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Chapter Five: Transmission ........................................................................................................42

037A Transmission’s Overall External Schematics ....................................................43
Main Technical Parameters  ......................................................................................43
Transmission’s Proper Use and Care ........................................................................44

Technical Specifications 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 ....................................................................................................50
Disassembling the Input Shaft Subassembly ............................................................56
Disassembling the Output Shaft Subassembly ..........................................................60
Disassembling the Shift Cover Subassembly ............................................................64
Disassembling the Differential Subassembly .............................................................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 and Tire ...........................................................................................................89

Chapter Seven: Brake System ...................................................................................................94

Brake System Components Arrangement Schematics ..............................................95
Brake System Maintenance .......................................................................................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 Importance ................................109

Steering Knuckle and Hub Brake Assembly

 ............................................................112

Front Brake Caliper ..................................................................................................118
Rear Brake ...............................................................................................................124
Rear Support Axle ....................................................................................................131

Chapter Eight: Steering System ...............................................................................................134

Troubleshooting .......................................................................................................135
Steering System Maintenance .................................................................................137
Power Steering Fluid Instructions ............................................................................141

Содержание Florid

Страница 1: ......

Страница 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...

Страница 3: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 281: ......

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