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GWFLORID Maintenance Manual

36

Clutch Operational System

Areas of Importance ...........................................................37
Troubleshooting ..................................................................37
Clutch Operational System .................................................38
  Components .....................................................................38
  Clutch Master Cylinder Removal ......................................38
  Clutch Master Cylinder Installation ...................................40
  Clutch Pedal Removal ......................................................40
  Clutch Pedal Installation ...................................................40
  Clutch Pedal Examination and Adjustment.......................41

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Summary of Contents for Florid

Page 1: ......

Page 2: ...lly designed tools Therefore before using any vehicle part following any maintenance procedure or working with a tool that has not been authorized by the Great Wall Motor Co Ltd check to make sure tha...

Page 3: ......

Page 4: ...ent s Working Agent 18 Torque Specifications for Key Operational Bolts 18 Vehicle Body s Basic Calibration Measurements 22 Chapter Three Fuel Supply and Exhaust System 29 Fuel Supply System 30 Compone...

Page 5: ...embly 68 Chapter Six Suspension System 71 Suspension System Technical Parameters 72 Front Suspension 73 Subframe and Front Stabilizer Bar 77 Lower Swing Arm 80 Drive Shaft 84 Rear Suspension 86 Wheel...

Page 6: ...184 Immobilizer System 186 CD Player 193 DVD Player 195 Chapter Eleven Air Conditioning System 202 Areas of Importance 203 Technical Parameters 203 Troubleshooting 204 Air Conditioning System s Struct...

Page 7: ...embly 234 Rear Door Lock Assembly 237 Trunk Door Lock Assembly 239 Wiper Arm and Vent Panel Assembly 240 Front Rear Window Glasses 241 Dashboard 242 Cooling Unit 246 Front Door Assembly 248 Rear Door...

Page 8: ...1 Overview Overview How to Use This Manual 2 Identifying Number Location 3 Comprehensive Repair Instructions 4 General Repair Methods and Operations 9...

Page 9: ...tenance work in order to find these specifications 4 Warnings Cautions Notes Warnings are highlighted in bold indicating the possibility of causing injury to oneself or to others Cautions are highligh...

Page 10: ...ction explains how to perform the maintenance as well as introduces other related matters such as specifications warnings and so on For example Illustration How and where to operate Work Subject What...

Page 11: ...gain b When reused the original sealant should first be cleaned and dried using compressed air Afterwards use the required locking sealant to coat the bolts nuts or threads c Precoated parts are marke...

Page 12: ...ue measured under higher temperature may exceed standard requirements espe cially if measured after driving the vehicle All measures should be taken after the engine has cooled down Circuit Maintenanc...

Page 13: ...rmed damaged or port lost before connecting the connector d The connector is not successfully connected until it makes a click sound 4 Wire harness connector inspection a Check while connecting the co...

Page 14: ...hange it to a socket of the same type c Any terminal that has been damaged deformed or corroded must be changed If the terminal is not locked to the case then the case needs to be replaced too Correct...

Page 15: ...ss Clip extractor Push out the king pin remove it and pry the kingpin bush Screw off the king pin and pry the shell Pry out the king pin remove the rivet and then pry off the shell Removal Screwdriver...

Page 16: ...ps to make reassembly more convenient 9 Store bolts and nuts separately because their hardness levels and designs are different according to the installation locations 10 Clean parts before they are i...

Page 17: ...l Parameters 13 Vehicle Structure Type and Parameters 15 Air Conditioning System Structure and Parameters 16 Electrical System Structure and Parameters 16 Grade Specification and Filled Quantity of Ea...

Page 18: ...ure angle 20 full load Breakover angle 16 full load Dynamic Performance Minimum stable speed of the direct gear km h 25 Direct drive 25 km h 100 km h acceleration time s 32 Acceleration time from stan...

Page 19: ...rotation speed kW r m 65 6000 77 6000 50 4200 Max torque rotation speed N m r m 115 4400 5200 138 4200 153 2000 2400 Total net weight kg 115 96 142 2 Idle speed r min 800 50 800 750 50 Fuel type and g...

Page 20: ...el joint The output end adopts a Rzeppa joint Air intake system Dry air filter paper filtering element Exhaust system Equipped with GW413EF engine two grade muffler with two grade three way catalytic...

Page 21: ...angle ratio i0 19 03 Brake system Service brake type The service brake system adopts a hydraulic vacuum power assisted type The front rear brakes are disc and drum brakes respectively The front brake...

Page 22: ...uter rearview mirror Elite type electrically actuated convertible body and electronically controlled mirror with defroster Luxury type manually folded body and electronically controlled mirror without...

Page 23: ...ed by a link mechanism driving air valve Refrigeration line water heating tube Refrigeration line a compound structure using a rubber cooling pipe and an aluminum pipe Water heating pipe molded rubber...

Page 24: ...ontrol Windshield system Front wiper inching high speed low speed and clearance gear with time slot adjustment with reset Rear wiper normal gear with reset Defog defrost device Rear wiper uses an elec...

Page 25: ...king Agent No Functioning component Quantity Specifications GW413EF GW4G15 1 Engine fuel 45L 93 and above high quality unleaded gasoline GW413EF GW4G15 engine 10 light diesel fuel YC4W75 31 engine 2 E...

Page 26: ...st pipe rear protection support Hexagon bolt for flange face 2 23 3 1 17 Between the front muffler and catalytic convertor Hexagon bolt for flange face 2 64 5 1 18 Connections between the front exhaus...

Page 27: ...t lock nut 2 23 3 1 44 Trailing arm spindle sleeve assembly Hexagon head bolt and flat washer subassembly 2 82 5 1 45 Rear shock absorber support shaft Hexagon nut for flange face 2 49 5 1 46 Rear sho...

Page 28: ...e line connectors M10 16 2 1 74 All of the brake line connectors M12 16 2 2 Vehicle body 2 1 Connected seat belt Front seat belt upper mounting bolt 7 16 2 42 5 2 2 Connected seat belt Seat belt lower...

Page 29: ...nter of the mounting holes When using the gauge adjust the two measuring needles until they reach an equal length then check the measuring needle and the gauge itself to ensure there are no gaps When...

Page 30: ...ameter mm Mark Axis X Y Z Diameter mm A 115 2 0 4 701 5 10 B 461 2 447 6 627 7 8 C 56 5 520 3 698 8 11 D 143 9 645 9 690 9 8 E 506 2 45 0 679 1 9 F 52 3 681 0 725 3 10 G 606 8 464 3 290 6 8 5 H 548 7...

Page 31: ...GWFLORID Maintenance Manual 24 Chassis LH side Front Front Upper Lower Unit mm...

Page 32: ...25 Overall Parameters Chassis Continued LH side Front Unit mm Axis Axis...

Page 33: ...GWFLORID Maintenance Manual 26 Subframe Unit mm 1195 1 5 Distance between the center points of both shaft s end surfaces 1381 0 5 Distance between points P and Q...

Page 34: ...door lower hinge mounting via hole 15 J Rear door contact switch via hole location hole 19 Mark Name Diameter mm Mark Name Diameter mm A Front door wire harness via hole location hole 38 E Process cu...

Page 35: ...ing holes 8 D Process cut Oblong hole 7 12 Mark Name Diameter mm Mark Name Diameter mm A Left D column inner decoration board laps over R angle B Right D column inner decoration board laps over R angl...

Page 36: ...System Fuel Supply System 30 Components 30 Fuel Tank Removal 31 Fuel Pump and Charcoal Canister Removal 31 Fuel Filter Removal 31 Fuel Filler Pipe Assembly Removal 32 Exhaust System 33 Components 33...

Page 37: ...clamp I Charcoal canister Fuel tank assembly Fuel tank heat shield assembly Charcoal canister air pipe Air return hose Fuel filler pipe assembly Electronic fuel pump Single hole clamp Electronic fuel...

Page 38: ...olts on the install panel of the fuel pump in diagnostic mode d Pay careful attention not to damage the fuel level sensor when taking the assembly out from the fuel tank 2 Assembly installation a Care...

Page 39: ...bly bracket and vehicle body Air return hose Fuel filler pipe connecting hose Fuel filler pipe assembly Q1461025 Q67639 Q673B20 Q67639 Q673B20 Fuel filler pipe assembly Fuel filler pipe sleeve Fuel fi...

Page 40: ...int Sealing ring Bolt Spring Rear three way catalytic converter assembly Gasket II Front heat shield Hexagon flange bolt Hexagon flange nut Middle heat shield Front exhaust hanger Exhaust pipe rear pr...

Page 41: ...esent to support the main muffler to avoid injury in case the muffler falls 2 Sub muffler assembly removal a Use a No 14 wrench open sleeve or ratchet wrench to remove the connecting bolt between the...

Page 42: ...ange of the exhaust manifold are used only for sealing If reused they may cause large deformations and result in a poor sealing effect Accordingly it is suggested not to use the sealing ring repeatedl...

Page 43: ...m Areas of Importance 37 Troubleshooting 37 Clutch Operational System 38 Components 38 Clutch Master Cylinder Removal 38 Clutch Master Cylinder Installation 40 Clutch Pedal Removal 40 Clutch Pedal Ins...

Page 44: ...ible malfunction causes so be sure to check each part in turn If necessary replace the part Symptoms Possible Causes Clutch vibration 1 Engine mounting bracket loose 2 Clutch plate axial runout is too...

Page 45: ...band elastic hoop and to remove the clutch feed connecting hose Caution Release the brake fluid in the reservoir before disconnecting the hose Steel band elastic hoop Clutch feed connecting hose Reser...

Page 46: ...h 3 Remove the pedal lock pin 4 Remove the return spring and the connecting pin 5 Remove the lock nuts of the clutch pedal with a M13 sleeve and an extension bar 6 Remove the clutch master cylinder Cl...

Page 47: ...er 4 Remove the clutch pedal bracket from the cowl 5 Remove the clutch pedal a Move the clutch pedal to the maximum stroke position b Take down the return spring c Remove the bolts and nuts d Take the...

Page 48: ...and then tighten the lock nut Tightening torque 20 N m 3 Check if the pedal free play is correct Step on the pedal until one can feel the resistance Pedal free play 13 7 mm 4 Adjust the free play a L...

Page 49: ...ons for Transmission Installation and Adjustment 44 Areas of Importance 45 Troubleshooting 46 037A Transmission Structural Schematics 47 Clutch 48 Gear Shift Fork and Fork Shaft 49 Transmission Case 5...

Page 50: ...037A transmission is a step mechanical transmission with differential two shaft front wheel drive application The forward gear has adopted the inertia synchronizer gear shifting mechanism which offers...

Page 51: ...should be checked to ensure that it is up to the oil filling mouth Add more if insufficient Excessive low oil level can lead to ineffective lubrication as well as burning of the bearings and gears Ex...

Page 52: ...with special transportation or storage requirements should have another discussion to reach an agreement on this matter in the supply contract Use parts Bolt code Specifications Quantity Tighten ing...

Page 53: ...ather plug fails Replace Damaged seal Replace Synchronizer is damaged Excessive gear shifting force Replace synchronizer Not applying clutch Use correct driving methods Synchronizer s spring expan sio...

Page 54: ...anetary gear 2 39 Gasket 2 40 Differential case 41 Planetary gear shaft 42 Differential ring gear 43 Bolt for flange face 8 44 Tapered roller bearing 45 Adjusting shim 46 T oil seal 47 Shaft retainer...

Page 55: ...acket Bolts with washer Bolts with washer Magnetic body Differential assembly Output shaft assembly Input shaft assembly T oil seal Tapered roller bearings Guide nozzle Clutch housing Release fork dus...

Page 56: ...spring Shaft retainers Lock pin No 3 gear shift fork shaft No 2 gear shift fork shaft No 3 guide block No 3 gear shift fork Set bolt Output shaft assembly Input shaft assembly Gasket Reverse gear idl...

Page 57: ...Reverse gear switch subassembly Washer Bush Oil drain slot Tapered roller bearings Adjusting shim Transmission case Clip Clip Adjusting shim 8 Washer Washer Hexagon head plug 39 2 Bolt for flange fac...

Page 58: ...e the clutch housing and the transmission case a Remove 8 bolts for flange face from the transmission case and clutch housing b Remove 5 bolts for flange face from the clutch housing and transmission...

Page 59: ...the reverse gear arm bracket assembly 6 Remove the No 1 gear shift fork shaft and the set bolts 7 Remove the elastic cylindrical pin from the No 1 guide block 8 Remove the No 1 gear shift fork No 1 ge...

Page 60: ...ndrical pin from the No 3 gear shift fork 10 Remove the elastic cylindrical pin from the No 3 guide block 11 Remove the No 3 gear shift fork compression spring and No 3 guide block 12 Remove the set b...

Page 61: ...Remove the No 2 gear shift fork shaft No 2 gear shift fork and No 2 guide block 14 Remove the input and output shaft subassembly 15 Remove the differential subassembly 16 Remove the magnetic body from...

Page 62: ...the inside of the transmis sion case 18 Remove the T oil seal with a screwdriver from the clutch housing 19 Remove the release fork and the release bearing from the clutch housing 20 Remove the set b...

Page 63: ...subassembly Needle bearing Retaining ring Shaft retainer Steel ball 5th gear thrust washer Needle bearing 4th gear subassembly 4th gear synchronizer ring Retaining ring Shaft retainer No 2 gear sleeve...

Page 64: ...57 Transmission 2 Remove each component from the 3rd synchronizer 3 Remove the 5th gear needle bearing 4 Remove the retaining ring 5 Remove the shaft retainer...

Page 65: ...emove the steel balls from the 5th gear thrust washer of the input shaft 8 Remove the 4th gear subassembly 4th gear needle bearing 4th gear synchronizer ring and the 4th gear bearing washer 4 types of...

Page 66: ...on 10 Remove each component of the input shaft s No 2 syn chronizer 11 Remove the input shaft s 3rd gear synchronizer ring and the 3rd gear subassembly 12 Remove the needle bearing from the 3rd gear o...

Page 67: ...subassembly 1st gear synchronizer ring No 1 gear sleeve No 1 gear hub No 1 Slider Spring expansion ring Shaft retainer Retaining ring Needle bearing 2nd gear synchronizer ring 2nd gear gear subassembl...

Page 68: ...e output shaft s 5th driven gear shaft retainer 3 Remove together the output shaft s 5th and 4th gear driven gear 4 Remove the output shaft spacer 5 Remove the output shaft s 3rd driven gear and the 2...

Page 69: ...e bearing and the 2nd gear subassem bly retaining ring 7 Remove the shaft retainer from the No 1 synchronizer gear hub of the output shaft 8 Remove the output shaft s No 1 synchronizer compo nents and...

Page 70: ...63 Transmission 10 Remove each component of output shaft s No 1 syn chronizer 11 Remove the front tapered roller bearing...

Page 71: ...Dust cover T oil seal Gear shifting block No 2 spring seat Pressure spring Shaft retainer Gasket Lock plate Shaft retainer Elastic cylindrical pin Shift guide block Select lever subassembly Manipulat...

Page 72: ...65 Transmission 2 Remove the shaft retainer on the shift lever and the se lect lever 3 Remove the lock plate 4 Remove the pressure torsion spring 5 Remove the No 2 spring seat...

Page 73: ...lever assembly 7 Remove the select lever subassembly 8 Remove the shaft retainer on the shift shaft and the se lect lever Caution Use a cord to fasten the shift lever in order to make the operation co...

Page 74: ...67 Transmission 10 Remove the shaft retainer from the shift shaft 11 Remove the shift shaft T oil seal from the manipulation lid 12 Remove the T oil seal from the manipulation lid...

Page 75: ...ngs Elastic cylindrical pin Odometer drive gear Differential case Differential ring gear Bolt for flange face Gasket Planetary gear Adjusting shim Axle shaft gear Planetary gear shaft Planetary gear G...

Page 76: ...bearings of the left differen tial 2 Remove the odometer drive gear from the differential 3 Remove the tapered roller bearings of the right differen tial 4 Remove the bolts for flange face of the diff...

Page 77: ...and the differential case gently pound to re move the differential ring gear with a soft hammer 6 Remove the elastic cylindrical pins from the differential case and the gear shaft 7 Remove 2 planetar...

Page 78: ...uspension System Suspension System Suspension System Technical Parameters 72 Front Suspension 73 Subframe and Front Stabilizer Bar 77 Lower Swing Arm 80 Drive Shaft 84 Rear Suspension 86 Wheel and Tir...

Page 79: ...Part Code Assembly locations for standard components Tightening torque N m Quantity Glue Grade Front suspen sion Q1861455TF2 M14 1 5 Q402 d2 32 t 5 FD Subframe vehicle body rear 145 15 2 Red glue 10...

Page 80: ...ension Components c Pull out the mount point on the steering knuckle to separate it from the mounting bracket under the front shock absorber Prop a wood stick or metal bar against the propeller shaft...

Page 81: ...ttention to personal protection 4 Remove the cotter pins and lock nuts of the steering tie rod and the lower swing arm Because the ball stud and steering knuckle act in conjunction with the tapered bo...

Page 82: ...nt shock absorber with coil spring assembly shown on the left Tightening torque 40 5 N m 5 Installation of the front shock absorber with coil spring assembly Installation follows the reverse order of...

Page 83: ...l spring s erection support front coil spring dust cover and the bumper in turn Tightening torque 40 60 N m 3 Retracting spring Alternately reversing rotate the bolts on the SST until all the spring t...

Page 84: ...1020 M10 1 25 FD with a sleeve and remove the strut bar As shown on the left There are four bolts two on the left and two on the right Tightening torque 49 5 N m Caution When removing the steering fue...

Page 85: ...ion screw off the hanger rod lock nuts and remove the hanger rod Caution These are non metal insert lock nuts and cannot be reused So please replace them with new ones after removal 2 Remove the stabi...

Page 86: ...79 Suspension System b The sliding side of the hanger rod should face upward so as to make the operation more convenient Correct Incorrect...

Page 87: ...ew off the lower swing arm s front mounting bolt Q1401495 t 4 M14 1 5 FD with a sleeve Tightening torque 136 10 N m 3 Screw off the lower swing arm s rear mounting bolt Q1401280 M12 1 25 FD with a sle...

Page 88: ...arm weld as sembly and the lower swing arm ball stud If the rotation is not flexible or if the ball stud is damaged the entire lower swing arm with ball stud assembly must be replaced 2 Ball stud dust...

Page 89: ...e SST Special Service Tools to press the new lower swing arm s large shaft sleeve into the correct position 5 Lower swing arm s small shaft sleeve removal replace ment and press fitting a Use a sander...

Page 90: ...83 Suspension System d On the press use SST Special Service Tools to press the new lower swing arm s small shaft sleeve into the correct position F SST SST...

Page 91: ...sassembly specifications remove the Front suspension system LH and wheel 2 Then use a pry bar to forcefully pry the connection between the differential and the drive shaft until the drive shaft obviou...

Page 92: ...fferential drive shaft s outer end until a clear and sharp clicking sound is heard Here the drive shaft and the transmission should have a clearance of about 1 mm 2 According to the front suspension a...

Page 93: ...ce Tools to clamp the coil spring so that it does not pop out and cause injury 3 Compression spring Hold up the rear twist beam upwards with a lift compressing the rear coil spring and damper Upper mo...

Page 94: ...arm spindle sleeve s outer tube in order to install the SST Special Service Tools Rear twist beam assembly removal 1 Hold up the rear twist beam assembly with a lift and remove the rear shock absorbe...

Page 95: ...T 3 Install the new trailing arm spindle sleeve assembly a Before installing the new trailing arm spindle sleeve assembly first to distinguish the installation direction for the trailing arm spindle s...

Page 96: ...mpy ride 2 The tear or rupturing of the tire 3 Rapid wear of the tire tread s center 1 Noisy turns 2 Uneasy turns 3 Tread edge wear is accelerated and uneven 4 The tire s rim is damaged or ruptured 5...

Page 97: ...nt tires are different 2 When any of the tire s tread has uneven wear and tear 3 When the tread pattern strip or pattern block of a front tire s single side is badly worn A B A Steering problems air p...

Page 98: ...solving if working switch the tires again Return the tires to their initial positions and inspect the front wheel alignment After solving switch the tires again Tire rotation For equal wear or tear f...

Page 99: ...ease do not change tires merely with manual hand tools or tire installation crowbars This will damage the tire chafer or the vehicle wheel s rim Use a wire brush or coarse steel wool to clean off grea...

Page 100: ...ructure of it are equal to the settings of original wheel If the wheel dimensions are not appropriate this will influence the wheel and bearing s life brake cooling effect speedometer and odometer cal...

Page 101: ...tenance 96 Brake Pedal 98 Parking Brake Control Mechanism Assembly 102 Vacuum Booster with Brake Cylinder Assembly 103 Anti lock Brake System 107 ABS General Problem Maintenance and Areas of Importanc...

Page 102: ...e cable assembly Rear brake assembly RH Rear brake drum Rear wheel speed sensor assembly RH Right parking brake cable assembly ABS controller assembly Right steering knuckle and hub brake assembly Bra...

Page 103: ...e dump valve is clear from any contaminate Hydraulic pressure system drainage If the brake fluid inside the whole hydraulic pressure system needs to be emptied open all the bleed screws with each conn...

Page 104: ...ake pipe but do not tighten it d Slowly step down and press on the brake pedal check if the brake fluid flowing out of the connector contains bubbles e Tighten the pipe fitting f Have the assistant lo...

Page 105: ...ile installing the return spring be careful to avoid operator injury from it bouncing back Troubleshooting Symptoms Possible causes Eliminating methods Brake pedal cannot return to the original positi...

Page 106: ...ly Caution Set it down gently to avoid damaging its surface finish 4 Remove the pedal pad bushing and limiting stopper from the pedal lever assembly Caution Ensure cleanliness of the entire set s surf...

Page 107: ...the brake lamp s switch wire connector loosen the lock nuts rotate the brake switch and unscrew it until no contact with the brake pedal s limiting stopper b Loosen the control rod lock nut and use co...

Page 108: ...lue is incorrect rotate the pedal push rod to adjust the free play b Start the engine to confirm the pedal free play c After adjusting the pedal free play check the pedal height d The relative height...

Page 109: ...s installation by reversing its removal sequence Please pay attention to the items below a The open end of the parking brake lever assembly s cable clamp should face down b While installing the parki...

Page 110: ...k one by one and tighten as necessary 1 Vacuum booster not sufficient 2 No boost when the engine is off 3 May lead to unsteady engine idling when severe 1 Under non operating conditions the vacuum boo...

Page 111: ...onnector and collect the fluid in the container then drain the brake fluid inside of the pump by stepping on the brake pedal 3 Remove the drain connection Use a M10 open end wrench to remove the drain...

Page 112: ...ing 2 Remove the brake reservoir assembly Push out the elastic cylindrical pin from the hole of the oil cup s foot with a suitably sized screwdriver and then pull out the oil cup from the pump in the...

Page 113: ...sing the following steps a Install the check valve seat b Install the check valve c Install the dust cover d Install the split ring e Install the lock nut f Install the rod clevis 3 Installaion of the...

Page 114: ...ing phase While service braking oil pressure output from the pump passes the inlet solenoid valve and enters the brake wheel cylinder The brake generates braking force and the wheel speed sharply decl...

Page 115: ...pedal is loosened and the brake pressure inside the pump drops to zero Open the normally closed valve one more time at this point The brake fluid inside the low pressure accumulator returns to the pum...

Page 116: ...d outlet solenoid valve failure Once the ignition switch is ON the ABS control unit automatically initiates a self check If an inlet and outlet solenoid valve short circuit or open circuit is found it...

Page 117: ...r there is a common brake system problem or an ABS problem the ABS must be terminated by pulling out its ABSECU connector or fuse At this time the ABS EBD loses function as well On muddy icy or snowy...

Page 118: ...failure C0090 Rear ABS outlet solenoid valve RH failure C0095 Rear ABS inlet solenoid valve RH failure C0110 Pump motor circuit failure operational error C0121 Solenoid valve relay circuit failure C0...

Page 119: ...front brake disc s brake linings runout on the two sides should be no more than 0 11 mm If oversized they should be repaired or replaced 4 Inspect front brake disc thickness Standard thickness 22 0 mm...

Page 120: ...ce runout is oversized or its thickness is smaller than the minimum thickness the brake disc should be replaced 8 Remove the front brake disc cover Remove the fastened brake disc cover bolts with a wr...

Page 121: ...e a hand held travel hammer to repeatedly hammer off the front hub flange assembly from the steering knuckle and front hub bearing Remove the front hub with bearing s inner ring b Remove the bearing s...

Page 122: ...ng knuckle and hub brake assembly installation 1 On the press press the front hub bearing assembly into the steering knuckle hole bearing mounting posi tion with SST SST SST SST 6 If the steering knuc...

Page 123: ...Put a dial torque wrench on the SST to slowly rotate the flange s flange assembly 45 4s which re quires a starting torque range of 0 1 0 3 N m 5 Install the snap ring for hole 72 Use a bent nose retai...

Page 124: ...e two wheel nut s symmetrical locations The front brake disc s brake linings runout on the two sides should be less than 0 11 mm 10 Install the brake caliper assembly Install the brake caliper on the...

Page 125: ...Inspect the inner and outer brake pad s friction material thickness By looking through the caliper s observation ports inspect the inner and outer brake pad friction material thickness If it is no lon...

Page 126: ...ims B b The group of inner and outer shims A c The group of inner and outer brake discs d One pair of yoke springs 5 Measure the brake disc thickness See steering knuckle and hub brake assembly examin...

Page 127: ...ount of brake fluid from the reservoir Make sure not to let the brake fluid overflow from the reservoir e Press in the piston with SST 9 Install the caliper assembly Loosen the rope remove the caliper...

Page 128: ...e piston from the caliper and at the same time remove the piston dust cover c Use a clean rag or other soft cloth to extract the piston Warning When using compressed air be sure not to place fingers i...

Page 129: ...bottom of the piston Use tools for example about 2 mm of iron wire to assist by stuffing the card holder into the cylinder bore card holder s groove Caution The tools being used should not be sharp as...

Page 130: ...xagon bolt for flange face Tightening torque 30 5 N m 8 Connect the brake line Connect the brake pipeline to the caliper Tightening torque 40 4 N m 9 Fill the brake reservoir up with brake fluid and e...

Page 131: ...trailing shoe assembly Brake back plate assembly Pressure spring bar Rubber plug of the adjuster s observation port Rubber plug of the observation port gap Washer Bleed screw cap Bleed screw Piston Ri...

Page 132: ...d pressure spring bar b Take out the brake leading and trailing shoe assembly from the brake back plate assembly take down the retainer spring and remove the cable connector Remark When taking out the...

Page 133: ...ing shoe assembly 8 Remove the brake wheel cylinder a Remove the brake line with a M10 open end wrench and use a clean plug to clog it b Use a M8 open end wrench to remove the two bolts thus removing...

Page 134: ...ling shoe assemblies should be replaced Remark If one of the brake shoe assembly needs to be replaced be sure to replace all the rear brake leading and trailing shoe assemblies to ensure even braking...

Page 135: ...tallation directions 2 Install the wheel cylinder assembly a Use two bolts to install the wheel cylinder assembly onto the brake back plate assembly Tightening torque 7 8 11 8 N m b Connect the brake...

Page 136: ...on the brake trailing shoe as sembly a Install the parking brake lever and insert the lever rotat ing shaft b Use pliers to install a new split ring in the lever rotating shaft 5 Install the return sp...

Page 137: ...10 Inspect the operating procedures of the automatic ad juster a Refer to the diagram for directions step on and off the brake pedal and make sure the self adjusting screws can rotate If they are una...

Page 138: ...screw the two wheel nut s opposite angles on the wheel bolt and fixed rear brake drum Remark Alternately tighten the two nuts and manually screw it down as much as possible Rear brake drum Rear brake...

Page 139: ...b Use a spring dynamometer to inspect the load applica tion Load application when start the engine 1 N m Caution If the load application is greater than 1 N m the rear wheel hub unit must be replaced...

Page 140: ...the trailing arm spindle sleeve is vertically forced out 3 Install the new trailing arm spindle sleeve with nylon bushing assembly a Before installing the new trailing arm spindle sleeve with nylon bu...

Page 141: ...GWFLORID Maintenance Manual 134 Steering System Troubleshooting 135 Steering System Maintenance 137 Power Steering Fluid Instructions 141 Technical Requirements 141...

Page 142: ...ring gear presses too small 4 Steering column s spider bearing broken 5 Steering tie rod ball stud lacks oil or is dam aged 6 Front shock absorber s support bearing bro ken 7 Damaged lower swing arm b...

Page 143: ...ositional parameters incor rect 6 Steering gear s gear rack meshing condition worsens and causes intense reverse resis tance 7 Steering column bearing and spider bearing damaged 8 Power steering pump...

Page 144: ...time possesses reasonable reverse efficiency to ensure the driver has a good feel for the road Steering system is as shown below Steering column assembly removal and installation 1 Remove the airbag...

Page 145: ...tion lock 5 Screw off the bolt 3404202 S08 connected the steering column and steering propeller shaft with a M13 socket wrench in the counterclockwise direction 6 Screw off the two flange bolts Q18408...

Page 146: ...aded hole the screw should align perfectly with the circular groove as shown on the left b When installing the steering wheel ensure that the front tires are in a straight line make the vehicle logo o...

Page 147: ...with the subframe from the overall vehicle disconnect the coupling nut of steering pipeline and steering gear s high low pressure oil port with a M19 wrench The removal of the steering pipeline is th...

Page 148: ...ile the other repeatedly turns the steering wheel from lock to lock for more than 10 laps until the steering fluid level is between MAX and MIN Start the engine and turn the wheel from lock to lock ag...

Page 149: ...Electrical Component s Module Schematics for the Overall Vehicle 151 Wire Harness Distribution Chart for the Overall Vehicle 152 Wire Harness Relationship and Plug in Connections Numbered Diagram 155...

Page 150: ...itch is at the ON position power is supplied by relay IG 15a represents a power cord for small capacity electronics When the ignition switch is at the ON position power is directly supplied by ignitio...

Page 151: ...e test pen along the connecting terminal Don t use too much force as to avoid cracking the connector Circuit inspection steps The principle of troubleshooting is to confirm the possible cause Once the...

Page 152: ...oster F13 10 A Combination meter F14 10 A Internal lighting F15 20 A Central lock controller F16 10 A Brake lamp switch F17 15 A Stereo F18 Reserve F19 Reserve F20 Reserve F21 25 A X Attached ACC Fron...

Page 153: ...2 fuse box Fuse number and bearer circuit Fuse number Current rating Fuse type Power Bearer circuit F29 30 A AutoFuse 30 Battery Starter relay F30 25 A Main relay F31 15 A Fuel pump relay F32 30 A Sl...

Page 154: ...ck side pin diagram Connected dashboard s wire harness A Connected dashboard s wire harness B Connected dashboard s wire harness C Connected dashboard s wire harness D Connected dashboard s wire harne...

Page 155: ...und B11 Empty B03 Power rearview mir ror switch CD B12 Window regulator motor B04 Ignition switch ACC B13 Front rear cigarette lighter backup power supply B05 Empty B14 Empty B06 Compressor control B1...

Page 156: ...ation switch left turn D10 Combination switch parking lamp D03 Right turn signal lamp D11 Parking lamp meter brightness D04 Ground D12 Sunroof Elite D05 Hazard warning switch D13 Empty D06 Empty D14 E...

Page 157: ...GWFLORID Maintenance Manual 150 Overall Vehicle s Grounding Point Schematics G01 G02 G03 G04 G05 G06 G07 G08...

Page 158: ...rness G06 Wire harness fixture un der the left A pillar Meter wire harness G06 On the dashboard brace reinforcement Meter wire harness G07 Rear fender trim LH Vehicle body wire harness G08 Near rear c...

Page 159: ...n sensor Front rear oxygen sensor Condenser fan motor Compressor clutch Alternator alternator regulator Tristate pressure switch Front fog lamp RH Washer motor Wheel speed sensor Front combination lam...

Page 160: ...Combination meter CD DVD Air conditioner speed adjuster AC switch rear defroster switch Air conditioner temperature sensor Front Passenger side airbag assembly Blower Glove box lighting Cigarette lig...

Page 161: ...gulator motor Middle low tone speaker Fog lamp License plate lamp Rear combination lamp LH Rear combination lamp RH Rear wheel speed sensor RH Parking brake switch Front door light switch LH Seat belt...

Page 162: ...LH Connected high pitched horn Battery negative Body ground Battery Left ground Connected brake lamp switch Connected brake fluid warning switch Connected theft deterrent indicator Theft deterrent ECU...

Page 163: ...nected engine wire harness Connected cab fuse box Connected engine compartment wire harness C01 C02 C03 Wire Harness Plug in Connectors and Pin Function Diagram Connector 1 Connected cab fuse box A 20...

Page 164: ...b fuse box C 14 Connected dashboard wire harness C05 C06 Connector 2 C04 Connected cab fuse box B 18 Connected dashboard wire harness Luxury Elite Comfort Luxury Elite Comfort Elite Comfort Luxury Eli...

Page 165: ...fuse box D 16 Connected dashboard wire harness Connector 3 Elite Elite C07 Connected dashboard wire harness Connected cab fuse box E 8 C08 Connected cab fuse box H 1 Connected dashboard wire harness...

Page 166: ...Vehicle Body Electronic System Connected dashboard wire harness A Connected engine compartment wire harness A C09 C10 Connector 4 Luxury Elite Comfort Luxury Elite Comfort Luxury Luxury Comfort Comfo...

Page 167: ...wire harness B Connected engine compartment wire harness B Connected dashboard wire harness A Connected engine wire harness A white Connected dashboard wire harness B Connected engine wire harness B...

Page 168: ...eter wire harness A Connected front left door wire harness A white Connected front left door wire harness B Connected meter wire harness B C13 C14 C15 Connector 6 Comfort Luxury Comfort Luxury Luxury...

Page 169: ...ted dashboard wire harness B Connected vehicle body wire harness Connected engine compartment wire harness C15 C16 C17 Connector 7 Connected dashboard wire harness A Connected vehicle body wire harnes...

Page 170: ...ed meter wire harness A Connected front right door wire harness A Connected meter wire harness B Connected front right door wire harness B C18 C19 Connector 8 Comfort Luxury Comfort Luxury Elite Elite...

Page 171: ...GWFLORID Maintenance Manual 164 Connected vehicle body wire harness Connected rear left door wire harness C20 C21 Connector 9 Comfort Luxury Elite Comfort Luxury Elite Elite Elite...

Page 172: ...e body wire harness Connected rear right door wire harness Connected vehicle body wire harness A Connected trunk wire harness A Connected vehicle body wire harness B Connected trunk wire harness B C22...

Page 173: ...GWFLORID Maintenance Manual 166 Connector 11 C24 Connected trunk wire harness 2 Connected trunk wire harness 1 C25 C26 Connected rear defroster Connected rear defroster...

Page 174: ...the Overall Vehicle Power start up system Connected ABS 1 Main relay EngineECU 74pin Shift position Pin position Theft deterrent ECU 6 ABS motor 40A Ignition switch Starter relay Clutch switch Batter...

Page 175: ...rake lamp Right brake lamp High mounted brake lamp Driver side airbag Frontpassengersideairbag Front wheel speed sensor LH Front wheel speed sensor LH Rear wheel speed sensor LH Front wheel speed sens...

Page 176: ...mbination meter A Driver seat belt switch Connected parking brake switch Fuel pump fuel sensor Coolant temperature sensor Engine speed sensor Speed sensor Connected combination meter B Brake fluid lev...

Page 177: ...d adjustive resistance Rear defroster alarm switch comfort luxury Right outer electric rearview mirror defroster Elite Left outer electric rearviewmirror defroster Elite Front passenger seat belt swit...

Page 178: ...er RH Rear medium woofer LH Front tweeter LH Front tweeter LH Front tweeter LH Front medium woofer LH Rear medium woofer LH Rear medium woofer RH Front medium woofer RH Front tweeter RH Linear control...

Page 179: ...t washer motor Rear washer motor Rear wiper motor Sunroof switch Rear wiper motor Front wiper motor Right combination switch wiper Connected front washer motor Connected rear washer motor To meter bri...

Page 180: ...al module Electronic throttle AC temperature sensor Knock sensor Engine speed sensor Phase sensor Fuel pump relay Connected combination meter Connected speed sensor Engine malfunction indicator lamp E...

Page 181: ...ch RH Window relay Window lock switch Front door switch RH Rear door switch LH Rear door switch RH Door electric door mainly control switch Front door electric switch RH Rear door electric switch LH R...

Page 182: ...beam High beam Over taking Over taking Lamp Off Low beam relay Parking lamp relay Flasher relay Connected combination meter A18 Connected central control ECU 8 Connected central control ECU 1 Connecte...

Page 183: ...etector No 1 Detector No 2 Detector No 3 Detector No 4 Theft deterrent coil Connected theft deterrent ECU Connected diagnostic port Detector No 1 Detector No 2 Detector No 3 Detector No 4 Connected th...

Page 184: ...177 Electrical Accessories Reverse Sensor 178 Combination Meter 180 Central Door Lock 181 Power Windows 184 Immobilizer System 186 CD Player 193 DVD Player 195 Electrical Accessories...

Page 185: ...o the sonic speed and the time difference between the emission of sound and the receipt of sound Reverse sensor system composition This system is composed of a reverse sensor head unit ECU four sensor...

Page 186: ...e location angle size or material of the object Furthermore the reflected signal in a complex environment may not be accurate System malfunction causes and solutions 1 A lack of power or a low supply...

Page 187: ...put 21 Seat belt unfastened indicator lamp 6 Vehicle speed signal output 22 Battery 7 Central door lock signal 23 Ignition 8 Clock test 24 High beam 9 Meter interior communication 25 High beam 10 Empt...

Page 188: ...in the learning state Step two Press any key on the remote controller within 10 seconds the buzzer will sound twice and the light will flash twice This is the first learning state Press any key on an...

Page 189: ...ner switch is connected Connected side window remote controller negative trigger Power sunroof relay Power supply 12 V Driver side door and window switch Negative Positive Power supply positive pole H...

Page 190: ...or This wire is connected to the trunk door motor and will output 12 V when the UNLOCK button of the remote controller or the manually unlock switch is pressed 15 Trunk door switch This wire is connec...

Page 191: ...le and safer system operation while in use the zero position will need constant calibration Manual calibration When the window stops at the rising soft stop position after rising for a period press th...

Page 192: ...mechanism dead center zero position b Within two seconds of the zero position after the motor is blocked release the button then press the button again for at least 20 s c After 20 s the window will...

Page 193: ...rocessor and peripheral components It com municates with the password transmitter assembly and engine ECU The theft deterrent controller assembly communicates with the engine ECU via the W wire while...

Page 194: ...r theft deterrent coil assembly and engine ECU are com bined into a immobilizer control system through relevant downline matching equipment or scanners The engine can only start up when the well match...

Page 195: ...nt controller change it and initiate re matching If the failure has nothing to do with the theft deterrent controller remove the electronic controller which is connected to the alarm s K wire such as...

Page 196: ...lt most likely exists in the alarm Replace the electrojet please refer to immobilizer system 444 component replacement Check whether the above failures exist If they do not the fault most likely exist...

Page 197: ...e theft deterrent controller s 8 core plug is 111 well connected Check whether the wire harness connecting the A5 pin R 222 wire of the 8 core plug and electrojet is well connected is not short circui...

Page 198: ...ed in it It will need the VIN inputted and must be matched with the original key otherwise the original key will not work Caution a Replace the new alarm remote controller or reset the alarm remote co...

Page 199: ...riginal key is still to be used If the original key will not be in use any more then it needs to rematch the new key 4 Match the engine ECU a Properly connect the engine ECU and the theft deterrent co...

Page 200: ...hicle body Use insulated conductor to connect the speaker and use insulating cement to cover the exposed connections Disc is not genuine Use a genuine disc Speaker is incorrectly connected Please refe...

Page 201: ...ACC and positive power line BATT Please refer to the Eelectrical connection diagram to correct the connection Radio antenna 1 2 3 4 5 6 7 8 Pin Definition 1 Karaoke control wire 2 Microphone audio out...

Page 202: ...ommunication wire reserve 12 Front left audio output 22 Power supply ground cable reserve 13 Front right audio output 23 Communication wire reserve 14 Rear right audio output 24 Disc changer right cha...

Page 203: ...tor blue video signal 32 Auxiliary audio input 2 reserve 9 Navigator audio input 21 Front left audio output reserve 33 Digital ground cable reserve 10 SV 6269 Microphone audio input SV 6268 NC 22 Fron...

Page 204: ...nnections Disc is not genuine Use a genuine disc Speaker is incorrectly connected Please refer to the Equipment connection drawing to correct the connection The sound quality is poor or distorted Spea...

Page 205: ...to the Equipment connection drawing Local search function is in the on state Switch off the local search function please refer to the Local search Radio reception failure and solution DVD playing fau...

Page 206: ...tion Symptoms Causes Solutions Cannot play MP3 Disc is scratched or dirty Clean the disc with soft cloth Laser head is dirty Clean the laser head with a laser head cleaning disc The disc is not suppor...

Page 207: ...Blue Blue white Green white Pink Reverse shift switch Yellow Rear view mirror power supply ground wire CAMERA B Rear view mirror power supply ground wire CAMERA GND Rear view mirror audio input CAMERA...

Page 208: ...hen changing the fuse please use the specified 15 A fuse Fuses with an unmatched size will lead to abnormal operation and even damage the player or cause a fire hazard 6 Please do not share the player...

Page 209: ...onditioning System s Structure Diagram and Fundamentals 207 Air Conditioning System Overview 207 Air Conditioning System Terminal Definition 208 Compressor 208 Electromagnetic Clutch 210 Vacuuming and...

Page 210: ...iquid refrigerant from the low pressure side 5 When undergoing maintenance pay attention that the amount of refrigerant being added is 510 10 g Observe through the check glass to determine if there is...

Page 211: ...of 0 with a open circuit resistance value of The cool ing system sometimes works some times not Compressor operates normally Cooling system has ice blockage Thermistor or thermometer bulb malfunction...

Page 212: ...ure too high high pressure side pressure too low a Compressor leaks b Compressor valve damaged 9 Low wind volume of the condenser blower can lead to poor heat dissipation Compressor operates abnormall...

Page 213: ...wer does not work Fuse blown or ill switch contact Blower motor burnt out Blower s high speed relay broken Speed adjustive resistance damaged Open circuit Water leakage Heater water pipe degradation p...

Page 214: ...regulation knob first otherwise it cannot start Operation The compressor is driven directly by the engine High temperature and high pressure refrigerant vapor exhausted from the compressor will pass t...

Page 215: ...afety instruction Cylinder Blade Exhaust valve Rotor Exhaust valve Compressor Entire outline structure shown on the left Rotary vane compressor s operation As the diagram shows when the rotor is rotat...

Page 216: ...ket onto the engine with four M10 1 25 Q1461030 FD bolts and a tightening torque of 45 5 N m and then install the compressor onto the bracket with a tightening torque of 22 3 N m 3 Take off the suctio...

Page 217: ...o very important If too big it leads to insufficient clutch pull in force If too small it may cause armature damage Clutch removal 1 Seize the clutch s triangular piece and secure the clutch s armatur...

Page 218: ...gauge High pressure gauge Manifold gauge Yellow Blue Yellow Red Air purge Blue Yellow Red Close Refrigerant tank Refrigerant tank Blue Red Yellow Low pressure High pressure Open Open Quick coupler Red...

Page 219: ...0 2 10 5 Pa and continue to vacuum for 15 minutes to exhaust the air which is entering the system following the oil Caution When replacing an old compressor with a new one be sure to bleed out some o...

Page 220: ...shooting 216 Vehicle Collision Diagnostics 226 Removal Method for Individual Components 227 Driver Side Airbag Module DAB Front Passenger Side Airbag Module PAB Clock Spring and Steering Wheel 228 Air...

Page 221: ...tion Furthermore wrap up the removed negative terminal with insulating tape After the battery power is cut off the capacitor in the airbag ECU will still maintain a set amount of electrical energy If...

Page 222: ...NSIONER Front passenger seat belt pretensioner low end 8 DRV PRETENSIONER Driver seat belt pretensioner high end 9 DRV PRETENSIONER Driver seat belt pretensioner low end 10 WARNING LAMP Warning lamp 1...

Page 223: ...ses of the malfunction diagnostic There are two SRS ECU malfunctions types classified by time current malfunction and history malfunction The malfunction types categorized by property are external mal...

Page 224: ...H 02H Removable 11 Driver side airbag assembly resistance too high or open circuit 01H 03H Removable 12 Front passenger side airbag assembly resistance too high or open circuit 01H 04H Removable 13 Fr...

Page 225: ...the SRS ECU through a battery the SRS ECU will light the warning lamp to inspect the light bulbs During the initialization stage the warning lamp will remain on for 6 7 s and in order to inform the d...

Page 226: ...tion Are other warning and indicator lamps on Yes Set the ignition switch to the LOCK position and then proceed to the next step No Detect the instrument cluster s power supply system and the grounded...

Page 227: ...step No Battery power supply is insufficient 2 Examine the conducting state of the wire harness between the ECU unit and combination meter Set the ignition switch to the LOCK position Disconnect the...

Page 228: ...stem electronic control unit circuit internal malfunction Possible causes SRS airbag system unit internal malfunction Operation Replace the SRS airbag system unit Refer to airbag system and SRS airbag...

Page 229: ...g connectors Install the battery s negative cable and set the ignition switch to the ON position Is the voltage of the switching connector s corresponding pin and ground higher than 9 V Yes Current tr...

Page 230: ...g working normally Normal Go to the next step Abnormal Replace the wire harness 4 Check whether the malfunction is on the clock spring or other components Set the dedicated detector at 2 position Inst...

Page 231: ...rmal Replace the wire harness 7 Front passenger side malfunction Type code 02 Trouble code 01 02 03 Front passenger side airbag module resistance too low or too high short circuit or grounded Detectin...

Page 232: ...rminal studs Connect the battery s negative cable Set the ignition switch to the ON position Is a trouble code displayed Yes Go to the next step No Replace the front passenger side airbag module See a...

Page 233: ...terminals are deformed 3 SRS ECU a Inspect whether the SRS ECU housing and bracket are sunken or depressed cracked deformed etc b Inspect for broken connectors as well as deformed terminals c Inspect...

Page 234: ...t them in a proper place or wrap them in tape 3 Removal sequence a Remove the auxiliary facia console b Reomve the connectors connected with the airbag ECU c Remove the SRS ECU 4 Installation sequence...

Page 235: ...n reverse order Driver side front airbag steering wheel and clock spring removal 1 Operation before removal a When the steering wheel and front tires are pointing straight ahead take out the ignition...

Page 236: ...ards and store it in a clean and dry place c Remove the steering wheel mounting bolt on the steering column Caution Due to the over tight occlusion of the spline and column the steering wheel and stee...

Page 237: ...module clock spring b Set the ignition switch to the ON position c The SRS warning lamp will remain on for 6 7 s and will then die out d If the warning lamp is always on or shows other symptoms after...

Page 238: ...le s wire harness which is used for deployment at a place as far away from the vehicle as possible and connect it to the two terminals removed from the vehicle battery caus ing it to deploy shown on t...

Page 239: ...ensioner wires and replace it with a 2 resistor to see whether airbag warning lamp is still on Disconnect the driver side seat belt pretensioner wires and replace it with a 2 resistor to see whether a...

Page 240: ...or Lock Assembly 239 Wiper Arm and Vent Panel Assembly 240 Front Rear Window Glasses 241 Dashboard 242 Cooling Unit 246 Front Door Assembly 248 Rear Door Assembly 251 Trunk Door Assembly 254 Front Bum...

Page 241: ...de handle of the front door on the out side handle framework Inside handle assembly Front door lock assembly LH Lock mounting screw Gasket Front door locking cable installing buckle Front door unlock...

Page 242: ...into the lock hole and then tighten the lock cylinder s mounting screw 5 Install the front door lock assembly Install the assembled assembly tighten the lock mounting screws pay attention to put the...

Page 243: ...ock removal For the removal please simply reverse the installation steps Caution The front door tie rod can be removed following the outside handle framework The front door tie rod can be removed afte...

Page 244: ...for the rear door lock assembly Separately install the rear door lock lock cable unlock cable cable installing buckle and rear door inside handle as sembly similar to the installation for the front d...

Page 245: ...inside handle clip to the door inner decoration board and then firmly press the inside handle clip dowel pin into the mounting hole 8 Install the rear door outside handle decorative cap and tighten t...

Page 246: ...sembly Install the trunk door main lock assembly and tighten the mounting screw 3 Install the trunk lock latch 4 For trunk lock removal please simply reverse the installation steps Trunk door lock ass...

Page 247: ...ne hood from the vent panel 5 Remove the screws from the two ends of vent panel 6 Remove the expansion button in the middle of the right and left vent panels 7 For wiper arm and vent panel Installatio...

Page 248: ...frame Rear window glass installation 1 Coat glass sealant primer on the rear door s sheet metal seam and rear window glass 2 Coat the rear window glass with glass sealant glass sealant height is 10 2...

Page 249: ...bly Fuse box Dashboard left trim strip Dashboard center console left trim strip Ash tray assembly Coin box bottom Coin box cover Front ash tray assembly Dashboard center console right trim strip assem...

Page 250: ...ter hood assembly 7 Remove the dashboard center console assembly a Remove the air conditioner s control buttons b Remove the four screws c Remove the dashboard center console assembly 8 Remove the CD...

Page 251: ...ve the four screws b Remove the small glove box assembly 14 Remove the ash tray assembly a Remove the two screws b Remove the ash tray assembly 15 Remove the coin box cover 16 Remove the coin box bott...

Page 252: ...or out and remove the dash board bottom and brace reinforcement assembly 19 Remove the dashboard bottom and brace reinforce ment assembly a Remove the two buckles b Remove the two screws c Remove the...

Page 253: ...mber from the vehicle body 6 Take the radiator out of its mounting hole 7 Remove the radiator inlet and outlet pipe Radiator filler assembly Radiator upper mount Radiator inlet connecting pipe Attachm...

Page 254: ...High rotational speed r min Counterclockwise 1850 250 2250 250 6 Check the sealing conditions of the radiator filler cap Connect the diagnostic scanner of the radiator filler cap and pressurize until...

Page 255: ...ner decoration board Front Door Assembly Components Front door triangular protector LH Front door protector assembly LH Front door armrest LH Front door internal weatherstrip LH Front door assembly LH...

Page 256: ...grease on the components before installing them a Coat MP grease to sliding surfaces and the gears of the window regulator Caution Do not coat MP grease to the spring of the window regulator b Coat MP...

Page 257: ...oor inner decoration board 10 Install the front door inside handle a Push the door handle into the door panel and slide it backward b Screw in the screws 11 Insert the wire harness of the front door p...

Page 258: ...p its head in tape g Take the door inner decoration board off Rear door outside triangu lar protector assembly LH Rear door assembly LH Rear door window rear guide rail LH Rear door inner triangular p...

Page 259: ...talling them a Coat MP grease to sliding surfaces and the gears of window regulator Caution Do not coat MP grease to the spring of the window regulator b Coat MP grease to the sliding surface of the d...

Page 260: ...rail LH Rear door glass run LH Rear door window LH Rear door window front guide rail LH Rear door external weatherstrip LH Rear door assembly LH 8 Install the rear door external weatherstrip Lower th...

Page 261: ...assembly Trunk door main lock assembly Trunk door right side air spring Trunk door hinge assembly Trunk door assembly Trunk door outside handle assembly Trunk door plate Trunk door handle Trunk door p...

Page 262: ...k door air spring removal 1 Open the trunk door 2 Remove the air spring mounting bolts from the trunk door 3 Remove the air spring mounting bolts from the side sheet metal of the rear body Trunk door...

Page 263: ...ad self tapping screw and large washer subassembly Q2754819 Q422 4 Front bumper left mounting bracket 5 Cross slot concave hexagon head self tapping screw and large washer subassembly Q2756319 Q421 6...

Page 264: ...off the hexagon head bolt and flat washer subassem bly Q1400616 that is on the left right side bracket of the bumper and connected to vehicle body 4 Remove the bumper bolts Screw off the mounting bolt...

Page 265: ...racket Screw off the cross slot concave hexagon head self tapping screw and large washer subassembly Q2756319 Q422 on the left right side mounting bracket of the front bumper and pull the left right s...

Page 266: ...ly Rear bumper trim panel buckle Expansion button 1 Cross slot concave hexagon head self tapping screw and large washer subassembly 2 Rear mounting bracket LH of the rear bumper 3 Rear bumper mounting...

Page 267: ...l the bumper out Pull the rear bumper out of the left right side bracket of the rear bumper and make the central part of the rear bum per slide out along the rear bumper central mounting bracket bolt...

Page 268: ...ne hood lock latch release mechanism 5 Remove the cable from the engine hood lock latch re lease mechanism assembly Installation Areas of Importance Different metals making direct contact will acceler...

Page 269: ...elt guide ring Rear seat belt retractor Seat belt lower mounting bolt Front seat belt retractor Front seat belt guide ring Seat belt lower mounting bolt Vertical adjuster mounting bolt Body B pillar s...

Page 270: ...en the seat belt retractor upper mounting bolt hexagon bolt for flange face Seat belt retractor upper mounting bolt torque is 9 3 N m 2 Remove the seat belt lower mounting bolt and B pillar lower deco...

Page 271: ...elt retractor lower mounting bolt torque is 45 5 N m 2 Install the guide ring Tighten the seat belt guide ring mounting bolt Guide ring mounting bolt torque is 45 5 N m 6 Install the B pillar lower tr...

Page 272: ...nt sharp and harmful substances from touching the seat belt Avoid winding or breaking the seat belt lock tongue and seat belt lock button Do not bleach or dye the seat belt woren band Wash it with neu...

Page 273: ...n hood 4 Tighten the front foundation bolt and install the front foundation hood Remarks Front seats are symmetrical Seats Components Areas of Importance 1 Pay attention to safety in the process of re...

Page 274: ...eat cushion Remarks Mounting bolt 2 refers to the rear seat backrest 1 mounting bolt Installation Special Note Different metals making direct contact will accelerate corrosion Make sure to use the cor...

Page 275: ...orque Sunroof panel Sunroof window weatherstrip Movable sun visor Slider Upper trim strip Lower trim strip Roof drip channel Guide device latch hook End piece Guide rail assembly Bolt Spring Wind guar...

Page 276: ...p of sand or dust ex ists on the surface of window panel weather strip Clean the weatherstrip surface and car roof hatch Check the sealing conditions between the guide rail front roof drip channel and...

Page 277: ...allation The window panel must be installed at the initial position window panel is closed 1 Window panel location The mark indicated by the arrow on the top of rear guide device which is on the windo...

Page 278: ...b If the prestress is excessive use a stick to compress the weatherstrip s clearance Replace the weatherstrip 1 Remove the window panel weatherstrip 2 Install the weatherstrip Start from the center o...

Page 279: ...e rail with a screwdriver Then move the sun visor forward push it to one side and pry the rear slider on the two sides of sun visor out of guide rail with a screw driver Finally pull out the sun visor...

Page 280: ...ation condition Instructions Only when the sunroof is on the initial position and the drive device and window panel are removed can the parallel operation conditions be adjusted 1 The mark indicated b...

Page 281: ......

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