Ground Z203 Instrument Panel Signal Ground 

Page 3088


71-55 

STOP LAMP 

71 

71 

Page 3089

71-56 



• 4G69 Engine 

The current flows through battery fusible link in positive junction box, to ECM main fuse in battery compartment 

junction box, to stop lamp fuse in engine room junction box, to pin 2 of stop lamp switch. The stop lamp 

switch is closed with the brake pedal depressed. The current then flows from pin 1 of stop lamp switch to pin 3 

of rear combination lamp LH, pin 3 of rear combination lamp RH and pin 2 of high-mounted stop lamp. The 

power is ground at pin 2 of rear combination lamp LH, pin 2 of rear combination lamp RH and pin 1 of highmounted 

stop lamp. This enables stop lamp and high-mounted stop lamp to operate. 

• ISF 2.8 Engine 

The current flows through engine room fusible link in positive junction box, to stop lamp fuse in engine room 

junction box, to pin 2 of stop lamp switch. The stop lamp switch is closed with the brake pedal depressed. The 

current then flows from pin 1 of stop lamp switch to pin 3 of rear combination lamp LH, pin 3 of rear 

combination lamp RH and pin 2 of high-mounted stop lamp. The power is ground at pin 2 of rear combination 

lamp LH, pin 2 of rear combination lamp RH and pin 1 of high-mounted stop lamp. This enables stop lamp and 

high-mounted stop lamp to operate. 

Service Hints 

• Z006 Stop Lamp Switch 

2 - 1:Closed with the brake pedal depressed. 




U002 High-mounted Stop Lamp Wire Harness Z006 Main Wire Harness 


Z063 




F107 

F111 

G104 

Z103 

U101 

F109 







Ground Points 


F202 


Ground 

G202 


Groundt 

Page 3090


71-57 

BACK-UP LAMP 

71 

71 

Page 3091

71-58 



When ignition switch is ON/ST, the current flows throug back-up lamp fuse in co-pilot side junction box, to pin 

1 of back-up lamp switch. The current flows from pin 2 of back-up lamp switch, and then to the circuit as 

follows: 

a. The current pass through pin 6 of rear combination lamp LH, and ground at pin 2 of rear combination lamp 

LH. This enables rear back-up lamp LH to operate. 

b. The current pass through pin 6 of rear combination lamp RH, and ground at pin 2 of rear combination lamp 

RH. This enables rear back-up lamp RH to operate. 

c. The current pass through the reverse radar control unit. Reverse radar control unit is then powered. 

d. The current pass through the multimedia system. Multimedia system is then powered. 

Service Hints 

• Z056 Back-up Lamp Switch 

1 – 2: Closed with the shift lever in “R” position. 





Z056 




F107 

G104 

Z103 

F109 





Ground Points 


F202 


Ground 

G202 


Ground 

Z203 

Instrument Panel Signal Groundt 

Page 3092


71-59 

TURN SIGNAL AND HAZARD WARNING LAMPS 

71 

71 

Page 3093

71-60 



• Turn Signal Lamp Working Condition 

Current flows through hazard waring fuse in co-pilot side junction box, to pin 1 of flasher, to supply power for 

flasher. 

When ignition switch is ON/ST, the current flows through turn signal fuse in co-pilot side junction box, to pin 12 

of combination switch. When operating the combination switch, the current flow output from pin 11 and pin 13 

of combination switch, to pin 5 and pin 12 of flasher, vehicle turning lamp is under working condition. 

• Turn Signal Lamp LH 

When the combination switch is in Left Turn position, the current flows output from pin 4 and pin 9 of flasher, 








• Turn Signal Lamp RH 

When the combination switch is in Right Turn position, the current flows output from pin 2 and pin 10 of flasher, 








• Hazard Warning Lamp 

When hazard warning switch is pressed, the signal flows from pin 8 of hazard warning switch, to pin 7 of 

flasher. Flasher is working condition; The current flows output from pin 2 , 4, 9, 10 of flasher. 















Service Hints 

• Z034 Hazard Warning Switch 

7 - 10:Closed with the hazard warning switch released. 

7 - 8:Closed with the hazard warning switch pressed. 

4 - 5 - 6:Closed with the hazard warning switch pressed. 

• Z011 Combination Switch 

12 - 11:Closed with the combination switch at Left Turn position. 

12 - 13:Closed with the combination switch at Right Turn position. 

Page 3094


71-61 




71 




71 



Z051 




F107 

G104 

Z105 

Z103 

F109 

V111 







Ground Points 


F202 


Ground 

G202 


Ground 

V205 Front Wire Harness Left Side Ground V206 Front Wire Harness Right Side Ground 


Page 3095

71-62 


FOG LAMP 

Page 3096


71-63 


• Front Fog Lamp 



relay, pass the coil of relay and then to pin 5 of combination switch. When the combination switch is set lamplet 

or headlamp (Low Beam/High Beam) position, the current flows output pin 8 of combination switch to connect 

the ground. The coil of relay creates a magnetic field, and switch is activated. The current flows through 

switch of relay, from the pin 30 of relay to front fog relay coil, to pin 3 of ombination switch. When front fog lamp 


front fog lamp relay creates a magnetic field, and switch is activated. The current flows through fog lamp fuse 

in co-pilot side junction box, to front fog lamp relay, and through switch of front fog lamp relay, to pin 1 of front 

fog lamp LH and pin 1 of front fog lamp RH, the power is ground at pin 2 of front fog lamp LH and pin 2 of front 

fog lamp RH. This enables front fog lamp LH and front fog lamp RH to operate. 

• Rear Fog Lamp 

The current flows through charge and instrument panel fusible link in positive junction box, to rear fog lamp 

fuse in co-pilot side junction box, to rear fog lamp relay. When front low beam lamp work and rear fog lamp 


rear fog lamp relay creates a magnetic field, and switch is activated. The current flows through rear lamp fuse 

in co-pilot side junction box, to rear fog lamp relay, and through switch of rear fog lamp relay, to pin 5 of rear 

combination lamp LH and pin 5 of rear combination lamp RH, the power is ground at pin 2 of rear combination 

lamp LH and pin 2 of rear combination lamp RH. This enables rear fog lamp LH and rear fog lamp RH to operate. 

• Fog Lamp indicator 

a. Front fog lamp indicator: When front fog lamp is woring, the current flows to pin A7 of instrument cluster and 

ground at pin B30 of instrument cluster. This enables front fog lamp indicator to operate. 

b. Rear fog lamp indicator: When rear fog lamp is working, the current flows to pin B21 of instrument cluster 

and ground at pin B30 of instrument cluster. This enables rear fog lamp indicator to operate. 

71 

71 

Service Hints 


8 - 1:Closed with the combination switch at Lamplet and Headlamp position 



C001 Front Bumper Wire Harness C002 Front Bumper Wire Harness 




Z051 




F107 

G104 

V120 

Z103 

F109 

C101 





Front Wire Harness & Front Bumper Wire Harness 

(Left Front Combination Lamps Positioning Plate Side) 

Page 3097

71-64 



Z105 

V111 



Ground Points 


F202 


Ground 

G202 


Ground 

V204 Front Wire Harness Central Ground Z203 Instrument Panel Signal Ground 

Page 3098


71-65 

INTERIOR LAMPS 

71 

71 

Page 3099

71-66 


Page 3100


71-67 


• Front Dome Light 


in co-pilot side junction box, to pin 1 and 2 of front dome light. Front dome light is working condition. 

a. Press front dome light switch, and the power is ground by the pin 3 of switch. This enables front dome light 

to operate. 

b. Dome light switch is at DOOR postion; If any front door is not closed, the front door ajar switch will turn to 

ON. The current flows from pin 4 of front dome lamp, to front door ajar switch. The power is ground by ajar the 

switch. This enables front dome light to operate. 

• central dome Light 


in co-pilot side junction box, to pin 1 of central dome light. central dome light is working condition. 

a. When central dome light is at ON position; The current flows from pin 3 (high equipped) or 2 (low equipped) 

of central dome light, to pin 5 of central dome light switch, press the switch, and the power is ground by the pin 

2 of switch. This enables central dome light to operate. 

b. When central dome light is at DOOR position (high equipped); If sliding door is not closed, the door ajar 

switch will turn to ON. The current flows from pin 2 of central dome lamp, to door ajar switch. The power is 

ground by ajar the switch. This enables central dome light to operate. 

• Step lamp 


in co-pilot side junction box, to pin 1 of step light and output from pin 2 of step light; If sliding door is not closed, 

the door ajar switch will turn to ON. The current flows from pin 2 of step light, to door ajar switch. The power is 

ground by ajar the switch. This enables step light to operate. 

• Ignition Switch Illumination 


in co-pilot side junction box, to pin 1 of ignition switch illumination; The current outputs from the pin 2 of ignition 

switch illumination, to pin B1 of central locking controller, the central locking controller control the ignition 

switch illumination to operation. 

• Trunk lamp 


in co-pilot side junction box, to pin 1 of trunk lamp and output from pin 2 of trunk lamp; If rear hatch door is not 

closed, the door ajar switch will turn to ON. The current flows from pin 2 of trunk lamp, to door ajar switch. The 

power is ground by ajar the switch. This enables trunk lamp to operate. 

• Door open Indicatior 

If any door is not closed, the door ajar switch will turn to ON. The ground signal input pin A15 and A30 of 

instrument cluster and this enables indicatior to operate. 

71 

71 





J001 Rear Hatch Wire Harness J003 Rear Hatch Wire Harness 







Page 3101

71-68 




F107 

G104 

G106 

J101 

Z103 

F109 

K101 

K102 









Ground Points 


F202 


Ground 

J201 


Z203 


Page 3102


71-69 

ILLUMINATION 

71 

71 

Page 3103

71-70 


Page 3104


71-71 



The current flows from charge and instrument panel fusible link, to pin 85 of lamplet relay, through the coil of 

tail light relay, and then to pin 5 of combination switch. When the combination switch is set lampet or headlamp 

(Low Beam/High Beam) position, the current flows output pin 8 of combination switch to connect the ground. 

The coil of lamplet relay creates a magnetic field, and switch is activated. The current flows through the pin 87 

of lamplet relay and through the lamplet and switch light fuse in co-pilot side junction box and the system 

getsss the power to operation. 

• Instrument Cluster Illumination 

When the combination switch is set lamplet or headlamp position, the current flows output lamplet fuse in copilot 

side junction box, to pin A6 of instrument cluster. This enables instrument cluster illumination to operate. 

• Hazard Warning Switch Illumination 

When the combination switch is set lamplet or headlamp position, the current flows output lamplet fuse in copilot 

side junction box, to pin 2 of hazard warning switch, to pin 3 of hazard warning switch, the power is 

ground at pin 3 of hazard warning switch. This enables hazard warning switch illumination to operate. 

• Headlamp Dimmer Switch Illumination 


co-pilot side junction box, to pin 3 of headlamp dimmer switch illumination, to pin 6 of headlamp dimmer 

switch illumination, the power is ground at pin 6 of headlamp dimmer switch illumination. This enables 

headlamp dimmer switch illumination to operate. 

• Instrument Dimmer Switch Illumination 


co-pilot side junction box, to pin 3 of instrument dimmer switch illumination, to pin 6 of instrument dimmer 

switch illumination, the power is ground at pin 6 of instrument dimmer switch illumination. This enables 

instrument dimmer switch illumination to operate. 

• Rear Window Defroster Switch Illumination 


co-pilot side junction box, to pin 3 of rear window defroster switch illumination, to pin 1 of rear window 

defroster switch illumination, the power is ground at pin 1 of rear window defroster switch illumination. This 

enables rear window defroster switch illumination to operate. 

• Outside Mirror Defroster Switch Illumination 


co-pilot side junction box, to pin 3 of outside mirror defroster switch illumination, to pin 1 of outside mirror 

defroster switch illumination, the power is ground at pin 1 of outside mirror defroster switch illumination. 

This enables outside mirror defroster switch illumination to operate. 

• Rear Blower Forward Switch Illumination 


co-pilot side junction box, to pin 3 of rear blower forward switch illumination, to pin 1 of rear blower 

forward switch illumination, the power is ground at pin 1 of rear blower forward switch illumination. This 

enables rear blower forward switch illumination to operate. 

• Dome Light Switch Illumination 


co-pilot side junction box, to pin 3 of dome light switch illumination, to pin 1 of dome light switch 

illumination, the power is ground at pin 1 of dome light switch illumination. This enables dome light switch 

illumination to operate. 

• Cigarette Lighter Illumination 


co-pilot side junction box, to pin 3 of cigarette lighter illumination, to pin 1 of cigarette lighter illumination, 

the power is ground at pin 1 of cigarette lighter illumination. This enables cigarette lighter illumination to 

operate. 

• Radio Illumination 


co-pilot side junction box, to pin A3 of radio illumination, to pin A8 of radio illumination, the power is ground 

at pin A8 of radio illumination. This enables radio illumination to operate. 

71 

71 

Page 3105

71-72 


• A/C Control Panel llumination 


co-pilot side junction box, to pin 32 of A/C control panel llumination, to pin 20 of A/C control panel 

llumination, the power is ground at pin 20 of A/C control panel llumination. This enables A/C control 

panel llumination to operate. 

• Diagnosis Switch llumination 


co-pilot side junction box, to pin 3 of diagnosis switch llumination, to pin 1 of diagnosis switch llumination, 

the power is ground at pin 1 of diagnosis switch llumination. This enables diagnosis switch llumination to 

operate. 

Service Hints 


5 - 8:Closed with the combination switch at Lamplet or Headlamp position. 










Z051 


Ground Points 


Z201 Instrument Panel Power Ground Z202 Instrument Panel Power Ground 

Z203 Instrument Panel Signal Ground Z204 Radio/Data Link Connector Ground 

Z205 


Page 3106


71-73 


71 

71 

Page 3107

71-74 



When ignition switch is ON/ST, the current flows through front wiper fuse and rear wiper fuse in co-pilot side 

junction box. System is then powered. 

• Front Wiper Switch LO 




• Front Wiper Switch MIST 




• Front Wiper Switch HI 

When the front wiper switch of combination switch is in HI position, the current flows from front wiper fuse, to 


through wiper motor to ground. This enables front wiper to operate at high speed. 

• Front Wiper Switch INT 

When the front wiper switch of combination switch is set INT, The intermittent current flows from pin 5 of 

combination switch, to front wiper motor. This enables front wiper to operate in the intermittent mode. 

• Front Washer switch ON 

When the front washer switch is in ON position, the current flows output from pin 2 of front washer pump, and 

through the front washer pump, output from pin 1 of front washer pump, to pin 7 of combination switch, and 

ground at pin 5 of combination switch. This enables front washer to function. 

• Rear Wiper Switch ON 

The current flows output from rear wiper fuse, to pin 86 and 87 of rear wiper relay, and then output from pin 30 

of rear wiper relay. When the rear wiper switch is in ON position, the current flows into pin 9 of combination 

switch, and then to ground at pin 6 of combination switch; The current flows into coil of rear wiper relay. The 

coil of relay creates a magnetic field, and switch is activated. The current flows through switch of relay, from 

the pin 30 of relay, to pin 4 of rear wiper motor, and through the rear wiper motor, to ground at pin 3 of rear 

wiper motor. This enables rear wiper to operation. 

• Rear Washer Switch ON 

When the rear wiper switch is in ON position, the current flows from rear wiper fuse, to pin 2 of rear washer 

pump, and output from pin 1 of rear washer pump, to pin 8 of combination switch, and ground at pin 6 of 

combination switch. This enables rear washer to operation. 



U001 High-mounted Stop Lamp Wire Harness V028 Front Wire Harness 



Z051 




F108 

F111 

Z101 

Z106 

U101 

V112 







Page 3108


71-75 


Z105 

V111 



71 

Ground Points 


F202 


Ground 

V204 


71 


Page 3109

71-76 



Page 3110


71-77 

Service Hints 

• Z025 Radio A, Z026 Radio B 

A4 - Ground Points:Approx.12 V with the ignition switch at ACC/ON position. 

A7 - Ground Points:Approx. 12 V 

• D011 Front Speaker LH 

1 - 2:Approx. 4 Ω 

• H006 Front Speaker RH 

1 - 2:Approx. 4 Ω 

• F013 Rear Speaker LH 

1 - 2:Approx. 4 Ω 

• G005 Rear Speaker RH 

1 - 2:Approx. 4 Ω 

71 

71 



D011 Front Door LH Wire Harness F013 Roof Wire Harness 1 

G005 Roof Wire Harness 2 H006 Front Door RH Wire Harness 

J003 Rear Hatch Wire Harness Z025 Main Wire Harness 






F110 

G106 

K102 

V116 

V119 

Z101 

Z105 

Z106 

Z101 

G105 

K101 

J101 

D106 

H106 

V112 

V111 

F108 

V112 





Rear Hatch Transition Wire Harness & Rear Hatch Wire Harness 


Front Wire Harness & Front Door LH Wire Harness 








Main Wire Harness & Roof Wire Harness 1 




Page 3111

71-78 


Ground Points 

Code 

Z204 



Page 3112


71-79 

POWER SOCKET 

71 

71 

Page 3113

71-80 



• Z030 Cigarette Lighter 

When ignition switch is ACC/ON, the current flows through cigarette lighter fuse in co-pilot side junction box, 

pin 2 of cigarette lighter. When pressing the cigarette lighter, the current flows output from pin 1 of cigarette 

lighter, and ground at pin 1 of cigarette lighter. This enables cigarette lighter to operate. 

• Z018 12V Power Output Socket 

When ignition switch is ON/ST, the current flows through cigarette lighter fuse in co-pilot side junction box, pin 

2 of power output socket. When pressing the power output socket, the current flows output from pin 1 of 

power output socket, and ground at pin 1 of power output socket. This enables power output socket to 

operate. 





Ground Points 

Code 

Z202 



Page 3114


71-81 


HORN 

71 

71 

Page 3115

71-82 



• Horn Control 

The current flows through charge and instrument panel fusible link in positive junction box, to horn fuse in copilot 

side junction box, to pin 85 of horn relay, and through the coil of horn relay, and then to the circuit as 

follows: 

Current flows from 2 pin of clock spring, to horn switch, when pressing the horn switch, the power is ground by 

switch. The coil of horn relay creates a magnetic field, and switch is activated. The current then flows through 

switch of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables horn to operate. 

• Horn of Anti-thief System 

Pin 86 of horn relay is controlled by pin 4 of central locking controller to coonect the ground; When pin 86 of 

relay to connect the ground, The coil of horn relay creates a magnetic field, and switch is activated. The 

current then flows through switch of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables 

horn to operate. 








Z105 

V111 



Ground Points 

Code 

V204 



Page 3116


71-83 


71 

71 

Page 3117

71-84 



When ignition switch is ON/ST, the current flows through back-up lamp fuse in co-pilot side junction box, to pin 

1 of back-up lamp switch. When shift lever in “R” position, the current flows from pin 2 of back-up lamp switch 

to pin 1 of reverse radar control unit. The reverse radar control system is then powered. 

• Reverse Radar Sensor LH 

The current outputs from pin 7 of reverse radar control unit, to pin 1 of reverse radar sensor LH, and through 

the sensor, output from pin 2 of reverse radar sensor LH, to pin 11 of reverse radar control unit, this detects the 

obstacle in rear left side. 

• Reverse Radar Central Sensor LH 

The current outputs from pin 8 of reverse radar control unit, to pin 1 of reverse radar central sensor LH, and 

through the sensor, output from pin 2 of reverse radar central sensor LH, to pin 11 of reverse radar control unit, 

this detects the obstacle in rear left central side. 

• Reverse Radar Central Sensor RH 

The current outputs from pin 4 of reverse radar control unit, to pin 1 of reverse radar central sensor RH, and 

through the sensor, output from pin 2 of reverse radar central sensor RH, to pin 11 of reverse radar control 

unit, this detects the obstacle in rear right central side. 

• Reverse Radar Sensor RH 

The current outputs from pin 15 of reverse radar control unit, to pin 1 of reverse radar sensor RH, and through 

the sensor, output from pin 2 of reverse radar sensor RH, to pin 11 of reverse radar control unit, this detects 

the obstacle in rear right side. 

Service Hints 

• Z056 Back-up Lamp Switch 

1 - 2:Closed with the shift lever in “R” position. 



R001 Rear Bumper Wire Harness R002 Rear Bumper Wire Harness 

R003 Rear Bumper Wire Harness R004 Rear Bumper Wire Harness 






Z110 

Q101 

Q102 

R101 

Main Wire Harness & Rear Bumper Transition Wire Harness 

(Left Rear Side of the Car Body) 

Rear Bumper Transition Wire Harness & Rear Bumper Wire Harness 

(Left Side Of the Rear Bumper) 

Ground Points 


Z203 Instrument Panel Signal Ground Z205 A/C System Ground 

Page 3118


71-85 

POWER MIRROR 

71 

71 

Page 3119

71-86 



When ignition switch is ACC/ON, the current flows through radio ACC fuse in co-pilot side junction box, to pin 

4 of outside mirror switch. System is then powered. 

• Outside Mirror LH (Up/Down) 




mirror LH to go up. 




mirror LH to go down. 

• Outside Mirror RH (Up/Down) 




mirror RH to go up. 




mirror RH to go down. 

• Outside Mirror LH (Left/Right) 

TThe current flows from pin 4 of electric outside mirror switch and output from pin 5 of electric outside mirror 



mirror LH to turn to left. 




mirror LH to turn to right. 

• Outside Mirror RH (Left/Right) 




mirror RH to turn to left. 




mirror RH to turn to right. 




H009 Front Door RH Wire Harness Z043 Main Wire Harness 



D104 

V117 

V114 

H104 





Page 3120


71-87 


V118 

Z101 

H105 

V112 





71 

Ground Points 

71 

Code 

V204 



Page 3121

71-88 


WINDOW DEFROSTER 

Page 3122


71-89 


• Outside Mirror Defrost 


box, to pin 2 of outside mirror defroster switch, when press the switch, pin 5 and pin 2 of outside mirror 

defroster switch connected, the current output from pin5, then flows to pin 85 of outside mirror defroster 

relay,and ground at pin 86. Then through the coil in outside mirror defroster relay pin30, and output from pin 87 

of outside mirror defroster relay. The coil of outside mirror defroster relay creates a magnetic field, and switch 

is activated. The current flows from outside mirror defrost fuse, through switch of outside mirror defroster relay, 

to pin 3 of outside mirror defrost grid and ground at pin 2 of grid. This enables outside mirror defroster to 

operate. 

71 

71 

Service Hints 

• Z024 Outside mirror Defrost Switch 

2 - 5:Closed with the outside mirror defrost switch in operation. 





Z051 




V114 

V116 

V118 

V119 

Z102 

D104 

D106 

H105 

H106 

V113 











Ground Points 



Z204 


Page 3123

71-90 



Page 3124


71-91 

71 

71 

Page 3125

71-92 


Page 3126


71-93 

71 

71 

Page 3127

71-94 



• instrument cluster power 

a. When ignition switch is ON/ST, the current flows through instrument IG fuse in co-pilot side junction box, to 

pin A1 and A20 of the instrument cluster. System is then powered. 

b.The current flows through charge and instrument panel fusible link in positive junction box, to co-pilot side 

junction box and then to pin A16 of instrument cluster. System is then powered. 

• Engine Coolant Fluid Level Warning Light 

The current flows through engine coolant fluid level warning light in instrument cluster, and output from pin B16 

of instrument cluster, to pin 1 of engine coolant temperature sensor, and ground at pin 2 of engine coolant 

temperature sensor (ISF2.8) or itself (4G69). This enables engine coolant fluid level warning light to operate. 

• Engine Coolant Temperature Indicator 

The current flows from pin B16 of instrument cluster, to pin 1 of engine coolant temperature sensor, and 

ground at pin 2 of engine coolant temperature sensor (ISF2.8) or itself (4G69). This enables engine coolant 

fluid temperature indicator to operate. 

• Engine Oil Pressure Warning Light 

The current flows through engine oil pressure warning light in instrument cluster, and output from pin B22 of 

instrument cluster, to pin 1 of engine oil pressure switch, and then to ground. This enables engine oil pressure 


• Low Fuel Indicator and Warning Light 

The current flows through low fuel warning light in instrument cluster, and output from pin A23 of instrument 

cluster, to pin 3 of fuel level sensor, and then ground at pin 2 of level sensor. This checks the fuel leveland 

shows the fuel level in instrument cluster, if the fuel is less, the warning light will be activated. 

• ABS Warning Light 

The current flows into pin A20 of instrument cluster, through ABS warning light in instrument cluster, and 

output from pin B20 of instrument cluster, to 27 of ABS module. If ABS system is fault, this enables ABS 


• EBD Warning Light 

The current flows into pin A20 of instrument cluster, through EBD warning light in instrument cluster, and 

output from pin B24 of instrument cluster, to 3 of ABS module. If ABS system is fault, this enables EBD 


• Charging Warning Light 

The current flows into pin A20 of instrument cluster, through charging warning light in instrument cluster, and 

output from pin B25 of instrument cluster, to pin 1 of generator. This identifies if the generator operates or not. 

• Safe Belt Indicator 

The current flows into pin A20 of instrument cluster, through safe belt indicator in instrument cluster, and 

output from pin A31 of instrument cluster, to pin 1 of driver seat belt warning switch and ground at pin 2. If 

driver do not fasten the safe belt, switch will close, this enables safe belt indicator to operate. 

• Buzzer of Safe Belt 

The current flows through buzzer in instrument cluster, and output from pin B9 of instrument cluster, to pin 1 of 

driver seat belt warning switch and ground at pin 2. If driver do not fasten the safe belt, switch will close, this 

enables buzzer to operate. 

• Air Bag System Warning Light 

The current flows into pin A20 of instrument cluster, through warning light in instrument cluster, and output 

from pin B27 of instrument cluster, to pin 7 of RCM. If Air bag system is fault, this enables air bag system 

warning light to operate 

• Parking Indicator 


B6 of instrument cluster, to pin 1 of parking brake switch. Through switch to ground, this enables parking indicator 

to operate 

• Brake Fluid Warning Light 

The current flows into pin A20 of instrument cluster, through brake warning light in instrument cluster, and 

output pin B28 of instrument cluster, to pin 1 of brake fluid level sensor, and ground at pin 2 of brake fluid level 

sensor. This checks the brake fluid level. 

Page 3128


71-95 

• Lamplet indicator 

The current flows into pin A6 of instrument cluster, through indicator in instrument cluster, and output pin B30 

of instrument cluster to ground. If lamplet or interior lamp work, the indicator will be activated. 

• Enging Pre-heating indicator 

ISF2.8 engine: The current flows into pin A1 of instrument cluster, through indicator in instrument cluster, and 

output pin A27 of instrument cluster, to pin 35 of ECM. If pre-heating system is working, the indicator will be 

activated. 

• Malfunction Indicator 

The current flows into pin A1 of instrument cluster, through malfunction indicator in instrument cluster, and 

output from pin B23 of instrument cluster, to pin 19 of ECM (4G69) or 22 of ECM (ISF2.8). If engine control 

system fault exist, this enables malfunction indicator to operate. 

• Maintenance Indicator 


A28 of instrument cluster, to pin 12 of ECM (4G69) or 36 of ECM (ISF2.8). If engine need to service, this 

enables indicator to operate. 

• Engine Stop Indicator 

ISF 2.8 engine: The current flows into pin A20 of instrument cluster, through indicator in instrument cluster, 

and output from pin A24 of instrument cluster, to pin 49 of ECM. ECM control the stop indicator. 

• Vacuum Warning Light 

ISF 2.8 engine: The current flows from pin A26 of instrument cluster, through indicator in instrument cluster, to 

pin 1 of vacuum warning switch. Through the switch to connect ground, this enables the warning light to operate. 

71 

71 















E101 

E103 

Z101 

Z111 

Z108 

V112 







Page 3129

71-96 


Ground Points 


V204 Front Wire Harness Central Ground Z203 Instrument Panel Signal Ground 

Z204 Radio/Data Link Connector Ground Z208 Vehicle Frame Left Side Ground 

Z210 


Page 3130


71-97 

ANTI-THEIF SYSTEM 

71 

71 

Page 3131

71-98 


Page 3132


71-99 


• System Power 

The current flows through charge and instrument panel fusible link in positive junction box, to co-pilot side 

junction box and circuit as follows: 

a. Through the central locking fuse, to pin B3 of central locking controller, system getsss the power of central 

locking. 

b. Through power window fusible link, to pin A8 of central locking controller, system getsss the power of electrical 

window. 

c. Through power window fusible link, to pin 12 of door control switch, switch is then powered. 

• Key Lock Signal 

a. When key lock switch is LOCK position, the current flows output from pin A9 of central locking controller, to 

pin 9 of front door lock actuator assembly RH and through the key lock switch, to ground at pin 7 of front door 

lock actuator assembly RH. This enables closed with door of all with mechanical operate. 

b. When key lock switch is OPEN position, the current flows output from pin A10 of central locking controller, 

to pin 10 of front door lock actuator assembly RH, and through the key lock switch, to ground at pin 7 of front 

door lock actuator assembly RH. This enables opened with door of all with mechanical operate. 

• Status of Front Door RH 

Current flows from pin B2 of central locking controller, to pin 1 of front door RH switch, through switch to 

ground, system getss the signal of front door status. 

• Status of Hood 

Current flows from pin B6 of central locking controller, to pin 1 of hood switch, through 2 pin of switch to 

ground, system getss the signal of hood status. 

• Collision Signal 

Signal is from pin 30 of restraint control module, to pin B8 of central locking controller. System getssgetss the 

Info of collision. 

• vehicle speed signal 

Signal is from pin A9 of instrumen cluster, to pin A17 of central locking controller. When the vehicle speed 

attach the value as design, system will lock all door that unlocked before. 

• Key Insert signal 

Current flows from pin B8 of central locking controller, to pin 3 of key insert switch, through the switch and 

ground at pin 4 of switch. System getss the key insert signal. 

• Door control switch 

Pin 1 and 2 of door control switch connect the pin A15 and A16 of central locking controller, through this 

connection, the controller getsss the signal that control the door window and lock from door control swith. 

• Door Actuator Control 

a. Front door LH unlock: The current flows output from pin A3 of central locking controller, to pin 1 of front door 

lock actuator assembly LH, and through the motor in front door lock actuator assembly LH, output from pin 4 of 

front door lock actuator assembly LH, to pin A2 of central locking controller. This enables front door LH open. 

On the contrary, the front door LH is closed. 

b. Front door RH unlock: The current flows output from pin A3 of central locking controller, to pin 1 of front door 

lock actuator assembly RH, and through the motor in front door lock actuator assembly RH, output from pin 4 

of front door lock actuator assembly RH, to pin A2 of central locking controller. This enables front door RH 

open. On the contrary, the front door RH is closed. 

c. Sliding door unlock: The current flows output from pin A3 of central locking controller, to pin 2 of sliding door 

lock actuator assembly, and through the motor in sliding door lock actuator assembly, output from pin 4 of sliding 

door lock actuator assembly, to pin A2 of central locking controller. This enables sliding door open. On the 

contrary, the sliding door is closed. 

d. Rear hatch unlock: The current flows output from pin A3 of central locking controller, to pin 2 of rear hatch 

lock actuator assembly, and through the motor in door lock actuator assembly, output from pin 1 of lock 

actuator assembly, to pin A2 of central locking controller. This enables rear hatch open. On the contrary, the 

rear hatch is closed. 

• Power Window Control 

a. Power window LH up: The current flows output from pin A7 of central locking controller, to pin 1 of power 

window LH, and through the motor, output from pin 2 of power window LH, to pin A6 of central locking 

controller. This enables power window LH up. On the contrary, power window LH is down. 

b. Power window RH up: The current flows output from pin A5 of central locking controller, to pin 1 of power 

window RH, and through the motor, output from pin 2 of power window RH, to pin A4 of central locking 

controller. This enables power window RH up. On the contrary, power window RH is down. 

71 

71 

Page 3133

71-100 




D007 Front Door LH Wire Harness D009 Front Door LH Wire Harness 


H010 Front Door RH Wire Harness H011 Front Door RH Wire Harness 

J002 Rear Hatch Wire Harness V034 Front Wire Harness 








F107 

G104 

G106 

J101 

V114 

V115 

V116 

V117 

V118 

V119 

Z102 

Z105 

Z103 

F109 

K101 

K102 

D104 

D105 

D106 

H104 

H105 

H106 

V113 

V111 






















(Right Side of the Instrument Panel ) 


(Right Side of the Instrument Panel ) 

Page 3134


71-101 

Ground Points 


V204 Front Wire Harness Central Ground Z201 Instrument Panel Power Ground 

71 

71 

Page 3135

71-102 


RESTRAINT CONTROL SYSTEM 

Page 3136


71-103 


When a car collides with an obstacle, it will quickly open an airbag filled with air, so that the occupants can 

throw themselves on the airbag when moving due to inertia, thereby easing the impact on occupants and 

absorbing collision energy to reduce personal injuries. 

When ignition switch is ON/ST, the current flows through airbag fuse in co-pilot side junction box, to pin 5 of 

restraint control module. System is then powered 

• Deployment of Airbag 


control module, to pin 4 of clock spring, to driver airbag. Current then flows from driver airbag, to pin 3 of clock 

spring, and back to pin 10 of restraint control module. Driver airbag is then activated. 


control module, to pin 1 of passenger airbag. Current then flows from pin 2 of passenger airbag, and back to 

pin 14 of restraint control module. Passenger airbag is then activated. 

• All Door Unlock 


control module, to pin A11 of central locking controller. Central locking controller getss the sginal of collision 

and unlock the all door. 


When the system comes into operation, restraint control module detects the operation of all parts of the 

system. Once the system or parts have faults, the system will switch on the SRS warning light to remind 

drivers of repair in time. 

71 

71 



M002 Diagnosis Wire Harness Z002 Main Wire Harness 




Z051 




M010 

Z113 



Ground Points 


Z203 Instrument Panel Signal Ground Z206 Airbag Ground 

Page 3137

71-104 

CONNECTOR VIEWS 


WIRING(RHD) - CONNECTOR VIEWS 

B001 Starter 


B R - 

B101 to Main Wire Harness 


1 W-B - 

2 R - 

B002 Starter Excitation 


B R - 

Page 3138


71-105 


71 

C001 Front Fog Lamp LH 



2 W-B Ground 

C002 Front Fog Lamp RH 



2 W-B Ground 



1 - - 

2 - - 

3 - - 

4 LG - 

5 W-B - 

6 LG - 

71 

Page 3139

71-106 



D009 Window Control Switch LH 


3 P-L 

Left Side Window 


D007 Power Window Motor LH 


1 G-R SIde Window Up 

4 L-Y 



5 - - 

2 R-L Side Window Down 

D010 Front Door Lock Assy LH 


D008 Outside Mirror Assy LH 


1 - - 

2 W-B 

3 B 

Outside Mirror Assy 

LH Ground 



4 R-Y Left Outside Mirror- 

1 G 

Front Left Door 

Unlock 

2 - - 

3 - - 

4 R Front Left Door Lock 

5 - - 

6 - - 

7 - - 

5 L-R 

6 R 





8 - - 

9 - - 

10 - - 

D009 Window Control Switch LH 


1 L-G 



2 - - 

D011 Front Speaker LH 


1 V 


Power +t 

2 P Front Left Speaker - 

Page 3140


71-107 

71 

D104 to Front Wire Harness A 


1 R - 

2 - - 

3 L-R - 

4 R - 

5 G - 

6 - - 

7 R-Y - 

8 B - 

D106 to Front Wire Harness C 


1 W-B - 

2 P - 

3 G-R - 

4 - - 

5 V - 

6 R-L - 

71 

D105 to Front Wire Harness B 


1 - - 

2 - - 

3 L-YL - 

4 P-L - 

5 - - 

6 - - 

7 - - 

8 L-G - 

Page 3141

71-108 



E001 ECM 


1 L Ignition Coil 42 Br-Y 


Low 

2 B Ground 43 - - 

3 B Ground 44 G-W Main Relay Control 

4 G Ignition Coil 45 - - 

5 - - 46 - - 

6 L-W Injector A- 47 W 

7 L-P Injector C- 48 O 

8 L-V Injector B- 49 W-R 






Sensor+ 

9 G 

10 L 


ECU Control 



50 - - 


11 P 


Sensor- 

52 W-B 


Sensor- 

12 Br Engine Maintenance 53 - - 

13 - - 54 L-Y Air Pressure MAP 

14 - - 55 - - 

15 - - 56 - - 

16 - - 57 - - 

17 W-B 


Control 


18 V-W Vehicle Speed 59 Br-G Acceleration Sensor+ 

19 L-W MIL 60 - - 

20 G-Br 


High 

61 - - 

Page 3142


71-109 

E001 ECM 


21 G-Y 


Low 

62 - - 

71 

22 - - 63 - - 

23 Y-B 



64 W-Y 

Canister Solenoid 

Valve- 

71 

24 L-R 



65 Y 


Power Output 

25 L-O Injector D- 66 SB 

Intake Air 

Temperature 


Power 2 

26 R-W 

27 V-G 



Switch 



68 B-G ECU-IG 

28 - - 69 - - 

29 - - 70 SB 


Power 

30 O 


Sensor+ 


31 - - 72 - - 

32 - - 73 B 

33 - - 74 Br-R 

Upstream And 



Throttle Position Sen- 

sor- 

34 - - 75 R-L ECU-K Line 

35 - - 76 Br-R 



Signal- 

36 - - 77 - - 

37 O-V Knock Sensor 78 - - 

38 - - 79 Y-B AC Request 

39 - - 80 - - 

40 - - 81 - - 

41 Y-P 


High 

Page 3143

71-110 


E002 Injector A 


1 G Injector+ 

2 L-W Injector A- 

E006 Mainfold Absolute Pressure/Intake Air 



1 L-Y Air Pressure MAP 

2 SB 



Power 2 


E003 Injector B 


1 G Injector+ 

2 L-V Injector B- 

4 Br-R 

Intake Air 

Temperature 


Signal- 

E007 Upstream Oxygen Sensor 


E004 Injector C 


1 G Injector+ 

2 L-P Injector C- 

1 B 

2 W 

3 L-R 

4 G 








Sensor+ 

E005 Injector D 


1 G Injector+ 

2 L-O Injector D- 



1 O 


Sensor+ 

Page 3144


71-111 



2 P 


Sensor- 

3 - Ground 

E012 Engine Coolant Temperature Sense 

Plug 


71 

71 

1 Y-G 


Gauge Sensor 

E009 Throttle Position Sensor 


1 SB 

2 Br-R 

3 V-G 


Power 


Sensor- 


E013 Compressor 


1 G-B 

Compressor Excitation 



1 W-B 


Sensor- 

E014 Starter Coil 


1 R 

Starter Excitation Output 

2 W-R 


Sensor+ 


E011 Knock Sensor 


1 O-V Knock Sensor 



1 Br-Y 

2 Y-P 


Low 


High 

Page 3145

71-112 




3 G-Y 

4 G-Br 


Low 


High 

E017 Ignition Coil 


1 G Ignition Coil 

2 L Ignition coil+ 

3 L Ignition Coil 

E016 Canister Solenoid Valve 


1 W-Y Canister Valve- 

2 G Canister Valve+ 



1 W-L 




49 R-G 


Injector - 

2 R-W 




50 R-Y 




3 - - 51 - - 

4 - - 52 - - 

5 B EGR Valve Motor+ 53 B 



6 - - 54 - - 

7 - - 55 - - 

Page 3146


71-113 



8 - - 56 - - 

71 

9 - - 57 - - 

10 - - 58 - - 

11 - - 59 - - 

71 

12 - - 60 - - 

13 R Sensor + 61 - - 

14 B Sensor - 62 Y-Br 



15 R CAN + 63 B Sensor - 

16 B CAN - 64 B 


Sensor - 

17 - - 65 B Sensor - 

18 - - 66 B Sensor - 

19 - - 67 B Sensor - 

20 - - 68 B 

21 - - 69 Y-Br 

22 - - 70 L 


Sensor - 


Signal 


Pressure Signal 

23 P-B 



71 - - 

24 - - 72 Y-Br 


Signal 

25 W-V 


Injector - 

73 W-L 


Injector - 

26 R-L 


Injector - 

74 W-Y 




27 - - 75 - - 

28 - - 76 - - 

29 B EGR Valve Motor - 77 B 



30 - - 78 - - 

31 B Inlet Metering Valve - 79 - - 

32 B Inlet Metering Valve + 80 B Sensor + 

33 - - 81 - - 

Page 3147

71-114 




34 - - 82 - - 

35 - - 83 - - 

36 - - 84 - - 

37 Y-Br 

38 Y-Br 


Signal 



Signal 

85 - - 

86 B Air Mass Flow Signal 

39 - - 87 R Sensor + 

40 B Sensor - 88 R 


Sensor + 

41 - - 89 R Sensor + 

42 - - 90 B Sensor + 

43 B 



91 B Sensor + 

44 B 


Sensor - 

92 R 


Sensor + 

45 - - 93 - - 

46 W-Y 



+ 

94 - - 

47 W-Y 


Sensor + 

95 B 



Signal 

48 - - 96 B 


Signal 

E039 Inlet Metering Valve 


1 B Inlet Metering Valve + 

2 B Inlet Metering Valve - 

E040 Coolant Temperature Sensor 


1 B Sensor - 

2 W-Y Sensor + 

Page 3148


71-115 

71 

E041 Water in Fuel Sensor 


1 W-Y 

2 B 


sensor + 


sensor - 

E044 Accuumulator Pressure Sensor 


1 B Sensor - 

2 Y-Br Pressure Signal 

3 R Sensor - 

71 

E042 Oil Pressure Switch 



E045 Ambient Air Pressure Sensor 


1 R Sensor + 

2 B Sensor - 


E043 CAN Datalink 


1 R CAN + 

2 B CAN - 

E046 Intake Manifold Press/Temp Sensor 


1 B 


Presure Signal 

2 R Sensor + 

3 P-B 

Intake Manifold Air 


4 B Sensor - 

Page 3149

71-116 


E047 Camshaft Position Sensor 


1 R Sensor + 

2 B Sensor - 



1 R-L Injector 2 - 

2 R-W Injector 2 + 

3 Y-Br 






1 W-V Injector 3 - 

2 W-L Injector 3 + 


1 R Sensor + 

2 B Sensor - 

3 Y-Br 





1 W-L Injector 4 - 

2 W-Y Injector 4 + 



1 R-G Injector 1 - 

2 R-Y Injector 1 + 



1 B Signal 

Page 3150


71-117 



2 B Sensor + 

3 B Sensor - 

4 - - 

E056 CAN Resistor 


1 R Resistor + 

2 B Resistor - 

71 

71 

E054 Intake Throttle Actuator 


1 B 

2 B 





Signal 

3 B Sensor - 

4 B Sensor + 

5 B 



E055 EGR Valve 


1 B EGR Control Valve - 

2 B EGR Control Valve + 

3 B 


Signal 

4 B Sensor - 

5 B Sensor + 

E101 to Main Wire Harness 1 


1 Br - 

2 L-W - 

3 Y-G - 

4 - - 

5 Y-B - 

6 R-W - 

7 Y - 

8 W-B - 

9 L - 

10 R - 

11 L - 

12 W-L - 

13 G-B - 

14 - - 

15 V-W - 

16 L - 

Page 3151

71-118 


E102 to Main Wire Harness 2 


1 - - 

2 Br-R - 

3 Br-G - 

4 SB - 

5 G - 

6 - - 

7 - - 

8 - - 

E103 to Main Wire Harness A (Diesel) 


1 - - 

2 G-B - 

3 Y-G - 

4 - - 

5 - - 

6 L-Y - 

7 W-B - 

8 - - 

9 R-L - 

10 B - 

11 Y-B - 

12 O - 

13 - - 

14 B-G - 

15 G-W - 

16 G - 

Page 3152


71-119 


F008 Rear Evaporator Module 


1 W-B Ground 

2 L Power Input 

3 Y-W 


+ 

4 Br Temperature Sensor - 

5 L Power Input 

6 Lg 

Rear Evaporator Air 

Flow Switch Power 



3 Y 


Output 

F010 Central Dome Light (Low Equipped) 


1 R Lighting Power Input 

2 Y Power Output 

71 

71 

F009 Front Dome Light 


1 R 

2 R 


Power Input 

Central Dome Light 

Power Input 

3 W-B Ground 

4 R-W Front Dome Light- 



1 R 


Input 

2 R-Y Dome Light- 

3 Y 


Output 



1 R 

Trunk Lighting Power 

Input 

2 R-Y Central Dome Light- 



1 V-W Rear Left Lamplet+ 

2 W-B 

Rear Left Combination 

Lamp Ground 

Page 3153

71-120 




3 G-W Rear Left Stop Lamp+ 

F107 to Main Wire Harness A 


3 Br - 

4 G-Y 

5 R-Y 

6 B-Y 

Rear Left Turn Signal 

Power Input 

Rear Left FogLamp 

Power Input 

Rear Left Back-up 

Lamp+ 

4 Y-W - 

5 B-Y - 

6 Y - 

7 L - 

8 W-B - 

9 R - 

10 R-W - 

11 LG - 

F013 Rear Speaker LH 


1 Y 


Power Input 

2 B Rear Left Speaker- 

12 R-Y - 

13 R-B - 

14 R-Y - 

15 G-B - 

16 G-Y - 

17 R - 

18 G - 

F014 Sliding Door Ajar Switch LH 


1 V-W Switch Signal Output 

F108 to Main Wire Harness B 


1 Y - 

2 B - 

3 - - 

4 R-B - 

5 R - 

F107 to Main Wire Harness A 


1 V-W - 

2 G-W - 

6 W - 

7 R - 

8 G-W - 

9 G-O - 

10 G-R - 

Page 3154


71-121 

F108 to Main Wire Harness B 


11 Br - 

12 G-Y - 

13 - - 



4 R - 

5 W - 

6 G-W - 

71 

71 



1 G-W - 

2 R-B - 

3 R - 

4 G-B - 

5 - - 

6 R-Y - 

7 - - 

8 B-Y - 

9 - - 

10 V-W - 

11 R - 

12 G - 

F111 to High-mounted Stop Lamp Wire 

Harness 


1 G-W - 

2 - - 

3 G-Y - 

4 B - 

5 W-B - 

6 - - 

7 G-R - 

8 Br - 



1 - - 

2 G-O - 

3 - - 

Page 3155

71-122 





2 R-B - 

G004 Rear Combination Lamp RH 


1 V-W Rear Right Lamplet+ 

2 W-B 

3 G-W 

4 G-B 

5 R-Y 

Rear Right 

Combination Lamp 

Ground 

Rear Right Stop 

Lamp+ 

Rear Right Turn 

Signal Power Input 

Rear Right Fog Lamp 

Power Input 

3 R - 

4 G-B - 

5 - - 

6 R-Y - 

7 - - 

8 B-Y - 

9 - - 

10 V-W - 

11 R - 

12 G - 

6 B-Y 

Rear Right Back-up 

Lamp+ 

G105 to Roof Wire Harness 1B 

G005 Rear Speaker RH 


1 W 


Power Input 

2 R Rear Right Speaker- 


1 - - 

2 G-O - 

3 - - 

4 R - 

5 W - 

6 G-W - 



1 G-W - 

Page 3156


71-123 

71 

G106 to Rear Hatch Transition Wire 

Harness 

71 


1 - - 

2 V-W - 

3 R - 

4 B-Y - 

5 - - 

6 R-B - 

7 G - 

8 R - 

9 G-O - 

10 G-W - 

Page 3157

71-124 



H006 Front Speaker RH 


1 L 


Power Input 

2 L-G Front Right Speaker- 

D009 Electric Outside Mirror Switch 


1 L-R 



2 - - 

3 L-Y 

4 G-R 


Left and Right Adjust 

Outside Mirror Switch 

Power 

H007 Power Window Motor RH 


1 R Side Window Up 

2 L Side Window Down 

5 R-Y Outside Mirror- 

6 W-B Ground 

7 R 

8 R-L 





H008 Outside Mirror Assy RH 


1 - - 

2 W-B 

3 B 


Ground 



4 R-Y Right Outside Mirror- 

5 L-Y 

6 R-L 



Input 



Input 



1 L-B 

2 L 

3 L-Y 

4 P-L 

5 L-G 

6 W-B 

Right Side Door Assy 


Right Side Door Assy 









Ground 

7 - - 

Page 3158


71-125 

8 - - 

9 G-R 


Lamplet Control 

10 - - 

11 - - 

12 W-L 




Power 



3 L-R - 

4 G-R - 

5 G - 

6 L-O - 

7 R-Y - 

8 R - 

71 

71 

H011 Front Door Lock Assy RH 


1 G Front Right Door Lock 

2 - - 

3 - - 

4 R 

Front Right Door 

Unlock 

5 - - 

6 - - 

7 W-B Ground 

8 - - 

9 L-O Key Lock 

10 L-R Key Unlock 

H105 to Front Wire Harness B 


1 L-B - 

2 L-Y - 

3 P-L - 

4 W-L - 

5 W-B - 

6 L - 

7 G-R - 

8 L-G - 



1 R - 

2 L-R - 



1 - - 

2 L - 

3 R - 

Page 3159

71-126 




4 B - 

5 L-G - 

6 G - 

Page 3160


71-127 


71 

J001 Rear Hatch Lock Assy-Switch 


J004 License Lamp 


71 

1 R-B 

2 W-B 

Rear Hatch/Trunk 

Lights Power Input 

Rear Hatch Lock 

Ground 

1 V-W Power 

2 W-B Ground 

J005 Camera 

J002 Rear Hatch Lock Assy-Motor 


1 R 

2 G 

Rear Hatch Latch 

Input 

Rear Hatch Unlocking 

Input 


1 W-B Camera Ground 

2 B-Y Camera Power Input 

3 G-W Video Output 

4 G-O Video Input 

J003 Trunk Lamp 


1 R 

2 R-B 


Input 


Output 



1 B-Y - 

2 R - 

3 V-W - 

4 - - 

5 G-W - 

6 G-O - 

7 R - 

Page 3161

71-128 




8 G - 

9 R-B - 

10 W-B - 

Page 3162


71-129 


71 

K101 to Roof Wire Harness 2 


1 - - 

2 V-W - 

3 R - 

4 B-Y - 

5 - - 

6 R-B - 

7 G - 

8 R - 

9 G-O - 

10 G-W - 

K102 to Rear Hatch Wire Harness 


1 B-Y - 

2 R - 

3 V-W - 

4 - - 

5 G-W - 

6 G-O - 

7 R - 

8 G - 

9 R-B - 

10 - - 

71 

Page 3163

71-130 



M001 Data Link Connector Resistance 


1 G-B CAN-H 

2 G-O CAN-L 

3 - - 

M101 to Instrument Panel Wire Harness 


1 - - 

2 W-B - 

3 - - 

4 W-L - 

5 R-L - 

6 G-O - 

7 G-B - 

M002 Data Link Connector 

8 W-B - 


1 - - 

2 - - 

3 - - 

4 W-B Ground 

5 W-B Ground 

6 G-B CAN-H 

7 R-L 

Data Link Connector 

K 

8 - - 

9 - - 

10 - - 

11 - - 

12 - - 

13 - - 

14 G-O CAN-L 

15 - - 

16 W-L Power Input 

Page 3164


71-131 


71 

P001 Rear Heater Solenoid Valve 


1 W-L 


Power Input 

2 W-B Ground 

P002 Rear Heater Motor 



P101 to Main Wire Harness 


1 W - 

2 L-B - 

3 L - 

4 B - 

5 W-B - 

6 W-L - 

7 - - 

8 - - 

71 

2 L-B 

Rear Heater Motor+ 

Input 



Page 3165

71-132 



Q101 to Rear Bumper Wire Harness 


1 R-W - 

2 R-L - 

3 R-B - 

4 R-G - 

5 - - 

6 - - 

7 - - 

8 B - 

Q102 to Main Wire Harness 


1 R-G - 

2 R-B - 

3 R-L - 

4 R-W - 

5 B - 

6 - - 

7 - - 

8 - - 

Page 3166


71-133 


71 

R001 Reverse Radar Sensor LH 


R004 Reverse Radar Sensor RH 


71 

1 R-G 


LH Input 

1 R-L 

Reverse Radar 

Sensor RH Input 

2 B 


LH Ground 

2 B 

Reverse Radar 

Sensor RH Ground 

3 - - 

3 - - 

R002 Reverse Radar Central Sensor LH 


1 R-B 

2 B 


Left Sensor Input 

Reverse Radar 


Ground 

3 - - 

R101 to Rear Bumper Transition Wire 

Harness 


1 R-W - 

2 R-L - 

3 R-B - 

4 R-G - 

5 - - 

6 - - 

7 - - 

8 B - 

R003 Reverse Radar Central Sensor RH 


1 R-W 

2 B 


Right Sensor 

Input 

Reverse Radar 


Ground 

3 - - 

Page 3167

71-134 





6 - - 

U001 Rear Wiper 

7 G-R - 

8 Br - 


1 Br Rear Wiper Return 

2 G-Y 

Rear Wiper Power 

Input 

3 W-B Ground 

4 G-R 

Relay to The Rear 

Wiper Power Output 

U102 to Rear Defrost LH Wire Harness 


1 - - 

2 B - 

U002 High-mounted Stop Lamp 


1 W-B 

2 G-W 


Lamp- 


Lamp+ 

U103 to Rear Defrost RH Wire Harness 


1 - - 

2 B - 



1 G-W - 

2 B - 

3 G-Y - 

4 B - 

5 W-B - 

Page 3168


71-135 


71 

V018 Left Headlight Dimming Motor 


V021 Front Turn Signal Lamp LH 


71 


2 LG 

3 W-B 

Left Headlamp 


Left Headlamp 

Dimming Motor 

Ground 

1 W-B 

2 R-Y 


Lamp LH Ground 


Lamp LH Power Input 


V019 Front Position Lamp LH 


1 W-B Ground 

2 V-W 

Front Left Position 

Lamp+ 


1 W-B 

2 L-B 

3 G-B 


Ground 

Front Right High 

Beam 

Front Right Low 

Beam 

V020 Headlamp LH 


1 W-B 

Left Headlamp 

Ground 

2 R-G Front Left High Beam 

3 R-B Front Left Low Beam 

V023 Right Headlight Dimming Motor 


1 G-R Motor Power 

2 Br 

3 W-B 



Right headlamp 

Dimming Motor 

Ground 

Page 3169

71-136 


V027 Alt Horn 


2 W-B Ground 

V024 Front Position Lamp RH 


1 W-B Ground 

2 V-W Front Position Lamp+ 

V028 Front Washing Reservoir Motor 



V025 Front Turn Signal Lamp RH 


2 G-R 

Front Washing 

Motor+ 

1 W-B 

2 R-L 


Lamp RH Ground 


Lamp RH Power Input 

V029 Rear Washing Reservoir Motor 


1 P Washing Motor - 

2 G-Y Washing Motor + 

V026 Bass Horn 


1 B Horn+ 

2 W-B Ground 



V027 Alt Horn 


1 B Horn+ 

1 L-W 

2 Y 

Front Wiper Lowspeed 

Input 

Front Wiper 

Intermittent Input 

3 G-R Power 

Page 3170


71-137 



4 L-R 

Front Wiper Highspeed 

Input 

71 

5 W-B 

Windshield Wiper 

Assy Ground 

V034 Engine Hood Switch 

71 


1 O-L 

2 W-B 


Input 


Ground 

V031 Triple Pressure Switch 


1 G-B AV Request Input 

2 W-B 

3 R-W 


Switch- 


Switch+ Input 

4 Y-B AV Request Output 

V111 to Main Wire Harness A 


1 Br - 

2 LG - 

3 P - 

4 V - 

V032 Vacuum Warning Switch 


1 B Switch + Input 

5 B - 

6 R-B - 

7 R-G - 

8 G-B - 

9 L-B - 

10 L-Y - 

11 - - 

12 R-L - 

V033 Brake Fluid Level Sensor 


1 R-W 

Brake Fluid Level 

Sensor + Input 

2 W-B Ground 

13 R-Y - 

14 V-W - 

15 G-R - 

16 LG - 

17 P - 

Page 3171

71-138 


V111 to Main Wire Harness A 


18 G-Y - 

19 Y-W - 

20 G-R - 

21 G-R - 

22 R-L - 

23 R - 

24 G - 

V113 toMain Wire Harness D 


1 L-B - 

2 G - 

3 R - 

4 W-L - 

5 L - 

6 L-O - 

7 L-R - 

V112 to Main Wire Harness C 


8 O-L - 

9 G-R - 

10 B - 

1 G-R - 

2 R-W - 

3 B - 

4 W-B - 

5 R-W - 

6 L-W - 

7 Y - 

8 L-R - 

9 Y-B - 

10 G-B - 

11 L - 

12 L-G - 

V114 to Front Door LH Wire Harness A 


1 R - 

2 - - 

3 L-R - 

4 R - 

5 G - 

6 - - 

7 R-Y - 

8 B - 

Page 3172


71-139 

71 

V115 to Front Door LH Wire Harness B 


1 - - 

2 - - 

3 L-Y - 

4 P-L - 

5 - - 

6 - - 

7 - - 

8 L-G - 

V117 to Front Door RH Wire Harness A 


1 R - 

2 L-R - 

3 L-R - 

4 G-R - 

5 G - 

6 L-O - 

7 R-Y - 

8 R - 

71 

V116 to Front Door LH Wire Harness C 


1 W-B - 

2 P - 

3 G-R - 

4 - - 

5 V - 

6 R-L - 

V118 to Front Door RH Wire Harness B 


1 L-B - 

2 L-Y - 

3 P-L - 

4 W-L - 

5 W-B - 

6 L - 

7 G-R - 

8 L-G - 

Page 3173

71-140 


V119 to Front Door RH Wire Harness C 


1 - - 

2 L - 

3 R - 

4 B - 

5 L-G - 

6 G - 

V120 to Front Bumper Wire Harness 


1 - - 

2 - - 

3 - - 

4 - - 

5 W-B - 

6 LG - 

Page 3174


71-141 


71 

X001 Pre-heater 


1 B Pre-heater+ 

X003 Pre-heater Relay B 


1 R Pre-heater Relay B 

71 

X002 Pre-heater Relay L 


1 B Pre-heater Relay L 

Page 3175

71-142 


Z - Main Wire Harness 

Z002 Instrument Cluster B 


B13 - - 

B14 - - 

Z001 Electronic Throttle 


1 B Throttle Sensor 1 - 

2 L-G Throttle Sensor 1 

3 W Throttle Sensor 1+ 

4 Y Throttle Sensor 2 - 

5 W-R Throttle Sensor 2 

6 Y-G Throttle Sensor 2 + 

B15 - - 

B16 

Y-G 


Gauge Sensor 

B17 - - 

B18 - - 

B19 - - 

B20 

B21 

Y-G 

R-Y 


Signal Input 

Rear Fog Lamp 

Indicator 

B22 

B23 

B24 

L-Y 

L-W 

Y-R 


Warning Light 

Engine Failure 

Warning Input 

EBD Warning Light 

Signal Input 

Z002 Instrument Cluster B 


B1 - - 

B2 - - 

B3 - - 

B4 - - 

B5 - - 

B6 

Y 

Instrument Parking 

Brake Light 

B7 - - 

B25 

P-L 

Instrument Charging 


B26 - - 

B27 

B-Y 

B28 R-W 


Signal Input 

Brake Fluid Sensor + 

Output 

B29 - - 

B30 W-B Instrument B Ground 

B31 R-G High Beam Indicator 

B32 G-B Right Turn Indicator 

B8 - - 

B9 

B-W 

Seat Belt Alarm + 

Output 

B10 V-W Speed Output 

B11 - - 

B12 - - 

Page 3176


71-143 

Z003 Instrument Cluster A 


A27 G-Y Preheat Indicator 

71 

Z003 Instrument Cluster A 


A1 R-B Instrument IG Power 

A2 - - 


A4 - - 

A5 - - 

A6 V-W Lamplet Signal Input 

A7 

LG 


Indicator 

A8 L Vehicle Speed Input 

A9 W-L Vehicle Speed Output 

A10 L-B Vehicle Speed Output 

A11 - - 

A12 - - 

A28 Br Engine Maintenance 

A29 - - 

A30 

R-W 

Front Door Open 

Indicator 

A31 B-W Seat Belt Warning 

A32 G-Y Left Turn Indicator 

Z004 Rear Hatch Lamp Switch Diode 


1 W-R 

2 R-B 

Door Open Indicator 

Input 

Rear Hatch Lamp 

Indicate Output 

71 

A13 

W-G 


Input 

A14 B Lighting PWM Signal 

A15 W-R Door Open Indicator 

A16 R Instrument Power 

A17 - - 

A18 - - 

A19 W-B Instrument A Ground 

A20 R-B Instrument IG Power 

A21 - - 

Z005 Left Side Sliding Door Lamp Diode 


1 W-R 

2 R-Y 


Input 


Output 

A22 - - 


A24 Y-W Engine Stop Light 

A25 - - 

A26 

B 

Vacuum Level Alarm 

+ Input 

Page 3177

71-144 


Z006 Stop Lamp Switch 


1 G-W Brake Power Output 

2 W-R 

3 L-Y 

Stop Lamp Power 

Input 


Switch Output 


Z008 Central Locking Controller Assy B 


B1 

B2 

B3 

W-R 

W-L 

R 


Illumination Control 

Front Right Door 

Open Signal Output 

Central Locking Spare 

Power 

B4 G-R Horn 

B5 - - 

Z007 Flasher 


1 B-Y Power 

2 G-B 


Lamp Power 

3 - - 

B6 

B7 

O-L 

V-W 

to Engine Hood 

Switch Output 

Lamplet Forget to 

Turn Off Hints 

B8 O-B Key Detection Switch 

B9 - - 

B10 W-B Ground 

B11 - - 

4 R-Y 


Lamp Power 

B12 - - 

5 G-V 

Left Turning Signal 

Input 

6 - - 

7 G-R 

Hazard Warning/Turn 

Signal 

8 W-B Ground 

9 G-Y 

10 R-L 


Lamp Power 


Lamp Power 

11 - - 

12 G-W 

Right Turning Signal 

Input 

Z009 Central Locking Controller Assy A 


A1 W-B Ground 

A2 R Lock Output 

A3 G Unlock Output 

A4 

A5 

G 

R 


Down Output 


Up Output 

Page 3178


71-145 

A6 

A7 

A8 

Z009 Central Locking Controller Assy A 


R-L 

G-R 

W-L 


Down Output 


Up Output 

Window Control 

Power Input 

A9 L-O Key Lock Input 

A10 L-R Key Unlock Input 

A11 Y Collision Signal Input 

A12 G-Y Left Turn Light Signal 

Z011 Combination Switch (Light) 


1 W-B Ground 

2 L 

3 B-W 

Rear Fog Lamp 

Switch 


Switch 

4 - - 

71 

71 

A13 

G-B 

Right Turn Light 

Signal 

5 G-R 

Lamplet Relay Control 

Input 


A15 

A16 

L-B 

L 

Door Assy 

Switch(Data) Output 

Door Assy 

Switch(Clock) Output 

A17 W-L Vehicle Speed Signal 

A18 R-B IG Power 

6 W to Day light Relay 

7 W-B Ground 

8 W-B Ground 

9 L-R to High Beam Relay 

10 W-R to Low Beam Relay 

11 G-V Left Turn Switch 

12 B-R Turn Light Power 

13 G-W Right Turn Switch 

Z010 Key Insert Switch 


1 - - 

2 - - 

3 O-B Switch Input 


Z012 Clock Spring 


1 - - 

2 G-R Horn Switch 

3 Y 


Interface ACU 

4 Y-B 


Interface ACU 

Page 3179

71-146 


Z013 Combination Switch (Wiper) 


1 - - 

2 L-R 

3 G-R 

4 L-W 

5 Y 

Wiper High Speed 

Output 

Wiper Switch Power 

Input 

Wiper Low Speed 

Output 

Wiper Intermittent 

Output 

6 W-B Ground 

Z015 Ignition Switch 


1 W 


Power Input 

2 R IG1 Power Output 

3 R ACC Output 

4 G-B 

5 R-B 

Start Control Power 

Output 


Power Input 

6 L Ignition Switch IG2 

7 Y-W Front Washer Motor - 

8 P Rear Washer Motor - 

9 W Rear Wiper 

10 - - 

Z017 A/C Control Panel B 

Z014 Ignition Switch Illumination 


1 R 



Input 


21 Y-W 

Rear Temperature 

Sensor- 

22 - - 

23 L-O 

Mix Damper 

Feedback 

2 W-R to Central Lock Unit 

24 L-G 


Mode Feedback 

25 - - 

26 B 

27 W-B 

Servo Motor 

(Mode)/ 


Output 

Servo Motor 

(Mode)/ 

(Temperature) 


Page 3180


71-147 

Z017 A/C Control Panel B 


28 Y-G Front Blower- 

29 V 



30 - - 

31 - - 

32 G 


Controller Back 

Lighting 


34 - - 


Z020 Blower Control Module 


1 W-B Ground 


3 Y-G Blower Control 


71 

71 

36 LG 

Rear AC Switch 

Request Output 

Z021 Servo Motor (Temperature) 

Z018 12V Power Output Socket 


1 W-B Ground 

2 R-Y 12V Power Output 

3 - - 


1 B 

2 L-O 

3 W-B 

Servo Motor 


Output 

Mix Damper 

Feedback 

Servo Motor 

(Temperature) 


4 - - 

5 L 

Warm Damper 

Control 

Z019 Front Blower 



1 R-W Front Blower+ 


Page 3181

71-148 


Z023 A/C Control Panel A 


8 G 

Blower Relay Control 

Power Input 

Z022 Rear Blower Forward Switch 


1 W-B 

2 R-B 

3 G 


Switch Ground 


Switch Power Input 



4 - - 

5 Gr-R 

6 W-B 

Solenoid Valve Power 

Output 


Switch Ground 

9 G-B AC Request Output 

10 R-B AC IG Power 

11 - - 

12 - - 

13 - - 

14 - - 

15 - - 

16 - - 

17 - - 

18 W-B Ground 

19 R-G 


Controller Battery 

Power Input 

20 W-B Ground 

Z024 Outside Mirror Defroster Switch 

Z023 A/C Control Panel A 


1 Gr 

2 L-B 

3 L-Y 

4 L 

Rear AC Solenoid 

Valve-Input 


Defrost 


Blowing Face 

Warm Damper 

Control 




1 W-B 

2 Y-L 

3 G 



Ground 



Power Input 



Lighting 

4 - - 

5 G-L 


Defroster Control 

Output 


Page 3182


71-149 

Z024 Outside Mirror Defroster Switch 


6 W-B 



Ground 

B5 

V 

Z026 Radio B 



Power Output 

B6 P Front Left Speaker- 

71 

B7 

Y 


Power Output 

71 

B8 B Rear Left Speaker- 

Z025 Radio A 


A1 - - 

A2 - - 

A3 G Radio illumination 

A4 G-R Radio ACC Input 

A5 - - 

A6 - - 

A7 R Radio Power Input 

A8 W-B Ground 

Z027 CD Player-C2 


1 B-Y Reverse Detection 


3 - - 

4 - - 

5 - - 

6 - - 

Z026 Radio B 


B1 

W 


Power Output 

B2 R Rear Right Speaker- 

B3 

L 


Power Output 

B4 L-G Front Right Speaker- 

Z028 CD Player-C1 


1 G-W VIDEO GND Input 

2 G-O VIDEO+ Output 

3 - - 

4 - - 

5 - - 

6 - - 

Page 3183

71-150 


Z031 Dome Light Switch 


Z029 Diagnosis Switch 

5 Y 


Input 

6 R Indicator Power Input 




3 G Illumination Power 

4 - - 

5 B-Y Switch Input 

6 R-B Switch Power 

Z032 Instrument Dimmer Switch 


1 - - 

2 - - 

3 G 


Switch Lamplet 

4 - - 

Z030 Cigarette Lighter 


5 B Lighting PWM Signal 

6 W-B 


Switch Ground 

1 W-B Ground 

2 R-B 

3 G 


Power Input 


Illumination 

Z033 Headlamp Dimmer Switch 


1 G-B Power 

Z031 Dome Light Switch 


1 W-B Ground 

2 W-B Ground 

3 G 


Illumination 

4 - - 

2 W-B 

3 G 

4 LG 

5 Br 

6 W-B 


Switch Ground 


Lighting 

Front Left Headlamp 

Adjustment 

Front Right 



Switch Ground 

Page 3184


71-151 

71 

Z034 Hazard Warning Switch 


1 - - 

2 G 

3 W-B 



Instructions 


Switch Ground 

4 - - 

5 - - 

6 - - 

7 W-B Ground 

8 G-R Switch Signal Output 

9 - - 

10 - - 

Z036 Turn Signal Lamp Diode LH 


1 G-Y 

2 R-Y 


Lamp Power 


Lamp Power 

Z037 Clutch Switch 


1 - - 

2 - - 

3 W-B Clutch Switch 

4 L-B Switch Control Output 

71 

Z035 Turn Signal Lamp Diode RH 


1 G-B 

2 R-L 


Lamp Power 


Lamp Power 

Z038 Servo Motor (Mode) 


1 B 


5V Output 

2 L-G 

3 W-B 


Mode Feedback 

Servo Motor 

(Temperature) 


4 - - 

5 L-Y 


Blowing Face 

Page 3185

71-152 


Z038 Servo Motor (Mode) 


6 L-B 


Defrost 

Z041 Servo Motor (Internal & External 

Circulation) 


1 - - 

Z039 Front Evaporator Thermistor 


1 V 




2 - - 

3 - - 

4 - - 



Z042 Reverse Radar Control Unit 


1 B-R Reverse Power Input 

Z040 Passenger Airbag Assy 


1 G-B 

2 G-R 


Interface ACU 

High-side 


Interface ACU 

Low-side 

2 G-R 

3 W-L 

4 R-W 

Front Right Reverse 


Reverse Radar 

Sensor Power Input 

Reverse Radar 


Output 

5 - - 

6 L-B Vehicle Speed Signal 

7 R-G 

8 R-B 

Reverse Radar 

Sensor LH Output 

Reverse Radar 


Output 


10 G-O 

Front Left Reverse 


Page 3186


71-153 

Z042 Reverse Radar Control Unit 


11 B 

Reverse Radar 

Sensor Ground 

71 

12 - - 

13 - - 

14 - - 

71 

15 R-L 

Reverse Radar 

Sensor RH Output 

16 W-B Ground 

Z044 Restraint control module (RCM) 


1 - - 16 - - 

2 - - 17 - - 

3 - - 18 - - 

4 - - 19 - - 

5 B-O Airbag Power Input 20 - - 

6 W-B Airbag Ground 21 - - 

7 B-Y 


Signal Output 

22 - - 

8 - - 23 - - 

9 R-L Airbag K 24 - - 

10 Y 

11 Y-B 


Interface ACU 


Interface ACU 

25 - - 

26 - - 

12 - - 27 - - 

13 G-B 


Interface ACU 

High-side 

28 - - 

Page 3187

71-154 


Z044 Restraint control module (RCM) 


14 G-R 


Interface ACU 

Low-side 

29 - - 

15 - - 30 Y 

Collision Signal 

Output 

Z045 Parking Brake Switch 


1 Y Parking Brake Switch 

Z047 Rear Heater Blower Switch 


1 W-B 


Switch Ground 

2 P 


Switch Input 

Z046 Front Left Door Lamp Switch 


1 R-W 

Door Open signal 

Output 

3 W-B 


Switch Ground 




Z049 to Positive Junction Box C 



Page 3188


71-155 

Z050 to Positive Junction Box A 


1 W 

Battery Compartment 


Input 

Z053 Diesel Filter Heater 


1 Br Power 

2 W-B Ground 

71 

71 

2 W-G 

Engine Room 


Input 

Z054 Preheating Relay Coil 

Z051 to Positive Junction Box D 



1 L-Y Coil Output 

2 L-B Coil Input 

1 R 

to Positive Junction 

Box D Power Input 

Z055 Step Lamp 


Z052 Left Side Sliding Door Lock Assy 


1 R Step Lamp Power 

2 R-Y Door Control Output 

1 - - 

2 G Unlock 

3 - - 

4 R Lock 

Z056 Back-up Lamp Switch (Gasoline) 


1 W-L 

2 B-Y 


Input 

Reverse Power 

Output 

Page 3189

71-156 


Z056 Back-up Lamp Switch (Diesel) 


1 W-L 

2 B-Y 


Input 


Output 

Z059 Front Wheel Speed Sensor LH 


1 W 

2 B 


Speed Sensor- 


Speed Sensor+ 

Z057 Odometer Sensor 


1 R-B Sensor Power 

2 W-B 

3 W-G 


Ground 


Output 

Z060 Rear Wheel Speed Sensor RH 


1 LG 

2 P 


Speed Sensor- 


Speed Sensor+ 

Z061 Rear Wheel Speed Sensor LH 

Z058 Front Wheel Speed Sensor RH 



1 L 

2 G 


Speed Sensor- 


Speed Sensor+ 

1 L-G 

2 Y-W 


Speed Sensor- 


Speed Sensor+ 

Page 3190


71-157 

71 

71 

Z062 ABS ECU 


1 R 

ABS Motor Power 

Input 

20 - - 

2 - - 21 - - 

3 Y-R 

4 L 

EBD Warning Lamp 

Signal Output 


Speed Sensor- 

22 - - 

23 - - 

5 - - 24 - - 

6 R-L Data Link Connector k 25 R-W 

ABS Solenoid Valve 

Power Input 

7 - - 26 - - 

8 W 


Speed Sensor- 

27 Y-G 


Signal Output 

9 - - 28 R-W ABS-IG Input 

10 - - 29 LG 


Speed Sensor- 

11 - - 30 G-W Brake Signal Input 

12 - - 31 Y-W 


Speed Sensor+ 

13 W-B Ground 32 - - 

14 - - 33 - - 

15 - - 34 - - 

16 G 

17 P 

18 L-G 


Speed Sensor+ 


Speed Sensor+ 


Speed Sensor- 

35 - - 

36 - - 

37 - - 

Page 3191

71-158 


Z062 ABS ECU 


19 B 


Speed Sensor+ 

38 W-B Ground 

Z064 Secondary Fan Motor 


1 W Secondary Fan+ 

2 Y 

Secondary Fan Low 

Speed+ 

Z066 Generator (Diesel) 


1 - - 


3 W-B 

Secondary Fan 

Ground 

Z067 Fuel Sensor/Fuel Pump 

Z065 Main Fan Motor 


1 R-W Fan High Speed+ 

2 R-B Fan Low Speed+ 


1 Br Fuel Pump Power 

2 W-B Ground 

3 V Fuel Sensor Signal 

4 W-B Ground 

3 W-B Main Fan Ground 

Z068 Data Link Connector 120 Resistance 

Z066 Generator Excitation (Gasoline) 


1 L IG End 



1 G-B CAN-H 

2 G-O CAN-L 

3 - - 

Page 3192


71-159 

Z069 Rear A/C Solenoid Valve 


1 L 

2 Gr 


Valve Power Input 


Valve Output 

Z070 Driver Seat Belt Warning Switch 


1 B-W Switch Signal Output 

2 W-B Ground 

71 

71 

A008 Front Door Lamp Switch RH 


1 W-L Switch Input 

Z072 ECM (Diesel) 


E1 

W-R 


Input 

E30 - - 

E2 W-B Engine ECU Ground E31 - - 

E3 

W-R 


Input 

E32 - - 

E4 W-B Engine ECU Ground E33 W-B 


Control 

E5 

W-R 


Input 

E34 

B-W 

Fan Control 

Feedback 

Page 3193

71-160 


Z072 ECM (Diesel) 


E6 W-B Engine ECU Ground E35 G-Y 

Preheat Indication 

Output 

E7 - - E36 Br Engine Maintenance 

E8 - - E37 - - 

E9 V-W Speed Output E38 - - 

E10 

B-Y 


Output 

E39 L-B Clutch Control Output 

E11 

R-W 


Switch + Output 

E40 - - 

E12 - - E41 B-G ECU-IG 

E13 - - E42 Y-G Throttle Sensor 2+ 

E14 G-B CAN-H E43 W-R Throttle Sensor 2 

E15 G-O CAN-L E44 L-G Throttle Sensor 1 

E16 - - E45 - - 

E17 - - E46 L-B 


Output 

E18 - - E47 R-Y Fan Low-speed Diode 

E19 - - E48 L 

A/C Low Level 

Approval Output 

E20 - - E49 Y-W Engine Stop Light 

E21 

L-Y 


Input 

E50 - - 

E22 L-W MILL Light E51 - - 

E23 - - E52 L-Y 


Switch Output 

E24 - - E53 - - 

E25 - - E54 - - 

E26 - - E55 Y Throttle Sensor 2- 

E27 Y-B A/C Request Input E56 B Throttle Sensor 1- 

E28 L Vehicle Speed Signal E57 W Throttle Sensor 1+ 

E29 W-B SW RET E58 - - 

Page 3194


71-161 

71 

Z073 Front Door Lamp Diode RH 


1 R-W Diode + 

2 W-L Diode - 

Z077 Acceleration Sensor 


1 Br-R 

2 Br-G 


Signal- 


Signal+ 

71 

3 SB 


Power+ 

Z074 Generator B+ 



Z078 Engine Oil Pressure Sitch 


1 L-Y 


Warning Light 

Z076 Downstream Oxygen Sensor 


1 B 

2 O 

3 Y-B 

4 G 


Signal- 


Signal+ 


Heating 


Sensor+ 

Z101 to Front Wire Harness C 


1 G-R - 

2 R-W - 

3 B - 

4 W-B - 

5 R-W - 

6 L-W - 

7 Y - 

8 L-R - 

9 Y-B - 

Page 3195

71-162 


Z101 to Front Wire Harness C 


10 G-B - 

11 L - 

12 L-G - 

Z103 to Roof Wire Harness 1A 


6 Y - 

7 L - 

8 W-B - 

9 R - 

10 R-W - 

11 LG - 

12 R-Y - 

Z102 to Front Wire Harness D 


1 L-B - 

2 G - 

3 R - 

13 R-B - 

14 R-Y - 

15 G-B - 

16 G-Y - 

17 R - 

18 G - 

4 W-L - 

5 L - 

6 L-O - 

7 L-R - 

8 O-L - 

9 G-R - 

10 B - 

Z105 to Front Wire Harness A 


1 Br - 

2 LG - 

3 P - 

4 V - 

Z103 to Roof Wire Harness 1A 


1 V-W - 

2 G-W - 

3 Br - 

4 Y-W - 

5 B-Y - 

5 B - 

6 R-B - 

7 R-G - 

8 G-B - 

9 L-B - 

10 L-Y - 

11 - - 

12 R-L - 

Page 3196


71-163 

Z105 to Front Wire Harness A 


13 R-Y - 

14 V-W - 

15 G-R - 

16 LG - 

17 P - 

18 G-Y - 

19 Y-W - 

20 G-R - 

21 G-R - 

22 R-L - 

23 R - 

24 G - 

Z106 to Roof Wire Harness 1B 


1 Y - 

2 B - 

3 - - 

4 R-B - 

5 R - 

6 W - 

7 R - 

8 G-W - 

9 G-O - 

10 G-R - 

11 Br 

12 G-Y 

13 - - 

Z107 to Battery Wire Harness B 


1 W-B - 

2 R - 

Z108 to Engine Wire Harness A 


1 - - 

2 G-B - 

3 Y-G - 

4 - - 

5 - - 

6 L-Y - 

7 W-B - 

8 - - 

Z109 to Rear Heater Wire Harness 


1 W - 

2 L-B - 

3 L - 

4 B - 

5 W-B - 

71 

71 

Page 3197

71-164 


Z109 to Rear Heater Wire Harness 


6 W-L - 

7 - - 

8 - - 

Z111 to Engine Wire Harness 1 


7 Y - 

8 W-B - 

9 L - 

10 R - 

11 L - 

12 W-L - 

13 G-B - 

Z110 to Rear Bumper Transition Wire 

Harness 


14 - - 

15 V-W - 

16 L - 

1 R-G - 

2 R-B - 

3 R-L - 

4 R-W - 

5 B - 

6 - - 

7 - - 

8 - - 



1 - - 

2 Br-R - 

3 Br-G - 

4 SB - 

5 G - 

6 - - 



1 Br - 

2 L-W - 

3 Y-G - 

4 - - 

5 Y-B - 

6 R-W - 

7 - - 

8 - - 

9 R-L - 

10 B - 

11 Y-B - 

12 O - 

13 - - 

14 B-G - 

15 G-W - 

Page 3198


71-165 



16 G - 

71 

71 

Z113 to Data Link Connector 


1 - - 

2 W-B - 

3 - - 

4 W-L - 

5 R-L - 

6 G-O - 

7 G-B - 

8 W-B - 

Page 3199

71-166 

WIRING(RHD) - WIRE HARNESS & CONNECTOR LOCATION VIEWS 

WIRE HARNESS & CONNECTOR LOCATION VIEWS 



C Front Bumper Wire Harness - Connector 

C001 Front Fog Lamp LH C002 Front Fog Lamp RH 

C Front Bumper Wire Harness- Inline 


Page 3200


71-167 

V Front Wire Harness - Connector 

00 

V018 

Left Headlight Dimming Motor 

V027 

Alt Horn 

V019 

V020 

Front Position Lamp LH 

Headlamp LH 

V028 

V029 

Front Washing Reservoir Motor 

Rear Washing Reservoir Motor 

71 

V021 

Front Turn Signal Lamp LH 


V030 

V031 

Windshield Wiper Assy 

Triple Pressure Switch 

71 

V023 

Right Headlight Dimming Motor 

V032 

Vacuum Warning Switch 

V024 

Front Position Lamp RH 

V033 

Brake Fluid Level Sensor 

V025 

Front Turn Signal Lamp RH 

V034 


V026 

Bass Horn 

V Front Wire Harness - Inline 

V111 

to Main Wire Harness A 

V116 

to Front Door LH Wire Harness C 

V112 

to Main Wire Harness C 

V117 

to Front Door RH Wire Harness A 

V113 

to Main Wire Harness D 

V118 

tto Front Door RH Wire Harness B 

V114 

to Front Door LH Wire Harness A 

V119 

to Front Door RH Wire Harness C 

V115 

to Front Door LH Wire Harness B 

V120 

to Front Bumper Wire Harness 

V Front Wire Harness - Ground 

V204 


V206 

Front Wire Harness Right Side Ground 

V205 

Front Wire Harness Left Side Ground 

Page 3201

71-168 



D Front Door LH Wire Harness - Connector 

D007 

Power Window Motor LH 

D010 

Front Door Lock Assy LH 

D008 

Outside Mirror Assy LH 

D011 

Front Speaker LH 

D009 

Window Control Switch LH 

D Front Door LH Wire Harness - Inline 

D104 


D106 


D105 


Page 3202


71-169 


71 

71 

H Front Door RH Wire Harness - Connector 

H006 

Front Speaker RH 

H009 

Electric Outside Mirror Switch 

H007 

Power Window Motor RH 

H010 


H008 

Outside Mirror Assy RH 

H011 

Front Door Lock Assy RH 

H Front Door RH Wire Harness - Inline 

H104 


H106 


H105 


Page 3203

71-170 


Z - MAIN WIRE HARNESS(CHASSIS & FRAME SECTION) 

Z Main Wire Harness - Connector 

Z049 

to Positive Junction Box C 

Z064 

Secondary Fan Motor 

Z050 

to Positive Junction Box A 

Z065 

Main Fan Motor 

Z051 

to Positive Junction Box D 

Z066 

Generator Excitation 

Z054 

Preheating Relay Coil(Diesel) 

Z069 

Rear A/C Solenoid Valve 

Z058 

Front Wheel Speed Sensor RH 

Z077 


Z059 

Front Wheel Speed Sensor LH 

Z078 


Z Main Wire Harness - Inline 

Z107 

to Battery Wire Harness B(Diesel) 

Z109 

to Rear Heater Wire Harness 

Z108 

to Engine Wire Harness A 

Z111 

to Engine Wire Harness 1(Gasoline) 

Page 3204


71-171 

71 

71 


Z046 

Z047 

Z052 

Z053 

Z055 

Z056 

Z057 

Z060 

Z061 

Front Left Door Lamp Switch 

Rear Heater Blower Switch 

Left Side Sliding Door Lock Assy 

Diesel Filter Heater 

Step Lamp 

Back-up Lamp Switch 


Rear Wheel Speed Sensor RH 

Rear Wheel Speed Sensor LH 

Z062 

ABS ECU 

Z067 

Fuel Sensor/Fuel Pump 

Z068 Data Link Connector 120 Resistance 

Z070 Driver Seat Belt Warning Switch 

Z071 Front Door Lamp Switch RH 

Z072 

ECM 

Z074 Generator B+ 

Z076 Downstream Oxygen Sensor 


Z112 to Engine Wire Harness 2(Gasoline) Z110 to Rear Bumper Transition Wire Harness 

Z Main Wire Harness - Ground 

Z207 

ABS Ground 

Z210 


Z208 

Vehicle Frame Left Side Ground 

Z209 


Page 3205

71-172 



ENGINE 4G69 


E001 

ECM 

E010 


E002 

Injector A 

E011 

Knock Sensor 

E003 

Injector B 

E012 

Engine Coolant Temperature Sense Plug 

E004 

Injector C 

E013 

Compressor 

E005 

Injector D 

E014 

Starter Coil 

E006 

E007 

E008 

Mainfold Absolute Pressure/Intake Air 


Upstream Oxygen Sensor 


E015 

E016 

E017 

Idle Air Control Valve 

Canister Solenoid Valve 

Ignition Coil 

E009 



E101 to Main Wire Harness 1 E102 to Main Wire Harness 2 

Page 3206


71-173 

E Engine Wire Harness - Ground 

E201 Ground (Near the Thermostat) 

71 

71 

Page 3207

71-Wiring.fm 

71-174 


ENGINE ISF2.8 


E013 

E036 

E037 

E038 

E039 

E040 

E041 

E042 

E043 

E044 

E045 

Compressor 

Engine Oil Pressure Switch (IC) 


(IC) 

Engine Electronic Control Module 

Inlet Metering Valve 

Coolant Temperature Sensor 

Water in Fuel Sensor 

Oil Pressure Switch 

CAN Datalink 

Accuumulator Pressure Sensor 

Ambient Air Pressure Sensor 

E046 Intake Manifold Press/Temp Sensor 

E047 


E048 






E053 

Mass Air Flow 

E054 

Intake Throttle Actuator 

E055 

EGR Valve 

E056 

CAN Resistor 


E103 

to Main Wire Harness A (Diesel) 

Page 3208


71-175 

Z - MAIN WIRE HARNESS(INSTRUMENT PANEL SECTION) 


71 

71 


Z002 

Z006 

Z008 

Z009 

Z010 

Z015 

Z017 

Instrument Cluster B 

Stop Lamp Switch 

Central Locking Controller Assy B 

Central Locking Controller Assy A 

Key Insert Switch 


A/C Control Panel B 

Z023 

A/C Control Panel A 

Z033 

Headlamp Dimmer Switch 

Z034 

Hazard Warning Switch 

Z035 Turn Signal Lamp Diode RH 

Z036 

Turn Signal Lamp Diode LH 

Z038 



Z101 to Front Wire Harness C Z102 to Front Wire Harness D 

Page 3209

71-176 



Z201 Instrument Panel Power Ground Z204 Radio/Data Link Connector Ground 

M Diagnosis Wire Harness - Connector 

M001 Data Link Connector Resistance M002 Data Link Connector 

M Diagnosis Wire Harness - Inline 

M101 

to Main Wire Harness 

69 

Page 3210


71-177 

71 

71 


Z001 

Electronic Throttle 

Z022 

Rear Blower Forward Switch 

Z003 

Instrument Cluster A 

Z024 

Outside Mirror Defroster Switch 

Z004 

Rear Hatch Lamp Switch Diode 

Z025 

Radio A 

Z005 

Left Side Sliding Door Lamp Diode 

Z026 

Radio B 

Z007 

Flasher 

Z027 

CD Player-C2 

Z011 

Combination Switch (Light) 

Z028 

CD Player-C1 

Z012 

Clock Spring 

Z029 


Z013 

Z014 

Z018 

Z019 

Z020 

Z021 

Combination Switch (Wiper) 

Ignition Switch Illumination 

12V Power Output Socket 

Front Blower 

Blower Control Module 

Servo Motor (Temperature) 

Z030 

Z031 

Z032 

Z037 

Z039 

Z040 



Instrument Dimmer Switch 

Clutch Switch 

Front Evaporator Thermistor 

Passenger Airbag Assy 

Page 3211

71-178 


Z041 

Z042 

Servo Motor (Internal & External 

Circulation) 

Reverse Radar Control Unit 

Z044 

Z045 

Restraint control module(RCM) 

Parking Brake Switch 


Z103 


Z106 


Z105 


Z113 

to Data Link Connector 


Z202 


Z205 


Z203 


Z206 

Airbag Ground 

Page 3212


71-179 




71 

71 

B Battery Wire Harness - Connector 

B001 Starter B002 Starter Excitation 

B Battery Wire Harness - Inline 

B101 


B Battery Wire Harness - Ground 


P Rear Heater Wire Harness - Connector 

P001 

P002 

Rear Heater Solenoid Valve 

Rear Heater Motor 

Page 3213

71-180 


P Rear Heater Wire Harness - Inline 

P101 


X Preheating Wire Harness - Connector 

X001 

Pre-heater 

X003 

Pre-heater Relay B 

X002 

Pre-heater Relay L 

Page 3214


71-181 


71 

71 

F Roof Wire Harness 1 - Connector 

F008 

Rear Evaporator Module 

F012 

Rear Combination Lamp LH 

F009 


F013 

Rear Speaker LH 

F010 

Central Dome light 

F014 

Sliding Door Ajar Switch LH 

F011 

Air Purifier 

F Roof Wire Harness 1 - Inline 

F107 

to Main Wire Harness A 

F110 


F108 

F109 

to Main Wire Harness B 


F111 

to High-mounted Stop Lamp Wire 

Harness 

F Roof Wire Harness 1 - Ground 

F202 


Ground 

Page 3215

71-182 








G Roof Wire Harness 2 - Connector 

G004 Rear Combination Lamp RH G005 Rear Speaker RH 

G Roof Wire Harness 2 - Inline 

G104 


G106 


G105 


G Roof Wire Harness 2 - Ground 

G202 

Roof Rear Right Department Ground 

Page 3216


71-183 

J Rear Hatch Wire Harness - Connector 

J001 

Rear Hatch Lock Assy-Switch 

J004 

License Lamp 

J002 

Rear Hatch Lock Assy-Motor 

J005 

Camera 

71 

J003 

Trunk Lamp 

J Rear Hatch Wire Harness - Inline 

71 

J101 


J Rear Hatch Wire Harness - Ground 

J201 


Q Rear Bumper Transition Wire Harness - Inline 

Q101 to Rear Bumper Wire Harness Q102 to Main Wire Harness 

R Rear Bumper Wire Harness - Connector 

R001 

Reverse Radar Sensor LH 

R003 

Reverse Radar Central Sensor RH 

R002 

Reverse Radar Central Sensor LH 

R004 

Reverse Radar Sensor RH 

R Rear Bumper Wire Harness - Inline 

R101 


U High-mounted Stop Lamp Wire Harness - Connector 

U001 Rear Wiper U002 High-mounted Stop Lamp 

U High-mounted Stop Lamp Wire Harness - Inline 


U102 

U103 

to Rear Defrost LH Wire Harness 

to Rear Defrost RH Wire Harness 

Page 3217

MEMO 

Page 3218


HORN ................................................................................................. 81-1 


COMPONENTS ........................................................................... 81-2 

REPLACEMENT .......................................................................... 81-3 

MULTI-MEDIA AND AIR-CONDITON CONTROLER ASSY ............. 81-4 

COMPONENTS ........................................................................... 81-4 

REPLACEMENT .......................................................................... 81-5 

REVERSE RADAR............................................................................. 81-7 


COMPONENTS ........................................................................... 81-8 

REPLACEMENT .......................................................................... 81-9 

ASTERN IMAGE .............................................................................. 81-11 

REPLACEMENT ........................................................................ 81-11 

81 

81 

81 

81 

Page 3219

Page 3220

COMMUNICATION SYSTEM - HORN 

81-1 

HORN 



Use the table below to help you find the cause of the problem. The numbers indicate the priority of 

the likely cause of the problem. Check each part in order. If necessary, replace these parts. 

81 



1. Horn (Damaged) 

2. Horn switch (Damaged) 

3. Harness (Damaged) - 


replacement 



81 

62 

1. Horn switch (Damaged) 

Chapter 51 steering column - combination 

switch assy, replacement 


2. Harness (Damaged) - 

3. Horn (Damaged) Chapter 81 communication system - horn, 

replacement 

4. Center Door Lock Controller 

Page 3221

81-2 


COMPONENTS 

1 Alt Horn 

2 Bass Horn 

4 Bolt 

5 Horn Transition Bracket Assy2 

3 Horn Transition Bracket Assy1 

Page 3222


81-3 

REPLACEMENT 

1. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper, 

replacememt”) 

2. REMOVE HORN. 

(a) Disconnect the horn connector. 

81 

81 

62 

(b) 

(c) 

Remove the horn retaining bolt. 

Remove the horn. 

3. INSTALL HORN. 

(a) Tighten the horn retaining bolt. 

(b) 

Connect the horn connector. 

4. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper, 

replacememt”) 

5. CHECK HORN OPERATION AFTER INSTALLATION. 

(a) 

Check horn volume and quality is normal or not. 

Page 3223

MEMO 

MULTI-MEDIA AND AIR-CONDITON CONTROLER ASSY 

COMPONENTS 

1 

2 Bolt 

Multi-Media And Air-Conditon controler 

assy 


5 Flat Washer 

3 Screw 

Page 3224

COMMUNICATION SYSTEM - MULTI-MEDIA AND AIR-CONDITON CONTROLER ASSY 

81-5 

REPLACEMENT 

1. REMOVE MULTI-MEDIA AND AIR-CONDITION CON- 

TROLER ASSY. 

(a) Pry-out the edge of multi-media and air-condition controler 

assy with a screwdriver, and then put out. 

NOTE 

Dip a cloth into screwdriver to prevent damage to exterior 

frame and panel. 

81 

81 

(b) 

Loosen 4 multi-media and air-conditon controler retaining 

screws. 

62 

(c) 

(d) 


Remove multi-media and air-conditon controler assy. 

2. INSTALL MULTI-MEDIA AND AIR-CONDITION ASSY. 

(a) Connect 4 connectors. 

Page 3225

81-6 

COMMUNICATION SYSTEM - MULTI-MEDIA AND AIR-CONDITON CONTROLER ASSY 

(b) 


(c) 

Install exterior frame of multi-media and air-condition 

controler assy. 

3. CHECK MULTI-MEDIA AND AIR-CONDITION CONTROLER ASSY OPERATION AFTER INSTAL- 

LATION. 

(a) Display resolution for 800X480. 

(b) Multi-media and air-condition controler assy button work normal. 

(c) No obvious noise and image fuzzy when useing. 

Page 3226

REVERSE RADAR 


COMMUNICATION SYSTEM - REVERSE RADAR 


81-7 

81 

1. Buzzer (Damaged) 

Chapter 81 communication system - 

reverse radar, replacement 

There is no chime within 

specified distance 

Chime sounds when the 

vehicle 

is out of specified distance 

2. Harness between sensor and 

controller (Damaged) 

3. Controller (Damaged) 

1. Sensor (Incorrect installation) 

2. Sensor (Damaged) 

3. Controller (Damaged) 

- 









81 

62 

Page 3227

81-8 


COMPONENTS 

1 Reverse Radar Sensor Assy 

2 Reverse Radar Sensor Assy 

3 Reverse Radar Controller Assy 

4 Bolt 

Page 3228


81-9 

REPLACEMENT 

REVERSE RADAR SENSOR ASSY 

1. REMOVE REAR BUMPER. (Refer to “Chapter 88 exterior and interior trim - rear bumper, replacement”) 

2. REMOVE REVERSE RADAR SENSOR ASSY. 

(a) Disconnect the reverse radar sensor connector. 

81 

81 

62 

(b) Separate both side of the reverse radar externa bush, 

release the reverse radar from the inside of the rear 

bumper. 

NOTE 

• Do not damage the painted surface of rear bumper. 

• Do not damage the reverse radar externa bush. 

3. INSTALL REVERSE RADAR SENSOR ASSY. 

(a) Position the reverse radar externa bush assy. 

(b) 

Position the reverse radar sensor assy. 

Page 3229

81-10 


(c) 

Connect the reverse radar sensor connector. 

4. INSTALL REAR BUMPER. (Refer to “Chapter 88 exterior and interior trim - rear bumper, replacement”) 

Page 3230


81-11 

REVERSE RADAR CONTROL UNIT 

1. REMOVE GLOVE BOX.(Refer to “Chapter 83 Instrument Panel - glove box, replacememt”) 

2. REMOVE REVERSE RADAR CONTROL UNIT. 

(a) Disconnect the reverse radar control unit connector. 

81 

81 

62 

(b) 

(c) 

Loosen reverse radar control unit screws. 

Remove reverse radar control unit. 

3. INSTALL REVERSE RADAR CONTROL UNIT. 

(a) Tighten reverse radar control unit screws. 

(b) 

Connect the reverse radar control unit connector. 

4. INSTALL GLOVE BOX.(Refer to “Chapter 83 Instrument Panel - glove box, replacememt”) 

Page 3231

81-12 

COMMUNICATION SYSTEM - ASTERN IMAGE 

ASTERN IMAGE 

REPLACEMENT 

1. REMOVE REAR HATCH UPPER GUARD BOARD.(Refer to “Chapter 88 exterior and interior trim 

- vehicle door inner guard board, replacememt”) 

2. REMOVE ASTERN IMAGE. 

(a) Loosen 4 rear hatch outside handle retaining screws. 

(b) 

Pry-out both side buckle of the outside handle. 

NOTE 

• Be carefull not to damage body paint. 

• Be carefull not to damage rear hatch outside handle. 

(c) Turn up the outside handle. 

(d) 

Disconnect the astern image connector. 

(e) 

(f) 

Loosen 2 astern image retaining screws. 

Remove astern image. 

Page 3232

COMMUNICATION SYSTEM - ASTERN IMAGE 

81-13 

3. INSTALL ASTERN IMAGE 

(a) Position the astern image and tighten 2 retaining screws. 

81 

(b) 

Connect astern image connector. 

81 

62 

(c) 

(d) 

Position the rear hatch outside handle and then retaining 

both side buckle. 

Tighten 4 retaining screws and install rear hatch outside 

handle. 

4. INSTALL REAR HATCH UPPER GUARD BOARD.(Refer to “Chapter 88 exterior and interior trim 

- vehicle door inner guard board, replacememt”) 

Page 3233

MEMO 

Page 3234

WINDSHIELDS, MIRRORS & GLASS 

WINDOW GLASS............................................................................... 82-1 

COMPONENTS ........................................................................... 82-1 

POWER WINDOW.............................................................................. 82-2 

INSPECTION ............................................................................... 82-2 

REPLACEMENT .......................................................................... 82-3 

WINDSHIELD ..................................................................................... 82-7 

REPLACEMENT .......................................................................... 82-7 

REAR WINDOW GLASS.................................................................. 82-12 

REPLACEMENT ........................................................................ 82-12 

SIDE WINDOW GLASS ................................................................... 82-15 

REPLACEMENT ........................................................................ 82-15 

OUTSIDE MIRROR .......................................................................... 82-17 

REPLACEMENT ........................................................................ 82-17 

82 

82 

82 

82 

82 

Page 3235

Page 3236

WINDSHIELD/WINDOWGLASS/REAR 

VIEW MIRROR - 

WINDOW GLASS 

WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR 

COMPONENTS 

1 Windshield 

2 Rear Window Glass 

3 Power Window LH 

4 Front Glass LH 

5 Middle Glass LH 

WINDOW GLASS 

6 Rear Glass LH 

7 Power Window RH 

8 Slip Door Glass 

9 Middle Glass RH 

10 Rear Glass RH 

82-1 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

Page 3237

82-2 

POWER WINDOW 

INSPECTION 


VIEW MIRROR - 

POWER WINDOW 

NOTE 

Inspect the RH side by the same procedures as the LH side. 

1. CHECK POWER WINDOW LIFT FOR DEFORMATION. 

(a) If there is any deformation, replace it with a new one. 

2. CHECK ROLLER FOR WEAR AND DEFORMATION. 

(a) Check roller for wear and deformation. 

(b) If there are any wear and deformation, replace the power window lift with a new one. 

Page 3238


VIEW MIRROR - 

REPLACEMENT 

POWER WINDOW 

82-3 

NOTE 

Replace the RH side by the same procedures as the LH side 


2. REMOVE FRONT DOOR CONTROLLER COVER. 

(a) Remove 2 retaining screws of the front door controller 

LH. 

82 

82 

82 

82 

82 

82 

(b) Using a screwdriver, pry up the front door controller 

cover. 

NOTE 

Be careful not to damager interior trim. 

82 

82 

82 

82 

82 

(c) 

Disconnect front door controller connector LH. 

82 

82 

82 

82 

82 

82 

3. REMOVE FRONT DOOR LOCK INNER HANDLE 

ASSY LH. 

(a) 

Remove the retaining screw. 

82 

82 

82 

Page 3239

82-4 


VIEW MIRROR - 

POWER WINDOW 

4. REMOVE FRONT DOOR INNER GUARD PLATE ASSY 

LH. 

(a) 

Using a screwdriver, pry the front door inner triangle 

plate LH. 

NOTE 

Be careful, not to damager interior trim. 

5. REMOVE FRONT DOOR INNER GUARD PLATE. 

(a) Using a screwdriver, pry the front door inner guard plate 

assy LH. 

6. REMOVE FRONT POWER WINDOW LIFT LH. 

(a) Loosen retaining screw, remove inner guard. 

(b) Disconnect the connector of the front door lock LH. 

(c) 

Connect front door controller connector, lower the glass 

to a proper position. 

NOTE 

The position you can see 2 window glass motor retaining 

screws. 

(d) 

(e) 

Loosen 2 retaining bolts of the power window LH. 

Carefully take out the glass. 

Page 3240


VIEW MIRROR - 

POWER WINDOW 

82-5 

(f) 

(g) 

(h) 

(i) 

Turn the ignition switch OFF and disconnect the front 

door controller connectors 

Remove retaining bolts of the front power window lift LH. 

Disconnect front power window lift connector. 

Take out the power window lift assy. 

82 

82 

82 

82 

82 

7. INSTALL FRONT POWER WINDOW LIFT LH ASSY. 

(a) Position the front power window lift LH assy. 

(b) Tighten the retaining screw of the front power window lift 

LH assy. 

Torque: 6.5 ~ 8.5 N·m 

(c) Connect front power window lift connector. 

82 

82 

82 

82 

(d) 

(e) 

Position the power window glass carefully. 

Tighten 2 retaining screws of power window LH. 

Torque: 6.5 ~ 8.5 N·m 

82 

82 

82 

82 

82 

(f) 

Install front door inner guard LH. 

82 

82 

82 

82 

82 

82 

Page 3241

82-6 


VIEW MIRROR - 

POWER WINDOW 

8. INSTALL FRONT DOOR INNER GUARD PLATE ASSY. 

(a) Install front door inner guard plate assy. 

NOTE 

Always use new clips when installing the guard plate 

9. INSTALL FRONT DOOR INNER TRIANGLE PLATE 

LH. 

(a) 

Install front door inner triangle plate LH. 

NOTE 

Always use new clips when installing the guard plate 

10. INSTALL FRONT DOOR LOCK INNER HANDLE ASSY 

LH. 

(a) 

Install the retaining screw. 

11. INSTALL FRONT DOOR CONTROLLER COVER LH. 

(a) 

Connect connectors. 

(b) 

(c) 

Position the front door controller cover properly. 

Install 2 retaining screws of the front door conreoller LH. 

Page 3242


VIEW MIRROR - 

WINDSHIELD 

REPLACEMENT 

WINDSHIELD 

82-7 

1. REMOVE ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood, replacement”) 

2. REMOVE FRONT WIPER ARM ASSY. (Refer to “Chapter 65 wiper and washer - wiper assy, 


3. REMOVE WINDSHIELD LOWER TRIM. (Refer to “Chapter 65 wiper and washer - front wiper link 


4. REMOVE REAR VIEW MIRROR ASSY. (Refer to “Chapter 82 windshield - rear view mirror, 


5. REMOVE A PILLAR UPPER INNER GUARD BOARD. (Refer to “Chapter 88 exterior and interior 

trim - side wall guard board, replacement”) 

6. REMOVE FRONT WINDSHIELD. 

(a) Using a special tool, remove the windshield moulding. 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

(b) 

Mark the windshield and body position as shown in the 

illustration. 

NOTE 

It is no need to mark if the windshield is not resued. 

82 

82 

82 

82 

82 

(c) 

(d) 

(e) 

Insert the piano wire between the body and the glass. 

Attach wooden blocks to both ends of the piano wire. 

Pull the piano wire around the glass and cut off the sealant. 

NOTE 

• To prevent vehicle paint damage, use adhesive tape 

on painted surfaces during windshield removal. 

• Place a plastic cover between the piano wire and the 

instrument panel to prevent the instrument panel 

from being scuffed when removing the glass. 

82 

82 

82 

82 

Page 3243

82-8 


VIEW MIRROR - 

WINDSHIELD 

(f) 

(g) 

Using 2 suckers, remove the windshield. 

Remove the front windshield glass. 

NOTE 

• Be carefully not to drop off the windshield. 

• Leave as much sealant as possible on the body 

when removing the front windshield. 

7. CLEAN WINDSHIELD. 

(a) Remove the sealant on the windshield with a knife. 

NOTE 

Do not damage the windshield. 

(b) Clean the windshield outer circle with cleaning solvent. 

NOTE 

• Do not touch the glass surface after cleaning. 

• Even if you use new windshield, you should also 

clean the windshield with cleaning solvent. 

8. CLEAN BODY SURFACE. 

(a) Remove the rough harden sealant left on the body with a 

knife and clean with a rag soaked with cleaning slovent. 

NOTE 

• Do not damage the body. 

• Even if the entire sealant has been cleared, you 

should also clean the body surface. 

(b) 

Cut the sealant with the knife around the glass frame. 

Leave 2 mm in thickness of sealant. 

NOTE 

Do not completely cut curing sealant without necessary. Do 

not damage the surface of the body paint. If the paint is 

damaged, brush paint or antirusting paint on the damaged 

surface 

Page 3244


VIEW MIRROR - 

(c) 

WINDSHIELD 

Clean the windshield primer with the alcohol. 

82-9 

82 

82 

82 

82 

82 

(d) 

Apply a layer of primer at the outside of the windshield. 

82 

82 

82 

82 

82 

82 

82 

82 

82 

NOTE 

• Do not touch the contact surface by hand after 

applying the primer. 

• Do not brush body primer on the windshield. 

• Do not touch water, dust or rarity on the brushing 

face. 

82 

82 

82 

82 

82 

82 

Page 3245

82-10 


VIEW MIRROR - 

WINDSHIELD 

9. INSTALL WINDSHIELD. 

(a) Position the windshield preperly. 

• Position the windshield properly with sucker as shown in 

the illustration. 

• Check and ensure the contact surface of the windshield 

edge is flat. 

• Align the reference marks on the glass and the body. 

(b) 

Reaction type polyurethane black primer with a brush in 

a mounting surface of the windshield. 

NOTE 

• Do not apply too much primer. 

• Dry the primer coat for 5 minutes or more. 

• Do not save the opened primer for later use. 

• Wipe the excess primer off with a clean rag before it 

dries. 

(c) Apply the polyurethane black glass sealant with sealer 

gun in a defined area. 

NOTE 

• Do not apply too much primer. 

• Wipe the excess sealant off with a clean rag before it 

dries. 

(d) Position the windshield preperly. 

• Before installation, torn off the paper of the double-sided 

adhesive on the windshield. 

• Using a sucker, position the glass so that the reference 

marks are aligned.Press it in gently along the rim. 

• Lightly press the glass front surface for close contact. 

• Using a scraper, remove any excess or protruding 

sealant. 

• Fasten the glass with rubber tape before the sealant has 

hardened. 

NOTE 

• Remove the rubber tape after 4 hours later. 

• Check that the stoppers are attached to the body 

correctly. 

• Check the clearance between the body and glass. 

Page 3246


VIEW MIRROR - 

WINDSHIELD 

82-11 

10. INSPECT FOR LEAKAGE AND REPAIR . 

(a) Perform the leakage test after the hardening period. 

(b) Seal any leaks with the porper sealant. 

(c) Remove the tape. 

82 

82 

82 

82 

11. INSTALL FRONT WIPER ARM ASSY. (Refer to “Chapter 65 wiper and washer - wiper assy, 


12. INSTALL WINDSHIELD LOWER TRIM. (Refer to “Chapter 65 wiper and washer - front wiper link 


13. INSTALL ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood, 


14. INSTALL REAR VIEW MIRROR ASSY. (Refer to “Chapter 82 windshield - rear view mirror, 


82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

Page 3247

82-12 


VIEW MIRROR - 

REAR WINDOW GLASS 

REPLACEMENT 


1. REMOVE REAR WIPER ARM ASSY. (Refer to “Chapter 88 exterior and interior trim - spoiler 


2. REMOVE REAR WINDOW DEFROST WIRING CONNECTOR. 

3. REMOVE REAR WINDOW GLASS BY THE SAME PROCEDURES AS FRONT WINDSHIELD. 

4. CUT THE SEALANT WITH THE KNIFE AROUND THE GLASS BRACKET. LEAVE 2 MM IN THICKNESS OF 

SEALANT. 

NOTE 

Do not completely cut curing sealant without necessary. Do not damage the surface of the body paint. 

If the paint is damaged, brush paint or antirusting paint on the damaged surface. 

5. REMOVE THE ROUGH HARDEN SEALANT LEFT ON THE BODY WITH A KNIFE AND CLEAN WITH A RAG 

SOAKED WITH CLEANING SLOVENT. 

6. POSITION THE REAR WINDOWSHIEDL, MARK THE REAR 

WINDOW AND BODY POSITION AS SHOWN IN THE 

ILLUSTRATION. 

7. APPLY A LAYER OF PRIMER AT THE INSIDE OF THE 

REAR WINDOW GLASS INSERTION STRIP. 

NOTE 


applying the primer. 

• Do not brush body primer on the rear windowglass. 


face. 

8. APPLY THE SEALANT AROUND THE WINDOW GLASS. 

Page 3248


VIEW MIRROR - 


82-13 

NOTE 

Apply sealant within 5 minutes after applying the primer. 

9. APPLY THE PRIMER ON THE GLASS INSTALLING 

SURFACE. AFTER 10 MINUTES INSTALL REAR 

WINDOW GLASS. 

82 

82 

82 

82 

82 

10. USING SPEICAL TOOLS, INSTALL THE REAR 

WINDSHIELD ON THE MOUNTING FRAME. 

82 

82 

82 

82 

82 

11. USING A SCRAPER, REMOVE ANY EXCESS OR 

PROTRUDING SEALANT. 

82 

82 

82 

82 

82 

12. AFTER FOUR HOUR, PERFORM THE TEST FOR REAR 

WINDOW WATER LEAKAGE. 

82 

82 

82 

82 

82 

Page 3249

82-14 


VIEW MIRROR - 


13. FOUND LEAKING, COATED WITH A SEALANT AFTER THE LEAKING PARTS DRY. 

NOTE 

• After installing rear window glass, wait one hour or more to let sealant hardened. 

• After installing rear window glass, place the vehicle on a flat ground for more than four hours. If 

need to run the car this moment, slowly drive the car in eight hours. 

• When all the windows are closed, do not close the door furiously. 

• After installing rear window glass, do not be over-load in two to three days. (As drive in 

irregular, uneven road.) 

Page 3250


VIEW MIRROR - 

SIDE WINDOW GLASS 

REPLACEMENT 


82-15 

1. REMOVE SIDE WALL INNER GUARD BOARD. (Refer to “Chapter 88 exterior and interior trim - 

side wall inner guard board, replacement”) 

2. REMOVE SIDE WINDOW GLASS BY THE SAME PROCEDURES AS WINDSHIELD. 

3. CUT THE SEALANT WITH THE KNIFE AROUND THE GLASS FRAME. LEAVE 2mm IN 

THICKNESS OF SEALANT. 

NOTE 

Do not completely cut curing sealant without necessary. Do not damage the surface of the body paint. 

If the paint is damaged, brush paint or antirusting paint on the damaged surface. 

4. REMOVE THE ROUGH HARDEN SEALANT PORTIONS ON THE BODY WITH A KNIFE AND CLEAN WITH A 

RAG SOAKED WITH CLEANING SLOVENT. 

5. MARK THE SIDE WINDOW AND BODY POSITION AS 

SHOWN IN THE ILLUSTRATION. 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

82 

6. STICK RUBBER FENDER AROUND THE GLASS TO AVOID SEALANT SPILLED WHEN INSTALLING. 

7. INSTALL SIDE WINDOW GLASS TRIM STRIP WITHOUT ANY CLEARENCE. 

8. APPLY A LAYER OF PRIMER AT THE OUTSIDE OF THE 

SIDE WINDOW GLASS INSERTION STRIP. 

NOTE 


applying the primer 

• Do not brush body primer on the windshield. 


face. 

82 

82 

82 

82 

82 

82 

82 

82 

82 

9. APPLY THE SEALANT AROUND THE WINDOW GLASS. 

NOTE 

Apply sealant within 5 minutes after applying the primer. 

Page 3251

82-16 


VIEW MIRROR - 


10. APPLY THE PRIMER ON THE SIDE BOARD WIDOW- 

GLASS FRAME. AFTER 10 MINUTES INSTALL SIDE 

WINDOW GLASS. 

11. USING SPECIAL TOOLS, POSITION THE GLASS SO 

THAT THE REFERENCE MARKS ARE ALIGNED. 

12. USING A SCRAPER, REMOVE ANY EXCESS OR 

PROTRUDING SEALANT. 

13. AFTER FOUR HOURS, PERFORM THE TEST FOR 

REAR WINDOW WATER LEAKAGE. 

14. FOUND LEAKING, COATED WITH A SEALANT AFTER THE LEAKING PARTS DRY. 

NOTE 

• After installing side window glass, wait one hour or more to let sealant hardened. 

• After installing side window glass, place the vehicle on a flat ground for more than four hours. If 

need to run the car this moment, slowly drive the car in eight hours. 

• When all the windows are closed, do not close the door furiously. 

• After installing side window glass, do not be over-load in two to three days. (As drive in 

irregular, uneven road.) 

Page 3252


VIEW MIRROR - 


REPLACEMENT 


NOTE 


82-17 

1. REMOVE FRONT DOOR INNER GUARD BOARD LH. 

(Refer to “Chapter 88 exterior and interior trim - 

vehicle door inner guard board, replacement”). 

(a) Remove front door inner guard board LH. 

82 

82 

82 

82 

82 

82 

2. REMOVE OUTSIDE MIRROR LH. 

(a) 

Disconnect connector. 

82 

82 

82 

82 

82 

(b) 

(c) 

Loosen 3 retaining nuts. 

Remove the outside mirror LH. 

82 

82 

82 

82 

82 

82 

3. DISMASSEMBLE OUTSIDE MIRROR LH. 

(a) Remove 3 bolts from the mirror base 

(b) Remove the mirror body. 

82 

82 

82 

Page 3253

82-18 


VIEW MIRROR - 


(c) 

(d) 

Disconnect the connector of the mirror heating. 

Remove the mirror. 

NOTE 

• Adjust the outside mirror to limit position, then pry 

out the mirror from the back of the outside mirror. 

• Be careful when disconnect the connector of the 

outside mirror. 

(e) 

Loosen 3 retaining screws of the mirror motor. 

(f) 

Disconnect the connector of the mirror motor. 

4. REMOVE THE OUTSIDE MIRROR CONTROLLER. 

(a) Loosen 2 front door controller cover. 

(b) Remove the front door controller cover. 

(c) 

Disconnect the connector of the front door controller 

switch. 

Page 3254


VIEW MIRROR - 


82-19 

(d) 

Remove the outside mirror control switch from the bottom 

of the controller cover. 

82 

82 

82 

5. INSTALL THE OUTSIDE MIRROR CONTROLLER. 

(a) Connect the front door controller switch connector. 

(b) Install the front door controller switch. 

82 

82 

82 

82 

82 

(c) 

(d) 

Position the front door controller switch connector. 


82 

82 

82 

82 

82 

82 

6. ASSEMBLE MIRROR. 

(a) Connect the harness of the mirror motor. 


82 

82 

82 

82 

(c) 

(d) 

Connect the connector of the mirror heating. 

Install the outside mirror. 

82 

82 

Page 3255

82-20 


VIEW MIRROR - 


(e) 

Tighten 3 bolts from the mirror base. 

7. INSTALL OUTSIDE MIRROR ASSY. 

(a) 

Tighten 3 retaining nuts. 

(b) 


8. INSTALL FRONT DOOR INNER GUARD BOARD LH. 

(Refer to “Chapter 88 exterior and interior trim - 

vehicle door inner guard board, replacement”). 

9. REMOVE INSIDE REAR VIEW MIRROR. 

(a) Remove inside rear view mirror cover. 

(b) Extraction the inside rear view mirror from the base. 

Page 3256


VIEW MIRROR - 


82-21 

10. INSTALL INSIDE REAR VIEW MIRROR. 

(a) Install inside rear view mirror. 

(b) Install inside rear view mirror cover. 

82 

82 

82 

11. REMOVE REAR LOWER VIEW MIRROR. 

(a) Use a screwdriver, pry out rear view mirror cover from the 

base. 

82 

82 

82 

82 

82 

(b) 

(c) 

Remove 4 retaining screws from the rear lower view 

mirror. 

Remove the rear lower view mirror. 

82 

82 

82 

82 

82 

82 

12. INSTALL REAR LOWER VIEW MIRROR. 

(a) Tighten 4 retaining screws of rear lower view mirror. 

82 

82 

82 

82 

(b) 

Install the rear lower view mirror cover. 

82 

82 

Page 3257

MEMO 

Page 3258

INSTRUMENT PANEL 

INSTRUMENT CLUSTER .................................................................. 83-1 

PRECAUTION.............................................................................. 83-1 

COMPONENTS ........................................................................... 83-2 

REPLACEMENT .......................................................................... 83-3 

DASHBOARD..................................................................................... 83-5 

PRECAUTION.............................................................................. 83-5 

COMPONENTS ........................................................................... 83-6 

REPLACEMENT .......................................................................... 83-7 

MIDDLE PLATFORM................................................................. 83-15 

REPLACEMENT ........................................................................ 83-15 

83 

83 

83 

83 

Page 3259

Page 3260

INSTRUMENT PANEL - 


83-1 


PANEL 

PRECAUTION 

1. POWER OFF. 

(a) Before removing or installing any electrical devices,please disconnect the battery negative cable first 

to avoid device damage or personal injury. 

(b) Make sure ingition switch is OFF if no specific instructions. 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

Page 3261

83-2 INSTRUMENT PANEL - INSTRUMENT CLUSTER 

COMPONENTS 

1 Instrument Cluster Assy 

2 Screw 

4 Oil Pressure Switch 

5 Coolant Sensor 

3 Odometer Sensor 

Page 3262



83-3 

REPLACEMENT 


2. ADJUST STEERING WHEEL TO THE LOWEST POSITION. 

3. REMOVE INSTRUMENT CLUSTER COVER ASSY. 

(a) Remove 2 instrument cluster cover mounting screws. 

(b) Using trim stick, pry out instrument cluster cover from the 

dashboard. 

83 

83 

83 

83 

83 

83 

(c) Pull instrument cluster cover out far enough to 

disconnect dimming switch connector on the left side of 

instrument cluster cover. 

83 

83 

83 

83 

(d) 

(e) 

Disconnect hazard warning switch connector on the 

right side of instrument cluster cover. 

Disconnect headlight height adjusting switch connector 

on the right side of instrument cluster cover. 

83 

83 

83 

83 

83 

(f) 

Remove instrument cluster cover. 

83 

83 

NOTE 

Care not to scratch the dashboard and take instrument 

cluster cover out from the right side of steering wheel. 

83 

83 

83 

Page 3263

83-4 INSTRUMENT PANEL - INSTRUMENT CLUSTER 

4. REMOVE INSTRUMENT CLUSTER ASSY. 

(a) 

(b) 

Remove 2 mounting bolts at the bottom of instrument 

cluster. 

Pull instrument cluster out. 

(c) 

(d) 

Turn instrument cluster over and disconnect 2 instrument 

cluster connectors. 

Remove instrument cluster through the space between 

steering wheel and dashboard. 

NOTE 

Take instrument cluster out from the right side of steering 

wheel, be careful not to scratch the dashboard and instrument 

cluster. 

5. INSTALL INSTRUMENT CLUSTER ASSY. 

(a) Connect 2 instrument cluster connectors. 

(b) 

(c) 

Position instrument cluster assy and fix instrument 

cluster into proper place. 

Tighten 2 instrument cluster mounting screws. 

6. INSTALL INSTRUMENT CLUSTER COVER ASSY. 

(a) Connect connectors at either side of instrument cluster 

cover assy. 

(b) Place instrument cluster cover inside and fix it into place. 

(c) Tighten 2 mounting screws. 

Page 3264


DASHBOARD 

83-5 

DASHBOARD 

PRECAUTION 

1. WHEN REMOVING INSTRUMENT PANEL, THE MEMORY OF THE AUDIO SYSTEM WILL BE 

LOST. 

NOTE 

It is recommended that reset the audio systems when work is finished. 

2. POWER OFF. 

(a) Before removing or installing any electrical devices, please disconnect the battery negative cable to 


(b) Make sure ingition switch is OFF if no specific instructions. 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

Page 3265

83-6 INSTRUMENT PANEL - DASHBOARD 

COMPONENTS 

1 Dashboard Body Assy 

2 Screw 

3 Center Lower Panel Bracket 

4 Screw 

5 Instrument Cluster Cover 

6 Tapping Screw 

7 Center Panel Assy 

8 Center Control Panel 

9 Steering Column Lower Cover 

10 Parking Brake Shield Assy 

11 Glove Box Assy 

12 Left Defost Vent Assy 

13 Right Defost Vent Assy 

14 Right Outlet Vent Panel Assy 

15 Center Lower Panel Assy 

16 Screw base 

Page 3266


DASHBOARD 

83-7 

REPLACEMENT 

1. PLACE TEH VEHICLE ON LEVEL GROUND OR LIFTER AND FACE TIRES STRAIGHT AHEAD. 



NOTE 

When disconnecting or connecting the battery cables, please turn off the ignition switch first and 

lighting switch and loosen the cable nut completely. Do not pry up the cable when peforming these 

operations。 


overhaul”) 

5. REMOVE STEERING COLUMN LOWER COVER. 

6. REMOVE COMBINATION SWITCH UPPER AND LOWER COVER. 



8. REMOVE INSTRUMENT CLUSTER ASSY. (Refer to “Chapter 83 instrument panel - instrument 

cluster , replacement”) 

9. REMOVE MULTI-MEDIA AND A/C CONTROLLER. (Refer to “Chapter 61 heater and air conditioner 

- multi-media and A/C controller assy , replacement”) 

10. REMOVE CENTER SWITCH PANEL. 

(a) Remove 4 center switch panel mounting screws. 

(b) Pull center switch panel out. 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

(c) 

(d) 

Disconnect 4 electrical connectors from the rear. 

Remove centre switch panel. 

83 

83 

83 

83 

83 

83 

11. REMOVE CIGARETTE LIGHTER. 

(a) Disconnect connector from the back of cigarette lighter. 

(b) Remove cigarette lighter. (Refer to “Chapter 66 audio 

system - electric device accessories , replacement”) 

83 

Page 3267


12. REMOVE ASHTRAY. 

(a) Depress release latch, pull ashtray out. 

13. REMOVE TRANSMISSION SHIFTING CONTROL LEVER BALL ASSY AND DUST COVER. (Refer 

to “Chapter 41 transmission - transmission operation mechanism assy, replacement”) 

14. REMOVE BOTH SIDE DEFOST VENT. 

(a) Using trim stick, pry up left defost vent assy. 

(b) The procedure to remove right defost vent assy is similar 

to the left side. 

15. REMOVE OUTLET VENT PANEL. 

(a) Using trim stick, along the edge pry outlet vent panel out. 

(b) Remove outlet vent panel. 

16. REMOVE GLOVE BOX ASSY. 

Page 3268


DASHBOARD 

83-9 

17. REMOVE CENTRE LOWER PANEL ASSY. 

(a) Remove 5 mounting screws on both and top side of the 

centre lower panel. 

83 

83 

83 

18. REMOVE PARKING BRAKE SHIELD. 

(a) Using trim stick, pry up parking brake shield along its 

edge. 

83 

83 

83 

83 

83 

83 

19. REMOVE CENTRE PANEL ASSY. 

(a) Remove 3 centre panel mounting screws. 

(b) Using trim stick, pry up centre panel. 

83 

83 

83 

83 

83 

20. REMOVE 12V POWER OUTLET SOCKET. 

(a) Disconnect 12V power outlet connect from the inside of 

dashboard. 

(b) Remove 12V power outlet socket from dashboard. (Refer 

to “Chapter 66 audio system - electric device accessories 

, replacement”) 

83 

83 

83 

83 

83 

21. REMOVE DIAGNOSTIC SOCKET. 

(a) Loosen 2 diagnostic socket mounting screws. 

(b) Remove diagnostic socket from the dashboard. 

83 

Page 3269


. 

22. REMOVE ENGINE HOOD AND FUEL FILLER DOOR 

HANDLE. 

(a) 

(b) 

Remove engine hood handle from dashboard. 

Remove fuel filler door handle from dashboard. 

23. REMOVE BOTH A-PILLAR HANDLES AND A PILLAR UPPER GUARD BOARDS. (Refer to 

“Chapter 88 exterior and interior - roof panel, replacement”) 

24. REMOVE DASHBOARD ASSY. 

(a) 

(b) 

Remove 11 mounting bolts/screws as shown. 

Remove instrument cluster carefully. 

NOTE 

Because there are many harnesses in the instrument panel, 

when removing the instrument panel, be careful not to hook 

the harness, so as not to damage the harness. 

25. INSTALL DASHBOARD ASSY. 

Page 3270


DASHBOARD 

83-11 

83 

83 

83 

83 

83 

83 

83 

83 

83 

(a) 

(b) 

(c) 

Position the dashboard body properly. 

Put the inside harness in order and wait for using when 

installing dashboard accessories. 

Tighten 11 mounting bolts/screws. 

26. INSTALL CENTRE PANEL ASSY. 

(a) Place centre panel into dashboard properly. 

(b) Tighten 3 mounting screws. 

83 

83 

83 

83 

83 

83 

83 

27. INSTALL OUTLET VENT PANEL ASSY. 

(a) Position outlet vent panel and press outlet vent panel 

evenly into place. 

83 

83 

83 

83 

28. INSTALL INSTRUMENT CLUSTER AND COVER. (Refer to “Chapter 83 instrument panel - 

instrument cluster , replacement”) 

29. INSTALL TRANSMISSION SHIFTING CONTROL LEVER BALL ASSY AND DUST COVER. (Refer 

to “Chapter 41 transmission - transmission operation mechanism assy, replacement”) 

Page 3271


30. INSTALL CIGARETTE LIGTHTER. 

(a) Install cigarette lighter, and connect the connector to the 

back of cigarette lighter. 

31. INSTALL CENTRE SWITCH PANEL. 

(a) Connect centre switch panel connector. 

(b) 

Tighten 4 centre switch panel mounting screws. 

32. INSTALL MULTI-MEDIA AND A/C CONTROLLER ASSY. (Refer to “Chapter 61 heater and air conditioner 

- multi-media and A/C controller assy, replacement”) 

33. INSTALL 12V POWER OUTLET SOCKET. 

(a) Install 12V power outlet socket. (Refer to “Chapter 66 

audio system - electric device accessories , replacement”) 

(b) Connect 12V power outlet socket connector. 

Page 3272


DASHBOARD 

83-13 

34. INSTALL GLOVE BOX ASSY. 

83 

83 

83 

35. INSTALL PARKING BRAKE SHIELD ASSY. 

(a) Position parking brake shield, then press it on dashboard 

into place. 

83 

83 

83 

83 

83 

83 

36. INSTALL CENTRE LOWER PANEL ASSY. 

(a) Position centre lower panel assy, then tighten 5 mounting 

screws on both and top side. 

83 

83 

83 

83 

83 

37. INSTALL ENGINE HOOD AND FUEL FILLER DOOR 

HANDLE. 

(a) Install engine hood and fuel filler door handle into place. 

(b) Pull engine hood and fuel filler door handle to confirm it is 

working properly. 

83 

83 

83 

83 

83 

38. INSTALL BOTH A-PILLAR HANDLES AND A PILLAR UPPER GUARD BOARDS. (Refer to 

“Chapter 88 exterior and interior - roof panel, replacement”) 




overhaul”) 

41. REMOVE STEERING COLUMN LOWER COVER. (Refer to “Chapter 51 steering column - steering 

column assy, overhaul”) 

42. CONNECT BATTERY NEGATIVE CABEL. 

83 

Page 3273



(a) Check electrical switches on instrument panel are functional and combination switch works normally. 

Page 3274


DASHBOARD 

83-15 

MIDDLE PLATFORM 

REPLACEMENT 

1. REMOVE MIDDLE PLATFORM ASSY. 

(a) Open centre glove box lid, remove rubber pad NO.1, and 

then remove 2 internal retaining bolts. 

(b) Remove cup holder rubber pad and then remove 2 

internal retaining bolts. 

(c) Remove centre glove box rubber pad NO.2 and then 

remove 2 interal retaining bolts. 

(d) Remove middle platform assy. 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

2. INSTALL MIDDLE PLATFORM ASSY. 

(a) Position the middle platform assy properly. 

(b) Tighten all bolts inside glove box and cup holder. 

(c) Cover glove box and cup holder rubber pads. 

(d) Close glove box lid. 

83 

83 

83 

83 

83 

83 

83 

83 

83 

83 

Page 3275

MEMO 

Page 3276

SEATS 

SEATS................................................................................................ 84-1 

PRECAUTION.............................................................................. 84-1 

DRIVER / ASSISTANT DRIVER SEAT.............................................. 84-2 

COMPONENTS ........................................................................... 84-2 

ADJUSTMENT............................................................................. 84-3 

REMOVAL & INSTALLATION AND 

DISASSEMBLY & ASSEMLBY.................................................... 84-7 

PASSENGER SEAT......................................................................... 84-15 

REPLACEMENT ........................................................................ 84-15 

PASSENGER SEAT......................................................................... 84-20 

COMPONENTS ......................................................................... 84-20 

84 

84 

84 

84 

84 

Page 3277

Page 3278

SEAT - SEAT 

84-1 

SEATS 

PRECAUTION 

WARNING 

• Never adjust the seat when vehicle is moving. 

• After adjusting the seat position fore-and-aft, be sure to attempt to slide the seat with track 

handle released and make sure the seat is locked completely. 

• After adjusting the angle of backrest, be sure to attempt to recline the backrest backward and 

make sure the backrest is locked completely. 

• Never move the vehicle before all pasengers sitting down properly. 

• When vehicle is moving, make sure the backrest is locked completely. Be sure to wear seat belt 

correctly and lean the backrest. Never sit on a folding seat or in the trunk. 

• Do not stand and ambulate when vehicle is moving. 

• Never place objects under the seat. Otherwise it will affect the performance of seat adjuster, 

even cause the seat slide unexpectedly. 

84 

84 

84 

Page 3279

84-2 

SEAT - DRIVER / ASSISTANT DRIVER SEAT 

DRIVER / ASSISTANT DRIVER SEAT 

COMPONENTS 

1 Driver Seat Assy 2 Assistant Driver Seat Assy 

Page 3280


84-3 

ADJUSTMENT 

1. PRECAUTION. (Refer to “Chapter 84 seat - seat, precaution”) 

2. PRECAUTION ON DRIVER SEAT ADJUSTMENT. 

(a) 

(b) 

Slide the driver seat backward as much as possible on the premise that the driver can push the pedal 

comfortably. 

If necessary, adjust the angle of driver seat backrest to keep the distance between steering wheel and 

your chest above 250 mm. 

NOTE 

Adjust the steering wheel towards your chest, instead of the head or neck. (Refer to “Chapter 51 

steering column - steering wheel assy, adjustment”) 

3. ADJUST HEADREST HEIGHT. 

(a) Press the lock button and hold it. 

84 

84 

84 

(b) 

Move the headrest up or down to the comfortable position. 

(c) 

Release the lock button. 

Page 3281

84-4 


(d) 

Attempt to move the headrest up and down to make sure 

the headrest is locked completely. 

NOTE 

If hear a “click”, the headrest is locked completely. 

4. ADJUST FORE AND AFTER POSITION. 

(a) 

Pull the handle up and hold it. 

(b) 

Slide the seat forward or rearward to the comfortable position. 

(c) 

Release the handle. 

(d) 

Attempt to slide the seat forward and rearward to make 

sure the seat is locked completely. 

NOTE 

If hear a “click”, the seat is locked completely. 

Page 3282


84-5 

5. ADJUST BACKREST RECLINING. 

(a) Pull the reclining adjuster handle up. 

84 

84 

84 

(b) 

Recline the backrest forward or rearward to the comfortable 

position. 

Page 3283

84-6 


(c) 

Release the reclining adjuster handle. 

(d) 

Attempt to recline the backrest forward and rearward to 

make sure the backrest is locked completely. 

NOTE 

The backrest can not be moved if it locked completely. 

Page 3284


84-7 

REMOVAL & INSTALLATION AND DISASSEMBLY & ASSEMLBY 

1. DISCONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging- battery, 


2. REMOVE DRIVER SEAT ASSY. 

(a) Slide the driver seat assy to the back end. 

84 

(b) 

Loosen the 2 bolts. 

84 

84 

(c) 

Slide the driver seat assy to the front end. 

(d) 

Loosen the 2 bolts. 

WARNING 

• Turn over the driver seat assy backward carefully and 

slowly. 

• Do not drag the electric lock catch wire harness. 

• Do not move the tracks to prevent malposition. 

Page 3285

84-8 


(e) 

Disconnect the electric lock catch wire harness connector. 

(f) 

Using a screwdriver, pry the electric lock catch wire harness 

connector from the driver seat. 

NOTE 

If the connector is broken, replace the electric lock catch 

assy. (Refer to “Chapter 63 seat belt - lock catch assy, 


(g) 

Remove the driver seat assy. 

3. REMOVE ASSISTANT DRIVER SEAT ASSY. 

NOTE 

WARNING 

Care must be taken because the seat assy is quite heavy. 

CAUTION 

• Do not score the surfaces of parts around. 

• Do not move the tracks when storing to prevent malposition. 

• Remove the assistant driver seat assy by the same procedures as the driver seat assy. 

• Skip step (e) and (f). 

4. DISASSEMBLE DRIVER SEAT ASSY. 

(a) Pull out the reclining adjuster handle cover. 

Page 3286


84-9 

(b) 

Loosen the screw. 

84 

(c) 

Remove the reclining adjuster trim cover handle side by 

the sequence shown in the illustration. 

NOTE 

• Move the trim cover backward first. 

• Then pull the trim cover outward. 

• Move forward and remove the trim cover. 

84 

84 

(d) 

Loosen the screw. 

(e) 

Remove the reclining adjuster trim cover electric lock 

catch side by the sequence shown in the illustration. 

NOTE 

• Move the trim cover backward first. 

• Then pull outward and remove the trim cover. 

Page 3287

84-10 


(f) 

(g) 

Loosen the bolt attaching the electric lock catch to the 

driver seat reclining adjuster. 

Remove the electric lock catch assy. 

(h) 

Pull out the electric lock catch wire harness through the 

hole between cushion pad and reclining adjuster. 

CAUTION 

Be careful not to damage the electric lock catch wire harness 

connector. 

(i) 

Turn the clips. 

(j) Turn the cushion pad, remove the clips. 

(k) Remove the cushion pad. 

NOTE 

Replace the clips with a new one. 

(l) 

(m) 

Loosen 4 retaining screws. 

Remove the driver seat bottom plate. 

Page 3288


84-11 

(n) 

(o) 

Loosen 4 retaining bolts. 

Remove the rail block. 

84 

5. DISASSEMBLE THE ASSISTANT DRIVER SEAT ASSY. 

NOTE 

• Disassemble the assistant driver seat assy by the same procedures as the driver seat assy. 

• Step (g), remove lock catch assy. 

• Skip step (h). 

84 

84 

6. ASSEMBLE DRIVER SEAT ASSY. 

(a) Position the rail block. 


(c) 

(d) 

Install driver seat bottom plate. 


(e) 

(f) 

Position the cushion pad properly. 

Install clips. 

Page 3289

84-12 


(g) 

Put the electric lock catch wire harness connector through the 

hole between cushion pad and reclining adjuster. 

(h) 

(i) 

Position the electric lock catch assy properly. 



(j) 

Install the electric lock catch side reclining adjuster trim 

cover and screw. 

(k) 

Install the reclining adjuster trim cover electric lock catch 

side by the sequence shown in the illustration. 

Page 3290


84-13 

(l) 


84 

(m) 

Install the reclining adjuster handle cover. 

84 

84 

7. ASSEMBLE ASSISTANT DRIVER SEAT ASSY. 

NOTE 

• Assemble the assistant driver seat assy by the same procedures as the driver seat assy. 

• Position the lock catch assy properly in step (k). 

• Skip step (j). 

8. INSTALL DRIVER SEAT ASSY. 

(a) Position the driver seat assy. 

WARNING 

Care must be taken because the driver seat assy is quite heavy. 

CAUTION 

• Do not score the surfaces of parts around. 

• Do not move the tracks to prevent malposition. 

(b) 

(c) 

Install the electric lock catch wire harness connector to 

mounting hole on the driver seat. 

Connect the electric lock catch wire harness connector. 

CAUTION 

• Do not score surfaces of parts around 


NOTE 

If the connector is broken, replace with a new one. (Refer to 

“Chapter 63 seat belt - lock catch assy, replacement”) 

Page 3291

84-14 


(d) 



CAUTION 

• Make sure the driver seat assy is at the back end. 

• Move the seat assy carefully and slowly then position it on 

the top of the base welding assy. 


• Do not move the sliding tracks to prevent malposition. 

(e) 

(f) 

Slide the driver seat assy to the front end. 



9. INSTALL ASSISTANT DRIVER SEAT ASSY. 

NOTE 

• Install the assistant driver seat assy by the same procedures as the driver seat assy. 

• Skip step (b) and (c). 



11. ADJUST DRIVER / ASSISTANT DRIVER SEAT ASSY. (Refer to “Chapter 84 seat- driver / assistant 

driver seat, adjustment”) 

Page 3292

SEAT - PASSENGER SEAT 

84-15 

PASSENGER SEAT 

REPLACEMENT 

1. REMOVE PASSENGER SEAT ASSY. 

(a) Loosen 4 seat trim cover clips. 

(b) Remove the side trim cover. 

84 

(c) 

(d) 

Remove 4 retaining bolts and 2 nuts. 

Remove passenger seat assy LH. 

84 

84 

NOTE 

• Do not lost screw washer. 

• Care must be taken because the seat assy is quite 

heavy. 

2. REMOVE THE THIRD/FOURTH/FIFTH ROW PASSENGER SEAT ASSY LH. 

NOTE 

Remove the third/fourth/fifth row passenger seat assy by the same procedures as the second row passenger 

seat assy. 

3. REMOVE THE PASSENGER SEAT ASSY RH. 

(a) Loosen 4 seat trim cover clasps. 

(b) Remove the seat trim cover. 

(c) 

(d) 

Remove 3 retaining bolts and 1 nut. 

Remove passenger seat assy RH. 

Page 3293

84-16 


4. REMOVE THE THIRD/FOURTH/FIFTH ROW PASSENGER SEAT ASSY RH. 

NOTE 

Remove the third/fourth/fifth row passenger seat assy by the same procedures as the second row passenger 

seat assy. 

5. DISASSEMBLE THE PASSENGER SEAT ASSY RH. 

(a) Pry up the clasp from the each side of the seat. 

NOTE 

Pry up the clasp from the right side first, otherwise the seat 

will be damaged. 

(b) Remove the cushion. 

(c) 

(d) 


Remove reclining adjuster. 

(e) 

(f) 


Remove reclining coil spring device. 

(g) 

(h) 

(i) 

Loosen 2 handle retaining screws. 

Remove the handle. 

Remove the seat rear trim cover. 

Page 3294


84-17 

(j) 

Press the lock button and remove the headrest. 

84 

(k) 

(l) 

Make the zipper open. 

Remove the backrest. 

84 

84 

6. ASSEMBLE THE PASSENGER SEAT ASSY RH. 

(a) Position the seat backrest. 

(b) Make the zipper close. 

(c) 

(d) 

(e) 

(f) 

Install the headrest. 

Position the seat rear trim cover. 

Tighten 2 handle retaining screws. 

Install the handle. 

Page 3295

84-18 


(g) 

(h) 


Install reclining coil spring device. 


(i) 

(j) 


Install reclining adjuster. 


(k) 

(l) 

(m) 

Position the cushion. 

Install seat retaining clips. 

Install passenger seat assy RH. 

7. DISASSEMBLE THE PASSENGER SEAT ASSY LH. 

NOTE 

Disassemble the passenger seat assy LH by the same procedures as the passenger seat assy RH. 

8. INSTALL PASSENGER SEAT ASSY LH. 

(a) 

Tighten 4 retaining bolts and 2 nuts. 

Page 3296


84-19 

(b) 

(c) 

Position the seat trim cover. 

Install 4 seat trim cover retaining clips. 

84 

9. INSTALL THE THIRD/FOURTH/FIFTH ROW PASSENGER SEAT ASSY LH. 

NOTE 

Install the third/fourth/fifth row passenger seat assy LH by the same procedures as the second row 

passenger seat assy LH. 

10. INSTALL PASSENGER SEAT ASSY LH. 

(a) Tighten 3 retaining bolts and 1 nuts. 


84 

84 

(b) 

Install the seat trim cover. 

11. INSTALL THE THIRD/FOURTH/FIFTH ROW PASSENGER SEAT ASSY RH 

NOTE 

Install the third/fourth/fifth row passenger seat assy RH by the same procedures as the second row 

passenger seat assy RH. 

Page 3297

84-20 


PASSENGER SEAT 

COMPONENTS 

PASSEBGER SEAT LH 

1 Seat Assy 

3 Clips 

2 Seat Trim Cover 

Page 3298


84-21 

PASSEBGER SEAT LH 

84 

84 

84 

1 Seat Assy 

Page 3299

84-22 


PASSEBGER SEAT RH 

1 Seat Assy1 2 Seat Assy2 

Page 3300


84-23 

PASSEBGER SEAT RH 

84 

84 

84 

1 Seat Assy 

2 Clips 

3 Seat trim Cover 

4 Washer 


6 Nut 

Page 3301

MEMO 

Page 3302

DOOR LOCKS 

FRONT DOOR LOCKS ...................................................................... 85-1 

COMPONENTS ........................................................................... 85-1 

REPLACEMENT .......................................................................... 85-2 

SLIDING DOOR LOCKS.................................................................... 85-7 

COMPONENTS ........................................................................... 85-7 

REPLACEMENT .......................................................................... 85-8 

REAR HATCH LOCK....................................................................... 85-12 

COMPONENTS ......................................................................... 85-12 

REPLACEMENT ........................................................................ 85-13 

ENGINE HOOD LOCK ..................................................................... 85-17 

COMPONENTS ......................................................................... 85-17 

REPLACEMENT ........................................................................ 85-18 

ALARM CONTROLLER................................................................... 85-19 

REPLACEMENT ........................................................................ 85-19 

85 

85 

85 

85 

85 

85 

Page 3303

Page 3304

FRONT DOOR LOCKS 

DOOR LOCKS 

COMPONENTS 

DOOR LOCKS - FRONT DOOR LOCKS 

85-1 

85 

13A 

85 

1 Outside Handle Assy 

2 Lock Catch Assy 

3 Inner Handle Assy 

4 Lock Block 

Page 3305

85-2 


REPLACEMENT 

NOTE 




NOTE 

• When disconnecting or connecting the battery cable, first turn off the ignition switch and 

lighting switch and completely loosen the cable nut. Do not pry up the cable when peforming 

these operation. 

• For the vehicle equipped with the power door locks, before disconnecting the battery negative 

cable, do not leave the key in the vehicle to avoid the door being locked. 

3. REMOVE FRONT DOOR CONTROLLER COVER LH. 

(a) Remove 2 retaining screws of the front door conreoller 

LH. 

(b) Using a screwdriver, pry up the front door controller cover. 

(c) 


4. REMOVE FRONT DOOR LOCK INNER HANDLE ASSY LH. 

(a) Remove 1 retaining screw. 

Page 3306


85-3 


LH. 

(a) 

Using a screwdriver, pry out the front door inner triangle 

plate LH. 

85 

(b) 

Using a screwdriver, pry out the front door inner guard 

plate assy LH. 

13A 

85 

6. REMOVE FRONT DOOR LOCK LH. 

7. REMOVE FRONT POWER WINDOW LIFT LH. (Refer to “Chapter 82 windshied/window glass/ 

outside mirror , replacement”) 

8. REMOVE FRONT DOOR LOCK LH. 

(a) Disconnect the front door lock actuator LH connector. 

(b) 

Remove retaining screws cover from the front door outer 

handle LH. 

Page 3307

85-4 


(c) 

(d) 

Remove retaining screws from the front door outer 

handle LH 

Remove front door outer handle carefully. 

(e) 

(f) 

Remove 1 retaining screw front door lock body LH 

Remove front door lock cylinder. 

(g) 

Disconnect the front door lock connecting rods from the 

front door lock body LH. 

NOTE 

Do not damage the connecting rods plastic clamp. 

(h) 

(i) 

Remove 3 retaining screws from the front door actuator 

LH. 

Remove the front door actuator LH. 

9. INSTALL FRONT DOOR LOCK LH. 

(a) Install front power window lift LH. (Refer to “Chapter 82 

windshied/window glass/outside mirror , replacement”) 

(b) Position the front door lock actuator properly. 

(c) Tighten 3 front door actuator LH retaining screws. 

(d) 

(e) 

Install front door outer handle assy. 

Connect the front door lock connecting rods from the 

front door lock body LH. 

Page 3308


85-5 

(f) 

Connect the front door lock actuator LH connectors. 

85 

10. INSTALL FRONT DOOR INNER GUARD PLATE ASSY 

LH. 

(a) 

Slap it by hand until all clips lock into position. 

NOTE 

Always use the new clips when installing the guard plate. 

13A 

85 

(b) 

Position the front door inner triangle plate LH properly 

and slap it by hand until all clips lock into position. 

NOTE 

Always use the new clips when installing the guard plate. 

11. INSTALL FRONT DOOR LOCK INNER HANDLE ASSY 

LH. 

(a) 

Install 1 retaining screw. 

12. INSTALL FRONT DOOR CONTROLLER COVER LH. 

(a) Connect 2 connectors. 

Page 3309

85-6 


(b) 

(c) 

Position the front door controller cover properly. 



14. INSPECT FRONT DOOR LOCK. 

NOTE 

• For the vehicle equipped with the power door locks, before disconnecting the battery negative 

cable, do not leave the key in the vehicle to avoid the door being locked. 

• For the vehicle equipped with the power door locks, when inspecting front door LH lock and 

unlock, both the slidind door and the front door RH should be activated simultaneously. 

Page 3310

SLIDING DOOR LOCKS 

COMPONENTS 

DOOR LOCKS - SLIDING DOOR LOCKS 

85-7 

85 

13A 

85 

1 Screw 

2 

Sliding Door Electric Control Concave 

Limiting Device 

3 Lower Damping Block 

4 Sliding Door Welding Assy 

5 Sliding Door Concave Limiting Device 

6 Sliding Door Convex Limiting Device 

7 Sliding Door Glass Assy 

8 Sliding Door Lock Assy 

9 Sliding Door Lower Guard Board 

10 Sliding Door Middle Guard Board 

11 Sliding Door Upper Guard Board 

12 

Sliding Door Electric Control Convex 

Limiting Device 

Page 3311

85-8 


REPLACEMENT 



NOTE 

For the vehicle equipped with the power door locks, before disconnecting the battery negative cable, 

do not leave the key in the vehicle to avoid the door being locked. 

3. REMOVE SLIDING DOOR LOWER GUARD BOARD ASSY 

RH. 

(a) 

Remove 2 sliding door inner handle retaining screws. 

(b) 

Remove the sliding door lower guard board assy. 

(c) 

Remove the water-proof film. 

(d) 

(e) 

(f) 

Disconnect the sliding door inner handle connecting rod. 

Loosen the sliding door inner handle screws. 

Remove sliding door inner handle. 

Page 3312


85-9 

4. REMOVE SLIDING DOOR LOCK ACTUATOR. 

(a) Disconnect the sliding door lock actuator connector. 

85 

(b) 

Disconnect the connecting rods from the sliding door 

lock actuator. 

13A 

85 

(c) 

(d) 

Remove 5 retaining bolts from the sliding door lock 

actuator. 

Remove the sliding door lock actuator. 

5. REMOVE SLIDING DOOR LOCK ASSY. 

(a) Disconnect the sliding door lock connecting rods. 

(b) 

(c) 

Loosen 3 retaining screws from the sliding door lock. 

Remove the sliding door lock. 

Page 3313

85-10 


6. INSTALL SLIDING DOOR LOCK. 

(a) Position the sliding door lock properly. 

(b) Tighten 3 sliding door lock retaining screws. 

(c) Connect the connecting rods to the sliding door. 

7. INSTALL SLIDING DOOR LOCK ACTUATOR. 

(a) Position the sliding door lock actuator properly. 

(b) Tighten 5 sliding door lock actuator retaining bolts. 

(c) 

Connect the sliding door lock actuator connector. 

(d) 

Connect the connecting rods to the sliding door lock actuator. 

(e) Connect the connecting rod to the sliding door inner handle . 

(f) 

Install the sliding door inner handle. 

Page 3314


85-11 

8. INSTALL SLIDING DOOR GUARD BOARD ASSY. 

(a) 

Install the water-proof film. 

85 

(b) 

Install sliding door lower guard board assy. 

13A 

85 

(c) 

Tighten the sliding door inner handle screws. 


10. INSPECT SLIDING DOOR LOCK/UNLOCK WITH KEY. 

NOTE 



Page 3315

85-12 

REAR HATCH LOCK 

COMPONENTS 

DOOR LOCKS - REAR HATCH LOCK 

1 Rear Hatch License Plate Lamp Shield 

2 Rear Hatch Upper Gaurd Board 

4 Rear Hatch Lock Catch 

5 Rear Hatch Lower Gaurd Board 

3 Rear Hatch Lock 

Page 3316


85-13 

REPLACEMENT 


NOTE 



85 

2. REMOVE REAR HATCH LOCK ASSY. 

(a) Remove 3 rear hatch lock retaining screw. 

(b) Remove rear hatch lock assy. 

13A 

3. REMOVE REAR HATCH LOWER GUARD BOARD ASSY. 

(a) Remove rear hatch inner handle retaining screw. 

85 

(b) 

Remove rear hatch lower guard board. 

4. REMOVE REAR HATCH LOCK ACTUATOR ASSY. 

(a) Disconnect the rear hatch lock actuator connector. 

Page 3317

85-14 


(b) 

Disconnect the rear hatch lock actuator connecting rods. 

(c) 

(d) 

Loosen the rear hatch lock actuator 3 retaining bolts. 

Remove the rear hatch lock actuator. 

5. REMOVE REAR HATCH LOCK CYLINDER ASSY. 

(a) Disconnect the rear hatch lock cylinder connecting rod. 

(b) Loosen 2 rear hatch lock cylinder retaining bolts. 

(c) Remove the rear hatch lock cylinder assy. 

6. REMOVE REAR HATCH INNER HANDLE LOCK . 

(a) Disonnect the rear hatch inner handle lock connecting 

rod. 

(b) Remove 3 rear hatch inner handle lock retaining screws. 

(c) Remove the rear hatch inner handle lock. 

7. INSTALL REAR HATCH INNER HANDLE LOCK . 

(a) Install 3 rear hatch inner handle lock retaining screws. 

(b) Connect the rear hatch inner handle lock connecting rod. 

Page 3318


85-15 

8. INSTALL REAR HATCH LOCK CYLINDER ASSY. 

(a) Position the rear hatch lock cylinder assy. 

(b) Install rear hatch lock cylinder connecting rod. 

(c) Tighten 2 rear hatch lock cylinder retaining screws. 

85 

9. INSTALL REAR HATCH LOCK ACTUATOR ASSY. 

(a) Position the rear hatch lock actuator assy properly. 

(b) Tighten 3 rear hatch lock actuator retaining bolts. 

13A 

85 

(c) 

Connect the rear hatch lock actuator connecting rods. 

(d) 

Connect the rear hatch lock actuator connector. 

10. INSTALL REAR HATCH LOWER GUARD BOARD ASSY. 

(a) 

Install the rear hatch lower guard board. 

Page 3319

85-16 


(b) 

Install the rear hatch lower inner handle screw. 

11. INSTALL REAR HATCH LOCK BLOCK. 

(a) Position the rear hatch lock block. 

(b) Tighten 3 rear hatch lock block retaining bolts. 

12. INSPECT REAR HATCH LOCK. 

NOTE 



Page 3320

ENGINE HOOD LOCK 

COMPONENTS 

DOOR LOCKS - ENGINE HOOD LOCK 

85-17 

85 

13A 

85 

1 Engine Hood Buffer Block 

2 Engine Hood Lock Assy 

4 Engine Hood Support Bar 

5 Engine Hood Support Bar Clip 

3 Engine Hood Assy 

Page 3321

85-18 

DOOR LOCKS - ENGINE HOOD LOCK 

REPLACEMENT 


2. REMOVE FRONT GRILLE.(Refer to “Chapter 82 exterior and interior trim front grille , replacement”) 

3. REMOVE ENGINE HOOD LOCK ASSY. 

(a) Remove 3 retaining bolts from the engine hood lock. 

(b) Remove the engine hood lock. 

(c) 

Disconnect the engine hood lock cable. 

4. INSTALL ENGINE HOOD LOCK ASSY. 

(a) Connect the engine hood lock cable. 

(b) 

(c) 

Position the engine hood lock properly. 

Install 3 retaining bolts to the engine hood lock. 

5. INSTALL FRONT GRILLE.(Refer to “Chapter 82 exterior and interior trim front grille , replacement”) 

Page 3322

DOOR LOCKS - ALARM CONTROLLER 

85-19 

ALARM CONTROLLER 

REPLACEMENT 


2. REMOVE STEERING WHEEL LOWER TRIM COVER. 

85 

3. REMOVE ALARM CONTROLLER ASSY. 

(a) Disconnect the alarm controller connector. 

(b) 

(c) 

Loosen 2 alarm controller retaining bolts. 

Remove alarm controller. 

13A 

85 

4. INSTALL ALARM CONTROLLER ASSY. 

(a) Tighten 2 alarm controller retaining bolts. 

(b) 

Connect the alarm controller connector. 

5. INSTALL STEERING WHEEL LOWER TRIM COVER. 


Page 3323

MEMO 

Page 3324

SLIDING ROOF 

SLIDING ROOF ASSY ....................................................................... 86-1 


COMPONENTS ........................................................................... 86-2 

OVERHAUL ................................................................................. 86-3 

86 

86 

86 

86 

86 

86 

86 

Page 3325

Page 3326

SLIDING ROOF ASSY 

SLIDING ROOF 


SLIDING ROOF - SLIDING ROOF ASSY 

Symptom Suspect Reference 

86-1 

86 

1. Sliding rail (Insufficient lubrication) Chapter 86 sliding roof - sliding roof assy, overhaul 

Abnormal 

working 

2. Sliding rail (Dusty) Chapter 86 sliding roof - sliding roof assy, overhaul 

3. Sliding roof control switch (Failure) Chapter 86 sliding roof - sliding roof assy, overhaul 

Sliding roof 

assy leakage 

4. Sliding roof control switch (Damage) Chapter 86 sliding roof - sliding roof assy, overhaul 

1. Sliding roof weatherstrip (Aging) Chapter 86 sliding roof - sliding roof assy, overhaul 

2. Sliding roof weatherstrip (Improper 

installation) 

Chapter 86 sliding roof - sliding roof assy, overhaul 

3. Sliding roof assy (Improper installation) Chapter 86 sliding roof - sliding roof assy, overhaul 

4. Sliding roof assy (Maladjusted) Chapter 86 sliding roof - sliding roof assy, overhaul 

14A 

86 

Page 3327

86-2 


COMPONENTS 

1 Front Sliding Roof 

2 Front Ceiling Insulation Felt 

4 Front Sliding Roof Switch Panel 

5 Front Sliding Roof Switch 

3 Front Ceiling Trim Cover 

Page 3328


86-3 

OVERHAUL 


2. REMOVE SLIDING ROOF CONTROL SWITCH. 

(a) Remove the sliding roof control switch carefully. 

NOTE 

Be careful, do not damage the interior. 

86 

(b) 

Disconnect the connector and remove the sliding roof 

control switch. 

14A 

86 

3. REMOVE SLIDING ROOF WEATHERSTRIP. 

(a) 

Remove the sliding roof weatherstrip slowly. 

4. REMOVE ROOF GUARD BOARD. (Refer to "Chapter 88 exterior and interior trim - roof guard 

board, replacement") 

5. REMOVE SLIDING ROOF CONTROL MOTOR. 

(a) Disconnect the connector of the sliding roof control 

motor. 

Page 3329

86-4 


(b) 

Remove 2 bolts and sliding roof control motor. 

6. REMOVE SLIDING ROOF CONTROLLER. 

(a) Disconnect the connector of the sliding roof controller. 

(b) 

(c) 

Loosen 2 controller retaining screws. 

Remove the sliding roof controller. 

7. REMOVE THE SLIDING ROOF ASSY. 

(a) Loosen 4 sliding roof visor retaining screws. 

(b) Remove sliding roof visor assy. 

r 

(c) 

Loosen 12 sliding roof retaining cover retaining screws. 

Page 3330


86-5 

(d) 

(e) 

Raise the sliding roof glass and guide assy gently. 

Rotation and remove the sliding roof assy. 

86 

8. INSPECT SLIDING RAIL. CLEAN UP AND LUBRICATE THE SLIDING ROOF RAIL IF NECESSARY. 

9. INSPECT SLIDING ROOF CONTROL MOTOR. 

(a) Check the sliding roof control motor operates smoothly. If it isn’t operating smoothly, replace the sliding 

roof control motor with a new part. 

10. INSPECT SLIDING ROOF CONTROL SWITCH. 

(a) Gently press the ”open” then release the button, the sliding roof should be completely opened. 

(b) Gently press the ”close” then release the button, the sliding roof should be completely closed. 

(c) Press and hold down the ”open” then the sliding roof will operate untill you release the button. 

(d) Press and hold down the ”close” then the sliding roof will operate untill you release the button. 

14A 

86 

11. INSTALL SLIDING ROOF ASSY. 

(a) Position the sliding roof assy. 

(b) Install the sliding roof retaining cover. 

(c) Tighten 12 sliding roof retaining cover retaining screws. 


(d) Position the sliding roof visor. 

(e) Tighten the sliding roof visor retaining screws. 


Page 3331

86-6 


12. INSTALL SLIDING ROOF CONTROL MOTOR. 

(a) Install the sliding roof control motor and tighten 2 bolts. 

(b) 

Install the connector of the sliding roof control motor. 

13. INSTALL SLIDING ROOF CONTROLLER. 

(a) Tighten 2 controller retaining screws. 

(b) 

Connect the connector of the sliding roof controller. 

14. INSTALL ROOF GUARD BOARD. (Refer to "Chapter 88 exterior and interior trim - roof guard 

board, replacement") 

Page 3332


86-7 

15. INSTALL THE SLIDING ROOF WEATHERSTRIP. 

WARNING 

The weatherstrip has a direct influence on the body sealing 

performance. Inspect the weatherstrip from aging, cracking 

and damage before installing them. Replace with new 

weatherstrip if necessary. 

86 

16. INSTALL THE SLIDING ROOF CONTROL SWITCH. 

(a) Connect the connector and install the sliding roof control 

switch. 

14A 

86 


18. INSPECT WHETHER SLIDING ROOF CONTROL MOTOR OPERATES SMOOTHLY OR NOT. 

19. INSPECT WHETHER SLIDNG ROOF ASSY IS INSTALLED PROPERLY OR NOT. 

20. INSPECT FOR LEAKAGE. 

(a) Inspect the sliding roof for leakage after operating the sliding roof many times. Readjust the position of 

the sliding roof assy if necessary. (Refer to “Chapter 86 sliding roof - sliding roof system, overhaul”) 

Page 3333

MEMO 

Page 3334

DOORS & ENGINE HOOD 

ENGINE HOOD .................................................................................. 87-1 

ADJUSTMENT............................................................................. 87-1 

REPLACEMENT .......................................................................... 87-3 

FRONT DOOR.................................................................................... 87-4 

COMPONENTS ........................................................................... 87-4 

ADJUSTMENT............................................................................. 87-5 

REPLANCEMENT........................................................................ 87-7 

SLIDING DOOR.................................................................................. 87-9 

COMPONENTS ........................................................................... 87-9 

ADJUSTMENT........................................................................... 87-10 

REPLACEMENT ........................................................................ 87-13 

REAR HATCH .................................................................................. 87-15 

COMPONENTS ......................................................................... 87-15 

ADJUSTMENT........................................................................... 87-16 

REPLACEMENT ........................................................................ 87-18 

87 

87 

87 

87 

87 

87 

87 

87 

Page 3335

Page 3336

DOORS - ENGINE HOOD 

87-1 

ENGINE HOOD 

DOORS 

ADJUSTMENT 

1. INSPECT HOOD. 

(a) Check that the clearance is within the specified value. 

87 

87 

87 

Hood -Fender Clearance 

Hood-Headlamp Clearance 

4.0 mm 

4.5 mm 

2. ADJUST HOOD. 

(a) Asjust the engine hood horizontally. 

• Loosen the hood side hinge bolts. 

• Move the hood to adjust the clearance within the specified 

value. 

Specified Value: 4.0 mm 

• After adjusting, tighten the hood side hinge bolts. 


Page 3337

87-2 


(b) 

Adjust the hood by turning the rubber damper. 

• Adjust the rubber damper so as to align the hood 

with the fender. 

NOTE 

Turn the rubber to let it move up and down. 

Page 3338


87-3 

REPLACEMENT 

1. REMOVE ENGINE HOOD. 

(a) 

Remove 2 retaining bolts from the engine hood hinge LH. 

87 

(b) 

(c) 

Remove 2 retaining bolts from the engine hood hinge 

RH. 

Remove engine hood. 

NOTE 

Be careful, the engine hood is too heavy, pay attention to 

prevent contact with the windshield lift under. 

87 

87 

2. INSTALL ENGINE HOOD. 

(a) Tighten 2 retaining bolts to the engine hood hinge LH. 

Torque: 28 ~ 32 N·m. 

(b) 

Tighten 2 retaining bolts to the engine hood hinge RH. 

Torque: 28 ~ 32 N·m. 

3. ADJUST ENGINE HOOD.(Refer to “Chapter 87 engine hood and doors - engine hood, adjustment”) 

Page 3339

87-4 

FRONT DOOR 

COMPONENTS 

DOORS - FRONT DOOR 

1 Front Door Glass Assy LH 

2 Front Door Adjustment Assy 

10 Front Door Power Lift Assy 

11 Front Door Glass Sealing Strip LH 

3 Front Door Glass Guide Slot Assy LH 

4 Front Door Sealing Strip LH 

5 Front Door Cylinder Assy 

6 Front Door Inner Triangle Plate LH 

7 Left Fender Plug Strip Assy 

8 Front Door Glass Inner Weather Bar LH 

12 Maintenance Panel II 

13 Front Door Controller Cover LH 

14 Front Door Inner Guard Board LH 

15 Screw 

16 Screw 

17 Front Door Lock Assy LH 

9 Front Door Glass Outer Weather Bar LH 

Page 3340


87-5 

ADJUSTMENT 

NOTE 

Adjust the RH side by the same procedures as the LH side 

1. INSPECT FRONT DOOR LH. 


87 

87 

87 

Front Door- Fender 

Front Door- Quarter Panel 

5.5mm 

5.0mm 

2. ADJUST FRONT DOOR LH. 

(a) Adjust the door vertically and horizontally by loosening 

the body side hinge bolts. 

(b) After adjusting, tighten the body hinge bolts. 


Page 3341

87-6 


(c) 

(d) 

Adjust the striker position by slightly loosening the striker 

mounting screws . 

After adjusting, tighten the striker mounting screws. 


Page 3342


87-7 

REPLANCEMENT 

1. REMOVE THE FRONT BUMPER.(Refer to“Chapter 88 interior and exterior trim- front bumper, 

replacement) 

2. REMOVE FRONT DOOR ASSY. 

(a) 

Disconnect front door connector from the front bumper 

bracket. 

87 

(b) 

Remove retaining bolts from the front door limiting device 

LH. 

87 

87 

(c) 

(d) 

Remove 4 retaining bolts from the front door hinge LH. 

Remove the front door assy. 

NOTE 

Use new parts when installing. 

3. REMOVE FRONT DOOR HINGE RH. 

NOTE 

Remove the RH side by the same procedures as the LH side 

4. INSTALL FRONT DOOR HINGE LH. 

(a) Position the front door LH properly. After adjusting the 

front door clearance, tighten 4 retaining bolts to the front 

door hinge LH. 


Page 3343

87-8 


(b) 

Install front door limiting device LH. 


(c) 

Connect front door connector from front bumper bracket. 

NOTE 

Use new parts when installing. 

5. ADJUST FRONT DOOR LH.(Refer to “Chapter 87 engine hood and doors - front door, adjustment”) 

6. INSTALL THE FRONT BUMPER.(Refer to“Chapter 88 interior and exterior trim- front bumper, 

replacement) 

7. CONNECT THE BATTERY NEGATIVE CABLE. 

8. INSTALL THE RRONT DOOR RH. 

NOTE 


Page 3344

SLIDING DOOR 

COMPONENTS 

DOORS - SLIDING DOOR 

87-9 

87 

87 

87 

1 Sliding Door Upper Inner Guard Board RH 

2 

Sliding Door Middle Inner Guard Board 

RH 

3 Sliding Door Glass Assy RH 

4 Sliding Door Slide Weatherstrip RH 

5 Sliding Door Slide Cover 

6 Sliding Door Glass Weatherstrip RH 

7 Sliding Door Weatherstrip 

8 Sliding Door Waterproof 

9 

10 Screw 

Sliding Door Lower Slideway Bracket 

Assy RH 

11 Sliding Door Lock Assy RH 

12 Sliding Door Lower Inner Guard Board 

Page 3345

87-10 


ADJUSTMENT 

1. INSPECT SLIDING DOOR. 


Front Of Sliding Door 

Rear Of Sliding Door 

5 mm 

5 mm 

Page 3346


87-11 

87 

87 

Upper Of Sliding Door 

Lower Of Sliding Door 

5 mm 

6 mm 

87 

2. ADJUST SLIDING DOOR. 

(a) Loosen the sliding door upper bracket nut. 

(b) Adjust the sliding door position. 

(c) 

(d) 

(e) 

Loosen the sliding door lower bracket bolts. 

Adjust the door vertically. 

After adjusting, tighten the sliding door bracket bolts. 


6.5 ~ 8.5 N·m(small bolts) 

Page 3347

87-12 


(f) 

Adjust the middle convex limiting device by slightly loosening 

the middle convex limiting device mounting screws 

and hitting the middle convex limiting device with a plastic 

hammer. 

(g) 

Adjust the lock catch by slightly loosening the lock catch 

mounting bolts and hitting the lock catch with a plastic 

hammer. 

(h) 

(i) 

Adjust the middle concave limiting device by slightly 

loosening the middle concave limiting device mounting 

bolts and hitting the middle concave limiting device with a 

plastic hammer. 

After adjusting, tighten those bolts and screws. 

Page 3348


87-13 

REPLACEMENT 

1. REMOVE SLIDING DOOR RH. 

(a) Remove 3 mounting bolts from the sliding door lower 

bracket. 

87 

(b) 

Remove 2 mounting bolts from the sliding door middle 

bracket. 

87 

(c) 

(d) 

(e) 

Remove 2 mounting nut from the sliding door upper 

bracket. 

Slid out the sliding door. 

Remove the sliding door. 

87 

(f) 

(g) 

Slid out the sliding door. 

Remove the sliding door. 

2. INSTALL SLIDING DOOR RH. 

(a) Tighten mounting nut to upper bracket. 


Page 3349

87-14 


(b) 

Install 2 mounting bolts from the sliding door middle 

bracket. 


(c) 

Install 3 mounting bolts from the sliding door lower 

bracket. 


6.5 ~ 8.5 N·m(small bolts) 

3. ADJUST SLIDING DOOR RH. (Refer to “Chapter 87 engine hood and doors - sliding door, 


Page 3350

REAR HATCH 

COMPONENTS 

DOORS - REAR HATCH 

87-15 

87 

87 

87 

1 License Plate Lamp Shield 

7 Nut 

2 Rear Hatch Upper Guard Board Assy 

3 Gas Prop Assy LH 

4 Clip 

5 Gas Prop Assy RH 

6 Gas Prop Adjustment Assembly 

8 Rear Window Glass Assy 

9 Rear Hatch Sealing Strip 

10 Rear Hatch lower Guard Board Assy 

11 Rear Hatch Waterproof Film 

12 Rear Hatch Lock Assy 

Page 3351

87-16 


ADJUSTMENT 

1. INSPECT REAR HATCH.. 

Check that the clearance is within the specified value. 

Rear Hatch - Quarter Panel 

5 mm 

Rear Hatch - Rear Bumper 

10 mm 

Page 3352


87-17 

2. ADJUST REAR HATCH. 

(a) Adjust the lock catch and limiting device by slightly 

loosening the lock catch and limiting device mounting 

bolts. 

(b) After adjusting, tighten the lock catch mounting bolts 

87 

(c) 

(d) 

Loosen the rear hatch hinge mounting bolts to adjust the 

rear hatch position. 

After adjusting, tighten the rear hatch hinge mounting 

bolts. 


87 

87 

Page 3353

87-18 


REPLACEMENT 

1. REMOVE ROOF PANEL ASSY. (Refer to “Chapter 8 Interior and Exterior - Roof panel assy, 


2. REMOVE GAS PROP ASSY RH. 

(a) 

Disconnect the rear washer hose and the connector. 

(b) 

(c) 

(d) 

Remove 2 upper mounting bolts from the gas prop assy 

LH. 

Remove 2 lower mounting bolts from the gas prop assy 

LH. 

Remove gas prop. 

WARNING 

• Do not disassemble it or throw it into fire. 

• Using a drill, make a hole in the gas prop to 

discharge the gas inside. 

3. REMOVE GAS PROP LH. 

NOTE 

Remove the LH side by the same procedures as the RH side. 

4. REMOVE REAR HATCH HINGE. 

(a) Hold the rear hatch and remove rear hatch hinge 

mounting bolts LH. 

(b) 

(c) 

Remove rear hatch hinge mounting bolts RH. 

Remove rear hatch. 

Page 3354


87-19 

5. INSTALL REAR HATCH. 

(a) Tighten 4 rear hatch hinge mounting bolts. 


87 

(b) 

Position the gas prop properly and tighten the snap ring. 

(c) 

(d) 

Connect the rear hatch connector. 

Connect the rear washer hose. 

87 

87 

6. INSTALL ROOF PANEL ASSY. (Refer to “Chapter 8 Interior and Exterior - Roof panel assy, 


7. ADJUST REAR HATCH. (Refer to “Chapter 87 engine hood and doors - rear hatch, adjustment”) 

Page 3355

MEMO 

Page 3356


FRONT GRILLE ................................................................................. 88-1 

COMPONENTS ........................................................................... 88-1 

REPLACEMENT .......................................................................... 88-2 

FRONT BUMPER ASSY .................................................................... 88-3 

COMPONENTS ........................................................................... 88-3 

REPLACEMENT .......................................................................... 88-4 

WHEEL MUDGUARD......................................................................... 88-7 

REPLACEMENT .......................................................................... 88-7 

REAR BUMPER ASSY .................................................................... 88-10 

COMPONENTS ......................................................................... 88-10 

REPLACEMENT ........................................................................ 88-11 

SUN VISOR ASSY ........................................................................... 88-13 

COMPONENTS ......................................................................... 88-13 

REPLACEMENT ........................................................................ 88-14 

STEP BOARD .................................................................................. 88-15 

COMPONENTS ......................................................................... 88-15 

REPLACEMENT ........................................................................ 88-16 

VEHICLE DOOR INNER GUARD BOARD...................................... 88-18 

REPLACEMENT ........................................................................ 88-18 

QUARTER PANEL GUARD BOARD............................................... 88-23 

REPLACEMENT ........................................................................ 88-23 

FLOOR DECORATIVE PARTS........................................................ 88-27 

COMPONENTS ......................................................................... 88-27 

REPLACEMENT ........................................................................ 88-28 

ROOF PANEL .................................................................................. 88-31 

COMPONENTS ......................................................................... 88-31 

REPLACEMENT ........................................................................ 88-32 

88 

88 

88 

88 

88 

88 

88 

88 

88 

Page 3357

Page 3358

FRONT GRILLE 


COMPONENTS 

EXTERIOR AND INTERIOR TRIM - FRONT GRILLE 

88-1 

88 

1 Front Grille 2 Bolt 

16A 

88 

Page 3359

88-2 

EXTERIOR AND INTERIOR TRIM - FRONT GRILLE 

REPLACEMENT 

1. REMOVE FRONT GRILLE. 

(a) Remove 2 front grille screws. 

(b) 

(c) 

Pull out front grille, remove 9 clips. 

Remove front grille. 

2. INSTALL FRONT GRILLE. 

(a) Position the front grille, install 9 clips. 

(b) 

Install 2 screws. 

Page 3360

FRONT BUMPER ASSY 

COMPONENTS 

EXTERIOR AND INTERIOR TRIM - FRONT BUMPER ASSY 

88-3 

88 

16A 

1 Clip 

2 Clip 

3 Front Grille 

4 Front Bumper 

5 Front Bumper Support LH 

6 Screw 

7 Front Bumper Support RH 

8 Bolt 

9 Washer 

10 Bolt 

88 

Page 3361

88-4 


REPLACEMENT 


2. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior and interior - front grille, replacement”) 

3. REMOVE FRONT BUMPER ASSY. 

(a) Disconnect the front fog lamper connector. 

(b) 

Remove 2 bolts from front bumper assy by upside. 

(c) Loosen 3 screws from front bumper assy . 

(d) 

Remove 3 bolts from front bumper assy by downside. 

Page 3362


88-5 

(e) Remove the both side front step board cover . 

(f) 

Remove the clip RH. 

88 

(g) 

(h) 

Remove the clip LH. 

Remove the front bumper assy. 

4. INSTALL FRONT BUMPER ASSY. 

(i) Position the front fog lamps assy. 

(j) Tighten front step board cover retaining screw RH. 

16A 

88 

(k) 

Tighten front step board cover retaining screw LH. 

(l) 

Tighten 3 bolts from front bumper assy by downside. 

Page 3363

88-6 


(m) 

Tighten 3 bolts from front bumper assy by upside. 

(n) 

(o) 

Tighten 3 screws from front bumper assy. 

Connect the connectors to front fog lamps. 

(p) 

Connect the connectors to front fog lamps. 



Page 3364

EXTERIOR AND INTERIOR TRIM - WHEEL MUDGUARD 

88-7 

WHEEL MUDGUARD 

REPLACEMENT 

1. REMOVE FRONT WHEEL MUDGUARD LH. 

(a) Remove 3 screws and front wheel mudguard LH. 

88 

2. REMOVE FRONT WHEEL MUDGUARD RH. 

NOTE 


3. REMOVE REAR WHEEL MUDGUARD LH. 

(a) Remove 4 screws and rear wheel mudguard LH. 

16A 

88 

4. REMOVE REAR WHEEL MUDGUARD RH. 

NOTE 


5. REMOVE ENGINE MUDGUARD LH. 

(a) Loosen 4 clips, remove the engine mudguard LH. 

6. REMOVE ENGINE MUDGUARD RH. 

NOTE 


Page 3365

88-8 


7. REMOVE FRONT WHEEL FRONT MUDGUARD LH. 

(a) 

Loosen 3 clips, remove the front wheel front mudguard 

LH. 

8. INSTALL FRONT WHEEL FRONT MUDGUARD LH. 

(a) 

Tighten 3 clips, install the front wheel front mudguard LH. 

9. INSALL ENGINE MUDGUARD LH. 

(a) 

Tighten 4 clips, install the engine mudguard LH. 

10. INSTALL ENGINE MUDGUARD RH. 

NOTE 


11. INSTALL FRONT WHEEL MUDGUARD LH. 

(a) 

Install the front wheel mudguard LH and install 3 screws. 

12. INSTALL FRONT WHEEL MUDGUARD RH. 

NOTE 

Intsall the RH side by the same procedures as the LH side. 

Page 3366


88-9 

13. INSTALL REAR WHEEL MUDGUARD LH. 

(a) Install the rear wheel mudguard LH and install 4 screws. 

88 

14. INSTALL REAR WHEEL MUDGUARD RH. 

NOTE 


16A 

88 

Page 3367

88-10 

REAR BUMPER ASSY 

COMPONENTS 

EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY 

1 Wheel mudguard Clip 

2 Wheel mudguard Clip Cover 

3 Clip 

4 Screw 

5 Rear Bumper Support RH 

6 Rear Bumper Support LH 

7 Rear Bumper Body Assy 

8 Rear Bumper Support Clip 

9 Rear Bumper Lower Side Support 

10 Bolt 

Page 3368


88-11 

REPLACEMENT 

1. REMOVE REAR BUMPER ASSY. 

(a) Remove 6 bolts from rear bumper assy by upside. 

88 

(b) 

(c) 

Remove 4 clips from rear bumper assy by downside. 

Pull out the rear bumper slowly. 

NOTE 

Be careful, not to damage the rear bumper. 

(d) 

(e) 

Disconnect the reverse radar connector. 

Remove the rear bumper assy. 

16A 

88 

2. INSTALL REAR BUMPER ASSY. 

(a) Connect the reversing radar connector. 

(b) Position the rear bumper and install the clips. 

Page 3369

88-12 


(c) 

Install 6 bolts from rear bumper assy by upside. 

(d) 

Install 4 clips from rear bumper assy by downside. 

Page 3370

SUN VISOR ASSY 

COMPONENTS 

EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY 

88-13 

88 

16A 

1 Sun Visor Assy RH 

2 Sun Visor Assy LH 

3 Bolt 

4 Bolt 

88 

Page 3371

88-14 

EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY 

REPLACEMENT 

1. REMOVE SUN VISOR ASSY LH. 

(a) Remove 2 bolts from the hook. 

(b) Remove 2 bolts from sun visor assy. 

(c) Remove sun visor assy. 

2. REMOVE SUN VISOR ASSY RH. 

NOTE 


3. INSTALL SUN VISOR ASSY LH. 

(a) Position the sun visor assy, install the hook. 

(b) Install 2 bolts to sun visor assy. 

(c) Install sun visor assy. 

4. INSTALL SUN VISOR ASSY RH. 

NOTE 


Page 3372

STEP BOARD 

COMPONENTS 

EXTERIOR AND INTERIOR TRIM - STEP BOARD 

88-15 

88 

1 Step Board LH 

2 Step Board RH 

3 Clip 

4 Clip 

5 Jack Cover 

6 Sliding Door Step Board Assy 

16A 

88 

Page 3373

88-16 


REPLACEMENT 

1. REMOVE FRONT STEP BOARD COVER ASSY LH. 

(a) Remove 2 upside clips from the step board LH. 

NOTE 

Change new clip, when installation. 

(b) 

(c) 

Remove 2 downside clips from the step board LH 

Remove the step board LH. 

NOTE 

Change new clip, when installation. 

2. REMOVE STEP BOARD COVER RH. 

NOTE 


3. REMOVE SLIDING DOOR STEP BOARD COVER 

ASSY RH. 

(a) Loosen 11 covers and screws. 

(b) 

(c) 

Disconnect the step lamp connector. 

Remove the sliding door step board cover RH. 

Page 3374


88-17 

4. INSTALL STEP BOARD LH. 

(a) Position the step board LH. 

(b) Install 2 upside clips to step board LH. 

88 

(c) 

Install 2 downside clips to step board LH. 

5. INSTALL FRONT STEP BOARD COVER ASSY RH. 

NOTE 


16A 

88 

6. INSTALL SLIDING DOOR STEP BOARD COVER ASSY 

RH. 

(a) Connect the step lamp connector 

(a) Position the sliding door step board cover 

(b) 

Install 11 covers and screws. 

Page 3375

88-18 

EXTERIOR AND INTERIOR TRIM - VEHICLE DOOR INNER GUARD BOARD 

VEHICLE DOOR INNER GUARD BOARD 

REPLACEMENT 


LH. 

(a) 

(b) 

Remove the clip from front door inner triangle plate LH. 

Remove the front door inner triangle plate LH. 

(c) 

Loosen 2 screws to remove the front door controller 

cover LH. 

(d) 

(e) 

Disconnect 2 front door controller cover connectors. 

Remove front door controller cover. 

(f) 

(g) 

Remove the screw of front door lock inner handle assy 

LH. 

Remove 2 door lock connecting rods, then remove front 

inner handle LH. 

Page 3376


88-19 

(h) 

Disengage 13 clips, remove the front door inner guard 

plate assy LH. 

NOTE 

Change new clips when installation. 

88 

2. REMOVE FRONT DOOR INNER GUARD PLATE ASSY RH. 

NOTE 


3. REMOVE SLIDING DOOR UPSIDE INNER GUARD 

BOARD. 

(a) 

Disengage 13 clips and remove the sliding door upside 

inner guard board. 

16A 

88 

4. REMOVE SLIDING DOOR MIDDLE GUARD BOARD. 

(a) Disengage 3 clips and remove the sliding door middler 

guard board. 

5. REMOVE SLIDING DOOR DOWNSIDE INNER GUARD 

BOARD. 

(a) Remove 2 sliding door lock retaining scerws. 

Page 3377

88-20 


(b) 

Disengage 18 clips and remove the sliding door downside 

inner guard board. 

6. REMOVE REAR HATCH UPPER GUARD BOARD. 

(a) Disengage 17 clips and remove the rear hatch upper 

guard board. 

NOTE 

Be carful not to damage the rear hatch upper guard board. 

7. REMOVE REAR HATCH LOWER GUARD BOARD. 

(b) Remove blot of rear hatch handle, remove the rear hatch 

handle. 

(c) 

Disengage 12 clips and remove the rear hatch upper 

guard board. 

NOTE 

Be carful not to damage the rear hatch lower guard board. 

8. INSTALL FRONT DOOR INNER GUARD PLATE ASSY 

LH. 

(a) Install the front door lock inner handle assy LH with the 

screw. 

Page 3378


88-21 

(b) 

(c) 

Install 2 door lock connecting rods, then install front inner 

handle LH. 

Install the door lock inner handle assy LH with the screw. 

88 

(d) 

(e) 

(f) 

Connect the connector of the front door controller cover 

LH. 

Position the front door controller cover LH. 

Install 2 screws. 

(g) 

Install the front door inner triangle plate LH. 

16A 

88 

9. INSTALL FRONT DOOR INNER GUARD PLATE ASSY RH. 

NOTE 


10. INSTALL SLIDING DOOR LOWER GUARD BOARD. 

(a) 

Install the sliding door lower guard board with 13 clips. 

Page 3379

88-22 


11. INSTALL SLIDING DOOR MIDDLER GUARD BOARD 

(a) 

Install the sliding door middler guard board with 3 clips. 

12. INSTALL SLIDING DOOR UPPER GUARD BOARD 

(a) 

Install the sliding door upper guard board with 18 clips. 

13. INSTALL REAR HATCH UPPER GUARD BOARD 

(a) 

Install the rear hatch upper guard board with 17 clips. 

14. INSTALL REAR HATCH LOWER GUARD BOARD 

(a) Install the sliding door lower guard board with 12 clips. 

(b) Install the rear hatch handle bolt. 

Page 3380

EXTERIOR AND INTERIOR TRIM - QUARTER PANEL GUARD BOARD 

QUARTER PANEL GUARD BOARD 

REPLACEMENT 


88-23 

88 

2. REMOVE REAR QUARTER PANEL GUARD BOARD 

LH. 

(a) 

(b) 

(c) 

Remove passengers seat assy. 

Remove driver seat meshbelt with retractor assy.(Refer to 

“Chapter 63 seat belt-anchor adjuster assy, replacement”) 

Disengage 17 clips and remove the rear quarter panel 

guard board LH. 

3. REMOVE REAR QUARTER PANEL GUARD BOARD RH. 

NOTE 


4. REMOVE MIDDLE QUARTER PANEL GUARD BOARD 

LH. 

(a) 

(b) 

(c) 

Loosen the retaining screw. 

Remove passenger seat meshbelt with retractor assy. 

(Refer to “Chapter 63 seat belt -anchor adjuster assy, 


Disengage 6 clips and remove the middle quarter panel 


16A 

88 

5. REMOVE MIDDLE QUARTER PANEL GUARD BOARD RH. 

NOTE 


6. REMOVE FRONT QUARTER PANEL GUARD BOARD 

LH. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

Loosen the retaining screw. 

7. REMOVE FRONT QUARTER PANEL GUARD BOARD RH. 

(a) Pull out front and sliding door sealing strip RH. 

(b) Loosen 2 retaining screwsm, remove B pillar handle. 

(c) Remove assistant driver seat belt lower bolt. 

(d) Disengage 17 clips and remove the front quarter panel guard board LH. 

Remove driver seat meshbelt with retractor assy. (Refer 

to “Chapter 63 seat belt -anchor adjuster assy, 


Remove driver seat assy. 

Disengage 17 clips and remove the front quarter panel 


Remove engine compartment cover. 

Remove front quarter panel guard board LH. 

Page 3381

88-24 


8. REMOVE B PILLAR UPPER GUARD BOARD LH. 

(a) Remove driver seat belt upper bolt. 

(b) Pull out front door sealing strip. 

(c) Remove the engine compartment cover support point. 

(d) Disengage 3 clips and remove B pillar upper guard board 

LH. 

9. REMOVE B PILLAR UPPER GUARD BOARD RH. 

NOTE 

• Remove the RH side by the same procedures as the LH side. 

10. REMOVE OTHER SIDE PILLAR INNER GUARD BOARD. 

• Remove other side pillar inner guard board by the same procedures as the LH side. 

• Skip step (c)and(d). 

• Add step“ Remove side pillar inner guard board screw”. 

11. REMOVE A PILLAR UPPER GUARD BOARD LH. 

(a) Pull out front door sealing strip. 

(b) Use a screwdriver to remove the bolt covers of A pillar 

handle. 

(c) Remove 2 bolts. 

(d) 

(e) 

Remove A pillar handle. 

Remove A pillar guard board. 

12. REMOVE A PILLAR UPPER GUARD BOARD RH. 

NOTE 


Page 3382


88-25 

13. INSTALL FRONT QUARTER PANEL GUARD BOARD 

LH. 

(a) 

(b) 

(c) 

(d) 

Install 17 clips and install the front quarter panel guard 

board LH. 


Install driver seat belt upper bolt. 

Install engine compartment cover. 

88 

14. INSTALL FRONT QUARTER PANEL GUARD BOARD RH. 

(a) Install 6 clips and install the front quarter panel guard board RH 

(b) Tighten 2 retaining screwsm, install B pillar handle. 

(c) Install front and sliding door sealing strip RH. 

15. INSTALL MIDDLE QUARTER PANEL GUARD BOARD 

LH. 

(a) 

(b) 

(c) 

Install 6 clips and install the middle quarter panel guard 

board LH. 


Install passenger seat meshbelt with retractor assy. 



16A 

88 

16. INSTALL MIDDLE QUARTER PANEL GUARD BOARD RH. 

NOTE 


17. INSTALL REAR QUARTER PANEL GUARD BOARD 

LH. 

(a) 

(b) 

(c) 

Install 17 clips and install the rear quarter panel guard 

board LH. 

Install passenger seat meshbelt with retractor assy. 



Install rear hatch sealing strip 

18. INSTALL REAR QUARTER PANEL GUARD BOARD RH. 

NOTE 


Page 3383

88-26 


19. INSTALL B PILLAR UPPER GUARD BOARD LH. 

(a) Install 3 clips and install B pillar upper guard board LH. 

(b) Remove the engine compartment cover support point. 

(c) Install upper driver seat belt retaining bolt. 

(d) Install rear hatch sealing strip 

20. INSTALL B PILLAR UPPER GUARD BOARD RH. 

NOTE 


21. 

• Install other side pillar inner guard board by the same procedures as the LH side. 

• Skip step (c)and(d). 

• Add step“ Tighten side pillar inner guard board screw”. 

22. INSTALL A PILLAR UPPER GUARD BOARD LH. 

(a) Install 3 clips and install A pillar upper guard board LH. 

(b) 

(c) 

(d) 

Position the A pillar handle, install 2 bolts. 

Install the bolt covers of A pillar handle. 

Install the front door sealing strip. 

23. INSTALL A PILLAR UPPER GUARD BOARD RH. 

NOTE 


Page 3384

EXTERIOR AND INTERIOR TRIM - FLOOR DECORATIVE PARTS 

FLOOR DECORATIVE PARTS 

COMPONENTS 

88-27 

88 

16A 

1 Stop Plate 

2 Front Floor Covering 

3 Stop Plate Cover LH 

4 Stop Plate Cover RH 

5 Assisant Driver Step Board Trim Strip 

6 Engine Compartment Covering 

7 Driver Step Board Trim Strip 

8 Engine Compartment Cover Holder Belt 

9 Screw 

10 Air Filter Cover Switch Assy 

11 Screw 

12 Clip 

13 Screw 

14 Clip 

15 Sliding Door Lower Trim Strip 

16 Sliding Door Step Board Covering 

17 Sliding Door Upper Trim Strip 

18 Wheel Casing Carpet LH 

19 Rear Hatch Floor Trim Strip 

20 Wheel Casing Carpet RH 

21 Rear Floor Covering 

22 Engine Rear Stop Plate Covering 

23 Clip 

24 Screw 

25 Clip 

88 

Page 3385

88-28 


REPLACEMENT 

1. REMOVE ENGIEN COMPARTMENT COVER. 

(a) 

(b) 

(c) 

Remove driver seat assy.(Refer to “Chapter 84 seat - driver/assisant driver seat, removal & installation 

and disassembly &reassemlby) 

Remove middle platform.(Refer to “Chapter 83 instrument panel - middle platform, replacement”) 

Remove driver step board trim strip, remove the driver side covering. 

(d) 

(e) 

(f) 

Remove the quarter panel front lower guard board cover, 

remove the nut. 

Loosen 3 retaining bolt. 

Remove engine compartment cover assy. 

2. REMOVE ENGIEN COMPARTMENT COVER UNDER ASSISTANT DRIVER SEAT. 

NOTE 

• Remove engine compartment cover under assistant driver seat by the same procedures as the 

engine compartment cover. 

• Skip step (d) 

3. REMOVE FRONT FLOOR COVERING. 

(a) Remove driver and assistant driver seat assy.(Refer to “Chapter 84 seat-driver/assistant driver seat 

,removal & installation and disassembly &reassemlby”) 

(b) Remove middle platform.(Refer to “Chapter 83 instrument panel - middle platform, replacement”) 

(c) 

(d) 

Remove driver step board trim strip. 

Remove front floor covering. 

4. REMOVE ENGINE REAR STOP PLATE COVERING. 

(a) Remove 9 engine rear stop plate covering retaining clips. 

(b) Remove engine rear stop plate covering. 

Page 3386


88-29 

5. REMOVE REAR FLOOR COVERING. 

(a) Remove passenger seat.(Refer to “Chapter 84 seat- passenger seat,replacement”) 

(b) Remove quarter panel guard board.(Refer to “Chapter 88 exterior and interior trim-quarter panel guard 

board,replacement”) 

(c) Remove rear hatch floor trim strip. 

(d) Remove rear floor covering. 

88 

6. INSTALL ENGINE COMPARTMENT COVER. 

(a) Tighten 3 retaining bolts. 


(b) Tighten the nut, install the engine comparement cover. 

16A 

88 

(c) 

Install driver step board trim strip, install assistant driver 

covering. 

7. INSTALL ENGINE COMPARTMENT COVER UNDER ASSISTANT DRIVER SEAT. 

NOTE 

• Install engine compartment cover under assistant driver seat by the same procedures as the 

engine compartment cover. 

• Skip step (d) 

8. INSTALL FRONT FLOOR COVERING. 

(a) Position the front floor covering. 

(b) 

(c) 

(d) 

Install driver step board trim strip. 

Install middle platform. (Refer to “Chapter 83 instrument 

panel - middle platform, replacement”) 

Install driver and assistant driver seat assy.(Refer to “Chapter 

84 seat-driver/assistant driver seat ,removal & installation and 

disassembly &reassemlby”) 

Page 3387

88-30 


9. INSTALL ENGINE REAR STOP PLATE COVERING. 

(a) Position the engine rear stop plate covering. 

(b) Install 9 retaining clips. 

10. INSTALL REAR FLOOR COVERING. 

(a) Position the rear floor covering. 

(b) Install rear hatch floor trim strip. 

11. INSTALL QUARTER PANEL GUARD BOARD LH.(Refer to “Chapter 88 exterior and interior trim - 

quarter panel guard board, replacement”) 

12. INSTALL PASSENGER SEAT. (Refer to “Chapter 84 seat - passenger seat, replacement”) 

Page 3388

ROOF PANEL 

COMPONENTS 

EXTERIOR AND INTERIOR TRIM - ROOF PANEL 

88-31 

88 

16A 

1 Front Sliding Roof 

2 Front Insulating Felt 

3 Front Trim Cover 

4 Front Sliding Roof Switch Panel 

5 Front Sliding Roof Switch 

6 Front Visor LH 

7 Front Visor RH 

8 Bolt 

9 Bolt 

10 Rear Insulating Felt 

11 Rear Trim Cover 

12 Bolt 

13 Bolt 

88 

Page 3389

88-32 


REPLACEMENT 


2. REMOVE MIDDLE INDOOR LAMP ASSY. (Refer to“Chapter 64 lighting - middle indoor lamp 

assy,replacement”) 

3. REMOVE PASSENGER SEAT BELT UPPER REAINING BOLT.(Refer to “Chapter 63 belt - 

Retractor Assy,Replacement.”) 

4. REMOVE UPPER GUARD BOARD.(Refer to “Chapter 88 Exterior and interior trim - quarter panel 


5. REMOVE SLIDING ROOF SEALING STRIP. 

6. REMOVE REAR AIR PURIFIER ASSY. 

(a) Pass on both side, remove air purifier cover. 

(b) 

Remove air filter. 

(c) 

Loosen 4 retaining screws. 

Page 3390


88-33 

(d) 

(e) 


Remove the air purifier. 

88 

7. INSTALL REAR AIR PURIFIER ASSY 


(b) 


16A 

88 

(c) 

Position the air filter. 

Page 3391

88-34 


(d) 

Install air purifier cover.. 

8. REMOVE REAR ROOF GUARD BOARD ASSY. 

(a) Disconnect the sealing strip of rear hatch. 

(b) Disengage 30 clips. 

(c) Remove the roof guard board assy. 

NOTE 

• Be careful, the roof guard board assy is too heavy. 

• Be careful, do not damage the interior trim. 

• Be sure change new clips when installation. 

9. REMOVE FRONT ROOF GUARD BOARD ASSY. 

(a) Remove 2 safety hammer retaining screws. 

(b) 

(c) 

(d) 

Pry out air conditioning control switch. 

Disconnect the air conditioning control switch connector. 

Remove the air conditioning control switch. 

(e) 

(f) 

Remove the front visors. 

Remove front indoor lamp assy. 

Page 3392


88-35 

(g) 

Remove the front handle. 

88 

(h) 

(i) 

Disengage 6 clips. 

Remove the front roof guard board assy. 

NOTE 

Be sure change new clips when installation. 

10. INSTALL FRONT ROOF GUARD BOARD ASSY. 

(a) Install 6 clips and intsll front roof guard board. 

16A 

88 

(b) 

Install the front handle. 

(c) 

(d) 

Install the front visors. 

Install front indoor lamp assy. 

Page 3393

88-36 


(e) 

Connect the air conditioning control switch connector. 

(f) 

Install 2 safety hammer retaining screws. 

11. INSTALL FRONT ROOF GUARD BOARD ASSY. 

(a) Install 30 clips and intsll rear roof guard board. 

(b) Install rear hatch sealing strip. 

12. INSALL UPPER GUARD BOARD.(Refer to “Chapter 88 Exterior and interior trim - quarter panel 


13. INSTALL MIDDLE INDOOR LAMP ASSY. (Refer to“Chapter 64 lighting - middle indoor lamp 


14. INSTALL REAR INDOOR LAMP ASSY. (Refer to“Chapter 64 lighting - rear indoor lamp 


15. INSTALL SLIDING ROOF SEALING STRIP. 

16. INSTALL PASSENGER SEAT BELT UPPER REAINING BOLT.(Refer to “Chapter 63 belt - 

Retractor Assy,Replacement.”) 

17. CONNECT BATTERY NEGATIVE CABLE 

Page 3394


IGNITION SWITCH ASSY.................................................................. 91-1 

INSPECTION ............................................................................... 91-1 

REMOVAL & INSTALLATION AND 

DISASSEMBLY & ASSEMBLY.................................................... 91-2 

91 

91 

91 

91 

91 

91 

91 

91 

91 

91 

Page 3395

Page 3396

VEHICLE CONTROL SYSTEM - IGNITION SWITCH ASSY 

91-1 

IGNITION SWITCH ASSY 


INSPECTION 

1. INSPECT IGNITION SWITCH ASSY. 

(a) Test the resistance and the continuity of all pins using the 

following table. 

91 

Standard: 

Switch position Terminal Specified condition 

LOCK AM1 - ACC - IG1 - AM2 - IG2 - ST ≥ 1 MΩ 

ACC AM1 - ACC < 2 Ω 

ON AM1 - ACC - IG1, AM2 - IG2 < 2 Ω 

START AM1 - IG1 , AM2 - IG2 - ST < 2 Ω 

NOTE 

If the resistance is out of the specification, replace the ignition switch assy. (Refer to “Chapter 91 

vehicle control system - ignition switch assy, removal & installation and disassembly & assembly”) 

17A 

91 

Page 3397

91-2 


REMOVAL & INSTALLATION AND DISASSEMBLY & ASSEMBLY 





overhaul”) 

4. REMOVE STEERING COLUMN PANEL. 

5. REMOVE CLOCKSPRING. (Refer to “Chapter 62 Supplemental Restraint System - clock spring, 


6. REMOVE COMBINATION SWITCH UPPER AND LOWER COVER. 



8. REMOVE IGNITION SWITCH HARNESS. 

(a) Disconnect ignition switch connector. 

(b) Disconnect ignition key switch connector. 

(c) Disconnect ignition switch illumination light connector. 

(d) 

Using prying tool remove 2 harness ties. 

9. REMOVE STEERING COLUMN. 

(a) Remove 3 steering column retaining bolts as shown in 

the figure. 

NOTE 

It is recommended to remove steering column for easier 

operation. 

Page 3398


91-3 

10. REMOVE IGNITION SWITCH ILLUMINATION LIGHT. 

(a) Pry out lock slot on both sides of illumination light as 

shown in the figure. 

(b) Remove illumination light. 

91 

11. REMOVE IGNITION SWITCH ASSY. 

(a) Remove 2 ignition switch anti-theft bolts. 

NOTE 

Using special chisel, cut out a groove on top surface of 

anti-theft bolts, then remove them. 

(b) Remove ignition switch assy. 

17A 

12. DISASSEMBLE IGNITION SWITCH ASSY. 

(a) 

(b) 

Insert the ignition key, then turn the ignition switch to the 

“ACC” position. 

Using a stick, press the lock latch of ignition switch. 

91 

(c) 

Pull out the ignition switch body. 

Page 3399

91-4 


(d) 

Remove 2 screws. 

(e) 

Remove the ignition switch connector. 

13. ASSEMBLE IGNITION SWITCH ASSY. 

(a) 

Install the ignition switch connector. 

NOTE 

Insert and turn it to align the key sets. 

(b) 


Page 3400


91-5 

(c) 

(d) 

Insert the ignition key, then turn the ignition switch to the 

“ACC” position. 

Install the ignition switch body. 

NOTE 

If hear a “click”, the ignition switch is installed properly. 

91 

(e) 

Align the lock slot on the steering column assy and the latch 

block on the ignition switch assy. 

NOTE 

The ignition switch lock latch will extrude only when the 

ignition key is pulled out. 

(f) Position the ignition switch assy properly, then tighten 2 

anti-theft bolts with a suitable tool. 

NOTE 

After installation, using a special tool, strike the top surface 

of anti-theft bolts where there is a groove into a flat surface. 

17A 

91 

14. INSTALL IGNITION SWITCH ILLUMINATION LIGHT. 

(a) Press the illumination light until lock slots snap in place 

as shown in the figure. 

Page 3401

91-6 


15. INSTALL STEERING COLUMN ASSY. 

(a) 

Position steering column, then tighten 3 retaining bolts. 


16. CONNECT IGNITION SWITCH HARNESS CONNECTOR. 

17. INSTALL STEERING COLUMN PANEL. (Refer to “Chapter 51 steering column - steering column 

assy, overhaul”) 

18. INSTALL COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination 


19. INSTALL CLOCKSPRING. (Refer to “Chapter 62 Supplemental Restraint System - clock spring, 


20. INSTALL COMBINATION SWITCH UPPER AND LOWER COVER. 


overhaul”) 



(a) Insert ignition key into ignition lock cylinder and switch the ignition key in the ACC ,ON and LOCK 

positions so that confirm ignition switch works normally . 

Page 3402

INDEX 


A 

A - CHASSIS & FRAME WIRE HARNESS(CONNECTOR 

VIEWS) ........................................................................ 71-112, 71-104 

A - CHASSIS & FRAME WIRE HARNESS(WIRE HARNESS & CON- 

NECTOR LOCATION VIEWS)...................................................71-190 

ADJUSTMENT(CLUTCH PEDAL) .................................................42-5 

ADJUSTMENT(DRIVER / ASSISTANT DRIVER SEAT) ...............84-3 

ADJUSTMENT(ENGINE HOOD) ...................................................87-1 

ADJUSTMENT(FRONT COMBINATION LAMP ASSY) ................64-7 

ADJUSTMENT(REAR HATCH) ...................................................87-16 

ADJUSTMENT(SLIDING DOOR) ................................................87-10 

ADJUSTMENT(STEERING WHEEL ASSY)..................................51-7 

ADJUSTMENT(WASHER NOZZLE)............................................65-16 

ANTI-LOCK BRAKE CONTROL SYSTEM(WIRING 

DIAGRAM) ....................................................................... 71-41, 71-39 

ANTI-THEIF SYSTEM(WIRING DIAGRAM) .................. 71-103, 71-97 

AUDIO SYSTEM ............................................................................66-1 

A/C RECEIVER DRIER FILTER ELEMENT ................................61-85 

B 

B - BATTERY WIRE HARNESS(CONNECTOR 

VIEWS) ........................................................................ 71-125, 71-104 

B - BATTERY WIRE HARNESS(WIRE HARNESS & CONNECTOR 

LOCATION VIEWS) ..................................................... 71-199, 71-179 

BLEEDING(CLUTCH FLUID).........................................................42-3 

C 

C - FRONT BUMPER WIRE HARNESS(CONNECTOR 

VIEWS) ........................................................................ 71-126, 71-105 

C - FRONT BUMPER WIRE HARNESS(WIRE HARNESS & CON- 

NECTOR LOCATION VIEWS)..................................... 71-186, 71-166 

CHARGING SYSTEM(WIRING DIAGRAM) .................... 71-39, 71-37 

CLOCK SPRING ..........................................................................62-13 

CLUTCH FLUID .............................................................................42-3 

CLUTCH PEDAL............................................................................42-4 

CLUTCH SLAVE CYLINDER.......................................................42-11 

CLUTCH SUB - ASSY .................................................................42-13 

CLUTCH SYSTEM.........................................................................42-1 

COMBINATION SWITCH ASSY ...................................... 51-12, 64-27 

COMMUNICATION SYSTEM(WIRING DIAGRAM)......... 71-85, 71-81 

COMPONENTS(AUDIO SYSTEM)................................................66-1 

COMPONENTS(CLUTCH PEDAL)................................................42-4 

COMPONENTS(CLUTCH SUB - ASSY) .....................................42-13 

COMPONENTS(COMBINATION SWITCH ASSY)......................51-12 

COMPONENTS(DASHBOARD) ....................................................83-6 

COMPONENTS(DRIVER / ASSISTANT DRIVER SEAT BELT) ...63-4 

COMPONENTS(DRIVER / ASSISTANT DRIVER SEAT) .............84-2 

COMPONENTS(FLOOR DECORATIVE PARTS) .......................88-27 

COMPONENTS(FRONT BUMPER ASSY)....................................88-3 

COMPONENTS(FRONT COMBINATION LAMP ASSY)...............64-2 

COMPONENTS(FRONT DOOR LOCKS)......................................85-1 

COMPONENTS(FRONT DOOR)...................................................87-4 

COMPONENTS(FRONT GRILLE).................................................88-1 

COMPONENTS(INSTRUMENT CLUSTER)..................................83-2 

COMPONENTS(PASSENGER SEAT BELT) ................................63-5 

COMPONENTS(POWER STEERING SYSTEM) ..........................52-5 

COMPONENTS(REAR BUMPER ASSY) ....................................88-10 

COMPONENTS(REAR COMBINATION LAMP ASSY) ...............64-10 

COMPONENTS(REAR HATCH LOCK) ...................................... 85-12 

COMPONENTS(REAR HATCH) ................................................. 87-15 

COMPONENTS(ROOF PANEL) ................................................. 88-31 

COMPONENTS(SLIDING DOOR LOCKS) ................................... 85-7 

COMPONENTS(SLIDING DOOR) ................................................ 87-9 

COMPONENTS(SLIDING ROOF ASSY) ...................................... 86-2 

COMPONENTS(STEERING SYSTEM) ........................................ 51-5 

COMPONENTS(STEP BOARD) ................................................. 88-15 

COMPONENTS(SUN VISOR ASSY) .......................................... 88-13 

COMPONENTS(TRANSMISSION OPERATION MECHANISM 

ASSY)............................................................................................ 41-1 

COMPONENTS(WIPER AND WASHER SYSTEM) ..................... 65-4 

COMPRESSOR OIL.................................................................... 61-17 

COMPRESSOR(ISF2.8).............................................................. 61-80 

COMPRESSOR(4G69) ............................................................... 61-78 

CONDENSER.............................................................................. 61-83 

CONNECTOR VIEWS.................................................. 71-112, 71-104 


(HOW TO USE THIS MANUAL).................................................... 71-6 

D 

D - FRONT DOOR LH WIRE HARNESS(CONNECTOR 

VIEWS)......................................................................... 71-127, 71-106 

D - FRONT DOOR LH WIRE HARNESS(WIRE HARNESS & CON- 

NECTOR LOCATION VIEWS) ..................................... 71-188, 71-168 

DASHBOARD................................................................................ 83-5 

DRIVER / ASSISTANT DRIVER SEAT ......................................... 84-2 

DRIVER / ASSISTANT DRIVER SEAT BELT ............................... 63-4 

E 


(CONNECTOR VIEWS) ............................................... 71-130, 71-108 

E - ENGINE WIRE HARNESS(WIRE HARNESS & CONNECTOR 


ELECTRIC DEVICE ACCESSORIES ......................................... 66-12 

ENGINE HOOD ............................................................................. 87-1 

F 



F - ROOF WIRE HARNESS 1(WIRE HARNESS & CONNECTOR 


FLOOR DECORATIVE PARTS................................................... 88-27 

FRONT BUMPER ASSY ............................................................... 88-3 

FRONT COMBINATION LAMP ASSY .......................................... 64-2 

FRONT DOME LIGHT ASSY ...................................................... 64-17 

FRONT DOOR .............................................................................. 87-4 

FRONT DOOR LOCKS ................................................................. 85-1 

FRONT GRILLE ............................................................................ 88-1 

FRONT HEATER CORE ............................................................. 61-25 

FRONT SPEAKER ASSY.............................................................. 66-4 

FUSE AND RELAY LOCATIONS(HOW TO USE 

THIS MANUAL) ............................................................................. 71-9 

G 



Page 3403

G - ROOF WIRE HARNESS 2(WIRE HARNESS & CONNECTOR 


GLOSSARY OF TERMS AND SYMBOLS(HOW TO USE THIS 

MANUAL) ...................................................................................... 71-7 

H 



H - FRONT DOOR RH WIRE HARNESS(WIRE HARNESS & 

CONNECTOR LOCATION VIEWS) ............................. 71-189, 71-169 

HEATER AND AIR CONDITIONING SYSTEM ............................. 61-1 


(WIRING DIAGRAM) ........................................................ 71-44, 71-42 

HIGH-MOUNTED STOP LAMP ASSY ........................................ 64-16 

HORN SWITCH ASSY .................................................................. 62-6 

HOW TO USE THIS MANUAL ...................................................... 71-1 

J 

I - INSTRUMENT PANEL WIRE HARNESS(WIRE HARNESS & 

CONNECTOR LOCATION VIEWS) .......................................... 71-196 

J - REAR HATCH WIRE HARNESS(WIRE HARNESS & 


IGNITION SWITCH ASSY............................................................. 91-1 

INSPECTION(COMPRESSOR OIL) ........................................... 61-17 

INSPECTION(IGNITION SWITCH ASSY) .................................... 91-1 

INSPECTION(POWER WINDOW)................................................ 82-2 

INSPECTION(WASHER NOZZLE) ............................................. 65-15 

INSTRUMENT CLUSTER ............................................................. 83-1 

INSTRUMENT CLUSTER(WIRING DIAGRAM)............... 71-96, 71-90 

INTRODUCTION(HOW TO USE THIS MANUAL) ........................ 71-1 

K 

K - REAR HATCH TRANSITION WIRE HARNESS(WIRE HARNESS 

& CONNECTOR LOCATION VIEWS).......................... 71-204, 71-182 

L 

L - REAR EVAPORATOR WIRE HARNESS(WIRE HARNESS & 


LICENCE LAMP ASSY................................................................ 64-14 

LIGHT SYSTEM(WIRING DIAGRAM).............................. 71-52, 71-49 

LIGHTING SYSTEM...................................................................... 64-1 

M 

M - DIAGNOSIS WIRE HARNESS(WIRE HARNESS & CONNECTOR 


MIDDLE PLATFORM .................................................................. 83-15 

MIDDLE SPEAKER ASSY ............................................................ 66-6 

MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY ....... 66-2 

MULTI-MEDIA AND A/C CONTROLLER ASSY ......................... 61-19 

MULTIMEDIA SYSTEM(WIRING DIAGRAM) .................. 71-80, 71-76 

N 

N - STEP LAMP WIRE HARNESS(WIRE HARNESS & CONNECTOR 


O 

O - DRIVER SEAT BELT WIRE HARNESS(CONNECTOR 

VIEWS)...................................................................................... 71-172 

O - DRIVER SEAT BELT WIRE HARNESS(WIRE HARNESS & CON- 

NECTOR LOCATION VIEWS) .................................................. 71-199 

ON-VEHICLE INSPECTION(HEATER AND AIR CONDITIONING 

SYSTEM) .......................................................................................61-7 

ON-VEHICLE INSPECTION(REFRIGERANT)..............................61-8 

ON-VEHICLE INSPECTION(STEERING SYSTEM) .....................51-6 

ON-VEHICLE INSPECTION(SUPPLEMENTAL RESTRAINT 

SYSTEM) .......................................................................................62-4 

OVERHAUL(CLUTCH SUB - ASSY) ...........................................42-14 

OVERHAUL(COMPRESSOR(ISF2.8))........................................61-80 

OVERHAUL(COMPRESSOR(4G69))..........................................61-78 

OVERHAUL(CONDENSER)........................................................61-83 

OVERHAUL(RETRACTOR ASSY)..............................................63-15 

OVERHAUL(STEERING COLUMN ASSY) .................................51-16 

OVERHAUL(STEERING GEAR ASSY).......................................52-28 

OVERHAUL(STEERING PROPELLER SHAFT ASSY) ..............51-19 

OVERHAUL(STEERING WHEEL ASSY) ......................................51-8 

OUTSIDE MIRROR .....................................................................82-17 

P 


(CONNECTOR VIEWS)................................................71-173, 71-131 

P - REAR HEATER WIRE HARNESS(WIRE HARNESS & 

CONNECTOR LOCATION VIEWS)..............................71-199, 71-179 

PASSENGER SEAT ....................................................................84-15 

PASSENGER SEAT BELT ............................................................63-5 

POWER MIRROR(WIRING DIAGRAM) ...........................71-90, 71-85 

POWER SOCKET(WIRING DIAGRAM) ...........................71-83, 71-79 

POWER SOURCE SECTION EXAMPLE(HOW TO USE THIS 

MANUAL).......................................................................................71-5 

POWER SOURCE(WIRING DIAGRAM) ..........................71-18, 71-19 

POWER STEERING LINE ASSY ................................................52-22 


RESERVIOR ASSY .....................................................................52-17 

POWER STEERING SYSTEM ......................................................52-1 

POWER WINDOW.........................................................................82-2 

PRECAUTION(CLUTCH SYSTEM)...............................................42-1 

PRECAUTION(DASHBOARD) ......................................................83-5 

PRECAUTION(HEATER AND AIR CONDITIONING 

SYSTEM) .......................................................................................61-1 

PRECAUTION(INSTRUMENT CLUSTER)....................................83-1 

PRECAUTION(LIGHTING SYSTEM) ............................................64-1 

PRECAUTION(POWER STEERING SYSTEM) ............................52-1 

PRECAUTION(SEAT BELT SYSTEM)..........................................63-1 

PRECAUTION(SEAT)....................................................................84-1 

PRECAUTION(SUPPLEMENTAL RESTRAINT SYSTEM) ...........62-1 

PRECAUTION(WIPER AND WASHER SYSTEM) ........................65-1 

PROBLEM SYMPTOMS TABLE(CLUTCH SYSTEM)...................42-2 

PROBLEM SYMPTOMS TABLE(HEATER AND AIR 

CONDITIONING SYSTEM) ...........................................................61-3 

PROBLEM SYMPTOMS TABLE(POWER STEERING 

SYSTEM) .......................................................................................52-2 

PROBLEM SYMPTOMS TABLE(SLIDING ROOF ASSY).............86-1 

PROBLEM SYMPTOMS TABLE(STEERING SYSTEM)......51-1, 51-2 

PROBLEM SYMPTOMS TABLE(WIPER AND WASHER 

SYSTEM) .......................................................................................65-2 

Q 

Q - REAR BUMPER TRANSITION WIRE HARNESS(CONNECTOR 

VIEWS) .........................................................................71-174, 71-132 

Q - REAR BUMPER TRANSITION WIRE HARNESS(WIRE 

HARNESS & CONNECTOR LOCATION VIEWS)........71-204, 71-182 

QUARTER PANEL GUARD BOARD...........................................88-23 

R 

R - REAR BUMPER WIRE HARNESS(CONNECTOR 

VIEWS) .........................................................................71-175, 71-133 

Page 3404

R - REAR BUMPER WIRE HARNESS(WIRE HARNESS & CONNEC- 

TOR LOCATION VIEWS) ............................................ 71-204, 71-182 

RCM .............................................................................................62-16 

REAR BUMPER ASSY ................................................................88-10 

REAR COMBINATION LAMP ASSY ...........................................64-10 

REAR HATCH..............................................................................87-15 

REAR HATCH LOCK ...................................................................85-12 

REAR HEATER CORE ................................................................61-35 

REAR SPERKER ASSY ................................................................66-8 

REAR WINDOW GLASS .............................................................82-12 

REFRIGERANT .............................................................................61-8 

REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEM- 

BLY(IGNITION SWITCH ASSY) ....................................................91-2 

REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEML- 

BY((DRIVER / ASSISTANT DRIVER SEAT)) ................................84-7 

REMOVAL & INSTALLATION(PASSENGER SEAT) ..................84-15 

REPLACEMENT(A/C RECEIVER DRIER FILTER 

ELEMENT) ...................................................................................61-85 

REPLACEMENT(CLOCK SPRING).............................................62-13 

REPLACEMENT(CLUTCH PEDAL) ..............................................42-6 

REPLACEMENT(CLUTCH SLAVE CYLINDER) .........................42-11 

REPLACEMENT(COMBINATION SWITCH ASSY)......... 51-13, 64-27 

REPLACEMENT(COMPRESSOR OIL) .......................................61-18 

REPLACEMENT(DASHBOARD) ...................................................83-7 

REPLACEMENT(ELECTRIC DEVICE ACCESSORIES).............66-12 

REPLACEMENT(ENGINE HOOD) ................................................87-3 

REPLACEMENT(FLOOR DECORATIVE PARTS) ......................88-28 

REPLACEMENT(FRONT BUMPER ASSY) ..................................88-4 

REPLACEMENT(FRONT DOME LIGHT ASSY) .........................64-17 

REPLACEMENT(FRONT DOOR LOCKS) ....................................85-2 

REPLACEMENT(FRONT GRILLE)................................................88-2 

REPLACEMENT(FRONT HEATER CORE) ................................61-25 

REPLACEMENT(FRONT SPEAKER ASSY).................................66-4 

REPLACEMENT(HIGH-MOUNTED STOP LAMP ASSY) ...........64-16 

REPLACEMENT(HORN SWITCH ASSY) .....................................62-6 

REPLACEMENT(INSTRUMENT CLUSTER) ................................83-3 

REPLACEMENT(LICENCE LAMP ASSY)...................................64-14 

REPLACEMENT(MIDDLE PLATFORM)......................................83-15 

REPLACEMENT(MIDDLE SPEAKER ASSY)................................66-6 

REPLACEMENT(MULTI-MEDIA AND AIR-CONDITON CONTROL- 

LER ASSY) ....................................................................................66-2 

REPLACEMENT(MULTI-MEDIA AND A/C CONTROLLER 

ASSY) ..........................................................................................61-19 

REPLACEMENT(OUTSIDE MIRROR) ........................................82-17 

REPLACEMENT(POWER STEERING LINE ASSY) ...................52-22 

REPLACEMENT(POWER STEERING PUMP WITH FLUID RESER- 

VIOR ASSY).................................................................................52-17 

REPLACEMENT(POWER WINDOW) ...........................................82-3 

REPLACEMENT(QUARTER PANEL GUARD BOARD)..............88-23 

REPLACEMENT(RCM)................................................................62-16 

REPLACEMENT(REAR BUMPER ASSY)...................................88-11 

REPLACEMENT(REAR COMBINATION LAMP ASSY) ..............64-11 

REPLACEMENT(REAR HATCH LOCK)......................................85-13 

REPLACEMENT(REAR HATCH) ................................................87-18 

REPLACEMENT(REAR HEATER CORE)...................................61-35 

REPLACEMENT(REAR SPERKER ASSY) ...................................66-8 

REPLACEMENT(REAR WINDOW GLASS) ................................82-12 

REPLACEMENT(REFRIGERANT) ..............................................61-14 

REPLACEMENT(ROOF PANEL).................................................88-32 

REPLACEMENT(SEAT BELT CATCH ASSY) ..............................63-9 

REPLACEMENT(SIDE WINDOW GLASS)..................................82-15 

REPLACEMENT(SLIDING DOOR LOCKS) ..................................85-8 

REPLACEMENT(SLIDING DOOR)..............................................87-13 

REPLACEMENT(STEERING FLUID) ..........................................52-13 

REPLACEMENT(STEP BOARD).................................................88-16 

REPLACEMENT(SUN VISOR ASSY) .........................................88-14 

REPLACEMENT(TELESCOPIC ANTENNA ASSY) ....................66-10 

REPLACEMENT(TRANSMISSION ASSY 

(TANGSHANAIXIN)) ....................................................................41-73 

REPLACEMENT(TRANSMISSION ASSY 

(YANCHENGZHONGMA ZM001)) .............................................. 41-10 

REPLACEMENT(TRANSMISSION OPERATION MECHANISM 

ASSY)............................................................................................ 41-3 

REPLACEMENT(VACUUM BOOSTER WITH CLUTCH 

MASTER CYLINDER ASSY)......................................................... 42-8 

REPLACEMENT(VEHICLE DOOR INNER GUARD BOARD) .... 88-18 

REPLACEMENT(WHEEL MUDGUARD) ...................................... 88-7 

REPLACEMENT(WINDSHIELD)................................................... 82-7 

REPLACEMENT(WIPER ASSY)................................................... 65-5 

REPLACEMENT(WIPER BLADE WITH BRACKET ASSY)........ 65-13 

REPLACEMENT(WIPER LINK WITH MOTOR ASSY) ................. 65-9 

RETRACTOR ASSY.................................................................... 63-15 

ROOF PANEL ............................................................................. 88-31 

S 

S - REAR DEFROST RH WIRE HARNESS(CONNECTOR 

VIEWS)...................................................................................... 71-176 

S - REAR DEFROST RH WIRE HARNESS(WIRE HARNESS & 

CONNECTOR LOCATION VIEWS) .......................................... 71-204 

SEAT ............................................................................................. 84-1 

SEAT BELT CATCH ASSY ........................................................... 63-9 

SEAT BELT SYSTEM ................................................................... 63-1 

SIDE WINDOW GLASS .............................................................. 82-15 

SLIDING DOOR ............................................................................ 87-9 

SLIDING DOOR LOCKS ............................................................... 85-7 

SLIDING ROOF ASSY .................................................................. 86-1 

STARTING SYSTEM(WIRING DIAGRAM) ...................... 71-37, 71-35 

STEERING COLUMN ASSY ....................................................... 51-16 

STEERING GEAR ASSY ............................................................ 52-28 

STEERING PROPELLER SHAFT ASSY .................................... 51-19 

STEERING WHEEL ASSY............................................................ 51-7 

STEP BOARD ............................................................................. 88-15 

SUN VISOR ASSY ...................................................................... 88-13 

SUPPLEMENTAL RESTRAINT SYSTEM..................................... 62-1 

SYSTEM PERFORMANCE(SUPPLEMENTAL RESTRAINT 

SYSTEM)....................................................................................... 62-3 

SYSTEM PRINCIPLES(SUPPLEMENTAL RESTRAINT 

SYSTEM)....................................................................................... 62-2 

SYSTEM WIRING DIAGRAM SECTION EXAMPLE(HOW TO 

USE THIS MANUAL)..................................................................... 71-2 

T 

T - REAR DEFROST LH WIRE HARNESS(CONNECT 

VIEWS)...................................................................................... 71-177 

T - REAR DEFROST LH WIRE HARNESS(WIRE HARNESS & CON- 

NECTOR LOCATION VIEWS) .................................................. 71-204 

TELESCOPIC ANTENNA ASSY ................................................. 66-10 

TRANSMISSION ASSY(TANGSHANAIXIN)............................... 41-73 

TRANSMISSION ASSY(YANCHENGZHONGMA ZM001) ........... 41-8 

TRANSMISSION OPERATION MECHANISM ASSY ................... 41-1 

W 

V - FRONT WIRE HARNESS(CONNECT VIEWS) ...... 71-179, 71-135 

V - FRONT WIRE HARNESS(WIRE HARNESS & CONNECTOR 


U - HIGH-MOUNTED STOP LAMP WIRE HARNESS(CONNECT 

VIEWS)......................................................................... 71-178, 71-134 

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS(WIRE HAR- 

NESS & CONNECTOR LOCATION VIEWS) ............... 71-204, 71-182 

VACUUM BOOSTER WITH CLUTCH MASTER CYLINDER 

ASSY ............................................................................................. 42-8 

WASHER NOZZLE...................................................................... 65-15 

VEHICLE DOOR INNER GUARD BOARD ................................. 88-18 

VEHICLE WITH REAR WIPER ASSY(COMPONENTS) .............. 65-4 

WHEEL MUDGUARD.................................................................... 88-7 

Page 3405

WINDOW DEFROSTER(WIRING DIAGRAM) ................. 71-93, 71-88 

WINDSHIELD ................................................................................ 82-7 

WIPER AND WASHER SYSTEM.................................................. 65-1 

WIPER AND WASHER(WIRING DIAGRAM)................... 71-77, 71-73 

WIPER ASSY ................................................................................ 65-5 

WIPER BLADE WITH BRACKET ASSY ..................................... 65-13 

WIPER LINK WITH MOTOR ASSY............................................... 65-9 

WIRE HARNESS & CONNECTOR LOCATION 

VIEWS.......................................................................... 71-186, 71-166 

WIRING DIAGRAM .......................................................... 71-18, 71-19 

X 

X - PREHEATING WIRE HARNESS(WIRE HARNESS & CONNEC- 

TOR LOCATION VIEWS)............................................. 71-199, 71-179 

Page 3406

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