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Geely CK MR479Q 2007, Workshop Manual

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Geely CK MR479Q 2007 Workshop Manual Download Page 368

361

6. Cowl Upper Assembly

Cowl upper assembly is mainly composed of cowl upper outer plate, cowl upper LH/RH end plate assembly,

instrument panel mounting plate, steering column mounting bracket upper/lower plate, cowl lower inner plate,

ventilator cover, etc., by welding them together.

Figure 5-2 Dismantle diagram of front sheet metal and cowl parts

1 Front Cross Member

2 Hood  Lock Bracket Assy.

3   L H / R H   S i d e   M e m b e r   E n d   P l a t e

4 Engine Hood Front Support Plate Assy.

5 LH/RH Front Cross Member 6.  LH/RH Front Mud Guard

7 Front Cross Member Assy.

8 Cowl Inner And Outer Plate Assy.

9  LH/RH Front Mud Guard

Reinforcement

10 Cowl Upper Baffle

1

2 

3

7

5

6

8

3

9

10 

6

4

Front

Summary of Contents for CK MR479Q 2007

Page 1: ......

Page 2: ...l Pump Oil Seal Replacement 33 Section 7 Engine Rear Oil Seal Replacement 34 Chapter 3 Lubrication System MR479Q MR479QA MR481QA 35 Section 1 Oil Pressure Gage Sensor Replacement 35 Section 2 Oil Pump Assembly Replacement 36 Section 3 Oil Filter Replacement 38 Section 4 Starter Replacement 39 Section 5 Generator Replacement 40 Chapter 4 Fuel System MR7131A MR7151A MR7161A 41 Section 1 Check Fuel S...

Page 3: ...g 64 Section 1 Overview 64 Section 2 General Engine Fault and Troubleshooting 64 Section 3 Engine Noise Diagnosis and Troubleshooting 77 Chapter 10 Engine Management Unit 81 Section 1 System Description 81 Section 2 System Component and Working Principle 82 Part II Chassis 85 Chapter 1 Transmission Control Device 85 Section 1 Transmission Control Device 85 Section 2 Lever Type Transmission Control...

Page 4: ...bly strut rod components 121 Section 6 Left Right Trailing Rod Assembly 123 Section 7 No 1 Transverse Arm Assembly 124 Section 8 No 2 Transverse Arm Assembly 125 Chapter 7 Wheel 126 Section 1 Tire Inspection 126 Section 2 Wheel Replacement 127 Chapter 8 Power Steering System 128 Section 1 Power Steering System 128 Section 2 Steering Drive and Control Mechanism 130 Section 3 Steering Pipeline Compo...

Page 5: ...ter 5 Light System 198 Section 1 Survey of Light Syst em 198 Section 2 Light System Symptom Inspection 202 Section 3 Headlamp Replacement 211 Section 4 Front Fog Lamp Replacement 215 Section 5 Rear Combination Lamp Replacement 217 Section 6 High Mounted Stop Lamp Replacement 218 Section 7 Interior Dome Lamp Replacement 219 Section 8 Rear Row Reading Lamp Replacement 220 Section 9 License Plate Lam...

Page 6: ...Faults Check Troubleshooting 313 Chapter 2 Inside outside Trim and Accessor y 318 Section 1 Configuration Index 318 I Outside Trim And Front Accessory 318 II Outside Trim and Rear Accessory 319 III Front inside trim 320 IV Rear inside trim 321 Section 2 Inside Outside Trim and Accessories Removal and Installation 322 I Front Bumper 322 II Engine Hood 324 III Outside Rear View Mirror IV Rear trunk ...

Page 7: ...dy Structure 359 Chapter 2 Body Repair 369 Section 1 Body Damage Forms and Requirements for Repair 369 Section 2 Typical Technology Of Body Panel Repair 372 Section 3 Repair after Body Damage 372 Section 4 Features and Composition of Automobile Body 377 Section 5 Painting Technique after Body Repair 383 Section 6 Service Data For Body 385 ...

Page 8: ...g for over 5 minutes The deflection of the old belt is regarded as the standard for inspection z Check V belt for tension and distortion after the engine cranks for 2 turns 7 Check ignition timing See Figure 2 a Warm up the engine b When using fault diagnosis tester Connect fault diagnosis tester to fault diagnosis interface socket Ignitiontiming MR479Q 10 2 BTDC before top dead center at idle MR4...

Page 9: ... when the engine roate speed is higher 5 Remove timing light 8 Check engine idle See Figure 3 Notice z Check idle when cooling fan motor is disconnected z Switch off all electrical accessories and A C 9 Check compression pressure See Figure 4 a Engine switched off b Detach high voltage cable c Detach spark plug d Check the compression pressure in the cylinder 1 Insert pressure gauge into the hole ...

Page 10: ...fter filling oil the piston ring or the cylinder may be abrased or damaged z If the pressure is still too low the valve is stagnation or poor seal or there is a leakage in gasket 10 Check CO HC a Start engine b Running engine at 2500rpm for approximately 3 minutes c Insert CO HC meter testing probe into tailpipe at least 40cm during idling d Check CO HC concentration at idle and 2500rpm Hint z Com...

Page 11: ...ers 1 Air leaks PCV hoses intake manifold Throttle body Brake booster circuit 2 Lean mixture gas causing misfire 1 Clogged air filter 2 Clogged PCV valve Faulty ECU Faulty fuel pressure regulator Faulty water temperature sensor Faulty air compressor Faulty injectors Faulty throttle position sensor Normal Low High High High Rough idle Black smoke from exhaust pipe Rough idle Rough idle High ...

Page 12: ...p belt See Figure 6 5 Install water pump V belt 6 Adjust V belt of steering assisting pump a Adjust power steering belt tension tighten bolt B b Tighten bolt A Torque 39N m 7 Install V belt A C compressor No 1 to crankshaft pulley 8 Adjust V belt A C compressor No 1 to crankshaft pulley a Adjust A C belt tension by tightening bolt B b Tighten nut A Torque 39N m 9 Install Generator V belt See Figur...

Page 13: ...nuts 4 oil seal gaskets cylinder head and gasket 4 Adjust piston of Cylinder 1 to the compression position a Turn crankshaft pulley align notch to timing mark 0 on Cylinder 1 See Figure 9 b Align mark K on camshaft timing pulley to the timing mark on bearing cap See Figure 10 Crank 360 if it is not aligned 5 Check valve clearance cool See Table 5 a Turn the crankshaft pulley for 360 Align notch to...

Page 14: ... 1 Turn the pulley to access the hole on the camshaft drive gear where the counter gear is installed See Figure 12 Hint The above condition allows the cylinders No 1 and No 3 of the intake camshaft to push up the valve tappet 2 Remove bolt and bearing cap No 1 3 Install camshaft counter gear to drive gear with service bolt See Figure 13 4 Uniformly loose and remove 8 bearing cap bolts in several p...

Page 15: ... light layer of engine oil on the thread and under the head of bearing cap bolts 7 Uniformly install and tighten 8 bearing cap bolts in several times in the sequence shown in the figure Torque 13N m 8 Remove service screw 9 Install the bearing cap No 1 in the direction of the forward arrow mark 10 Apply a light layer of engine oil on the thread and under the head of bearing cap bolts 11 Alternativ...

Page 16: ...clip d Install gasket under of cylinder head e Install the cylinder head cover with 4 seal gaskets and 4 screw caps Torque 7 8N m f Install 2 ventilation hoses to cylinder head cover g Connect generator wire joint h Connect generator wires i Connect oil pressure switch connector j Install wire clip k Connect A C compressor switch connector 9 Install electronic ignition coil and high voltage cable ...

Page 17: ...se Heater Outlet Hose Fuel Sub Assembly Efi Fuel Pipe Clamp MT Transmission Control Cable Assembly AT Transmission Control Cable Assembly MT Clutch Release Cylinder Assembly Radiator Outlet Pipe Radiator Inlet Pipe Starter Assembly AT Oil Cooler Outlet Pipe AT Oil Cooler InletPipe Radiator Assembly Battery Front Exhaust Pipe Assy 3 way catalytic converter Muffler Tail Pipe Figure 20 ...

Page 18: ...elt No 1 Right Engine Mounting Insulator Door Assembly Steering Column Assembly Front Shaft Hub Left Nut Left Front Speed Sensor Left Engine Mounting Bracket Steering Column Hole Cover Hole Cover Steering Column Glove Compartment Front exhauxt pipe assembly Gasket Gasket One off accessory ...

Page 19: ...12 Component 3 Figure 22 Flywheel Clutch Disc Clutch Cover Clutch Release Bearing Clutch Release Fork Release Fork Support Release Fork Boot ...

Page 20: ...nut 14 Disconnect front wheel vehicle speed sensor with ABS 15 Detach steering tie rod ball stud pin assembly 16 Detach front lower swing arm sub assembly 17 Detach front propeller assembly See Figure 25 Detach front propeller from the shaft hub with plastic hammer 18 Disconnect transmission shift cable or gear shift level assembly 19 Disconnect clutch cylinder assembly or disconnect clutch cable ...

Page 21: ... injector assembly and remove intake manifold Remove 2 bolts and intake manifold support and remove 7 bolts 2 nuts intake manifold and gasket See Figure 27 37 Remove knock sensor 38 Remove water temperature gauge sensor 39 Remove crankshaft position sensor 40 Remove engine oil pressure switch 41 Remove water inlet hose housing 42 Remove water outlet hose joint 43 Detach exhaust manifold See Figure...

Page 22: ...gure 33 Install the intake manifold with new gasket with 7 bolts and 2 nuts Uniformly tighten bolts and nuts in several time 57 Install injector assembly 58 Install rear end cover 59 Install flywheel sub assembly See Figure 34 a Install flywheel to crankshaft b Install and uniformly tighten and connect bolt as shown in the figure Torque 78N m 60 Install clutch assembly 61 Install flywheel and ring...

Page 23: ...ipe assembly 73 Connect steering shaft assembly and steering column hole cover See Figure 36 74 Connect wire harness 75 Install belt adjusting bracket of A C compressor 76 Connect A C compressor 77 Install generator assembly 78 Install A C compressor to crankshaft pulleyV belt 79 Install generator belt 80 Install engine assembly with transaxle 81 Install radiator assembly 82 Install throttle body ...

Page 24: ...Right Engine Mounting Fan Generator V Belt V Belt No 1 Cylinder Head Gasket Gasket Timing Chain Or Timing Belt Cover Assembly No 2 Crankshaft Or Pulley Cover Sub Assembly Crankshaft Pulley Timing Belt Guide Timing Chain Timing Belt Cover Sub Assembly Generator Assembly Timing Belt Fan Pulley Vane Type Pump V Belt V Power Steering ...

Page 25: ... steering pump V belt 11 Remove water pump fan pulley 12 Remove high pressure cable 13 Remove cylinder head cover sub assembly 14 Remove generator assembly See Figure 39 15 Put the piston in Cylinder 1 to TDC compression position a Turn crankshaft pulley to align its notch to the timing mark 0 on the timing belt cover See Figure 40 b Check if the K mark on camshaft timing pulley and the timing mar...

Page 26: ...the crankshaft align the mark on crankshaft timing pulley to the oil pump 24 Install timing belt See Figure 45 Notice The engine must be cool a Install timing belt Check the tension force between crankshaft timing pulley and camshaft timing pulley Hint Align the marks if re using the timing belt when removing The engine s rotating direction should be the same with the arrow s when installing belt ...

Page 27: ...2 Install power steering pump V belt 33 Install A C compressor fan to crankshaft pulleyV belt 34 Install cylinder head cover sub assembly a Wipe off all seal packing material b Apply the seal glue on cylinder head cover as shown in Figure 48 c Install gasket onto cylinder head cover d Install cylinder head cover with 4 seal gaskets and 4 nuts Torque 7 8N M e Install 2 ventilation hoses onto cylind...

Page 28: ...ll oil pipe and water hose 40 Install left right propeller shaft 41 Install left right front wheel 42 Check engine oil for leakage 43 Install all connected wire harnesses and the cables on engine and vehicle body ...

Page 29: ...Belt No 1 Cylinder Head Cylinder Head Gasket Crankshaft Bearing Cap Crankshaft Timing Belt Washer Crankshaft Counter Gear Wave Gasket Snap Ring Camshaft Camshaft No 2 Oil Seal Camshaft Timing Pulley Fan Pulley Generator Assembly Crankshaft Or Pulley Cover Sub Assembly Timing Belt Cover No 2 Air Filter Assembly W Hose Right Engine Mounting Seal ...

Page 30: ...ct generator wire joint b Disconnect generator circuit c Disconnect A C compressor switch connector e Open wires clips f Disconnect wire harness from the cylinder head cover g Disconnect 2 ventilation PCV hoses from cylinder head cover h Remove 4 screws 4 seal gaskets cylinder head and gasket 16 Remove generator assembly See Figure 50 17 Remove timing belt cover 18 Remove crankshaft gear or pulley...

Page 31: ...y is quite small keep camshaft horizontal when removing it Take the following steps to avoid the damage a Remove the camshaft 1 Turn the camshaft to access the hole of the counter gear installed on camshaft drive gear Hint The intake camshaft lobe of Cylinder 1 and 3 can push up their own valve tappet 2 Remove 2 bolts and bearing cap No 1 3 Install the counter gear on the intake camshaft with the ...

Page 32: ...haft a Install exhaust camshaft and turn camshaft counterclockwise to make the dowel pin cross the vertical line a little See Figure 59 b Apply grease to a new oil seal lip and install it into the oil seal See Figure 60 Figure 59 c Install camshaft counter gear 1 Clamp the camshaft s hexagon head with a vise 2 Install camshaft gear spring camshaft counter gear and waved washer Figure 61 Hint Align...

Page 33: ...gon head Tighten the timing pulley bolt See Figure 64 Torque 59N M Figure 63 Figure 65 28 Install the timing belt a Align the marks on timing belt and the one on camshaft timing pulley b Install timing belt Check tension force between the crankshaft timing pulleys See Figure 65 29 Check valve timing a Loose idler bolt b Turn crankshaft from TDC clockwise for 2 cycles c Check and align each pully t...

Page 34: ... pump pulley 36 Install power steering pump V belt 37 Install A C compressor to crankshaft pulleyV belt 38 Install generator V belt 39 Install left right rear mounting bracket of engine 40 Install ignition coil and high voltage cable 41 Hoist the engine back into the compartment 42 Install propeller shaft 43 Install air filter assembly with hose 44 Install oil pipe and water hoses 45 Install left ...

Page 35: ...Component 1 Figure 68 Vane Pump Assembly V Power Steering Throttle Body Assembly Gasket Dipstick Inlet Pipe Gasket Wire Harness O Ring Timing Chain Or Timing Belt Cover No 2 Crankshaft Or Pulley Cover Sub Assembly Fan Pulley Fuel Delivery Pipe No 1 ...

Page 36: ...n Pipe Seal Cylinder Head Cover Camshaft Camshaft Bearing Cap Oil Seal Camshaft Timing Pulley Cylinder Head Sub Assembly Cylinder Head Gasket Cylinder Head Cover Gasket Camshaft No 2 Exhaust Manifold Insulator No 1 Gasket Exhaust Manifold Manifold Mounting ...

Page 37: ...le Left Scuttle Ventilation Grille Right Engine Mounting Bracket Generator Assembly Accelerator Cable Assembly Wiper Arm Subassembly EFI Fuel Hose Clamp Fuel Pipe Sub Assembly Heater Outlet Hose A Radiator Outlet Hose Radiator Inlet Hose Heater Inlet Hose Vane Type Pump V Belt V Power Steering V Belt No 1 Fan Generator V Belt ...

Page 38: ...ach water pump fan pulley 12 Disconnect ignition coil and high voltage cable 13 Detach cylinder head cover sub assembly 14 Detach generator assembly 15 Detach the camshaft 16 Detach the throttle body assembly 17 Detach intake manifold stay No 2 18 Take out the dipstick 19 Detach No 1 fuel delivery pipe 20 Detach the wire harness 21 Detach the steering assisting pump assembly 22 Detach exhaust mani...

Page 39: ...throttle body assembly 36 Install camshaft 37 Install engine cylinder head cover 38 Hoist the engine back to the compartment 39 Install engine right left and rear brackets 40 Install propeller shaft 41 Install ignition coil and high pressure cables Install air filter assembly with hose 42 Install oil pipe and water hose 43 Install left right front tire 44 Install all the wire harnesses and cables ...

Page 40: ...the oil seal 3 Install oil pump oil seal See Figure 76 a Smear grease to a new oil seal lip b on the oil seal with hammer until the edge of the oil pump case is filled with the seal packing 4 Install crankshaft timing pulley See Figure 77 a Align pulley set key to the key groove b Place the flange face inward Install timing pulley 5 Install timing belt 6 Check engine oil for leakage Figure 76 Figu...

Page 41: ...gure 78 5 Remove rear crankshaft end cover 6 Remove engine rear oil seal See Figure 75 7 Install engine rear oil seal See Figure 76 8 Install flywheel sub assembly See Figure 79 a Fix crankshaft b Install flywheel to crankshaft as the sequence shown in the figure c Install and uniformly tighten and install bolt Torque 78N m 9 Install clutch plate assembly 10 Install clutch case assembly 11 Install...

Page 42: ... if it is too low Fill oil to F 2 Check oil for deterioration Water entry discolor and dilution Replace oil if it is obviously deteriorated 3 Detach oil pressure sensor assembly See Figure 80 4 Install oil pressure gage sensor See Figure 81 Start engine to normal operation temperature 5 Check for oil pressure 6 Smear adhesive on 2 or 3 threads of the oil pressure sensor Install oil pressure sensor...

Page 43: ...ve the dipstick guide 5 Detach oil sump sub assembly See Figure 83 6 Detach oil strainer sub assembly See Figure 84 7 Detach oil pump assembly See Figure 85 8 Remove oil pump oil seal 9 Install oil pump oil seal 10 Install oil pump assembly 11 Install oil strainer sub assembly 12 Install oil sump assembly See Figure 86 Figure 84 Figure 85 Figure 83 Figure 86 ...

Page 44: ...ll the dipstick guide See Figure 87 14 Install crankshaft timing pulley See Figure 77 15 Install timing belt idler sub assembly No 1 16 Install timing belt 17 Fill in engine oil 18 Check oil for leakage Figure 87 ...

Page 45: ...ilter sub assembly See Figure 89 Figure 88 Figure 89 3 Install drain plug Clean and use new washer to install drain plug Torque 54N m 4 Oil fill Capacity Oil refill amount with the filter replaced 3 0L Oil refill amount without the filter dry fill replaced 2 80L Dry fill 3 3L 5 Check oil for leakage ...

Page 46: ...39 Section 4 Starter Replacement 1 Detach starter assembly See Figure 90 2 Install starter assembly Torque Bolt 37N m Figure 90 ...

Page 47: ...t wire joint of generator b Remove wire of generator c Disconnect oil pressure switch interface d Disconnect A C compressor switch connector e Open wire clips f Detach 2 bolts and generator 3 Install generator assembly Torque M12 bolt 18N m M14 bolt 58N m 4 Transmit belt tilt and tension state inspection ...

Page 48: ...ector if there is no pressure b Turn the ignition switch to OFF position 3 Check fuel pressure a Check battery electrical pressure to be above 12V b Detach negative terminal cable from the battery c Install pressure gage from the fuel delivery pipe See Figure 92 d Connect battery negative terminal e Measure fuel pressure Fuel pressure 304 343kPa Check fuel pipe union fuel pump fuel filter if the p...

Page 49: ...fuel pump or wire if the running is not as specified See Figure 94 The test should be conducted within 10s to prevent coil from damage 2 Fuel injector assembly Injection Volume 40 50cm3 s Error between each injector less than 10 cm 3 Replace injector if the injection volume is not as specified a Check for leakage Disconnect the cable from the battery The fuel drop min is no more than 1 drop Figure...

Page 50: ...and pull the connector from the injector b Remove 2 screws and detach fuel delivery pipe with injector 5 Remove fuel injector assembly 6 Install injector assembly a Smear a light layer of oil on two O rings and install them to injector See Figure 97 b Install 4 injectors to feul delivery pipe by rotating them left and right See Figure 98 c Install retain frame to each injector Figure 95 Figure 96 ...

Page 51: ...Temperarily install 2 bolts to attach the fuel delivery pipe to intake manifold d Check injector for smooth rotation See Figure 100 Hint If injector doesn t rotate smoothly replace O ring with the injector connector upward e Tighten the 2 bolts and attach the fuel delivery pipe to intake manifold See Figure 101 Torque 15N m Figure 100 Figure 101 Figure 99 Washer Rotate Upward ...

Page 52: ...45 Section 4 Fuel Pump Replacement Figure 102 ...

Page 53: ...oose fuel tank cap Be careful not to bend the fuel level sensor arm when pulling out fuel pump 6 Install fuel pump assembly See Figure 104 Replace ring seal Align the tab on the fuel pump to the notch on the fuel tank port Tighten the fuel tank cap with special tool Torque 40N m 7 Install fuel gas exhaust hose a Install return hose b Install fuel hose c Check fuel for leakage Figure 103 Figure 104...

Page 54: ... after starting the engine b Select ACTIVE TEST and PURGE VSV Vacuum Solenoid Valve from the display on the fault diagnosis tester Confirm vacuum at VSV port c Connect the vacuum pipe after completing ACTIVE TEST d After conducting ECM DATA MONITOR on the fault diagnosis tester select PURGE VSV to check operation e Start the vehicle after warming up the engine to confirm the VSV status is changed ...

Page 55: ...r if the operation is not as specified 3 Blow air in through the fuel tank hole Check and ensure air flows out from the other hole without resistance Replace the carbon carnister if the operation is not as specified c Clean the carbon carnister Plug the blowing tube bleed air in through 4 71kpa fuel tank hole and goes out from the exhaust port See Figure 111 Figure 110 Figure 111 2 Vacuum Solenoid...

Page 56: ...sembly It should be easy for air to pass through the cylinder head Notice z Do not suck air through valve z Never put any object into the valve Replace PCV if the operation is not as specified z Blow air in from the intake manifold side Check that the air flow should be difficult Replace PCV if the operation is not as specified See Figure 115 Figure 115 Air Figure 114 ...

Page 57: ...50 Chapter 5 Exhaust System MR7131A MR7151A MR7161A Component1 Figure 116 ...

Page 58: ... free length of the spring Free length 42mm Using the new gasket install the front exhaust pipe to the exhaust manifold Notice z Do not use removed gasket any more 5 Install front exhaust pipe assembly Torque 43N m 6 Install intermediate exhaust pipe assembly Using the new gasket install the intermediate exhaust pipe to the front exhaust pipe Torque 44N m 7 Install tail exhaust pipe assembly Using...

Page 59: ...r cap while the engine and radiator are still hot as fluid and steam can be sprayed under pressure b There should not be excessive deposits of rust or scale around the radiator and the coolant should be free from oil c Reinstall the radiator cap 4 Thermostat Hint The thermostat temp indicates the valve opening temperature See Figure 119 a Immerse the thermostat in water and gradually heat the wate...

Page 60: ...tor 93 C See Figure 123 a Start engine and make the coolant temp higher than 93 C b Check that the cooling fan turns Replace it with water temperature switch if it doesn t run 3 Check the cooling fan See Figure 124 a Disconnect the cooling fan connector b Connect the battery and ammeter to the connector c Check that the cooling fan rotates smoothly and check the reading on the ammeter Standard amp...

Page 61: ...rse order of the removal 2 Replace thermostat 1 Remove thermostat See Figure 126 2 Install thermostat a Install a new gasket to the thermostat See Figure 127 b Align the main valve of the thermostat to the top of the stud Insert the thermostat into the water inlet case Hint The main valve is set at around 10 C as shown in the figure See Figure 128 3 Install inlet connector Figure 127 Figure 128 3 ...

Page 62: ... See Figure 130 Figure 127 Figure 128 9 Install the cooling fan assembly a Fix the reservoir assembly on the cooling fan bracket with the bolt Torque 16 N m b Install the fan and fan shroud with 3 bolts Torque 7 5N m c Install the cooling fan assembly to radiator assembly with 3 bolts Torque 16N m d Connect the overflow pipe on the reservoir assembly and radiator assembly Fix it with the spring ba...

Page 63: ...56 Chapter 7 Clutch MR7131A MR7151A MR7161A Component 1 Hydraulic Manipulation Figure 131 ...

Page 64: ...release fork boot 4 Detach clutch release bearing 5 Detach clutch release bearing fixed clamp 6 Remove clutch fork pivot pin 7 Align the clutch cover to the mark on the flywheel Detach clutch cover See Figure 133 8 Remove clutch plate 9 Check and remove clutch plate assembly See Figure 134 10 Check clutch cover See Figure 135 Depth wear A 0 6mm Width wear B 5mm Figure 132 Figure 133 Figure 134 Fig...

Page 65: ...en the bolt in the sequence shown Torque 19 N m 2 Shake the clutch plate up and down left and right to ensure it is centered then tighten the bolt 15 Check and adjust the clutch cover See Figure 138 Check the diaphragm tip flatness with the dial gauge with roller Max roughness 0 5mm 16 Install the release fork pivot pin 17 Install clutch release fork boot 18 Install clutch release bearing fixed cl...

Page 66: ...59 Chapter 8 Maunal Transaxle Assembly MR7131A MR7151A MR7161A Component 1 Figure 139 ...

Page 67: ...eft right front propeller assembly 16 Hoist the engine from compartment See Provision 20 Section 2 Chapter 2 17 Detach starter assembly 18 Detach engine mounting bracket 19 Detach manual transaxle assembly 20 Install engine mounting bracket 21 Install manual transaxle assembly 22 Connect engine vibration insulating cushions 23 Install starter assembly 24 Install left right front propeller assembly...

Page 68: ...ensor Replacement 1 Disconnect vehicle speed sensor See Figure 142 2 Remove bolt and vehicle speed sensor 3 Install vehicle speed sensor See Figure 142 4 Connect vehicle speed sensor connector See Figure 143 Figure 142 Figure 143 ...

Page 69: ...ection 3 Transmission Case Oil Seal 1 Remove transmission case oil seal See Figure 144 2 Install transmission case oil seal See Figure 145 Notice Be careful not to damage oil seal lip Figure 144 Figure 145 ...

Page 70: ...63 Section 4 Transaxle Case Oil Seal Replacement 1 Using special tool remove transaxle case oil seal See Figure 146 2 Install transaxle case oil seal See Figure 147 Figure 144 Figure 145 ...

Page 71: ...ne starting failure engine starting failure normally include starter does not run or starter runs but fails to crank the engine or cranks the engine but cranks slowly starter can crank but fail to start the engine There are many causes that result in starting failure such as failures in starting system ignition system fuel injection system and engine mechanical failure 1 starter does not run or fa...

Page 72: ...laced if the testing lamp does not light up check whether the main fuse EFI relay fuse ignition switch and ECU terminal are OK repair or replace them if they are not OK d If there is low fuel pressure the injection amount would be small and the engine won t start you should check the fuel filter for block and fuel pump safety valve for damage and check whether the fuel pressure regulator is within...

Page 73: ...ifold is likely to be mixed with gasoline and it is hard to start troubleshoot or replace them d Idle control valve can not be opened to maximum position due to mechanical wear aging or control circuit failure the idle control valve shall be replaced and the control circuit failure shall be troubleshot e If the water temperature sensor data is not accurate it may cause small injection check the wa...

Page 74: ...or fault Engine can not start Check the starting system Repair or replace the part if it is faulty Check the high voltage spark No high voltage spark or weak spark OK Check the ignition system Is there any sign of cranking No sign of cranking There is sign of cranking Check the electric fuel pump for operation Check the air cleaner filter Operative Inoperative OK Clogged Check the injector Check t...

Page 75: ...ed piston ring failure is likely to cause low compression pressure in the cylinder you should carefully repair intake exhaust valve and seat or replace them failed piston ring shall be replaced 4 Diagnosis and Troubleshooting for hard starting and trouble shooting procedure Figure 149 III Fuel Pipeline and Circuit Faults for Poor Engine Operation Poor engine operation includes insufficient power p...

Page 76: ...eaner is clogged Clogged Troubleshooting OK Check the idle control valve NG Repair or replace OK Check the fuel pressure Excessivly low Service the electric fuel pump fuel filter and fuel pressure regulator OK Check the vacuum pressure sensor NG Replace OK Check the water temperature sensor and intake air temperature sensor NG Replace OK Check the start switch signal No Service the start signal wi...

Page 77: ...cient Check whether throttle valve can be fully open Unable to be fully open Adjust OK Check whether the air cleaner is clogged Clogged Clean or replace OK Check the throttle valve position sensor for failure Abnormal Repair or replace OK Check the water temperature switch and thermostat NG Replace OK Check the vacuum pressure sensor for failure NG Replace OK Check the fuel pressure Excessively lo...

Page 78: ...correct and shall be adjusted h Fuel pressure regulator is damaged and shall be replaced i Air cleaner is clogged and shall be cleaned or replaced 3 Diagnosis procedure for poor acceleration Figure 151 Figure 151 Poor acceleration Check the air tightness of the intake air system Poor seal Repair OK Check whether the air cleaner is clogged Clogged Clean or replace OK Check the throttle valve positi...

Page 79: ...eshooting a Poor idle control valve operation repair or replace it b Low idle speed and faulty or improperly adjusted idle control valve troubleshoot it c Water temperature sensor fault repair or replace it d Poor intake system seal need to be repaired e High voltage spark is too weak spark plug carbon deposit or electrode clearance is too small need to be repaired cleared and adjusted f Pressure ...

Page 80: ...on repair or replace it e Check valve is damaged and needs to be replaced Figure 152 Rough ildling easy for engine shut off Check whethe the air tightness of the intake system is good Poor Troubleshooting OK Check idle control valve for operation Inoperative Disassemble or replace Operative Reset the initial idle speed Check the spark plug Poor Adjust the clearance or replace OK Check the fuel pre...

Page 81: ...not tightly closed repair or replace it g Fuel evaporation control valve is always open repair or replace it h Speed sensor fault repair or replace it 9 Idle fluctuation 1 Symptom when idling the engine speed fluctuates 2 Causes and Troubleshooting a Intake pressure temperature sensor fault repair or replace it b Check valve is damaged and needs to be replaced c Water temperature sensor water temp...

Page 82: ...otherwise replace it Repair and dredge Improve the ventilation Repair or replace the water pump Troubleshooting replace the motor if it is damaged Replace Repair and dredge Repair or replace the oil pan if there is oil leakage refill the oil if it is not supplemented in time Cause Bad radiator cover Clogged cooling tube Poor ventilation Water leakage Anti freeze liquid not replaced Bad thermostat ...

Page 83: ...hrottle valve position sensor c c c c c c c c Vehicle speed sensor c Fuel pump system c c c c c c Fuel pressure regulator c c c c c c c c c c Fuel filter and pipeline c c c c c c c Injector c c c c c c c c c Starter signal c c Ignition coil c c c Spark plug c c c c c c c c High pressure cable c c Ignition timing c c c c c c c Igniter in the ECU c c c c Throttle valve c c c c c Throttle valve body ...

Page 84: ...amaged resulting in slow infiltration of coolant into cylinder and the water vapor entry into the exhaust pipe after combustion cylinder head gasket shall be replaced to resume the normal condition Section 3 Engine Noise Diagnosis and Troubleshooting Abnormal sounds generated during engine operation e g knocking sound chuckle hiss rattle are called noise Engine noise is primarily generated in valv...

Page 85: ...hing that can not be closed repair the bushing or replace it 5 Valve and valve seat can not be tightly closed and noise is generated leading to abnormal engine operation Valve shall be grinded to fit otherwise it shall be replaced 3 Gear noise is mainly caused by excessive wear of the gear which results in excessive clearance generating the noise during the operation The counter gear shall be repl...

Page 86: ...ension not as specified result in rotation or rupture Replace the insert Connecting rod bearing insert burned Replace the insert Poor lubrication for connecting rod bearing Drill the lubricant hole to normal improve the lubricant line Excessive main bearing raidal play Replace the main bearing Main bearing cover bolt loosened Tighten Main bearing insert burned Replace the insert Poor lubrication f...

Page 87: ...xial declination Replace the bushing Pistion counter ellipse Replace the piston Excessively small clearance between the pistion and cylinder wall Repair the cylinder or replace the piston Excessively small backlash and end gap for the piston ring Repair or replace the piston ring Poor lubrication for cylinder wall and piston Dredge the oil line to improve the lubricant splashing problem Piston pin...

Page 88: ...ing the information about the orders to the actuator I Engine Fuel System Electronic Control System Engine fuel system electronic control focuses on the quantified electronic control of the fuel and actually is the electronic control over the excessive air coefficient ECU controls the by controlling the fuel injection When the engine is running ECU receives the informa tion about the air flow from...

Page 89: ... and Working Principle ECU receives information from the sensors and sends control signals to actuators after processing and analyzing these information It plays a role of nerve center in the electronic control system ECU hardware consists of input level micro computer and output level see figure 153 Figure 153 Ignition advance angle control Starting condition ª fixed ignition advance angle Runnin...

Page 90: ...data collection shall be made first for analog signal and the sampling shall be maintained also Speed and crankshaft position reference signal from the sensor is processed in a dedicated circuit to restrain the interference pulse 2 Microcomputer The microcomputer of the engine electronic control unit is integrated in a single chip microcomputer consist ing of the following 1 Microprocessor micropr...

Page 91: ...ion output level 2 Ignition input level The ignition output level is designed to amplify the ignition signal from the microprocessor into the primary current of the ignition coil 3 Electric fuel pump output level ECU microcontroller control the pump relay through electric fuel pump output level and then control the on and off of the electric fuel pump based on the current operating conditions 4 Ot...

Page 92: ...he problem Check each part in order If necessary replace these parts Section 2 Lever Type Transmission Control Device Components Symptom 1 Transmission control device selector position changing cable improperly assembled 2 Cable or related parts worn 3 Cable assembly incorrect 4 Transmission faulty 1 Transmission control device selector position changing cable improperly assembled 2 Cable or relat...

Page 93: ...r dust cover and the body 4 Remove dust cover retainer 5 Remove control pull rod assembly 1 Remove the pull rod connecting bolt Place 2 2 Remove 2 hex flange bolts Place 1 3 Remove the 2 flange nuts attaching the control pull rod to the body in the trench 6 The installation is in the reverse order of the above operation Notice 1 Pull rod to transmission attach bolt torque 40 50N m 2 The torque of ...

Page 94: ...n of the vehicle properly tighten the set screw of the shift lever 6 Check whether the shift control is flexible and reliable the shift lever shall be vertical when in neutral shift Section 3 Cable Type Transmission Control Module Components Shift Lever Assembly E Shaped clip plate Cotter Pin Big Washer Big Washer Cotter Pin E Shaped clip plate Transmission Assembly Cowl Baffle Shift Control Devic...

Page 95: ...Remove the shift cushion 5 Remove transmission control device assembly 1 Remove the set nut on the cable seal press plate 2 Remove the cotter pin and the flat washer connecting the cable and the rocker arm on the transmission 3 Remove the E shaped clip plate on the cable bracket retaining the cable Shift Control Cables E Shaped Clip Plate Ball Seat Shift Lever Assembly Lever Ball Pin Spindle II Sp...

Page 96: ...e impacted 2 The shift device cushion should be correctly assembled Otherwise it will affect the seal effect 3 Torque of the 4 nuts attaching the shift assembly to the floor 20 25N m 4 The set nut attaching the selector control cable to the shifter shall be adjusted properly if the set nut is improperly adjusted the shift operation will be affected when in neutral shift the shift lever shall be in...

Page 97: ...r pedal and vehicle body 2 Separate the accelerator cable 3 Detach the accelerator cable 4 Install the accelerator cable and accelerator pedal assembly in the reverse order of the Notice 1 Accelerator pedal assembly fixing bolt torque 20 25N m 2 Properly adjust the position of the accelerator cable set screw to ensure the adequate tension of the accelerator cable 3 Check whether the accelerator co...

Page 98: ...ority of the likely cause of the problem Check each part in order If necessary replace these parts Section 2 Clutch Cable Control Mechanism Components Symptom Suspected Area 1 Clutch pedal position Too low 2 Control mechanism Stagnation 3 Clutch pedal free stroke too large Clutch does not release 1 Hydraulic pipe line Air in line 1 Control system Incorrect assembly adjustment 2 Clutch assembly Fau...

Page 99: ...ng nut on the clutch cable Re adjust the clutch pedal height if necessary 3 Check that the clutch pedal operates in flexible and reliable way Notice 1 Make sure the clutch is fully applied and completely released when control the clutch pedal 2 The clutch pedal must have certain free stroke Otherwise the full application of the clutch may be impacted 3 Tighten the lock nut after adjustment Connect...

Page 100: ...ate the clutch cable from the clutch pedal 2 Install the clutch cable assembly in the reverse order of the above procedure Notice 1 The clutch cable assembly on the cowl panel set bolt torque 20 25N m 2 Check and adjust the pedal according to the above mentioned requirement in Adjustment Adjusting Bolt Stroke Free Stroke Minimum Distance from the Cowl Panel Adjusting Bolt Nut Install Height Adjust...

Page 101: ...ervoir Cowl Baffle Clutch And Brake Pedal Assembly Clutch Master Cylinder Clutch Master Cylinder Master Cylinder Bracket Clamp Clamp Connect The Pipe Assembly Hose Union Reservoir Hose 2 Reservoir Hose 1 Clog Bolt Rubber Washer Union Nut Hydraulic Hose L Shaped Clip Plate L Shaped Clip Plate Pivot ...

Page 102: ... washer pin shaft to separate the clutch hydraulic control master cylinder from the clutch pedal 3 Remove the connecting pipe Loose the threaded connector connecting pipe and the clutch master cylinder Remove the connecting pipe 4 Remove the clutch pedal assembly Remove the nuts bolts 2 bushing sleeve clutch pedal assembly 5 Remove the hydraulic hose Loosen the union thread connecting clutch hydra...

Page 103: ...N m 4 Clutch hydraulic control master cylinder set bolt torque 20 25N m 5 Torque of the union thread connecting the pipe and clutch master cylinder 12 16N m 6 Torque of the threaded connector connecting the clutch hydraulic hose and pipe 12 16N m 7 Bleed the air in the clutch hydraulic control system 8 Check the clutch hydraulic control system for leakage 9 Check the clutch hydraulic control syste...

Page 104: ... The table below is helpful to find the cause of the problem The numbers indicate the priority of the likely cause of the problem Check each part in order Repair or replace these parts or assemblies if necessary Symptom Inspection Area 1 Rzeppa Constant velocity universal joint worn 2 Tripod constant velocity universal joint worn Noise Rzeppa Type Tripod Type Rzeppa Constant Velocity Joint Tripod ...

Page 105: ...y universal joint 2 Snap ring 3 Clip Band 4 Rzeppa Type Constant velocity universal joint boot 5 Band 6 Shaft 7 Band 8 Tripod constant velocity universal joint boot 9 Band 10 Snap ring 11 Tripod constant velocity universal joint 12 Snap ring ...

Page 106: ... lower swing arm assembly ball stud pin lock bolt and nut on the knuckle 2 Detach the lower swing arm assembly ball stud pin from the knuckle 6 Remove the constant velocity propeller shaft assembly Appropriately pull the brake outward use a rubber hammer or brass bar to tap the propeller shaft to remove it Notice Actions shall be taken to prevent the propeller from being dropped off do not damage ...

Page 107: ...d remove the boot Notice Replace the band if it is distorted 9 Disassembly the tripod constant velocity universal joint 1 Remove the old grease 2 Use the mark pen to place a matchmark on the inboard and outboard joint Notice Do not punch the marks 3 Remove the outboard knuckle 4 Use snap ring pliers to remove the snap ring 5 Use mark pen to place matchmarks on the tripod ball joint and outboard jo...

Page 108: ...se order of removal procedure Notice 1 Apply proper amount of long life grease as specified when assembling the tripod velocity universal joint and Rzeppa Constant velocity universal joint and then assemble it according to the matchmark 2 Keep both sides of the spline shaft clean the boot intact and the band assembled into place 3 The tripod constant velocity joint spline shaft and the differentia...

Page 109: ...heel nut torque 95 115N m 8 Make sure that the propeller shafts for 1 3L engine and 1 5L engine are not interchanged at the time of replacement 9 Check the ABS sensor signal check and adjust the front wheel alignment if necessary ...

Page 110: ...rber mount is used for the relative rotation upon steering of the shock absorber rigidly connected to the steering knuckle to the shock absorber mount flexibly connected to the body L type lower swing arm is secured to the lower engine compartment with the press plate through elastic rubber bushing and hinge and its outer end is connected to the steering knuckle through the ball stud pin which is ...

Page 111: ...ffness not comply with or damage 3 Shock absorber Worn 1 Tire Worn or improperly inflated 2 Steering linkage Loose or damaged 3 Stabilizer bar Bent or broken 4 Shock absorber Worn or damaged 1 Tire Worn or improperly inflated 2 Tire Dynamic balance is not as specified 3 Shock absorber Worn or damaged 4 Wheel alignment Incorrect 5 Ball stud pin Worn or damaged 6 Hub bearing Worn or damaged 7 Steeri...

Page 112: ...ower Swing Arm Assembly Lower Swing Arm LF Bracket Lower Swing Arm RF Bracket Front Stabilizer Bar Assembly Stabilizer Bar Right Link Rod Assembly RF Brake Assembly Connected to Brake Clip Front Brake Hose RF Strut Assembly Connected to Brake Body Body Right Lower Swing Arm Assembly Lower Trailing Arm Rear Elastic Hinge Fixed to Shock Absorber ABS Sensor Wire Harness Shock Absorber ...

Page 113: ... specified value Only adjust the one side tie rod is not allowed 3 Make sure the left and right tie rods are of the same length The difference should be less than 0 5mm 4 Tighten the lock nut of tie rod Torque 45 50N m 4 Inspect wheel limited turn angle Turn the steering wheel fully and measure the turning angle Wheel angle If the wheel angle is less than the specified value check whether the leng...

Page 114: ...er Thrust Ball Bearing Spring Upper Seat Front Coil Spring Upper Insulator Front Coil Spring Left Brake Assembly ABS Sensor Wire Harness Front Brake Hose Stabilizer Bar Left Link Rod Assembly LF Shock Absorber Assembly Front Coil Spring Lower Insulator Front Bumper Front Shock Absorber Protecting Sleeve ...

Page 115: ... front brake hose from the front shock absorber bracket 4 Remove the stabilizer bar link rod assembly Remove the nut connecting the stabilizer bar link rod assembly and the shock absorber 5 Remove the front shock absorber with the coil spring 1 Remove the nuts and bolts connecting the shock absorber and brake 2 Remove the 4 nuts connecting the front shock absorber and vehicle body Notice reliable ...

Page 116: ...The assembly of the front strut assembly is in the reverse order of disassembly Notice 1 Use special fixture when installing the nut on the shock absorber piston rod be careful not to let the spring rebound Torque 80 90 N Sm 2 Install the 4 bolts attaching the front strut assembly to the body Torque 25 30N m 3 Install the 2 bolts and nuts of the front strut assembly and the brake Torque 90 100N m ...

Page 117: ...ing Arm Assembly Components Lower Swing Arm Rear Spring Joint Cover Left lower Swing Arm Assembly Lower Swing Arm LF Bracket Lower Swing Arm LR Bracket Right lower Swing Arm Assembly RF Brake Assembly LF Brake Assembly Body ...

Page 118: ...ower swing arm assembly and front brake 2 Remove the 4 bolts on lower swing arm rear spring joint cover 3 Remove the bolts and nut between lower swing arm assembly and lower swing arm front bracket 2 Remove the swing arm assembly Remove the swing arm assembly as shown in the figure Left Right ...

Page 119: ...assembly 1 Install the bolts and nuts connecting the lower swing arm assembly and lower swing arm front support frame Notice Do not tighten the bolts 2 Attach the left lower swing arm assembly ball stud pin to the steering knuckle with bolts and nuts Torque 80 90N m 3 Install the attaching bolt between the lower swing arm rear spring joint cover and the body Torque 80 90N m 7 Set nut 1 Lower the v...

Page 120: ... Rod Assembly Front Stabilizer Bar Clamp Front Stabilizer Bar Rubber Bushing Right Bracket Welding Assembly Front Stabilizer Bar Clamp Front Stabilizer Bar Rubber Bushing Left Bracket Welding Assembly Stabilizer Bar Left Link Rod Assembly LF Strut Assembly Front Stabilizer Bar RF Strut Assembly ...

Page 121: ...move the front stabilizer bar Remove the 4 bolts front stabilizer bar rubber bushing front stabilizer bar clamp 3 Remove the front stabilizer bar left support frame welding assembly Remove the nuts connecting the stabilizer bar left support frame welding assembly and vehicle body 4 Install the front stabilizer bar support frame welding assembly Set the front stabilizer bar support frame welding as...

Page 122: ...abilizer bar 2 The 4 bolts connecting the stabilizer bar clamp and front stabilizer bar support frame welding assembly differ in length The two short ones are close 6 Install stabilizer bar link rod assembly 1 Attach the stabilizer bar link rod to the stabilizer bar with nuts Torque 40 50 N m 2 Attach the stabilizer bar link rod to the front shock absorber bracket with nuts Torque 40 50 N m to eng...

Page 123: ...place these parts Items Parameter Items Parameter Shock absorber operating cylinder diameter mm 56 Camber 20 30 Shock absorber piston rod diameter mm 18 Wheel toe in mm 1 5 Shock absorber stroke mm 230mm Remark Wheel alignment parameter is at free load Symptom Suspected Area 1 Tires Worn or improperly inflated 2 Wheel alignment Incorrect 3 Hub bearing Worn or damaged 4 Suspension parts Worn or dam...

Page 124: ...rut Assembly Clip RR ABS Sensor Wire Harness RR Brake Hosex2 No 2 Transverse Arm Left Trailing Rod Assembly Body Body Body Body No 1 Transverse Arm No 1 Rocker Arm Clip RR Brake Pipe RR Brake Hose RR Brake Right Trailing Rod Assembly Rear Stabilizer Bar Assembly No 2 Transverse Arm Rear Stabilizer Bar Retainer Rod Components ...

Page 125: ... camber Notice If the camber is not within the specification check the suspension parts for damage low performance Replace it if necessary Toe in C D 1 5 mm C a m ber 20 30 Front No 2 Transverse Arm Assembly Rear Wheel Toe In Adjusting Panel Rear Wheel Toe In Adjusting Plate No 2 Transverse Arm Assembly No 1 Transverse ArmAssembly No 1 Transverse Arm Assembly Rear Wheel Toe In Adjusting Cam Rear W...

Page 126: ... retaining bolt of ABS rear wheel sensor on rear shock absorber bracket 3 Separate brake pipe and rear strut assembly Remove the elastic clip on the pipeline bracket attaching the brake pipeline Cushion Dumper Dust Prevent Sleeve Rear Suspension Spring Lower Insulator Rear Left Shock Absorber Upper Mount Cushion Upper Mount Rear Suspension Spring Insulator Rear Suspension Conical Spring ...

Page 127: ...tor rear suspension spring rear shock absorber cushion rear shock absorber dust preventing sleeve rear suspension spring lower insulator in order 6 The assembly is in the reverse order of the disassembly Caution 1 when installing the nut on the shock absorber piston rod upper end use special fixture and be careful that the spring may rebound Torque 32 38N m 2 Rear strut assembly to body thread tor...

Page 128: ...bilizer bar and mount 2 Remove the rear stabilizer bar retaining ring and the rubber ring 3 Remove the 4 bolts connecting rear stabilizer bar and vehicle body Rear Stabilizer Bar Rubber Bushing Rear Stabilizer Bar Clamp Rear Stabilizer Bar Rear Stabilizer Bar Retainer Rear Stabilizer Bar Rubber Ring Rear Stabilizer Bar Retainer Rubber Ring Bushing Strut Rod Mount Strut Rod Welding Components ...

Page 129: ...tabilizer bar clamp 2 Remove the rear stabilizer bar rubber bushing 5 The installation is in the reverse order of the removal Caution 1 The torque of the bolt attaching the stabilizer bar assembly to the body 22 25N m 2 The torque of the bolt attaching the strut rod components to No 2 the transverse arm assembly 22 25N m 3 The torque of the nut attaching the rear stabilizer bar to the strut rod co...

Page 130: ...necting the trailing rod assembly and vehicle body 3 The parts installation is in the reverse order of the removal Caution 1 The torque of the bolt attaching the trailing rod assembly to the body 81 96N m 2 The torque of the bolt attaching the trailing rod assembly to the rear brake assembly 81 96N m 3 The above bolts shall be tightened to the specified torque at Non load 4 Check rear wheel alignm...

Page 131: ... connecting the No 1 transverse arm assembly and vehicle body 2 Install the No 1 transverse arm assembly 1 The torque of the thread attaching the transverse arm to the body 81 96N m 2 The torque of the thread attaching the transverse arm to the rear brake assembly 81 96N m 3 Check the rear wheel alignment replace it as necessary Pivot bracket No 1 Transverse arm welding components No 1 Trailing ar...

Page 132: ...mbly 1 Use the nut rear wheel toe in adjust cam rear wheel toe in adjust plate to attach the No 2 transverse arm assembly to the body 2 Install the No 2 transverse arm assembly to the rear brake wheel hub Torque 81 96N m 3 Use the bolt to attach the strut rod component to the No 2 transverse arm assembly Torque 22 25N m 4 Check the rear wheel alignment adjust it by adjusting the rear wheel toe in ...

Page 133: ...nter otherwise it may affect the normal safe running of the vehicle and even result in accidents 2 If the wheel rim is damaged you must go to the authorized service center for service and replacement Never use the wheel rim of any other model 3 Changing tire position It is recommended to change the tire for each 10000km driving See the figure for where to change each tire 4 Inspect wheel dynamic b...

Page 134: ...th tire nut wrench 3 Four jacks support the vehicle body two at each side as shown in the figure The jack should be near to the to be replaced wheel with solid base 4 Remove the wheel nut Caution 1 Make sure the parking brake control handle has been pulled up before jacking up the vehicle 2 Wheel nut torque 95 115N m 3 Check the four wheel alignment when necessary ...

Page 135: ...replacement of parts incorrect replacement might affect the performance of the steering system and lead to driving accidents 2 Cautions for SRS System This vehicle is equipped with SRS Supplemental Restraint System driver side air bag and front passenger side air bag Failure to carry out service operations in the correct sequence could cause the unexpected deployment of the air bag during servicin...

Page 136: ...gnment incorrect 4 Steering knuckle worn 5 Swing arm ball stud pin joint worn 6 Steering column bent or binding 7 Power steering pump assembly Worn 8 Power steering gear assembly Fault 1 Tire improperly inflated 2 Front wheel alignment incorrect 3 Steering column bent or binding 4 Power steering gear assembly Oil pressure too low 1 Steering knuckle worn 2 Swing arm ball stud pin joint worn 3 Inter...

Page 137: ...sm Components Steering Wheel Assembly Air Bag Assembly Lower Cover Upper Cover Head Light Dimmer Switch Combined Switch Bracket Nut Dust Cover Steering Column Assembly Wiper Switch Assembly Press Plate of Dustcover Universal Joint Intermediate Shaft ...

Page 138: ...e air bag assembly Warning Make sure the upper surface of the air bag assembly is kept upward when placing it Do not disassemble the air bag assembly 5 Remove steering wheel assembly 1 Remove the nut 2 Remove the steering wheel cover set bolt 3 place the matchmarks on the steering wheel and main shaft assembly 4 Use special tool to remove the steering wheel assembly 6 Remove the steering column up...

Page 139: ...the universal joint Remove the locking bolt between the joint yoke and the power steering gear 9 Remove steering column assembly 1 Remove the wire harness connector on the steering column assembly 2 Remove 2 bolts 2 nuts and the steering column assembly 10 Remove ignition switch lock core assembly 1 Remove the ignition switch wire harness 2 Remove the screw then remove the ignition switch assembly...

Page 140: ...h and the steering column upper and lower cover tighten the 3 screws attaching the combination switch and the steering column 5 Torque of the universal joint yoke and steering gear assembly locking bolt 22 34N m 6 Torque of the 4 set bolts of the dust cover and press plate 16 26N m 7 When installing the steering wheel assembly align the matchmarks of the steering wheel and steering main shaft asse...

Page 141: ...e run the engine at idle for a few minutes 6 Turn the steering wheel to left or right limit position and keep it there for 2 3 seconds then turn the steering wheel to the opposite limit position and keep it there for 2 3 seconds Repeat it several times 7 Shut off the engine check for foaming or emulsification in the reservoir If there is foaming or emulsification bleed power steering system repeat...

Page 142: ...gine The torque of the M10 bolt is 45 79N m the torque of the M8 bolt is 16 26N m 7 Install the drive belt make sure the installation position is correct 8 Install the power steering high and low pressure pipe 1 Connect the union thread of the high and low pressure pipe to the steering gear torque 19 33N m 2 Use the retaining clip to secure the low pressure pipe to the cowl baffle panel of the bod...

Page 143: ...136 Section 4 Power Steering Gear Retaining Device Components Front Cowl Panel Assembly Cotter Pin Cotter Pin ...

Page 144: ... Boot Lock Nut Tie Rod LH Ball Stud Pin Joint Sub assembly Joint Sub assembly Replacement 1 Drain the power steering system fluid 2 Separate the tie rod from the steering knuckle 1 Remove the cotter pin loosen the groove type lock nut 2 Separate the tie rod ball stud joint from the steering knuckle taper hole ...

Page 145: ...haft spline lock bolt on the universal joint yoke torque 22 34N m 4 Tighten the 4 set bolts of the boot band and boot torque 16 26N m 5 Install the union thread of the power steering high and low pressure pipe to the power steering gear torque 19 33N m 6 Connect the tie rod ball stud pin with the steering knuckle make sure that the mating surface of the tie rod ball stud pin and the steering knuck...

Page 146: ...uid Problem symptoms table 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 Symptom Cause 1 Brake system fluid leaks 2 Brake system air in 3 Piston Cup in Sub pump worn or damaged 4 Rear brake shoe clearance out of adjustment 5 Master cylinder faulty 6 Booster...

Page 147: ...at the above procedure to bleed the brake pipeline of the air for each wheel cylinder Notice Fill brake fluid into the reservoir all the time when bleeding 3 Check fluid level in reservoir Check the fluid level and fill fluid if necessary Symptom Suspect area 1 Wheel cylinder piston stuck 2 Brake shoe lining oily 3 Disc scratched 4 Brake shoes or lining cracked or distorted 5 Wheel hub bearing wor...

Page 148: ...ly and brake pedal support bracket 2 Remove 3 bolts connecting the clutch and brake pedal assembly and front cowl panel cross member Remove the clutch and brake pedal assembly 3 Remove the brake pedal Remove the bolt and nut Torsion Spring liner brake pedal arm assembly spacer 4 Remove the brake pedal arm assembly Remove brake pedal mat and cushion gasket from the brake pedal arm 5 The installatio...

Page 149: ... switch lock nut 2 Adjust the brake lamp switch to the right position 3 Check the brake lamp switch Make sure the brake lamp is light by depressing the brake pedal for5 15mm 4 Tighten the brake lamp switch lock nut 2 Check pedal freestroke 1 Shut off the engine and depress the brake pedal several times until there is no more vacuum left in the booster 2 Depress the pedal until the resistance begin...

Page 150: ... is air tight b Operating check Depress the brake pedal and start the engine If the pedal goes down slightly operation is normal 2 Check the vacuum check valve 1 Remove the connecting pipe with the check valve 2 Check the direction from the booster to the engine Check valve for ventilation It should not ventilate in the reverse order 3 Replace it if it is faulty Notice Pay attention to the matchma...

Page 151: ...left disc caliper 6 Remove the sliding pin boot Disk Brake Wheel Cylinder Bracket Sliding Pin Boot Inner Floating Clip Plate Screw Plug Brake Caliper Housing Inner Damper Inner Pad Backing Plate Inner Pad Outer Pad Outer Pad Backing Plate Outer Damper Outer Floating Clip Plate Alarm Plate Wheel Cylinder Piston Wheel Cylinder Piston Seal Wheel Cylinder Boot Steel Wire Snap Ring Short Pin Set Bolt S...

Page 152: ...ssed air Be careful of the splashed brake fluid 10 Remove the piston oil seal Remove the oil seal from the brake cylinder with a screwdriver 11 Check the brake cylinder and piston Check the cylinder wall and piston for rust and damage 12 Check the thickness of the brake pad Measure the thickness with a ruler Standard thickness 10mm Minimum thickness 1mm 13 Check the front brake alarm plate Make su...

Page 153: ...cylinder Apply lithium soap base glycol grease to the piston surface Never rotate the piston into the brake cylinder by force 4 Install the brake caliper to tighten the bolt torque 85 90 N m 5 Replace the noise insulator when replacing the worn brake pad Make sure the clip plate is in normal status Otherwise replace the floating clip plate 6 Make sure the brake pad and disc surface are clean Oil o...

Page 154: ...r Plate Brake Bottom Plates Left Cable Plate Left Torsion Spring Adjusting Pawl Shaft Pin Left Adjusting Pawl Left Adjusting Plate Brake Shoe I Wheel Hub Bearing II Rear Spindle Cap Wheel Hub Bearing I Stop Washer Wheel Hub Bolt Rear Ring Gear Rear Brake Drum Rear Spindle Cover Brake Shoe I Shoe Guide Friction Shoe Boot Cup Piston Wheel Cylinder Spring Piston Boot Cup Parking Brake Left Swing Arm ...

Page 155: ...wing arm Remove the parking brake cable end joint with a screwdriver 6 Remove the brake shoe I brake shoe II 1 using special tool remove brake shoe positioning spring and pin 2 remove brake shoe I and I after separating the return spring 7 Remove the rear brake automatic adjustment lever Remove the brake adjustment lever spring and adjustment lever 8 Remove the return spring on the brake shoe Remo...

Page 156: ...rake shoe 12 Check brake wheel cylinder Check the cylinder wall piston cup for damage 13 Install brake wheel cylinder accessory 1 Apply lithium soap base glycol grease to 2 brake wheel cylinder cups and pistons 2 Replace two new cups and boots 14 Install the brake wheel cylinder Brake wheel cylinder set bolt torque 9 13 N m 15 Apply high temperature grease Apply high temperature grease to the cont...

Page 157: ...ll the brake fluid 22 Bleed the air in the brake system 23 Check the fluid level in the reservoir 24 Check the brake fluid for leakage 25 Install the rear tire tire nut torque 95 115 N m 26 Check parking brake operating handle Check the parking brake control handle stroke and adjust if necessary See parking brake system Adjust Bolt Back Plate ...

Page 158: ...t 9 HECU controller assembly 10 RR No 1 Brake Pipe Compo 11 Bolt 12 Insu lator 13 LF Brake Pipe Compo 14 HECU Controller Bracket Assembly 15 Hexagon Bolt Spring Washer and Plate Washer Compo 17 Hex Bolt Spring W asher and Flat Washer Compo 18 LR No 1 Brake Pipe Compo 19 5 Pipe Clip 20 RR Brake Pipe Compo 21 RL Brake Pipe Compo 22 Rear brake Hose Assembly 23 Rear brake No 3 Brake Pipe Compo 24 Sing...

Page 159: ...thread Separate the rear right brake pipe compo and rear right No 1 brake pipe compo 3 Remove the rear brake pipe No 3 4 compo 1 Loose the union thread connecting the hose Remove E shaped clip on the pipe bracket Separate the brake pipe 2 Remove pipe No 3 4 compo Connect RF Brake Rear RH Brake Pipe Compo Rear LH Brake Pipe Compo Rear LH No 1 Brake Pipe Compo Rear RH No 1 Brake Pipe Compo C o n n e...

Page 160: ...ipe clips 3 Remove rear left right brake pipe compo 6 Remove front brake hose assembly 1 Loose the union thread that connects the front brake hose to LR and RR brake pipe 2 Remove E shaped clip on the hose bracket 3 Loose the union thread that connects the front brake hose to the front brake Remove the front brake hose assembly from the front brake 7 Remove the front left front right brake pipe co...

Page 161: ...he bracket Using special wrench remove 3 inner torx bolts and insulator 13 Installation is in the reverse order of the procedure above Notice 1 The HECU controller bracket to body bolt torque 20 25N m 2 Hose and pipe union thread torque 12 16N m 3 All the hose pipe should be fixed The distorted clamp and E shaped clip should be replaced Never interfere the hoses and pipes with other parts 4 Bleed ...

Page 162: ...ent 1 Check the parking brake handle stroke Parking brake handle stroke the vehicle is in reliable brake when pulling the parking brake handle up to 4 7 clicks and the brake lamp is ON The maximum control force should be no more than 196N The wheel can turn freely when fully releasing the parking brake handle Otherwise please adjust it 2 Parking brake handle stroke 1 Remove parking brake handle bu...

Page 163: ...and parking brake control lever assembly 2 remove parking brake cable retaining clip 3 remove the rear wheel 4 remove the brake drum 5 remove the parking brake cable from parking brake swing arm in the rear brake 4 Install the left right parking brake cable assembly in the reverse order of the removal Notice check the parking brake handle stroke Re adjust the parking brake handle stroke as specifi...

Page 164: ...r itself Consult the self inspecting procedure described on the Tester Operation Manual II HOW TO PROCEED WITH TROUBLESHOOTING The basic operation procedure for troubleshooting is as follows 1 Customer fault analysis a Ask the customer for the conditions and environment when faults happen 2 Confirm the fault symptoms and check the DTCs and storage data a Check the battery positive voltage Voltage ...

Page 165: ...eature is Input Signal Inspection Inspect if the signals from different switches are correctly inputted into the ECU These features can quickly narrow the range of troubleshooting to make an efficient troubleshooting analysis In the model of Free Cruiser the systems below all possess the diagnosis feature 1 EFI system 2 ABS system 3 Supplemental Restraint System SRS 2 When a DTC is checked the ver...

Page 166: ...ficult to reappear So here are some effective symptom simulation tests KEY POINTS OF SYMPTOM SIMULATION TEST In the symptom simulation test no doubt it is important to confirm the fault symptom but the fault position or fault components must be also found out So before the test and the pre inspection of connection narrow the range of the circuit where faults may occur according to the fault sympto...

Page 167: ...he suspected area to check if the fault occurs NOTES The heating temperature must be less than 60 æ 140 H The temperature shall not exceed the one that can damage the component Do not directly heat the ECU parts 4 Another way When electrical overload may be the major cause of the fault Connect all electrical loads to check if the fault occurs ...

Page 168: ...h and the battery as shown c Disconnect the magnet exciting coil from the terminal A d Check if the clutch pinion gear is moving out If the clutch pinion gear is not moving out replace the magnetic switch e Connect the battery as shown above Disconnect the battery positive from the terminal to make the clutch pinion gear disengaged f Check if the clutch pinion gear has returned If the clutch pinio...

Page 169: ...ified current Specified current 90 A or less at 11 5 V if the current is not normal replace the starter 3 WIRING a Check that the connecting wire between the positive and the starter is stable and reliable and the insulating bush is in good condition in order to avoid a fire caused by electric spark b Check that there is continuity in the wire and if the insulating bush is not damaged If the harne...

Page 170: ...Y a Disconnect the starter connector b Remove the nut and disconnect the starter cable c Remove the 2 bolts and the starter assembly 2 INSTALL STARTER ASSEMBLY Install according to the inverted order of removal Torque Bolt 37N m 378kgf cm 27ft lbf Harness 9 8N m 100kgf cm 7 0ft lbf ...

Page 171: ...ion The battery electrolyte is very corrosive DO NOT overturn the battery 2 Read the instructions for battery 3 Children are forbidden to touch the battery 4 Avoid fire electromagnetic wave and strong light Avoid electric spark while repair avoid short 5 Wear protecting glasses 6 Danger of explosion The explosive mixed gas will be produced while charging 7 How to deal with a scrapped battery The s...

Page 172: ...lled out in order to void damaging the battery REMOVAL 1 Remove the negative ground cable 2 Remove the battery positive cable 3 Loosen the fixing clamp on the battery INSTALLATION Install according to the inverted order of removal Tighten the torque Tighten the battery cable clip to 6N m 61kgf cm 4ft lbf Tighten the fixing clamp to 12N m 123kgf cm 8 6ft lbf ...

Page 173: ...motor for 60 seconds to remove the surface charge b Turn the ignition switch OFF and turn off the electrical systems Then measure the battery voltage between the negative and positive terminals of the battery Standard voltage 12 5 12 9V at 20 C HINT If the voltage is less than specification charge the battery 2 CHECK BATTERY TERMINALS FUSE BOX AND FUSE a Check that the battery terminals are not lo...

Page 174: ...h your hand to confirm that the belt has not slipped out of the groove on the pulley 4 CHECK ALTERNATOR WIRING Check that the wiring is in good condition 5 LISTEN FOR ABNORMAL NOISES FROM ALTERNATOR Check that there is no abnormal noise from the alternator while the engine is running 6 INSPECT CHARGE WARNING LIGHT CIRCUIT 1 Turn the ignition ON Check that the charge warning light comes on 2 Start ...

Page 175: ...al B of the alternator 4 Ground the negative pole of the voltmeter c Check the charging circuit With the engine running from idle to 2 000 rpm check the reading on the ammeter Standard amperage 10A or less Standard voltage 13 2V 14 8V 8 INSPECT CHARGING CIRCUIT WITH LOAD a With the engine running at 2 000 rpm turn on the high beam headlights and place the blower switch at 4 Check the reading on th...

Page 176: ...s and 2 slip rings of the rotor Standard resistance 2 7 3 1 2 Inspect the rotor bending Standard less than 0 5 mm of radial motion If it is not normal calibrate or replace the rotor Pulley Bearing Cover Ｓｔａｔｏｒ Bearing Rotor Wire Clamp Brush Gasket Rectifier Frame Connecting Insulator Brush Holder Brush Holder Cover Rear Cover Bearing Retainer Bearing IC Regulator Rotor Winding Inspection Ω ...

Page 177: ...he armature winding respectively and the other pole of the meter to the stator core If the resistance reading is infinitely great the armaturewindingiswell insulated Ifnot itneedsrepairing and replacing IV ALTERNATORASSEMBLYREPLACEMENT MR479Q MR479QA MR481QA a Disconnect the alternator connector b Loosen the Bolt A B C c Loosen the V belt Then remove the alternator 2 INSTALL ALTERNATOR ASSEMBLY To...

Page 178: ...ed Signal Ground The Sensor Revolution Signal Water Temperature Signa Fuel Level Gauge Tachometer Speedometer Water Temperature Gauge Feul Level Gauge Odometer High Beam Lamp Rear Defrost Lamp Rear Defog Lamp Backlight Water Temperature Warning Power Steering Fuel Warning Charge Brake Fluid Oil Pressure Engine Malfunction Driver s seat belt Park Brake SRS main SRS sub ...

Page 179: ...E Y YELLOW B BLACK P PIN G GREEN W WHITE O ORANGE Gr GRAY Br BROWN V VIOLETL g LIGHT GREEN The first letter represents the base color The second letter represents the color of the stripe e g VG violet green V violet G green Color of connector A is white and B is black V G ...

Page 180: ...al outpu YR 12 Fuel senso B 13 Alternator WR 14 Brake fluid level switc GR 15 Oil pressure switc YG 16 Rear defrost YB 1 Rear fog lamp Gr 2 Engine malfunction GY 3 Seat belt switch R 4 Power source Y 5 Engine coolant temperature senso YW 6 Park switch G 7 Power source groun B 8 Power source groun B 9 ABS R 10 SRS Main RY 11 Engine revolution signal BBl 12 Live wire Fire wire WG 13 High beam lamp R...

Page 181: ...mptoms of the combination meter These malfunctions can be solved by the procedure in the section of the Malfunction Diagnosis Serial No MALFUNCTION SYMPTOM 1 The whole combination meter does not operate 2 Speedometer malfunction 3 Tachometer malfunction 4 Water temperature gauge malfunction 5 Fuel gauge malfunction 6 Odometer malfunction ...

Page 182: ...LUSTER 10A in the main fuse box for continuity 2 Check fuse AM 30A in the main fuse box for continuity 3 Check fuse MAIN 80A in the fuse box for continuity Result and solution If a certain fuse is burnt replace a fuse with the same capacity Ignition Switch Main Fuse Box Combined Meter Assembly Battery Fuse Box ...

Page 183: ...ombination meter assembly Turn the ignition switch ON Inspect voltage between terminals Standard Result and solution Normal Replace the combination meter assembly Abnormal Repair or replace the harness or connector Tester connection Condition Standard condition B4 ground Turn the ignition switch ON 10 14V Tester connection Condition Standard condition B7 ground Normal condition Continuity B8 groun...

Page 184: ...inals Standard Result and solution If it is abnormal go to b Inspect the combination meter assembly speed input signal If normal go to c Inspect the combination meter assembly Tester connection Condition Standard condition A9 ground Normal condition Continuity Speedometer Sensor Combined Meter Assembly Ground the Speedometer Sensor Speedometer Sensor 8V Power Source Speed Signal Tester connection ...

Page 185: ...e the voltage between terminal A9 and A11 Standard voltage is as follows Voltage changes alternately Result and solution Normal Replace the combination meter assembly If abnormal inspect the speed sensor 2 Inspect the speed sensor Inspect continuity Inspect continuity between terminals Standard Tester connection Condition Standard condition 2 ground Normal condition Continuity Turning Wheels Below...

Page 186: ...ront wheels up Push the shift lever to NEUTRAL Turn the ignition switch to ON Slowly turn the front wheel measure the voltage between terminal 1 and 2 Standard voltage is as follows Voltage changes alternately Result and solution Normal Repair or replace the harness or connector Abnormal replace the speed sensor Turning Wheels Below 0 5V Tester connection Condition Standard condition 3 ground Turn...

Page 187: ...ard 3 Inspect voltage between terminals Result and solution Abnormal Repair or replace the harness or connector Normal Replace the combination meter assembly Tester connection Condition Standard condition B7 ground Normal condition Continuity B8 ground Normal condition Continuity Tester connection Condition Standard condition B4 ground Turn the ignition switch to ON 10 14V ...

Page 188: ... retain the connection of connectors 2 Connect the oscilloscope to the terminal B11 and ground 3 Start the engine 4 Inspect the signal wave form Standard Show the correct wave form Result and solution Normal Inspect and replace the combination meter assembly Abnormal Inspect the engine ECU revolution out put signal Engine ECU Combined Meter Assembly Engine Revolution Signal ...

Page 189: ...in the connection of connectors 2 Connect the oscilloscope to the terminal 54 and ground 3 Start the engine 4 Inspect the signal wave form Standard Show the correct wave form Result and solution Normal Repair or replace the harness or connector Abnormal Inspect the engine control system ...

Page 190: ...played on the diagnosis tester Standard The same with the actual engine coolant temperature Result and solution If it is normal the water temperature gauge has no malfunction If abnormal Inspect the combination meter assembly b Inspect the combination meter assembly 1 Inspect resistance Remove the combination meter assembly and disconnect connectors Inspect continuity between terminals Water Tempe...

Page 191: ...emperature cabinet Adjust the temperature in the constant temperature cabinet and measure the resistance of the water temperature sensor Standard Result and solution Normal Repair or replace the harness and connector If abnormal replace the water temperature sensor Tester connection Condition Standard condition C 60 164 5 5Ω 1 2C 90 56 3Ω H 115 28 7 2Ω B5 ground Condition Standard condition C 60 1...

Page 192: ...terminals Standard Result and solution Normal Replace the combination meter assembly If abnormal inspect the fuel level sensor 2 Inspect the fuel level sensor Remove the fuel level sensor Adjust the height of the fuel level sensor and measure its resistance Tester connectio n Condition Standard conditio n E 110 6Ω 1 2 32 5 3Ω F 3 2Ω A12 ground Fuel Level Sensor Combined Meter Assembly Fuel Signal ...

Page 193: ...ce in accordance with the Circuit Diagram the indicators will light correspondingly If it dose not light replace the combination meter If it lights repair or replace the harness or connector 7 ODOMETER MALFUNCTION Inspect first supposing the problem to be from the speedometer If the speedometer is normal the combina tion meter needs replacing when the odometer is abnormal Condition Standard condit...

Page 194: ...r assembly Only one illumination lamp does not light up 1 Combination meter assembly All illumination lamps do not light up Symptom Suspected Area 1 Harness or connector 2 ECM 3 Combination meter assembly 1 Harness or connector 2 Alternator 3 Combination meter assembly 1 Harness or connector 2 Hand brake switch 3 Combination meter assembly 1 Harness or connector 2 Brake fluid level switch 3 Combin...

Page 195: ...tor 2 Central controller or rear defrost switch 3 Combination meter assembly 1 Harness or connector 2 Electric Power Steering controller 3 Combination meter assembly 1 Harness or connector 2 Engine coolant temperature sensor 3 Combination meter assembly 1 Harness or connector 2 Seat belt buckle switch 3 Combination meter assembly ABS warning light does not light up SRS warning light does not light...

Page 196: ...spect the voltage between terminal A 11 and A 9 of the combination meter Standard 7 wave forms of the high low electrical level change per second NOTICE Hold the ignition switch ON when inspected connect the connector 3 INSPECT TACHOMETER Inspect its operation 1 Start the engine using a handy tachometer to compare 2 The value displayed on the handy tachometer and the value indicated on the tachome...

Page 197: ...nected when measured 5 INSPECT WATER TEMPERATURE GAUGE 1 Inspect resistance When the water temperature is indicated in the red area inspect the resistance between terminal B 5 and B 7 on the combination meter connector Tachometer r min handy tachometer r min 800 740 860 1000 900 1100 2000 1850 2150 3000 2800 3200 4000 3800 4200 5000 4800 5200 6000 5750 6250 Standard indication Resistance Ω E 104 1...

Page 198: ...rning light should go out 3 Short connector terminal to the ground with a wire the oil pressure warning light should light up 8 INSPECT OIL PRESSURE SENSOR 1 Disconnect the connector from the oil pressure sensor 2 Inspect continuity between its terminal and ground Engine is stopped Continuity Engine runs No continuity 9 INSPECT PARK BRAKE WARING LIGHT 1 Disconnect the connector from the park brake...

Page 199: ...m the reservoir 3 Inspect continuity between terminals Float up No continuity 4 Use siphon to take fluid out of the reservoir 5 Inspect continuity between terminals Float down Continuity 6 Pour the fluid into the reservoir 13 INSPECT THE REAR DEFROST INDICATOR 1 Turn the ignition switch ON and start the engine 2 Press the defrost switch the rear defrost indicator will light up 3 Turn the ignition ...

Page 200: ...rness 1 Wiper switch assembly 2 Wiper motor assembly 3 Harness 4 Central controller 1 Wiper fuse 2 Wiper switch assembly 3 Wiper motor assembly 4 Harness 1 Wiper switch assembly 2 Wiper motor assembly 3 Harness 4 Central controller Washer fluid dose not jet out 1 Washer hose and nozzle When the washer switch places on OFF wiper blade can not return or stay in a wrong place 1 Wiper motor assembly T...

Page 201: ...battery positive and the terminal 2 to the negative as shown below Inspect that the washer fluid flows out of the can 4 If not replace the washer pump 2 WIPER SWITCH ASSEMBLY a Inspect the continuity Inspect each terminal on connector for continuity Standard Switch position Tested terminal Specified condition MIST 8 10 Continuity OFF 3 10 Continuity INT 8 6 3 10 Continuity LO 8 10 Continuity HI 8 ...

Page 202: ...or operates at low speed If it is not as specified replace the motor b Inspect the high speed shift Connect the connector terminal 3 to the battery positive and the connector terminal 2 E to the negative check that the motor operates at high speed If it is not as specified replace the motor c Inspect automatic return 1 Connect the connector terminal 5 to the battery positive and the connector term...

Page 203: ...n the specified torque c Connect the connector d Operate the wiper make the washer fluid spraying on the windshield check if the operation of wiper and its starting position is normal If not remove the wiper arm blades assembly and make some proper adjustment Hint Make the top of the new shaft of the wiper motor crankshaft arm filled with lubricating oil II WIPERBLADESREPLACEMENT 1 REMOVE BLADES F...

Page 204: ...Disconnect the connector b Remove the 2 tapping screws that are for mounting the wiper switch take out the wiper switch from the bracket of the combination switch IV WASHERNOZZLE ADJUSTMENT 1 INSPECT WASHER NOZZLE a Start the engine check if the position where the washer fluid from the nozzle sprays the windshield is in the central or upper of the area wiped by the blades b Change the direction ho...

Page 205: ...CTRICAL EQUIPMENTS a Disconnect the battery ground cable 2 Notes when replacing a headlamp bulb a Before replacing a halogen bulb turn the headlamp OFF to make it cool b When installing a new halogen bulb do not touch the glass part of the bulb with bare hands c If there is oil stain on the surface of halogen bulb headlamp and front fog lamp when the lamps are turned ON its service life will be sh...

Page 206: ...ation lamp Turn signal lamp PY21W 12V 21W Rear combination lamp Brake Position lamp P21 5W 12V 21 5W Rear combination lamp Rear fog lamp P21W 12V 21W Rear combination lamp Back up lamp P21W 12V 21W C5W 12V 5W W5W 12V 5W Rear row reading lamp C5W 12V 5W Side turn signal lamp WY5W 12V 5W High mounted stop lamp incl rear trunk lamp W5W 12V 5W License plate lamp W5W 12V 5W Door courtesy lamp W5W 12V 5...

Page 207: ...embly LH Front Fog Assembly Front Headlamp Height Adjusting Switch Headlamp Switch Lamp Control Switch Haedlamp DIM Switch Turn Signal Lamp Switch Hazard Warning Switch Parking Brake Switch Backup Lamp Switch Brake Switch Door Courtesy Lamp Switch LH Front Rear Door Courtesy Lamp Assembly LH Front Combined ...

Page 208: ...201 High Mounted Stop Lamp LH Rear Combined Lamp Rear Trunk Lamp Switch License Plate Lamp RH rear Combined Lamp ...

Page 209: ... fuse 3 Harness 1 Lamp switch assembly 2 Harness 1 Bulb 2 LH or RH headlamp fuse 3 Harness 1 Lamp switch assembly 2 Harness 1 Lamp switch assembly 2 Harness 1 Bulb 2 Harness 1 Bulb 2 Harness 1 Fuse 2 Light control switch 3 Harness 1 Beam control switch 2 Harness Low beam dose not light One side Low beam dose not light All High beam dose not light One side High beam dose not light All Tail lamps on...

Page 210: ...EADLAMP Head lamp is normal Only one side front fog lamp dose not light Symptom Suspected Area 1 Bulb 2 Light switch assembly 3 Harness 1 Bulb 2 Tail lamp fuse 3 Harness 1 Bulb 2 Harness Rear fog lamp dose not light up with light control switch on FRONT FOG LAMP Small lamp is normal Rear fog lamp dose not light up with light control switch on FRONT FOG LAMP Small lamp is abnormal Only one side rea...

Page 211: ...ard and Turn does not operate Hazard warning lamp does not operate Turn is normal Hazard warning lamp is abnormal Hazard is abnormal Turn signal dose not light up in one direction Symptom Suspected Area 1 Brake lamp fuse 2 Brake lamp switch 3 Harness 1 Brake lamp switch 2 Harness 1 Bulb 2 Harness 1 Bulb 2 Harness Brake lamps on both sides do not light up Brake lamp remains always ON Brake lamp dos...

Page 212: ... Fuse 2 Harness 1 Bulb 2 Room lamp assembly 3 Harness 1 Door courtesy lamp switch 2 Central controller 3 Harness 1 Bulb 2 Switch 1 Bulb 2 Rear row reading lamp assembly 3 Harness Interior lamp dose not light All One door is ajar room lamp dose not light up on DOOR It is normal on ON Central LH RH room lamps do not light up Rear row reading lamp is abnormal Room lamp assembly is normal Room lamp do...

Page 213: ...stration Turn Switch Left Turn Straight Run Right Turn Lamp Switch Horn High Beam Dipped Beam Lamp Handle FogLightHandle Front Fog Lamp Front Fog Lamp Front Fog Lamp Front And Rear Fog Lamp Front And Rear Fog Lamp Headlamp Headlamp Headlamp Position Lamp Position Lamp Position Lamp 9 9 9 9 9 9 9 5BB1 5BB2 5BB3 5BB1 9NB4 9NB1 9NB5 Symptom Suspected Area 1 Bulb 2 Rear trunk lamp switch 3 Harness Rea...

Page 214: ...ct each terminal for continuity when the switch is on every position according to the table If it is not as specified replace the switch Switch position Tested terminal Condition OFF 5BB2 5BB3 No continuity TAIL 5BB2 5BB3 Continuity Switch position Tested terminal Condition LO 5BB1 9NB5 Continuity HI 9NB2 9NB3 Continuity PASSING 9NA1 9NB3 Continuity 5B 5BB1 5BB2 5BB3 5BA1 5BA3 9N 9NB1 9NB2 9NB3 9N...

Page 215: ...amp switch operates If it is not as specified replace the switch 4 HAZARD WARNING LAMP SWITCH ASSEMBLY Inspect hazard warning lamp switch for continuity Inspect continuity between the 2 terminals when the switch operates If it is not as specified replace the switch Switch position Tested terminal Condition OFF 5BB3 9NB4 9NB1 No continuity Front fog lamp 5BB3 9NB4 Continuity Rear fog lamp 5BB3 9NB1...

Page 216: ... Inspect each terminal on room lamp assembly for continuity If it is not as specified replace the dome lamp or the switch Switch position Tested terminal Condition ON 1 Ground the body Continuity OFF 1 Ground the body No continuity Tested terminal Condition ON 1 2 Continuity OFF 1 2 2 3 No continuity DOOR The door is ajar 2 3 Continuity DOOR The door is closed 2 3 No continuity ON Switch is presse...

Page 217: ...y Inspect front fog lamp relay for continuity a Inspect continuity between terminals If it is not as specified replace the relay b Impose a battery voltage 10V 14V between terminal 86 and terminal 85 then inspect continuity between terminal 30 and terminal 87 If not replace the relay Switch position Tested terminal Condition ON 1 2 Continuity OFF 1 2 No continuity Tested terminal Condition 86 85 C...

Page 218: ...OVAL 1 Remove front bumper See bumper replacement 2 Remove the 3 mounting bolts A B C as shown in the illustration on the headlamp 3 Remove the electrical connector 4 Move the assembly forwards and upwards then remove it Electrical Connector ...

Page 219: ...1 Replace the high and low beam bulbs y Turn and remove the dust cover counter clockwise y Pull out the bulb plug y Press and release the wire clip y Pull out the lamp holder and remove the bulb y Replace the bulb 2 Replace the turn signal lamp bulbs y Remove the 3 screws on the dust cover with screwdriver y Turn the lamp holder counter clockwise Pull out the lamp holder and remove the bulb y Repl...

Page 220: ...mps to the wall is 10 m 2 Inspect the headlamp beam y Set up a screen as shown in the illustration to adjust the headlamp aim y Cover the other lamps while a certain headlamp is adjusted y Start the engine y Turn the headlamp low beam ON y Then turn the adjusting screws controlling the beams Make the main beam the brightest point at the specified height that is the corner point of the cut off line...

Page 221: ...hten it 1 Adjust the positions of the screw bolts as shown in the illustration below y Turn A for adjustment in horizontal direction within an allowed scope y Turn B for adjustment in vertical direction within an allowed scope V LH V RH V line Central of the Headlamp Central of the Headlamp Corner Point of the Cut off Line Dim and Bright Cut Line Angle A B ...

Page 222: ...the front fog lamp assembly II INSTALLATION 1 Install the front fog lamp assembly 2 Install the mounting bolts 3 Install the electrical connector 4 Install the front bumper 5 Adjust the condition of the vehicle 6 Adjust the front fog lamp beam III FRONT FOG LAMP BULB REPLACEMENT 1 Press and Turn counter clockwise then remove the dust cover 2 Pull out the bulb 3 Replace the bulb A B Electrical Conn...

Page 223: ...e with the standard value 2 Start the engine 3 Turn the fog lamp switch ON 4 Adjust the fog lamp beam Turn the bolt A for adjusting fog lamp beam in vertical direction NOTES Turn the screwdriver counter clockwise to make the light beam up clockwise make the light beam down ...

Page 224: ... seal strip and interior trimming 2 Remove the 3 mounting bolts A B C as shown in the illustration 3 Remove the rear combination lamp electrical connector 4 Pull the rear combination lamp assembly backwards Seal Strip Interior Trimming Buckle and Plug A B C Electrical Connecto r ...

Page 225: ...al strip III REAR COMBINATION LAMPBULB REPLACEMENT 1 Remove the O ring seal 2 Turn the lamp holder counter clockwise Pull out the lamp holder 3 Remove the bulb and replace the bulb Section 6 High Mounted Stop Lamp Replacement z Remove the High mounted stop lamp in direction 1 and 2 as shown above in the illustration z Disconnect the connector Partition High Mounted Stop Lamp ...

Page 226: ...ld off at the point a with a screwdriver 2 Remove the 2 mounting bolts with a screwdriver take care not to touch the bulb 3 Pull the High mounted stop lamp assembly downwards 4 Pull out the electrical connector Roof Panel Interior Tri m Lamp Body Lamp Shield a Fixing Screw ...

Page 227: ...g lamp off at the point a with a screwdriver Position 1 as shown in the illustration 2 Pull out the rear reading lamp downwards with an angle Position 2 as shown in the illustration 3 Remove the electrical connector Section 9 License Plate Lamp Replacement 1 Remove the license plate lamp with a screwdriver 2 Remove the electrical connector ...

Page 228: ...tion problems Hint Besides the static noise fault there are also the faults called interference multipath transfer and fade out These faults are caused not by electrical noise but by the nature of the radio waves themselves 1 Interference Besides static noise fault AM broadcasts are also susceptible to other types of noises es pecially at night This is because AM radio waves are reflected by the I...

Page 229: ...tand the feedback information from the customers well so make the best use of the following questionnaire and diagnose the fault accurately HINT In the case that the noise occurrence condition does not meet any of the above check based on the Recep Multipath Transfer Fade out Radio Wave Operating condition when noise occurs Cause Noise occurs at a specific place Strong possibility of foreign noise...

Page 230: ... exposure Be sure to operate the player correctly as instructed 6 MAINTENANCE 1 Tape player magnet head cleaning 1 Raise the cassette door with your finger Next using a pencil or similar object push in the guide 2 Using a cleaning pen or cotton applicator soaked in cleaner clean the magnet head surface pinch rollers and tape press wheel 2 CD player disc cleaning If the disc gets dirty clean the di...

Page 231: ...ND B Constant Status Continuity A8 Null A9 Null A10 TAIL GW Position lamp switch turned to ON 10 14V B1 RR PB The audio system is on Wave form is synchronized with the output sound B2 RL YR The audio system is on Wave form is synchronized with the output sound B3 RR P The audio system is on Wave form is synchronized with the output sound B4 Null B5 Null B6 RL YW The audio system is on Wave form is...

Page 232: ...en CD box and main unit 2 CD box 3 CD 4 CD Player main unit 1 Wire between CD box and main unit 2 CD box 3 CD 4 CD PLAYER main unit 1 Wire between CD box and main uni t 2 CD box 1 CD box 2 CD box installation Sound quality poor only when playing CD Volume faint CD sound jump Tape jammed malfunction with tape speed or auto reverse CD could not be inserted or ejected after inserted Power coming in b...

Page 233: ...ge between terminals under each operating condition as shown in the table Standard Normal Repair or replace wire harness connector Abnormal Check or replace radio assembly Main Fuse Box Radio and CD Battery Fusible Link Box Ignition Switch Tester connection Condition Standard Status GND Constant Status Continuity Tester Connection Condition Standard Status B GND Constant Status 10 14V ACC GND Igni...

Page 234: ...en terminals under each operating condition as shown in the table below Standard Abnormal Repair or replace wire harness and connector Normal Check and replace radio assembly Main Fuse Box Radio and CD Fusible Link Box Battery Light Control Switch Battery Tester Connection Condition Standard Status TAIL GND Combined Switch Light switch 10 14V ...

Page 235: ... Next Step 2 Control volume and adjust volume balance Operate the radio assembly to adjust volume balance and find soundless speaker Check and replace the radio assembly if all the speakers are soundless Check and replace the soundless speakers if some of the speakers are soundless Main Fuse Box Radio and CD Ignition switch Fusible Link Box Battery Left Rear Speaker Right Rear Speaker Left tweeter...

Page 236: ... rear speaker assembly Normal Check wire harness and connector 6 Check wire harness and connector Abnormal Repair or replace wire harness and connector Normal Check and replace radio assembly 7 Check and replace radio assembly B ACC GND a Check the continuity between terminals under each operating condition as shown in the table below Standard b Check the voltage between terminals under each opera...

Page 237: ...ch to ACC Turn on the radio to AM Insert a flat pan screwdriver or metal object similar to thin wire into the hole in the antenna coaxial cable Check the speaker for noise Standard There is noise Normal Check and replace radio assembly Abnormal Check and replace antenna coaxial cable sub assembly 5 Cassette tape can not be inserted or played 1 Check for foreign object Check the radio assembly and ...

Page 238: ...JECT of the radio assembly Check if the tape ejects Standard The tape is ejected Abnormal Check and replace radio assembly Normal Check cassette tape 2 Check cassette tape Check the ejected tape for trademark peeled off or tape box distortion or other issues Standard There is nothing wrong with the tape Abnormal There is something wrong with the tape Normal Replace it with another tape and re chec...

Page 239: ... reoccurs Normal The magnet head is dirty Abnormal Check and replace radio assembly 8 Tape jammed malfunction with tape speed or auto reverse 1 Check for foreign objects Check the radio assembly and tape player for foreign objects and defects Standard No foreign objects or defects Abnormal Clean foreign objects Normal Replace it with another tape and re check 2 Replace it with another tape and re ...

Page 240: ...n in the table below Standard 3 Check the voltage between terminals under each operating condition as shown in the table below Standard Normal Replace the signal wire connecting magnet head unit and CD box Abnormal Check the radio assembly B ACC GND 3 Check the radio assembly B ACC GND 1 Check the continuity between terminals under each operating condition as shown in the table below Standard Test...

Page 241: ...e sure the working CD is music and it is not distorted cracked dirty scratched or defected Standard Working music CD Description Semi transparent CD or CD of strange shape can not be played Music CD recorded in PC CD ROM and recorded CD R can not be played Adapter is not needed to play 8cm CD Abnormal There is something wrong with CD Normal Check and insert a proper CD 3 Check and insert a proper ...

Page 242: ... CD player is due to temperature changes CD may not play Normal Formulation of dew condensation due to temperature changes Leave it for a while before using it Abnormal Check the signal wire between the radio and disc box 7 Check the signal wire for short circuit or open circuit Yes Replace the signal wire No Replace the disc box 8 Replace the disc box Standard The faulty is cleared Normal Box fau...

Page 243: ...r or anti static preservative Standard The fault is cleared Normal The disc is dirty Abnormal Replace it with another CD and re check 2 Replace it with another CD and re check Standard The fault is cleared Normal CD failure Abnormal Check when it will happen 3 Check when it will happen Check where sound jump will happen Standard Drive on bumpy road Normal Replace CD box Abnormal Compare with other...

Page 244: ...disk cabin Check if sudden temperature change occurs inside the disk cabin Standard Sudden temperature change occurs inside the disk cabin Description Formulation of dew condensation inside the CD player is due to temperature changes CD may not play Normal Formulation of dew condensation due to temperature changes Leave it for a while before using it Abnormal Check and replace CD box ...

Page 245: ...gative terminal cable All cassette tapes and CDs must be taken out before radio removal and installation If the cassette tapes and CDs can not be taken out due to radio fault Do not take them out by force Drive the vehicle to Service Station Make sure the grounding bolts are tightened before antenna removal and installation There will be noise when receiving electric wave if the grounding bolts ar...

Page 246: ...239 Tweeter Antenna Cable Antenna Assembly Front Speaker Assembly Rear Speaker Assembly ...

Page 247: ...sembly 1 Disconnect connector 2 Remove 4 self tapping screw and speaker assembly IV Tweeter speaker assembly 1 Remove front outside rear view mirror cover 2 Remove tweeter speaker assembly 1 Disconnect connector 2 Remove 2 self tapping screw and speaker assembly V Rear speaker assembly 1 Remove rear speaker baffle 2 Remove rear speaker assembly 1 Disconnect connector 2 Remove 4 self tapping screw ...

Page 248: ...bly 1 Remove the roof interior trim 2 Disconnect connector 3 Remove antenna nut 4 Remove the overhead antenna assembly VIII CD DVD 1 Remove the left side rear trunk interior trim 2 Disconnect connector 3 Remove 4 bolts and disc box ...

Page 249: ...ssembly Option 4 If there is any abnormality in the wire harness of the SRS replace it with a new one Correct or replace the abnormal wire harness in accordance with Table 1 Figure 1 Table 1 No Designation Description 1 Belt pretensioner Driver Low Seat belt pretensioner driver side low position 2 Belt pretensioner Driver High Seat belt pretensioner driver side high position 3 Belt pretensioner Pa...

Page 250: ...tc shall be removed and kept in place to avoid the effects of overheat Over 93 æ 7 When the SRS is serviced a diagnostic scan meter is used to clear the DTC to enable the normal work of the warning light 11 DAB Lo Driver airbag low position 13 Option PAB Hi Passenger airbag high position 14 Option PAB Lo Passenger airbag low position 20 Passenger Airbag Deactivation Indicator Passenger airbag deac...

Page 251: ...nd find out whether the warning light is on 2 Six seconds after the process of ON OFF confirm that the warning light goes out permanently 3 Otherwise diagnosis and checking have to be involved in 3 System Diagnosis The SRS ECU HAE2 5 will perform a series of circular diagnostic tests to check the readiness of the SRS functions This test can avoid unexpected explosion of the restrain system and in ...

Page 252: ...uit Yes 7 Ignition circuit 2 passenger airbag groun d Yes 8 Ignition circuit 2 passenger airbag connected to power source Yes 9 Ignition circuit 3 driver seat belt pretensioner high resistance or open circuit Yes 10 Ignition circuit 3 driver seat belt pretensioner low resistance or short circuit Yes 11 Ignition circuit 3 driver seat belt pretensioner groun d Yes 12 Ignition circuit 3 driver seat b...

Page 253: ...ensioner separate ignition for 6 times No replace SRS ECU HAE2 5 No Trouble Description DTC 1 Ignition circuit 1 driver airbag high resistance or open circuit B1 346 2 Ignition circuit 1 driver airbag low resistance or short circuit B1 347 3 Ignition circuit 1 driver airbag ground B1 348 4 Ignition circuit 1 driver airbag connected to power source B1 349 5 Ignition circuit 2 passenger airbag high ...

Page 254: ...nnected 14 Ignition circuit 4 passenger seat belt pretensioner low resistance or short circuit B1 368 15 Ignition circuit 4 passenger seat belt pretensioner ground B1 369 16 Ignition circuit 4 passenger seat belt pretensioner connect to power source B1 370 17 High voltage of power source B1 111 18 Low voltage of power source B1 112 19 Warning light trouble connected to power source or light bulb s...

Page 255: ...port time Short Range of deviation Sensor not in steady mode Sensor selfcheck trouble 11 Continuous abortion of ignition circuit check Nonexecution of circular diagnostic test Repeated algorithm calculation Close for 2 or more than 2 seconds Safety sensor is open circuit when calculating the trouble with algorithm 13 Ignition current All the ignition currents are normal when the current SRS is dep...

Page 256: ... the working voltage is supplied If the history troubles happened for less than 5 times the warning light will be on for 6s after ignition on and then go out In the initiation stage the SRS ECU HAE2 5 will not check crash and arrest deployment until the circuit of SRS ECU HAE2 5 goes stable Thus after ignition on the display mode of the warning light is one of the following states displayed in the...

Page 257: ...e microcontroller as stated below Malfunction of the battery supplying power to SRS ECU HAE2 5 the warning lights are turned on continuously by means of the drive function of the selfcheck light Loss of internal working voltage the warning light remains on Reset due to trigger failure of the watchdog the warning light blinks Microcontroller out of work the warning light always lights up Incomplete...

Page 258: ...ith step 5 2 Check light bulb CAUTION Mishandling of SRS components may release unexpectedly airbag and seat belt pretensioner probably lead ing to a serious accident Read the service cautions before handling a SRS component 1 Turn the ignition switch to LOCK 2 Disconnect the negative terminal cable from the battery and wait for at least 60s 3 Remove the instrument cluster 4 Measure and see if the...

Page 259: ... then continue with step 5 2 Check the continuity of the wire harness between ECU and instrument cluster 1 Turn the ignition switch to LOCK 2 Disconnect negative terminal cable from the battery 3 Open the guard plate of the central passage 4 Disconnect the connector of the instrument cluster 5 Connect the negative terminal cable of the battery 6 Turn the ignition switch ON 7 Check whether the volt...

Page 260: ...r the terminals are in good condition and whether the shorting bar is broken Yes replace the ECU No reconnect the ECU connector and then continue with next step 3 Make sure of the nonrecurrence of the trouble after repair 1 Turn the ignition switch to LOCK 2 Disconnect the negative terminal cable from the battery and wait for at least 60s 3 Connect all the ECU connectors 4 Connect the connector of...

Page 261: ...e that may not appear prior to this test Performing this test may results in body injury or damaged system due to misoperations Therefore preparations must be made before checking Internal circuit trouble of SRS ECU Possible Cause Internal trouble of SRS unit Operation Replace the SRS unit see SRS System Removal Installation of SRS Unit Checking Conditions DTC B1112 Low power source voltage of SRS...

Page 262: ...ry and wait for over 1 minute 12 Remove left trim plate 13 Disconnect the adaptor connector of SRS unit 14 Reconnect the battery negative terminal cable and turn the ignition switch ON check whether the voltage between the corresponding pin of the connector and the pin ground is higher than 9V Yes completion of trouble diagnosis No replace the wire harness 5 Driver side trouble DTC B1 346 B1 347 B...

Page 263: ... 4 Any DTC displayed Can it be cleared Yes replace the driver airbag assembly See SRS Driver Airbag Assembly Removal Instillation No continue with next step 3 Check the connector of clock spring wire harness 1 Turn the ignition switch to LOCK 2 Loosen the negative terminal cable from the battery and wait for over 1 minute 3 Remove steering column hood 4 Loosen the connector of the clock spring 5 A...

Page 264: ...or SRS DTC B1 352 B1 353 B1 354 B1 355 CAUTION If it is not handled properly the airbag assembly and retractable seat belt may be triggered and deployed tensioned leading to serious injury to a person Therefore prior to handling read the service cautions carefully See service cautions for SRS If there is passenger airbag The resistance between pins 13 and 14 of SRS unit connector is out of range T...

Page 265: ...t step Yes replace passenger airbag assembly See SRS Passenger Airbag Assembly Removal Installation 4 Check the wire harness between passenger airbag assembly and SRS ECU 1 Turn the ignition switch to LOCK 2 Loosen the negative terminal cable from the battery and wait for over 1 minute 3 Remove steering column hood 4 Loosen the connector of the clock spring 5 Loosen the connectors of driver and pa...

Page 266: ...ag assembly in relation to steering wheel 1Check and see if there is abnormal noise in the steering wheel the action of the same is good or the clearance is normal 2Check the union joint of the wire harness for damage and the terminal for distortion 3 ECU 1 Check the brackets of the ECU Case for recess crack distortion etc 2 Check the union joint for damage and terminal for distortion 3 Check the ...

Page 267: ...al cable shall be protected with insulating tape for insulation 2 Airbag assembly and clock spring shall not be removed or repaired They shall be replaced if there is any trouble 3 Pay enough attention to airbag assembly and clock spring when using avoiding dropping them onto the ground or into water or oil In addition if there is any pitting crack or distortion on them replace with new ones 4 Whe...

Page 268: ...h the description of mark In addition if the mark is damaged or stained it shall be replaced 1 Driver airbag assembly see Fig 1 2 Clock spring see Fig 2 3 ECU see Fig 3 4 Sun Visor see Fig 4 5 Steering wheel Fig 5 Warning Mark Figure 1 Warning Mark Figure 2 Warning Mark Figure 3 Warning Mark Warning Mark Figure 4 Sun Visor Figure 5 ...

Page 269: ...ck after installation 1Turn the ignition switch ON 2The warning light goes on within 6s and then goes out 3 If the light doesn t go out check the trouble and eliminate it NOTICE 1 Work must be started 60s after the negative terminal cable is detached from battery The detached negative terminal cable shall be protected with insulating tape for insulation 2 Never attempt to dismantle or repair an EC...

Page 270: ... spring 1 Remove the driver airbag assembly disconnect the connector 2 Remove steering wheel gently see the precautions 3 Open the upper closure of the combination switch locate and disconnect the connector of wire harness in the lower end 4 Remove clock spring from the steering wheel 4 Installation procedures of the driver airbag assembly 1 Pre Check Steering wheel Connect the wire harness Driver...

Page 271: ...he battery 6 Check after installation 6 Removal of steering wheel see the figure below 1 Remove the installation screws from the middle and remove the steering wheel Disconnect the horn connector NOTICE Due to the tight engagement of the spline and the steering column it is hard to separate the steering wheel from the column Don t try to remove the steering wheel by force otherwise the clock sprin...

Page 272: ...nents of the steering wheel and airbag assembly 1 When the center of the clock spring is aligned install the components of the steering wheel and airbag assembly 2 After being installed rotate the left and right sides of the steering wheel to position and make sure there is no abnormality NOTICE In case of scrapping an airbag it shall be noted that the airbag shall be deployed according to the spe...

Page 273: ... pitting crack and distortion 4 Check the installation status of the airbag assembly 2 Check the clock spring Check the following items and replace the clock spring if any badness is found 1 Check the joint and protecting tube for damage and the terminal for distortion 2 Check the case for damage 3 Check and see if the joint terminal at the upper end of the clock spring are in conduction with that...

Page 274: ...or to deployment 1 Deploy inside a vehicle 1Park the vehicle in a flat area NOTICE Never insert probe directly from the lower end of the connector NOTICE The airbag shall be deployed before being scrapped The airbag shall be deployed outside the vehicle before being changed The airbag shall be deployed in the vicinity of a smoke detector since smoke will appear when the airbag is deployed When bei...

Page 275: ...h other short circuited Unexpected deployment resulted from static electricity shall be prevented 4 From the yellow connector of the clock spring lead the airbag adapter wire harnesses out of the vehicle by means of the wire harnesses for deployment see the figure below 5 To restrain the noise close all the windows and doors and put on the vehicle cover NOTICE Work must be started 60s after the po...

Page 276: ...o the following procedures 4 Driver airbag assembly 1 Remove the driver airbag assembly from the vehicle Vehicle Cover Wire Harness for Deployment NOTICE Make sure there is no man inside or near the vehicle and then carry out the operations After the driver airbag is deployed the gas generator is of high temperature Keep it for 30 minutes until it gets cool for use If the driver airbag assembly ca...

Page 277: ...with the two wire harnesses for deployment and make sure to wrap up the connecting location with insulating tape for insulation see the figure below 5 Install the unused bolts on to the inside bolt of the driver airbag assembly and tie a thick wire securing the wheel rim 6 Pass the deployment wire harness of the driver airbag assembly through an old tire with rim and fix upwards the driver airbag ...

Page 278: ...nals of the battery removed from the vehicle and deploy the airbag see the figure below 9 the deployed driver airbag assembly shall be scrapped according to the scrapping procedures Wire Harness for Deployment Old Wheels without Hub Wire Harness for Deployment NOTICE Make sure to deploy the driver airbag assembly when there is no person close by After the driver airbag is deployed the gas generato...

Page 279: ...de 01901 III Read and Clear the DTC 1 After selecting the 02 Read DTC in the function menu it displays the total amount of the fault if there is no DTC then it displays no DTC Then press OK button to proceed to next page to review the DTC and its description Generally there is a P or O before the DTC indicating that it is a Persistent fault or Occasional fault Persistent fault remains existing all...

Page 280: ...ccasional DTC and Non occasional DTC System Problem There is no problem current ABS Warning Light does not light up The problem still exists ABS Warning Light goes on Step Action Screen Display Normal Result 1 HCU diagnosis hydraulic pump test Pump motor operates 2 LF Wheel Depress the brake pedal 3 LF Wheel normally open valve open normally closed valve closed wheel locked Wheel locked 4 LF Wheel...

Page 281: ...t 2 3 4 Inspection Table No Reference Page 1 282 2 283 The brake force on both sides is not uniform The brake force is insufficient ABS operates when the brake pedal is slightly depressed vehicle is stationary ABS operates when the brake pedal is slightly depressed vehicle is driving When the ABS operates the brake pedal vibrates severely 4 285 5 286 6 287 No DTC output failure in communicating wi...

Page 282: ...ctor Pin Layout ABS ECU Connector End Views Electrical Wiring Diagram Combination Meter ABS Warning Light Drive Module ABS ECU ABS RR Wheel Sensor ABS LR Wheel Sensor ABS RF Wheel Sensor ABS LF Wheel Sensor Brake Lamp Switch ...

Page 283: ... wire harness between the motor and the ECU is disconnected Use the scan meter to perform the test by activating the HCU function to drive the motor Power supply is disconnected or grounded Motor wire harness is disconnected Motor is damaged Remove the motor wire harness connector connect it to the Battery to see whether the motor operates Check the fuse and ABS ECU connector Connect the motor wir...

Page 284: ...0285 00283 00285 00287 00290 Likely Causes Description When no open in the circuit can be detected and there is no signal output when the vehicle speed exceeds 20km h this DTC is set Hint The likely cause may be the sensor inadvertently not installed short circuit in the sensor coil or wire harness excessive clearance between the sensor and the ring gear or damaged ring gear The sensor is not inst...

Page 285: ...DTC 00283 00285 00287 00290 Likely Causes Description When the vehicle speed exceeds 20km h if the sensor signal goes beyond the tolerance range this DTC is set Hint The weak signal may result from the poor connection or short circuit of the sensor coil or wire harness damaged ring gear or excessively big clearance between the sensor and the ring gear The intermittent poor connection or short circ...

Page 286: ... sensor connector or wire harness is short to ground or power supply Fault in the sensor signal processing circuit in the ABS ECU Repair the connector Check the sensor on each wheel Remove the ABS ECU connector check whether the resistances among the following terminals is within the specification Standard 1 0 1 3K LF 1 2K RF 19 20K LR 5 6K RR 22 23K Check the corresponding sensor connector Does t...

Page 287: ...n connection this DTC is set ABS wire harness pin connection error ABS ECU programming error Repair the wire harness Use the scan meter to check whether the ABS ECU programming is correct Correct 01901 Check the ABS wire harness pin connector for continuity Pin connector ABS ECU pin 12 and 14 Reprogram Abn Yes No ...

Page 288: ... ABS system 50A fuse Disconnect the ABS wire harness from the ECU turn the ignition switch to ON mea sure the voltage among the following termi nals of the ABS wire harness Terminal 8 and 9 9 5 16 5V Terminal 24 and 25 9 5 16 5V Terminal 8 and 4 9 5 16 5V Check the ABS wire harness connector Retest Abn again Check the Battery voltage Refer to Occasional Problem Service Key Points Replace the ABS E...

Page 289: ...or determines that the input vehicle speed is suspect this DTC is set High frequency electromagnetic wave interference Damaged sensor or its wire harness Damaged ABS ECU Replace the ABS ECU Check the sensor output voltage Check the wire harness between the ECU and the sensor Replace the sensor Abn Ok No Check the sensor Ok ...

Page 290: ...ctor does the warning light goes on with the ignition switch ON Check whether the ABS warning light is burned Check whether the warn ing light power supply cir cuit and ground circuit in the wire harness is open Check the connector of the warning light power supply circuit and ground circuit in the wire harness Does the fault reoccur Abn Replace Repair the wire harness No Yes Abn Abn Ok Yes No Ok ...

Page 291: ...on One of the Likely Causes is that ABS warning light drive module is damaged or there is an open in the ABS warning light circuit The warning light drive module is damaged ABS warning light drive module circuit open ABS ECU is damaged Repair the wire harness Check whether there is an open circuit in the wire be tween the ECU and ABS warning light drive module Check the ABS warning light drive mod...

Page 292: ...eck each sensor Check each sensor ring gear Check the wheel bearing clearance Check the ABS ECU socket and the middle connector No Installed it correctly Abn Abn Abn Abn Ok Yes No Ok Ok Replace Replace Repair the connector Use scan meter for HCU di agnosis Yes Does the fault reoccur Yes No Refer to Occasional Problem Service Key Points Replace the ABS HCU Remove the ABS ECU connector check whether...

Page 293: ...ng Brake fluid leakage Air in the system Brake disc severely worn Brake fluid level switch faulty Tighten the pipe connector as specified Visually inspect whether the hydraulic pipe connector is leaking Check the brake disc wear Replace the brake disc Abn Ok Abn Check the brake fluid level switch Ok Bleed and check Ok Use the scan meter HCU to diagnose and check the nor mally closed valve seal Ok ...

Page 294: ...d the brake pedal stroke Scan meter HCU function can be used to check the fault of the normally open valve Boost faulty Normally close valve faulty Replace the HCU Use Scan meter HCU function can be used to check the normally open valve Check the booster and the pedal stroke with Non ABS tra ditional method Ok Abn ...

Page 295: ...he MK 20 ABS ECU on other vehicles ABS scan meter faulty check it af ter repairing it Replace Check the power cable ground wire and diagnostic wire in the diagnos tic interface Check the diagnostic interface or wire harness No Yes No Yes Continuity Check ABS power supply fuse Ok Replace the ABS ECU Repair the diagnostic interface or harness Is there any scan meter Abn Remove the ABS ECU connector ...

Page 296: ...ht switch pedal not depressed ON 8 18 0 0 0 5 V Brake light switch pedal depressed ON 8 18 10 0 14 5 V Diagnostic interface OFF Diagnostic interface K 7 0 0 0 5 Ω LF Wheel Speed Sensor Resistance OFF 1 20 1 2 1 3 KΩ RF Wheel Speed Sensor Resistance OFF 19 20 1 2 1 3 KΩ LR Wheel Speed Sensor Resistance OFF 5 6 1 0 1 3 KΩ RR Wheel Speed Sensor Resistance OFF 22 23 1 0 1 3 KΩ LF Wheel Sensor Output V...

Page 297: ...ress the pedal When LR wheel can not rotate the pedal does not descend Normally closed valve inspection ON two valves and pumps are energized simultaneously Depress the pedal LR wheel can rotate freely the pedal does not descend Normally open valve inspection ON Depress the pedal When RR wheel can not rotate the pedal does not descend Normally closed valve inspection ON two valves and pumps are en...

Page 298: ...r to Front Wheel Sensor Drawing For rear wheel refer to Rear Wheel Sensor Drawing When use the oscilloscope to measure For front wheel refer to the related standard For rear wheel refer to the related standard 5 The fact that the output voltage is not within the above range may result from the following causes Excessive clearance between the sensor and the ring gear Sensor fault Check the sensor r...

Page 299: ...T 4 brake fluid do not use the mineral oil 9 Use the brake fluid to immerse the seal and the O ring do not use the engine oil or brake grease 10 After service check the regular brake system and ABS brake function for normal and reliable operation 11 Check all hydraulic pipe union for leakage II HECU Removal 1 Turn off the ignition switch and disconnect the battery negative ground cable 2 Remove th...

Page 300: ...293 8 Remove the whole HECU from the bracket ABS HECU Assembly ABS HECU Brake Pipe Removal Schematic ...

Page 301: ...to the HCU tighten the torque 3 1Nm 6 Connect the motor wire harness be careful that the retaining clip shall be in place IV ECU Replacement 1 Depress the retaining clip on the union joint side and remove the wire harness 2 Remove the 4 screws as shown in the figure and discard them 3 Remove the HCU from the ECU 4 Install the new ECU to the HCU 5 Use the new screw to attach the ECU to the HCU tigh...

Page 302: ...oir until the liquid level reach the MAX and bleed it as specified 6 With the ignition switch ON ABS Warning Light must goes on for 1 7 seconds then goes off 7 Clear the DTC memory check if there is DTC again 8 Drive the vehicle to confirm the ABS function you must feel that the pedal rebound VI ECU Program Note when replacing the HECU or ECU you shall program the new ECU otherwise the ABS Warning...

Page 303: ...e diagnostic interface Select function 04 Press OK button to confirm Depress the brake pedal and keep the hydraulic cylinder push rod rebound Release the brake pedal loosen the left and right brake caliper bleeder screw press button Depress the brake pedal 10 times tighten the left and right brake caliper bleeder screw press button Repeat the above I II III steps 7 times and press button The scree...

Page 304: ...e control of air temperature humidity and velocity of flow in the compartment is realized by independent or joint working of heating and Refrigeration system Section 1 The Structure Working Principle of Refrigeration System The structure of Refrigeration system is shown in Figure 1 Figure 1 The Structure and Working Principle of Refrigeration System 1 Compressor 2 Condenser 3 Receiver Drier 4 Pres...

Page 305: ...l the compartments gets the desired temperature See Table 1 for the Refrigeration system parameter Table 1 Refrigeration system parameter Parameter Control the mixture of cool and hot air Nominal Refrigeration W 4200 Displacement mL r 108 Model SW 5H11 Electromagnetic Clutch Power Dissipation W 45 SW 100 135 Maximum Airflow m 3 h 400 Airflow adjustment 4th Shift Manual Motor Power Consumption W 18...

Page 306: ... Parameter and Structure Heating system uses water heating structure which uses the engine coolant as the heat source leads the the coolant into the heating radiator installed in the vehicle compartment and has the interior or exterior air blow across the radiator with the blower to increase its temperature The system consists of the blower assembly heating control assembly and heater assembly Fig...

Page 307: ...cated in the middle of the instrument panel All adjustment except the A C switch and inside and outside circulation switch are made by rotating the control knob The A C control panel is shown in Figure 4 1 Temperature adjustment control knob control the mix ratio of the cold and hot air by adjusting the air mix door use the control knob to achieve continuous temperature adjustment 2 Outlet control...

Page 308: ...es 4 doors controlling the air outlet vents where the upper center one controls the front outlet vent each of the upper left and right sides controls a defogger outlet vent and lower foot outlet vent Figure 5 shows the working principle of temperature adjustment door The d c e f in the figure indicate the outlet air flow direction as the result of the adjustment of the control knob in the heating ...

Page 309: ...ne from the evaporator temperature sensor 17 if the engine is at idle ECU first increases the engine speed to 950 50r min lest the A C operation enhance the load and lower the engine speed or result in engine off And then the ECU can respond If the engine is in accelerating condition ECU does not respond immediately either and respond 5 seconds later after the end of the accelerating condition ECU...

Page 310: ...sure switch reaches 1 7MPa radiator fan rotates 5 High pressure protection When the pressure sensed by the pressure switch reaches 2 6MPa the compressor clutch is de energized and stops operation 6 Normal pressure When system pressure reaches 0 25MPa 2 4MPa control the A C idle speed Color of wire R Red Bl Blue Y Yellow Lg Light green Br Brown B Black P Pink G Green W White Gr Gray 1 Battery 2 Mai...

Page 311: ...frigerant If liquid refrigerant gets in your eyes or on your skin Wash the area with much cool water Go immediately to hospital for professional treatment Refrigerant Preservation Refrigerant preservation container is a high pressure resistant equipment If it is put in hot treatment the explosion may arise and the resulting metal fragments and the splashed liquid refrigerant will result in severe ...

Page 312: ... 3 Connect the high pressure tube to the high pressure refill valve 4 Connect the intermediate tube to the vacuum pump Vacuumization 1 Open all valves Notice Close all valves of the manifold gauge immediately after the vacuum pump stops operation If the valve is still open after the vacuum pump stops operation then the vacuum pump oil will return to refrigerant circulation loop and reduce the A C ...

Page 313: ...gine is working 4 Open the manifold gauge low pressure side valve 5 Close the manifold gauge low pressure side valve when the manifold gauge low pressure side reading is increased to 0 098Mpa 1 0kgf cm2 6 Check cooling pipeline hose for leakage with leak detector Proceed to step 8 if there is no leakage Tighten the union joint if there is leakage at the loosened union joint and go to next step 7 R...

Page 314: ... all door and windows 9 Measure the environment temperature and the reading of the high pressure side and low pressure side from the manifold gauge Shoot the Refrigeration system trouble as required if it is not as specified in the technical specification The Performance Inspection of the Refrigeration System 1 Check refrigerant pressure Go to next step if the pressure value is correct Shoot the R...

Page 315: ...move blower 7 The installation is in the reverse order of the removal 2 Heater Removal Installation 1 Remove water hose No 1 and 2 2 Remove instrument panel 3 Remove the band 4 Remove 2 wind door cables 5 Remove heater 6 The installation is in the reverse order of the removal 3 The Evaporator Removal Installation 1 Remove evaporator inlet and outlet pipeline 2 Remove instrument panel 3 Remove ther...

Page 316: ... for crack damage or oil leakage Replace the evaporator core if any of the above mentioned fault occurs 4 Check the fin for bending Flat it with a flat head screwdriver if it is bent Check Heater 1 Remove the heater 2 Remove heating core from the heater 3 Check for crack damage or refrigerant leakage Replace the heating core if any of the above mentioned faults occurs 4 Check the fin for bending F...

Page 317: ... The Condenser Removal Installation 1 Disconnect the negative terminal cable from the battery 2 Drain the refrigerant from the system Notice If anything moisture or any foreign matter enters into the Refrigeration system for circulation the cooling performance of the Refrigeration system will obviously deteriorate with abnormal noise Plug the port immediately after removing any cooling circulation...

Page 318: ... connector 9 Remove the pipe clamp 10 Remove liquid pipe II 11 The installation is in the reverse order of the removal Notice If anything moisture or any foreign matter enters into the Refrigeration system for circulation the cooling performance of the Refrigeration system will obviously deteriorate with abnormal noise Plug the port immediately after removing any cooling circulation component to p...

Page 319: ...t is connected with nuts Tighten the nuts with a wrench or a torque wrench 3 Clip the slider block recess with pliers or other similar tool and clamp the pipe used to connect slider block Tighten the bolt or the nuts at the connecting points with a torque wrench 7 A C control panel removal installation 1 Disconnect the negative terminal cable from the battery 2 Remove the auxiliary console 3 Disco...

Page 320: ...n valve inlet it indicates that the part is faulty and the pipe may be blocked 2 Low pressure area expansion valve outlet evaporator compressor inlet its temperature change trend is from cool to cold If the temperature change is not this trend it indcates that the part is faulty 3 Compressor compressor inlet and outlet high low side shall have apparent feel of temperature difference if there is no...

Page 321: ...alve is frosted There is water mixed in the refrigeration system Occational air bubble Insufficient refrigerant or air mixed in the system Clear there is oil stripe on the glass Outlet is not cold no refrigerant Foamy and turbid Excessive freezing oil Checked Part Check Points There shall be no dirt and rust on the radiator that hinder the heat exchange The radiator surface has no damage fissure a...

Page 322: ... gas in the system Loosen receiver and condenser inlet connector discharge the non clotted gas Excessive freezing oil in the system Check compressor freezing oil level adjust it Excessive high temperature of condenser inlet Perform the check at the place with good ventilation There is dust in the condenser core air channel within the condenser is blocked or suffocated Use compressed air or water t...

Page 323: ...or outlet for fitness replace it as necessary Expansion valve opening is too small Adjust expansion valve Expansion valve fault spinal corrosion or leakage Replace expansion valve The refrigerant pipeline between the expansion valve sensing unit and the expansion valve is damaged or broken Check and replace the expansion valve and pipeline Expansion valve blocked by ice or dirt Recycle the refrige...

Page 324: ...utput air temperature adjustment switch damaged Replace Heating System Table 3 Problem Cause and Troubleshooting of Noise Problem Cause Troubleshooting Drive belt loose or worn Replace the drive belt Cooling electric fan touches other parts Service and eliminate the impact Blower motor mechanical friction Service and fill the oil No oil on the motor bearing dry friction Fill the grease or replace ...

Page 325: ...Front fender See the engine hood adjustment Front bumper See front bumper removal installation The engine hood See the engine hood removal installation Electric outside rear view mirror See electric outside rear view mirror removal installation 5 Cowl vent grille 10 Front mudguard skirt 4 9 Fuel fill port cap 2 Radiator grill assembly 7 3 8 ...

Page 326: ...ow glass Rear license box Rear door weatherstrip See rear trunk lid removal installation See rear door removal installation Rear bumper See rear bumper removal installation Rear door glass Front door weatherstrip See rear door removal installation See front door removal installation 6 Rear mudguard skirt 13 Rear trunk lock 7 Roof garnish 4 11 Rubbing strap 5 12 1 8 Outer door sill under the trim b...

Page 327: ...rument panel end shield 12 Auxiliary console assembly 3 A C panel assembl 10 4 11 1 A pillar inside trim 8 2 9 Lower end shield assembly Front row seat Front door insdie trim Instrument panel assembly Glove compartment assembly Steering column cover Front door sill inside trim Front end of auxiliary console ...

Page 328: ...nk lower trim cover 5 B pillar upper inside trim 14 Lower rear trim assembly Rear seat See rear seat removal installation Front seat belt Rear seat belt See front seat belt removal installation See Rear seat belt removal installation See seat belt inspection See seat belt inspection 8 B pillar lower inside trim 17 Rear door sill inside trim 9 Safe handle 18 Carpet sound insulator 7 16 3 A pillar i...

Page 329: ...ting Plate Cross Head Counter Sunk Self tapping Screw 6 Front Bumper Mounting Bracket to Body Bolt 7 Front Bumper Mounting Bracket Sub assembly 8 Secondary Bumper Assembly 9 Front Bumper Mounting Bracket to Secondary Bumper Assembly Bolt 10 Front Bumper Cushion 1 1 Secondary Bumper Assembly Lower Buckle and Plug 12 License Mounting Plate Assembly 13 Secondary Bumper As sembly Lower Connecting Bolt...

Page 330: ...dy 8 Remove the secondary bumper assembly and the front bumper mounting bracket sub assembly 9 Remove front bumper mounting plate 11 Remove front bumper cushion Remove the front license plate Remove the mounting plate assembly 12 Remove fog lamp 13 The installation is in the reverse order of the removal 2 Notice For Removal Of The Front Bumper 1 Pull the front bumper to separate it from the bumper...

Page 331: ...s under the help of the assistant to prevent the engine hood from dropping down and resulting in body injury 4 The assistant lifts the engine hood removes the engine hood hinge bolt and the engine hood 5 Remove the ventilator louver and remove the hinge arm 6 Remove the hinge arm bracket attach bolt Remove the hinge arm bracket from the body 7 Remove the engine hood lock 8 Remove the engine hood l...

Page 332: ...ront fender Loose the bolt and move the engine hood for adjustment 4 Close the engine hood 5 Check for alignment 6 Open the engine hood and adjust it as specified 7 Adjust the engine hood bumper 8 Check for alignment 9 Adjust the engine hood master lock striker Loose 3 pin bolts on the engine hood lock Move the engine hood lock for adjustment 10 T ighten the bolt between the engine and the hinge 1...

Page 333: ...e of the outside rear view mirror is designed to be built in the vehicle to facilitate the operator s direction adjustment The optional flat mirror is generally selected for driver side to ensure the sense of reality and distance Spherical mirror is used for front passenger side to enlarge the rear field of vision In addition outside rear view mirror has also the feature of electrical heating and ...

Page 334: ... Geely Logo 7 Rear License Plate Assembly 8 Rear License Plate Assembly Mounting Nut 9 Rear trunk Lid Weatherstrip 10 Rear trunk Lid inside Trim Board 1 1 Rear trunk Lid Cushion 12 Rear trunk Door Lock Cylinder Assembly13 Rear trunk Lid inside Trim Board Clip 14 Rear trunk Lid Hinge Attaching Bolt 15 Rear trunk Door Lock Cable Assembly 16 Rear trunk Door Oil Filler Cable Assembly 17 Rear trunk Lid...

Page 335: ...e seat mounting nut Remove the rear trunk lid hinge seat and the rear trunk lid hinge 7 Remove rear trunk door oil filler cable assembly 8 Remove cushion 9 Remove rear trunk lid hinge pin Remove rear trunk lid hinge from the bracket 10 Remove rear trunk lid weatherstrip 11 Remove rear trunk lid inside trim board clip Remove rear trunk lid inside trim board 12 Remove rear license plate assembly mou...

Page 336: ... 9 Hexigon Bolt Spring and Flat Gasket Set 1 Rear Bumper Removal Installation 1 Disconnect the negative terminal cable from the battery 2 Remove the cross pan head tapping screw and big washer set 3 Remove 4 hexagon bolt on the mounting bracket 4 Remove 2 cross pan head screw GB973 M6X16 5 Pull the rear bumper out from the body 6 Remove the cross pan head screw GB973 M6X16 and hexagon bolt spring ...

Page 337: ...rop and result in body injury Be careful not to make the bumper drop before separating the rear bumper from the bumper rail 3 Notice On Installing The Rear Bumper 1 Press the rear bumper joint into the vehicle body to connect the rear bumper mounting bracket assembly and the bumper rail 2 Insert the rear bumper end tab into the corresponding hole of the rear fender to flush with the outer surface ...

Page 338: ...at from the vehicle 2 Turn the headrest lock handle to Non LOCK Remove headrest and bracket 3 Remove the attaching screw Remove adjuster hinge cover from the front seat 4 Remove the 4 snap ring under the rear side of the seat back Remove the set bolt and nut at the both side of the seat back 5 Remove seat coupling plastic gasket 6 Remove the seat cushion track assembly and adjuster assembly 7 Pres...

Page 339: ... headrest support 3 Install the adjuster and track assembly with bolts 4 Install the coupling plastic gasket Install the seat back assembly to the seat cushion with bolts and nuts Install the snap ring to the rear seat back 5 Install the adjuster hinge cover with 2 screws Remove the Headrest and Bracket Remove the Front Seat Adjuster Hinge Cover Remove the Seatback Snap Ring and Set Bolt Track Ass...

Page 340: ...backwards 15mm x 10 150mm 3 The headrest can be adjusted in 3 positions in height Rear Seat 1 Rear seat back 1 Removal a Lift the rear seat back lock handle upwards Turn seat back down forwards Remove 4 set bolts Remove seat backassembly from the vehicle b Remove seat back lock handle and handle seat Install Front and Rear Seat Snap Ring Install Headrest Support Track Assembly Adjuster Assembly In...

Page 341: ...bolts Tighten bolt torque 3 92 6 86N m 2 Rear seat cushion assembly 1 Removal a First remove therear seat back b Lift the front of the seat cushion Disconnet the seat cushion from the clamp on the floor push backwards separate it from the hook Remove seat cushionassembly from the vehicle c Remove the snap ring on the seat cushion d Remove the snap ring in the cover Remove cover e Remove the clamp ...

Page 342: ...ee Points Emergency Lock Retractor Pretension Seat Belt It is composed of retractor assembly belt buckle assembly and height adjuster assembly 1 Height Adjuster Assembly 2 Retractor Assembly 3 Belt Buckle Assembly 4 anchorage 1 Belt Buckle Belt buckle is enclosure type See Figure Replacement Of The Seat Belt Buckle 1 Remove the seat adjuster hinge cover 2 Remove the bolt from the belt buckle on th...

Page 343: ...the belt buckle and the attachment matches the connecting mode of the to be installed vehicle module Check if the opening of the buckle is flexible 5 See if the screw thread of the nut welded on the cover is clear when installing the bolt Assemble the bolt after clearing the welding residue if there is any 6 When the retractor belt is pulled out there should be no obstacles around the belt such as...

Page 344: ...removal 5 Rear Seat Belt Buckle Removal Installation 1 Remove rear seat cushion 2 Remove the bolt 3 Remove rear seat belt buckle 4 The installation is in the reverse order of the removal 6 Seat Belt Inspection 1 Ensure correct installation of seat belt 2 Check the metal component of the seat belt for damage 3 If the vehicle has been vibrated during the accident pull out the seat belt from the retr...

Page 345: ...side shield 12 Remove left side shield 13 As to the vehicle installed with A C control mechanism disconnect the front A C wire See the removal and installation of A C control mechanism 14 Disconnect the instrument panel wire harness connector 15 Remove the bolt 16 Take out the instrument panel from the open driver side door 17 The installation is in the reverse order of the removal Warning It is d...

Page 346: ... the intermediate instrument panel 3 Remove the audio device 4 Remove A C control mechanism 5 Remove in the order below in the figure 6 The installation is in the reverse order of the removal Torque 18 6 25 5 N m 1 instrument panel wire harness 2 instrument panel cross member 3 instrument panel 1 2 3 ...

Page 347: ...in the reverse order of the removal 5 Combination Instrument Panel Removal Installation 1 Remove the screw 2 Using the flat screwdriver wrapped with vinyl tape disconnect the clip 3 Pull combination instrument panel towards yourself Remove pillar 4 The installation is in the reverse order of the removal 6 Lower End Shield Removal Installation 1 Using the flat screwdriver wrapped with vinyl tape di...

Page 348: ...nyl tape disconnect the clip 5 Pull the intermediate instrument panel forward and then remove the clip 6 Remove LDC Liquid Crystal Display component connector 7 The installation is in the reverse order of the removal 8 Glove Compartment Removal Installation 1 Open the glove compartment 2 Pull the glove compartment up and separate it from the instrument panel 3 The installation is in the reverse or...

Page 349: ... the removal 10 The auxiliary Console Removal Installation 1 Remove in the order listed below 2 The installation is in the reverse order of the removal 1 1 2 3 4 5 6 7 8 9 10 11 12 1 Auxiliary console left front end 2 Shift boot frame 3 Shift boot end shield 4 T ray 5 Auxiliary console front part 6 Auxiliary console outer end shield upper plate 7 Auxiliary console outer end shield 8 Auxiliary cons...

Page 350: ...Screw 1 Removal 1 Remove the installed right front door sill left front door sill self tapping screw cross screwdriver 2 Use an opener to remove the right A pillar inside trim A pillar inside trim right front door sill left front door sill 2 Installation 1 Install the right A pillar inside trim A pillar inside trim right front door sill left front door sill to the corresponding position with clip ...

Page 351: ...llar lower inside trim right B pillar lower inside trim tapping screw with a cross screwdriver 2 Remove the left B pillar lower inside trim right B pillar lower inside trim with a opener 3 Remove the seat belt swing ring 4 Remove the right B pillar upper inside trim leftB pillar upper inside trim tapping screw with the cross screwdriver 5 Remove the right B pillar upper inside trim leftB pillar up...

Page 352: ... 10 Cross Pan Head Self tapping Screw 11 D Clip 1 Removal 1 Remove the installed door sill and C pillar lower inside trim tapping screw and E clip with a cross screwdriver 2 Remove C pillar upper inside trim with a opener 3 Remove C pillar lower inside trim with a opener 2 Installation 1 Clip C pillar inside trim and rear door sill onto the corresponding position in order 2 Tap C pillar upper insi...

Page 353: ... sun visor assembly with a cross screwdriver Remove the left right sun visor assembly 3 Remove the plastic clip used to install roof inside trimassembly with opener Remove the lower dome lamp connector and roof inside trimassembly 2 Installation 1 Install the dome lamp connector into the corresponding hole and clip the plastic clip onto the corresponding hole in the vehicle body Fix the roof insid...

Page 354: ...l left rear door sill front and rear part of the auxiliary console 2 Remove the cross pan head screw and remove the foot pedal 3 Remove carpet and cowl lower sound insulator cowl upper sound insulator cowl outer panel heat insulator 2 Installation 1 Install the accelerator pedal assembly brake and clutch pedal assembly parking brake control mechanism assembly onto the vehicle body 2 Install the ca...

Page 355: ...eaker Grill 17 Rear Damper Cover 1 Removal 1 Remove the connector and remove the high mounted stop lamp 2 Remove C pillar upper inside trim 3 Remove the rear partition inside trim 4 Remove the right speaker grill and left speaker grill with a cross screwdriver 5 Remove the lower rear board trim assembly clip with opener Remove the lower rear board trim assembly 6 Remove the right rear combination ...

Page 356: ...rill to the rear partition inside trim with a cross screwdriver 4 Install the rear partition inside trim to the vehicle body 5 Install the high mounted stop lamp and the C pillar upper inside trim XV Engine Hood Inside Trim Engine Hood Inside Trim Diagram Engine Hood Inside Trim 1 Engine Hood Inside Trim 2 E Clip 1 Removal 1 Open the engine hood and gas spring 2 Remove the clip and remove the engi...

Page 357: ... Board 5 Power Window Motor 6 Power Window Actuator 7 Door Inside Handle 8 Protection Device 9 Door Outside Handle 10 Front Door Lock Hole 11 Front Door Glass 12 Door Window Regulator Run 13 Front Door Weatherstrip A 14 Front Door Lower Weatherstrip 15 Front Door Weatherstrip B 16 Front Door Lock Striker 11 16 10 8 9 3 15 14 13 4 5 6 1 12 2 7 ...

Page 358: ...Notice on Removing the Connector for detailed information 4 Remove front door hinges 5 Remove the front door 6 The installation is in the reverse order of the removal 7 Adjust the front door See Door Adjustment for detailed information Front Door inner trim 1 Front Door Inner Trim Board Assembly 2 Front Door Inner Handle Assembly 3 Trim Board 4 Door Handle 5 Set Screw 1 2 4 3 5 2 ...

Page 359: ...ion 1 Lift the front door window glass make the distance between the front window glass top and rear door top weatherstrip to be 130mm 2 Disconnect the negative terminal cable from the battery 3 Remove the front door frame 4 Remove the hole cover 5 Remove the screw 6 Insert your hand into the front door component hole to lift the front window glass 7 The installation is in the reverse order of the...

Page 360: ...tallation 1 Remove front door component 2 Remove the screw and then remove the front door lock and the door lock actuator 3 The installation is in the reverse order of the removal Power Window Glass Regulator Actuator Power Window Glass Regulator Motor Front Door Componen t Screw Front Door Lock Latch and Lock Motor ...

Page 361: ...gulator Run 12 Glass Run 13 Quarter Window Weatherstrip 14 Rear Door Weatherstrip A 15 Rear Door Lower Weatherstrip 16 Rear Door Weatherstrip B 17 Rear Door Lock Striker 1 Rear Door Removal Installation 1 Disconnect the negative terminal cable from the battery 2 Remove the connector 3 Remove rear door hinges 4 Remove the rear door 5 The installation is in the reverse order of the removal 6 Adjust ...

Page 362: ...ssembly 3 C o n t r o l l e r Trim Board 4 Door Handle 5 Set Screw 1 Rear doorinside trim board removal installation 1 Remove the set screw See Figure 5 2 Remove the rear door inside trim board assembly 3 Disassemble the inside trim board assembly as required 4 The installation is in the reverse order of the removal 1 2 3 4 5 ...

Page 363: ... window glass channel from the glass guide 5 Insert your hand into the rear door service hole and lift out the rear window glass 6 The installation is in the reverse order of the removal 3 Rear door glass regulator removal installation 1 Remove the set bolt See the figure Rear Door Weatherstrip Glass Guide Window Glass Channel Rear Door Glass Set Bolt ...

Page 364: ...emoval in stallation 1 Remove the rear door component 2 Remove the screw and then remove rear door lock and the door lock actuator 3 The installation is in the reverse order of the removal Power Window Glass Regulator Actuator Rear Door Component Power Window Glass Regulator Motor Rear Door Lock Latch and Lock Motor Screw ...

Page 365: ...hicle body 2 Loose the front door or the rear door hinges assembly bolt or door lock striker assembly screw and reinstall it to the door if the measured result is not as specified in the technical standard Clearance a 5mm b 5mm c 4 3mm d 4 3mm e 3 8mm f 4 6mm 3 Tighten the bolt or the screw ...

Page 366: ...s I Main Body The main body is mainly composed of the front sheet metal cowl parts floor assembly LH RH side wall assembly Rear back panel assembly trunk shelf assembly and roof panel assembly etc by welding them together as shown in the Figure 5 1 Figure 5 1 MAIN BODY 1 Front Sheet Metal Cowl Parts 2 Roof Panel Assy 3 LH RH Side Wall Assy 4 Rear Shelf Assy 5 Rear Back Panel Assy 6 Floor Assy 1 2 ...

Page 367: ...brackets such as the engine LH RH side suspension bracket LH RH front suspension shock absorber bracket etc and to mount the LH RH front fenders 3 Engine Hood Front Support Plate Assembly Engine hood front support plate is mainly composed of LH RH headlamp mounting bracket assembly hood front support plate sub assembly and LH RH front support plate reinforcement by welding them together Engine hoo...

Page 368: ...ilator cover etc by welding them together Figure 5 2 Dismantle diagram of front sheet metal and cowl parts 1 Front Cross Member 2 Hood Lock Bracket Assy 3 L H R H S i d e M e m b e r E n d P l a t e 4 Engine Hood Front Support Plate Assy 5 LH RH Front Cross Member 6 LH RH Front Mud Guard 7 Front Cross Member Assy 8 Cowl Inner And Outer Plate Assy 9 LH RH Front Mud Guard Reinforcement 10 Cowl Upper...

Page 369: ... lower space of the tunnel is used to mount components such as transmission shift pull rod park brake drawing cable exhaust pipes with 3 way catalytic converter Carpet and sound insulator mat are mounted in the inner side of the compartment The first and the second cross member LH RH side member and side rails which are on the front floor form a frame structure It can provide great load bearing ca...

Page 370: ...mantle diagram Figure 5 4 Decomposition Diagram of Quarter Parts 1 LH RH Front Pillar Inner Plate 2 LH RH Upper Side Member Front Inner Plate 3 LH RH Front Pillar Outer Plate Reinf orcement 4 LH RH Upper Side Member Inner Plate Assy 5 LH RH Doorframe Lower Side Member Outer Plate Reinforcement 6 LH RH Central Pil lar Outer Plate Reinforcement 7 LH RH Rear Wheel House Inner Plate Sub assy 8 LH RH R...

Page 371: ... by welding them together Figure 5 5 is the dismantle diagram Figure 5 5 Dismantle Diagram of Rear Quarter Assembly 1 Rear Floor 2 Rear Back Panel 3 Rear BackPanel Reinforcement 4 Trunk Lid Lock Mounting Plate 5 Trunk Lid Cross Beam The rear back panel is used for effect of a cross member to strengthen the intensity of the rear part of the body and form an opening of the trunk 1 2 3 4 5 ...

Page 372: ...ss members and reinforcement members are used to strengthen the rigidity of the roof panel in trans verse direction Figure 5 6 Decomposition Diagram of Roof 1 Roof Panel 2 Front Roof Cross Member 3 Roof Central Reinforcement 4 Rear Roof Cross Member VI Trunk Shelf Assembly Trunk shelf assembly is mainly composed of parts such as trunk shelf panel trunk shelf front reinforcement plate drip channel ...

Page 373: ...ouble insurance lock system is designed for safety especially in the course of running with a high speed to prevent the engine hood from being raised which often causes traffic accidents The angle of the hood that is fully opened is 52 As shown in Figure 5 8 Figure 5 8 Engine Hood Hinge 1Hinge Bracket 2 Hinge Arm 3 Pin Shaft II Front Fender The matching relationship between the front fender and ho...

Page 374: ...m a whole steel plate which is for improving the rigidity and assembly accuracy In order to assure the safety when the vehicle is crashed on the side of the body anti impact bar and central reinforcement plate are equipped in the door Door plate assembly is composed of the outer and inner sub assemblies Use a special folded edge machine to wrap along the full circle of the door outer plate and the...

Page 375: ...ct Bar Assy 9 Rear Door Outer Plate IV Trunk Lid Welding Assembly Trunk lid assembly is mainly composed of parts such as trunk lid outer plate trunk lid inner plate trunk lid hinge mounting plate trunk lid lock mounting plate etc by welding them together As shown in Figure 5 12 Figure 5 12 Decomposition Diagram of Trunk Lid 1 Hinge Mounting Plate 2 Hinge Spring 3 Trunk Lid Hinge 4 T runk Lid Inner...

Page 376: ...wever at most times accidents like crash and turnover result in bending and torsioning deflection because of the great overload on partial areas General conditions of the body damage are as follows 1 The Front Central Is Crashed Figure 5 13 Figure 5 13 The Front Central Is Crashed Because the front central is damaged by outside force the left and right hood is usually stretched inwards therefore t...

Page 377: ...om the left or right of the hood to the front suspension mounting place to get this part easily deformed 3 Crashed By Outside Force Forming An Angle To The Center Line Of The Vehicle Figure 5 15 FIGURE 5 15 Outside Force Forming An Angle to The Center Line of The Vehicle Figure 5 15 shows the situation when it is crashed by outside force forming an angle to the centerline of the vehicle When the f...

Page 378: ...cause of the integral body construction and the thin steel sheet during the procedure of panel operation strengthen the force loading part after reshaping and take measures to reduce partial stress in those places where stress gathers 2 After the panel operation specially make sure to spread rust proof primer on the inner and outer surfaces to avoid rusting 3 When repairing the body you can either...

Page 379: ... applied force for propping back should be almost the same with the outside force that causes damage Reaction force should be imposed at the back of the pulling action point to make the propping force adjustable Inspect the deformation during the process of propping back Proper heating is applied on correspondent parts to remove internal stress 2 Strengthening When partial damage break or crackle ...

Page 380: ...pear and become bigger and bigger Rust is easily generated on the outer plate of the skirt drip channel and at the joints of doors and sashes and at the interlayer formed by outer plate and frame jointing places 3 3 3 3 3 Recess Recess is a kind of structural damage caused by crash or squeezing on the outer plate of the body As to slight recess the metal dose not extend It belongs to plastic defor...

Page 381: ...m the area that needs cutting b Cut a paper example c Cut the metal plate according to the paper example d Paste the metal piece cut onto the surface of the area that needs cutting off e Use a draw needle tip to make an outline along the sides of the metal piece And cut off the damaged or rusted area along the outline f Use a wooden hammer or a backing block to smooth the cut and use a file to fil...

Page 382: ...is small the heating area should be smaller Diameter approx 10 15mm Quickly knock the heated points with a wooden hammer while they are hot A backing block is recommended to push it up After it cools down use an iron hammer to gently knock for smoothness The shrinkage order is from the highest point gradually to the center and then to the edge Heat and then flatten the extended area repeatedly til...

Page 383: ...ou should clean up the greasy dirt and rusty spot at the welding points and also make sure that the plates are well aligned For the breakup welding that occurs at the flanging edges an intermittent gas welding can be applied at the edge of the plate to make the plate edge melted after the 2 plates are well aligned The every seam length of the intermittent weld is about 30mm and the interval of wel...

Page 384: ...the body is integral body construction the main body is concurrently used as frame to support all load The 3 compartment 5 door layout adopted gets the space availability the biggest and favorable to arrange the space of drivers and passengers Figure 5 21 Figure 5 12 Outside Dimensions ...

Page 385: ...eel plate is adopted in many key parts of the body to reinforce the body on the place that force concentrates Figure 5 22 Figure 5 22 High Tensile Steel Plates 1 Engine Hood Outer Plate 2 LH RH Fender 3 LH RH Central Pillar Inner Plate 4 Trunk Lid Outer Plate 5 LH RH Door Outer Plate 2 1 3 5 4 ...

Page 386: ...owl Lower Cross Member 11 Cowl Panel 2 Vibration Reduction And Sound Insulation 1 1 1 1 1 Take measures on the structure of the body a Reasonably layout reinforcing ribs to improve the rigidity of parts and to reduce noise by restraining vibration b Fill the floor joint seam with sealant to strengthen the floor sealing and weaken the noise c Increasing the thickness of the cowl is very effective t...

Page 387: ...380 5 24 1 2 3 4 Figure 5 24 COWL 1 Cowl 2 Heat Insulating Protecting Board 3 Front Cross Member 4 Heat Insulating Pad ...

Page 388: ...cially the floor and cowl are located in the harshest outside environment The mud splashing from road dust and sand wheel noise engine noise and hot air will get in the interior environment by every opening After the body assemble welding completes apply a line of sealant on all joints of the body to avoid water and vapor permeating into the metal joint and also to ensure the quality for the follo...

Page 389: ...electrophoresis None is better than it and the technique management is also extremely strict 4 4 4 4 4 Intermediate Coating The intermediate coating is one located between the base coating primer and the surface coating The function is mainly to improve the flatness of the workpiece surface and the base coating and to create a good base for top paint The brilliance and fullness of the painting lay...

Page 390: ...at needs repairing 4 Air dry or heat dry the putty 5 Manually polish the putty to make it smooth 6 Manually polish with water to clear up tracks caused by sand paper 7 Clear up the dust and the greasy dirt and dry the putty polishing liquid 8 Clean the greasy dirt on the polishing surface 9 Use shield cover or paper to keep out the area that need not repairing III Intermediate Coating Painting 1 P...

Page 391: ...resin paint for 2 or 3 times 2 Air dry or heat dry VI Polishing 1 After painting you can polish with wax to remove the repairing paint shadow for decoration consideration 2 Take off the shield After painting take off the paper and clean the paint scattered on the other area 3 Inspect the quality of appearance ...

Page 392: ...between door and sill 7mm 0 5mm Clearance between fuel fill port cover and side wall 3mm 0 5mm Clearance between rear bumper and side wall plate 1mm 0 5mm Clearance between Rear tail lamp and side wall plate 1mm 0 5mm Clearance between windshield and drip channel 4 5mm Glass is lower than drip channel 0 5 1mm Clearance between glass and roof panel 4 5 7mm and lower than 0 5 1mm Trunk lid folding e...

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