Geely FC Workshop Manual Download Page 236

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Air conditioner--Fan assembly

(d) Disassemble servo motor assembly joint of in-out air cycle

flow choke.

(e) Disassemble three screws and bolts.

(f) Disconnect fixed claw and disassemble electric engine of

fan.

(g) Disassemble fan assembly.

225

Fixing claw

Fixing clamp

Fixing claw

Locking point

Summary of Contents for FC

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Page 3: ...s persistent Geely style of fashion appearance and high performance price ratio FC is equipped with engine JL4G18 completely developed and produced by Geely group Engine JL4G18 applies the following advanced technology such as VVT full aluminum cylin der body plastic intake manifold completely new VVT inside seal method completely new OCV valve filtering method etc with M7 9 7 electric injection s...

Page 4: ...stics in proper sequence clear demarcations easy to understand excellent in picture and its accompanying essay simple and clear which is very applicable for a quite large number of FC automobile main tenance technicians and service personnel to refer to This manual is mainly compiled by Geely International Corporation Geely Automobile En gine No 2 Plant and engineering technicians of service corpo...

Page 5: ... not specified or recommended in this manual will cause personnel injury or vehicle damage Therefore please consider ensuring the safety of technicians and vehicle at first before performing maintenance z If it is necessary to replace parts please replace with parts of the same or similar size with original ones It is forbidden to use inferior parts z In order to effectively avoid technician injur...

Page 6: ...ing 21 Exhaust gas control Exhaust gas control system 23 On vehicle inspection 23 Inspection 25 Engine mechanism Engine assembly 26 Inspection 26 Drive belt 29 Replacement 29 Valve clearance 30 Adjustment 30 Engine assembly 36 Replacement 36 Timing chain assembly 45 Replacement 45 Camshaft 52 Replacement 52 Crankshaft front oil seal assembly 60 Replacement 60 Crankshaft rear oil seal assembly 62 R...

Page 7: ...erhaul 90 Handling 93 Lower left control arm assembly 94 Replacement 94 Front stabilizer bar 96 Overhaul 96 Front left lower control arm ball joint assembly 99 Replacement 99 Rear suspension Rear suspension system 100 Table on trouble occurrence 100 Rear wheel alignment 101 Adjustment 101 Rear strut assembly 102 Overhaul 102 Handling 104 Rear stabilizer bar 105 Overhaul 105 Rear shaft assembly 106...

Page 8: ...nge 156 Parking rear brake pull cable assembly 158 Change 158 Parking brake assembly 161 Overhaul 161 Transmission Disassemble assembly 165 Assemble the assembly 191 Steering column Steering system 192 Note 192 Malfunction phenomenon table 192 Inspection on automobile 193 Steering column system 194 Overhaul 194 Power steering Power steering system 198 Note 198 Malfunction phenomenon table 199 Insp...

Page 9: ...75 Change 277 Light Light System 279 Notes 279 The phenomena table 279 Inspect the car 281 Inspect 283 Front combination light LH 286 Subassembly 286 Change 287 Adjustments 287 Front fog light 289 Components 289 Change 290 Adjustment 290 Side turning light 291 Components 291 Rear combination light LH 292 Components 292 Change 293 Rear fog light 294 Components 294 Change 295 Number plate light 296 ...

Page 10: ...29 Inspect the vehicle 329 Position drawing 331 Trouble table 331 INSPECT 332 Panel combination panel combination panel 334 Trouble table 334 Vehicle inspection 335 Inspection 339 Panel 340 Preparation 340 Change 340 Combination instrument assembly 347 Disassembly and assembly 347 Chair Front chair 348 Subassembly 348 Overhaul 349 Rear chair separating type 352 Overhaul 352 Rear chair fixing type ...

Page 11: ...Rear bumper 381 Subassembly 381 Change 382 Name plate 383 Change 383 Exterior seal tape of left front door glass LH 384 Change 384 Exterior seal tape of left rear door glass 385 Change 385 Light fender 386 Change 386 Top left trim tape 387 Replacement 387 Left lower fender of automobile body LH 388 Subassembly 388 Change 389 Inner trim board of top 390 Change 390 Automobile control system Ignition...

Page 12: ...l mass Front axle Rear axle Front axle Rear axle Weight distribution No load Full load Min turning diameter Min gound clearance Approach angle full load Departure angle full load Front wheel camber Kingpin inclination angle caster angle Convergence of front wheels Rear wheel camber Convergence of rear wheels Left wheel inside outside Right wheel inside outside Candera Brief introduction on Geely m...

Page 13: ...r with hydraulic power Double pipeline vacuum boosterwithABS EBD anti lock system Disc brake Disc brake Strut type front independent suspension Longitudinal swinging arm and anti twist beam compound rear suspension Breakaway BalI cage and tripot type constant velocity universal joint Loaded all metal body Honeycomb cordierite carrier noble metal catalyst Swirl or swash plate compressor Item name N...

Page 14: ...Max climbing speed Slide Distance full load initial speed 50km h Fuel consumption with 4 operating modes Average fuel consumption at specified operating mode Dust sealing degree Rain protection seal limit value Weighted acceleration root of mean square Equivalent mean value Reduced comfort boundary Average mileage to first failure Average mileage between failures Efficient degree Item name Power p...

Page 15: ...ng conditions 1 Towing tail vehicle equipped with camp frame or top storage racks 2 Repeated on short distance driving within 8 km and the temperature is below 0 3 Vehicles driven for long distance under idle speed or low speed over a long period of time such as police car taxi or delivery truck 4 Continuously driving at high speed for more than 2 hours frequently With 80 of max ve hicle speed 5 V...

Page 16: ... mount Ignition system 9 Spark plug 10 Battery Fuel and exhaust gas control system 11 Fuel filter 12 Air filter core 13 Connecting conditions of fuel tank cover fuel pipe and fuel evaporation control valve 7 14 Activated carbon canister Chassis and vehicle body 15 Brake pedal and parking brake 16 Brake pad and brake disc 17 Brake fluid 18 Brake Pipe and hose 19 Power steering oil 20 Steering wheel...

Page 17: ...es dust or insects and clean hose connections 5 Replace at initial 60000km and replace every 30000km in future 6 Only Geely genuine ultra long engine coolant or equivalent high quality ethylene glycol engine coolant without silicate amines nitrite borate and with long life compound organic acid technology are allowed to use and coolant should be repeated several times until it is filled up 7 Indic...

Page 18: ...of engine oil Every 5 000 km or 6 moths Replacement of engine oil filter Every 5 000 km or 6 moths Inspection of brake pad and brake disc Every 5 000 km or 3 moths Inspection or replacement of transmission oil Every 60 000 km or 24 moths Inspection of front and rear suspension Every 10 000 km or 6 moths Screwing down the bolts and nuts of the chassis and vehicle body Every 10 000 km or 6 moths B 2...

Page 19: ...ine is running there being impulse current output at the terminal indicates that there is no trouble with ECU and stepping motor control system and if idling is not stable at the moment and deviates greatly from specified value the stepping motor should be replaced If there is no impulse current output at the terminal turn on air conditioner to test again and still no impulse current output indica...

Page 20: ...valve shaft should not swing 2 All channels should not be blocked 3 Throttle valve plate should rotate flexibly and act smoothly 4 When the throttle is at closed position there should be no clearance between throttle stop bolts and throttle lever Note it is not allowed to adjust the throttle stop bolts 3 Throttle position sensor 4G18 3600080 a Resistance inspection 1 Remove the wiring harness conn...

Page 21: ...ting principle Fig 1 Note A B and C represent 3 pins of sensor and see pin root for the mark Measuring method Removing the joint place digital universal meter at ohm gear and connect 2 terminals respectively to 1 pin and 2 pin and the resistance under normal temperature should be more than 1M Place digital universal meter at millivolt gear and knock around knock sensor with a hand hammer there sho...

Page 22: ...er at ohm gear and connect 2 terminals respectively to 1 pin and 2 pin of sensor and rated resistance at 5 and other corresponding resistance values could be measured ac cording to the characteristic curve in above drawing Analog method could also be applied in measurement Use an elec tric blower to blow air into the sensor pay attention not to keep them too near and observe the change of resistan...

Page 23: ...ion to clean and maintain bypass air passage frequently 4 After removing battery or ECU pay attention to self teach stepping motor in time Self teach method of M7 system turn on ignition switch but not start engine immediately and start it after 5 seconds If engine idle speed is found bad at the moment it is necessary to repeat the above steps Simple measuring method removing the joint place digit...

Page 24: ...r joint b Disassemble ventilation hose c Remove 2 bolts and throttle control pull cable bracket d Remove 2 preheating water inlet and outlet hoses of throttle e Remove 2 bolts and 2 nuts and remove throttle body from intake air manifold 6 Remove stepping motor of throttle body 4G18 3600070 Remove 3 screws and stepping motor 7 Install stepping motor of throttle body Install stepping motor 8 Install...

Page 25: ...lames out c Uncouple battery negative wire d Couple electric fuel pump joint 5 Fuel system a There will be a great amount of gasoline flowing out when disassembling high pressure fuel pipe therefore it is required to observe the following procedures 1 Take measures to prevent gasoline leaking 2 Disassemble fuel pipe 3 Completely discharge the oil in fuel pipe 4 Cover the fuel pipe with plastic bag...

Page 26: ...inlet of fuel distribution pipe with plastic bag to avoid foreign materials entering the fuel distribution pipe injection nozzle 6 Inspection of fuel leakage 1 After completing maintenance check there is leakage with the whole fuel system 2 Connect hand held tester to diagnostic joint 3 Turn ignition switch to ON and turn main switch of hand held tester to ON 4 Switch hand held tester to function ...

Page 27: ...ion Purchase new fuel hose and take out fuel pipe joint b Take measures to prevent gasoline leaking c Disassemble fuel pipe clamp at fuel pipe joint of fuel rail component d Disassemble fuel hose from fuel pipe of fuel rail component e As shown in the diagram install special tool pressure gauge with special tool and fuel pipe joint f Check there is fuel leakage g Start engine h Measure the fuel pr...

Page 28: ... hose joint 2 Install special tool and fuel hose joint to fuel pipe Note Only after performing precautions could the connection operation of fuel hose joint fast joint mode be allowed to perform Warning before connecting fuel pipe joint fast joint mode please read precautions carefully 3 Install o ring to injection nozzle 4 Connect special tool joint and hose to injection nozzle and hold down the ...

Page 29: ...f foreign matters z Cover the fuel pipe with plastic bag to avoid pipe damage and foreign matters entering 5 Remove fuel pipe assembly Remove 2 bolts and oil feed pipe together with injection nozzle 6 Remove injection nozzle components Pull out 4 injection nozzles from oil feed pipe 7 Install injection nozzle components Coat a thin layer of gasoline on o ring and rotate left and right to push inje...

Page 30: ...ck injection nozzle o ring and replace if there is damage b Install isolator on cylinder head c Install fuel rail component together with injection nozzle Torque d Install fuel pipe fixing clip Torque m 10 Check the function of electric fuel pump and check there is fuel leakage 19 ...

Page 31: ...uel hose and oil return pipe assembly Notes z Check there is contaminant looked like dirt around the joint before operating and clean it off in the case of contaminant z Be careful of the contaminant looked like dirt because fast joint depends on o ring to seal fuel pipe and joint z Do not perform this operation with tools z Do not bend or distort nylon hose z Cover the joint with plastic bag afte...

Page 32: ...inant that looked like dirt around the joint before operating and clean it off in the case of contaminant Be careful of the contaminant that looked like dirt because fast joint depends on o ring to seal fuel pipe and joint Do not perform this operation with tools Do not bend or distort nylon hose Cover the joint with plastic bag after removing the fuel hose When the joint is stuck with fuel pipe c...

Page 33: ...uel tank assembly 15 Remove fuel tank main fuel hose and oil return pipe assembly 16 Remove No 2 fuel evaporation hose assembly 17 Remove No 1 fuel tank gasket 18 Remove No 1 fuel tank protector Remove rivet with electric drill and then remove fuel tank protector 19 Install No 1 fuel tank protector Install fuel tank protector with rivet 20 Install No 1 fuel tank gasket As shown in the diagram inst...

Page 34: ...ine at least to 3500rpm b Check the operating noise of injection nozzle with listening device c When throttle is released check the operating noise of injection nozzle recovers after stop 3 Check fuel evaporation exhaust control system a Check the pipe clamps of connecting pipeline between charcoal canister and carbon canister solenoid valve are firmly clipped and check there is leakage b Check th...

Page 35: ...al meter at ohm gear and connect 2 terminals respectively to 1 white pin and 2 black pin and the resistance under normal temperature is 1 6 6 Check fuel tank cover Visually check fuel tank cover and gasket are distorted or damaged Exhaust gas control Exhaust gas control system 24 Oxygen sensor Main relay ...

Page 36: ... canister assembly Check the function of carbon can ister according to the following tables Standard 2 Carbon canister control valve a For carbon canister control valve check the conduction be tween terminals Resistance b Check the control valve operates 1 Supply battery voltage to its terminal 2 Check air is flown as the arrow direction on valve body 25 Inspection Methods Standard Close B hole an...

Page 37: ...ion timing before top dead center Note when checking ignition timing place transmission at neutral position Hint After run the engine for 5 seconds with rotating speed of 1000 1300rpm check the engine could recover to idle running 8 Check engine idle speed a Warm up engine and run it at idle speed b Read engine rotating number in data flow with diagnostic instrument c Check idle speed Idle speed a...

Page 38: ...essure increases after engine oil is injected the piston ring of this cylinder or the cylinder has been worn or scratched If the pressure is still too low the valve may be stuck or not fully closed or the cylinder head gasket leaks 10 Check CO HC a Start engine b Keep the rotating speed of engine at 2500rpm for about 180 seconds c When the engine is idle running insert the test bar of CO HC gauge ...

Page 39: ...clearance incorrect 2 Valve clearance incorrect 3 Air inlet and exhaust valve leaky 4 Cylinder leaky 1 Vacuum leak PCV hose Intake manifold Throttle body Idle speed stepping motor Vacuum booster and pipelines 2 Fire caused by too thin mixing ratio 1 Air filter core blocked 2 PCV valve blocked 3 EFI system malfunction Fuel pressure regulator malfunction Water temperature sensor malfunction Intake p...

Page 40: ...drive belt Slowly turn drive belt tensioner clockwise to loosen it Then remove drive belt and put back drive belt tensioner slowly and gently 3 Install drive belt Slowly turn drive belt tensioner clockwise to loosen it Then install drive belt and put back drive belt tensioner slowly and gently 29 ...

Page 41: ...for one circle again and align the above marks 6 Check valve clearance a Only check the valves shown in the diagram 1 Measure the clearance between valve tappet and cam shaft with plug gauge 2 Record valve clearance measuring value exceeding specification and this value will be used to determine valve tappet thickness that needs change Valve clearance cold vehicle Intake air Exhaust b Turn cranksh...

Page 42: ...efore installing chain tensioner a Turn crankshaft to cylinder 1 top dead center position b Align the marks on timing chain and camshaft timing sprocket c Remove 2 bolts and chain tensioner d Fix camshaft with adjustable wrench and then loosen the fixed bolts of exhaust camshaft timing sprocket Note be careful not to damage valve lifter e As sequences shown in the diagram loosen camshaft bearing c...

Page 43: ...the timing chain hood j Remove valve lifter k Measure the thickness of this valve lifter with micrometer 1 Calculate the thickness of new valve tappet and adjust valve clearance within specification Exhaust Hints New valve tappet chosen should be near the value cal culated as much as possible The thickness of valve tappet is from 5 06mm to 5 74mm and there is one specification every 0 02mm therefo...

Page 44: ...ace exhaust camshaft in cylinder head p Temporarily lock fixed bolts q Check exhaust side camshaft bearing cover forward remark and figure and tighten the bolts as sequences shown in the diagram Torque r Install camshaft front bearing cover Torque s Fix camshaft with adjustable wrench and then tighten the fixed bolts of camshaft timing sprocket Torque Note be careful not to damage valve lifter 33 ...

Page 45: ... tensioner 1 Check o ring is clean and buckle on the hook as shown in the diagram 2 Coat engine oil on the chain tensioner and then install it Note when installing the chain temsioner buckle on the hook again if plunger has ejected 3 Turn crankshaft counterclockwise to separate the hook from lock pin on the plunger Mark Mark Mark Timing chain hood surface Groove Pressing in 34 Lifting Hook Pressin...

Page 46: ...ealant FIPG materials c Coat sealant on 2 positions shown in the diagram Notes Wipe off all the oil stains on junction plane After coating sealant finish installation of cylinder head cover within 3 minutes After installing do not refill engine oil within 2 minutes d Install cylinder head cover components with 9 bolts 2 seal washers and 2 nuts Evenly tighten bolts and nuts at several times Torque ...

Page 47: ...le radiator hose inlet end 14 Disassemble radiator hose outlet end 15 Disassemble cold air pipe inlet hose 16 Disassemble cold air pipe outlet hose 17 Remove transmission control pull cable assembly 18 Disassemble warm air water inlet hose 4G18 1300102 19 Disassemble warm air water outlet hose 4G18 1300108 20 Disassemble the hoses of all joints to connect vehicle body end 21 Uncouple engine wire h...

Page 48: ...move the nuts on left side of front shaft hub a Completely knock out the concave part of fixed nuts with special tool and hammer Notes Completely knock out the concave part of fixed nuts before removing the fixed nuts Do not damage thread of drive shaft Do not sharpen the sharp end of special tool Place the special tool in groove with its plane facing upward b Remove fixed nuts with socket wrench ...

Page 49: ...t perform the same steps at another side 32 Remove oil return pipe assembly After removing 3 retaining clips and 2 bolts of power steer ing oil reservoir remove the oil return pipe from vehicle 33 Remover engine assembly 4G18 1000000 and transmission assembly a Erect engine hanger b Remove 4 bolts 2 nuts and right engine mounting assembly c Remove through bolt and nut and then remove left engine m...

Page 50: ...e diagram install front and rear hooks of engine Torque Hint install engine hooks to front and rear sides of engine g Lift engine assembly with chain pulley block and en gine lifting device Engine mechanism Engine assembly Special tool 39 41 Remove exhaust manifold upper heat shield components 4G18 1008120 42 Remove exhaust manifold assembly 4G18 1008100 43 Remove fuel rail injector assembly 4G18 ...

Page 51: ... Torque m 58 Install speed sensor Install speed sensor and harness clips Torque 59 Install phase sensor Torque 60 Install drive belt tensioner device Torque nut m Bolt m 61 Install the hoses on all hose joint of engine Install clips and hose 62 Install oil pressure alerter a Clean thread of oil pressure alerter and coat adhesive Adhesive anaerobic pipe thread sealing adhesive 1545 Kesaixin 1545 b ...

Page 52: ...rque c Install fuel pipe retaining clip 68 Install exhaust manifold gasket and exhaust manifold assembly Torque 69 Install exhaust manifold upper heat shield components Torque 70 Install intake manifold assembly Install new gasket and intake manifold assembly Torque m 71 Install throttle supporting plate Torque 72 Install flywheel components and clutch assembly a Fix crankshaft with special tool b...

Page 53: ... with transmission assembly on engine crane b Install engine assembly to vehicle c Temporarily install side member and 6 bolts d Install left engine mounting assembly Torque e Install right engine mounting assembly f Insert special tool into location hole on right side of sub frame and vehicle g Temporarily lock bolt A at first and then lock bolt B h Insert special tool into location hole on left ...

Page 54: ...ft shaft hub nut a Install fixed nut with socket wrench 39mm Torque b Drive the cutout part of hub nut into groove with chisel Hint perform the same steps at another side 81 Install left end front stabilizer link assembly Fix bolts with hex socket wrench Torque Hint perform the same steps at another side 82 Install left side transversal lever assembly a Connect transversal lever assembly to steeri...

Page 55: ...nd its hose 90 Install steering middle shaft assembly a Align alignment mark on steering middle shaft b Install 2 bolts Torque m c Install steering column cover 91 Install front exhaust pipe assembly 92 Install front chassis bracket Torque 93 Install battery and connect wire 94 Install engine plastic hood components 95 Install front wheel and engine bottom shield 96 Refill transmission lubricant 9...

Page 56: ... engine wire harness 9 Remove ignition coil assembly 10 Remove cylinder head cover components a Remove fuel pipe retaining clip and 2 PCV hoses from cylinder head cover b Remove 9 bolts 2 seal washers cylinder head cover components and gasket 11 Remove right engine mounting assembly a Remove PS oil pump reservoir and put it aside b Place wooden block between jack and engine prop erly place the jac...

Page 57: ...head and body with screw driver and remove it Note be careful not to damage timing chain hood the contact surface of cylinder head and body 21 Remove crankshaft front oil seal assembly 4G18 1006150 Remove oil seal with screwdriver 22 Remove speed sensor signal panel 4G18 3600011A 23 Remove chain tension rail components 4G18 1006120 24 Remove chain guide rail components 4G18 1006130 25 Remove timin...

Page 58: ...chain links on the timing chain c Install crankshaft timing sprocket with special tool d Install timing chain on camshaft timing sprocket and align the chain link having yellow mark with camshaft timing sprocket 27 Install chain guide rail components Torque m 28 Install chain tension rail components Torque 29 Install speed sensor signal panel Install signal panel with F mark toward forward Toward ...

Page 59: ...t surface b As shown in the diagram coat sealant on the edge diameter 3 5mm 4 5mm Sealant silicon rubber flange sealant 1596 Kesaixin 1596 c Install timing chain hood with 12 bolts and nuts Torque Notes Eliminate all grease on contact surface After coating sealant finish installation of timing chain hood within 3 minutes After installing do not refill engine oil within 2 minutes 32 Install chain t...

Page 60: ...e damping pulley in b Install damping pulley bolts with special tool Torque c Turn crankshaft counterclockwise to separate the hook from lock pin on the plunger d Turn crankshaft clockwise and check the chain ten sion rail is blocked by plunger Hint if the plunger does not eject press the chain ten sion rail toward chain tensioner with screwdriver or fingers to separate the hook from lock pin and ...

Page 61: ...all cylinder head cover components a Install gasket to cylinder head cover b Eliminate all old seal materials c Coat sealant on 2 positions shown in the diagram Sealant silicon rubber flange sealant 1596 Kesaixin 1596 Notes Eliminate all grease on contact surface After coating sealant finish installation of cylinder head cover within 3 minutes After installing do not refill engine oil within 2 min...

Page 62: ...ngine mechanism Timing chain assembly 41 Install alternator mounting components Torque 12mm bolt head 14mm bolt head m 42 Refill coolant 43 Check there is coolant leakage 44 Check there is oil leakage 51 ...

Page 63: ...ng chain hood surface as shown in the diagram Hint if not turn crankshaft for one circle 360 again and align the above marks 6 Remove drive belt Slowly turn drive belt tensioner clockwise to loosen it Then remove drive belt and put back drive belt tensioner slowly and gently 7 Remove right engine mounting assembly a Remove PS oil pump reservoir and put it aside b Place wooden block between jack an...

Page 64: ...and then loosen the fixed bolts of camshaft timing sprocket Note do not damage valve lifter e As sequences shown in the diagram loosen camshaft bear ing cover bolts on exhaust camshaft at several times and remove the bearing cover at the same time f As shown in the diagram remove exhaust camshaft tim ing sprocket g As sequences shown in the diagram loosen camshaft bear ing cover bolts on intake ca...

Page 65: ...eal 5 oil ducts of intake camshaft journal with vinyl rubber cloth Hint there are 2 advance side oil ducts in the groove of intake camshaft and clog one of them with rubber block 2 In opposite side of the groove prick a hole on vinyl rubber cloth of advance side oil duct surface and delay side oil duct surface 3 Send in 2 oil ducts advance side oil duct and delay side oil duct with the surface rub...

Page 66: ...ide oil duct with the surface rubber cloth pricked under the pressure of 150Kpa Warning cover the oil ducts with cloth to avoid oil injecting out in pushing e Ensure whether the timing sprocket of VVT driver will turn toward timing advance direction in decreasing the pressure of timing delay oil duct Hint camshaft timing sprocket will turn toward advance direction only after the lock pin is releas...

Page 67: ...inserted into groove Warning it is strictly forbidden to turn camshaft timing sprocket toward timing delay side toward right b Check there is no clearance between sprocket flange and camshaft c Fix camshaft timing sprocket and then tighten flange bolt Torque 70 5N m d Check VVT driver assembly could move to timing delay side and is locked at max timing delay position f As shown in the diagram alig...

Page 68: ... m l Fix camshaft with variable wrench and then tighten the fixed bolts of exhaust camshaft timing sprocket Torque 54 10 8N m Note be careful not to damage valve lifter m Check the alignment marks on timing chain and cam shaft timing sprocket and then align the groove of damp ing pulley with the timing mark on timing chain hood as shown in the diagram Fixing Tightening 57 Mark Mark Mark Timing cha...

Page 69: ...he hook again if plunger has ejected 3 Turn crankshaft counterclockwise to separate the hook from lock pin on the plunger 4 Turn crankshaft clockwise and check the sliding parts are blocked by plunger Hint if the plunger does not eject press the ten sion rail toward chain tensioner with screwdriver or fingers to separate the hook from lock pin and make the plunger eject Pushing into Turning Plunge...

Page 70: ...oil on contact surface After coating sealant finish installation of cylinder head cover within 3 minutes After installing do not refill engine oil within 2 minutes d Install cylinder head cover and harness bracket with 9 bolts 2 oil seal washers and 2 nuts Evenly tighten bolts and nuts at several times Torque nut 29 5 8N m Bolt 69 13 8N m 16 Install drive belt tensioner device Torque nut 29 5 8N m...

Page 71: ... drive belt tensioner slowly and gently 3 Remove right engine mounting assembly a Remove PS oil pump reservoir and put it aside b Place wooden block between jack and engine properly place the jack and then remove right engine mounting assembly 4 remove damping pulley a Remove pulley bolts with special tool b Remove damping pulley with special tool Special tool Special tool 60 Crankshaft front oil ...

Page 72: ...e on new oil seal lip Note do not let oil seal lip contact with foreign matters b Gently knock new oil seal in with special tool and hammer until the seal surface is parallel and level with the end sur face edge of mounting hole Note wipe off redundant grease on crankshaft 7 Install damping pulley a Align the key groove on the pulley with the key on the crankshaft and slide pulley in b Install pul...

Page 73: ...G18 1002130 a Coat a little MP grease on new oil seal lip Note do not let oil seal lip contact with foreign matters b Gently knock new oil seal in with special tool and hammer until the seal surface is parallel and level with the end sur face edge of mounting hole Note wipe off redundant grease on crankshaft 5 Install flywheel components and clutch assembly a Fix crankshaft with special tool b Cle...

Page 74: ...nder head bolts and plain washer Notes Be careful not to let washer fall into cylinder head Incorrect disassembling sequence will cause cylin der head warp or chap 5 Remove cylinder head gasket components 4G18 1003160 6 Install cylinder head gasket components Put new cylinder head gasket on the cylinder body Notes Pay attention to installation direction Gently put down cylinder head to avoid damag...

Page 75: ...ne oil on camshaft journal b Put 2 camshafts on cylinder head and with cylinder 1 cam shaft end toward the direction shown in the diagram c Check forward remarks and figures of all bearing cover and tighten the bolts as sequences shown in the diagram Torque Camshaft front bearing cover Camshaft bearing cover 9 Check idle speed and ignition timing 10 Check compression pressure 11 Check CO HC 64 ...

Page 76: ...the surfaces are parallel and level with each other Notes Gently knock gasket toward positive direction Do not repeat using the gasket that has been removed Do not push the gasket in by means of tightening bolt connection c Install exhaust pipe Torque 43 N m 7 Install oxygen sensor Torque 44 N m 9 Install rear exhaust pipe together with rear guard assembly 64000044 a Measure free length of compres...

Page 77: ...if coolant is too dirty it is required to replace coolant c Install back radiator cap Inspection 1 Temperature regulator Hint the figure on temperature regulator is the opening temperature of valve Cooling Cooling system On vehicle inspection 1 Check there is leakage with cooling system Warning when the temperature of engine and radiator is high do not remove radiator cap to avoid be ing scalded b...

Page 78: ...nds or more Note pump radiator tester with constant speed Hints Pumping speed 1 time 3 seconds or more If air could not be released by vacuum valve please replace radiator cap b Pump tester and check opening pressure of relief valve Standard opening pressure 74 108KPa Min opening pressure 59KPa Note pumping speed means that the speed could be increased after the first time pumping speed to close v...

Page 79: ...asured by water temperature sensor on water outlet d Check cooling fan runs Hint if it does not run please replace water temperature sensor 3 Check cooling fan a Uncouple cooling fan joint b Connect battery and ampere meter to cooling fan joint c Check cooling fan runs normally and check ampere meter reading Standard current 7 12A d Connect back cooling fan joint Inspection 1 Electronic fan relay ...

Page 80: ...owly turn drive belt tensioner clockwise to loosen the belt then remove drive belt and put back drive belt tensioner slowly to completely loosen the tensioner 4 Remove alternator assembly a Remove rubber cover and nuts b Uncouple alternator joint c Remove 2 bolts and alternator 5 Remove water pump assembly Remove 6 bolts water pump and o ring 69 ...

Page 81: ...pump assembly a Install new o ring on water pump b Install water pump with 6 bolts Torque bolt A Bolt B 7 Install alternator mounting components Torque 12mm bolt head 14mm bolt head 8 Refill engine coolant 9 Check there is leakage with coolant 70 ...

Page 82: ... cover and nuts b Uncouple alternator joint c Remove 2 bolts and alternator 5 Remove water inlet pipe 6 Remove temperature regulator 7 Install temperature regulator a Install new gasket to temperature regulator b As shown in the diagram install temperature regulator with inching valve toward upward 8 Install water inlet pipe and joint Torque 9 Install alternator installation components Torque 12mm...

Page 83: ...ps of 2 wire harnesses from fan cover 7 Remove mounting bracket assembly on radiator 64000058 8 Remove radiator together with electronic fan assembly 64000057 9 Remove electronic fan together with fan cover assembly 64000060 a Screw off fixed nuts connecting electronic fan together with fan cover assembly with radiator b Uncouple fan motor joint c Remove 2 bolts of fan d Remove fan motor at the sa...

Page 84: ... radiator cap c Pour coolant into expansion tank until the level is up to FULL mark line d Run engine with vehicle warning up until thermostat valve is opened Hint During vehicle warning up press radiator water inlet hose and outlet hose with hands several times e Engine flames out until coolant temperature falls to cold Then open radiator cap and check coolant level f If coolant level is too low ...

Page 85: ...grade oil Recommended viscosity is shown as below The temperature increases from left to right 3 Remove oil pressure alerter assembly a Uncouple oil pressure alerter joint b Install oil pressure alerter with special tool 4 Install oil pressure gauge Install oil pressure gauge 5 Warm up vehicle 6 Check oil pressure Oil pressure 7 Install oil pressure alerter a Coat adhesive on 2nd or 3rd circle thr...

Page 86: ...tect environment waste oil and oil filter must be abandoned at named place 1 Remove engine right bottom shield 2 Discharge engine oil 3 Remove oil filter assembly 4G18 1012100 Remove oil filter with special tool 4 Install oil filter assembly a Check and clean oil filter junction plane b Coat oil seal of new oil filter with clean oil c Tighten oil filter with hands to the extent that oil seal just ...

Page 87: ...ge 45 2 Remove oil pump assembly 4G18 1011100 Remove 5 bolts oil pump and oil pump gasket 3 Install oil pump assembly a Install new gasket on cylinder body b Align the guide groove of oil pump drive rotor with the key on crankshaft and slide the oil pump in c Install oil pump with 5 bolts Torque 76 ...

Page 88: ...2 pin and 3 pin of sensor and the resistance at should be 8601 2 801 2 c Connect speed sensor joint d Place digital universal meter at AC voltage gear and connect 2 terminals respectively to 2 pin and 3 pin of sensor and start engine there should be voltage output at the moment It is recommended to check with vehicle oscilloscope Ignition Ignition system Inspection 1 Spark plug a Clean spark plug ...

Page 89: ...park plug during checking When there is falling or collision with ignition coil please replace with a new one Running engine time for each time should not be more than 2 seconds If there is no spark please perform test as the following steps c Install spark plug with 16mm spark plug sleeve Torque d Install ignition coil and igniter Torque 4 Test procedure in the state of not spark 78 Perform step ...

Page 90: ...pushed outside pull in coil and hold in coil c As shown in the diagram uncouple negative wire from ter minal C after the above connections and check drive pin ion is still at the state of being pushed outside Hold in coil d Push drive pinion toward armature side and measure the clearance between drive pinion end and stop ring Standard clearance 1 0 5 0mm e Uncouple negative wire from electromagnet...

Page 91: ...ram connect battery with ampere meter k Read current value displayed on ampere meter l Current value specification 90 A or lower at 11 5 V 2 Starter relay 80 Terminal 50 Terminal 30 Ampere meter Specified conditions Normal state Conduction Conduction Terminal connected by three use meter Conditions Supply battery voltage to No 1 and No 2 terminals ...

Page 92: ...ions 1 Check positive and negative wire of battery is con nected correctly 2 When performing quick charge to battery please uncouple battery wire 3 Do not test with high pressure insulation resistance tester 4 do not uncouple battery wire during engine running 81 ...

Page 93: ...drive belt a Check belt is excessively worn or cable is broken etc Hints If any inferior part is found please replace drive belt It is allowable for the crack at the edge of drive belt rib If there is block falling with belt rib please replace with new belt b Check the belt is correctly installed in guide groove Hint Check with hands to ensure that the belt does not slide out from the groove of pu...

Page 94: ...n b Check the reading of ampere meter Standard amperage 30A or more Hints If amperage is less than standard value please repair alternator If battery is under the state of full charge amperage may be less than standard value sometimes c Check charge system circuit 1 Check the readings of ampere meter and voltmeter with engine from idle speed to 2000rpm Standard current 10A or less Standard voltage...

Page 95: ...lowly turn drive belt tensioner clockwise to loosen the belt then remove drive belt and put back the tensioner slowly to completely loosen it 3 Remove alternator components a Remove rubber cover and nuts b Uncouple alternator joint c Remove 2 bolts and alternator 4 Install alternator components Torque 12mm head bolt m 14mm head bolt 84 ...

Page 96: ...Starter components Replacement 1 Remove engine lower left shield 2 Remove starter components b Uncouple starter joint b Remove nuts and uncouple starter wire c Remove 2 bolts and starter 3 Install Starter components Torque bolt Wire harness 85 ...

Page 97: ...arts abrasion 6 Steering gear poor adjustment or breakage 1 Vehicle overload Bottoming 2 Spring elastic fatigue 90 3 Absorber abrasion 90 1 Tire abrasion or improper tire pressure 109 Swaying left and right 2 Stabilizer bar bending or breakage 96 shaking forward and backward 3 Absorber abrasion 90 1 Tire abrasion or improper tire pressure 109 2 Wheel poor balance 109 3 Absorber abrasion 90 Front w...

Page 98: ...is used under the condition of speed above 160 km h b Check tire run out with dial indicator Tire run out 3 0mm 2 Measurement of vehicle height Vehicle height General road Coarse road Measuring point A Height for ground and front wheel center B Height for ground and bolt center in front of lower control arm C Height for ground and fixed bolt center of rear axle beam D Height for ground and rear wh...

Page 99: ...e end levers of left and right rack to adjust toe in Hint try adjusting toe in to medium value d Ensure that the end lever length of left rack equals that of right rack e Tighten lock nuts at the end of transversal lever Torque 74 5 N m f Install dust cover fixing clip Hint ensure that the dust cover does not distort 5 Inspection of turning angle a Completely rotate steering wheel to the bottom an...

Page 100: ...f it is necessary to repeat using bolts or nuts please coat oil to thread of nuts c Clean nut absorber and attachment face of steering knucle d Temporarily install 2 nuts e Push or pull lower end of absorber in the direction that cam ber requires adjustment to adjust the camber f Tighten nut Torque 153 10 N m g Install front wheels Torque 103 10 N m h Check camber 89 ...

Page 101: ... front wheels 2 Separate front left stabilizer link assembly 64000097 Remove nuts and disassemble stabilizer link from absorber Hint if ball joint rotates with nuts please fix bolts with hexagonal wrench 6mm 3 Remove front absorber and helical spring a Remove bolts and disassemble brake hose andABS speed sensor wire harness bracket b Remove 2 nuts and bolts under absorber c Remove 3 nuts above abs...

Page 102: ...g dustproof seal ring spring seat upper insulator spring limit block and lower insulator 6 Check front left absorber assembly 61001036 Press in and pull out absorber piston rod and check there is abnormal resistance or abnormal sound If anything unusual occurs please replace absorber Note When abandoning absorber please refer to Page 86 7 Install front left absorber assembly 61001036 a Install low...

Page 103: ...r bearing h Fix upper shock absorber bearing with special tool and install new nuts Torque 47 5 N m i Remove special tool j Install dust cover k Coat upper absorber bearing with grease Note do not coat grease on rubber surface of upper shock absorber bearing 8 Install front shock absorber and helical spring a Install 3 nuts above shock absorber Torque 39 3 N m b Install 2 fixed bolts of shock abso...

Page 104: ... care ful in operating The gas is colorless odorless and nontoxic 93 c Install 2 nuts to lower end of absorber Torque 153 10 N m Hint coat oil on thread of nuts d Install brake hose and ABS speed sensor wire harness bracket with bolts Torque 19 N m 9 Install front left stabilizer link assembly 64000097 Install stabilizer link with nuts Torque 74 5 N m Hint if ball joint rotates with nuts please fi...

Page 105: ...41 7 Remove front left brake assembly 64000134 see Page 142 8 Separate left side transversal lever assembly 9 Separate lower left control arm assembly 64000091 Remove bolts and 2 nuts and separate lower control arm from lower end ball joint 10 Remove front left shaft hub assembly see Page 123 11 Remove lower left control arm assembly 64000091 Remove 2 bolts nuts and lower control arm 12 Temporaril...

Page 106: ... stabilizer link assembly 64000097 Hint the installation procedures of right side are the same as that of left side 21 Align suspension a Install front wheels and lay down vehicle from the lift Torque 103 10 N m b Align suspension components by means of lifting ve hicle several times 22 Completely lock up lower left control arm assem bly 64000091 Completely tighten 2 bolts and nuts Torque 137 10 N...

Page 107: ...ide are the same as that of left side 8 Check front left stabilizer link assembly a As shown in the diagram before installing nuts shake joint bolts forward and backward 5 times b Shake nuts continuously with torque wrench at the speed of one circle per 2 4 s and then read out torque value at the 5th circle Rotating torque 0 05 1 0 N m 9 Separate left side transversal lever assembly see Page 113 1...

Page 108: ...ssembly see Page 205 22 Connect steering oil return pipe see Page 205 23 Connect left side transversal lever assembly see Page 113 24 Connect right side transversal lever assembly see Page 113 25 Install front left stabilizer link assembly 64000097 a Install front stabilizer link with 2 nuts Torque 74 5 N m Hint if ball joint rotates with nuts please fix bolts with hexagonal wrench 6mm 26 Install ...

Page 109: ...ter line 32 Install dust cover inside steering column 33 Refill power steering oil see Page 200 34 Discharge air of power steering oil see Page 200 35 Check there is oil leakage 36 Check and adjust front wheel alignment see Page 87 Front suspension Front stabilizer bar 98 ...

Page 110: ... assembly 64000093 see Page 123 10 Check lower left control arm ball joint assembly 64000093 a As shown in the diagram before installing nuts shake joint bolts forward and backward 5 times b Shake nuts continuously with torque wrench at the speed of one circle per 2 4 s and then read out torque value at the 5th circle Rotating torque 1 0 4 9 N m 11 Install lower left control arm ball joint assembl...

Page 111: ...ent incorrect 101 3 Shaft hub bearing abrasion 129 4 Suspension parts abrasion 1 Vehicle overload Bottoming 2 Spring elastic fatigue 102 3 Absorber abrasion 102 Swaying left and right 1 Tire abrasion or improper tire pressure 109 shaking forward and 2 Rear stabilizer bar bending or breakage 105 backward 3 Absorber abrasion 102 1 Tire abrasion or improper tire pressure 109 Rear wheel shimmy 2 Wheel...

Page 112: ...thin specification check and replace relevant suspension parts 4 Inspection of camber a Install camber caster kingpin gauge or erect wheel alignment tester b Check camber Camber general road Toe in Total Coarse road Toe in Total For camber could not be adjusted therefore check suspension components are damaged or worn if camber measuring value is not within specification and replace parts if neces...

Page 113: ...re tire trim cover assembly 4 Remove rear floor trim 5 Remove trunk left garnish 68000112 6 Remove rear left strut assembly 64000098 a Support rear shaft with a jack b Remove 2 nuts and bolts Rear suspension Rear strut assembly c Remove nuts gasket and rear strut assembly 7 Remove rear left strut assembly 64000098 a Compress helical spring with special tool Note do not use pneumatic wrench or the ...

Page 114: ...bsorber please refer to Page 97 9 Install rear left strut assembly 64000098 a Compress helical spring with special tool Note do not use pneumatic wrench or the special tool will be damaged b Install helical spring to absorber Hint install lower end of helical spring into notch of lower spring seat c Install spring absorber and suspension bracket d Encase upper separator into spring bracket e As sh...

Page 115: ...spension components by means of lifting vehicle several times 13 Completely lock up rear strut assembly Completely tighten nuts Torque m 14 Check rear wheel alignment see Page 101 Handling 1 Handle rear left strut assembly 64000098 a Completely pull out shock absorber piston rod b As shown in the diagram drill a small hole on cylinder body between two lines with electric drill to make inside gas f...

Page 116: ... Overhaul 1 Remove rear stabilizer bar assembly Remove 2 bolts nuts and stabilizer bar 2 Install rear stabilizer bar assembly Install 2 bolts nuts and stabilizer bar Torque Hint install the tag on balance bar toward rear right side of vehicle Front Tag 105 ...

Page 117: ...eel speed sensor wire harness a Uncouple sensor joint b Remove 2 bolts and disassemble wire harness retaining clip 5 Remove rear left right brake assembly 64000137 64000139 See Page 144 6 Remove rear stabilizer bar assembly see Page 105 7 Disassemble rear left right strut assembly see Page 102 8 Remove rear shaft assembly 64000120 a Support rear shaft assembly with a jack b Remove 2 bolts gasket a...

Page 118: ...ver assembly a Align the dent on new bush with the matching mark previously making on axle beam and then temporarily encase gum cover into axle beam b Encase gum cover into axle beam with special tool Notes The hook of special tool should be deeply and actually inserted into gum cover Do not damage the rubber port of gum cover O Do not deform gum cover frame 12 Install right side rear shaft gum co...

Page 119: ...ar shaft assembly 108 18 Install rear left brake caliper assembly see Page 144 19 Install rear right brake caliper assembly see Page 144 20 Align suspension a Lay down vehicle from the lift after installing rear wheels Torque b Align suspension components by means of lifting ve hicle with a jack several times 21 Completely lock up rear shaft assembly 64000120 a Completely tighten bolts and pull on...

Page 120: ...ere is spare tire or not 3 Check wheel balance a Check and adjust with off the car balancing machine b Check and adjust with in the car balancing machine if necessary Unbalanced mass after adjusting 4 Check axial clearance of front wheel bearing see Page 123 5 Check end surface run out of front wheel shaft hub see Page 123 6 Check axial clearance of rear wheel bearing see Page 129 7 Check end surf...

Page 121: ...Tire and wheel wheel and tire system 11 Check the function of absorber is normal Check there is oil leakage Check liner clamp is worn Shake the front and rear of vehicle 110 ...

Page 122: ...unction phenomenon table Malfunction phenomenon Possible malfunction part Reference page Offset 1 Steering connecting rod loosened or abraded 2 Bearing of shaft hub abraded 123 1 Ball joint abraded 123 Shake of front wheels 2 Bearing of shaft hub abraded 123 3 Steering connecting rod loosened or abraded Abnormal noise 1 Inner joint abraded 113 2 Exterior joint abraded 113 Exterior joint assembly 5...

Page 123: ...age 123 f Assemble front brake g Assemble front brake caliper assembly Torque 106 10 N m H Assemble front wheel Torque 103 10 N m 2 Check the bearing of rear wheel hub a Disassemble rear wheels b Disassemble rear brake caliper assembly c Disassemble rear brake d Check the axial clearance of bearing referring to page 129 e Check the terminal run out of shaft hub referring to page 129 f Assemble rea...

Page 124: ... assemble oil discharging plug Torque 45 5 N m 3 Disassemble front wheels 4 Disassemble fixing nut of drive shaft 64000083 a Use special tool and hammer to unclench the concave part of fixing nut b Disassemble the fixing nut 5 Disassemble speed sensor assembly of left front wheels equipping with ABS 67000020 a Disassemble the bolt and disassemble sensor wiring har ness and brake hose from the abso...

Page 125: ...ssemble the seal board of left front fender b Use special tool to disassemble front drive shaft assembly Note do not damage oil seal 10 Fix left front shaft hub assembly Note if supporting automobile weight only with bearing shaft hub bearing will be damaged for example when moving automobile in process of disassembling drive shaft So if it is not necessary to support automobile weight with shaft ...

Page 126: ...f cover b Mesh clamp type Liking that shown in figure use pliers to disassemble No 2 fixing clamp of inner joint dust proof cover 13 Disassemble inner joint dustproof cover of left front drive shaft Disassemble dustproof cover from left inner joint 14 Disassemble inner joint of left front drive shaft a Remove old lubricating grease of inner joint b Make mark on inner joint and drive shaft Note do ...

Page 127: ...e use pliers to disassemble fixing clamp c Disassemble dynamic absorber of drive shaft 16 Disassemble No 2 fixing clamp of exterior joint dustproof cover of left front drive shaft a Use screw driver to disassemble No 2 fixing clamp of exte rior joint dustproof cover 17 Disassemble fixing clamp of exterior joint dustproof cover of left front drive shaft a Use screw driver to disassemble fixing clam...

Page 128: ...letely Do not damage dustproof cover lid 22 Assemble the clasp of inner joint of left front drive shaft Assemble new clasp 23 Assemble exterior joint dustproof cover B type and C type a Twist ethylene adhesive tape on gear slot of exterior joint to preventdamage b Assemble following parts on drive shaft by sequence 1 No 2 fixing clamp of exterior joint dustproof cover 2 Exterior joint dustproof co...

Page 129: ...xing type Tighten small fixing clamp of exterior joint 1 Put small fixing clamp on dustproof cover firmly 2 Put special tool on small fixing clamp 6 Lock special tool to tighten small fixing clamp Note do not tighten special tool too much 4 Use special tool to adjust the clearance of small fixing clamp Clearance 0 8mm 26 Assemble dynamic absorber of driveshaft right drive shaft a A type and C type...

Page 130: ... clamp with screw driver 28 Assemble inner joint of left front drive shaft a Twist ethylene adhesive tape on gear slot of exterior joint to preventdamage b Assemble following parts on drive shaft by sequence 1 No 2 fixing clamp of inner joint dustproof cover 2 Inner joint dustproof cover 3 Fixing clamp of inner joint dustproof cover c Align the mark made before disassembly and assemble triangle jo...

Page 131: ...ing clamp type Liking that shown in figure use screw driver to assemble fixing clamp of dust proof cover inner joint b Mesh clamp type Liking that shown in figure use pliers to assemble fixing clamp of inner joint dust proof cover 31 Assemble No 2 fixing clamp of dust proof cover in ner joint of left front drive shaft a Single contact fixing clamp type Liking that shown in figure use screw driver ...

Page 132: ...ing on hori zontal position 33 Assemble left front drive shaft assembly 64000082 a Spread ATF on gear slot of inner joint shaft assembly b Put gear slot of drive shaft in integrated transmission then use copper stick and hammer to knock drive shaft to its position Note z make the placket of clasp face the downside to assemble z Be careful not to damage the seal oil Hint Whether the drive shaft con...

Page 133: ...with ABS 67000020 a Assemble speed sensor absorber with bolts Torque 49 5 N m b Assemble speed sensor on the steering knuckle with bolts Torque 8 N m Note z Do not damage speed sensor z Prevent it from contacting with sundries z When assembling the sensor the wiring harness of sensor could not bend 38 Assemble fixing nuts of drive shaft 68000083 a Assemble fixing nuts Torque 216 15 N m b Use chise...

Page 134: ...pecial tool and hammer to unclench concave part of fixing nuts b Disassemble fixing nuts 3 Disassemble speed sensor assembly of left front wheel 67000020 a Disassemble the bolts then disassemble the wiring har ness of sensor and brake hose b Disassemble the bolts then disassemble speed sensor from steering knuckle 4 Disassemble left front brake caliper assembly Disassemble two bolts to disassemble...

Page 135: ...l arm from lower ball joint 8 Disassemble left front shaft hub assembly a Use plastic hammer to disassemble transmission shaft from shaft hub Note do not damage the dustproof cover and the sta tor of ABS speed sensor b Disassemble two bolts and nuts then disassemble steer ing knuckle with shaft hub 9 Disassemble left front lower control arm ball head assembly 64000093 a Disassemble cotter pin and ...

Page 136: ...le exterior on bearing b Use special tool and press to disassemble the bearing from steering knuckle 14 Assemble left front shaft hub bearing Use special tool and press to assemble the bearing on steer ing knuckle 15 Assemble left front brake bottom board Assemble bottom board with three bolts 16 Assemble left front shaft hub assembly Use special tool and press to assemble shaft hub 17 Assemble th...

Page 137: ... too much z Do not damage the exterior joint dustproof cover of drive shaft z Do not damage the stator of speed sensor 20 Assemble left lower control arm assembly 64000091 Assemble lower control arm and ball head with two nuts and bolts Torque 142 10 N m 21 Assemble left transversal lever assembly a Connect transversal lever to steering knuckle b Assemble screw cap and new cotter pin Torque 49 5 N...

Page 138: ...ke branch pump assembly on steering knuckle Torque 106 10 N m 31 Assemble speed sensor assembly of left front wheel 67000020 a Assemble wiring harness of speed sensor and brake hose on the absorber with bolts Torque 29 N m b Use the bolts to assemble speed sensor to steering knuckle Torque 8 0 N m Note Do not damage the speed sensor z Prevent it from contacting with sundries z When assembling the ...

Page 139: ...ng knuckle 5 Disassemble left front shaft hub bolt Use special tool and screw driver to disassemble shaft hub bolt 6 Assemble left front shaft hub bolt a Liking that shown in figure assemble gasket and screw cap on new shaft hub bolt b Use screw driver to fix and lock the screw cap to make the bolt enter the hole 7 Assemble left front brake bottom board Assemble three bolts and assemble bottom boa...

Page 140: ...liper assemble Disassemble two bolts and take down brake caliper 3 Disassemble the wiring harness of rear wheel speed sensor equipping with ABS Disassemble the joint of rear wheel speed sensor 4 Disassemble left rear brake assembly 64000137 5 Disassemble left rear shaft hub and bearing assembly Disassemble four bolts then take down lower shaft hub and bearing assembly 8 Assemble left rear shaft hu...

Page 141: ... of shaft hub Use centimeter to check the terminal run out of exterior sur face of shaft hub Maximal value 0 07m If terminal run out exceeds the maximal value change the shaft hub 12 Assemble left rear brake assembly 64000137 13 Assemble left rear brake branch pump assembly Torque 46 5 N m 14 Assemble rear wheels Torque 103 10 N m 15 Check the ABS speed sensor signal 16 Inspection on road Drive sh...

Page 142: ...d to the position in figure or you could not change shaft hub bolt b Use special tool and screw driver to disassemble shaft hub bolt 5 Assemble left rear shaft hub bolt a Liking that shown in figure assemble new gasket and screw cap on new shaft hub bolt b Use screw driver to fix and lock screw cap to make the bolt enter hole 6 Assemble left rear brake assembly 64000137 7 Assemble left rear brake ...

Page 143: ...anging any subassembly for this will influence the perfor mance of brake system and incur the running becomes unsafe It is necessary to use those parts with same type or same grade when changing z When repairing brake system it is very important to keep the surface of every part clean 132 ...

Page 144: ...andle travel adjusted badly 154 3 Parking brake pull cable lag 156 158 4 Brake block damaged or distorted 141 144 Brake lag 5 Piston locked 141 144 6 Piston freezed 141 144 7 Tensility or return spring invalid 161 8 Vacuum booster lever adjusted badly 138 9 Vacuum boosting system vacuum leakage 138 10 Brake main pump invalid 138 1 Piston locked 141 144 2 Brake block oil dirt 141 144 Brake offset 3...

Page 145: ...4 4 Support sheet of brake block loose 141 144 Brake noise 5 Sliding pin abraded 141 144 6 Brake block oil dirt 141 144 7 Brake block sclerosesed 141 144 8 Support pin or return spring invalid 161 9 Muffle gasket damaged 141 144 10 Localizing spring damaged 161 Malfunction phenomenon Possible malfunction part Reference page 134 ...

Page 146: ...dal several times and step down brake pedal then release inflating bolt to discharge air c Lock exhaust bolt until brake liquid stops flowing out then release brake pedal d Repeat b and c until air is discharged completely e Repeat the procedure above and release the air in brake pipeline of every wheel Torque 12 7 17 6 N m 4 Check the brake liquid storage tank Check the liquid level in storage ta...

Page 147: ... 60mm If it is wrong remove the malfunction in brake system Brake pedal assembly Adjustment 1 Check and adjust the height of brake pedal a Check the height of brake pedal Pedal distance from floor 136 0 146 0mm b Adjust the height of brake pedal 1 Disassemble lower trim board of panel 2 Disassemble switch joint of brake light 3 Loosen locking nut of brake switch and disassemble the switch of brake...

Page 148: ...he height from pedal to floor Brake Remove malfunction Brake pedal bracket Brake pedal bushing Brake pedal shaft Locking shaft Brake main pump lever pin Brake pedal Brake pedal Rubber gasket 137 N m Regulated torque Do not use the part repeatedly Lithium soap base glycol lubricating grease ...

Page 149: ...brake pedal sev eral times to check brake pedal The height from floor should not change 2 Step down brake pedal then start the engine Hint if pedal drops a little this shows working is normal 2 Check vacuum check valve a Check vacuum check valve 1 Remove pipe clamp and disassemble vacuum pipe 2 Disassemble vacuum check valve 3 Blow air to check in the direction from booster to engine the check val...

Page 150: ...racket c Disassemble vacuum hose on vacuum booster d Disassemble four screw caps and U shaped joint e Take out vacuum booster and gasket 8 Assemble vacuum booster with brake pump assem bly 64000164 a Assemble U shaped joint on booster lever b Assemble new gasket and vacuum booster with four nuts Torque 13 N m c Connect vacuum hose to vacuum booster d Use the bolts and nuts to assemble carbon canis...

Page 151: ...ssemble carbon canister assembly 4G18 1129020 13 Assemble air filter assembly 64000033 14 Add brake liquid in liquid storage tank 15 Discharge the air in brake main pump 16 Discharge the air in brake system 17 Check and adjust the height of brake pedal 18 Check the pedal free travel 19 Check the height from pedal to floor 20 Check the liquid level in storage tank 21 Check whether the brake liquid ...

Page 152: ...g pin of brake branch pump Disassemble sliding pin on branch pump bracket 7 Disassemble dustproof cover on brake branch pump Disassemble two dustproof covers from brake branch pump of disk 8 Disassemble left front brake branch pump Disassemble two bolts and brake branch pump bracket 9 Disassemble dustproof cover of branch pump Use screw driver to disassemble oil seal loop and dustproof cover 10 Di...

Page 153: ...ake disk a Lock the brake disk temporarily with shaft hub nut Torque 103 10 N m b Use centimeter to measure the terminal run out of brake disk on the position with 10mm apart from the exterior edge of brake disk Maximal run out quantity 0 05mm c If terminal run out of brake disk exceeds or equals to maxi mal value firstly check the axial clearance of bearing then check the terminal run out of shaf...

Page 154: ...front brake branch pump bracket 27 Assemble support sheet of brake block 143 28 Assemble brake block Note when changing brake block muffle gasket should be changed with brake block at the same time a Spread brake lubricating grease on both sides of every muffle gasket b Assemble muffle gasket on every brake block c When assembling inner brake block abrasion indicator should face the upside Note do...

Page 155: ...hose of brake branch pump then disassemble brake hose Hint gasket has two types two sheets type and one sheet type b Disassemble two bolts and brake branch pump 5 Disassemble the bushing of brake branch pump Disassemble two bushings from brake branch pump 6 Disassemble dustproof bushing of rear brake Disassemble three dustproof bushings 7 Disassemble dustproof cover of branch pump Use screw driver...

Page 156: ...rminal run out to assemble brake disk 16 Check the terminal run out of disk a Lock the disk temporarily with screw cap of shaft hub Torque 103 10 N m b Use centimeter to measure the terminal run out of brake disk on the position with 10mm apart from the exterior edge of brake disk Maximal run out quantity 0 15mm c If terminal run out of brake disk exceeds or equals to maxi mal value firstly check ...

Page 157: ...ble fixing loop Note do not damage dustproof cover 21 Assemble dustproof bushing of rear brake a Spread lithium soap base glycol lubricating grease on the surface of three dustproof bushings b Assemble three dustproof bushings in brake branch pump 22 Assemble the bushing of brake branch pump bracket Assemble two bushings of brake branch pump bracket 23 Assemble brake branch pump a Assemble branch ...

Page 158: ...ck abrasion indicator should face upside Note do not attach any oil dirt or lubricating grease on the surface of brake block and brake disk c Assemble two guide pins of brake block d Assemble fixing clamp of anti abrasion spring 25 Add brake liquid in storage tank 26 Discharge the air in brake main pump referring to page 135 27 Discharge the air in brake pipeline referring to page 135 28 Check the...

Page 159: ...brake pedal is stepped down b Make electromagnetic valve SFRH and SFRR be ON at the same time and check the brake pedal should not be stepped down Note Time when motor relay locates ON could not exceed 5 seconds when it is necessary to operate continually interval time should be over 20 seconds c Make electromagnetic valve SFRH and SFRR be OFF at the same time and check the brake pedal should be a...

Page 160: ...mark the name of every oil pipe and tie it on oil pipe e Disassemble screw caps two bolts and hydraulic control unit and bracket 5 Disassemble hydraulic control unit assembly Disassemble three bolts and hydraulic control unit from the bracket 6 Assemble hydraulic control unit assembly Assemble three bolts and hydraulic control unit on the bracket with three bolts Torque 4 7 N m 149 Connect the fro...

Page 161: ...hydraulic control unit d Assemble bolt and connect the joint 8 Assemble gasket of right front wing 9 Assemble right front wheel 10 Add brake liquid in storage tank 11 Discharge the air in main pump 12 Discharge the air in brake pipeline 13 Check the liquid level of brake liquid 14 Check whether brake liquid leaks 15 Use handle tester to check the hydraulic control unit 150 Connect the front of mai...

Page 162: ...automobile body and absorber d Disassemble bolt and left front sensor Note do not attach any sundries on top of sensor 4 Assemble speed sensor of left front wheel a Use bolt to assemble left front sensor Torque 8 0 N m Note do not attach any sundries on top of sensor b Use two bolts to assemble fixing clamp of sensor wiring harness on automobile body and absorber Bolt A 9 0 N m Bolt B 29 N m c Con...

Page 163: ...r shaft hub on pliers with soft gasket Note when changing shaft hub assembly it is neces sary to shake intensively to make it break off b Use punch pin and hammer to knock out two pins c Use special tool and two bolts M12 1 5 to disassemble speed sensor of rear wheel from rear shaft hub Note z If sensor stator is damaged change the shaft hub assembly z Do not scratch the surface of shaft hub and s...

Page 164: ...the supervising part of speed sensor of rear wheels z Press speed sensor of rear wheels straightly and slowly 8 Assemble left rear shaft hub and bearing assembly referring to page 129 9 Assemble brake disk 10 Assemble left rear brake branch pump 11 Assemble wiring harness of speed sensor of rear wheels 12 Assemble rear wheels Torque 103 10 N m 13 Check and adjust wheel alignment 14 Check the signa...

Page 165: ...ing brake handle locates 196N 6 9 sounds 5 Adjust the travel of parking brake handle a Disassemble upper trim board of central box b Disassemble central box c Release locking screw cap then rotate adjusting screw cap until handle travel accords with the specification d Tighten locking screw cap Torque 5 0 N m e Assemble central box f Assemble trim board on central box Malfunction phenomenon Possib...

Page 166: ...itch assembly Disassemble the screw and parking brake switch 6 Assemble parking brake switch assembly Assemble parking brake switch assembly with screw 7 Assemble parking brake pull cable a Connect parking brake pull cable to handle and assemble adjusting screw cap and locking screw cap b Assemble parking brake handle with two bolts Torque 13 N m c Connect the joint of parking brake switch 8 Check...

Page 167: ...ree Way Catalytic Converter assembly 7 Disassemble heat insulation board of front exhaust pipe Disassemble there screw caps and heat insulation board of front exhaust pipe 8 Disassemble parking front brake pull cable assembly 9 Assemble parking front brake pull cable assembly 10 Assemble heat insulation board of front exhaust pipe Assemble heat insulation board of front exhaust pipe with there scr...

Page 168: ...ull cable assembly 12 Assemble front bottom board bracket 13 Assemble parking brake handle assembly 14 Check the travel of parking brake handle referring to page 154 15 Adjust the travel of parking brake handle referring to page 154 157 ...

Page 169: ...ull cable assembly from brake back board 10 Disassemble front bottom board bracket 11 Disassemble front part exhaust pipe 12 Disassemble heat insulation board 13 Disassemble parking left rear brake pull cable assembly Parking brake Parking rear brake pull cable assembly a Disassemble fixing clamp of rear wheel speed sensor wiring harness b Disassemble four bolts and parking left rear brake pull ca...

Page 170: ...ttom board bracket 18 Connect parking left rear brake pull cable assembly Assemble parking left rear brake pull cable assembly to brake back board with bolt Torque 7 8 N m 19 Spread high temperature lubricating grease 20 Assemble support lever of parking brake shoe LH 21 Assemble parking brake exterior shoe assembly LH 22 Assemble parking brake inner shoe assembly LH 159 ...

Page 171: ... shoe LH 25 Check the assembly of parking brake 26 Assemble rear brake 27 Adjust the clearance of parking brake shoe 28 Connect brake branch pump bracket assembly 29 Assemble rear wheels Torque 103 10 N m 30 Check the travel of parking brake lever 31 Adjust the travel of parking brake lever 32 Check whether exhaust system leaks 160 ...

Page 172: ...til wheel could rotate freely 4 Check the inner diameter of brake drum Use centimeter or other measures with same grade to mea sure inner diameter of brake drum Standard inner diameter 173mm Maximal inner diameter 174mm 5 Disassemble support lever of parking brake shoe LH a Use needle nosed pliers to disassemble two springs on upside of shoe b Disassemble support lever of parking brake shoe 6 Disa...

Page 173: ...iameter of brake drum then mesh it with shoe friction plate If the contact between brake shoe and brake drum is not applicable use brake drum to abrade and repair shoe or change brake shoe assembly 11 Disassemble lever of parking brake shoe LH Useneedle nosedplierstodisassembleparkingbrakepullcable then disassemble lever of parking brake shoe 12 Spread high temperature lubricating grease Spread hi...

Page 174: ...adjusting bolt b Assemble parking brake shoe adjustor c Use needle nosed pliers to assemble return spring 17 Assemble support lever of parking brake shoe LH a Spread high temperature lubricating grease on contacting surface between shoe support lever and tension spring b Assemble support lever of parking brake shoe c Use needle nosed pliers to assemble upper two tension springs Parking brake Parki...

Page 175: ...e a Lock screw cap of shaft hub temporarily b Disassemble hole plug then use screw driver to turn the adjustor until brake drum is locked by shoe c Return the adjustor for 8 gears d Check whether shoe has lag e Assemble hole plug 21 Assemble rear disk type brake branch pump assem bly LH 22 Assemble rear wheels Torque 103 10N m 23 Check the travel of parking brake drag lever 24 Adjust the travel of...

Page 176: ...ar shaft of output shaft and screw it out lastly loosen fastening bolt of shift cover take out shift cover assembly and loosen connecting bolt of transmission to take out transmission shell Transmission Disassemble assembly Transmission Disassemble assembly 165 Connecting bolt of cover Cover Fastening bolt of shift cover Stop disc spring of output shaft bearing Support cover of rear shaft of outpu...

Page 177: ... spring of fork shaft liking that shown in figure Clamp the upside of fork shaft which is protected by some cloths and take it out liking that shown in figure Take out reverse gear and reverse gear shaft Disassemble two bolts and swing arm bracket of reverse gear liking that shown in figure 166 ...

Page 178: ...sassemble interlocking pin with magnetic stick and take out fork shaft and fork Disassemble bolt and fork shaft liking that shown in figure Disassemble clip spring liking that shown in figure Take out fork by disassembling clip spring 167 ...

Page 179: ... oil pipe Take our bushing liking that shown in figure Take our oil seal Take our exterior ring of tapered shaft with special tool liking that shown in figure Disassemble oil guide cover Transmission Disassemble assembly 168 ...

Page 180: ... is 0 1 0 35 mm Check the axial clearance of fifth gear liking that shown in figure its standard value is 0 1 0 50 mm Check the radial clearance of forth gear and fifth gear liking that shown in figure its standard value is less than 0 058mm Transmission Disassemble assembly 169 Third gear ...

Page 181: ...f input shaft to disassemble gear cover gear hub and five gear Check the axial clearance of forth gear its standard value is 0 1 0 55mm Take down clip spring used by shaft with clip spring wrench Take out fixing ball with magnetic stick and take down the gear and third and forth synchronous gear loop Transmission Disassemble assembly 170 ...

Page 182: ...nd third gear with pressure machine liking that shown in figure Note hold lower end of shaft with hand to make it stand Take down radial ball bearing with pressure machine and hold lower end of shaft with hand to make it stand Disassemble synchronizer assembly liking that shown in figure Transmission Disassemble assembly 171 ...

Page 183: ...t hurt its surface Take down clip spring liking that shown in figure Disassemble interlocking bracket shift swing lever spring and A gasket liking that shown in figure Disassemble shift swing lever and connecting bolt Disassemble clip spring liking that shown in figure and dis connect it Transmission Disassemble assembly 172 ...

Page 184: ...f cover from shift cover and take down gasket liking that shown in figure Take out the shift cover oil seal with wrench liking that shown in figure Take out the other oil seal on shift cover with same method Transmission Disassemble assembly 173 ...

Page 185: ...ing of speedmeter driving wheel side liking that shown in figure Take down driving gear of speedmeter Disassemble by sequence the fastening bolts of differential Take out elastic cylindrical pin with pin taker and take out second planetary gears and gaskets two axle shaft gears and gaskets and planetary gear shaft by sequence Transmission Disassemble assembly 174 ...

Page 186: ...is value it is necessary to change synchronous loop Check the distance between gear cover and shift fork with clearance gauge its maximal value is 0 35mm or it is neces sary to change gear cover or shift fork Measure the minimal diameter of abrasion surface A of input shaft with micrometer its value is 33 985mm and the mini mal diameter of surface B is 30 985mm if the value exceeds this scope it i...

Page 187: ... gear liking that shown in figure the maximal flop value is 0 056mm Take down tapered bearing liking that shown in figure Note 1 Hold the lower end of shaft to prevent it falling 2 Clamp inner ring of bearing to make it reliable Disassemble tapered bearing on the other end with same method 1 gear 2 gear Transmission Disassemble assembly 176 ...

Page 188: ...ft to prevent it falling Move first and second gear to first gear Disassemble third gear with pressure machine and hold the lower end of shaft to prevent it falling at this time disassemble roller bearing synchronous loop and second gear Disassemble clip spring with clamp spring pliers and do not hurt bearing surface of shaft Transmission Disassemble assembly 177 ...

Page 189: ...s necessary to change the synchro nous loop Check the clearance between gear cover fork slot and fork with clearance gauge its maximal value is 0 35mm if exceed ing this value it is necessary to change fork Check the abrasion and damaged situation of output shaft and measure the exterior diameter of bearing platform with micrometer its minimal value is 33 985mm if measured re sult is less than thi...

Page 190: ... stretched Note do not hurt the shaft surface Assemble synchronous ring roller bearing and second gear Press third gear in output shaft with pressure machine liking that shown in figure its direction likes that shown in figure Use pressure machine to press forth and fifth gear in output shaft with the method in figure its direction likes that shown in figure Transmission Disassemble assembly 179 ...

Page 191: ...n in figure Note adjust to bearing inner ring and put it into position Assemble roller bearing third gear and third gear synchro nizer loop liking that shown in figure and assemble synchro nizer assembly by the direction in figure Transmission Disassemble assembly 180 ...

Page 192: ...ssemble third and forth ssynchronizer assemble by the direction in figure at this time assemble forth gear on input shaft Assemble fixting ball liking that shown in figure and assemble fifth gear stop gasket in input shaft by this ball Transmission Disassemble assembly 181 ...

Page 193: ...e roller bearing fifth gear fifth gear synchronous loop with same method above Assemble synchronizer assembly with pressure machine by the direction in figure Press radial ball bearing in with pressure machine Transmission Disassemble assembly 182 ...

Page 194: ...apered bearing in output shaft with method in figure Note make sure the bearing inner ring has been put into position Press rear tapered bearing in output shaft with method above Note make sure the bearing inner ring has been put into position Transmission Disassemble assembly 183 ...

Page 195: ...r oil seal liking that shown in figure and the distance from oil seal end surface to oil seal hole end surface is 0 0 5mm after pressing it in Assemble the gasket on shift guide shaft and assemble dust proof cover in shift guide shaft then assemble them on shift cover Press a new clip spring on shift reverse shaft liking that shown in figure Transmission Disassemble assembly 184 ...

Page 196: ...s liking that shown in figure Assemble first and second gear fork on fork shaft and put fork shaft in first and second gear cover then assemble first and second guide block at the same time tighten the bolts the torque is 16Nm Press elastic cylindrical pin in guide block liking that shown in figure Transmission Disassemble assembly 185 ...

Page 197: ...ar fork shaft liking that in figure Assemble reverse gear block and fork shaft clip spring liking that shown in figure Assemble third and forth gear fork shaft in clutch shell body and assemble third and forth shift fork in gear cover slot and tighten them Bolt torque is 16N m Transmission Disassemble assembly 186 ...

Page 198: ...erse gear block in corresponding hole of reverse gear swing arm bracket Put the head of reverse gear swing arm in the slot between those reverse gear shafts liking that shown in figure Assemble reverse gear fork spring and fifth reverse gear guide block on fifth reverse fork shaft and put fifth reverse gear pulling fork in fifth gear cover then assemble them in clutch shell Transmission Disassembl...

Page 199: ... shift swing lever on shift reverse shaft by the sequence in figure then press elastic cylindrical pin in the hole of shift swing lever at the same time the distance from its end surface to hole should be 0 0 5mm after pressing it in Press in a new clamp spring liking that shown in figure Take out oil with the method in figure and assemble a new oil seal in transmission shell body Transmission Dis...

Page 200: ...kets in differential shell and put planetary gear shaft lastly assemble a new elastic cylindrical pin liking that shown in figure Assemble differential gear ring by the direction in figure and screw connecting bolts of differential Assemble speedmeter driving gear by the direction in figure Transmission Disassemble assembly 189 ...

Page 201: ...ng bolts liking that shown in figure its torque is 29N m Spread anti loose fastening glue on connecting bolts of re verse shaft and use a new gasket to cover on the bolt then tighten reverse shaft on transmission shell its torque is 29N m Assemble shift fixing assemble on transmission shell its torque is 37N m Transmission Disassemble assembly 190 ...

Page 202: ...earing in support cover of output rear shaft by the direction in figure lastly press down end cover and tighten connecting bolts of end cover their torque is 12N m Transmission Assemble the assembly Transmission Assemble the assembly 191 Connecting bolt of end cover End cover Stop disc spring of output shaft bearing Support cover of output rear shaft ...

Page 203: ...ion system Malfunction phenomenon table Following table could help you find the reason of malfunction And the number in table is only used for indicat ing possible preferred sequence Please check each part by sequence if necessary change this part Malfunction phenomenon Possible malfunction part Referred page 1 Tyre tyre pressure is wrong 109 2 Power steering oil level low 200 3 Driving belt loose...

Page 204: ...stem Steering column Steering system Inspection on automobile 1 Check the free clearance of steering wheel a Park the automobile and the front wheels are towards the front b Turn the steering wheel to left and right with your fingers lightly and check the free clearance Maximal free clearance 30mm Maximal free clearance 193 ...

Page 205: ... it is necessary to put the surface of airbag assembly towards the upside ñ ñ ñ ñ ñ Do not disassemble airbag assembly Note when disassembling airbag assembly pay attention not to pull airbag wiring harness 3 Disassemble steering wheel assembly 67100001 a Disassemble the fixed screw cap of steering wheel b Make corresponding marks on steering wheel and main shaft assembly c Use special tool to dis...

Page 206: ...isassemble dust proof cover in steering column Disassemble two screw caps then take down dust proof cover in steering column 10 Disassemble steering shaft assembly a Disconnect joint and fixed clap of wiring harness b Loosen three fixed bolts of steering column assembly 11 Disassemble the clamp of ignition switch 68000020 a Use central punch to make hole on the central part be tween two tapered bo...

Page 207: ...core and key assembly 68000019 Assemble ignition switch with locking core and key assembly with two screws 16 Assemble ignition switch key tank assembly a Make sure ignition switch key tank assembly locates at ACC position b Assemble ignition switch key tank 17 Steering locking function a When taking out the key check whether steering locking organization is locked b When inserting the key and tur...

Page 208: ... 5 rounds 24 Assemble steering wheel assembly 67010001 a Align the mark on steering wheel and main shaft assembly b Assemble the fixed screw cap of steering wheel c Connect the joint 25 Assemble safety airbag assembly at the side of driver 67010011 Warning z Forbid using SRS parts on other automobiles when changing any part it is necessary to use new product z If safety airbag assembly at the side...

Page 209: ...bag system MR7180 equips with SRS auxiliary protection system such as safety airbag at the side of driver and safety airbag at the side of passenger if repairment does not accord with correct sequence it might incur SRS explodes suddenly in repairing term to make heavy accident Before repairing including disassem bling or assembling checking or changing parts it is necessary to read the notes in c...

Page 210: ...Wheel alignment wrong 87 3 Steering column bent 4 Power steering gear 205 1 Steering system joint abraded 2 Lower control arm ball head abraded 99 Clearance is too big 3 Middle shaft sliding fork abraded 4 Front wheel bearing abraded 123 5 Power steering gear 205 1 Power steering oil level low 200 Abnormal noise 2 Power steering joint abraded 3 Power steering oil pump 203 4 Power steering gear 205...

Page 211: ...eft or right to bottom and keep this state for 2 3 seconds then turn it to the other direction for 2 3 seconds 2 Repeat 1 for several times g Engine extinguishes h Check whether there is any foam or emulsification phenomenon If there is any foam or emulsification phenomenon and it is necessary to exhaust air second time it is necessary to check whether the system has any leakage i Check the oil le...

Page 212: ...rring to page 205 b Connect special tool liking that shown in figure Note when checking the valve of special tool should be opened c Exhaust the air in power steering system d Start the engine and keep it at idling speed e Turn steering wheel from left bottom to right bottom for several times to make oil temperature Power steering Poser steering system increase Oil temperature 80 C f Keep the engi...

Page 213: ... Connect oil pressure supply pipe with power steering gear referring to page 205 l Exhaust the air in power steering system 5 Check the steering force a Put the steering wheel at central position b Disassemble safety airbag assembly at the side of driver c Start engine and make it run at idling speed d Measure the steering force of two directions Steering force reference 5 5 Nx x x x xm Hint befor...

Page 214: ...ar bracket of power steering pump Disassemble the bolt and rear bracket of power steering pump 7 Disassemble power steering oil pump assembly 64000132 a Disconnect the joint of oil pressure switch b Disassemble two bolts two screw caps then take down the power steering oil pump assembly 8 Assembly power steering oil pump assembly a Assemble power steering oil pump assembly with two bolts and two s...

Page 215: ...h only this could make practical torque value 11 Connect the N0 1 oil pipe of oil storage tank to power steering oil pump assembly Connect oil pipe with fixed clamp 12 Assemble driving belt 13 Assemble front wheel Torque 103 10 Nx x x x xm 14 Add power steering oil 15 Exhaust the air in power steering system 16 Check whether there is any oil leakage 17 Assemble right bottom defender board of engin...

Page 216: ...emble sliding shaft 6 Disassemble front wheel 7 Disassemble right bottom defender board 68000004 8 Disassemble left bottom defender board 68000003 9 Disconnect left end terminal of transversal lever a Disassemble cotter pin and screw cap b Use special tool to disassemble the left end terminal of transversal lever from steering knuckle Hint disassemble the other with same method 10 Disassemble righ...

Page 217: ... one bolt and two nuts and disassemble control arm from left steering knuckle Hint disassemble the other with same method 14 Disassemble engine cover assembly 15 Support engine assembly 16 Disassemble auxiliary automobile bracket assem bly 64000087 a Disassemble two bolts then disassemble side rail from right front engine suspension b Disassemble two bolts then disassemble carling from au tomobile...

Page 218: ...21 Disassemble left transversal lever ball head a Make mark on transversal lever ball head and gear end b Loosen fixed nut then disassemble transversal lever ball head and fixed nut Hint disassemble the other side with same method 22 Disassemble right transversal lever ball head 23 Check left transversal lever ball head a Insure the left transversal lever ball head is clamped on pliers b Assemble ...

Page 219: ... steering gear b Use wrench 22mm to fix steering gear then use special tool to disassemble gear terminal lever Note use special tool by the direction in figure Hint Make mark on RH and LH gear terminal lever 28 Assemble the parts of steering gear terminal lever a Assemble new claw gasket and assemble gear terminal lever temporarily Hint Align pliers claw of gasket with steering gear concave slot b...

Page 220: ... shown in figure bend iron wire to rotating di rection to prevent it from hurting dust proof cover Hint assemble the other side with same method 30 Assemble No 1 dust proof cover of steering gear 31 Assemble left ball head of transversal lever a Screw locking cap and transversal lever ball head in gear terminal lever until aligning the mark b After adjusting front wiring harness tighten the screw ...

Page 221: ...ck the A bolt and B bolt temporarily c Use special tool to align the left side of auxiliary bracket with the hole of body then lock the A bolt and B bolt Torque A bolt 157 10 Nx x x x xm B bolt 113 10 Nx x x x xm d Use special tool to align the right side of auxiliary bracket with the hole of body then lock the A bolt and B bolt Torque A bolt 157 10 Nx x x x xm B bolt 113 10 Nx x x x xm e After co...

Page 222: ... steer ing gear 64000131 a Connect the in out oil pipe fixed clamp of power steering gear with bolt Torque 7 8 Nx x x x xm b Use special tool to connect the in out oil pipe assembly of power steering gear Torque 41 Nx x x x xm Hint z Use the torque wrench whose lever length is 345mm z Special tool should be parallel with torque wrench only this could make practical torque value Hint connect the ot...

Page 223: ...t wheel face the front Hint lift up front wheel shaft 48 Assemble helix cable assembly equipping with SRS 49 Assemble steering wheel assembly 67010001 a Align the mark between steering wheel and main shaft of steering column b Lock the fixed screw cap of steering wheel temporarily 50 Add power steering oil referring to page 200 51 Exhaust the air in power steering system referring to page 200 52 C...

Page 224: ...brication So it is necessary to avoid 7 Do not open the high pressure valve of filling instru ment package when compressor is working If opening the valve at this time Refrigerant will flow back into refrigerant tank to incur the tank will break So only the low pressure valve could be opened or closed 8 Do not fill Refrigerant too much Too much refrigerant will make many problems such as lack cool...

Page 225: ...ction between terminals If the function does not accord with the regulation it is necessary to change pressure switch Inspection 1 1 1 1 1 No 1 thermal resistor a Check the resistance between No 1 terminal and No 2 ter minal of No 1 heat sensitive resistance at different temperatures liking that shown in figure Conduc tion Not conduc tion 214 Resistance 2 2 2 2 2 5 5 5 5 5 1 1 1 1 1 5 5 5 5 5 5 5 ...

Page 226: ...r bubble disappears 4 There is obvious temperature difference Applicable or too much Referring to item 5 and 6 on outlet and enter of compressor 5 Window becomes clear after air Too much 1 Reclaim refrigerant conditioner is closed 2 Exhaust air and supply applicable clean refrigerant 6 After air conditioner is closed refrigerant Applicable makes bubble then becomes clear When environment temperatu...

Page 227: ...l e n e w refrigerant z Dryer locates at full humidity state z Water vapor of refrigerant freezes on the outlet orifice of expansion valve to ob stacle freezing cycle Phenomenon Possible reason Diagnose Method 3 Lack refrigerant Situation too cold periodically then lose cooling degree z The pressure of high and low pressure end is low z There is air bubble on window z Refrigerant leaks Some part o...

Page 228: ...ure side is vacuum and pressure at high pressure side is low z The pipeline of front and rear end of expansion valve or adjuster frosts or dews z Refrigerant flow in cool ing system is obstructed by water vapor or dust z Refrigerant flow is ob structed by expansion valve 1 Check the expansion valve 2 Remove the dirt in ex pansion valve with high pressure air 3 Change condenser 4 Take out vacuum an...

Page 229: ...gine has malfunction Phenomenon Possible reason Diagnose Method State cooling degree is not enough z The pressure of high and low pressure end is high z Pipeline of low pressure end is too hot to contact z There is bubble on window Air enters cooling system 1 Check whether the Re frigerant oil is too dirt or lack 2 Take our vacuum and fill new refrigerant z There is air in cooling system z It does...

Page 230: ...en degree of expansion valve is too big Phenomenon Possible reason Diagnose Method State cooling degree is not enough z The pressure of low pressure end is too high z The pressure of high pres sure end is too low There is inner leakage in compressor R e p a i r o r c h a n g e t h e compressor z Compressor is bad z Expansion valve leaks or sliding part is damaged Phenomenon Possible reason Diagnos...

Page 231: ...Air conditioner Refrigerant Reading of filling meter referred value 220 Pressure of low pressure side Fan HI phase Blower LO phase Pressure of high pressure side ...

Page 232: ...inguish the engine d Drain the refrigerant 2 Fill refrigerant a Use vacuum pump to take out vacuum b Fill the refrigerant HFC 134a R134a Standard quantity 660 10g 3 Heat the engine 4 Check whether the refrigerant leaks Air conditioner Refrigerant 221 Bubble disappearing point Too much filling refrigerant Increase 100g Filling quantity of refrigerant Pressure at the high pressure side Refrigerant q...

Page 233: ...er Refrigerant pipeline Refrigerant pipeline Parts Regulated torque 222 Ü Ü Ü Ü Ü Â Â Â Â Â ÂÝ ÂÝ ÂÝ ÂÝ ÂÝ Ä Ä Ä Ä Ä Refrigerant low pressure hose Pipeline nut Refrigerant high pressure hose Refrigerant liquid pipe ...

Page 234: ...sassemble control box of air conditioner Disconnect flat linking wire and disassemble control box of air conditioner 7 Disassemble electric circuit board of air conditioner control module a Disassemble two screws b Disassemble electric circuit board from air conditioner con trol box 8 Disassemble control panel wiring of air conditioner a Disassemble two screws b Disassemble control panel wiring of...

Page 235: ...ble engine ECU a Disassemble two fixed clamps and engine ECU cover b Disassemble two screws and disconnect engine ECU 5 Disassemble panel assembly a Disassemble the bolts and screws from panel b Disassemble the screws and air conduct 6 Disassemble fan assembly a Disassemble fixed clamp and turn over the carpet b Disassemble fixed claw and disconnect joint plug Air conditioner Fan assembly Fixing c...

Page 236: ...clamp d Disassemble servo motor assembly joint of in out air cycle flow choke e Disassemble three screws and bolts f Disconnect fixed claw and disassemble electric engine of fan g Disassemble fan assembly 225 Fixing claw Fixing clamp Fixing claw Locking point ...

Page 237: ...ric engine assembly of indoor cycle flow choke 8 Disassemble fan motor assembly Disassemble three screws and fan electric engine assembly 9 Disassemble fan motor control assembly automatic air conditioner Disassemble two screws and fan electric engine control assembly Air conditioner Fan assembly 226 ...

Page 238: ...er intake hose of heating Slide out fixed clamp and disassemble water intake hose of heating 7 Disassemble cathode wire of battery 8 Make front wheels face the front 9 Disassemble safety airbag assembly at the side of driver 10 Disassemble steering wheel 11 Disassemble combination instrument cover 68000077 12 Disassemble combination instrument assembly 68000081 13 Disassemble ventilation orifice a...

Page 239: ... of shift organization 68000076 26 Disassemble air conditioner control panel assembly 67000148 27 Disassemble the assemble bracket of CD machine 28 Disassemble ventilation pipe assembly of evaporator 67000149 29 Disassemble air conditioner control assembly 30 Disassemble parking brake lever hole cover 31 Disassemble auxiliary panel assembly 32 Disassemble step trim board of right front door 680100...

Page 240: ...ness c Disassemble five bolts and panel framework body assembly 41 Disassemble wind outlet of Defogger Release five fixed claws and disassemble wind outlet of de fogger 42 Disassemble control cable assembly of air mixing flow choke manual air conditioner a Disassemble pull cable from fixed clamp b Disassemble control cable of air mixing flow choke 43 Disassemble engine ECU Disassemble two bolts an...

Page 241: ...sassemble two screws c Disconnect fixed claw and disassemble air conditioner central heating core assembly 46 Disassemble servo motor of module state flow choke automatic air conditioner Disassemble three screws and servo motor of module state flow choke Air conditioner Air conditioner central heating core assembly 230 Fixing claw Fixing claw ...

Page 242: ...ir conditioner pipeline 49 Disassemble expansion valve a Disassemble expansion valve from air conditioner group b Disassemble two O shape rings from air conditioner pipeline 50 Disassemble No 1 air conditioning heat sensitive resistance 51 Disassemble evaporator a Disassemble six screws and air conditioning group parts b Pull out evaporator 52 Disassemble central heating core Disconnect fixed claw...

Page 243: ...d Refrigerant oil on two O shape loops and assemble it on air conditioner pipeline Refrigerant oil ND OIL No 8 or other products with same grade b Use planetary wrench 5 0mm to assemble air conditioner pipeline with two planetary bolts Torque 3 5 Nx x x x xm c Assemble two screws and extending cover 55 Assemble panel framework body assembly Assemble panel strengthening beam and five bolts 56 Assem...

Page 244: ...le upper panel assembly 59 Assemble air conditioner control assembly 60 Assemble helix cable 61 Assemble steering wheel 62 Check whether the steering wheel position is right 63 Check horn button assembly 64 Assemble horn button assembly 65 Check SRS warning light 66 Assemble refrigerant No 1 low pressure hose a Spread Refrigerant oil on new O shape loop and assemble it on hose b Assemble refrigera...

Page 245: ...n system 5 Disassemble right bottom defending cover of engine 6 Disassemble driving belt 7 Disassemble compressor and electromagnetic clutch a Disconnect the joint b Disassemble three screws and electromagnetic clutch 8 Check the Refrigerant oil 234 When upgrading compressor assembly it is necessary to reclaim the refrigerant in system at first Refrigerant oil quantity added by new compressor shou...

Page 246: ...il on new O shape loop and assemble it on No 1 refrigerant high pressure hose Refrigerant oil 100PG c Connect No 1 refrigerant high pressure hose to compres sor and electromagnetic clutch and assemble the bolts Torque 9 8 N m 12 Assemble refrigerant No 1 low pressure hose a Disassemble the cover on pipeline joint b Spread Refrigerant oil on new O shape loop and assemble it on No 1 refrigerant low ...

Page 247: ...assembly 2 Recycle the HFC 134a R134a 3 Disassemble the Refrigerant liquid pipe A a Disassemble the bolt from the condenser assembly and disconnect the Refrigerant liquid pipe A b Disassemble the O shape ring from the Refrigerant liquid pipe Notice The pipeline should be covered immediately to prevent damp or dust from getting into the system 4 Disassemble the Refrigerant NO 1 high pressure hose a...

Page 248: ...er b Put the O shape ring in the cover c Spread freezing lubricant at the connecting part between the O shape ring and the cover Refrigerant oil 100PG d Use the 10mm hexagon wrench key to assemble the cover to condenser assembly Torque 12 3 N m 8 Assemble condenser assembly 9 Assemble Refrigerant NO 1 high pressure hose a Disassemble the cover from the tie in of the pipe b Daub enough Refrigerant ...

Page 249: ...efrigerant liquid pipe A c Spread enough Refrigerant oil to lubricate at the conencting part between the O shape ring and the cover Refrigerant oil 100PG d Use the bolt to connect the Refrigerant liquid pipe A with condenser assembly Torque 5 4 N m 11 Fill with Refrigerant Regulated quantity 660 10g 12 Warm the engine 13 Check whether the Refrigerant leaks 238 ...

Page 250: ...bag assembly and gas generator in it Forbid connect AC or DC with over 20V with ECU to avoid damage Supplemental restraint system Note Warning This product is the SRS supplemental restraint system equipped by JILI YUANJIN vision type automobile when the automobile frontal face is impacted heavily this product could reduce the possible hurt for driver and passen ger at the front seat but this produ...

Page 251: ... Safety airbag at the side of passenger Safety airbag at the side of driver Helix cable Airbag controller 1 All safety airbag joints should be yellow to be easy to distinguish the joints on other automobile parts this could guarantee the safety performance and reliability of safety airbag joint each kind of joint has special function and design 240 Number a b c d e Function Disassemble airbag suba...

Page 252: ... it from releasing 2 Airbag anti explosive organization Each joint has a short circuit sheet when the joint is disassembled short circuit sheet will connect the terminal of device power supply with that terminal of igniter Mother joint Father joint Supplemental restraint system Note 241 Body Body Body When connecting the joint When disconnecting the joint Short circuit spring sheet Short circuit s...

Page 253: ...ing wheel and instrument panel After airbag charging is closed the gas ejects from the gas outlet at the side or at the back of airbag II Disassemble the connecting joint of lower helix cable and wiring harness of steer ing wheel 1 Put your finger on sliding block 2 Move the sliding block to release the clasp 3 Pull out the male joint Liking that shown in figure some joints of wiring harness use t...

Page 254: ...rm inserting it until locking after assemble pull it to check whether it is locked when locking confirm exterior joint returns to former position at the same time assembling sound could hear Hint When moving the sliding block do not contact it Pay attention to do not distort the release board if release board is distorted it is neces sary to change it with new helix cable Figure 3 Figure 4 1 Inser...

Page 255: ...gain this self checking could be made six times if indicating light illuminates all the time after six times there is some malfunction in power supply b Assembling malfunction of airbag subassembly Assembling malfunction of airbag subassembly is that malfunction which only needs to change or repair airbag subassembly without needing to change ECU including the situation that airbag subassembly is ...

Page 256: ...function in SRS is Assembling malfunction information of subassembly could see follow table 1 Table1 Assembling malfunction information indicating table for airbag subassembly Schematic drawing for slow flash indicating light Supplemental restraint system Malfunction treatment 245 Ignition switch ON Illuminate Extinguish Number Malfunction type Slow flash times N times Remark 1 Igniter at the side...

Page 257: ...1 Electronic acceleration offset malfunction Short short short and long 0001 2 Electronic acceleration self checking malfunction Short short long and short 0010 3 SCM inner RAM is wrong Short short long and long 0011 4 Inner parameter is wrong Short long short and short 0100 5 Inner malfunction or acceleration storage space is full and ignition record has been made Short long short and long 0101 6...

Page 258: ... 11 Ignition circuit 3 pre tension safety belt at the side of driver connects with the grounding OK 12 Ignition circuit 3 pre tension safety belt at the side of driver connects with the power supply OK 13 Ignition circuit 4 pre tension safety belt at the side of passenger the resistance is too high or open circuit OK 14 Ignition circuit 4 pre tension safety belt at the side of passenger the resist...

Page 259: ...viding electricity for safety airbag controller KD4 1 disables indicating light illumi nates by the automatic light driving function Inner working voltage loses indicating light illuminates usually New setup caused by the unsuccessful watchdog trigger indicating light flashes Micro processor does not work indicating light illuminates usually Insert of connecter of safety airbag controller KD4 1 is...

Page 260: ...with new safety airbag module forbid repairing it Interruption situation could happen between safety airbag module and steering wheel lower defend ing cover and when new airbag module is assembled on steering wheel its surrounding clearance must be even Assemble and disassemble of driver airbag module should accord with correct step to work 3 Automobile is impacted and airbag explodes a Make malfu...

Page 261: ...tortion and crack Check whether wiring harness of safety airbag has any cut crack or the joint has any flaw If there is any crack on connector between panel and safety airbag it is necessary to change it with new product When new airbag module is assembled on its position its surrounding clearance should be even Assemble and disassemble of passenger airbag module should accord with correct step to...

Page 262: ...and grounding system of instrument package fuse then make step 5 2 Check the bulb Warning wrong treatment for safety airbag system parts will incur safety airbag and pre tension safety belt are opened accidentally this might happen heavy accident Please read service warning of safety airbag system before disposing safety airbag parts a Set ignition switch at LOCK position b Cut off cathode wire of...

Page 263: ... of diagnostic interface diagnose two ends of K wire Yes make next step No repair or change the wiring harness then make step 5 j Guarantee cathode of battery is cut off and keep this state for one minutes at least cut off connec tor of ECU k Disconnect the plug of instrument package l Check whether it conducts between ECU plug voltage K wire airbag indicating light terminal and plug of instrument...

Page 264: ...cking DTC makes the inspection it might incur wrong operation to hurt human or system when making this inspection so it is necessary to make preparation before the inspection Inner circuit of electronic control unit of safety airbag system has malfunction Power voltage of electronic control unit of safety airbag system is too low Test condition Warning Test condition for this malfunction is the ma...

Page 265: ...and keep this state for one minute at least c Disassemble the shell body of steering column d Loosen the connector of helix cable e Disassemble glove box with safety airbag assembly at the side of passenger f Loosen the connector of safety airbag assembly at the side of passenger g Disassemble left inner trim board h Loosen the connectors of all safety airbag system units i Assemble cathode cable ...

Page 266: ...refully Refer to repairing warning of safety airbag system Is every related part of helix cable normal Whether the relationship between pins is normal whether there is any unnecessary short circuit open circuit and other phenomenon Normal make next step Abnormal change the helix cable Refer to safety airbag system disassembling and assembling of helix cable 2 Confirm whether the malfunction is on ...

Page 267: ...e treatment it is necessary to read repairing warnings carefully Refer to repairing warning of safety airbag system Malfunction of safety airbag at the side of passenger resistance is too big or too small short circuit grounding and so on Test condition Warning If the treatment is wrong safety airbag assembly and pre tension safety belt might be triggered to unfold to make heavy human hurt so befo...

Page 268: ... the side of passenger 3 Check the wiring harness between safety airbag assembly at the side of passenger and electronic control unit of safety airbag system a Set ignition switch at LOCK position b Loosen the cathode cable of battery and keep this state for one minute at least c Disassemble the shell body of steering column d Loosen the connector of helix cable e Loosen the connector of safety ai...

Page 269: ...ety airbag system unit has malfunction 7 Malfunction of pre tension safety belt Diagnostic procedure 1 Check the connector warning of safety belt pre tension If the treatment is wrong pre tension safety belt might be triggered to unfold to make heavy hu man hurt so before the treatment it is necessary to read repairing warnings carefully Refer to repairing warning of safety airbag system a Set the...

Page 270: ...tem unit and grounding position has malfunction The circuit between impact output circuit and electronic control unit of safety airbag system happens open circuit or short circuit Circuit between safety airbag system unit and grounding position happens open circuit or short circuit Safety airbag system unit has malfunction 1 Check whether this airbag controller has impact output function a Set ign...

Page 271: ...or power supply 1 When safety airbag has been unfolded Following parts should be changed with new ones a Safety airbag assembly at the side of passenger b ECU c Safety airbag assembly at the side of driver d Pre tension safety belt at the side of driver and passenger Check the following parts if they are abnormal change them with new ones a Helix cable b Steering wheel steering column combination ...

Page 272: ...s of assembling operation 1 When assembling ECU assembly pay attention to that ECU assembly could not be impacted 2 Inspection after the assembling a Set the ignition switch at ON position b Indicating light illuminates at 7 second and continues to extinguish c If it does not extinguish it is necessary to check and remove malfunction Note if ECU could not be assembled correctly safety airbag will ...

Page 273: ...bination switch 8 Disassemble helix cable 1 Slide the upper cover of combination switch 2 Disassemble airbag joint from helix cable 3 Disassemble three fixed claws and helix cable Note disassembled helix cable should be stored in clean and dry environment 9 Check the helix cable 1 When assembling new helix cable check whether the yel low fixed clamp on helix cable is good if yellow clamp drops ple...

Page 274: ...n nected to its position 9 After assembling use malfunction diagnostic tool or malfunction indicating light to check and confirm the malfunction has been removed 3 Make three fixed claws mesh steering column When changing with new helix cable it is necessary to disassemble yellow clamp before assembling 4 Insert the plug of airbag wiring harness in the plug of helix cable and make this connection ...

Page 275: ...reatment before exploding 1 Park the automobile on flat place 2 Disassemble the cathode and anode of battery and disassemble the battery from automobile Note do not work until disassembling the cathode and anode of battery for 60 seconds 3 Safety airbag assembly should be unfolded by following sequence 2 Safety airbag assembly at the side of driver 1 Disassemble three screws and lower cover of com...

Page 276: ...wiring harness 3 Connect the conversion wiring harness of safety airbag with one wiring harness with over 10 m used for unfolding and the connecting part should be twisted with insulation adhesive tape to insulate and prevent from wrong unfolding for static 4 Connect conversion wiring harness of safety airbag on yellow joint of helix cable then lead it out of automobile with unfolding wiring harne...

Page 277: ...the wiring harness twisted on fixed bolts to avoid them loosen if wiring harness loosen they might incur airbag assemble loosens for shake when airbag explodes This is very dangerous d Place the airbag module upwards and bind the con necting bolts at the two sides of airbag module in wheel hub bolt holes of wheel Adjust the fixed position of airbag module to make the joint hang in the wheel hub ho...

Page 278: ...to keep upper surface face upwards Supplemental restraint system Scrap treatment for safety airbag Old tire without hud Wiring harness for explosion Wiring harness for explosion Left and right small bracket 267 5 Fix three scraped old tyres without wheel hub on the fixed tyre of safety airbag assembly at the side of driver The terminal end of unfolding wiring harness is 10m apart from wheel of fix...

Page 279: ...irbag module in wheel tightly After twisting the tyre twice with the wiring har ness twisted on middle small bracket bind it on tyre After twisting the tyre twice with the wiring harness twisted on left and right small bracket bind it on tyre Adjust the fixed position of airbag module to make the joint hang in the wheel hub hole of wheel Then fix the wiring harness getting through the center of le...

Page 280: ... wiring harnesses to bind tyre tightly if shake is produced when airbag explodes airbag module will break off to make danger Width 185mm Inner diameter 360mm 6 Cut off the joint of wiring harness used for unfolding of safety airbag assembly at the side of driver at the place apart from the automobile then connect it with two ends of battery 7 Treatment for explosive module Disassemble the safety a...

Page 281: ...tool at the same time the environment implementing this operation should be apart from electronic interruption When exploding the safety belt pre tension crimper the environment implementing this operation should be 10m apart from safety belt pre tension crimper assembly When exploding the safety belt pre tension crimper safety belt will be very hot please do not dispose it in 30 minutes after exp...

Page 282: ...f rear door 3 Disassemble lower fixed bolts and trim cover of safety belt 4 Disassemble lower inner trim board of middle column 5 Liking that shown in figure disassemble the joint of safety belt pre tension crimper c Assemble special tool 1 Assemble lower fixed bolts and trim cover of safety belt 2 Connect two special tools with lower fixed bolts and trim cover of safety belt Note to avoid damagin...

Page 283: ... cut off safety belt at its position closing to shrinker b Confirm the function of special tool c Assemble special tool 1 Connect two joints of special tool to the joint of safety belt pre tension crimper Note to avoid damaging the joint and wiring har ness of special tool do not lock the twice lock of dual lock organization 2 Place the safety belt pre tension crimper on ground and cover it with t...

Page 284: ... bind the bag for treatment with other parts N m Regulated torque Trim board of pedal of front door Front safety belt locker assembly Trim cover of safety belt lower fixed bolt Trim board of pedal of rear door Front safety belt crimper assembly Lower inner defending board of middle column Trim cover of safety belt upper fixed bolt 41 Q184C1020 41 Q184C1020 41 Q184C1020 41 Q184C1020 273 ...

Page 285: ...per assembly 68010044 a Use right angled screwdriver to disassemble trim cover of upper fixed bolt of safety belt Hint use adhesive tape to twist its top end before using b Disassemble the bolts and crimper assembly c Use right angled screwdriver to disassemble trim cover of upper fixed bolt of safety belt Hint use adhesive tape to twist its top end before using d Disassemble the bolts and lower f...

Page 286: ...6 4 Step bolt M8 20 of hexagon flange face 68000203 5 Cushion assembly of rear row seat 68010074 6 Rear platform with sun blind assembly 68010032 7 Plastic clamp of column trim board 68000089 8 Rear safety belt crimper assembly 68010048 9 Middle waistband of rear row safety belt with locker assembly 68010043 10 High mount brake light assembly 67010008 N m Regulated torque 5 4 9 8 2 6 1 0 7 1 3 8 4...

Page 287: ...Combination part of Hexagon head bolt and flat washer M6 14 Q1400614 6 Backrest assembly of rear row seat 68010076 7 Step bolt of hexagon flange face 68000203 8 Combination part of hexagon bolt with flat big washer M10 1 25 22 Q1401022 9 Cushion assembly of rear row seat 68010074 10 Rear safety belt crimper assembly 68010048 11 Middle waistband of rear row safety belt with locker assembly 68010043...

Page 288: ...t 68010076 6 Disassemble high mount brake light assembly 68010008 7 Disassemble inner trim board assembly of right rear column 68010027 8 Disassemble inner trim board assembly of left rear column 68010026 9 Disassemble rear platform with sun blind assembly 68010032 a Use special disassembling tool to disassemble three fixed clamps b Pull out safety belt from the clearance then disassemble rear pla...

Page 289: ...k the inclining angle when ELR starts to lock 1 Confirm whether safety belt could be pulled out if the angle exceeds 45 Note do not disassemble the crimper b Use the bolts to assemble rear safety belt crimper assembly Torque 41 N m c Use the bolts to assemble floor side clamp Torque 41 N m d Check the lock of ELR 1 After safety belt is assembled on automobile check whether the safety belt could be...

Page 290: ...e of pressured gas in halogen bulbs the bulb of front assembled headlamp and front fog light the bulb may explode and pieces of broken glass disperse around So deal with it carefully c If the time after disassembling the bulb from lamp carrier is too long the mirror may be polluted by dirties or hydrosphere You should prepare a new bulb then replace it d Replace it with the lamp of same wattage e ...

Page 291: ...turn light switch 2 wiring harness 3 bulb 1 turn light switch 2 wiring harness 1 bulb 2 wiring harness The light control switch switches on the front fog lights do not light front combination lights are normal Lamp switch turn to HEAD front fog lights do not light front combination light do not light Only one front fog light do not light Rear fog lights do not light front combination lights are no...

Page 292: ...assenger side light does not light 1 room light fuse 1 driver cap side door control switch 2 wiring harness 3 bulb 1 right front door control switch 2 wiring harness 3 bulb 1 right rear door control switch 2 wiring harness 3 bulb 1 left rear door control switch 2 wiring harness 3 bulb 1 bulb 1 Door control switch 2 Wire harness 1 ignition switch 2 fuse 3 light relay 4 wiring harness 1 door fuse 2 ...

Page 293: ...ct rear fog light switch a inspect rear fog light wiring 1 Disassemble the joint from switch sides and inspect the joint from wiring harness as following table Avometer terminals 1 earth 2 earth 3 earth 5 earth 6 earth 7 earth condition normal light control switch OFF ON normal light control switch OFF ON front fog light switch OFF ON normal regular situation conduction 0V 10 14V 10 14V not conduc...

Page 294: ...er room light turns off immediately Inspect 1 Front combination headlight dimmer switch assembly a Inspect the conduction of light control switch 1 Inspect switch on every positions the conduction among terminals as following table Switch positions Avometer terminals regular situations OFF not conduction Position light 12 6 conduction Lamp 12 6 conduction Lamp 7 10 conduction b Inspect conduction ...

Page 295: ...ction among terminals as following table Standard 3 Room front top light assembly 67010007 equipped with electric sunroof 67010009 a Inspect the conduction of room front roof light 1 Inspect the conduction between terminal 1 and terminal 2 when switch works Standard ON conduction OFF not conduction 4 Room front top light assembly 67010005 do not equipped with electric sunroof a Inspect the conduct...

Page 296: ...duction 9 Front fog light relay 67000071 a Inspect the conduction of front fog light relay 1 Inspect the conduction among terminals Standards Avometer terminals regular situations 1 2 conduction 3 5 not conduction 10 Inspect rear fog light switch of instrument block left switch units 67010003 a Inspect battery s positive wire connects to terminal 1 nega tive connects to terminals 7 b Connect a 3 4...

Page 297: ...ft front combination light units Front combination light bulb Front combination light bulb Front combination light bulb joint Ultrasonic sensor joint Radiator cover assembly Front fog light joint Light seat cap Bulb joint Bulb Bulb Front fog light joint Front bumper 286 ...

Page 298: ...z Front combination light around does not be distorted or damaged z Park the car on flat road z Tyre pressure limits to the regular number value z The driver is on driving seat and the car is ready to go gasoline tank in full z The car weaves fore and aft for many times b Inspect front combination light focus 1 Prepare for thicker white paper 2 Arise the paper plumb at the distance of 300cm from h...

Page 299: ...e bolt A to make the headlight focus limits to the regular d Adjust level direction Use the adjustable bolt B to make the headlight focus limits to the regular 10 Inspect front combination light whether it irradiates on the area as drawing 11 If not adjust light on vertical line or level line Adjusting bolt B Adjusting bolt A 288 1209 0 939 8 Numbers for approach sequence Distant light Low beam li...

Page 300: ...Light Front fog light joint Front fog light Components 289 Front fog light joint Left front fog light unit Bulb ...

Page 301: ... the drawing of front combination light on page 286 1 Replace front fog light bulb a Disassemble front fog light seal cap b Press front fog light bulb spring c Disassemble the bulb Adjustments 1 Adjust front fog light optic axis a Tyre pressure limits to regular number values b Start the engine c Adjust fog light optic axis by turning the optic axis adjust able button on the vertical direction 290...

Page 302: ...Light Side turning light Side turning light Components Side turning light 291 ...

Page 303: ...Light Rear combination light Rear combination light LH Components Left rear combination light Bulb 292 ...

Page 304: ...ructions comes when necessary z The replace procedure are the same on the left and right side z Referring to the drawing of front combination light on page 286 1 Disassemble left rear combination light assembly 67000108 a Disassemble three bolts and rear combination light b Disassemble two bulbs 293 ...

Page 305: ...Light Rear fog light Rear fog light Components 294 Rear fog light joint Left rear fog light Bulb ...

Page 306: ...emble Instructions comes when necessary z The replace procedure is the same on the left and right side z Referring to the drawing of front combination light on page 286 1 Disassemble rear fog light a Disassemble two bolts b Disassemble rear fog light by using vice screw driver 295 ...

Page 307: ...cket 2 Disassemble number plate light of trunk cover 3 Disassemble number plate light assemble 68000097 a Disassemble the joints b Disassemble number plate light using vice screw driver Clues on Before using vice screw driver its cusp should enwind adhesive tape c Disassemble the bulb 296 Fixing claw ...

Page 308: ...isassemble high brake light assembly 67010008 a Loosen two fixed jaw just as drawing b Loosen two fixed jaw and disassemble high brake light assembly as the drawing then take the joint apart Light High brake light assembly 297 Fixing claw ...

Page 309: ...bination switch Change 1 Disassemble decorative board under steering column 67000129 2 Disassemble left combination switch assembly 67000078 a Take the joint apart b Loosen fixed jaw and pull left combination switch assembly Fixing claw 298 ...

Page 310: ...ng harness 1 right assembled switch 2 washer generator 3 wiring harness 1 cleaner hose and nozzle 1 right assembled switch 1 2 wiring harness Reference pages 302 302 303 302 303 302 303 302 Inspect the car Inspect the function of cleaner generator 1 Add some rinsing to wiper water tank then disassemble cleaner generator joint 2 Connect battery wire with cleaner generator joint terminal2 negative w...

Page 311: ... assembled switch to OFF 2 Connect battery positive wire with joint terminal WIG connect negative to terminal EW 3 Connect voltmeter positive wire with joint terminal WS connect negative to terminal EW 4 Switch on cleaner switch and inspect its going b Inspect intermittent function of wiper 1 Connect voltmeter positive wire with joint terminal SWL connect negative to terminal EW 2 Connect battery ...

Page 312: ...tion does not in conformity with regulations replace wiper c Free stop position 1 Connect battery positive wire with joint terminal SWL connect negative to terminals ES to make generator work at low speed Disassemble terminal SWL lead to make generator stop except stop position 2 Connect terminal SWL with terminal AS 3 Connect battery positive wire with joint terminal SWL to make generator work at...

Page 313: ...le the lower trim board of the steering gear 2 Disassemble right combination switch assembly 67000079 a Disassemble the joints b Press fixed jaw to separate meshing then disassemble right combination switch assembly Notes Do not overly press fixed jaw or it may de damaged 302 Fixing claw ...

Page 314: ...d buckles to disassemble the seal from gen erator cap to fire barrier 5 Disassemble ventilation cover on passenger side Disassemble five fixed jaws so as to disassemble ventilation cover on passenger side 6 Disassemble ventilation cover on driver side Disassemble five fixed jaw so as to disassemble ventilation cover on driver side 7 Disassemble wiper connecting rod assembly 68000053 a Disassemble ...

Page 315: ...er connecting rod rubber pin b Use two bolts to assemble wiper connecting rod Torque 5 5 N m c Connect the joints 11 Assemble assistant wiper arm assembly 68000059 a Use steel brush to clean small tooth slot of wiper pivot b Use bolt cap to fix wiper arm on passenger side to make wiper blade at the position as drawing Torque 20 5 N m 12 Assemble main wiper arm assembly 68000057 a Use steel brush t...

Page 316: ...rom wiper shelf 3 Disassemble wiper blade fixed branch vane 4 Assemble wiper blade fixed branch vane Note Be careful do not assemble front and rear branch blade by mistake 5 Assemble wiper blade Put the head of wiper blade on big end side on the direction of wiper arm connecting shaft side when you assemble left wiper blade Note Pull the wiper blade into wiper shelf completely Wiper and cleaner Wi...

Page 317: ...r and cleaner Cleaner nozzle Cleaner nozzle Adjustments 1 Inspect cleaner nozzle When engine works inspect whether wiper water blast spurt in the area of wind shield bias as the drawing 306 Adhesives strip ...

Page 318: ...station s information according to your need After taking back negative terminal set former station again b Before disassemble assemble the radio inspect and take cassette and CD out in Clues on the malfunction of disassemble assemble the radio is because the tape or CD can not take out Do not take it out by force Drive the car to the service station c Do not touch the audio film of loudhailer 2 R...

Page 319: ... assembly Radio assembly Change 1 Disassemble the CD machine assembly referring to page 342 2 Disassemble radio assembly a Disassemble four bolts as the drawing b Take the joint apart then disassemble radio assembly 308 ...

Page 320: ... 68000140 4 Disassemble left front door loudhailer assembly 67000127 a Disassemble three rivets b Disassemble the joint then disassemble left front loudhailer 5 Diasassemble left front door loudhailer assembly 67000127 a Use three new rivets to assemble new left front door loudhailer assembly b Connect the joint 6 Replace right front door loudhailer just as upper method Audio system Left front doo...

Page 321: ...oor inner guard board as sembly 68010049 3 Disassemble left front door water screen assembly 68000140 4 Disassemble left front door small loudhail cover assembly 67000131 5 Disassemble left front door small loudhailer assem bly 67000129 a Disassemble maintenance hole cap then take the joint apart b Disassemble two nuts and left front small loudhailer assembly 310 ...

Page 322: ...Change 1 Disassemble rear platform sun blind assembly 68010032 referring to page 277 2 Disassemble rear loudhailer assembly 67000133 Disassemble eight tapping screws and two loudhailers Audio system Rear loudhailer 311 ...

Page 323: ...ble glove box 11 Disassemble right front pillar trim board 12 Disassemble left front pillar trim board 13 Disassemble the joint of the safety airbag at the side of the passenger 14 Disassemble panel 15 Disassemble right front door trim board 16 Disassemble right side trim board 17 Disassemble antenna assembly 67000136 a Take removable antenna pillar plug apart from radio 18 Assemble antenna assemb...

Page 324: ...Circuitry Power supply Circuitry Power supply Components For reference only Center power distribution Engine room main fuse box engine room assistant fuse box 313 ...

Page 325: ... condition system 9 electric injection system 10 audio system air condition instrument room light trunk light door light 11 AM2 startup system 12 spare safety 13 spare safety 14 spare safety 15 spare safety 16 electric chair Aldine 17 electric fan 18 ABS system 19 ABS system 20 left distance headlight 21 right distantce headlight 22 left low beams 23 right low beams 314 ...

Page 326: ...pare 36 front fog light 37 AMI ignition system 38 TAILposition light number plate light 39 brake light 40 electric sunroof 41 instrument system air condition system defrost system Re verse Radar rear light turn light 42 CIG air condition system audio system electric rear view mirror cigarette lighter 43 washer 44 spare 45 wiper 46 spare 47 center control light control system anti burglary system A...

Page 327: ...Whether horn relay mark HORN is conduct If the conduction situation does not accord with regulations re place the relay Horn alt Horn undertone 316 Condition regular situations Normal 1 2 conduction Supply battery voltage 3 5 conduction to Terminal 1 and 2 avometer connection terminal ...

Page 328: ...lectric window generator Electric window main switch Left front door electric window lift Windshield window glass wing mirror Electric window control system Position drawing For reference only Inspect the car 1 Inspect electric window a Inspect basic function manual operation function 1 Turn the ignition switch to ON 2 Inspect the window whether it descends when you press electric window switch Pu...

Page 329: ...he regulations the input side of electric window main switch may have malfunction b Inspect the joint terminal voltage when connect the joint If the voltage does not accord with the regulations electric window main switch may have malfunction c Inspect whether AUTO headlamp LED lights when connect the joint turn the ignition switch from OFF to ON 318 Avometer terminals conditions regular situation...

Page 330: ...ons 1 POWER fuse center power distribution box 2 window shift main relay center Distribution box 3 wiring harness 1 ignition switch 2 left front door control Panel assembly 3 wiring harness 4 electric window generator 1 left front door control panel assembly 2 electric window generator driver seat 1 left front control panel assembly 2 electric window switch 3 electric window generator 4 wiring har...

Page 331: ...nspect electric window switch assembly Active switch inspect the conduction among the joint terminals If the conduction does not limit to regulations replace electric window main switch 3 Inspect left rear electric window motor assembly a Inspect the function of left rear electric window assembly 1 Inspect whether the motor works calmly 4 Inspect electric window shift relay 67000061 Check the cond...

Page 332: ...p left trim tape 68000128 11 Disassemble top right trim tape 68000129 12 Disassemble front windscreen sealed trim board 68000062 a Use blade to cut trim tape as the drawing Note Do not cut the bodywork b Disassemble rudimental trim type steel wire 321 13 Disassemble front windscreen assembly 68000061 a Use a steel wire to drill through windows and bodywork b Tie something like wood block at both t...

Page 333: ...art of front windscreen brim whether it is flat c Mark signal between bodywork and glass d Disassemble front windscreen e Use blade to remove granulation area Note leave agglutinant as much as possible on the bodywork f Use duster cloth with cleaner to clean the agglutinant on the incision Clues on When all the agglutinant has been removed completely clean the bodywork g Use brush to daub M primin...

Page 334: ...tes z Use G priming paint over three minutes z Opened G priming paint can not use for the next time j Cut a hole on glue canister sharp mouth k Put the glue canister in the sealed glue jet gun l Daub agglutinant on the front windscreen A 12mm B 8mm 18 Assemble front windscreen sealed trim tape 68000062 Assemble the new trim tape in the bodywork manually 19 Inspect water leakage and repair a Actual...

Page 335: ...assembly 68010027 referring to page 390 11 Disassemble high brake light assembly 68010008 12 Disassemble rear platform front below trim board 68010034 13 Disassemble rear wind window sealed trim tape 68000104 a Use blade to cut the trim tape as the drawing steel wire 324 Notes Do not damage the bodywork by blade b Disassemble rudimental trim tape 14 Disassemble rear ventilation window assembly 680...

Page 336: ...ation window e Use blade to remove coarseness area Note leave agglutinant as much as possible on the bodywork f Use duster cloth with cleaner to clean the agglutinant on the cutting surface Clues on When all the agglutinant has been removed completely clean the bodywork g Use brush to daub M priming paint on the contacting part of bodywork Notes z Dry M priming paint for three minutes z Do not dau...

Page 337: ... Cut a hole on glue canister sharp nose k Put the glue canister in the sealed glue jet gun l Daub agglutinant on the front windscreen A 12mm B 8mm C 6 5mm D 13mm 19 Disassemble rear seat back assembly fixed 68010076 referring to page 354 20 Disassemble rear right side back assembly separate 68010079 referring to page 352 21 Disassemble rear seat left side back assembly separate 68010078 referring ...

Page 338: ...t work Rear ventilation window Demist defrost do not work electric rear mirror defrost dose not work components name 1 DEF main relay 2 DEF IP fuse 3 DEF m fuse 4 demist switch 5 wiring harness 1 demist wire 2 wiring harness 1 electric rear mirror reference pages Malfunction phenomena table Demist Defrost switch 327 Demist wire ...

Page 339: ... Inspect the conduction of rear window demist defrost relay mark DEF If the conduction does not accord with the regulations replace relay 328 Conditions avometer terminals regular situations Always 1 2 conduction Supply battery voltage between terminal1 and 3 5 conduction Terminal2 ...

Page 340: ...n and stop at it 3 When retractable switch at retractable position and left right rearview mirror at steering position either if any one of the rearmirrors can be pushed back to steering posi tion by hand then press retractable switch to retract able position inspect whether rearview mirrors move to restricted position only in steering position and stop at it 4 When retractable switch at retractab...

Page 341: ... again inspect whether rearview mirrors work Clues on Turn ignition switch to OFF if you press retractable switch and turn ignition switch to ACC then left and right rearview mirrors will move to opposite position d Inspect whether rearview mirrors work when restricted by others 1 When left and right rearview mirrors move to retractable position or steering position restrict left and right rearvie...

Page 342: ...able Trouble rearview mirrors do not work rearview mirrors work abnormally Components name 1 accessory fuse 2 rearview mirror switch 3 wiring harness 1 rearview mirror switch 2 wiring harness Reference page 332 332 331 Left rear view mirrors Electric rear view mirrors switch Right rearview mirrors ...

Page 343: ...n Left 2 8 6 7 Conduction Right 2 7 6 8 Conduction Switch positions Avometer terminals Regular situations Position of driving 8 9 7 10 Conduction Position of retracting 8 10 7 9 Conduction Replace the switch if it does not accord with the regulations 2 Inspect rear rear view mirror a Inspect motor function of rearview mirror b Inspect function of electric retracted motor Battery terminals Position...

Page 344: ...f driving B between position of driving and retracting C position of retract Connection style Connect wire G to positive Connect wire D to negative Connect wire D to positive connect wire G to negative Connect wire G to positive connect wire D to negative Connect wire D to positive Connect wire G to negative Actuated style Not actuated A B C C B A Not actuated Positions of rearview mirror A positi...

Page 345: ...ls low Oil pressure light fails Possible parts of trouble 1 harness or joint 2 engine ECU 3 combination instrument assembly 1 harness or joint 2 engine ECU 3 combination instrument assembly 1 harness or joint 2 ABS ECU 3 combination instrument assembly 1 harness or joint 2 ABS ECU 3 combination instrument assembly 1 harness or joint 2 airbag sensor assembly 3 combination instrument assembly 1 harn...

Page 346: ...ossible parts of trouble 1 harness or joint 2 panel safety fuse 3 combination instrument assembly 1 harness or joint 2 Fuel guage sensor 3 combination instrument assembly Reference pages 335 335 335 Vehicle inspection 1 inspect speed counter 1 Use speedometer tester to inspect allowed error of speedometer and action of speedometer Reference Km h speed indicated by speedometer actual speed 20km h 1...

Page 347: ... 3 800 4 200 5 000 4 750 5 250 6 000 5 700 6 300 7 000 6 650 7 350 DC 13 5V 25 C 1 Disassemble the joint of fuel meter 2 Turn ignition switch to ON inspect indictor position of fuel guage Indictor position F 3 Connect short terminal1 and terminal2 of wiring harness sides Turn ignition switch to ON inspect indictor position of fuel guage Indictor position F 5 Inspect low fuel level indictor 4 Inspe...

Page 348: ...rn ignition switch to ON inspect untied indictor light seat belt lights on 8 Inspect low oil pressure indictor 1 Disassemble the joint of oil pressure switch 2 Turn ignition switch to ON 3 Earth terminals of wiring harness sides inspect low oil pressure indictor Low oil pressure indictor light 9 Inspect oil pressure switch 1 disassemble joints of oil pressure switch 2 Inspect the conduction of oil...

Page 349: ...unction 1 Disassemble combination instrument 2 Connect battery positive wire to terminal A5 and nega tive to terminal A1 and A2 3 Connect battery negative wire to terminal A17 and B8 inspect buzzer which should work discontinuously 4 When buzzer works connect battery positive wire to ter minal A4 inspect whether buzzer stop working 12 Inspect brake system indictor a Inspect parking brake system in...

Page 350: ...ools to absorb brake liquid in storage tank 5 Check the conduction between switch side joint terminals Sink switch is ON conduction 6 Pour brake liquid into storage tank Inspection 1 Check the switch of indicating light of brake liquid level Check the conduction between switch side joint terminals Float switch is OFF not conduction Sink switch is ON conduction 2 Check parking brake switch Check th...

Page 351: ...luence SRS airbag Before imple menting these works it is necessary to read the notes in SRS chapter Change 1 Schedule for bolt screw and screw cap Note when using screw driver to unclench fixing clasp or fixing clamp it is necessary to wrap the needled top of wrench with adhesive tape Hint when disassembling or assembling panel if necessary use the figure and code in following table to choose bolt...

Page 352: ... screw b Liking that shown in figure unclench two fixing clamps c Disassemble the joint then disassemble Combination in strument assembly 9 Disassemble panel left ventilation hole assembly 68010010 Use disassembling tool for trim tape to disassemble panel left ventilation hole assembly Hint before using screw driver it is necessary to wrap its needled top with adhesive tape 10 Disassemble panel ri...

Page 353: ...ch eight fixing clamps then dis assemble DVD assembly and panel central ventilation hole assembly Hint before using screw driver it is necessary to wrap its needled top with adhesive tape c Disconnect panel central ventilation hole assembly 15 Disassmble lower panel right storage box assem bly 68100008 a Disassemble A screw and gas spring on storage box b Bend upper part of storage box to release ...

Page 354: ... Disassemble upper lower trim board of steering column 64000128 64000129 21 Disassemble left combination switch assembly 67000078 referring to page 298 22 Disassemble right combination switch assembly 64000079 referring to page 302 23 Disassemble gas spring Unclench fixing clamp then disassemble gas spring 343 24 Disassemble evaporator ventilation pipe assembly 67000149 Disassemble four fixing cla...

Page 355: ...d Hint before using screw driver it is necessary to wrap its needled top with adhesive tape 28 Disassemble left front door pedal trim board 68010020 29 Disassemble lower inner trim board of right de fender 68010016 a Disassemble plastic nuts of lower inner trim board of right defender b Unclench fixing clamp then disassemble lower inner trim board of right defender liking that shown in figure 30 D...

Page 356: ...e assembly c Disassemble six D bolts d Disassemble six fixing clamps and panel lower board 33 Disassemble left storage box of lower panel 68010007 34 Assemble upper panel assembly 68010004 Assemble upper panel assembly with D bolt and two A screws D bolt 18 N m 35 Assemble CD machine assembly 67000126 a Assemble pedal central ventilation hole assembly on CD machine assembly D D D D D D 345 ...

Page 357: ...o page 261 37 Assemble steering wheel assembly 67010001 referring to page 194 38 Check the central position of steering wheel 39 Check the safety airbag assembly at the side of driver 67010011 referring to page 249 40 Assemble the safety airbag assembly at the side of driver 67010011 41 Check the warning light of SRS airbag Fixing clamp 4 Fixing clamp 346 ...

Page 358: ... unclench three fixing clamps and four fixing clasps then disassemble combination penal cover 347 Panel combination instrument Combination instrument assembly 2 Disassemble Combination instrument assembly 68000081 a Disassemble the screw b Liking that shown in figure unclench two fixing clamps c Disassemble the joint then disassemble Combination instrument ...

Page 359: ... waist support Adjusting lever of waist support lever Rear cover of chair sliding rail With waist support Waist support adjustment assembly Declining adjust ment releasing handle Chair gasket bracket auxiliary assembly Front cover of chair sliding rail Chair vertical adjusting button Lower trim cover of front chair gasket Exterior trim cover of front chair gasket Chair gasket Chair front and rear ...

Page 360: ...mble right rear lower trim board of driver chair 68010065 Hint before using screw driver it is necessary to wrap its needled top with adhesive tape d Use screw driver to disassemble right front lower trim board of driver chair 68010064 Hint before using screw driver it is necessary to wrap its needled top with adhesive tape e Disassemble the joint f Disassemble four bolts and front chair Note Do n...

Page 361: ...erior cover of chair backrest with gasket d Disassemble the clamp then disconnect exterior cover of chair backrest with chair backrest gasket e Disassemble two screws and waist support lever 10 Disassemble exterior cover of chair gasket a Disassemble fixing clamp then disassemble exterior cover of chair backrest with gasket b Disassemble the clamp then disconnect exterior cover of chair backrest w...

Page 362: ...vent Chair Front chair Locking loop pliers Locking loop pliers 351 exterior cover of chair backrest from crinkling 16 Assemble chair backrest assembly a Use four bolts to assemble chair backrest assembly Torque 45 N m b Over turn exterior cover of chair backrest to assemble clamp c Assemble the clamp 17 Assemble left front safety belt locking assembly 68010040 a Use the bolt to assemble left front...

Page 363: ... rear row chair right backrest assem bly 68010079 Disassemble the bolt and rear row chair right backrest assembly 7 Disassemble rear row chair left backrest assembly 68010078 Disassemble two bolts and central backrest hinge 8 Disassemble exterior cover of rear row backrest small a Disassemble fixing clamp then disassemble rear row chair gasket cloth b Disassemble fixing clamp then disassemble head...

Page 364: ...ary to prevent exterior cover of cushion from crinkling 13 Assemble exterior cover of rear row chair backrest small Use new clamp to assemble exterior cover of rear row chair backrest in gasket Hint z Do not damage or dirty exterior cover of cushion z When assembling clamp it is necessary to prevent exterior cover of cushion from crinkling 14 Assemble rear backrest central hinge assembly Use two b...

Page 365: ... b Disassemble the clamp then disconnect exterior cover of rear row chair backrest with gasket 5 Disassemble exterior cover of rear row chair cushion Disassemble the clamp then disconnect exterior cover of cush ion with gasket 6 Assemble exterior cover of rear row chair cushion Use new clamp to assemble exterior cover of rear row chair cushion in gasket Hint Do not damage or dirty exterior cover o...

Page 366: ... open elec tric window at the side of driver to prevent its function from losing and lock the key in automobile 1 Insert key in ignition switch 2 Open the door and press middle control switch on the door at the side of driver to locker closing side at this time door locker could not close 3 Open the door and press locker button on the door at the side of driver to locker closing side at this time ...

Page 367: ...o locker opening side out of automobile 4 Take down the key close and use remote control key to lock driver door In this situation above check that door could not open locker even if door control switch handle operation is pressed to locker closing side out of automobile only applicable for the automobile equipping with remote control door locker control system Hint z In following situation check ...

Page 368: ... supply Power supply 1G2 in Power supply 1G2out Power supply Power supply Power supply Power supply Power supply Power supply Power supply Power supply Power supply Power supply Power supply Grounding wire Sunroof Rain wiper Brake light Anti steal Power supply Instrument Rear fog light ...

Page 369: ...on func tion Only one door locker does not work Possible malfunction part 1 DOOR fuse panel J B 2 Wiring harness 1 Electric window main switch door control switch 2 Wiring harness 1 Door at the side of driver assembly door control switch 2 Wiring harness 3 Door locker connecting rod is loosen 1 Anti versa lock supervising switch 2 Door control light switch 3 Wiring harness 1 Door locker electric m...

Page 370: ...at shown in figure supply battery voltage to terminal and check the function of door locker If the function does not accord with the regulation change the door locker assembly Open Close Open Close 359 Position of switch Terminalconnectedbyavometer Regulatedsituation LOCK 2 4 Conduction OFF Not conduction UNLOCK 1 2 3 Conduction Condition Function Supply battery anode to No 6 terminal cathode to N...

Page 371: ... locker assembly Liking that shown in figure supply battery voltage to terminal and check the function of door locker If the function does not accord with the regulation change the door locker assembly Open Close Open Close 360 Condition Function Supply battery anode to No 6 terminal cathode to No 5 terminal Open Supply battery anode to No 5 terminal cathode to No 6 terminal Close Condition Functi...

Page 372: ... anti stealing controller and electric injection ECU constitutes a multi layer effective electronic anti stealing system verified by password If customer key loses anti stealing ECU is changed or engine ECU is changed it is necessary to match again in repairing station When automobile leaves the factory safety password is delivered directly to owner for keeping with the type of secrecy If it is ne...

Page 373: ...ng to page 390 2 Disassemble the glass of sunroof a Use planetary wrench to disassemble planetary screw b Pull the glass upwards to disassemble it 3 Disassemble waterproof adhesive tape of sunroof 4 Disconnect connection of wiring harness 5 Disassemble shell body of sunroof a Disassemble four drain hoses b Liking that shown in figure disassemble four bolts and six screw caps then disassemble shell...

Page 374: ...he glass of sunroof a Check the phase difference between sunroof waterproof ad hesive tape and top gasket Front end and rear end 0 1 5mm Rear corner 0 1 5mm 0 1 5mm b Adjustment Use T25 planetary wrench to loosen the screw to adjust the sunroof on correct position then lock the screw 10 Inspection for water leakage a After the adjustment check whether the sunroof leaks water b If sunroof leaks wat...

Page 375: ...oof switch keystroke 1 the sunroof will automatically slide to closing state If spot contacting it or pressing keystroke 1 or 2 for long time in running process sunroof glass will stop running immediately 2 Turns ignition switch to ON if the sunroof is at opening state when pressing sunroof switch keystroke 1 for long time the sunroof will automatically slide to closing state If releasing keystrok...

Page 376: ...alfunction phenomenon Sunroof system does not work Sunroof system works abnormally Possible malfunction part 1 Ignition switch 2 Control switch of sunroof 3 25A 15 fuse 4 Wiring harness 1 Control switch of sunroof 2 Wiring harness Reference page 365 Terminal connected by avometer 2 4 2 5 Condition Spot contact or press keystroke 2 for long time Spot contact or press keystroke 1 for long time Regul...

Page 377: ...the clearance of engine cover is in regulated value shown in table 2 Adjust engine cover assembly a Adjust engine cover assembly by loosening the hinge bolt at the side of engine cover Torque 13 N m b Adjust engine cover assembly by turning the gasket c Adjust engine cover assembly by loosening three bolts of engine cover locker Torque 7 0 N m ...

Page 378: ... cover automobile door Front automobile door Front automobile door Subassembly Regulated torque 1 2 3 4 5 6 7 8 9 1 0 1 1 1 8 1 7 1 6 1 5 1 4 22 20 1 9 2 1 1 3 1 2 32 26 27 3 1 30 29 28 27 26 25 33 24 23 367 ...

Page 379: ...iated raised countersunk head screw Hexagon flange face bolt Combination part of hexagon head self tapping screw with flat gasket Right front door glass lift assembly Hexagon flange face bolt Right front door board bracket Cross slot plate head self tapping screw Right front small speaker cover assembly Right front door control panel assembly Freerson plate head self tapping screw Right front door...

Page 380: ...defending board assembly 68010049 a Disassemble the screw b Without equipping with door control light use screw driver to disassemble door inner defending board assembly c Equipping with door control light use screw driver to disassemble door inner defending board assembly then disassemble the joint again d Equipping with door control light use screw driver to disassemble door control light 3 Disa...

Page 381: ...le the joint b Disassemble connecting rod from exterior handle c Disassemble the bolt and screw d Use planetary socket wrench T30 to disassemble three planetary screws and door locker e Disassemble two screws and left front door locker organi zation driver 14 Spread lubricating grease on automobile body Spread MP lubricating grease on sliding and turning parts of lift assembly 15 Disassemble left ...

Page 382: ... again anti clamping protection function does not work z After implementing AUTO UP operation to close window completely if automobile window could not be operated downwards it is necessary to set up the lift again f Check the function of electric window 371 18 Check the function of electric window 19 Assemble repairing hole cover of left front door Hint z When assembling repairing hole cover pull...

Page 383: ...oosen hinge bolt at the side of automo bile body to adjust the door Torque 26 N m b Loosen hinge bolt at the side of automobile body to adjust the door Torque 26 N m c Loosen lightly fixing screw of locking pedestal and use plas tic hammer to knock lightly locking pedestal to adjust its position d Lock fixing screw of locking pedestal again Torque 23 N m At the side of automobile body At the side ...

Page 384: ...semble left rear door repairing hole cover Disassemble repairing hole cover 5 Disassemble exterior seal tape of left rear door glass 68000196 6 Disassemble seal tape of left rear glass guide slot 68000199 a Disassemble seal tape of left rear glass guide slot 7 Disassemble left rear door window glass guide slot assembly 68000187 Disassemble two bolts and comparting pillar of rear window 8 Disassemb...

Page 385: ...ft rear door locker organization driver and two screws b Use planetary socket wrench to assemble left rear door locker organization assembly and three screws Torque 5 0 N m c Assemble the bolt d Connect the joint 14 Assemble left rear door glass lift assembly 67000124 Torque 5 5 N m 15 Assemble left rear door repairing hole cover a Assemble repairing hole cover on door steel board Hint z z z z z W...

Page 386: ...ver automobile door Rear automobile door Adjustment Hint working procedure for right side is same as the left side 1 Check the clearance of left rear door a Check whether following data is in standard value 375 ...

Page 387: ...screw cap at the side of automobile door to adjust the door Torque 26 N m c Loosen lightly fixing screw of locker pedestal and use plastic hammer to knock lightly the locker pedestal to adjust its position d Lock the fixing screw of locker pedestal again Torque 23 N m At the side of automobile body 376 At the side of automobile body At the side of automobile door At the side of automobile door ...

Page 388: ...rance of trunk cover a If you want to make front and rear left and right adjustment please loosen the bolt at first b If the front end of trunk cover needs to adjust vertically please increase or decrease the number of washers between hinge and trunk cover Torque 7 0 N m c Use the hammer and copper stick to knock lightly the locker pedestal to adjust Torque 5 5 N m 377 ...

Page 389: ...pring II of trunk cover locates the lower end so it is necessary to work from left side to right side when assembling but it is necessary to work by opposite sequence when disassembling 1 Disassemble torsion spring of trunk cover 68000100 a Disassemble torsion spring I from middle bracket b Assemble special tool at the side of hinge c Push the special tool downwards then pull trunk cover hinge upw...

Page 390: ...mper Subassembly Inner gasket of right front wheel Inner gasket of left front wheel Fixing pedestal of radar probe Radar probe head Radar probe head Fixing pedestal of radar probe head Front fog light assembly Radiator cover assembly Front bumper Equipping with fog light 379 ...

Page 391: ... Disassemble the fixing clamp of screw and inner gasket of left front wheel in the scope of front bumper which could be disassembled 3 Disassemble inner gasket of right front wheel 68000228 4 Disassemble front bumper 68000005 a Disassemble four screws and two fixing clamps b Disassemble fixing clasp and front bumper c Equipping with fog light disassemble two joints of fog light d Equipping with ra...

Page 392: ...pping with reversing radar reversing radar probe head Equipping with radar fixing pedestal of radar probe head Left decoration of luggage cas Right decoration of trunk Rear trim board of trunk Trim board of right rear wheel Mudguard of left rear wheel Rear bumper Mudguard of right rear wheel Trim board of left rear wheel 381 ...

Page 393: ...heel 68000223 a Disassemble two screws and mudguard of left rear wheel 6 Disassemble mudguard of right rear wheel 68000224 7 Disassemble trim board of left rear wheel 68000230 a Usescrewdrivertodisassemblefixingclaspfromrearbumper b Use disassembling tool for fixing clasp to disassemble fix ing clasp c Disassemble trim board of left rear wheel Hint Disassemble trim board of left rear wheel in the ...

Page 394: ...erior inner trim board Rear bumper Nameplate Change 1 No 2 nameplate of trunk cover 2 No 3 nameplate of trunk cover 3 No 6 nameplate of trunk cover 4 Nameplate of front wing board 1 2 3 C h i n a Geely 383 ...

Page 395: ...nstruction z Changing procedure for right side is same as left side protective adhesive tape 384 1 Disassemble exterior seal tape of left front door glass 68000158 a Affix protective adhesive tape to the lower part of exterior seal tape of left front door glass b Use disassembling tool or scraper for trim tape to disas semble exterior seal tape of left front door glass Hint before using scraper th...

Page 396: ...struction z Changing procedure for right side is same as left side Protective adhesive tape 385 1 Disassemble exterior seal tape of left rear door glass 68000196 a Affix protective adhesive tape to the lower part of exterior seal tape of left rear door glass b Use disassembling tool or scraper for trim tape to disas semble exterior seal tape of left rear door glass Hint before using scraper the ne...

Page 397: ...mble number plate light defender 68000107 Disassemble four screw caps then disassemble the defender 3 Assemble rear logo assembly 61000019 a Use white gasoline to clean the assembling surface of logo b Use heating light to heat defender and logo c Assemble the logo Note do not heat logo excessively 2 Fixing clamp 386 ...

Page 398: ...fixing clamp z If fixing clamp is damaged when disassembling change it with new one 2 Assemble top left trim tape 68000128 Note when only changing fixing clamp a Disassemble adhesive tape remaining on the surface of body affixed trim tape then use white gasoline to clean the surface b Use heating light to heat the assembling surface of fixing clamp and automobile body Automobile body 40 60 C Trimt...

Page 399: ...Exterior inner trim board Left lower fender of automobile body Left lower fender of automobile body LH Subassembly 388 Lower fender Mudguard of left front wheel Fixing clasp ...

Page 400: ...ide is same as the left side Please refer to the subassembly figure of body left lower fender on page 388 389 1 Disassemble mudguard of left front wheel 68000221 a Disassemble three screws and mudguard of left front wheel 2 Disassemble body left lower fender 68000049 a Use disassembling tool for fixing clamp to disassemble eight fixing clamps b Disassemble the screw c Use disassembling tool for tr...

Page 401: ...sted by adhesive tape b Use same method to disassemble the trim board at the other side 4 Disassemble trim board of left rear door pedal 68010022 5 Disassemble lower inner trim board at the front of right fender 68010016 a Disassemble fixing clamp b Use screw driver to disassemble right trim board Hint before using screw driver its needled top should be twisted by adhesive tape C Use same method t...

Page 402: ...ard of right rear pillar assembly 68010027 a Use screw driver to disassemble inner trim board of right rear pillar assembly Hint before using screw driver its needled top should be twisted by adhesive tape b Use same method to disassemble the trim board at the other side 20 Disassemble inner trim board of left rear pillar as sembly 68010026 21 Disassemble inner trim board of right front pillar ass...

Page 403: ... disassemble the trim board at the other side 25 Disassemble left sun shade assembly 68010084 26 Disassemble indoor front top light assembly 67010005 Use screw driver to disassemble front top light cover and dis assemble fixing screw with cross wrench then disconnect the joint Hint before using screw driver its needled top should be twisted by adhesive tape 27 Disassemble indoor rear top light ass...

Page 404: ...eedled top should be twisted by adhesive tape b Disassemble three fixing clamps and inner trim board of top c Take out inner trim board of top from rear door 33 Assemble inner trim board of top 68010035 a Liking that shown in figure align the mark then fix the wir ing harness of top with adhesive tape b Use three fixing clamps to assemble inner trim board of top 34 Assemble the pothook of sun shad...

Page 405: ...e ignition switch Check the conduction of ignition switch joint and terminal If the conduction does not accord with the regulation change the switch 2 Check the anti versa lock key warning switch If the conduction does not accord with the regulation change the switch 394 Position of switch Terminalconnectedbyavometer Regulatedsituation LOCK Not conduction ACC 1 3 Conduction ON 1 2 3 5 6 Conduction...

Page 406: ...Ignition switch starting charging Electrical schematic diagram Ignition switch starting charging 395 ...

Page 407: ...Electric injection control of engine Electrical schematic diagram Electric injection control of engine 396 ...

Page 408: ...Anti locking brake system ABS Brake distribution EBD Electrical schematic diagram Anti locking brake system ABS Brake distribution EBD 397 ...

Page 409: ...Electric glass lifter Electrical schematic diagram Electric glass lifter 398 ...

Page 410: ...Electric sunroof Electric chair Electrical schematic diagram Electric sunroof Electric chair 399 ...

Page 411: ...Wiper and water injection Brake light Electrical schematic diagram Wiper and water injection Brake light 400 ...

Page 412: ...Electric rearview mirror Electrical schematic diagram Electric rearview mirror 401 ...

Page 413: ...Reversing radar system Electrical schematic diagram Reversing radar system 402 ...

Page 414: ...Safety airbag system Electrical schematic diagram Safety airbag system 403 ...

Page 415: ...Air conditioning system Defrosting system Electrical schematic diagram Air conditioning system Defrosting system 404 ...

Page 416: ...Door control system Anti stealing system Central control system Light system Electrical schematic diagram Door control system Anti stealing system Central control system Light system 405 ...

Page 417: ...Adjustment for headlight height Speaker cigar lighter Audio system Electrical schematic diagram Adjustment for headlight height Speaker cigar lighter Sound system 406 ...

Page 418: ...Combination instrument Electrical schematic diagram Combination instrument 407 ...

Page 419: ...Self diagnosis Chip anti stealing system Electrical schematic diagram Self diagnosis Chip anti stealing system 408 ...

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Geely FC, Workshop Manual

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