GREAT WALL HOVER - Service - Manual PDF

Preface
Since the Great Wall Hover is put into the market, it has won the favor from the cus-
tomers for its elegant appearance, excellent performance&price ratio,concept of double
area and eternal safety. This vehicle is provided with the Mitsubishi engines of 4G63,
4G64 and 4G69 and the Great Wall engines of GW2.8TC, GW2.8TCI, and GW2.5TCI,
and also the manual transmissions from Shanghai Gear, TAGC and ZOMAX. ABS and
airbags are optional. Before of its complex structure, high technical intervention and diffi-
culty of maintenance, its maintenance needs the reference of related documents. Upon
the request of the after-sale maintenance technical personnel of Great Wall, we have
prepared this Hover Maintenance Manual. The manual is oriented towards the aftersale
maintenance technical personnel of the Great Wall, and mainly introduces the disass-
embly of the various systems of Hover (refer to the maintenance manual of motor for the
introduction of the motor), the troubleshooting, matters needing attention for maintenance
and the related technical parameters.
During the preparation of this book, a lot of professional personnel have given su-
pport and help, here we would like to express our sincere thanks.
Though we have made efforts to prepare this manual earnestly, we cannot guaran-
tee that the content in the manual is totally accurate and without error. The user cannot
raise improper request to the Great Wall Company with the manual as legal basis. We
cannot bear any responsibility for the losses caused by using this manual. Confined to
the knowledge of the editor, the fault and errors are inevitable, your advice and comment
are appreciated.
The final authority for the interpretation of this manual belongs to the Great Wall Mo-
tor Co., Ltd.
Editor
Preface
Table of Contents
Introduction How to use the manual
Chapter 1 General Description of Complete Vehicle
Chapter 2 Fuel-supply System
Chapter 3 Exhaust System
Chapter 4 Clutch
Chapter 5 Transmission
SC5M2D-C SC5M4D-C
038M1
038M
ZM001DB
ZM001DF
ZMOO1M ZMOO1MF
Transfer case(4555)
Chapter 6 Drive shaft
Chapter 7 Suspension and axle
Chapter 8 Wheels and Tyres
Chapter 9 Brake
Chapter 10 Steering System
Chapter 11 Body Electrical Appliance
05
05 Top model
06
08
K1-NCAP
TK
Chapter 12 Electric Appliance
Chapter 13 Air Conditioning System
Chapter 14 Safety airbag(Siemens)
Chapter 15 Interior and Exterior Trims of Vehicle Body
Chapter 16 Body & Stamping Parts
Chapter 17 Bolt Tightening Torque (Chassis)
Introduction-1
Introduction
How to use this manual ................................................... 2

Identification mark............................................................ 4
Comprehensive maintenance instruction ...................... 4
Introduction-2
How to use this manual

In order to help you to use this manual, the chapter
name and main topics are given at the upper side of
each page.
To introduce to you the maintenance items, there is an
index on the first page of each chapter.
At the beginning of each chapter, there are also the
matters needing attention of all the maintenance ope-
rations.
Please read the following matters needing attention be-
fore starting the maintenance work.
The failure diagnostic list of each system can help you
to diagnose the failure of the system and find out the
causes of failure.
The maintenance method with regard to the possible
causes is given in the column of maintenance method
to facilitate you to acquire the method of solving the
problem quickly.
Maintenance procedure
Most part of the maintenance operation can be started
from referencing the illustration. These illustrations help
you recognize the parts and show the mutual coordina-
tion.
For example:
washer
★upper arm shaft
upper arm bush
210 210
upper arm bush
washer upper arm
upper ball pin
78
◆split pin
N·m :specified torque

◆ Used component which can not be used any more
★ Pregummed components 145
Introduction-3
The maintenance procedure is explained in the form

step by step:
• The illustration shows what to do and where to do.
• The topic of maintenance work tells you what to do.
• The detailed instruction tells you how to finish the
maintenance work and introduce other related is-
sues, such as specification and warning, etc.
For example:
Work topics: what to do
3. Check the drive of ball pin

illustration: (a) Remove the ball pin.
what to do and where to do Detailed instruction: How to do
(b) As shown in the Figure, shake the ball pin back

and forth for several times before mounting the
cap nut,
(c) Turn the but with torque meter continuously, turn
one cycle every 2 to 4 seconds, read the torque
meter at the fifth cycle.
Tightening torque (for rotary):
Upper ball pin 0.1-4N·m Specification
Lower ball pin 0.1-4N·m
This format can help the experienced technical per-

sonnel to locate the causes of failure quickly. The ma-
intenance personnel can browse the work topics, and
reference the detailed explanation below it only when
necessary. The important specification and warnings
are given in bold face letter.
Specification
In the whole manual, each maintenance step is given
with corresponding specification in bold face letter, so
there is no need to stop working to look at the specifi-
cation.
Warning, Attention, Remarks
• The Warning is given in bold face letter, which
means there is the possibility of harming both the
person himself and others.
• The Attention is written in bold face letter, which
means there is the possibility of damaging the parts
under maintenance.
• The Remarks is written separately in the instruc-
tion, it is also in bold face letter. Its main function is
to make some additional explaining to help you to
finish the repair work more efficiently.
Introduction-4
Identification mark
VIN nameplate
The identification code of the car
nameplate The identification code of the car is a unique code of
17 bits to identify the car. Besides appearing on the
label plate of the entire car, it is also inscripted on the
external right side of the right stringer (chassis number)
and on the VIN nameplate at the upper left part of the
panel.
vehicle VIN NO.
Motor serial number

The manufacture number of motor is inscripted on the
right side of the cylinder .
Comprehensive maintenance ins-

truction
1. Use the protection plate, seat and floor covering
cloth to make the car clean and prevent it from be-
ing damaged.
2. During the disassembling, place the components
in order for the convenience of assembly.
3. Observe the following issues:
(a) Before conducting the electrical work, remove the
negative pole of the cable from the accumulator
terminal.
(b) When it is necessary to remove the accumulator
for checking or maintenance, the cable shall be
removed from the negative pole (-) connected to
the car body.
(c) In order to avoid the damage of accumulator ter-
minal, when removing the cable, loosen the termi-
nal nut, then pull the cable upwards vertically, do
not twist or pry it.
(d) Please use cleaning cloth to clean the accumula-
tor terminal. Do not use file or other similar tools,
which may scuff them.
Introduction-5
(e) Mount the cable terminal onto the binding post

of the loosened nut, then tighten the nut. Does
not use hammer to knock at the terminal onto the
post.
(f) Do remember to check whether the positive pole
(+) terminal cap is in its position.
4. Check all the soft tubes and wire terminal, check to
see whether they are connected correctly and fir-
mly.
5. Used component which can not be used any more.
(a) The following spare parts needs always to be re-
newed: split pin, seal gasket, O ring and oil seal,
etc.
(b) For the used component which can not be used
any more, it is indicated by symbol “◆” in ele-
ments diagram.
6. Precoated component
The precoated component includes the bolt and nut
locking sealant
which is precoated with the locking sealant in factory.
(a) If the precoated component is tightened, loosed
or moved by any reason, it must be recoated with
the specified sealant.
(b) Coating procedure of precoated component
Remove the old sealant from the screw of component
by washing.
Dry it by compressed air.
Coat the screw of components with the specified loc-
king sealant.
(c) The precoated component is indicated by symbol
“★” in elements diagram.
7. It can use the sealant or seal ring to prevent the
leakage if necessary.
8. Abide by all specifications for bolt torque strictly. It
should use the torque wrench.
9. Determine the necessity of using special mainte-
nance tools and special maintenance material ac-
cording to the practical situation of maintenance.
Use them on the necessary position, and go on
with the maintenance according to proper procedu-
res.
10. To replace the fuse, check to see whether the rated
current of new fuse is correct. Do not exceed the
rated current of the fuse, or do not use the fuse
with low rated current.
11. When jacking up or supporting the car, lift or su-
pport the car on proper position with care.
(a) If only jacking up the car in the front part or rear
part, choke up the wheel to ensure the safety.
(b) After the car is jacked up, use frame to support it.
It is dangerous to conduct maintenance on the car
that is only jacked up with one screw jack, even
for the minor maintenance that can be finished
quickly.
Introduction-6
12. Paying attention to the following matters to avoid

the damage of components:
(a) If it is not absolutely necessary, do not open the
housing of the ECU and the computers (if the IC
terminals are touched, the IC may have electros-
error correct tatic damage).
(b) When removing the vacuum tube, pull the end of
the tube instead of the central part of the tube.
(c) When pulling the wire terminal, pull the terminal
itself instead of the wire.
(d) Take care to not make the electrical components
fallen, such as the sensor or relay. If they fall to
the hard ground, they must be replaced.
(e) Never use the striking wrench to remove or install
the electric thermostat or thermostat sensor.
(f) When checking the conducting state of the wire
connector, insert the multimeter with care, do not
bend the terminal.
(g) When using the vacuum meter, do not insert the
soft tube onto large connector. Use the stepped
terminal. Once the soft tube is swelled and tighte-
ned, there may be leakage.
General Description of Complete Vehicle-1
General Description of Complete

Vehicle
CC6460K and CC6460KY wagon (4G64)....................................... 2
CC6460KM55 and CC6460KM75 wagon
(2.5TCI right-hand drive). ............................................................... 12
CC6460KM07 and CC6460KM27 wagon
(4G63 left-hand drive)..................................................................... 16
CC6460KM19 and CC6460KM39 wagon (4G69) ........................... 21
CC6460K and CC6460KY Wagon (4G64)

Basic Parameters of Complete Vehicle
Item CC6460K CC6460KY
Size parameters (no-load) (mm)
Length 4620
Width 1800
1710 (vehicle body)/1775 (plus tail fin, luggage rack)/1810
Height
1700 (vehicle body)/1765 (plus tail fin, luggage rack)/1800
Axle base 2700
Wheel base: Front/Rear 1515/1520
Front suspension 850
Rear suspension 1070
Quality parameters
Loading weight (kg) 5 persons×65kg/person+150kg
Curb weight (kg) 1720 1830
Max. gross mass (kg) 2195 2305
Load distribution on no-load axle : Front/rear (kg) 890/830 980/850
Load distribution on full-load axle load distribution: Front/rear
980/1215 1070/1235
(kg)
Trafficability parameters
Min. turning diameter (m) ≤13
Min. ground clearance (mm) ≥180 ≥175
Approach angle (°) ≥28 (no-load)
Departure angle (°) ≥27.5 (no-load)
Power performance:
Min. stable speed of direct drive (km/h) ≤25
Accelerating time of direct drive 30km/h~100km/h (s) ≤32
Accelerating time of initial starting of Gear 1 shifting to
≤20
100km/h (s)
Top speed (km/h) ≥160
Max. climbing capacity (%) ≥35
Economical efficiency
Sliding distance with initial speed 50km/h (m) ≥500
Fuel consumption under 90km/h constant speed driving
≤10.19
(L/100km)
≤13.24
(L/100km)
Fuel consumption under simulation of urban and suburban
≤11.9 ≤12.5
comprehensive working conditions (L/100km)
Brake performance
Service braking distance of initial braking speed of 50km/h (m) ≤19 (no -load), ≤20 (full load)
Emergency braking distance of initial braking speed of
≤38
50km/h (m)
Grade parking brake (%) ≥20 (no -load), ≥18 (full load)
Stability
Max. side cross stable angle under no-load and static status (°) ≥35
Control stability (minute) Nan≥60 and NZ≥60
Smoothness
Acceleration weighted mean square valueσw(m/s2) ≤0.6883
Equivalent mean value Leq (dB) ≤116.5
Reducing comfort limit TCD (h) ≥1.2
Tightness
Dust-proof tightness M (%) ≥95
Waterproof tightness (minute) ≥93
Noise
Outside noise when driving in acceleration speed dB (A) ≤74
Inside noise when driving in uniform speed of 50km/h dB(A) ≤79
Parotid noise beside the driver dB(A) ≤90
Emission
Conform to exhaust emission of Euro II CO≤2.2g/km, (HC+NOX)≤0.5g/km
Pollutant drainage in low and idle speed: (750±50) r/min CO≤0.1%, HC≤50ppm
Pollutant drainage in high and idle speed: (2000±50) r/min CO≤0.07%, HC≤50ppm
Structure Types and Technical Parameters of Main Systems and Assemblies
Engine
No. Item Specifications and parameters
1 Model 4G64S4M
Four-cylinder, in-line, water cooling, single over-head
2 Mode
camshaft four-stroke petrol engine
3 Fuel supply type Multi-ignition fuel injection (MPI)
4 Measure method of air intake Speed-intensive
5 Mode of combustion chamber Single-slope roof
6 Cylinder diameter×stroke (mm) 86.5×100
7 Total displacement (L) 2.351
8 Compression ratio 9.5:1
Max. power and corresponding rotation speed
9 93/5250
(kW/r/min)
Max. torque and corresponding rotation speed
10 190/2500
(N•m/rpm)
11 Min. fuel consumption (g/kW•h) ≤254
12 Stable idle speed (r/min) 750±30
13 Idle control Electronic closed-loop control
14 Mean speed of piston (m/s) 17.5
15 Mean effective pressure (kPa) 1036
16 Cylinder compression pressure: 250r/min (kPa) 1320
1-3-4-2; without distributor block, ignition directly through
17 Ignition order and control
electronic control
18 Ignition plug clearance (mm) 1.0~1.1
BKR5E-11 or K16PR-U11 or RC10YC4
19 Ignition plug model
BKR6E-11 or K20PR-U11 or RC8
20 Ignition plug manufacturer NGK or DENSO or Torch
21 Valve clearance (mm) 0 (hydraulic tappet)
Valve timing phase: open/closed air intake valve 18°in front of upper dead point/53°back of lower dead point
22
　　　　　　　　　open/closed exhaust valve 50°in front of lower dead point/18°back of upper dead point
23 Lubrication type Combined type of pressure and splash
Oil pressure of main oil way: idle speed/
24 (≥78.5)/(245~490)
3000rpm (kPa)
25 Max. oil temperature (℃) 130
26 Oil consumption (g/kW•h) 2
27 Oil and fuel consumption ratio (%) ≤0.8
28 Cooling type Closed-circuit forced water cooling
29 Starting type Electric starter
30 Net mass (kg) 167
31 Overall dimension: length×width×height (mm) 730×653×667
32 Emission in idle speed: CO(%)/HC(ppm) ≤0.5/≤100
With three-way catalytic converter, air-fuel ratio closed-loop control,
33 Emission control level of work condition code
conform to GB18352.2-2001 standard when carrying light vehicle
Air Intake System
Dry-type Air Cleaner.
Exhaust System
It is equipped with first-level silencer, with second-level three-way catalytic device.
Fuel Supply System
Adjustment of accelerator pedal: free play of accelerator pedal is 155mm. If it does not conform to the
standard value, adjust the adjusting nut on the cable bracket.
Fuel tank is made of plastic, with the capacity of 67L; Fuel supply control is mechanical pedal fuel
supply control, with integral electronic fuel pump; The fuel is vaporized to activated carbon pot, and it
is controlled by electronic valve.
Cooling System
Forced circulation water cooling, electronic fan, and aluminium ribbon-tubular radiator.
Clutch
It is equipped with friction, disc type, single plate diaphragm spring clutch, hydraulic control
mechanism. Outer diameter D and inner diameter d of friction plate is 225mm and 150mm
respectively. The material is F810.
Adjustment of Clutch Pedal
1. Measure the height (from pedal cushion to the floor) and free play (fork level pin clearance) of
the clutch pedal. The standard value of height of clutch pedal: keep alignment to brake pedal,
and the free play of clutch pedal is 5-15mm;
2. Firstly adjust the height of pedal, and then adjust the free play of the pedal. Turn the push rod
till it reaches the standard value and fix the bolt and nut;
3. If the free play of the clutch pedal is beyond the standard value, turn the adjusting bolt to the
standard value and fix the bolt and nut. When adjusting the free play of the pedal, do not impel
the push rod to the master cylinder;
4. If the clearance between the clutch pedal and the floor does not conform to the standard
value when the free play of clutch pedal is separated from the clutch, it may be caused by the
malfunction of master cylinder or clutch because of entering of air in the hydraulic system. So,
conduct deflation for the system or remove and inspect the master cylinder or clutch.
Transmission
No. Item Specifications and parameters
1 Model SC5M2D-C SC5M4D-C
Manual mechanical step speed A l l s y n c h r o n i z e r w i t h m a n u a l
transmission of all synchronizer, 5 mechanical step speed transmission
2 Mode forward gears, 1 reverse gear, and of transfer case, 5 forward gears, 1
direct control reverse gear, and direct control
72 (transmission), 222.25
3 Central distance (mm) 72 (transfer case)
4 Max. input torque (N·m) 196
5 Max. input rotation speed (r/min) 5500
Gear Gear Gear R Gear H Gear
Gear I Gear II Gear V (reverse)
6 Speed ratio III IV (high) L (low)
3.967 2.136 1.360 1.000 0.856 3.578 1.000 1.925
7 Gear pair of odometer 8:25
8 Gross dry mass (kg) 38 68 (including transfer case)
Overall dimension: length×width× 1 0 7 0 m m × 4 6 6 m m × 3 9 9 m m 1070mm×460mm×380mm (excluding
9
height (excluding the height of control lever) the height of control lever)
Drive Axle
The rear drive axle assembly of CC6460K wagon includes three cross axle universal joints, two drive
axles and maintenance-free sectional structure with expansion spline and intermediate support.
The front and rear drive axle assembly of CC6460KY wagon includes two cross axle universal joints,
a drive axle and maintenance-free integral structure with expansion spline.
Front Axle
The front axle of CC6460K wagon is a double-transverse arm independent suspension breakaway
front axle.
For CC6460KY wagon, it is equipped with double-transverse arm independent suspension breakaway
steering drive axle, hyperbolic gear single-stage main reducing gear, common bevel gear differential,
universal drive half axle, ball cage universal joint with constant speed. The main reducing ratio i0=4.55,
and the max. input torque is 900N•m.
Rear Axle
It is equipped with non-breakaway drive axle, integral punching welding axle case, hyperbolic gear
single-stage main reducing gear, common bevel gear differential, and semi-floating half axle. The
main reducing ratio i0=4.55, and the max. input torque is 900N•m.
Wheel and Tyre
Rim Offset Tyre Rolling radius
Tyre type Tyre specification Wheel type
specification distance pressure of tyre
P235/65 Light alloy spoke plate wheel 5°deep-groove
Radial tyre 38mm 230KPa 353mm
R17 104T with inner offset distance rim 17×7JJ
Suspension
The front suspension is equipped with torsion bar spring, binocular inflatable hydraulic shock
absorber, anti-sway bar, double-transverse arm independent suspension. The distance between the
fixing nut center of front axle of lower suspension arm and level ground is 295mm±1mm.
The rear suspension is equipped with four-bar linkage, coil spring, binocular inflatable hydraulic shock
absorber, anti-sway bar and dependent suspension.
Frame
It is a peripheral trapezoidal frame, and welded by two box-shaped section longitudinal beams and
several box-shaped or pipe-shaped section beams.
Steering System
It is equipped with rack and pinion power steering system and hydraulic boost steering, and also
provided with breakaway preposition steering trapezoidal structure. Four-radius steering wheel
diameter φ is 380mm with adjustable angle and energy-absorbing steering column.
No. Item Parameters No. Item Parameters

Revolution circles of
1 Camber angle of wheel 0°±30′ 6 3.64
steering wheel n
Angle gear ratio of
2 Kingpin inclination angle 12°30′±30′ 7 18.2
steering system i0ω
Force gear ratio of
3 kingpin caster angle 3°30′±30′ 8 198.0
steering systemi0p
Positive efficiency of
4 Toe-in (mm) 0~2 9 ≥75%
steering gear η+
Steering angle of interior Negative efficiency
5 32/28 10 ≥60%
and exterior wheel(°) of steering gear η-
1. Four-wheel Alignment Adjustment

Inspect and adjust front wheel alignment value and adjust toe-in on four-wheel alignment instrument
(a) Adjustment of kingpin caster angle: the standard value is 3°30′±30′(adjust the differential value of
left and right kingpin caster angle within the range of 30′);
(b) Adjustment of toe-in: the standard value is 0~2mm. Toe-in is adjusted by turning the steering tie-
rod. Before adjusting toe-in, turn the tie-rod evenly on left and right sides. Screw up the locking
nut after the adjustment, with the tightening torque of 55-65N•m.
(c) Central fixing of steering wheel: according to the display of the alignment instrument, turn the
front wheel to right ahead, take off the steering wheel without changing the position of steering
lever, and install the steering wheel in the center. Spoke plate of steering wheel should be in the
central place and the “Great Wall” mark on the steering wheel should be in driver’s orthophoria
position. Screw up the nut with the tightening torque of 25-35N•m.
2. Check of Max. Steering Angle:
(a) Check of Max. Steering Angle:
Left steering of left wheel: ≥32°, Left steering of right wheel: ≥28°;
Right steering of left wheel: ≥28°, Right steering of right wheel: ≥32°;
(b) Under no-load state, the distance between the fixing bolt center of front axle of lower suspension
arm and level ground shall be 295mm±1mm. If the dimension is not in this range, adjust the bolt
height of adjusting arm of torsion bar;
(c) The reference height of vehicle: deviation on left and right side shall be less than 10mm;
3. Check of Free Clearance of Steering Wheel:
Adjust the direction of the vehicle, stop the engine, and turn the steering wheel to left with the force of
about 4.9N in circular direction, stop the operation when the resistance increases; turn the steering wheel
to right, and stop the operation when the resistance begins to increase; the arc value in the exterior of the
steering wheel is the free clearance of the steering wheel, and the standard value shall be not more than
20°. The turning angle from middle position to left or right shall be not more than 10°.
Brake System
The front wheel brake is ventilated disc brake, and rear wheel brake is disc-drum brake. The type of
service brake is dual-circuit vacuum power-assisted hydraulic brake, which acts on front and rear disc
brake. The type of parking brake is mechanical cable, which acts on drum brake of rear wheel.
The free play of brake pedal is 4mm~6mm, and the operating stroke of the pedal is 120mm. The
operating stroke of brake handle is 3 teeth ~ 9 teeth.
1. Adjustment of Brake Pedal
Measure the operating stroke of brake pedal. The standard value is 120mm. If the height is not
satisfied, adjust it according to the following sequence:
(a) Separate wiring connector of braking lamp switch, screw off the closed nut, and turn the braking
switch until not contacting with the brake pedal stopper;
(b) Screw off the closed nut of control connecting rod and turn the control connecting rod with slip
joint pliers to adjust the height of brake pedal to the standard value. After it is up to the standard
value, lock the locking nut;
(c) After turning the braking lamp switch to exactly contact with the brake pedal stopper, continuously
turn 1/2~1 circles and screw up the closed nut;
(d) Connecting wiring connector of braking lamp switch;
(e) Under the loosening state of brake pedal, the braking lamp shall not be on.
2. Standard value of free play of brake pedal: 4-6mm
(a) Under the stop condition of the engine, step the brake pedal 2~3 times. After getting rid of
the effect of brake booster, push the brake pedal by hands until encountering resistance, and
measure the displacement (free play). It shall conform to the specified standard value;
(b) If the clearance is less than the specified value, check whether the clearance between post rod of
braking lamp switch and brake pedal conforms to the specified value. If the clearance is over the
specified value, it can be determined that the clearance between connecting fork pin of driving
rod and brake pedal arm is over the specified value.
3. Start the engine and step the brake pedal with the force of about 700N to check whether there
is oil leakage for the master brake pump and each connecting parts of brake pipeline. If it leaks,
repair it.
4. Working State Test of Brake Booster
Make working state test of brake booster according to the following methods:
(a) Start the engine to run for 1~2 minutes, and then stop it. Step on the brake pedal several times
with normal force. Except for full step of the first step, the rising of the height of brake pedal
each time shows that the brake booster is normal. If the height of peal height does not change, it
means that the brake booster is damaged;
(b) After stopping running of the engine and ensuring the gradual increase of the brake pedal height
by stepping on the brake pedal several times, start the engine with stepping on the brake pedal.
If the brake pedal moves downwards, the brake booster is normal. If the brake pedal moves
upwards, the brake booster is damaged;
(c) Stop the engine by stepping on the brake pedal when the engine is running. If the height of the
brake pedal does not change in 30 seconds, the brake booster is in good condition. If the brake
pedal moves upwards, the brake booster is damaged.
5. Adjustment of Parking Brake System:
(a) To orient the steel lock, pull the parking brake rod with the force of about 400N to count the
striking teeth after pulling the brake rod to limit position over 3 times. Standard value of parking
brake stroke is 3 teeth ~ 9 teeth;
(b) If the stroke of parking brake rod is excessive and does not conform to the requirements, adjust
it according to the following methods. Loosen the parking brake rod and screw off the adjusting
nut. Remove the block cover of the hole on the adjuster from brake assembly, turn the adjuster
with screwdriver according to the arrowhead direction until the brake drum cannot be turned.
Turn 5 teeth reversing the arrowhead direction. Turn the adjusting nut, and adjust the stroke of
parking brake rod to standard value.
(c) If the stroke is less than the standard value, screw off the adjusting nut to make the stroke
achieve the standard value.
(d) Check whether the adjusting nut and the screw rod are loosening after the adjustment, and
adjust the nut to check whether it is correctly fixed in the nut fixing seat.
(e) Jack up the rear of the vehicle and loosen the parking brake rod after the adjustment to check
whether it drags the brake disc when the rear wheel turns.
(f) Running-in of parking brake: When pulling the parking brake rod with the force of about
200-250N, run 400m with the speed of about 60km/h for 2-3 times, and then test it on the slope
with the inclination of 30% for parking.
Vehicle Body
No. Item Structure and parameters
1 Vehicle body
Cab-behind-engine, two-carriage, five doors, five seats, all-metal close
1.1 Type of vehicle body
type, hard-top body-chassis frame construction
1.2 White body Punching, welding, all-metal close type structure
Framed and clamping-plate door lock, hinge with side anti-collision
1.3 Door assembly lever, four side doors with positive opening; rear tail door with outward
opening. Central control door lock, motor glass lifter
1.4 Engine hood With upward and backward openings and single arm hinge
2 Interior and exterior trim of body and accessories
Softening design, conform to the requirements of ergonomics and
2.1 Interior trim
comfort
2.2 Instrument panel Injection structure, metal skeleton
A, B, C columns and door
2.3 Injection molding, glove box mounted on door panel
inner panel
2.4 Handrail in the vehicle Metal skeleton, PVC case, with PUR foaming layer in the middle
Panoramic bent windshield. Front windshield: Interlayer glass, with the
thickness of 4.76mm. Rear windshield: Toughened glass, with electric
2.5 Windshield
heating defrosting resistance wire of 3.5mm thick. Other windows:
Toughened glass with the thickness of 3.5mm
Exterior rear-view mirror: Electric and electric heating defrosting, non-
glare, with convex reflectors on both sides, radius of curvature of
2.6 Rear-view mirror
1400mm. Interior rear-view mirror: Manual, non-glare, plane interior
mirror
Seats for driver and auxiliary driver: Independent seat, with adjustable
2.7 Seat front and rear position, backrest angle and seat headrest. Rear seat:
Independent seat, with adjustable backrest angle and seat headrest
Fixing in two points for rear middle seat, emergency locking mechanical
2.8 Safety belt
safety belt fixed by three points for other seats
2.9 Sun visor Deluxe, with headlight and dressing mirror
2.10 Sunroof Electric sunroof
2.11 Front and rear bumpers Integral design, PP injection molding
Check and Debugging of Body Accessories
Steadily stop the vehicle, check to verify that the operation of opening, close and locking mechanism
of the door, engine hood, oil filling cover, cover of instrument panel tool case, front and rear ash
tray cover, glove box cover of central console of the floor, CD disc changer (VCD disc changer) and
electric outlet hole cover are reliable and flexible, without seizure, incomplete close and abnormal
sound;
Electrical System
Power supply, starting and
1
charging system
One wire system, voltage direct current of 12V, ground earth with
1.1 Circuit
negative pole
55D26R maintenance-free, 12V voltage, rate capacity of 60Ah in 20
1.2 Battery hours, reserve capacity of 101min, low temperature starting current of
475A
1.3 Starter 12V, 1.2kW
1.4 Generator With the internal adjuster generator. 14V, 90A
2 Lighting and signal system

White, 60W main upper beam, one for left and right side separately,
2.1 Headlamp 55W auxiliary upper beam, one for left and right side separately. Bench
mark center height of headlamp H: 920mm±20mm
Front position lamp: White, 5W, one for left and right side separately.
2.2 Position lamp
Rear position lamp: Red, 5W, one for left and right side separately
Amber. Front and rear turning lamp: 21W, one for left and right side
2.3 Turning lamp
separately. Side turn lamp: 5W, one for left and right side separately
Front fog lamp: white, 55W, one for left and right side separately. Rear
2.4 Fog lamp
fog lamp: red, one for left and right side separately
Red, 21W, one for left and right side separately, high mount brake lamp,
2.5 Brake lamp
10W, 2 in the middle
2.6 License plate lamp White, 5W, one for left and right side separately
2.7 Reversing lamp White, 21W, one for left and right side separately
2.8 Danger alarming signal lamp All turning signal lamp, danger alarming switch control
2.9 Rear reflex reflector Red, non-triangle, combined with rear fog lamp to be combination lamp
Interior front, middle and rear White. Interior front ceiling lamp: 10W, 2. Interior middle ceiling lamp:
2.10
ceiling lamp 10W, 1. Interior rear ceiling lamp: 5W, 1
2.11 Cigar lighter lighting Blue, 3W, 1
2.12 Ash tray lighting White, 3W, 1
3 Instrument system
Speedometer, engine speed indicator, water temperature gauge, fuel
3.1 Combination meters
gauge
3.2 Indicator light -
4 Auxiliary electrical system
Front and rear windscreen wiper direct current motor. Front windscreen
wiper: double lever, electric gear 3 (high and low speed + adjustable
4.1 Windscreen wiper system batch), 2 wiper blades, 55W. Rear windscreen wiper: single arm, electric
gear 1, 1 wiper blade, 21W
Front windshield is warm-air type; Rear windshield is electric heating
4.2 Demister and defroster
windscreen, controlled by the switch
Totally controlled by the driver, independent control for other doors and
4.3 Motor glass lifter
windows
4.4 Central control door lock With remote control
4.5 On-vehicle power socket 12V, 2
4.6 Radio, CD and loudspeaker Stereo radio, six-disc CD, quadruple
4.7 Cigar lighter 12V, 1
4.8 Horn High and low tone
4.9 Safety airbag Electronic master and auxiliary airbags
1. Check of Instrument Indicator
Check of indicator, alarming lamp and instrument:
(a) When the ignition lock is “ON” and the engine starts, operate the corresponding system to check
the functions of turning indicator lamp, charging indicator lamp, oil pressure indicator lamp,
parking brake and brake fluid level alarm indicator lamp, vacuum boost brake alarm lamp, fuel
filter indicator lamp, headlamp high beam indicator lamp, front fog lamp indicator lamp, door
open alarm lamp, back door open alarm lamp, low oil level alarm lamp, engine malfunction
indicator lamp, 4WD indicator lamp, safety belt alarm lamp, instrument illumination lamp,
etc. on the instrument panel. If their functions are abnormal, find out the causes and conduct
troubleshooting;
(b) When the ignition lock is “ON” and the vehicle is running, operate the corresponding system to
check whether the functions of fuel gauge, coolant temperature gauge, engine speed indicator,
speedometer and odometer on the instrument panel are normal.
2. The functions of headlamp upper and lower beam, dimmer lamp, tail lamp, turning lamp, brake
lamp, front and rear fog lamp, malfunction alarm lamp, interior lamp, instrument panel lamp,
ignition switch lamp of the complete vehicle shall be normal, without no light, constant light
and wrong light phenomenon.
3. Performance Check of Front Headlamp
(a) The light intensity of upper beams of each headlamp ≥20000 cd/piece
(b) Left and right deflection of beam center (when the beams flash on the screen with the distance of
10m):
Left upper beam headlamp: Left 17cm Right 35 cm
Right upper beam headlamp: Left 35 cm Right 35 cm
Left lower beam headlamp: Left 17cm Right 35 cm
Right lower beam headlamp: Left 17cm Right 35 cm
(c) Central height of the beams (when the beams flash on the screen with the distance of 10m):
Lower beam headlamp: 0.7~0.9 H; Upper beam headlamp 0.9~1.0 H
H indicates the central height of headlamp, which is 920±20mm.
4. Adjustment of Multifunction Instrument:
(a) Drive the vehicle on the trench, insert speed sensor plug, and then drive the vehicle on wide
proving road, press ADJ switch not less than 3 seconds until the azimuth indicator begins to
flash. After slowly turning the vehicle over a circle within 2 minutes, the azimuth indicator stops
flashing to indicate the actual normal azimuth.
Note: E-east, W-west, S-south, N-north.
(b) Adjust the time
Press “MODE” switch over 2 seconds to adjust the time. Press MODE switch to adjust “minutes”,
press MODE key once again to adjust “hours”. The time can be adjusted by pressing “▼” and
“▲” keys. After finishing the adjustment, press “MODE” switch over 2 seconds to quit the time
adjustment mode.
(c) Check whether the functions of sea level elevation meter and speed response indicator are
normal.
(d) Drive the vehicle on the trench again and pull out the speed sensor plug.
5. Adjustment of Ejection Height of Wiper Nozzle Washing Solution
(a) Turn the ignition switch on the position of “ON” and open the switch of wiper nozzle to check
whether the ejection position of front washing solution nozzle is evenly distributed on the middle
height position of front windshield glass.
(b) The ejection position of rear washing solution nozzle deviates to right about 20mm-120mm
from the center of rear windshield glass and the height is about 50mm from the center of the
windshield glass. If the deviation is large, adjust the nozzle.
(c) Open the wiper switch to check whether the turning of the wiper and the ejection of the washing
solution nozzle are normal. When closing the wiper switch, the wiper blade should be back to the
initial position automatically.
A/C System
Front and rear warm-cold A/C, vapor compression refrigeration, hot water
1 Structure type
heating
Refrigerating output of 3.5kW, heat exchange output of 3.5kW, air flow of
2 Performance parameters
350m3/h
Control board button control, temperature automatic control, air door micro-
motor drive, with automatic control of interior temperature, and selection and
3 Control adjustment function of air outlet position mode, heating/refrigeration mode,
interior/exterior circulation mode of air, air speed and temperature
4 Refrigerant R134a
5 Compressor SD7V16 variable displacement compressor, with max. displacement of 160ml
6 Condenser Parallel stream structure, with flat-tube thickness of 26mm
Two-box structure, layered evaporator, F-type expansion valve, centrifugal
7 Evaporator
blower
8 Dry fluid reservoir Outer diameter of φ60.5mm
Refrigeration pipe and Refrigeration pipe: combined type of rubber cooling hose and aluminium pipe.
9 heating water pipe Heating water pipe: rubber molding pipe
Outdoor temperature sensor, indoor temperature sensor, evaporator
10 Sensor temperature sensor
11 Pressure switch Tri-state pressure switch
Non-metal Material Consumption Breakdown

Grade, specifications
Name and technical Use Unit Quantity Remarks
conditions
Transmission
Proper
Silicone oil lever, three-eyelet Kg
quantities
rubber block
Short longitudinal front
Thread locking and fixing bolt, hub cover Proper
1271 L
fastening sealant bolt, transmission lever quantities
bolt, frame fixing
Silicone flange Proper
1596 (super grey) Installing ring flange L
sealant quantities
Ethylene- -35℃ eth-
Radiator and
Antifreeze coolant ylene glycol based Kg 7
auxiliary water tank
antifreeze coolant
Molybdenum
disulphide extreme- Torsion bar spline, Proper
No. 3 L
pressure lithium- first shift shaft quantities
based grease
Glass bottom
5001TF Glass bottom painting m 0.03
composition
Air-intake pipe of
Proper
Butyl rubber belt 6×2×700 air cleaner, door L
quantities
diaphragm seal
Power steering fluid DEXRON3(ATF-3) Steering oil cup L 1
Clutch oil DOT4 Clutch master pump L 0.15
Vacuum booster
Brake fluid DOT4 L 0.525
fluid reservoir
For vehicles
GL-4 75W/90 Transmission L 2.2 exported to high-
cold areas
For vehicles
GL-4 75W/90 Transfer case L 2.7 exported to high-
cold areas
GL-4 80W/90 Transmission L 1.4
GL-4 80W/90 Transfer case L 2.5
For vehicles
exported to high-
GL-5 75W/90 Rear axle L 2.9
cold areas
2.9L=5.14PTS
GL-5 80W/90 Rear axle L 2.9 2.9L=5.14PTS
Gear oil of For vehicles
the vehicle GL-5 140 Transmission L 1.4 exported to high-
cold areas
For vehicles
GL-5 140 Transfer case L 2.7 exported to high-
cold areas
For vehicles
exported to high-
GL-5 140 Rear axle L 2.9
cold areas
2.9L=5.14PTS
For vehicles
exported to high-
GL-5 140 Front axle L 1.4
cold areas
1.4L=2.46PTS
GL-5 75W/90 Front axle L 1.4
GL-5 80W/90 Front axle L 1.4 1.4L=2.46PTS
HV3 Front windshield glass L 0.6
Glass cement Liftgate glass, Side
7120 L 0.9
window glass
Proper
Joint sealing rubber LY-22 Luggage rack Kg
quantities
Warm air water
Fluid sealing rubber LY-609 L 0.02
pipe, gear lever
Windshield washer Q35 Front and rear windows L 3

Refrigerant R134a A/C system Kg 0.73
Apply to
SL 10W-40 Oil pan L 4.3 4G64S4M
model engine
Apply to
4G64S4M model
Lubricating oil
SL 5W-30 Oil pan L 4.3 engine, for ve-
of engine
hicles exported to
high-cold areas
Proper
Glass activator VP04604 Glass Ｌ
quantities
Lithium-based HP-R from JINZHI Front axle, Proper
Kg
grease Company chassis parts quantities
Seat back, battery Proper
Industrial vaseline Kg
terminal quantities
CC6460KM55 and CC6460KM75 Wagon (2.5TCI Right-hand Drive)

Model CC6460KM55 CC6460KM75
Mode 4×2 4×4
Rated passenger (person) 5
Curb weight of the complete vehicle (kg) 1840 1929
Front axle (kg) 998 1077
Axle load No-load
Rear axle (kg) 842 852
distribu-
tion Front axle (kg) 1180 1180
Full load
Length (mm) 4620
Overall dimensions Width (mm) 1800
Height (mm) 1810 1800
Axle base (mm) 2700
Front (mm) 1515
Wheel base
Rear (mm) 1520
Front suspension (mm) 850
Rear suspension (mm) 1070
Approach angle (°) ≥28
Departure angle (°) ≥27.5
Front wheel alignment (no load）
Toe-in of front wheel (mm) 0~2
Camber angle of front wheel (°) 0°±30′
Kingpin inclination angle (°) 12°30′±30′
Kingpin caster angle (°) 3°30′±30′
Front wheel steering angle (°) 32°(inside)/28°(outside)
Power performance:
Min. stable speed of direct drive (km/h) ≤25 ≤25
Accelerating time of direct drive 30km/h~100km/h
≤28.5 ≤28.5
(s)
Accelerating time of initial starting of gear 1
≤22.5 ≤22.5
shifting to 100km/h (s)
Top speed (km/h) ≥140 ≥140
Max. climbing capacity (%) ≥35 ≥35
Fuel consumption under 90km/h constant speed
≤7.6 ≤7.6
driving (L/100km)
≤10.9 ≤10.9
driving (L/100km)
Brake performance
Service braking distance of initial braking speed
≤19 (no-load), ≤20 (full load)
of 50km/h (m)
Emergency braking distance of initial braking
≤38
speed of 50km/h (m)
Grade parking brake (%) ≥20 (no-load), ≥18 (full load)
Noise
Outside noise when driving in acceleration speed
≤75
dB (A)
Inside noise when driving in uniform speed of
≤79
50km/h dB(A)
Structure Type and Technical Parameters of Main System and Assembly

Engine
Vehicle type code CC6460KM55 CC6460KM75
Item Specifications and parameters
Engine model GW2.5TCI
Four-cylinder, in-line, water cooling, four-stroke, supercharge inter-
Mode
cooling, high-pressure common rail diesel engine
Cylinder diameter×stroke (mm) 93×92
Total displacement (L) 2.499
Compression ratio 17.2:1
Max. power and corresponding rotation
80/3600
speed (kW/r/min)
Max. torque and corresponding rotation
300±5/1800~2400
speed (N·m/rpm)
Stable idle speed (r/min) 800±30
Max. net power (kW) 74
Transmission
Model 038M1 038M
5 forward gears, 1 reverse gear, and direct 5 forward gears, 1 reverse gear, and direct
Mode
control control
Gear I 3.8305 Gear I 3.8305
Gear II 2.3300 Gear II 2.3300
Gear III 1.4364 Gear III 1.4364
Gear IV 1.0000 Gear IV 1.0000
Speed ratio
Gear V 0.7887 Gear V 0.7887
Gear R (reverse) 4.2200 Gear R (reverse) 4.2200
Gear H (high) 1.00
Gear L (low) 2.48
Front Axle
The front axle of CC6460KM55 wagon is a double-transverse arm independent suspension
breakaway front axle.
For CC6460KM75 wagon, it is equipped with double-transverse arm independent suspension
breakaway steering drive axle, hyperbolic gear single-stage main reducing gear, common bevel gear
differential, universal drive half axle. The main reducing ratio i0=3.9.
Rear Axle
It is equipped with integral drive axle, punching welding axle case, hyperbolic gear single-stage main
reducing gear, common bevel gear differential, and semi-floating half axle. The main reducing ratio
i0=3.9.
Wheel and Tyre
Rolling ra- Static ra-
Tyre type Tyre specification Rim specification Tyre pressure
dius of tyre dius of tyre
5°deep-groove
Radial tyre 235/65 R17 104T 230KPa 358mm 334mm
rim 17×7JJ
Suspension
absorber, anti-sway bar, double-transverse arm independent suspension.
Frame
It is equipped with peripheral trapezoidal frame, and welded by two box-shaped section longitudinal
beams and several box-shaped or pipe-shaped section beams.
Steering System
It is equipped with rack and pinion power steering system, energy-absorbing steering column and
adjustable steering wheel angle.
Brake System
It is equipped with hydraulic dual-circuit, vacuum booster and ABS anti-lock braking system. The front
wheel brake is ventilated disc brake, and rear wheel brake is disc-drum brake. The type of parking
brake is mechanical cable, which acts on drum brake of rear wheel.
Air Intake System
Dry-type Air Cleaner, exhaust gas turbo charge inter-cooling system.
Exhaust System
It is equipped with first-level silencer, with first-level oxygen catalytic converter. For Euro III, it is
equipped with OBD.
Fuel Supply System
Fuel tank is plastic, with the capacity of 70L, and fuel supply control is mechanical pedal electronic
control.
Cooling System
Forced circulation water cooling, electronic fan and aluminium ribbon-tubular radiator.
Clutch
It is dry-type single plate diaphragm spring clutch, with hydraulic control. Outer diameter D of friction
plate is 265mm.
Front Axle
The rear drive axle assembly of CC6460KM55 wagon includes three cross axle universal joints, two
drive axles, and maintenance-free sectional structure with expansion spline and intermediate support.
The front and rear drive axle assembly of CC6460KM75 wagon includes two cross axle universal
joints, a drive axle and maintenance-free integral structure with expansion spline.
Vehicle Body
Assembly Structure and parameters
Cab-behind-engine, two-carriage, four doors, five seats, all-metal close
Type of vehicle body
type
Vehicle White body All-metal close type structure
body Framed, four doors with positive opening, clamping-plate door lock,
Door assembly hinge, with side anti-collision beam. Central control door lock, motor
glass lifter. Rear tail door with upward opening.
Injection molding, main materials are modified PP, and the skeleton is
Instrument panel
sheet-metal structure
Front and rear bumpers Integral design, modified PP injection molding
Front windshield is hyperbolic compressed glass. Rear windshield is
Windshield
Interior and toughened glass, with electric heating defrosting.
exterior trim Exterior rear-view mirror Electric and electric heating defrosting
The position of the seat can be manually adjusted to front and rear di-
Driver’s seat rection (the stroke of 200), and the backrest angle can be manually ad-
Seat justed.
Rear seat Rear seats are independent, and the backrest can be turned and folded.
The safety belt for master driver is three-point emergency locking warn-
Safety belt ing type, rear middle seat is equipped with two-point safety belt, and
Body ac- other three belts are three-point emergency locking safety belt
cessories Windscreen wiper sys-
Electric crank and rocker mechanism
tem
Sun visor Steering mechanism self-locking device
Electrical System
System Structure and parameters
Combination meter Electronic
Instrument
Indicator light LED
system
Sensor and dimming switch Conform to related system
One wire system, ground earth with negative pole, voltage direct
Circuit
current of 12V
Power supply, Generator 110A, built-in adjuster
starting and
Starter 12V,2.8kW
charging system
A/C system Cold-warm automatic A/C
Battery 80Ah
Signal system Horn Snail bi-tone horn
Audible equipment CD player, tape player
Cigar lighter 12V, 1
Rear window defrost Rear windshield is electric heating windscreen
Central control door lock With remote control
Auxiliary elec- Door handle External pulling door handle
trical system Glass lifter Electric
BOSCH ABS8.0 version, with EBD function (Electronically Brake
ABS electric control system
Distribution)
Safety airbag Safety airbags for master and auxiliary drivers
A/C System
1 Structure type Automatic warm-cold A/C, vapor compression refrigeration, hot water heating
Performance
2 Refrigerating output of 3.5kW, heat exchange output of 3.5kW, air flow of 350m3/h
parameters
Control board button control, temperature automatic control, air door micro-motor drive,
with automatic control of interior temperature, and selection and adjustment function of
3 Control
air outlet position mode, heating/refrigeration mode, interior/exterior circulation mode of
air, air speed and temperature
4 Refrigerant R134a
7 Evaporator Two-box structure, layered evaporator, F-type expansion valve, centrifugal blower
Refrigeration Refrigeration pipe: combined type of rubber cooling hose and aluminium pipe. Heating
9 pipe and heating
water pipe water pipe: rubber molding pipe
10 Sensor Outdoor temperature sensor, indoor temperature sensor, evaporator temperature sensor

Grades and Specifications of Operating Agent for Operating Parts of Wagon
No. Operating parts Quantity Specifications
0# light diesel oil (choose -10#, -20# or -35# according to
1 Engine fuel (RON) 70L±3L
the temperature in the winter) (GB252-2000)
Conform to API standard: above CI grade, with viscosity
Lubricating oil for of 15W-40 and 5W-40 or conform to A-CEA standard: A3/
2 4.1L±0.1L
engine B4 15W-50, 5W-40 (specifically choose according to the
local temperature)
Main filling quantity:
8.5L±0.5L Ethylene— -35℃ ethylene glycol based antifreeze cool-
3 Coolant
Auxiliary filling quantity: ant
0.7L±0.1L
4 Clutch fluid 0.15L(within the mark) DOT4 synthetic brake fluid
Manual transmis- 2WD: 2.7L
5 API GL-4 grade hyperbolic gear oil
sion 4WD: 2.9L
Front drive axle 1.4L±0.1L

6 API GL-5 grade hyperbolic gear oil
Electric control shift
0.19L±0.01L
fork of front axle
7 Rear drive axle 2.9L±0.1L API GL-5 grade hyperbolic gear oil
8 Power steering fluid 1.0L(within the mark) ATF DEXRON III hydraulic transmission oil
9 Brake fluid 0.525L(within the mark) DOT4 synthetic brake fluid
10 Battery terminal 1.0g Industrial vaseline
Normal temperature: use cleaning water with hardness
Windshield washing less than 205g/1000kg. Low temperature (-18℃±3℃):
11 2.5L±0.2L
solution use methanol aqueous solution with concentration of
50%
12 A/C Refrigerant 700g±50g R134a
Other motion friction
13 － Universal lithium-based grease for 2# vehicle
pair
CC6460KM07 and CC6460KM27 Wagon (4G63 Left-hand Drive)

Model CC6460KM07 CC6460KM27
Mode 4×2 4×4
Chassis model CC6460K CC6460KY
Rated passenger (person) 5
Curb weight of the complete vehicle (kg) 1720 1830
Max. loading mass (kg) -
Front axle (kg) 880 970
no-load
Axle load Rear axle (kg) 840 860
distribution Front axle (kg) 980 1070
Full load
Length (mm) 4620/4650
Overall dimensions Width (mm) 1800
Height (mm) 1810 1800
Axle base (mm) 2700
Front (mm) 1515
Wheel base
Rear (mm) 1520
Front suspension (mm) 850/880
Rear suspension (mm) 1070
Approach angle (°) ≥28
Departure angle (°) ≥27.5
Front wheel alignment (no-load）
Toe-in of front wheel (mm) 0~2
Camber angle of front wheel (°) 0°±30′
Kingpin inclination angle (°) 12°±30′
Kingpin caster angle (°) 3°30′±30′
Front wheel steering angle (°) 32°(inside)/28°(outside)
Power performance:
Min. stable speed of direct drive (km/h) ≤25 ≤25
Accelerating time of direct drive 30km/h~100km/h (s) ≤45 ≤45
Accelerating time of initial starting of gear 1 shifting to
≤20 ≤20
100km/h (s)
Top speed (km/h) ≥150 ≥150
Max. climbing capacity (%) ≥30 ≥30

≤8.12 ≤8.12
driving (L/100km)
≤10.92 ≤10.92
driving (L/100km)
Brake performance
Service braking distance of initial braking speed of
≤19 (no-load), ≤20 (full load)
50km/h (m)
≤38
50km/h (m)
Grade parking brake (%) ≥20 (no-load), ≥18 (full load)
Noise
Outside noise when driving in acceleration speed dB
≤74
(A)
Inside noise when driving in uniform speed of 50km/h
≤78
dB(A)
Structure Types and Technical Parameters of Main Systems and

Assemblies
Engine
Engine model 4G63S4M
Four-cylinder, in-line, water cooling, single over-head camshaft, four-
Mode
stroke, multiple-point electro-injection gasoline engine
Compression ratio 10:1
90/5250
speed (kW/r/min)
170/2500-3000
speed (N·m/rpm)
Transmission
Model ZM001DB ZM001DF
Manual mechanical step speed transmission All synchronizer with manual mechanical step
Mode of all synchronizer, 5 forward gears, 1 speed transmission of transfer case, 5 forward
reverse gear, and direct control gears, 1 reverse gear, and direct control
Gear I 3.992 Gear I 3.992
Gear V 0.857 Gear V 0.857
Gear R (reverse) 4.22 Gear R (reverse) 4.22
Speed ratio Gear H (high) 1.00
Gear L (low) 2.48
Front Axle
Rear Axle
i0=4.22.
Wheel and Tyre
Tyre Rolling radius Static radius
Tyre type Tyre specification Rim specification
pressure of tyre of tyre
P235/65 R17 104T
235/65 R17 104T 5°deep-groove rim 17×7J 353mm 295mm
Radial tyre 230kPa
P235/70 R16 104T 5°deep-groove rim 16×7J 332mm 257mm
235/70 R16 104T
Suspension
Frame
Steering System
Brake System
It is equipped with hydraulic dual-circuit layout, and ABS anti-lock braking system. The front wheel
brake is ventilated disc brake, and rear wheel brake is disc-drum brake. The type of parking brake is
mechanical cable, which acts on drum brake of rear wheel.
Air Intake System
Dry-type Air Cleaner
Exhaust System
It is equipped with first-level silencer, with second-level three-way catalytic device.
Fuel Supply System
Fuel tank is plastic, with the capacity of 70L, and fuel supply control is mechanical pedal type, with
built-in electronic fuel pump.
Cooling System
Clutch
plate is 225mm.
Drive Axle
Vehicle Body
type
Door assembly hinge, with side anti-collision lever. Central control door lock, motor
Instrument panel
Windshield
Seat justed.
Body acces- other three belts are three-point emergency locking safety belt
sories Windscreen wiper system Electric crank and rocker mechanism
Electrical System
Instrument system Indicator light LED
One wire system, ground earth with negative pole, voltage di-
Circuit
rect current of 12V
Power sup- Generator 90A, with vacuum pump and built-in adjuster
ply, starting and
Starter 12V, 1.2kW
charging system
Battery 60Ah
Auxiliary electri- Door handle External pulling door handle
cal system Glass lifter Electric
BOSCH ABS8.0 version, with EBD function (Electronically
Brake Distribution)
A/C System
Performance
parameters
3 Control
4 Refrigerant R134a
9 pipe and heating

Use lead free gasoline for the vehicles of high quality
1 Engine fuel (RON) 70±3L
above 93# (GB 17930—2006)
Lubricating oil for SL grade, lubricating oil with viscosity of SAE 10W-40
2 4.0L±0.1L
engine grade
Main filling quantity: 6.5L
±0.5L Ethylene— -35℃ ethylene glycol based antifreeze cool-
3 Coolant
0.7L±0.1L
4 Clutch fluid 0.15L (within the mark) DOT4 synthetic brake fluid
5 Manual transmission 1.4L±0.1L API GL-4 grade hyperbolic gear oil
Front drive axle 1.4L±0.1L

6 Electric control shift API GL-5 grade hyperbolic gear oil
0.19L±0.01L
fork of front axle
7 Rear drive axle 2.9L±0.1L API GL-5 grade hyperbolic gear oil
8 Power steering fluid 1.0L (within the mark) ATF DEXRON III hydraulic transmission oil
9 Brake fluid 0.525L (within the mark) DOT4 synthetic brake fluid
Windshield washing
11 2.5L±0.2L less than 205g/1000kg. Low temperature (-18℃±3℃):
solution
use methanol aqueous solution with concentration of 50%
pair
CC6460KM19 and CC6460KM39 Wagon (4G69)

Item CC6460KM19 CC6460KM39
Size parameters (no-load) (mm)
Length 4620
Width 1800
Height 1810 1800
Axle base 2700
Wheel base: Front/Rear 1515/1520
Front suspension 850
Rear suspension 1070
Quality parameters
Loading weight (kg) 2195 2305
Curb weight (kg) 1720 1830
Load distribution on no-load axle : Front/rear (kg) 880/840 970/860
Load distribution on full-load axle load distribution: Front/rear
980/1215 1070/1235
(kg)
Trafficability parameters
Approach angle (°) ≥28 (no-load)
Departure angle (°) ≥27.5 (no-load)
Power performance:
Min. stable speed of direct drive (km/h) ≤25
Accelerating time of direct drive 30km/h~100km/h (s) ≤32
Accelerating time of initial starting of Gear 1 shifting to
≤20
100km/h (s)
Top speed (km/h) ≥160
Max. climbing capacity (%) ≥35
≤10.00
(L/100km)
≤13.24
(L/100km)
Fuel consumption under simulation of urban and suburban
≤10.50 ≤10.80
comprehensive working conditions (L/100km)
Brake performance
Service braking distance of initial braking speed of 50km/h (m) ≤19 (no -load), ≤20 (full load)
≤38
50km/h (m)
Grade parking brake (%) ≥20 (no -load), ≥18 (full load)
Noise
Outside noise when driving in acceleration speed dB (A) ≤74
Inside noise when driving in uniform speed of 50km/h dB(A) ≤79
Structure Types and Technical Parameters of Main Systems and

Assemblies
Engine
Engine model 4G69S4N
Four-cylinder, in-line, water cooling, single over-head camshaft, four-
Mode
stroke, multiple-point electro-injection gasoline engine
Compression ratio 9.8:1
100/5250
speed (kW/r/min)
200/2500-3000
speed (N·m/rpm)
Transmission
Model ZM001DB ZM001DF
5 forward gears, 1 reverse gear, and direct 5 forward gears, 1 reverse gear, and direct
Mode
control control
Gear I 3.992 Gear I 3.992

Gear V 0.857 Gear V 0.857
Gear R (reverse) 4.22 Gear R (reverse) 4.22 0
Speed ratio Gear H (high) 1.000
Gear L (low) 2.48 0
Front Axle
Rear Axle
i0=4.22.
Wheel and Tyre
Tyre Rolling radius Static radius
Tyre type Tyre specification Rim specification
pressure of tyre of tyre
Radial tyre P235/65 R17 104H 5°deep-groove rim 17×7J 230kPa 358mm 334mm
Suspension
Frame
Steering System
Brake System
It is equipped with hydraulic dual-circuit layout, vacuum assistance，and ABS anti-lock braking
system. The front wheel brake is ventilated disc brake, and rear wheel brake is disc-drum brake. The
type of parking brake is mechanical cable, which acts on drum brake of rear wheel.
Air Intake System
Dry-type Air Cleaner
Exhaust System
It is equipped with first-level silencer, with second-level three-way catalytic device.Euro IV emission
with OBD.
Fuel Supply System
Fuel tank is plastic, with the capacity of 70L, and fuel supply control is mechanical pedal type, with
built-in electronic fuel pump.
Cooling System
Clutch
plate is 225mm.
Drive Axle
Vehicle Body
type
Door assembly hinge, with side anti-collision lever. Central control door lock, motor
Instrument panel
Windshield
Seat justed.
Body acces- other three belts are three-point emergency locking safety belt
sories Windscreen wiper system Electric crank and rocker mechanism
Electrical System
Instrument system Indicator light LED
One wire system, ground earth with negative pole, voltage di-
Circuit
rect current of 12V
Power sup- Generator 90A, built-in adjuster
ply, starting and
Starter 12V, 1.2kW
charging system
Battery 60Ah
Auxiliary electri- Door handle External pulling door handle
cal system Glass lifter Electric
BOSCH ABS8.0 version, with EBD function (Electronically
Brake Distribution)
A/C System
Performance
parameters
3 Control
4 Refrigerant R134a
9 pipe and heating

Use lead free gasoline for the vehicles of high quality
1 Engine fuel (RON) 70±3L
above 93# (GB 17930—2006)
Lubricating oil for For grade above SAE SL (selecting lubricating oil type
2 4.0L±0.1L
engine based on environment according to SAE standard).
Main filling quantity: 6.5L
±0.5L Ethylene— -35℃ ethylene glycol based antifreeze cool-
3 Coolant
0.7L±0.1L
4 Clutch fluid 0.15L (within the mark) DOT4 synthetic brake fluid
2.4L±0.1L （4WD） API GL-4 grade hyperbolic gear oil，

SAE number for domestic application: 80W/90GL-4;
SAE number for high-temperature climate
Manual transmission
5 2.5L±0.1L （2WD） application:140GL-5;
SAE number for high-frigid climate application:
75W/90GL-4
Front drive axle 1.4L±0.1L API GL-5 grade hyperbolic gear oil,
SAE Number for high temperature application: 140;
6 Electric control shift SAE Number for normal temperature application:
0.19L±0.01L 80W/90;
fork of front axle
SAE Number for extremely cold application: 75W/90
API GL-5 grade hyperbolic gear oil，
SAE Number for high temperature application: 140;
7 Rear drive axle 2.7L±0.1L SAE Number for normal temperature application:
80W/90;
SAE Number for extremely cold application: 75W/90
8 Power steering fluid 0.763L±0.032L ATF DEXRON III hydraulic transmission oil
9 Brake fluid 0.45L±0.035L DOT4 synthetic brake fluid

Windshield washing less than 205g/1000kg. Low temperature (-18℃±3℃):
11 2.0L±0.5L
solution use methanol aqueous solution with concentration of
50%
pair
Fuel-supply System-1
Fuel-supply System
Fuel-supply System I (of Petrol, with Canister

Installed in Front) ........................................................................... 2
Fuel-supply System II (of Petrol, with Canister
Installed Behind)............................................................................. 7
Fuel-supply System III (of Diesel, without Primary Filter) .......... 12
Fuel-supply System III (of Diesel, with Primary Filter) ................ 16
Fuel-supply System I
Elements Diagram
Petrol (with Canister Installed Front)
Adjusting nut
Throttle control cable
Accelerator pedal assembly
Air outlet rubber

hose of canister
Quick fitting joint
Steel strip type elastic hoop
Engine oil inlet rubber hose
Engine oil return rubber hose
Hose fixing clip

Filter bracket
Canister Air inlet B worm Evaporating hose 2
rubber hose drive hose Fuel filter
of canister Petrol inlet hose of filter Fuel tank evaporating
hoop Petrol outlet Front section of fuel rubber hose
hose of filter tank outlet pipe
Fuel evaporating pipe 2 Fuel evaporating
pipe 1
Rear section of fuel tank Evaporating hose 1
outlet pipe
Interconnecting hose
Rear section of fuel of oil return pipe
tank return pipe Fuel tank return pipe
Clip seat for rigid pipe
Fuel tank lock
Pressure plate for fuel filler rubber pad
Fuel pump gland Fuel filler rubber pad
Fuel pump Tank rear band
Tank front band Fuel tank assembly
Seal
Fuel filler assembly
ring
Tank protecting plate
Steel strip type

elastic hoop
Tank pallet
N·m : specified torque

Attention: If it is necessary to disassemble the

oil circuit for the maintenance of fuel-supply
system, the pressure inside the fuel system should
be released to avoid fuel injection under high
pressure.
Disassembly of Fuel Tank
1. Remove the engine oil inlet and return rigid pipes,
fuel tank inlet and return rigid pipes and the
interconnecting hose of fuel rigid evaporating pipe.
Then release the pressure inside the oil circuit
system gently, using a piece of cotton cloth to
block the joints, to prevent against oil injection
under high pressure.
2. Remove the hoops (two in total) of the connecting
rubber hose between the fuel filler at the rear part of
the tank and the ventilating pipe.
3. Remove the bolts for tank installation (six in total);
4. Remove the fuel tank and let the joints of return

pipe and fuel evaporating pipe and the harness
connectors drop out;
5. Separate the fuel tank, the tank pallet and its

protecting plate after removing the two tank
fastening bands (with four bolts) and the tank
protecting plate (with one bolt), if necessary.
Removal and Installation of Fuel Pump

Removal of Fuel Pump
1. Clear away the accumulated dirt around the fuel
tank joint flange;
2. Dismount the fuel pump gland by using a special
tool to screw the fuel pump gland anticlockwise;
3. Remove the fuel tank and the bracket assembly.
Attention should be paid to avoid damaging the
liquid level sensor;
4. Dismount and discard the seal ring.
Installation of Fuel Pump
1. Clean the pump installation flange, the tank fitting
surface and the tank seal ring;
2. Install the fuel pump and bracket assembly with
care to protect the liquid level sensor from being
damaged.
3. Place the pump assembly appropriately, with the
arrow on the pump aligned with the alignment mark
on the fuel tank;
4. Use a special tool to screw down the fuel pump
gland in a tightening torque of 100N•m.
Removal of Fuel-supply System Parts
Removal of Petrol Filter
1. R e m o v e t h e h o s e h o o p s w i t h a f l a t h e a d
screwdriver and dismount the connecting rubber
hoses at both ends of petrol filter;
2. Then unscrew the bolts on the petrol filter bracket
to take down the filter for overall replacement.
Removal of Canister
1. Firstly clip and remove the elastic hoop with a pair
of pliers and remove the two connecting rubber
hoses on the canister;
2. Pull the canister upwards along the canister.
Removal of Fuel Filling Pipe

1. Remove the bolts on the fuel filler cover (three in
total);
2. Remove the fixing bolt between fuel filling pipe and
frame (one in total);
4. Remove the elastic hoops of the connecting rubber
hose between fuel filling pipe and fuel tank (two in
total).
Removal of Fuel Pipe

1. Disconnection of the joints between the fuel inlet
and return pipes of engine guide rail and the fuel-
supply pipes;
(a) Remove the elastic hoops;
(b) Remove the quick fitting joints by pressing the buttons
of quick fitting joints and pulling them out;
(c) Remove the triple plastic clip.
2. Removal of the front section of fuel rigid pipe

(a) Remove the connecting elastic hoops at both
ends of the front section of fuel rigid pipe;
(b) Pull the fuel pipe off clip fixing holder to remove
this rigid pipe;
(c) Take the front section out after dismounting the
fixing seat on the longitudinal beam and turning
the seat by 90° clockwise or anticlockwise, if
necessary.
3. Removal of the rear section of fuel rigid pipe

ends of the rear section of fuel rigid pipe;
(b) Pull the fuel pipe out of clip fixing holder on the
tank and remove the rigid pipe.
Removal and Adjustment of Throttle

Control System
Removal of Accelerator Pedal
1. Remove the two bolts that fix the pedal;
Removal of Throttle Control Cable

1. Unscrew the locking nuts and disconnect the
engine;
2. Remove the plastic clip that fastens the throttle

control cable to the pedal, and take down this end
of the cable;
3. At the engine compartment’s side, clamp the clip
with a pair of pliers and take down the fixing clip
seat on the facade of engine compartment.
Adjustment of Throttle Control Mechanism

1. To eliminate the free play of accelerator pedal,
adjust the adjusting nut of throttle control cable.
2. To make the throttle valve fully open as the
accelerator has been stepped to the limit, adjust
the pedal play by adjusting the accelerator pedal
limiting bolts.
Fuel-supply System II
Elements Diagram
Petrol (with Canister Throttle control cable
Installed Behind)
Adjusting nut
9-12
Engine oil inlet

pipe assembly
Triple clip seat
Plastic fuel evaporating Engine oil return pipe assembly

pipe assembly
Fuel filter assembly Fuel filter bracket
Fuel evaporating pipe II assembly
Q673B12
Q673B14
Rear section of
tank outlet pipe
Engine oil return pipe Triple clip seat
for oil pipes
Canister
Evaporating hose II Canister air intake assembly
hose assembly
Fuel tank outlet pipe assembly
Canister air outlet

Fuel tank return pipe assembly hose assembly
Fuel tank gland Fuel tank lock Pressure plate for
100 fuel filler rubber pad
Fuel filler rubber pad
Fuel pump
Tank rear band
Steel strip type
Tank front band elastic hoop
Fuel tank assembly Seal ring
65-75
Tank pallet
N·m : specified torque

Attention: If it is necessary to disassemble the

oil circuit for the maintenance of fuel-supply
system, the pressure inside the fuel system should
be released to avoid fuel injection under high
pressure.
1. Remove the engine oil inlet and return rigid pipes,
fuel tank inlet and return rigid pipes and the
interconnecting hose of fuel rigid evaporating pipe.
Then release the pressure inside the oil circuit
system gently, using a piece of cotton cloth to
block the joints, to prevent against oil injection
under high pressure.
the tank and the ventilating pipe;
4. Remove the fuel tank outlet and return pipes;

Removal and Installation of Fuel Pump

Removal of Fuel Pump
1. Clear away the accumulated dirt around the fuel
tank joint flange;
3. Remove the fuel tank and the bracket assembly.
Attention should be paid to avoid damaging the
liquid level sensor;
Installation of Fuel Pump
1. Clean the pump installation flange, the tank fitting
surface and the tank seal ring;
2. Install the fuel pump and bracket assembly with
care to protect the liquid level sensor from being
damaged.
3. Place the pump assembly appropriately, with the
arrow on the pump aligned with the alignment mark
on the fuel tank.

Removal of Petrol Filter
1. R e m o v e t h e h o s e h o o p s w i t h a f l a t h e a d
screwdriver and dismount the connecting rubber
hoses at both ends of petrol filter;
2. Then unscrew the bolts on the petrol filter bracket
to take down the filter for overall replacement.
Removal of Canister
1. Firstly clamp and remove the elastic hoops with
a pair of pliers and remove the two connecting
rubber hoses on the canister;
2. Dismount the canister air filter off the spare
tyre beam welding assembly in manual way,
alternatively;
3. Remove the fixing bolts and pull the canister
upwards along the canister.

total);
frame cross beam (one in total);
total).
Removal of Fuel Pipes

1. Disconnection of the joints between the fuel inlet
and return pipes of engine guide rail and the fuel-
supply pipes;
(a) Remove the elastic hoops;
(b) Remove the quick fitting joints by pressing the buttons
of quick fitting joints and pulling them out;
(c) Remove the triple plastic clip seat.
2. Removal of the front section of fuel rigid pipe

ends of the front section of fuel rigid pipe;
(b) Pull the fuel pipe off clip fixing holder to remove
this rigid pipe;
(c) Take the front section out after dismounting the
fixing seat on the longitudinal beam and turning
the seat by 90° clockwise or anticlockwise, if
necessary.
3. Removal of the rear section of fuel pipe

(a) Remove the connecting elastic hoops at both ends of
the rear section of fuel pipe and remove the C worm
hoop;
(b) Pull the fuel pipe out off the clip fixing holder on the
tank and remove the rigid pipe.
Removal and Adjustment of Throttle

Control System
1. Remove the two bolts that fix the pedal.
Removal of Throttle Control Cable

1. Unscrew the locking nuts and disconnect the
engine;
2. Remove the plastic clip that fastens the throttle

control cable to the pedal, and take down this end
of the cable;
3. At the engine compartment’s side, clamp the clip
with a pair of pliers and take down the fixing clip
seat on the facade of engine compartment.
Adjustment of Throttle Control Mechanism

1. To eliminate the free play of accelerator pedal,
adjust the adjusting nut of throttle control cable.
2. To make the throttle valve fully open as the
accelerator has been stepped to the limit, adjust
the pedal play by adjusting the accelerator pedal
limiting bolts.
Fuel-supply System III

Elements Diagram
Diesel (without strainer)

Hexagon flange bolt
Accelerator pedal bracket

Bracket No.1 for the assembly of fuel

fine filter and oil water separator

Hexagon flange bolt

Assembly of fuel fine filter and oil water separator
Engine oil inlet pipe assembly Fuel tank outlet pipe assembly
Engine oil return rubber hose
Fuel tank return

Engine oil return pipe assembly pipe assembly
Triple clip seat for oil pipes
Fuel tank lock
Fuel filler
rubber pad Fuel pump gland
Fuel level sensor assembly
Pressure plate for Hexagon flange bolt
fuel filler rubber pad Seal ring
Fuel filler
assembly Fuel tank band
Hexagon flange bolt
Tank pallet

3. Remove the fuel tank outlet and return pipes;

Removal and Installation of Fuel Level

Sensor Assembly
Removal of Fuel Level Sensor Assembly
1. Clear away the accumulated dirt around the joint
flange of fuel level sensor assembly;
3. Remove the fuel level sensor assembly. Attention
should be paid to avoid damaging the fuel level sensor;
Installation of Fuel Level Sensor

1. Clean the sensor installation flange, the tank fitting
surface and the pump seal ring;
2. Install the fuel level sensor assembly with care to
protect the liquid level sensor from being damaged;
gland with a tightening torque of 100N•m.

total);
total).
Removal of Fuel Pipes
1. Removal of the assembly of fuel tank outlet and
return pipes
ends of outlet pipe and of inlet pipe;
(b) Pull the fuel pipe off clip fixing holder to remove it.
2. Removal of the assembly of engine oil inlet and

return pipes
(a) Remove the connecting elastic hoops at both ends
of the engine oil inlet and return pipe assembly
and remove the C worm hoop;
tank and remove the fuel pipe.
Removal of the Assembly of Fuel Fine Filter and

Oil Water Separator
1. Remove the rubber hoses, steel strip type elastic
hoops and hexagon flange bolts at both ends of
the oil water separator;
2. Remove the bolts of fixing bracket No.1 for oil

water separator;
3. Remove the bolts of fixing brackets No.1 and No.2

for oil water separator.
Removal of Throttle Control System

1. Remove the three bolts that fix the pedal;
2. Remove the two bolts that fix the accelerator pedal

bracket.
Fuel-supply System IV
Elements Diagram
Diesel (with strainer)
Hexagon flange bolt

Bracket No.1 for the assembly of

fuel fine filter and oil water separator

Fuel strainer assembly
Hexagon flange bolt
Assembly of fuel fine filter Fuel strainer bracket
and oil water separator
Engine oil inlet pipe assembly
Outlet rubber
hose of fuel filter Hexagon flange bolt
Inlet rubber hose of fuel filter

Fuel tank outlet
pipe assembly
Engine oil return

rubber hose Engine oil return
pipe assembly
Fuel tank return
pipe assembly
Triple clip seat for oil pipes

Fuel tank lock

Fuel pump gland
Pressure plate for fuel Fuel level sensor assembly
filler rubber pad Hexagon flange bolt
Seal ring

Fuel tank band
Tank protecting
plate
Hexagon flange bolt
Tank pallet
Diesel (with strainer)

Specially for 2.5TCI Right Q1840616FD
Hexagon flange bolt
Steering Vehicle
Q1840625FD
Hexagon flange bolt
Electronic accelerator pedal

Fuel strainer assembly
Hexagon flange bolt
Assembly of fuel fine filter Fuel strainer bracket
and oil water separator
Outlet rubber
hose of fuel filter
Hexagon flange bolt
Engine oil inlet
pipe assembly Inlet rubber hose of fuel filter
Fuel tank outlet
pipe assembly
Engine oil return

rubber hose
Quadruple clip
seat for oil pipes
Fuel tank return
Engine oil return pipe assembly
pipe assembly
Fuel tank lock

Quintuple clip seat for oil pipes

Fuel pump gland
Pressure plate for fuel Fuel level sensor assembly
filler rubber pad
Hexagon flange bolt Seal ring
Fuel tank band
Tank protecting
plate
Hexagon flange bolt
Tank pallet

3. Remove fuel tank outlet and return pipes;

protecting plate, if necessary, after removing the
two tank fastening bands (with four bolts) and the
tank protecting plate (with one bolt).
Removal and Installation of Fuel Level

Sensor Assembly
Removal of Fuel Level Sensor Assembly
1. Clear away the accumulated dirt around the joint
flange of fuel level sensor assembly;
3. Remove the fuel level sensor assembly. Attention
should be paid to avoid damaging the fuel level sensor;
Installation of Fuel Level Sensor

1. Clean the sensor installation flange, the tank fitting
surface and the pump seal ring;
3. Place the fuel level sensor assembly appropriately,
with the arrow on the sensor aligned with the
alignment mark on the fuel tank;
gland with a tightening torque of 100N•m.
Removal of Fuel-supply Parts

total);
total).
Removal of Fuel Pipe
1. Removal of the assembly of fuel tank outlet and
return pipes
ends of outlet pipe and of inlet pipe;
(b) Pull the fuel pipe off clip fixing holder to remove it.
2. Removal of the assembly of engine oil inlet and

return pipes
ends of the engine oil inlet and return pipes and
remove the C worm hoop;
tank and remove the fuel pipe.
Removal of Fuel Strainer Assembly

1. Dismount the rubber hoses and hoops off at both
ends of the fuel strainer assembly;
2. Remove the two hexagon flange bolts that fix the

fuel strainer and remove the primary filter.
Removal of the Assembly of Fuel Fine Filter and

Oil Water Separator
1. Remove the rubber hoses, steel strip type elastic
hoops and hexagon flange bolts at both ends of
the oil water separator;
2. Remove the bolts of fixing bracket No.1 for oil

water separator;
Note: For the bracket for oil water separator of 2.5 TCI
right hand drive vehicle is welded to the frame, there is
no process regarding its removal.
3. Remove the bolts of fixing brackets No.1 and No.2

for oil water separator.
Removal of Throttle Control System

1. Remove the three bolts that fix the pedal;
2. Remove the two bolts that fix the accelerator pedal

bracket.
Exhaust System-1
Exhaust System
Exhaust System I (for Diesel Engine) ........................................... 2

Exhaust System II (for EURO-III Gasoline Engine) ...................... 5
Exhaust System III (for EURO-II Gasoline Engine) ...................... 8
Exhaust System-2
Exhaust System I
Exhaust System I
Diesel engine Three-hole rubber block
Liner I for catalytic converter Hexagon flange bolt

Liner II for catalytic
Hexagon flange bolt converter
Hexagon flange bolt
Intermediate section
assembly of exhaust pipe
Hexagon nut Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Oxygen catalytic converter assembly
Hexagon nut
Sealing gasket for exhaust pipe outlet
Hexagon nut
Silencer assembly
Hexagon flange bolt Hexagon flange bolt
Shock-absorbing rubber Hexagon flange bolt

block for silencer
Hexagon flange bolt
Hexagon flange bolt
Three-hole rubber block
Silencer liner
Hexagon flange bolt
Rear section assembly of exhaust pipe
Hexagon flange bolt

Exhaust System-3
Warning: Only after the vehicle has been stopped

for 30 minutes can any component of exhaust
system be removed, lest the hot components might
injure the personnel.
Removal of Exhaust System

Removal of Rear Section Assembly of Exhaust
Pipe
1. Use the M15 sleeve, ratchet wrench, and the
lengthened bar to dismount the nuts which connect
the rear flange of silencer assembly with the rear
section of exhaust pipe. Then, take out the sealing
liner between flanges.
2. Remove the three-hole rubber block for tail of rear
section of exhaust pipe.
3. Remove the three-hole rubber block for head of
rear section of exhaust pipe.
Note: The silencer liner between the rear flange of
silencer and the flange for rear section of exhaust
pipe functions to seal them. The silencer liner
installed may be distorted due to the pressure and
then its sealability will be degenerate, so that it can
not be reused.
Removal of Silencer Assembly
1. If necessary, remove the rear section of exhaust
pipe by removing rear section of exhaust pipe at
first. Or else, just dismount the connecting nuts
which are located between the silencer and the
flange for rear section of exhaust pipe.
2. Use the M15 sleeve and ratchet wrench (or open-
end wrench) to dismount the connecting nuts
which are located between the flange of silencer
assembly and the rear flange for intermediate
section of exhaust pipe. During the course
of dismounting these nuts, someone shall be
specially assigned to support the silencer, lest it
might fall off and injure the operating personnel.
3. Use the M13 sleeve and ratchet spanner to loosen
four nuts which fasten the shock-absorbing rubber
block for silencer (it is recommended to loosen
them instead of directly dismounting them.)
4. Now, the silencer assembly can be taken off.
Note that the liner II for catalytic converter located
between the silencer and the intermediate section
of exhaust pipe mainly functions to seal them; the
silencer liner installed may be distorted due to the
pressure and then its sealability will be degenerate,
so that it can not be reused.
Exhaust System-4
Removal of Intermediate Section of Exhaust

Pipe
pipe and the silencer by removing rear section
of exhaust pipe and silencer at first. Or else, just
loosen two nuts which fasten the top of shock-
absorbing rubber block for silencer.
2. Dismount the connecting nuts which are located
between the front flange for intermediate section
of exhaust pipe and the rear flange of oxygen
catalytic converter.
3. Dismount the rear three-hole rubber block for
intermediate section of exhaust pipe.
4. Now, the intermediate section of exhaust pipe can
be taken off.
Note: The liner II for catalytic converter located
between the oxygen catalytic converter and the
intermediate section of exhaust pipe mainly
functions to seal them. The liner installed may
be distorted due to the pressure and then its
sealability will be degenerate, so that it can not be
reused.
Removal of Oxygen Catalytic Converter

Assembly
1. Remove the intermediate section of exhaust pipe
by removing intermediate section of exhaust pipe.
2. Use the M13 sleeve, lengthened bar and ratchet
wrench to loosen and dismount the outlet bolts for
bent exhaust pipe of turbocharger, and then take
Hexagonal headed bolt connecting off the oxygen catalytic converter.
bent exhaust pipe with oxygen Note: The joint liner between these two flanges is
catalytic converter
used to seal them. This liner is a stamped stainless
steel product, so that it must not be reused.
Installation of Exhaust System Assembly

1. The clearances between the exhaust pipe assembly
and the components on both sides shall be greater
than 15mm.
than 15mm.
3. The tightening torques for nuts of front section of
exhaust pipe and for nuts of exhaust manifold shall
be 70±5N•m.
4. After installing the shock-absorbing rubber block
assembly for silencer and the silencer assembly,
make sure that the shock-absorbing rubber block
is exposed to the even force.
Exhaust System-5
Exhaust System II
Components Diagram
Gasoline Engine (EURO-III)
Heat insolating
cover for front wall Heat insolating
cover for front floor
Liner I for catalytic

converter Three-hole
Hexagon flange nut rubber block
Hexagon flange nut
Hexagon flange nut
Liner for outlet of
Liner II for catalytic
exhaust manifold
converter
Hexagon flange nut
Hexagon flange nut Catalytic converter
assembly
Fore-stage purifier
Oxygen sensor
Oxygen
sensor Hexagon flange nut
Hexagon flange nut
Heat isolating
cover for front floor
Hexagon flange nut
Shock-absorbing rubber Silencer assembly

block for silencer
Hexagon flange nut

Silencer liner
Hexagon flange nut

Hexagon flange nut
Hexagon flange nut

Rear section assembly
of exhaust pipe
Hexagon flange nut

Exhaust System-6

Removal of Exhaust System

Removal of Rear Section Assembly of Exhaust
Pipe
the rear flange of silencer assembly with the rear
section of exhaust pipe. Then, take out the sealing
liner between flanges.
Note: The silencer liner between rear flange of
silencer and flange for rear section of exhaust pipe
functions to seal them. The silencer liner installed
may be distorted due to the pressure and then its
reused.
Removal of Silencer Assembly

which are located between the flange of silencer
assembly and the rear flange for intermediate
section of exhaust pipe. During the course
of dismounting these nuts, someone shall be
specially assigned to support the silencer, lest it
might fall off to injure the operating personnel.
Note: The liner II for catalytic converter located
between silencer and catalytic converter mainly
functions to seal them. The silencer liner installed
may be distorted due to the pressure and then its
reused.
Exhaust System-7
Removal of Catalytic Converter Assembly

2. Pull off the plug of oxygen sensor from the rear
of catalytic converter, remove the oxygen sensor
by the M22 open-end wrench, and then dismount
the connecting nuts which are located between
the front flange of catalytic converter and the rear
flange of fore-stage purifier.
3. Dismount the three-hole rubber block for rear
section of catalytic converter.
4. Now, the catalytic converter can be taken off.
Attention: The liner II for catalytic converter located
between catalytic converter assembly and fore-
stage purifier mainly functions to seal them. The
liner installed may be distorted due to the pressure
and then its sealability will be degenerate, so that it
can not be reused.
Removal of Fore-stage Purifier Assembly
1. Remove the catalytic converter assembly by
removing catalytic converter.
2. Pull off the plug of oxygen sensor, and remove the
oxygen sensor by the M22 open-end wrench. Later,
use the M18 sleeve, oversized lengthened bar and
ratchet wrench to loosen and dismount the outlet
bolt for bent exhaust pipe of turbocharger. Now,
the oxygen catalytic converter can be taken off.
Note: The joint liner between these two flanges is
used to seal them. This liner is a stamped stainless
Installation of Exhaust System Assembly

1. The clearances between the exhaust pipe and the
components on both sides shall be greater than
15mm.
2. Apply the adequate silicon oil into the installation
hole for three-hole rubber block. After the
installation, make the rubber block subject to the
even force.
be 85±5N•m.
Exhaust System-8
Exhaust System III

Components Diagram
Gasoline Engine (EURO-II)

Heat isolating cover for purifier
Clamp for heat isolating
cover for purifier
Fastening bolt for clamp Three-hole rubber block
Joint liner component Purifier liner assembly 2

Nut for exhaust
pipe outlet
Purifier liner
assembly 1 Catalytic converter
Hexagon flange nut
Nut for exhaust Front section of
pipe outlet exhaust pipe
Shock-absorbing rubber
Silencer assembly
block assembly for silencer
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Liner assembly Rear section assembly

of exhaust pipe
Trim cover for
silencer mouth
Exhaust System-9

Removal of Exhaust Pipe Assembly

Removal of Tail Pipe
the rear flange of silencer assembly with the flange
for rear section of exhaust pipe. Then, take out the
sealing liner between flanges.


Note: The silencer liner between the rear flange of
silencer and the flange for rear section of exhaust
pipe functions to seal them. The silencer liner
installed may be distorted due to the pressure and
then its sealability will be degenerate, so that it can
not be reused.
Removal of Silencer
which are located between the front flange of
silencer assembly and the rear flange of purifier.
During the course of dismounting these nuts,
someone shall be specially assigned to support the
silencer, lest it might fall off to injure the operating
personnel.
Exhaust System-10

Note: The liner II for purifier located between the
purifier and the front section of exhaust pipe main-
ly functions to seal them; the liner installed may be
distorted due to the pressure and then its sealabil-
ity will be degenerate, so that it can not be reused.
Removal of Purifier
2. Dismount the connecting nuts which are located
between the front flange of purifier and the rear
flange for front section of exhaust pipe.
3. If the silencer has been removed, the purifier
can be directly taken out; or else, smoothly push
the purifier backwards, and keep certain space
between purifier and silencer so as to guide out the
welding bolts of purifier.
4. Now, the purifier can be taken off.
Attention: The purifier liner assembly 1 located
between the silencer and the front section of
exhaust pipe mainly functions to seal them; the
liner installed may be distorted due to the pressure
and then its sealability will be degenerate, so that it
can not be reused.
Removal of Front Section of Exhaust Pipe
1. Remove the purifier by removing purifier.
2. Use the M18 sleeve, oversized lengthened bar and
ratchet wrench to loosen and dismount the nuts for
exhaust pipe outlet. Then, take off the front section
of exhaust pipe.
Attention: The joint liner between these two flanges
is used to seal them. This liner is a stamped stainless
Installation of Exhaust Pipe Assembly
than 15mm.
2. Apply the adequate silicon oil into the installation
hole for three-hole rubber block. After the installation,
make the rubber block subject to the even force.
be 85±5N•m.
Clutch-1
Clutch
Troubleshooting ............................................................... 2
Inspection and adjustment of clutch pedal.................... 3
Air discharge of clutch..................................................... 3
Cluch control mechanism................................................ 4
Clutch assembly .............................................................. 8
Clutch-2
Troubleshooting
failure cause inspection content
Shift difficulty or can not Large free stroke of clutch pedal Adjust the free stroke of pedal
shift Clutch Pipe has air Discharge the air in clutch system
Failure of clutch cylinder Replace
Failure of clutch master cylinder Replace
The installation position of clutch Inspect the clutch disc; replace
disc is not in position; large de-
viation; oil on the friction lining or
broken
The clutch disc is dirty or with fo- Repair if necessary
reign material
Failure of clutch cover Replace
Disengagement of trans- The clutch guide bearing is worn. Replace the guide bearing
mission
Slide of clutch Insufficient free stroke of clutch Adjust the free stroke of pedal
pedal
Oil on the clutch disc friction lining Inspect the clutch disc and replace it
or broken
Failure of press disc Replace the clutch cover
Separation rocker arm assembly Check the separation rocker arm as-
is blocked sembly
Clutch clamping stagna- Oil on the clutch disc friction lining Inspect the clutch disc and replace
tion/vibration or broken
Failure of press disc Replace the clutch cover
Clutch membrane spring is bend Correct the clutch membrane
Loose of engine bracket Repair if necessary
Soft of clutch pedal Clutch pipe has air Discharge the air in clutch
Failure of clutch cylinder Replace
Failure of clutch master cylinder Replace
Loud noise of clutch Component in clutch housing is Repair if necessary
loose
Throw-out bearing is worn or dirty Replace
Guide bearing is worn Replace
Separation rocker arm assembly Repair if necessary
or pull-rod is blocked
Clutch-3
Inspection and adjustment of clutch

Pedal travel adjusting point
pedal
1. Check the height and travel of pedal
Height measured from the front wall: LHD (178 ± 5)
mm
Pedal travel of diesel vehicle: RHD (135 ± 5) mm
the adjustment Pedal travel of petrol vehicle: RHD (120 ± 5) mm
point of pedal Adjust the height and travel of pedal if incorrect.
height
2. Adjust the height and travel of pedal if necessary.
Pedal height (a) Unscrew the locking nut and rotate the locking bolt
until to the correct height. Screw down the locking
nut.
(b) Unscrew the locking nut, and rotate the push rod
until the pedal travel is correct. Tighten the locking
Pedal travel nut.
Front wall
3. Check the correctness of free stroke of pedal

Step on the pedal lightly until fell the clutch start to ge-
nerate the resistance.
Free stroke of pedal: 5-15mm
4. Adjust the free stroke of pedal if necessary

(a) Screw off the locknut, rotate the push rod until the
free stroke is correct.
(b) Tighten the lock nut
(c) Check the height of the pedal after adjusts the
free stroke of pedal.
(d) On the condition that ensure the free stroke of
Free travel
clutch pedal assembly: The height difference bet-
ween the brake pedal, clutch pedal and the front
apron is 0~8mm.
Air discharge of clutch

Remarks: It should discharge the air if there is residual
air in the clutch system.
Caution: Do not leave the clutch liquid on the pa-
inted surface, otherwise it should be washed off
immediately.
Fill the brake fluid in the clutch storage tank
Check the liquid tank frequently. Filling if necessary.
Clutch-4
Cluch control mechanism

Components
Gasoline
clutch master
cylinder pipe
25-30
pipe clip
clutch master cylinder
hex flange nut

23±3
spring clip
20±2
clutch cylinder (with transmission)
snap ring
seal washer
hex bolt assembly (with transmission)
bolt with hole for hose connection 30-42
clutch hose
40±2

Clutch-5
Diesel, LHD
Fuel pipe assembly of trimmer valve
Trimmer valve assembly
hex flange nut

23±3
hex bolt
Q1840612FD 25-30
10±1
16±2
clutch master cylinder pipe
pipe clip
spring clip
clutch cylinder (with transmission)

20±2
snap ring
bolt with hole for hose connection

40±2
hex bolt assembly (with transmission)
30-42
seal washer
N·m :specified torque clutch hose
Clutch-6
Diesel, RHD
hex flange nut

23±2
clutch master cylinder pipe
27.5±2.5
45±5
spring clip
clutch cylinder
20±0.5
snap ring
clutch hose
seal washer
bolt with hole for hose connection
35±2

Clutch-7
Removal of clutch master cylinder, clut-

ch cylinder
1. Use the No.16 open-end wrench to remove the
hose connecting bleed bolt, use the cloth to cover
the oil outlet of auxiliary pump to avoid the splash
of brake fluid; step on the clutch pedal for several
times to drain the clutch.
2. Remove the split pin and cylinder pin connected

the master pump connecting fork to the pedal;
use the No.13 socket spanner to remove two nuts
Q32008 which is used to install the master pump.
Check the clutch master cylinder, replace the com-
plete master pump if the internal of master pump
has the abnormal noise and damage of leakage etc.
Cautions for installation of clutch opera-

tion device
1. Installation of clutch hard pipe : Check the hard
pipe for deformation, check to see whether the cur-
ling at the port of connection pipe is complete and
without damage, if there is no problem after con-
firmation, it can be installed and fixed in the front
wall clip and hard-tube clip.
2. Coat each rotary parts of peal with the lithium base
grease.
3. Check the surface of clutch hoes, no surface crac-
king, oil leakage and dog leg is allowed, use the
split washer and spring clip to fix the clutch hose
on the support frame of car body.
4. Connect the joints of the general pump oil pipe and
the general pump and sub pump according to the
required tightening torque.
5. The air in the clutch oil path needs to be exhausted
after filling oil (except the vacuum filling): step on
the clutch pedal after filling the oil tank, when fe-
eling difficult in stepping, use the open-end wren-
ch with specification of 11 to loosen the air bleed
plug screw to exhaust the air, then tighten the
plug screw, repeat the operation for several times.
Tighten the air bleed plug screw of the sub pump
when there is no foam in the flowing oil liquid. Su-
pplement the oil of the oil tank to the level between
the Max and the Min.
Clutch-8
Clutch assembly
Components
profile spring
release bearing assembly
separation rocker arm assembly

separation rocker arm ball support
leather cup
bolt, spring washer assembly

19
clutch cover assembly

clutch disc assembly
Removal of clutch assembly

1. Remove the transmission
Remarks: Do not dry the transmission oil.
2. Remove the clutch cover and clutch disc
(a) Make the alignment mark on the clutch cover and
flywheel
(b) Remove the fixed bolt gradually, until release the
tension of spring
(c) Remove the fixed bolt, pull out the clutch cover
and clutch disc.
3. Remove the bearing and separation fork from the
transmission
(a) Remove the clip and pull out the bearing .
(b) Remove the separation rocker arm assembly and
leather cup.
4. Disassembly procedure
(a) Clutch cover assembly, clutch disc assembly
(b) Profile spring, throwout bearing assembly
(c) Dustproof cover, separation rocker arm assembly
(d) Separation rocker arm ball support
Warning: When maintaining the clutch assem-
bly, it is now allowed to use the sand mill or dry
brush and compressed air for cleaning, lest there
is powder (use wet cloth). The clutch disc has the
Clutch-9
“harmful fiber”, if there is powder scrap during

maintaining, the harmful fiber in the powder scrap
will floats in the air, when human inhales the air
containing the harmful fiber, it will cause great da-
mage to human health.
Checking the clutch components

1. Whether there is breakage of the clutch disc
The maximum of the rivet head: 0.3mm
If there is problem, the clutch disc needs to be repla-
ced.
2. Check the radial run-out tolerance of the clutch

disc
Use dial gauge to check the radial run-out tolerance of
the clutch disc.
The maximum radial run-out tolerance: 0.8mm
If the radial run-out tolerance exceeds the maximum
value, the clutch disc needs to be replaced.
3. Measure the radial run-out tolerance of the flywheel

Use the dial gauge to measure the radial run-out tole-
rance of the flywheel.
Maximum radial run-out tolerance: 0.2mm
If the radial run-out tolerance exceeds the maximum
value, the flywheel needs to be replaced.
4. Check the guide bearing

Rotate the bearing with hand along the direction of the
axis.
If the bearing cannot be rotated or there is great resis-
tance, the guide bearing needs to be replaced.
Remarks: The bearing is lubricated eternally, so there
is no need for cleaning and lubrication.
Clutch-10
5. If necessary, replace the guide bearing.

(a) Use the special tools to remove the guide bearing.
special tools
(b) Use special tools to install the guide bearing

Remarks: Install the guide bearing into the flywheel,
make sure that the bearing can rotate well.
special tools
6. Check to see whether there is wearing of the dia-

phragm spring
Use caliper to check the wearing depth and width of
the diaphragm spring
Limit value: maximum depth 0.6mm
Maximum width 5.0mm
7. Check the throwout bearing

Rotate the bearing with hand along the axis direction.
If the bearing can not rotate or the resistance is too lar-
ge, it is necessary to replace the throwout bearing.
Remarks: Apply appropriate grease before removing
and installing the throwout bearing.
Installation of clutch
1. Install the clutch disc on the flywheel
Use the special tools to install the clutch disc on the
flywheel.
Clutch-11
2. Installtion of clutch cover

4 1 (a) Align the matching mark of clutch shell with that of
matching mark
flywheel .
(b) Tighten the bolt evenly. Exert force along the edge
of the clutch cover repeatedly until binding tightly.
5 Tighten the bolt.
Tightening force: 19N m
3
Remarks: First tighten the upper most bolt of the 3 bol-
6 2 ts near the location pin.
3. Check the end surface runout of diaphragm spring

clutch finger. Use the special tools to check the
alignment of diaphragm spring.
Maximum displacement: 0.5mm
If the displacement is greater than the specified value,
use the special tools to adjust the face runout amount
of the diaphragm spring clutch finger.
special tools
4. Coat the following components with the molybde-

num disulfide lithium base grease (NLGI NO.2) or
multi-purpose grease
• contacting point of separation rocker arm assembly
and bearing bush
• contacting point of separation rocker arm assembly
and subcylinder push bar
• separation rocker arm assembly supporting point
• gear box 1st axle spline
5. Install the leather cup, separation rocker arm as-
sembly, clutch cover assembly and throwout bea-
ring in the transmission.
6. Install the transmission

Transmission(SC5M2D-C, SC5M4D-C)-1
Transmission(SC5M2D-C, SC5M4D-C)
Specification of transmission ......................................... 2

Inspection of SC5M2D-C transmission: ......................... 3
Disassembly of transmission (SC5M2D-C) .................... 5
Disassembly of clutch housing assembly /bearing
housing assembly ............................................................ 17
Operating instruction of transmission SC5M4D-C ........ 22
Repair of transmission SC5M4D-C ................................. 23
Disassembly of rear housing assembly ......................... 27
Disassembly of transfer case assembly ........................ 29
Rear output shaft assembly ............................................ 33
Specification of transmission
Structure diagram of SC5M2D-C and SC5M4D-C transmission: shown in figure
Structure diagram of SC5M2D-C transmission
Structure diagram of SC5M4D-C transmission

1. Speed ratio of transmissio

Gear Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ R
Speed ratio 3.967 2.136 1.360 1.000 0.856 3.578
2. Speed ratio of transfer case SC5M4D-C

Gear synchronizer H L
Speed ratio 1.000 1.925
3. Central distance of main shaft
transmission 72 mm
transfer case 222.25 mm
4. Instruction for repair specification of transmission
Inspection item Repair specification
End clearance of gear of Axle 1 (mm) 0 ~ 0.06 Adjusted by axial retainer
Clearance between bearing block and bearing of Axle 1 (mm) 0 ~ 0.1 Adjusted by adjusting shim
End clearance of gear hub of Gear 3/ 4 synchronizer (mm) 0 ~ 0.08 Adjusted by axial retainer
Clearance of rear end cone bearing of intermediate shaft (mm) 0 ~ 0.05 Adjusted by adjusting shim
End clearance of gear hub of high and low gear (mm)
0 ~ 0.08 Adjusted by axial retainer
SC5M4D-C
Clearance between the rear output shaft rear bearing and
0 ~ 0.1 Adjusted by adjusting shim
back cover (mm) SC5M4D-C
Clearance of rear input shaft bearing (mm) SC5M4D-C 0 ~ 0.06 Adjusted by adjusting shim
oil filling screw plug (SC 1701005) Inspection of SC5M2D-C transmission:

1. Check the oil level of transmission:
Screw off the oil discharge plug of the transmission;
discharge all lubricate oil; screw on the oil discharge
plug to the specified torque; the torque is: 30~35N·m.
Fill the transmission with the transmission oil through
the oil filling port, oil number is hyperbolic gear oil
SAE80W/90, which meet API GL-4, oil capacity are
oil filling screw plug (SC 1701005)
2.2L. Tighten the oil-filling plug to the specified torque
of 30~35N·m. (for area with high or low temperature
refer to the maintenance specification)
2. Replacement of oil seal of rear hosing:

The replacement of the oil seal of rear housing is
shown in figure. Disconnect the drive shaft from the
rear housing; remove the oil seal by the flat screwdri-
ver, then use the special tools to knock the rear
rear housing oil seal housing oil seal in the rear housing. It should pay atten-
tion to the installation of oil seal, shown as figure. Coat
the lip of oil seal with the specified transmission oil.
3. Removal, installation and inspection of transmis-

sion
The preoperation before removal and after installation
of transmission is: Remove and install the manipulator
cover assembly, drain and fill the transmission oil ac-
cordance with the regulation; after remove and install
the drive shaft. Separate each plug-in part from the ve-
hicle transmission .
4. Inspection of manipulator cover assembly

bolt A(SC-1704004)
Shown as figure, remove the adhesive on the surface
before installation, use the screwdriver( M8×1.25) to
clean the adhesive in the screw hole; coat the installed
part of bolt screw with the specified screw adhesive.
Firstly, install two positioning bolts A, then install other
two bolt A and bolt C respectively. The tightening tor-
que of all bolts is 15~22N·m.
bolt C(SC-1704003)
SC5M2D-C transmission assembly
handle of gearlever
manipulator cover assembly
★ 15-22
dustproof seal cover

26-36 elastic cylindrical pin 6×22
select & shift seating
spring cylindrical pin rear housing ★ 14-19
reverse lamp swit- assembly
clutch housing assembly ch bracket

connection components
bearing housing
assembly
◆oil seal 39.6 52×1052×10
odometer driven gear

assembly
odometer seating
◆bush lock plate
26-36
location compres-
sion cylindrical pin 14-19
cylindrical compression spring φ1.0×5.8×41

★ Pregummed component
※ Use the special tools
Disassembly of transmission (SC5M2D-C)

1. Remove the hexagon bolt M8×18 and lock plate.
Caution: The tightening torque is 14-19N·m when
install the hexagon bolt;
2. Remove the odometer driven gear assembly

Use the special tools to remove the odometer driven
gear assembly
3. Remove the rear housing assembly

(a) Remove 6 M10×1.25×30 hexagon bolts
installs 6 M10×1.25×30 hexagon bolts.
(b) Use the rubber hammer to knock the rear housing

and take out the rear housing assembly.
4. Remove 2 location pins and bushes.

Manipulator cover assembly
master control lever assembly
15-22 ◆pin 7×40
rubber cover
◆bush bulb
nut M8
bulb base
15-22
stop plate of main rod
◆bush
reverse lock assembly
bulb jacket

gearbox assembly (one)
★ 20-30
rubber choke plug
bleed plug assembly
◆elastic cylindrical pin 6×22 selection and shifting shaft

◆bush
gearbox ★ 20-30
selection and shifting block

★ 20-30
steel ball 7.938
◆aluminum gasket
◆location pin
reverse lamp switch
oil guiding plate
◆bush 6
10-13

gearbox assembly (two)

◆pin 5×22
◆pin 6×22
gear 3/4 declutch
reverse gear 5
reverse gear 5 shift fork gear 3/4 shifting
block
gear 1/2 shifting
block
◆circlip for shaft odometer drive gear
declutch shift shaft for
first and secondea ball bearing steel ball
◆circlip for shaft ◆circlip for shaft
bush ※ 160-190
ball bearing
lower cover pla- gear 5 drive gear
te assembly
15-20 aluminum washer
N·m specified torque 30-35

◆ Used component which can not be used any more.
gearbox assembly (three)
gear 5 needle bea-

reverse driven gear assembly ring bushing
reverse needle bearing bushing ※reverse gear 5 syn- gear 5 driven gear
chronizer assembly assembly
support axial lock plate thrust
synchronizer washer
gear ring
grease baffle of air duct n e e d l e needle
15-22 bearing bearing steel ball 4.762
※ 250-270
needle bearing
20-60
※reverse shaft
◆split pin
reverse gear
gear 3/4 shift fork 15-22 thrust washer
gear 1/2 shift fork
◆pin 6×22 spacing ring

◆adjusting shim reverse drive gear

5. Remove the reverse lamp switch M12×1.25

Caution: When install the reverse lamp switch M12
×1.25, the tightening torque is 26-36 N·m
6. Remove the gearbox

(a) Use the wrench to remove the 5 M8×55 bolts, 1
M8×6 bolt and 2 M8×110 bolts
Caution: When install 5 M8×55 bolts, 1 M8×6 bolt
and 2 M8×110 bolts. tightening torque is
(b) Remove the gearbox assembly
7. Use the circlip pliers to remove the circlip for shaft
8. Remove the odometer drive gear

9. Use the magnetic rod to take out the steel ball
Caution: It is necessary to circlip for shaft when
install the circlip for shaft
Mark Thickness（mm）
white 1.44±0.01
blue 1.52±0.01
black 1.60±0.01
12. Use the drawing die to remove the axle 2 ball bea-
ring
14. Use the opener to pry out the riveted place of lock
nut of intermedi ate shaft
15. Remove the self-locking screw plug, spring, steel

ball
(a) Use the special tools to remove 3 locking screw
plugs M10× 1.25×19
install the locking screw plug M10×1.25×19.
(b) Use the magnetic rod to remove 3 springs
(c) Use the magnetic rod to remove 3 steel balls
16. Remove the lower cover plate assembly

(a) Use the wrench to remove the 12 bolts M8×16
Caution: When install 12 bolts M8×16, the tighte-
ning torque is 15-20N·m
(b) Remove the lower cover plate assembly
17. Remove the declutch shift shaft assembly

(a) Use the punch to remove the reverse gear 5 shift
fork elastic cylindrical pin
(b) Use the punch to remove the Gear 1/2 shift fork
elastic cylindrical pin
(c) Use the punch to remove the Gear 3/4 shift fork
cylinder pin.
(d) Remove the reverse gear 5 declutch shift shaft

assembly
(e) Remove the gear 3/4 declutch shift shaft assem-

bly
(f) Remove the reverse gear 5 shift fork
18. Remove the lock nut of intermediate shaft

Caution: When install the lock nut of intermediate
shaft , the tightening torque is 160-190N·m
19. Remove the Gear 1/2 declutch shift shaft assembly,

intermediate shaft rear ball bearing, 5th-Gear drive
gear
20. Remove the Gear 1/2 shift fork

21. Use the special tools to remove the second shaft

lock nut
Caution: When install the second shaft lock nut,
the tightening torque is : 250-270N·m
22. Remove the thrust plate
23. Use the magnetic rod to remove the steel ball
24. Remove the 5th-Gear driven gear assembly

Caution: When install the 5th-Gear driven gear as-
sembly, it should use the plug gage to test the 5th-
Gear driven gear assembly axial clearance, ensure
the axial clearance is within 0.170-0.284mm
25. Remove the 5th-Gear driven gear needle bearing

26. Remove the synchronizer gear ring

Caution: When install the synchronizer gear, it
should use the plug gage to test the synchronizer
gear ring axial clearance, ensure the axial clearan-
ce is within 1.25-1.65mm
27. Use the pliers to remove the split pin on the rever-
se shaft lock nut.
28. Use the special tools to remove the reverse lock

nut
Caution: when install the reverse lock nut, the tig-
htening torque is within 20-60N·m
29. Remove the thrust plate
30. Remove the 5th/reverse -Gear synchronizer assem-

bly
(a) Use the special tools to remove the 5th/reverse
-Gear synchronizer assembly
(b) Remove the sleeve and 5th/reverse -Gear syn-

chronizer assembly
31. Remove the reverse gear
32. Remove 2 needle bearings of reverse gear
33. Remove the reverse driven gear
34. Remove the needle bearing of reverse driven gear

35. Remove the reverse drive gear
36. Remove the intermediate shaft spacing ring
37. Remove 8 countersunk screws

Caution: when install the countersunk screw, the
tightening torque is within 15-22N·m
38. Remove the support axial lock plate
39. Remove the air duct grease baffle

Clutch housing assembly / Bearing housing assembly

throwout bearing
assembly ◆non-standard spring
second shaft assembly
washer 8 needle bearing
◆bush
10-13
first shaft assembly
first bearing ◆oil seal
◆circles for shaft

separation rocker
leather cup arm ball support clutch cylinder assembly
aluminum waher16
◆¦adjusting shim 30-35
30-42
separation rocker arm assembly
front space ring of intermediate shaft

N·m :Specified torque intermediate shaft assembly
Disassembly of clutch housing ass-

embly /bearing housing assembly
40. Use the special tools to remove the reverse shaft
41. Use the magnetic rod to take out 2 interlocking

pins
42. Remove the first bearing block assembly

(a) Use the special tools to install 6 M8 bolts.
Caution: When install 6 M8 bolts, the tightening
torque is 10-13N·m
(b) Remove the first bearing blocks assembly ; take

out the adjusting shim
Caution: It should select the adjusting shim when
install the adjusting shim
white 0.88±0.01
blue 0.98±0.01
black 1.08±0.01
43. Remove the bearing snap ring
44. Remove the intermediate shaft assembly
45. Remove the first shaft assembly
46. Remove the needle bearing

47. Remove the 3rd/4th-Gear shift fork
48. Remove the second shaft assembly

(a) Use the rubber hammer to knock the second shaft
(b) Remove the needle bearing bushing of reverse

driven gear
(c) Remove the double inner-race ball bearing ass-

emblyRemove the double inner-race ball bearing
assembly
(d) Remove the second shaft assembly

Secondary shaft assembly

◆circlips for synchronizer gear ring
shaft
3rd-Gear driven gear assembly second shaft
needle bearing
3rd/4th-Gear
synchronizer
assembly
1st-Gear driven gear assembly
2nd-Gear driven gear assembly

needle bearing sleeve
2nd-Gear synchronizer gear ring
1st/2nd-Gear synchronizer assembly double inner-race
N·m : specified torque 1st-Gear synchronizer gear ring
49. Disassembly of second shaft assembly

(a) Remove the second shaft rear retainer
Caution: It should select the circlip for shaft when
install the circlip for shaft.
white 2.18±0.01
blue 2.26±0.01
green 2.34±0.01
(b) Remove the 3rd/4th-Gear synchronizer assembly
(c) Remove the 3rd/4th-Gear synchronizer gear ring

Caution: When install the 3rd/4th-Gear synchroni-
zer gear ring, it should use the plug gage to measu-
re the end surface clearance of gear ring to ensure
it is within 1.25-1.65mm
(d) Remove the 3rd-Gear driven gear assembly

Caution: When install the 3rd-Gear driven gear as-
sembly, it should use the plug gage to measure the
3rd-Gear driven gear assembly axial clearance to
ensure it is within 0.17-0.284mm0.17-0.284mm
(e) Remove the 3rd-Gear driven gear needle bearing
(f) Use the special tools to press the second shaft to

remove the inner race of double inner-race ball
bearing
(g) Remove the 1st-Gear driven gear

Caution: When install the 1st-Gear driven gear, it
should use the plug gage to measure the 1st-Gear
driven gear axial clearance to ensure it is within
0.17-0.284mm
(h) Remove the 1st-Gear driven gear needle bearing

(i) Remove the sleeve
(j) Remove the 1st-Gear synchronizer gear ring
(k) Remove the 1st/2nd-Gear synchronizer assembly
(l) Remove the 2nd-Gear synchronizer gear ring ,

2nd-Gear driven gear and second shaft
Caution: When install the 2nd-Gear driven gear, it
should use the plug gage to measure the 2nd-Gear
driven gear axial clearance to ensure it is within
0.17-0.284mm
Operating instruction of transmis-

hand ball of main steering column
sion SC5M4D-C
1. The schematic diagram of transmission operating
gear position is on the handle of steering column.
During the process after vehicle is started and in trave-
ling, it must step the clutch pedal to bottom before the
shifting. If need shift from 5th-Gear to reverse-Gear, it
hand ball of auxiliary steering column should move the shifting bar to the neutral position of
3rd/4th-Gear. Shift to R-Gear after stop the vehicle sta-

bly, otherwise, it can not shift.
During the traveling process. It should always pay at-
tention to the shifting to make the vehicle matches to
the speed of engine. The correct shifting can improve
the economical efficiency and prolong the service life
of engine. Do not shift from high-Gear to low-Gear on
the condition that the pointer of tachometer may enter
into red area, otherwise, the engine will be damaged.
Warning: Do not shift to reverse-Gear when the ve-
hicle moves forwardly, otherwise the transmission
will be damaged.
2. Operation of 4WD
The operating auxiliary steering column can be shifted
to 4WD status.
For position of auxiliary steering column and corres-
ponding operating condition refer to table.
Auxiliary steering
drive Operating condition
column position
Use this gear position when run in the general railway and high
2H 2WD
speed highway
Use this gear position when run in the deep snowland, sand
4H High speed 4WD
ground or uneven road in normal speed
When use the gear position during using of winch, it could not
N Neutral gear
drive the vehicle
Use this gear-position when run in uneven road such as mud
4L Low speed 4WD land or climbing or downward （especially when need increase
the power）
3. Caution for operation:

(a) Do not use 4WD in good surface, otherwise the
tyre and components of drive system will be da-
maged easily and increase the consumption of
fuel, and cause the noise of drive system.
(b) Please run in 1st-Gear under “4L” gear position
when run in very low speed in field.
oil filling screw
plug(JK72-1701005)
oil filling screw
plug(SC-1802317) Repair of transmission SC5M4D-C
1. Inspection of oil level of transmission and transfer
case:
Screw off the oil drainage screw plug of main box and
transfer case; drain all lubrication oil, tighten the oil
drain plug to specified torque.
The torque is: 30-35N·m. Fill the main box and trans-
transmission
fer case with the transmission oil through the oil filling
oil-drain screw-plug assembly transfer case port. The number is hyperbolic gear oil SAE80W/90,
(JK72－1701070)
comply with API GL-4. The oil quantities are main box:
2.2 L, transfer case: 2.7 L. (for high and low temperatu-
re environment refer to maintenance specification). Tig-
hten the oil filling screw plug to specified torque. The
torque is: 30-35N·m.
2. Replacement of oil-seal of transfer case

rear output shaft oil seal (SC-1802323)
The replacement of transfer case oil seal is shown
as figure. Disconnect the drive shaft from the transfer
case, use the flat head screwer to remove the oil seal
Caution: Do not damage the housing hole during
the disassembly.
Then use the special tools to knock the transfer
front output shaft oil seal (SC-1802504) case oil seal into the transfer case. It should pay
attention to the installation dire tion of oil seal. The
oil seal is flush with the port of transfer case.
Shown as figure. Coat the lip of oil seal with the
specified general synthetic gear oil.
3. Disassembly and check of transmission
The preoperation before the removal and after insta-
llation of transmission is : When remove and install
the manipulator cover assembly, drain and fill with the
specified transmission and transfer case lubrication oil.
When remove and install the front and rear drive shaft,
separate each plug-in part of transmission from the ve-
hicle.
bolt B (SC-1704003) bolt B (SC-1704003)

Inspection of manipulator cover assembly:
bolt A (SC-1704004)
The bolt dimension is different for different installation
position. Do not confuse it during the installation. It
should install the fixing bolt A firstly.
The tightening torque of bolt A and B bolt is 15-22N ·m.
installation position of fastening blot

Transmission SC5M4D-C assembly

manipulator cover assembly
15-22
◆elastic cylindrical pin6×22
test switch bracket
washer 8
reverse lamp switch bracket

26-36 wire clip
select & shift seating
cylindrical compression spring
30-42
φ1.2×6.2×28
wire clip
steel ball 6.356.35 transmission se-

26-36 parated case
cylindrical compression spring

φ1.0×5.8×41 ◆bush
spring cylindrical pin
stud M10×1.25
◆washer 10
30-42
26-36
location sp
ring cylindrical pin
cylindrical compression spring φ10×5.8×41
Manipulator cover assembly
handle of transfer case
auxiliary steering
column assembly
15-22
handle of
gearlever
◆pin 7×36
◆washer
ball head base master control
lever assembly
rubber cover
◆bush
ball head
ball head base
auxiliary steering
column stop plate
manipulator cover 15-22 ◆bush 15-22

assembly ◆washer
rubber cover ◆pin 7×40
reverse lock
assembly
ball head stop plate of main bar
N·m :specified torque nut M8 ball head hood

Rear housing assembly

26-36
30-42
24-33 26-36
mushroom lock spring
φ1.8×10×34 ◆aluminum gasket 12
steel ball 7.938（3) rear housing

mushroom lock spring
◆aluminum gasket14 φ1.6×7.5×38.5
◆adjusting shim dustproof seal gui-

24-33 de bushing
◆oil seal 39.6×52×10
★ 14-19
★ 14-19
※odometer driven
gear assembly
odometer seating lock plate
Disassembly of rear housing ass-

embly
1. Remove the M8×18 hexagon bolt and the lock pla-
te
Caution: When install the M8×18 hexagon bolt, the
tightening torque is 14-19N·m
2. Remove the odometer driven gear assembly

Use the special tools to remove the odometer driven
gear assembly
3. Remove the rear cover assembly

(a) Remove 6 M10×1.25×30 hexagon bolts
Caution: When install 6 M10×1.25×30 hexagon
bolts, the tightening torque is 14-19N·m.
(b) Use the plastic hammer to knock the rear cover

slightly and take out the rear cover
(c) Take out the adjusting shim

Caution: It should select the adjusting shim as fo-
llows when install it.
white 1.58±0.01
green 1.68±0.01
Transfer case assembly (one)

◆aluminum gasket18
30-35
30-35
high speed gear chain waved spring
front output shaft assembly ◆aluminum gasket18
★ 26-36
transfer case cover

rear output shaft assembly
transfer case housing assembly

Transfer case assembly (two)

2nd/4th drive shifting block cylindrical compression spring
◆pin 5×26 φ1.8×23×42
2nd/4th drive declutch
shift shaft interlocking
cylinder pin
split retainer
spring base
spacing ring
2nd/4th drive shift fork
high/low gear de- high/low gear shift fork assembly

clutch shift shaft
14-19
transfer case housing assembly high/low gear dupli-
◆O-RING cate gear
lock plate
needle bearing
◆bush
side cover plate rear intermediate shaft thrust washer

thrust washer
needle bearing spacing ring
15-20

Transfer case assembly (three)

duplicate ball bearing disk spring ◆circlips for hole
auxiliary gear
◆circlips for shaft spacing ring
◆oil seal 45×68.2×15
back plate ◆bowel patch

rear input shaft
◆circlips for shaft
ball bearing
transfer case
dustproof seal housing front output shaft
guide bushing
ball bearing
◆oil sea l36×52×10
Disassembly of transfer case ass-

embly
4. Remove the shouldered lock screw plug
Use the wrench to remove the shouldered lock screw
plug M16×1.5×12
Caution: The tightening torque is 26-36N m when
install the shouldered lock screw plug M16×1.5×
12.
5. Remove the upper and lower drive switch M12×

1.25
Caution: When install the upper and lower drive
switch M12×1. 25, the tightening torque is within
26-36N·m
6. Remove the 2nd/4th drive switch M14×1.25

Caution: When install the 2nd/4th drive switch M14
×1.25, the tightening torque is with in 26-36N·m
7. Remove the shouldered lock screw plug M14×1.5

×10
Caution: When install the shouldered lock screw
plug M14×1.5×10, the tightening torque is within
26-36N·m
8. Remove the shouldered lock screw plug

(a) Use the wrench to remove the shouldered lock
screw plug M12×1.25×10
Caution: When install the shouldered lock screw
plug M14×1.5×10, the tightening torque is within
26-36N·m
(b) Takeout mushroom lock spring
(c) Use the magnetic rod to take out the steel ball
9. Remove the transfer case cover

(a) Use the wrench to remove 12 connecting bolts
M10×1.25×65 between the transfer case cover
and tranafer case housing.
install the bolt M10×1.25×65.
(b) Remove the select & shift seating elastic cylindri-

cal pin
(c) Remove the high/low drive declutch shift shaft

elastic cylindrical pin
(d) Remove the 2nd/4th declutch shift shaft elastic

cylindrical pin
(e) Use the circlip pliers to remove the bearing snap

ring
(f) Use the rubber hammer to knock out the trans-

fer case cover assembly slightly and remove the
transfer case cover assembly
10. Remove the high and low gear drive declutch shift
shaft
11. Remove the second and fourth drive declutch shift

shaft
12. Use the plastic hammer to knock out the rear

output shaft assembly, front output shaft assembly
and chain out slightly
13. Remove the second/fourth shift block and high and

low gear shift fork
14. Remove the housing of transfer case

(a) Use the wrench to remove 4 bolts M10×1.25×35
and 2 nuts M10×1.25 connected the gearbox and
tranafer case housing
Caution: The tightening torque is 30-42 N•m when
install the connecting bolt of gearbox and housing
of transfer case
(b) Remove the housing of transfer case
15. Remove a location pin
For the disassembly of gearbox refer to “Disassembly

of gearbox in SC5M2D-C”
Rear output shaft assembly

low-speed driven gear
high and low gear hub
rear output shaft
needle bearing
oil guide plate assembly
drive sprocket
sprocket needle bearing bushing 87-120
ball bearing
◆circlips for shaft
high and low needle bearing
gear sleeve
N·m :specified torque spacing plate needle bearing ball bearing

second/fourth dri-
◆ Used component which can not be used any more. ve geared sleeve assembly
spacer of drive sprocket
※ Use the special tools second/ fourth drive gear hub
Disassembly of rear output shaft assembly

(a) Use the special tools to remove the lock nut
Caution: The tightening torque is 87-120N m when
install the lock nut.
(b) Remove the ball bearing
(c) Remove the oil guide plate
(d) Remove the spacing ring
(e) Use the magnetic rod to remove the steel ball
(f) Remove the drive sprocket and needle bearing

Caution: When install the drive sprocket, it should
use the plug gage to measure the drive sprocket
axial clearance and ensure within 0.19-0.338mm
(g) Remove the drive geared sleeve
(h) Use the magnetic rod to remove the steel ball
(i) Dismantle the drive gear sleeve
(j) Remove the gear hub
(k) Remove the spacing plate

(l) Use the circlip pliers to remove the circlip.

Caution: It should select the circlip for shaft accor-
ding the angle when install it.
white 2.36±0.01
blue 2.44±0.01
green 2.52±0.01
(m) Remove the high and low geared sleeve and gear
hub
(n) Remove the low-speed driven gear, needle bea-

ring and rear output shaft
Caution: When install the low-speed driven gear,
it should use the plug gage to measure the axial
clearance of low-speed driven gear axial clearance
to ensure the axial clearance is 0.17-0.284 mm
Transmission(038M1)-1
Transmission(038M1)
Precautions ..................................................................................... 2
Troubleshooting ............................................................................. 3
Transmission .................................................................................. 4
Input Shaft Subassembly............................................................... 14
Output Shaft Subassembly............................................................ 17
Intermediate Shaft Subassembly .................................................. 26
Front Cover Component ................................................................ 28
Rear Body Subassembly ............................................................... 29
Intermediate Plate Component...................................................... 33
Assembly of Transmission ............................................................ 42
Precautions
Precautions of Disassembly
The component shall be handled gently in the process of transmission disassembly to avoid
bruise, especially for the joint surface; besides, the component shall be placed in a proper
order to avoid loss and mistaking.
Precautions of Assembly
1. All components shall be cleaned before assembly (except for the bearing, the rubber parts
and the pad).
2. Repetitive use of all kinds of oil seal, retainer ring for shaft and elastic pin shall be avoided.
3. Lubricating oil shall be applied on the friction surfaces and lubricating grease shall be
applied on oil seal lips.
4. Rolling elements shall not be used to transmit pressure in the assembly of bearings.
5. Inclination shall be avoided in the assembly of lip oil seal.
6. The splits of expansion circle springs at both sides shall not be overlapped in the assembly
of synchronizer component.
7. Lubricating oil leakage of the component shall be avoided when the transmission is in
normal working position.
Troubleshooting
Malfunction
Cause Analysis Troubleshooting
Classification
Difficulty in gear The clutch is not used. Use the correct driving method.
engagement The clutch is incompletely released. Check and replacement
The synchronizer ring gear is seriously worn out. Replacement
The positioning spring is too rigid. Replacement
Too loud or The oil level is too low. Feed the oil to the prescribed level.
abnormal noise The lubricating oil is unqualified. Replace with the prescribed oil.
The oil is not timely changed. Replace the oil and the broken component.
The axial positioning and the clearance of gears Check and adjustment
are inappropriate.
The bearing is broken. Replacement
There is burr or bruise on the tooth part. Repair or replace the gear.
Oil leakage and Feed excessive oil leads to too high oil level. Make the oil level to the prescribed position.
oil penetration The bolt is loosened or the installation of bolt is Reinstall the bolt and tighten it with
omitted. prescribed torque.
The ventilation plug is out of function. Replacement
The seal is damaged. Replacement
Damage of the The force for gear shift is too heavy. Replacement
synchronizer The clutch is not used. Use the correct driving method.
The synchronizer expansion circle spring is Replacement
damaged.
The drive shaft is inappropriately installed. Check and adjustment
Gear-off The control mechanism has malfunction. Check and adjustment
The installation of the positioning spring or steel Reinstallation
ball is omitted.
The positioning spring is out of function. Replacement
The gear sleeve fork groove is seriously worn Replacement
out.
The fork is seriously worn out. Replacement
Burning of the The oil level is too low. Replace the broken components and feed
bearing and gear oil.
The lubricating oil is unqualified. Replace the broken components and feed
lubricating oil.
The oil is not timely changed and the oil is dirty Replace the broken components and feed
lubricating oil.
Different oil is mixed and additives are used. Replace the broken components and feed
lubricating oil.
Difficulty in gear The synchronizer spring is out of function. Replacement
disengagement The internal groove of synchronizer ring gear is Replacement
worn out.
The synchronizer ring gear is seized on the Replacement
conical surface
The fork or fork shaft is distorted. Replacement
Transmission
Elements Diagram
15 18
19 16
14
13 20
23 21
9 22
◆10
6 ◆7
11
1
◆23 17
12
◆8 13
4 5
2 3
1.Clutch shell 2.Fork strut 3.Release fork component

4.Release bearing assembly 5.Protecting cover for fork 6.Front cover component
7.Input shaft bearing check ring 8.Intermediate shaft front bearing check ring 9.Transmission shell
10.Bowl plug blade 11.Cylindrical pin 12.Hexagonal-head screw plug
13.Seal ring 14.Gear shift shaft 15.Gear shift block
16.Flange screw 17.Rear body subassembly 18.Shift lever cover component
19.Positioning mechanism component H 20.Positioning mechanism component L 21.Reverse gear switch assembly
22.Clip 23.Hollow positioning pin
◆ Disposable components
Disassembly of Shell
1. Remove the hexagonal-head bolt and the seal
washer and discharge the lubricating oil.
2. Remove the hexagonal-head bolt and the seal

washer and discharge the lubricating oil.
3. Remove the dust boot, the release fork component

and the release bearing subassembly.
4. Remove the reverse gear switch component.
5. Remove the fork strut.
6. Remove the bolts fixing the clutch shell.
7. Use the hammer to lightly strike the clutch shell

and then remove it.
8. Remove the six bolts connecting the shift lever

cover and the rear body and then take down the
shift lever cover.
9. Remove the components of the left and right

positioning mechanisms.
10. Remove the flange bolt.
11. Remove the connecting bolt for the rear body and
the transmission shell, lightly strike it and then
remove the rear body subassembly.
12. Remove the front cover.

Remove the connecting bolts for the front cover and
the transmission shell, lightly strike it and then remove
the front cover.
13. Remove the input shaft bearing check ring and the
intermediate shaft front bearing check ring.
14. Lightly strike the transmission shell and remove it.
Removal of Control Components

1. Fix the intermediate plate component on the bench
vice.
2. Remove the positioning spring screw plug.
3. Use magnetic body to take out the positioning

spring and the steel ball.
4. Remove the positioning flange bolts of fork 1# and

fork 2#.
5. Remove the clamping retainer rings of fork shaft 1#

and fork shaft 2#.
6. Remove the gear shift fork shaft 2# and the fork 2#.
7. Use the magnetic body to take out the short

interlock pin and the interlock guide post.
8. Remove the shaft of gear shift fork 1# and the fork

1#.
9. Remove the clamping retainer ring of fork shaft 3#.
10. Remove the elastic cylindrical pin.
3#.
12. Use the magnetic body to take out the short

interlock pin and the positioning steel ball.
13. Remove the reverse gear shifting fork shaft.

14. Take out the steel ball and the positioning spring in
the reverse gear rocker.
15. Remove the reverse gear rocker component.
16. Remove the bolt of reverse gear rocker bracket and

take down the bracket.
Removal of Running Component

1. Remove the retainer ring for odometer shaft .
2. Remove the odometer driving gear and the steel

ball.
3. Remove the retainer ring for odometer shaft.
4. Remove the retainer ring for shaft at the rear

bearing of output shaft.
5. Remove the rear bearing of output shaft.
6. Remove the sleeve.
7. Remove the intermediate shaft fifth-speed coupling

gear.
8. Remove the Gear 5 synchronizer ring, the

intermediate shaft fifth-speed gear component and
the needle bearing of intermediate fifth-speed gear.
9. Remove the thrust gasket and pin of fifth-speed

gear.
10. Remove the output shaft bearing baffle bolts and

take down the bearing baffle.
11. Take off the reverse gear idler shaft and the reverse
gear idler.
12. Remove the rear bearing of intermediate shaft.

13. Remove the intermediate shaft.
14. Take down the input shaft subassembly.
15. Remove the output shaft bearing snap ring.
16. Strike the intermediate plate and take down the

output shaft group.
Input Shaft Subassembly

Elements Diagram
Gear 4 synchronizer ring
Input shaft
components
Input shaft bearing
◆Retainer ring
for input shaft
Input shaft needle bearing
Removal of Input Shaft Subassembly

1. Remove the Gear 4 synchronizer ring and the input
shaft needle bearing.
2. Remove the retainer ring for input shaft.
3. Remove the input shaft bearing.

Assembly of Input Shaft Subassembly

1. Mount the input shaft bearing.
2. Select and match the retainer ring for input shaft.

Select and match the retainer ring of input shaft to
achieve the minimum axial clearance.
Axial clearance: <0.1mm
3. Mount the retainer ring for input shaft.
4. Mount the Gear 4 synchronizer ring .

(a) Apply the gear oil on the conical surface of the
coupling gear 4# and then mount the Gear 4
synchronizer ring.
(b) Inspect the axial clearance between the Gear 4

synchronizer ring and the gear.
Reference value: (1.2±0.5)mm
5. Check the synchronizer ring.

Rotate the ring gear and push it in so as to check its
braking working.
6. Mount the input shaft needle bearing.

Apply the gear oil in the internal cavity of the input
shaft component and then mount the input shaft needle
bearing in it.
Output Shaft Subassembly

Elements Diagram
10
9
8
4 6 7
5
2 3 26
24 25
◆1
23
22
◆21
20
19
17
16 18
15
14
13
12
11
◆31
◆30
29
28
◆27
1. Retainer ring for shaft of gear hub 2# 　　2. Gear sleeve 2# 3. Expansion ring of synchronizer 2#
4. Sliding block 2# 　　5. Gear hub 2# 6. Gear 3 synchronizer ring
7. Third-speed gear needle bearing 　　8. Third-speed gear component 9. Output shaft
10. Pin 　　11. Second-speed gear component 12. Second-speed gear needle bearing
13. Inner ring of Gear 1 synchronizer ring 　　14. Intermediate ring of Gear 1 synchronizer ring 15. Outer ring of Gear 2 synchronizer ring
16. Sliding block 1# 　　17. Compression spring 18. Gear hub 1#
19. Outer ring of Gear 1 synchronizer ring 　　20. Gear sleeve 1# 21. Retainer ring for shaft of gear hub 1#
22. Gear 1 needle sleeve 　　23. First-speed gear needle bearing 24. First-speed gear component
25. First-speed gear thrust gasket 　　26. Output shaft bearing 27. Output shaft bearing check ring
28. Output shaft fifth-speed gear 　　29. Sleeve 30. Output shaft rear end bearing
31. Retainer ring for rear shaft of output shaft
Removal of Output Shaft Subassembly

1. Remove the output shaft fifth-speed gear, the output
shaft bearing, the first-speed gear thrust gasket
and first-speed gear component successively.
2. Remove the Gear 1 synchronizer ring component,

the first-speed gear needle bearing and the first-
speed gear needle bearing sleeve in proper order.
3. Remove the retainer ring for shaft of gear hub 1#.

Use screwdriver to remove the retainer ring for shaft of
gear hub 1#.
4. Remove the Gear 1/2 synchronizer component, the

Gear 2 synchronizer ring component, the second-
speed gear component and the second-speed gear
needle bearing successively.
5. Remove the Gear 1/2 synchronizer component.

7. Remove the Gear 3/4 synchronizer component,

the Gear 3 synchronizer ring, the third-speed
gear component and the third-speed gear needle
bearing in proper order.
8. Remove the Gear 3/4.synchronizer component.
Inspection of Component before

Assembly of Output Shaft
1. Measure the reversed gap between the ring gear
and the gear.
Use the feeler gauge to measure the reversed gap
between the ring gear and the gear.
Gear Reference Value (mm)
Gear 1 1.2±0.55
Gear 2 1.2±0.55
Gear 3 1.2±0.45

Rotate the ring gear and then push it in so as to check
its braking working.
3. Inspect the clearance between the fork 1# and the

gear sleeve 1#.
Use the vernier caliper to measure the size of the slot
of fork 1# (reference value: 5.28mm) and the size of
the boss of gear sleeve 1# (reference value: 5mm).
Reference value of clearance: 0.28mm

gear sleeve 2#.
Use the vernier caliper to measure the size of the claw
of fork 2# (reference value: 10mm) and the size of the
slot of gear sleeve 2# (reference value: 10.2mm).
5. Inspect the output shaft.

(a) Use the micrometer to measure the outer diameter
of the output shaft at each gear.
A 38.000
B 47.000
C 38.987
(b) Use the micrometer to measure the width of the

output shaft flange.
Reference value: 5.0mm
(c) Use the dial indicator to measure the radial swing

tolerance of the shaft.
Reference value: less than 0.015mm
(d) Use the bore gauge to measure the bore diameter

at each gear.
Gear 1 46.0275
Gear 2 53.0275
Gear 3 44.0275
Assembly of Output Shaft Subassembly

1. Mount the Gear 1/2 synchronizer component.
(a) First mount three springs and then use screwdriver
or other thin tools to press the springs into three
1# slide blocks respectively.
(b) Mount the gear sleeve 1#.

Note: Gear 1/2 synchronizer is directional and the
identification of the specific direction relies on the
sizes of a and b as shown in the figure.
Gear 2 side
2. Mount the gear 3/4 synchronizer component.

Mount the gear hub 2#, the slide block 2# and the
expansion ring of synchronizer 2# on the gear sleeve
2# in proper order.
Gear 4 Side
Note:
· The Gear 3/4 synchronizer is directional and the
identification of the specific direction relies on
the sizes of a and b as shown in the figure.
· Overlapping of the splits of the two expansion
rings should be avoided.
3. Mount the third-speed gear component and the

Gear 3/4 synchronizer component on the output
shaft.
(a) Apply the gear oil on the shaft and the third-speed
gear needle bearing.
(b) Put the synchronizer ring on the third-speed
gear component and align the groove opening of
synchronizer ring with the sliding block.
(c) Mount the needle bearing into the third-speed
gear component.
4. Press the Gear 3/4 synchronizer component on the

output shaft.
5. Select and match the retainer ring for shaft.

Select and match a retainer ring for shaft to achieve
the minimum axial clearance.
Axial clearance: clearance <0.1mm
6. Mount the retainer ring for shaft.
7. Measure the axial clearance of the third-speed gear

component.
Use the feeler gauge to measure the axial clearance of
the third-speed gear component.
8. Mount the second-speed gear component and the

Gear 1/2 synchronizer component.
(a) Apply the lubricating oil on the second-speed gear
needle bearing.
(b) P u t t h e G e a r 2 s y n c h r o n i z e r r i n g o n t h e
second-speed gear and align the three claws
of intermediate rings with the three grooves of
coupling gears.
(c) Mount the second-speed gear needle bearing and

second-speed gear component in proper order.
(d) Mount the Gear 1/2 synchronizer component.

Note: The Gear 1/2 synchronizer is directional.


Use the screwdriver to mount the retainer ring for shaft.
11. Measure the axial clearance of the second-speed

gear component.
the second-speed gear component.
12. Mount the first-speed gear component.

Mount the first-speed gear needle bearing sleeve, the
needle bearing, the Gear 1 synchronizer ring gear
component and the first-speed gear component in the
order as shown in the figure.
Note: Apply the gear oil on the output shaft, the
needle bearing and the first-speed gear conical
surface before aligning the three claws of
intermediate ring of Gear 1 synchronizer with the
coupling gear groove for installation.
13. Mount the first-speed gear thrust gasket.

Mount the pin and the first-speed gear thrust gasket on
the output shaft in proper order.
Note: The pin must be completely set in the thrust
14. Pay attention to the following points for installation

of output shaft bearing
Note:
· The side of the output shaft bearing with check
ring groove shall face back.
· In the process of press assembly, use the tool
like screwdriver to prop up the first-speed gear
trust gasket to avoid its dropping affecting
press assembly of the bearing.
15. Measure the axial clearance of the first-speed gear

component.
the first-speed gear component.
16. Mount the output shaft fifth-speed gear.

17. Measure the radial clearance of the gear.

Use the micrometer to measure the radial clearance of
the gear.
Gear 1 0.0265
Gear 2 0.0265
Gear 3 0.0265
Intermediate Shaft Subassembly

Elements Diagram
◆Intermediate
shaft front bearing
◆Retainer ring for shaft
at the front bearing of
intermediate shaft
Intermediate shaft
coupling gear
Removal of Intermediate Shaft Subassembly

1. Remove the retainer ring for shaft at the front
bearing of intermediate shaft.
2. Remove the intermediate shaft front bearing.
Assembly of Intermediate Shaft Subassembly

1. Inspect the components before assembly.
Measure the diameters of the intermediate shaft rear
bearing and the intermediate shaft fifth-speed gear.
Measured Part Reference Vlue (mm)

A 34.00
B 30.00
2. Mount the intermediate shaft front bearing.

Mount the intermediate shaft front bearing in the order
as shown in the figure.
Note: Make the side with groove face down in the
assembly.

Select and match a retainer ring to achieve the
minimum axial clearance.

Front Cover Component

Elements Diagram
Front cover
◆T-oil seal
Removal of Front Cover Component

Remove the T-oil seal
Mounting of T-oil Seal

Note: Apply the lubricating grease on the outside
of oil seal before mounting the oil seal.
Rear Body Subassembly

Elements Diagram
◆12
◆6 5
◆11
◆9
3
2
1
10
1.Hexagon bolt (with washer) 2.Oil guide groove 3.Reverse gear limitation mechanism component
4.Rear body component 5.Positioning spring screw plug 6.Elastic cylindrical pin
7.Positioning mechanism component H 8.Positioning mechanism component L 9.T-oil seal
10.Oil guide nozzle 11.Dust boot of rear body 12.Rear body liner
Removal of Rear Body Subassembly

1. Remove the gear shift shaft and gear shift block
from the rear body subassembly.
2. Use the tool to remove the dust boot of rear body.

3. Use the tool to remove the positioning spring

screw plug
4. Use the tool to remove the elastic cylindrical pin

and take down the reverse limitation mechanism
component.
5. Use the tool to remove the screw plug.
6. Remove the hexagon bolt (with washer) and the oil

guide.
7. Use the tool to remove the oil seal of rear body.

Inspection of Component before

Assembly of Rear Body Subassembly
1. Rotate the interlock block to check its flexibility.
2. Use the inside gauge for measuring.
Assembly of Rear Body Subassembly

1. Mount the oil guide and the hexagon bolt (with
washer) and then mount the oil guide nozzle.
2. Use the tool to mount the screw plug.
3. M o u n t t h e r e v e r s e l i m i t a t i o n m e c h a n i s m
component.
(a) M o u n t t h e r e v e r s e l i m i t a t i o n m e c h a n i s m
component into the limiting hole.
(b) Mount the elastic cylindrical pin.
4. Mount the positioning spring screw plug.
5. Mount the oil seal of rear body.

Note: The clearance between the surface of the
(0±0.05)mm
mounted oil seal and the attachment face of oil seal
of rear body shall be (0±0.05) mm.
6. Use the tool to mount the dust boot of rear body.

Intermediate Plate Component

Elements Diagram
12 13
◆14
8 9 10
15
1 17
16
18
2
10
1 7 11
3 4
6
◆5
1.Fork locating bolt 2.Fork 2# 3.Fork 1#

4.Reverse gear shifting rocker bracket 5.E-retainer ring 6.Reverse gear shifting rocker
7.Reverse gear fork 8.Positioning spring screw plug 9.Fork shaft positioning spring
10.Steel ball 11.Intermediate plate 12.Shaft of gear shifting fork 2#
13.Shaft of gear shifting fork 1# 14.Elastic cylindrical pin 15.Component of fork 3#
16.Shaft of gear shift fork 3# 17.Interlock guide post 18.Short interlock pin
Assembly of Intermediate Plate

Component
1. Fix the intermediate plate.
Fix the intermediate plate on the bench vice.
2. Mount the output shaft subassembly.

Mount the output shaft subassembly in the intermediate
plate.
3. Mount the output shaft bearing snap ring.
4. Mount the sleeve.

Mount the sleeve in the output shaft.
5. Mount the output shaft rear bearing.


8. Mount the input shaft subassembly.

Mount the input shaft subassembly in the output shaft
by rotation and make align the synchronizer ring
groove with the sliding block.
9. Mount the intermediate shaft subassembly in the

intermediate plate.
10. Mount the intermediate shaft rear bearing.

Note: The bearing snap ring is mounted in the
intermediate shaft rear bearing.
11. Mount the reverse gear idler and the reverse gear
idler shaft.
Mount the reverse gear idler and the reverse gear idler
shaft on the intermediate plate.
Note: The end of reverse gear idler with fork groove
shall face back and insert the reverse gear idler
shaft into its rear end.
12. Mount the output shaft rear bearing baffle.

Use the torque socket wrench to mount it and then
tighten the bolt.
Tightening torque: (12.6~23.4) N•m
13. Mount the fifth-speed gear thrust gasket.

Mount the pin in the intermediate shaft pin hole and
then mount the fifth-speed gear thrust gasket.
Note: The fifth-speed gear thrust gasket is
directional.
Inside
14. Mount the fifth-speed gear of intermediate shaft.

(a) Mount the gear sleeve 3#.
(b) Mount the sliding block of synchronizer 3#, the
expansion ring of synchronizer, the spring of
synchronizer and the retainer ring for shaft in
proper order.
(c) Mount the intermediate fifth-speed gear needle

bearing, intermediate fifth-speed gear component
and the ring gear of Gear 5 synchronizer.
15. Mount the fifth-speed coupling gear.
16. Measure the axial clearance of fifth-speed gear.

the fifth-speed gear component.


19. Mount the reverse gear shifting rocker bracket.

Use the torque socket wrench to mount and tighten the
bolt.
20. Connect the reverse gear rocker and reverse gear

fork.
Use the screwdriver to mount the E-retainer ring to
connect the reverse gear shifting rocker and reverse
gear fork.
21. Mount the connected reverse gear shifting rocker

and the connected reverse gear fork in the place as
shown in the figure.
22. Mount the steel ball and reverse positioning spring.

Mount the steel ball and reverse positioning spring in
the reverse gear shifting rocker.
23. Mount the reverse gear shifting fork shaft.

Mount the reverse gear shifting fork shaft with its tip
facing frontward on the intermediate plate and reverse
gear rocker bracket.
24. Mount the steel ball and interlock guide post.

(a) Mount the steel ball into the reverse gear shifting
rocker.
(b) Mount the interlock guide post in the intermediate
plate and set the steel ball in the reverse gear
shifting fork shaft.
25. Mount the component of fork 3# and the shaft of

gear shift fork 3#.
Mount the component of gear shift fork 3# in gear
sleeve 3# and insert the shaft of gear shift fork 3# into
the fork shaft hole of the component of gear shift fork
3#.
26. Mount the clamping retainer ring.

Use the screwdriver to respectively mount the two
clamping retainer rings in the reverse gear fork shaft
and the shaft of gear shift fork 3# as shown in the
figure.
27. Mount the interlock guide post.

Mount the interlock guide post in the intermediate
plate.
28. Mount the shaft of gear shift fork 1# and the gear
shift fork 1#.
Apply lubricating grease in the pin hole of the shaft of
gear shift fork 1# and mount the short interlock pin in it.
Then insert the mounted shaft of gear shift fork 1# into
Rear side
the fork 1# through the intermediate plate.

Note:
· The gear shift fork 1# is directional.
· Dropping of the short interlock pin shall be
avoided in the process of assembly.

Mount the interlock guide post on the intermediate
plate.
30. Mount the shaft of gear shift fork 2# and gear shift
fork 2#.
The shaft of gear shift fork 2# shall pass through the
fork shaft holes of the intermediate plate, the shift fork
Rear side
侧
1# and the shift fork 2# in order.
Note: The gear shift fork 2# is directional.
31. Fix the component of fork 3#.

Use the special tool to mount the elastic cylindrical pin
so as to fix the component of fork 3# and the shaft of
gear shift fork 3#.

retainer rings for shaft in the shaft of gear shift fork
1# and the shaft of gear shift fork 2# as shown in the
figure.
33. Fix the fork 1# and fork 2#.

bolt.
34. Mount the steel ball, the positioning spring and the
positioning spring screw plug.
(a) Mount the steel ball and the positioning spring.
(b) Mount the screw plug and use the torque socket
wrench to tighten it.
35. Mount the retainer ring for shaft of odometer.

36. Mount the steel ball and the odometer driving gear.
37. Mount the retainer ring for odometer shaft.
38. Mount the magnetic body.

Mount the magnetic body in the position as shown in
the figure.
Assembly of Transmission
1. Apply the sealant on the joint surface of the
transmission shell and intermediate plate.
First remove the greasy dirt on the joint surface and
then apply the silicon rubber with a diameter of about
1.2mm on it.
Note: The mounting shall be done on the
transmission shell in 10 minutes after the silicon
rubber is applied.
2. Mount the transmission shell.

Mount the transmission shell on the mounted
intermediate plate component.
3. Mount the bearing snap ring.

Mount the check ring of input shaft bearing and the
snap ring of intermediate shaft front bearing.
4. Apply the silicon rubber on the joint surface of the

front cover component.
1.2mmon it.
rubber is applied.
5. Mount the front cover.

8 bolts.
Note: The bolts shall be tightened diagonally.
6. Mount the gear shift shaft and gear shift block.

Mount the gear shift shaft and gear shift block on the
rear body subassembly.
7. Apply the silicon rubber on the surface of the rear

shell component.
1.2mm on it.
rubber is applied.
8. Mount the rear body.

Use the screwdriver to lightly knock it so as to mount
the rear body.
9. Mount the connecting rear body, intermediate plate

and the bolt of the shell.
10. Mount the flange bolt and fix the gear shift block
on the gear shift shaft.
11. Use the tool to mount the positioning mechanism

component.
Average spreading of the silicon rubber

12. Apply the silicon rubber on the surface of the shift
lever cover component.
1.2mm on it.
Note: The mounting shall be done on the rear shell
in 10 minutes after the silicon rubber is applied.
13. Mount the shift lever cover component.

Tighten the four bolts connecting the shift lever cover
and rear body.
Tightening: (14.4~21.6) N•m
14. Mount the component of odometer driven gear.

Tightening torque for the bolt: (6~10) N•m
15. Mount the reverse gear switch subassembly.

16. Mount the clutch shell on the transmission shell

and then tighten the bolt.
17. Mount the fork strut.

Tightening torque: (38~56) N•m
18. Apply the molybdenum disulfide averagely on the

spline of input shaft, the front cover socket and the
head of the fork strut.
19. Mount the release fork component, the release

bearing subassembly and the release fork
protecting cover.
20. Mount the clutch sub-pump.

Tighten the bolt connecting the clutch sub-pump and
the clutch shell.
21. Mount the seal washer and the hexagonal head

screw plug.
Transmission(038M)-1
Transmission(038M)
Precautions ....................................................................... 2
Transmission .................................................................... 4
Input Shaft Subassembly................................................. 13
Output Shaft Subassembly.............................................. 16
Intermediate Shaft Subassembly .................................... 25
Front Cover Component .................................................. 27
Rear Body Subassembly ................................................. 28
Intermediate Plate Component........................................ 31
Assembly of Transmission .............................................. 39
Precautions
Precautions of Disassembly
The component shall be handled gently in the process of transmission disassembly to avoid
bruise, especially for the joint surface; besides, the component shall be placed in a proper or-
der to avoid loss and mistaking.
1. All components shall be cleaned before assembly (except for the bearing, the rubber parts and
the pad).
2. Repetitive use of all kinds of oil seal, retainer ring for shaft and elastic pin shall be avoided.
3. Lubricating oil shall be applied on the friction surfaces and lubricating grease shall be applied
on oil seal lips.
4. Rolling elements shall not be used to transmit pressure in the assembly of bearings.
5. Inclination shall be avoided in the assembly of lip oil seal.
6. The splits of expansion circle springs at both sides shall not be overlapped in the assembly of
synchronizer component.
7. Lubricating oil leakage of the component shall be avoided when the transmission is in normal
working position.
Troubleshooting
Malfunction
Cause Analysis Troubleshooting
Classification
Difficulty in gear The clutch is not used. Use the correct driving method.
engagement The clutch is incompletely released. Check and replacement
The synchronizer ring gear is seriously worn Replacement
out.
The positioning spring is too rigid. Replacement
Too loud or abnor- The oil level is too low. Feed the oil to the prescribed level.
mal noise The lubricating oil is unqualified. Replace with the prescribed oil.
The oil is not timely changed. Replace the oil and the broken compo-
nent.
The axial positioning and the clearance of Check and adjustment
gears are inappropriate.
The bearing is broken. Replacement
There is burr or bruise on the tooth part. Repair or replace the gear.
Oil leakage and oil Feed excessive oil leads to too high oil level. Make the oil level to the prescribed po-
penetration sition.
The bolt is loosened or the installation of bolt Reinstall the bolt and tighten it with
is omitted. prescribed torque.
The ventilation plug is out of function. Replacement
The seal is damaged. Replacement
D a m a g e o f t h e The force for gear shift is too heavy. Replacement
synchronizer The clutch is not used. Use the correct driving method.
The synchronizer expansion circle spring is Replacement
damaged.
The drive shaft is inappropriately installed. Check and adjustment
Gear-off The control mechanism has malfunction. Check and adjustment
The installation of the positioning spring or Reinstallation
steel ball is omitted.
The positioning spring is out of function. Replacement
The gear sleeve fork groove is seriously worn Replacement
out.
Burning of the bea- The oil level is too low. Replace the broken components and
ring and gear feed oil.
The lubricating oil is unqualified. Replace the broken components and
feed lubricating oil.
The oil is not timely changed and the oil is dir- Replace the broken components and
ty feed lubricating oil.
Different oil is mixed and additives are used. Replace the broken components and
feed lubricating oil.
Difficulty in gear The synchronizer spring is out of function. Replacement
disengagement The internal groove of synchronizer ring gear Replacement
is worn out.
The synchronizer ring gear is seized on the Replacement
conical surface
The fork or fork shaft is distorted. Replacement
Transmission
Elements Diagram
16
18
19
17
11
◆12
◆9
8
14 6
1 15
20
21
4 13
◆10
5 7
2 10.Intermediate shaft front bearing check ring
3 11.Transmission shell
12.Bowl plug blade
1.Clutch shell 13.Hexagonal-head screw plug
2.Clutch sub-pump assembly 14.Cylindrical pin
3.Bolt with washer 15.Rear body subassembly
4.Fork strut 16.Shift lever cover component
5.Release fork component 17.Hollow positioning pin
6.Release bearing subassembly 18.Reverse gear switch assembly
7.Protecting cover for fork 19.Clip
8.Front cover component 20.Hollow positioning pin
9.Input shaft bearing check ring 21.Intermediate Plate Component
Disassembly of Shell
1. Remove the hexagonal-head bolt and the seal was-
her and discharge the lubricating oil.
2. Remove the four bolts connecting the shift lever

cover and the rear body and then take down the
shift lever cover.
3. Remove the clutch sub-pump assembly.
4. Remove the dust boot, the release fork component

and the release bearing subassembly.
5. Remove the reverse gear switch component.
6. Remove the fork strut.
7. Remove the bolts fixing the clutch shell.

8. Use the hammer to lightly strike the clutch shell

and then remove it.
9. Remove the rear body component

Remove the bolt connecting the rear body with the in-
termediate plate, then remove the rear body.
10. Remove the front cover.

Remove the connecting bolts for the front cover and
the transmission shell, lightly strike it and then remove
the front cover.
11. Remove the input shaft bearing check ring and the
intermediate shaft front bearing check ring.
12. Lightly strike the transmission shell and remove it.

Removal of Control Components

1. Fix the intermediate plate component on the bench
vice.
2. Remove the positioning spring screw plug.
3. Use magnetic body to take out the positioning

spring and the steel ball.
4. Remove the positioning flange bolts of fork 1# and

fork 2#.
5. Remove the clamping retainer rings of fork shaft 1#

and fork shaft 2#.
6. Remove the gear shift fork shaft 2# and the fork 2#.
7. Use the magnetic body to take out the short inter-

lock pin and the interlock guide post.

1#.
9. Remove the clamping retainer ring of fork shaft 3#.
10. Remove the elastic cylindrical pin.

3#.
12. Use the magnetic body to take out the short inter-
lock pin and the positioning steel ball.
13. Remove the reverse gear shifting fork shaft.
14. Take out the steel ball and the positioning spring in
the reverse gear rocker.
15. Remove the reverse gear rocker component.

16. Remove the bolt of reverse gear rocker bracket and

take down the bracket.
Removal of Running Component

1. Remove the retainer ring for shaft at the rear bea-
ring of output shaft.
2. Remove the rear bearing of output shaft .
3. Remove the sleeve.
4. Remove the intermediate shaft fifth-speed coupling

gear.
5. Remove the Gear 5 synchronizer ring, the inter-

mediate shaft fifth-speed gear component and the
needle bearing of intermediate fifth-speed gear.
6. Remove the thrust gasket and pin of fifth-speed

gear.
7. Remove the output shaft bearing baffle bolts and

take down the bearing baffle.
8. Take off the reverse gear idler shaft and the reverse
gear idler.
9. Remove the rear bearing of intermediate shaft.

10. Remove the intermediate shaft.
11. Take down the input shaft subassembly.
12. Remove the output shaft bearing snap ring.
13. Strike the intermediate plate and take down the

output shaft group.
Input Shaft Subassembly

Elements Diagram
Gear 4 synchronizer ring

◆Retainer ring for input shaft
Input shaft components

Input shaft bearing
Input shaft needle bearing
Removal of Input Shaft Subassembly

1. Remove the Gear 4 synchronizer ring and the input
shaft needle bearing.
2. Remove the retainer ring for input shaft.
3. Remove the input shaft bearing.

Assembly of Input Shaft Subassembly

1. Mount the input shaft bearing.
2. Select and match the retainer ring for input shaft.

Select and match the retainer ring of input shaft to
achieve the minimum axial clearance.
3. Mount the retainer ring for input shaft.
4. Mount the Gear 4 synchronizer ring.

(a) Apply the gear oil on the conical surface of the
coupling gear 4# and then mount the Gear 4 syn-
chronizer ring.
(b) Inspect the axial clearance between the Gear 4

synchronizer ring and the gear.
Reference value: 1.2±0.5mm

Rotate the ring gear and push it in so as to check its
braking working.
6. Mount the input shaft needle bearing.

Apply the gear oil in the internal cavity of the input shaft
component and then mount the input shaft needle bea-
ring in it.
Output Shaft Subassembly

Elements Diagram
10
9
8
4 6 7
5
2 3 26
24 25
◆1
23
22
◆21
20
19
17
16 18
15
14
13
12
11
◆31
◆30
29
28
◆27
10.Pin
11.Second-speed gear component
12.Second-speed gear needle bearing
13.Inner ring of Gear 1 synchronizer ring
14.Intermediate ring of Gear 1 synchronizer ring
15.Outer ring of Gear 2 synchronizer ring
16.Sliding block 1#
17.Compression spring
18.Gear hub 1#
1.Retainer ring for shaft of gear hub 2# 19.Outer ring of Gear 1 synchronizer ring
2.Gear sleeve 2# 20.Gear sleeve 1#
3.Expansion ring of synchronizer 2# 21.Retainer ring for shaft of gear hub 1#
4.Sliding block 2# 22.Gear 1 needle sleeve
5.Gear hub 2# 23.First-speed gear needle bearing
6.Gear 3 synchronizer ring 24.First-speed gear component
7.Third-speed gear needle bearing 25.First-speed gear thrust gasket
8.Third-speed gear component 26.Output shaft bearing
9.Output shaft 27.Output shaft bearing check ring
28.Output shaft fifth-speed gear
29.Sleeve
30.Output shaft rear end bearing
31.Retainer ring for rear shaft of output shaft

Removal of Output Shaft Subassembly

1. Remove the output shaft fifth-speed gear, the
output shaft bearing, the first-speed gear thrust
gasket and first-speed gear component successi-
vely.
2. Remove the Gear 1 synchronizer ring component,

the first-speed gear needle bearing and the first-
speed gear needle bearing sleeve in proper order.

Use screwdriver to remove the retainer ring for shaft of
gear hub 1#.
4. Remove the Gear 1/2 synchronizer component, the

Gear 2 synchronizer ring component, the second-
speed gear component and the second-speed gear
needle bearing successively.

7. Remove the Gear 3/4 synchronizer component,

the Gear 3 synchronizer ring, the third-speed gear
component and the third-speed gear needle bea-
ring in proper order.
Inspection of Component before Assem-

bly of Output Shaft
1. Measure the reversed gap between the ring gear
and the gear.
Use the feeler gauge to measure the reversed gap bet-
ween the ring gear and the gear.
Gear 1 1.2±0.55
Gear 2 1.2±0.55
Gear 3 1.2±0.45
Rotate the ring gear and then push it in so as to check
its braking working.

gear sleeve 1#.
Use the vernier caliper to measure the size of the slot
of fork 1# (reference value: 5.28mm) and the size of
the boss of gear sleeve 1# (reference value: 5mm).

gear sleeve 2#.
Use the vernier caliper to measure the size of the claw
of fork 2# (reference value: 10mm) and the size of the
slot of gear sleeve 2# (reference value: 10.2mm).
5. Inspect the output shaft.

(a) Use the micrometer to measure the outer diame-
ter of the output shaft at each gear.
A 38.000
B 47.000
C 38.987
(b) Use the micrometer to measure the width of the

output shaft flange.
(c) Use the dial indicator to measure the radial swing

tolerance of the shaft.
Reference value: less than 0.015mm
(d) Use the bore gauge to measure the bore diameter

at each gear.
Gear 1 46.0275
Gear 2 53.0275
Gear 3 44.0275
Assembly of Output Shaft Subassembly

1. Mount the Gear 1/2 synchronizer component.
(a) First mount three springs and then use screwdri-
ver or other thin tools to press the springs into
three 1# slide blocks respectively.
(b) Mount the gear sleeve 1#.

Note: Gear 1/2 synchronizer is directional and the
The side of the second-speed gear
2. Mount the gear 3/4 synchronizer component.

Mount the gear hub 2#, the slide block 2# and the ex-
pansion ring of synchronizer 2# on the gear sleeve 2#
The side of the fourth-speed gear
in proper order.
Note:
The Gear 3/4 synchronizer is directional and the
Overlapping of the splits of the two expansion
rings should be avoided.
3. Mount the third-speed gear component and the

Gear 3/4 synchronizer component on the output
shaft.
(a) Apply the gear oil on the shaft and the third-speed
(b) Put the synchronizer ring on the third-speed gear
component and align the groove opening of syn-
chronizer ring with the sliding block.
(c) Mount the needle bearing into the third-speed
gear component.
4. Press the Gear 3/4 synchronizer component on the

output shaft.

7. Measure the axial clearance of the third-speed gear

component.
the third-speed gear component.
8. Mount the second-speed gear component and the

Gear 1/2 synchronizer component.
(a) Apply the lubricating oil on the second-speed gear
needle bearing.
(b) Put the Gear 2 synchronizer ring on the second-
speed gear and align the three claws of inter-
mediate rings with the three grooves of coupling
gears.
(c) Mount the second-speed gear needle bearing and

second-speed gear component in proper order.
(d) Mount the Gear 1/2 synchronizer component.

Note: The Gear 1/2 synchronizer is directional.


11. Measure the axial clearance of the second-speed

gear component.
the second-speed gear component.
12. Mount the first-speed gear component.

Mount the first-speed gear needle bearing sleeve, the
needle bearing, the Gear 1 synchronizer ring gear
component and the first-speed gear component in the
order as shown in the figure.
Note: Apply the gear oil on the output shaft, the
needle bearing and the first-speed gear conical
surface before aligning the three claws of interme-
diate ring of Gear 1 synchronizer with the coupling
gear groove for installation.
13. Mount the first-speed gear thrust gasket.

Mount the pin and the first-speed gear thrust gasket on
the output shaft in proper order.
Note: The pin must be completely set in the thrust
gasket after mounting the first-speed gear thrust
gasket.
14. Pay attention to the following points for installation

of output shaft bearing.
The side of the output shaft bearing with check
ring groove shall face back.
In the process of press assembly, use the tool like
screwdriver to prop up the first-speed gear trust
gasket to avoid its dropping affecting press assem-
bly of the bearing.
15. Measure the axial clearance of the first-speed gear

component.
the first-speed gear component.
16. Mount the output shaft fifth-speed gear.

17. Measure the radial clearance of the gear.

Use the micrometer to measure the radial clearance of
the gear.
Gear 1 0.0265
Gear 2 0.0265
Gear 3 0.0265
Intermediate Shaft Subassembly

Elements Diagram
◆Retainer ring for shaft at the front bearing of intermediate shaft
◆Intermediate shaft front bearing
Intermediate shaft coupling gear
Removal of Intermediate Shaft Subass-

embly
1. Remove the retainer ring for shaft at the front bea-
ring of intermediate shaft.
2. Remove the intermediate shaft front bearing.
Assembly of Intermediate Shaft Subass-

embly
1. Inspect the components before assembly.
Measure the diameters of the intermediate shaft rear
bearing and the intermediate shaft fifth-speed gear.
Measured Part Reference Value (mm)
A 34.00
B 30.00
2. Mount the intermediate shaft front bearing.

Mount the intermediate shaft front bearing in the order
as shown in the figure.
Note: Make the side with groove face down in the
assembly.

Select and match a retainer ring to achieve the mini-
mum axial clearance.

Front Cover Component

Elements Diagram
Front cover
◆T-oil seal
Removal of Front Cover Component

Remove the T-oil seal.
Mounting of T-oil Seal.

Note: Apply the lubricating grease on the outside
of oil seal before mounting the oil seal.
Rear Body Subassembly

Elements Diagram
Positioning mechanism component L
◆T-oil seal
Positioning mechanism component H

Reverse gear limitation
mechanism component
Positioning spring screw plug
◆Elastic cylindrical pin
Rear body component
Oil guide nozzle
Disassembling and installing of the rear

body subassembly
Replace the oil seal
(a) Remove the oil seal using SST.
(b) Press in the new oil seal using SST.
Inspection and replacement of limit me-

chanism set
1. Remove the limit mechanism set
(a) Remove the screw plug with torque socket wren-
ch.
(b) Drift out the elastic straight pin with drift pin and
hammer.
(c) Remove the limit mechanism set
2. Check the limit mechanism set

Turn and push into the limit block with hands and it
could return automatically. Otherwise, replace it.
3. Install the limit mechanism set

(a) Encase the limit mechanism set into the rear
housing.
(b) As shown in the drawing, drive in the elastic
straight pin with drift pin and hammer.
(c) Coat sealant on the screw plug thread.

(d) Fasten the screw plug with torque socket wrench
Replace the positioning mechanism

component
1. Remove the positioning mechanism component
2. Push in the positioning pile of the positioning me-

chanism, make sure it can return automatically.
Otherwise, replace it.
3. Install the positioning mechanism component

Tightening torque: 25.9-48.1N•m
Intermediate Plate Component

Elements Diagram
12 13
◆14
8 9 10
15
1 17
16
18
2
10
1 11
7
3 4
6
◆5
1.Fork locating bolt 10.Steel ball

2.Fork 2# 11.Intermediate plate
3.Fork 1# 12.Shaft of gear shifting fork 2#
4.Reverse gear shifting rocker bracket 13.Shaft of gear shifting fork 1#
5.E-retainer ring 14.Elastic cylindrical pin
6.Reverse gear shifting rocker 15.Component of fork 3#
7.Reverse gear fork 16.Shaft of gear shift fork 3#
8.Positioning spring screw plug 17.Interlock guide post
9.Fork shaft positioning spring 18.Short interlock pin
Assembly of Intermediate Plate Compo-

nent
1. Fix the intermediate plate.
Fix the intermediate plate on the bench vice.
2. Mount the output shaft subassembly.

Mount the output shaft subassembly in the intermedia-
te plate.
3. Mount the output shaft bearing snap ring.
4. Mount the sleeve.

Mount the sleeve in the output shaft.
5. Mount the output shaft rear bearing.


8. Mount the input shaft subassembly.

Mount the input shaft subassembly in the output shaft
by rotation and make align the synchronizer ring gro-
ove with the sliding block.
9. Mount the intermediate shaft subassembly in the

intermediate plate.
10. Mount the intermediate shaft rear bearing.

Note: The bearing snap ring is mounted in the interme-
diate shaft rear bearing.
11. Mount the reverse gear idler and the reverse gear
idler shaft.
Mount the reverse gear idler and the reverse gear idler
shaft on the intermediate plate.
Note: The end of reverse gear idler with fork gro-
ove shall face back and insert the reverse gear
idler shaft into its rear end.
12. Mount the output shaft rear bearing baffle.

Use the torque socket wrench to mount it and then tig-
hten the bolt.
13. Mount the fifth-speed gear thrust gasket.

Mount the pin in the intermediate shaft pin hole and
then mount the fifth-speed gear thrust gasket.
Note: The fifth-speed gear thrust gasket is directio-
nal.
Inside
14. Mount the fifth-speed gear of intermediate shaft.

(a) Mount the gear sleeve 3#.
(b) Mount the sliding block of synchronizer 3#, the
expansion ring of synchronizer, the spring of syn-
chronizer and the retainer ring for shaft in proper
order.
(c) Mount the intermediate fifth-speed gear needle

bearing, intermediate fifth-speed gear component
and the ring gear of Gear 5 synchronizer.
15. Mount the fifth-speed coupling gear.
16. Measure the axial clearance of fifth-speed gear.

the fifth-speed gear component.


19. Mount the reverse gear shifting rocker bracket.

bolt.
20. Connect the reverse gear rocker and reverse gear

fork.
Use the screwdriver to mount the E-retainer ring to
connect the reverse gear shifting rocker and reverse
gear fork.
21. Mount the connected reverse gear shifting rocker

and the connected reverse gear fork in the place as
22. Mount the steel ball and reverse positioning spring.

Mount the steel ball and reverse positioning spring in
the reverse gear shifting rocker.
23. Mount the reverse gear shifting fork shaft.

Mount the reverse gear shifting fork shaft with its tip
facing frontward on the intermediate plate and reverse
gear rocker bracket.
24. Mount the steel ball and interlock guide post.

(a) Mount the steel ball into the reverse gear shifting
rocker.
(b) Mount the interlock guide post in the intermedia-
te plate and set the steel ball in the reverse gear
shifting fork shaft.
25. Mount the component of fork 3# and the shaft of

gear shift fork 3#.
Mount the component of gear shift fork 3# in gear slee-
ve 3# and insert the shaft of gear shift fork 3# into the
fork shaft hole of the component of gear shift fork 3#.

clamping retainer rings in the reverse gear fork shaft
and the shaft of gear shift fork 3# as shown in the figu-
re.

Mount the interlock guide post in the intermediate pla-
te.
28. Mount the shaft of gear shift fork 1# and the gear
shift fork 1#.
Apply lubricating grease in the pin hole of the shaft of
gear shift fork 1# and mount the short interlock pin in it.
Then insert the mounted shaft of gear shift fork 1# into
Rear side
the fork 1# through the intermediate plate.

Note:
The gear shift fork 1# is directional.
Dropping of the short interlock pin shall be avoided
in the process of assembly.

Mount the interlock guide post on the intermediate pla-
te.
30. Mount the shaft of gear shift fork 2# and gear shift
fork 2#.
The shaft of gear shift fork 2# shall pass through the
fork shaft holes of the intermediate plate, the shift fork
Rear side
侧
1# and the shift fork 2# in order.
Note: The gear shift fork 2# is directional.
31. Fix the component of fork 3#.

Use the special tool to mount the elastic cylindrical pin
so as to fix the component of fork 3# and the shaft of
gear shift fork 3#.

Use the screwdriver to respectively mount the two re-
tainer rings for shaft in the shaft of gear shift fork 1#
and the shaft of gear shift fork 2# as shown in the figu-
re.
33. Fix the fork 1# and fork 2#.

bolt.
34. Mount the steel ball, the positioning spring and the
positioning spring screw plug.
(a) Mount the steel ball and the positioning spring.
(b) Mount the screw plug and use the torque socket
wrench to tighten it.
35. Mount the magnetic body.

Mount the magnetic body in the position as shown in
the figure.
1. Apply the sealant on the joint surface of the trans-
mission shell and intermediate plate.
1.2mm on it.
Note: The mounting shall be done on the transmis-
sion shell in 10 minutes after the silicon rubber is
applied.

Mount the transmission shell on the mounted interme-
diate plate component.
3. Mount the bearing snap ring.

Mount the check ring of input shaft bearing and the
snap ring of intermediate shaft front bearing.
4. Apply the silicon rubber on the joint surface of the

front cover component.
1.2mmon it.
applied.
5. Mount the front cover.

8 bolts.
Note: The bolts shall be tightened diagonally.
6. Mount the gear shift shaft and gear shift block.

Mount the gear shift shaft and gear shift block on the
rear body subassembly.
7. Apply the silicon rubber on the surface of the rear

shell component.
1.2mm on it.
applied.
8. Mount the rear body.

Use the screwdriver to lightly knock it so as to mount
the rear body.
9. Mount the connecting rear body, intermediate plate

and the bolt of the shell.
10. Install the flange bolt connecting the gearshift

shaft with the shift block of the gearshift shaft
11. Apply the silicon rubber on the surface of the shift

lever cover component.
1.2mm on it.
Note: The mounting shall be done on the rear shell
in 10 minutes after the silicon rubber is applied.
12. Mount the shift lever cover component.

Tighten the four bolts connecting the shift lever cover
and rear body.
Tightening: 14.4-21.6N•m
13. Mount the reverse gear switch subassembly.

14. Mount the clutch shell on the transmission shell

and then tighten the bolt.
15. Mount the fork strut.

Tightening torque: 38-56N•m
16. Apply the molybdenum disulfide averagely on the

spline of input shaft, the front cover socket and the
head of the fork strut.
17. Mount the release fork component, the release bea-

ring subassembly and the release fork protecting
cover.
18. Mount the clutch sub-pump.

Tighten the bolt connecting the clutch sub-pump and
the clutch shell.
19. Mount the seal washer and the hexagonal head

screw plug.
Transmission (ZM001DB)-1
Transmission (ZM001DB)
Structure Characteristics............................................................... 2
Structure Diagram ......................................................................... 2
Technical Parameters..................................................................... 2
Proper Use and Maintenance ........................................................ 3
Malfunction and Troubleshooting ................................................. 3
Disassembly of Transmission ....................................................... 4
Assembly of Transmission ............................................................ 7
Adjustment of Technical Conditions ............................................ 18
Precautions of Assembly ............................................................... 18
Tightening Torques for Threaded Parts ....................................... 19
Structure Characteristics
This product is a mechanical triaxial manual transmission whose control mode is floor-type direct
control. It has 5 forward gears and 1 reverse gear, while the former one is of gear-ring inertia full
synchronizing type and the latter one is of sliding type; this product adopts split-type structure
as a whole, all-alloy shell and gears with small module and slender teeth, so that it becomes the
preferential product matching with the light duty vehicle such as pickup truck, SUV and MPV due
to features as compact structure, strong refitting capability (matching with multiple engines), high
strength, good performance, low noise and light weight.
Structure Diagram
Third-speed and First-speed and second-speed gear sleeves
Clutch shell fourth-speed Third-speed Second- First-speed Fifth-speed Shift lever
gear sleeves gear speed gear gear gear cover Gearshift lever
Input shaft Front cover Intermediate Reverse Reverse Intermediate fifth- Fifth-speed Output shaft
shaft gear shaft gear idler speed gear gear sleeve
Shell Intermediate plate Rear body odometer
Technical Parameters
Center Distance
72
(mm)
Input Torque (N.m) 230
Net Weight (kg) 35
1st 2nd 3rd 4th 5th Rev
Variable-speed Ratio
3.99 2.15 1.33 1.00 0.85 4.22
Odometer
18:6
Speed Ratio
Type of
Gear oil 75W/90 (GL-4)
Lubricating Oil
Lubrication Oil
2.4
Volume (L)
Matching Engine 4G64, 4G63
Control Mode Direct control (floor-type)
1st 3rd 5th
Gear Mode
2nd 4th Rev

Proper Use and Maintenance

1. Correct Gear Shifting
(a) Gear shifting shall be carried out correctly at proper time in accordance with traveling speed and
road conditions. In case of gear shifting, the clutch shall be fully disengaged and the gear shifting
force shall be gentle rather than violent, or else the synchronization may become invalid.
(b) Do not start at a high speed, so as to avoid collision of teeth.
(c) During traveling, do not put hand on the gearshift lever all the time, so as to avoid early abrasion
of gear shift fork.
(d) In case of vehicle reversing, the vehicle must be stopped, so as to avoid noise arising from gear
shifting and gear damage.
2. Sufficient Lubrication
(a) Use the specified lubricating oil whose brand is APIGL-4SAE75W/90; please do not use
lubricating oil with poor quality or mix lubricating oil of different brands.
(b) The lubrication method applied in this product is splash lubrication. For lubrication, the lubricating
oil (2.4L) shall be filled as required, namely the vehicle shall be parked on flat road and the
lubricating oil shall be filled until the oil filler is reached.
3. Check and Replacement of Lubricating Oil
(a) The new car (under running-in status) must be subject to replacement of lubricating oil after
traveling for 1,500km.
(b) Check the lubricating oil level once traveling 10,000km, and refill lubricating oil when it is
insufficient until the oil filler is reached; when phenomena such as dilution, gumming and
excessively dirty oil are detected, the lubricating oil shall be replaced.
(c) Replace the lubricating oil once for traveling 40,000km and disassemble the product to check
and clean it.
Malfunction and Troubleshooting
Malfunction Possible Cause Troubleshooting Method
The bearing is damaged. Replace the bearing.
Collision or pitting of tooth surface of gear. Repair or replace the gear.
The axial position or clearance is improper or the
Excessive Check, repair and adjust them.
internal parts scrape with each other.
loud noise
or abnormal The lubricating oil level is too low or the lubrication is Fill lubricating oil to the specified
sound insufficient. position.
The lubricating oil with poor quality which doesn’t meet Replace it with the specified lubricating
the requirements is used. oil.
Certain internal parts in clutch are damaged. Check, repair and adjust them.
The clutch is improperly adjusted so that it is subject to Adjust it.
Difficulty in incomplete disengagement.
gear shifting The control mechanism is improperly adjusted. Adjust it.
The ring gear of synchronizer is severely worn out. Replace the ring gear.
The oil seal is worn out or damaged. Replace the oil seal.
Too much oil is filled, resulting in too high oil level. Check and adjust the level.
The sealant is unevenly coated or the packing plate is Recoat the sealant or replace the
Oil penetration damaged. packing plate.
The bruise on joint surface is not repaired in time. Repair it.
The ventilation plug is blocked. Wash and put through it.
The gear sleeve or coupling gear is severely worn out. Replace it.
The control mechanism is improperly installed or damaged. Check, adjust or replace it.
The gear shift fork is severely deformed or worn out. Replace it.
Gear-off
The positioning spring or steel ball is severely Check and replace it.
deformed or damaged.
The axial clearance of gear is too large. Check and adjust it.
Gear shifting The interlock pin is lost or severely damaged. Replace it.
error
The lubrication is insufficient or the lubricating oil is Check and replace it.
Abnormal disqualified.
failure of The lubricating oil is too dirty. Replace it.
bearing The parts in transmission are not clean enough. Wash them.
The quality of bearing fails to meet the requirements. Replace it.
Disassembly of Transmission
1. Dismount the clutch release bearing subassembly,
release fork, clutch shell, front cover components,
input shaft, front snap ring of intermediate shaft
bearing, control lever assembly, control cover
subassembly, positioning mechanism components,
rear body subassembly (the steel ball, spring
and positioning bolt for gearshift shaft for gear
5 positioning before dismounting the rear body
subassembly) and shell in order.
2. Dismantle the control parts of intermediate plate
components (take out the positioning spring for
each gear, steel ball, positioning bolt for fork,
elastic pin, fork shaft for each gear and gear shift
fork in order) in the following steps:
(a) Dismount the positioning screw plug for each fork
shaft, the spring and the steel ball.
(b) Dismount the shift fork lock pin subassembly

for each gear, elastic cylindrical pin, positioning
screws for Gear 1/2 shifting fork and clamping
retainer ring. When dismounting the first two parts,
the punch whose diameter is less than 5 (e.g. 4.5)
can be used to punch the pin out from the other
side specified in the figure.
(c) Dismount the Gear 5/reverse gear shifting fork,

Gear 5 shifting fork shaft and Gear 5 shifting fork
in order.
(d) Take out the interlock steel balls in Gear 5/reverse

gear shifting guide block and intermediate plate,
dismount the Gear 5/reverse gear shifting guide
block, reverse gear shifting fork shaft and reverse
gear shifting block rocker subassembly and
then take out the interlock guide pillar from the
dismounted reverse gear shifting fork shaft.
(e) Take out the interlock pin, and dismount the Gear
1/2 shifting fork shaft to take out the interlock
guide pillar in it.
(f) Take out the short interlock pin, and then dismount
the Gear 3/4 shifting fork shaft as well as the Gear
1/2 shifting fork and Gear 3/4 shifting fork.
3. Dismount the moving parts of intermediate plate

components.
(a) Dismount the rear retainer ring for intermediate
shaft, fifth-speed coupling gear, fifth-speed gear
subassembly for intermediate shaft, intermediate
fifth-speed needle bearing, thrust washer for fifth-
speed gear and steel ball (Φ6.35) in order.
(b) Dismount the retainer ring for odometer driving

gear, the odometer driving gear, the output shaft
rear bearing baffle and the output shaft rear
bearing snap ring in order.
(c) Dismount the retainer ring for odometer driving

gear, the odometer driving gear, the output shaft
rear bearing baffle and the output shaft rear
bearing snap ring in order.
(d) Dismount the intermediate subassembly and its

rear bearing.
(e) Input shaft subassembly (do not lose the needle in

it) and Gear 3/4 synchronizer ring.
(f) Dismount the output shaft subassembly.
4. At last, orderly dismount the each bearing group

shown in the attached figure; please refer to the
assembly of transmission specified below (the
disassembly order is reverse to the assembly
order).
1. Assembly of output shaft assembly
(a) Assemble the Gear 3/4 synchronizer components
as shown in the figure, and then mount the third-
speed gear needle bearing, third-speed gear
components, Gear 3/4/5 synchronizer ring, Gear
3/4 synchronizer components as well as retainer
ring for shaft of three/fourth-speed gear hub
(optional, for axial clearance less than 0.1mm).
Note: Set the Gear 3/4 synchronizer gear hub with

its one side which has a 45° step facing to the input
shaft and the synchronizer gear sleeve with the
side which has a big chamber facing to the input
shaft; please stagger the splitting directions of
expansion circle springs for above synchronizers.
(b) Assemble the Gear 1/2 synchronizer components

as shown in the figure, mount the second-
speed gear needle bearing, second-speed gear
components, Gear 1/2 synchronizer ring, Gear 1/2
synchronizer components, coat lubricating grease
to the steel ball (Φ6.35) to mount the input shaft
and then mount the first-speed gear, first-speed
needle bearing, first-speed gear shaft sleeve,
bearing and fifth-speed gear. At last, mount the
retainer ring for shaft of fifth-speed gear (optional,
for axial clearance less than 0.1mm).
Note: The installation direction of the Gear 1/2

synchronizer components shall be against with
that of input shaft, namely the side with fork groove
shall face to the intermediate plate; please stagger
the splitting directions of the two expansion circle
springs for above synchronizers.
2. Install the input shaft into the intermediate plate.

(a) Strike in the intermediate plate while pulling the
output shaft. Mount the output shaft into the
intermediate plate.
(b) Mount in the rear bearing snap ring for output

shaft with snap ring pliers.
Remarks: The snap ring shall contact with the
intermediate plate surface firmly.
3. Mount the input shaft into the output shaft.

(a) Mount the input shaft bearing on the input shaft
and use the snap ring pliers to mount the input
shaft retainer ring (optional, for axial clearance
less than 0.1mm).
(b) Coat lubricating grease on the 13 needle bearings,

mount the needle into input shaft and then put the
Gear 3/4/5 synchronizer ring.
(c) Rotate the input shaft into the output shaft, so

Alignment that the three grooves on synchronizing ring are
aligned with the synchronizer sliding block.
4. Mount the intermediate shaft into the intermediate

plate.
(a) Mount the snap ring on the intermediate shaft rear
bearing.
(b) Mount the intermediate shaft into the intermediate

plate, hold the intermediate shaft, and then mount
the intermediate shaft rear bearing.
5. Mount the rear bearing pressure plate.

Mount and screw down the screws with torque socket
wrench.
Tightening torque: (see the table )
6. Mount the reverse gear idler and shaft.

(a) Mount the reverse gear idler and shaft.
(b) Mount the reverse gear idler shaft pressure plate

and tighten the bolts.
Tightening torque: (see the table)
7. Install the reverse gear rocker bracket.

Set two small hollow positioning pins on the
intermediate plate, mount the reverse gear rocker
bracket and tighten the 2 bolts.
8. Mount the lock ball and fifth-speed gear thrust

washer.
Lock ball
9. Mount the intermediate shaft fifth-speed gear with

fifth-speed engagement sleeve assembly and
needle bearing.
(a) Assemble the intermediate shaft fifth-speed gear
assembly as shown in the figure.
Note: Set one side of the synchronizer gear sleeve
whose spline has a chamber facing to the rear
body, and please stagger the splitting directions
of the two expansion circle springs for above
synchronizers.
(b) Apply gear oil to the needle bearing.

(c) Mount the intermediate shaft fifth-speed gear
provided with fifth-speed engagement sleeve and
needle bearing.
10. Mount the synchronizing ring and fifth-speed

coupling gear.
(a) Fit the synchronizing ring on the conical face of
fifth-speed coupling gear.
(b) Dismount the intermediate plate from the bench

vice.
(c) Put the transmission straight as shown in the
figure to mount the fifth-speed coupling gear and
make the synchronizing ring groove aligned with
the synchronizer sliding block.
(d) Select one split ring which can limit the axial
clearance to be the minimum.
(e) Mount the split ring with copper bar and hammer.
11. Measure the axial clearance for intermediate shaft

fifth-speed gear.
Measure the axial clearance for intermediate shaft fifth-
speed gear with feeler gauge.
Standard clearance: 0.1-0.3
Maximum clearance: 0.3
12. Mount the Gear 3/4 shifting fork shaft as well as

Gear 1/2 shifting fork and Gear 3/4 shifting fork.
(a) Mount the Gear 1/2 shifting fork and Gear 3/4
shifting fork.
(b) Mount the Gear 3/4 shifting fork shaft into the
intermediate plate and gear shifting fork.
(c) Install the fixing bolt for Gear 3/4 shifting fork,
and tighten the bolts. (The lock pin is applied by
this product for part coupling, and the splitting
direction of lock pin shall face to the fork shaft.)
13. Mount the Gear 1/2 shifting fork shaft and Gear 1/2
shifting fork.
(a) Coat lubricating grease on the interlock guide
pillar and mount it on the gear 1/2 shift fork shaft.
(b) Mount the short interlock pin into the intermediate

plate with magnetic bar.
(c) Mount the Gear 1/2 shifting fork shaft in to the
Gear 1/2 shifting fork and the intermediate plate.
(d) Mount the fixing bolt for gear 1/2 shifting fork and
tighten the bolt.
14. Mount the reverse gear shifting fork shaft, reverse

gear shifting lever as well as reverse gear rocker
and shifting block.
(a) Mount the reverse gear shifting block, reverse
gear shifting lever and 2 E-shape rings on the
reverse gear rocker.
(b) Mount the opening end of reverse gear rocker on
the reverse gear rocker bracket.
(c) Coat lubricating grease on the interlock guide

pillar and mount it on the reverse gear shifting fork
shaft.
(d) Mount the interlock pin into the intermediate plate

with magnetic bar.
(e) Mount the reverse gear shifting fork shaft into the
reverse gear shifting lever and intermediate plate.
15. Install the Gear 5/reverse gear shifting guide block,

Gear 5 shifting fork and Gear 4/5 shifting fork shaft.
(a) Mount the Gear 5/reverse gear shifting guide
block onto the reverse gear shifting fork shaft.
(b) Mount the Gear 5 shifting fork.
(c) Mount the lock ball into the Gear 5/reverse gear
shifting guide block with magnetic bar.
(d) Mount the Gear 5 shifting fork shaft.
(e) Mount the interlock steel ball into the intermediate

(f) Mount the Gear 5 shifting fork shaft into the
intermediate plate.
(g) Strike the elastic cylindrical pin into the Gear 5

shifting fork with punch and hammer (with the
opening end of elastic cylindrical pin facing to the
fork shaft).
(h) Mount the Gear 5/reverse gear shifting fork shaft

into the Gear 5/reverse gear shifting guide block
as well as the intermediate plate.
(i) Punch the elastic cylindrical pin into the Gear 5/

reverse gear shifting guide block with punch and
hammer (with the opening end of elastic cylindrical
pin facing to the fork shaft).
16. Mount the split washers for gear shifting fork shaft
and strike 3 split washers in with steel bar and
hammer.
17. Mount the lock balls, springs and screw plugs.

(a) Mount the lock balls, springs and screw plugs.
Note: Mount the short spring (fifth-speed) into the
bottom of intermediate plate.
(b) Apply sealant on the thread of screw plugs.

(c) Mount the screw plugs and screw them down with
torque socket wrench.
18. Mount the odometer driving gear.

(a) Apply sealant on the transmission shell as shown
in the figure (the gluing line is sealed at the inner
side of threaded hole).
(b) Put the intermediate plate straight as shown in the

figure.
(c) Mount the transmission shell on the intermediate
plate as shown in the figure.
20. Install the front bearing snap ring.

(a) Put two snap rings on the input shaft bearing and
intermediate shaft front bearing with snap ring
plier.
(b) Mount the front cover (with sealant coated).

(c) Coat sealant on the thread of screw plugs.
(d) Mount and tighten the bolts.
21. Mount the rear body, gear shifting shaft and

shifting block.
(a) Before closing the transmission, mount the parts
for rear body such as limitation mechanism and oil
guide.
(b) Apply sealant on the rear body as shown in the
figure (the gluing line is sealed at the inner side of
threaded hole).
(c) Mount the shift shaft with shift lever into the rear
body but not onto the proper position, and then
apply the 3rd gear of transmission.
(d) Put the shifting block in through the upper opening
of rear shell, so that the shift shaft can get through
the shifting block. Do not tighten the bolt at the
moment.
(e) Insert the shift lever into the groove for Gear 3/4
shifting fork shaft, and then align the Gear 5/
reverse gear shifting fork shaft with mounting hole
for rear body shell to put it into the rear body shell.
(f) Mount and tighten the bolts for rear body shell.
(g) Mount and tighten the bolts for shifting block.

22. Mount the self locking steel balls, springs and
screw plugs.
(a) Coat sealant on the thread of screw plugs.
(b) Mount the lock balls, springs and screw plugs.
23. Check the following items after mounting the rear

shell or transmission shell.
(a) Check if the input shaft and output shaft rotate
freely.
(b) Check if the gear shifting for each gear is obvious
and reliable, and if the reverse locking function
works.
24. Mount the positioning mechanism components.

Note: Separate the left one from the right one, as
the left one has smaller elastic force (looking from
the output shaft to the input shaft of transmission).
25. Mount the reverse switch seat and the reverse-gear

switch,
26.Mount the transmission control cover of
transmission.
(a) Apply sealant before mounting transmission
control cover (the gluing line is sealed at the inner
(b) Mount and tighten the bolt.
27.Mount the odometer driven gear.

(a) Mount the speedometer driven gear.
(b) Mount and tighten the bolts.
28.Mount the clutch casing.

(a) Mount the clutch casing.
29. Mount the external parts: oil charge/drain plug,
ventilation plug, cable clip, grounding wire, release
strut and fork cover.
30. Carry out checking.
Adjustment of Technical Conditions
Check the reserved gap δ for each gear in accordance with the table below:
Gear Gear 1/2 Gear 3/4/5

Standard clearance(mm) 1.3~1.9 1.0~1.6
Limit clearance(mm) 0.8 0.8
Check the clearance for each gear in accordance with the table below:
Gear Gear 1/2/3 Gear 5

Axial clearance(mm) 0.1~0.25 0.1~0.3
1. The dismounted oil seals, retainer rings for shaft and elastic pins can not be reused.
2. All parts must be clean and free from dust, chip, rust, oil stain and other abnormal substances.
3. All the friction surfaces which will be subject to movement relatively must be coated with
lubricating oil.
4. All oil seal must be pressed in vertically with its lip coated with lubricating grease.
5. In case of bearing assembly, do not use rolling elements to transmit pressure.
6. In case of synchronizer component assembly, the openings of expansion circle springs at both
sides shall be staggered.
7. A certain gear shall be applied for the assembly during transportation and installation. It is
forbidden to set it straight or make it subject to severe impact when neutral is applied.
Tightening Torque of Each Threaded Part

Tightening
Name of Fastener (Specification) Fastener No. Quantity Remarks
Torque (N.m)
Positioning screws for gear 1/2 shift Coat adhesive
ZM001A-1702034 1 13-17
fork sealant
Bolt with gasket at odometer bracket ZMQ150B0820 1 15-20
Bolt with gasket for reverse gear Coat adhesive

ZMQ150B0850 2 17-22
rocker bracket sealant
Cross screw for rear output bearing Coat adhesive
Q2580820 4 17-22
baffle sealant
Hexagonal-head bolt with gasket for
Coat adhesive
reverse gear idler shaft pressure plate ZMQ150B0820 1 15-20
sealant
(at the intermediate plate)
ZMQ150B0825 8 15-20 Coat sealant
front cover
Hexagonal-head bolt with gasket for Coat adhesive
ZMQ150B0825 6 15-20
control cover sealant
ZMQ151C1045 9 30-45
clutch casing
Bolts for shell, intermediate plate and
ZMQ151C1080 7 30-45
rear body
ZMQ151C10125 1 30-45
rear body
Clutch fork strut ZM001A-1601012 1 30-45
Positioning spring screw plug ZM001A-1702076 6 17-22 Coat sealant
Reverse gear switch ZM002A-1701040 1 30-50
Oil filling plug ZM001A-1701050 1 30-50
Oil drain plug ZM001A-1701051 1 30-50
Hexagonal-head bolt with gasket for oil Coat adhesive

ZMQ150B0814 1 15-20
guide sealant
Hexagonal-head bolt with gasket at oil Coat adhesive
ZMQ150B0814 2 5-10
reservoir sealant
Coat adhesive
Positioning bolt for gear shifting block ZM001B-1702059 1 15-20
sealant
Positioning mechanism components ZM001B-1701540 2 30-50
Transmission(ZM001DF)-1
Transmission(ZM001DF)
Structure Characteristics................................................. 2
Structure Diagram ............................................................ 2
Technical Parameters....................................................... 2
Proper Use and Maintenance .......................................... 3
Malfunction and Troubleshooting ................................... 4
Disassembly of Transmission ......................................... 5
Assembly of Transmission .............................................. 8
Adjustment of Technical Conditions .............................. 18
Precautions of Assembly ................................................. 18
Tightening Torque of Each Threaded Part ..................... 19
Structure Characteristics
This product is a mechanical triaxial manual transmission whose control mode is floor-type direct con-
trol. It has 5 forward gears and 1 reverse gear, while the former one is of gear-ring inertia full synchro-
nizing type and the latter one is of sliding type; this product adopts split-type structure as a whole, all-
alloy shell and gears with small module and slender teeth, so that it becomes the preferential product
matching with the light duty vehicle such as pickup truck, SUV and MPV due to features as compact
structure, strong refitting capability (matching with multiple engines), high strength, good performance,
low noise and light weight.
Structure Diagram
Third-speed and fourth-speed gear sleeves First-speed and second-speed gear sleeves
Third-speed gear Fifth-speed gear Gearshift lever
Clutch shell
Second-speed gear First-speed gear Shift lever cover
Fifth-speed gear sleeve

Intermediate shaft
Input shaft Reverse gear idler Output shaft
Shell Rear body
Front cover Intermediate plate
Reverse gear shaft Intermediate fifth-speed gear
Center Distance (mm) 72
Input Torque (N•m) 230
Net Weight (kg) 35
1st 2nd 3rd 4th 5th Rev
Variable-speed Ratio
3.99 2.15 1.33 1.00 0.85 4.22
Odometer Speed Ratio 18:6
Type of Lubricating Oil Gear oil 75W/90 (GL-4)

Lubrication Oil Volume (L) 2.4
Matching Engine 4G64
Control Mode Direct control (floor-type)
1st 3rd 5th
Gear Mode
2nd 4th Rev

Proper Use and Maintenance

1. Correct Gear Shifting
(a) Gear shifting shall be carried out correctly at proper time in accordance with traveling speed and
road conditions. In case of gear shifting, the clutch shall be fully disengaged and the gear shifting
force shall be gentle rather than violent, or else the synchronization may become invalid.
(b) Do not start at a high speed, so as to avoid collision of teeth.
(c) During traveling, do not put hand on the gearshift lever all the time, so as to avoid early abrasion
of gear shift fork.
(d) In case of vehicle reversing, the vehicle must be stopped, so as to avoid noise arising from gear
shifting and gear damage.
2. Sufficient Lubrication
(a) Use the specified lubricating oil whose brand is APIGL-4SAE75W/90; please do not use lubrica-
ting oil with poor quality or mix lubricating oil of different brands.
(b) The lubrication method applied in this product is splash lubrication. For lubrication, the lubricating
oil (2.4L) shall be filled as required, namely the vehicle shall be parked on flat road and the lubri-
cating oil shall be filled until the oil filler is reached.
3. Check and Replacement of Lubricating Oil
(a) The new car (under running-in status) must be subject to replacement of lubricating oil after tra-
veling for 1,500km.
(b) Check the lubricating oil level once traveling 10,000km, and refill lubricating oil when it is insuffi-
cient until the oil filler is reached; when phenomena such as dilution, gumming and excessively
dirty oil are detected, the lubricating oil shall be replaced.
(c) Replace the lubricating oil once for traveling 40,000km and disassemble the product to check
and clean it.

Malfunction Possible Cause Troubleshooting Method
Excessive loud noise The bearing is damaged. Replace the bearing.
or abnormal sound Collision or pitting of tooth surface of gear. Repair or replace the gear.
The axial position or clearance is improper or Check, repair and adjust
the internal parts scrape with each other. them.
The lubricating oil level is too low or the lubrica- Fill lubricating oil to the spe-
tion is insufficient, cified position.
The lubricating oil with poor quality which Replace it with the specified
doesn’t meet the requirements is used. lubricating oil.
Certain internal parts in clutch are damaged. Check, repair and adjust
them.
Difficulty in gear shif- The clutch is improperly adjusted so that it is Adjust it.
ting subject to incomplete disengagement.
The control mechanism is improperly adjusted. Adjust it.
The ring gear of synchronizer is severely worn Replace the ring gear.
out.
Oil penetration The oil seal is worn out or damaged. Replace the oil seal.
Too much oil is filled, resulting in too high oil le- Check and adjust the level.
vel.
The sealant is unevenly coated or the packing Recoat the sealant or repla-
plate is damaged. ce the packing plate.
The bruise on joint surface is not repaired in Repair it.
time.
The ventilation plug is blocked. Wash and put through it.
Gear-off The gear sleeve or coupling gear is severely Replace it.
worn out.
The control mechanism is improperly installed Check, adjust or replace it.
or damaged.
The gear shift fork is severely deformed or worn Replace it.
out.
The positioning spring or steel ball is severely Check and replace it.
deformed or damaged.
The axial clearance of gear is too large. Check and adjust it.
Gear shifting error The interlock pin is lost or severely damaged. Replace it.
Abnormal failure of The lubrication is insufficient or the lubricating Check and replace it.
bearing oil is disqualified.
The lubricating oil is too dirty. Replace it.
The parts in transmission are not clean enough. Wash them.
The quality of bearing fails to meet the require- Replace it.
ments.
Disassembly of Transmission
1. Dismount the clutch release bearing subassembly, release fork, clutch shell, front cover com-
ponents, input shaft, front snap ring of intermediate shaft bearing, control lever assembly,
control cover subassembly, positioning mechanism components, rear body subassembly (the
steel ball, spring and positioning bolt for gearshift shaft for gear 5 positioning before dismoun-
ting the rear body subassembly) and shell in order.
2. Dismantle the control parts of intermediate plate components (take out the positioning spring
for each gear, steel ball, positioning bolt for fork, elastic pin, fork shaft for each gear and gear
shift fork in order) in the following steps:
(a) Dismount the positioning screw plug for each fork

shaft, the spring and the steel ball.
(b) Dismount the shift fork lock pin subassembly

for each gear, elastic cylindrical pin, positioning
screws for Gear 1/2 shifting fork and clamping re-
tainer ring. When dismounting the first two parts,
the punch whose diameter is less than 5 (e.g. 4.5)
can be used to punch the pin out from the other
side specified in the figure.
(c) Dismount the Gear 5/reverse gear shifting fork,

Gear 5 shifting fork shaft and Gear 5 shifting fork
in order.
(d) Take out the interlock steel balls in Gear 5/reverse

gear shifting guide block and intermediate plate,
dismount the Gear 5/reverse gear shifting guide
block, reverse gear shifting fork shaft and reverse
gear shifting block rocker subassembly and then
take out the interlock guide pillar from the dis-
mounted reverse gear shifting fork shaft.
(e) Take out the interlock pin, and dismount the Gear
1/2 shifting fork shaft to take out the interlock gui-
de pillar in it.
(f) Take out the short interlock pin, and then dismount
the Gear 3/4 shifting fork shaft as well as the Gear
1/2 shifting fork and Gear 3/4 shifting fork.
3. Dismount the moving parts of intermediate plate

components.
(a) Dismount the rear retainer ring for intermediate
shaft, fifth-speed coupling gear, fifth-speed gear
subassembly for intermediate shaft, intermediate
fifth-speed needle bearing, thrust washer for fifth-
speed gear and steel ball (Φ6.35) in order.
(b) Dismount the output shaft rear bearing baffle and

the output shaft rear bearing snap ring in order.
(c) Dismount the reverse gear rocker bracket com-

ponents, reverse gear idler shaft pressure plate
as well as the reverse gear idler components and
reverse gear idler shaft.
(d) Dismount the intermediate subassembly and its

rear bearing.
(e) Input shaft subassembly (do not lose the needle in

it) and Gear 3/4 synchronizer ring.
(f) Dismount the output shaft subassembly.
4. At last, orderly dismount the each bearing group

shown in the attached figure; please refer to the
assembly of transmission specified below (the di-
sassembly order is reverse to the assembly order).
1. Assembly of output shaft assembly
(a) Assemble the Gear 3/4 synchronizer components
as shown in the figure, and then mount the third-
speed gear needle bearing, third-speed gear com-
ponents, Gear 3/4/5 synchronizer ring, Gear 3/4
synchronizer components as well as retainer ring
for shaft of three/fourth-speed gear hub (optional,
for axial clearance less than 0.1mm).
Note: Set the Gear 3/4 synchronizer gear hub with
its one side which has a 45° step facing to the input
shaft and the synchronizer gear sleeve with the
side which has a big chamber facing to the input
shaft; please stagger the splitting directions of ex-
pansion circle springs for above synchronizers.
(b) Assemble the Gear 1/2 synchronizer components

as shown in the figure, mount the second-speed
gear needle bearing, second-speed gear compo-
nents, Gear 1/2 synchronizer ring, Gear 1/2 syn-
chronizer components, coat lubricating grease to
the steel ball (Φ6.35) to mount the input shaft and
then mount the first-speed gear, first-speed nee-
dle bearing, first-speed gear shaft sleeve, bearing
and fifth-speed gear. At last, mount the retainer
ring for shaft of fifth-speed gear (optional, for axial
clearance less than 0.1mm).
Note: The installation direction of the Gear 1/2 syn-
chronizer components shall be against with that
of input shaft, namely the side with fork groove
shall face to the intermediate plate; please stagger
the splitting directions of the two expansion circle
springs for above synchronizers.
2. Install the input shaft into the intermediate plate.
(a) Strike in the intermediate plate while pulling the
output shaft. Mount the output shaft into the inter-
mediate plate.
(b) Mount in the rear bearing snap ring for output
Remarks: The snap ring shall contact with the interme-
diate plate surface firmly.
3. Mount the input shaft into the output shaft.

(a) Mount the input shaft bearing on the input shaft
and use the snap ring pliers to mount the input
shaft retainer ring (optional, for axial clearance
less than 0.1mm).
(b) Coat lubricating grease on the 13 needle bea-

rings, mount the needle into input shaft and then
put the Gear 3/4/5 synchronizer ring.
(c) Rotate the input shaft into the output shaft, so that
the three grooves on synchronizing ring are alig-
Align
ned with the synchronizer sliding block.
4. Mount the intermediate shaft into the intermediate

plate.
(a) Mount the snap ring on the intermediate shaft rear
bearing.
(b) Mount the intermediate shaft into the intermediate

plate, hold the intermediate shaft, and then mount
the intermediate shaft rear bearing.
5. Mount the rear bearing pressure plate.

Mount and screw down the screws with torque socket
wrench.
6. Mount the reverse gear idler and shaft.

(a) Mount the reverse gear idler and shaft.
(b) Mount the reverse gear idler shaft pressure plate

and tighten the bolts.
7. Install the reverse gear rocker bracket.

Set two small hollow positioning pins on the interme-
diate plate, mount the reverse gear rocker bracket and
tighten the 2 bolts.
8. Mount the lock ball and fifth-speed gear thrust was-

her.
Lock ball
9. Mount the intermediate shaft fifth-speed gear with

fifth-speed engagement sleeve assembly and nee-
dle bearing.
(a) Assemble the intermediate shaft fifth-speed gear
assembly as shown in the figure.
Note: Set one side of the synchronizer gear slee-
ve whose spline has a chamber facing to the rear
body, and please stagger the splitting directions
of the two expansion circle springs for above syn-
chronizers.
(b) Apply gear oil to the needle bearing.

(c) Mount the intermediate shaft fifth-speed gear
provided with fifth-speed engagement sleeve and
needle bearing.
10. Mount the synchronizing ring and fifth-speed

coupling gear.
(a) Fit the synchronizing ring on the conical face of
fifth-speed coupling gear.
(b) Dismount the intermediate plate from the bench

vice.
(c) Put the transmission straight as shown in the fi-
gure to mount the fifth-speed coupling gear and
make the synchronizing ring groove aligned with
the synchronizer sliding block.
(d) Select one split ring which can limit the axial clea-
rance to be the minimum.
(e) Mount the split ring with copper bar and hammer.
11. Measure the axial clearance for intermediate shaft

fifth-speed gear.
Measure the axial clearance for intermediate shaft fifth-
speed gear with feeler gauge.
Standard clearance: 0.1-0.3
Maximum clearance: 0.3
12. Mount the Gear 3/4 shifting fork shaft as well as

Gear 1/2 shifting fork and Gear 3/4 shifting fork.
(a) Mount the Gear 1/2 shifting fork and Gear 3/4 shif-
ting fork.
(b) Mount the Gear 3/4 shifting fork shaft into the in-
termediate plate and gear shifting fork.
(c) Install the fixing bolt for Gear 3/4 shifting fork, and
tighten the bolts. (The lock pin is applied by this
product for part coupling, and the splitting direc-
tion of lock pin shall face to the fork shaft.)
13. Mount the Gear 1/2 shifting fork shaft and Gear 1/2
shifting fork.
(a) Coat lubricating grease on the interlock guide pi-
llar and mount it on the gear 1/2 shift fork shaft.
(b) Mount the short interlock pin into the intermediate

(c) Mount the Gear 1/2 shifting fork shaft in to the
Gear 1/2 shifting fork and the intermediate plate.
(d) Mount the fixing bolt for gear 1/2 shifting fork and
tighten the bolt.
14. Mount the reverse gear shifting fork shaft, reverse

gear shifting lever as well as reverse gear rocker
and shifting block.
(a) Mount the reverse gear shifting block, reverse
gear shifting lever and 2 E-shape rings on the re-
verse gear rocker.
(b) Mount the opening end of reverse gear rocker on
the reverse gear rocker bracket.
(c) Coat lubricating grease on the interlock guide pi-

llar and mount it on the reverse gear shifting fork
shaft.
(d) Mount the interlock pin into the intermediate plate

with magnetic bar.
(e) Mount the reverse gear shifting fork shaft into the
reverse gear shifting lever and intermediate plate.
15. Install the Gear 5/reverse gear shifting guide block,

Gear 5 shifting fork and Gear 4/5 shifting fork shaft.
(a) Mount the Gear 5/reverse gear shifting guide
block onto the reverse gear shifting fork shaft.
(b) Mount the Gear 5 shifting fork.
(c) Mount the lock ball into the Gear 5/reverse gear
shifting guide block with magnetic bar.
(d) Mount the Gear 5 shifting fork shaft.
(e) Mount the interlock steel ball into the intermediate

(f) Mount the Gear 5 shifting fork shaft into the inter-
mediate plate.
(g) Strike the elastic cylindrical pin into the Gear 5

shifting fork with punch and hammer (with the
opening end of elastic cylindrical pin facing to the
fork shaft).
(h) Mount the Gear 5/reverse gear shifting fork shaft

into the Gear 5/reverse gear shifting guide block
as well as the intermediate plate.
(i) Punch the elastic cylindrical pin into the Gear 5/re-
verse gear shifting guide block with punch and ha-
mmer (with the opening end of elastic cylindrical
pin facing to the fork shaft).
16. Mount the split washers for gear shifting fork shaft
and strike 3 split washers in with steel bar and ha-
mmer.
17. Mount the lock balls, springs and screw plugs.

(a) Mount the lock balls and springs (4 lock balls and
4 springs).
Note: Mount the short spring (fifth-speed) into the bo-
ttom of intermediate plate.
(b) Apply sealant on the thread of screw plugs.

(c) Mount the screw plugs and screw them down with
torque socket wrench.

(a) Apply sealant on the transmission shell as shown
in the figure (the gluing line is sealed at the inner
(b) Put the intermediate plate straight as shown in the

figure.
(c) Mount the transmission shell on the intermediate
plate as shown in the figure.
19. Install the front bearing snap ring.

(a) Put two snap rings on the input shaft bearing and
plier.
(b) Mount the front cover (with sealant coated).

(c) Coat sealant on the thread of screw plugs.
(d) Mount and tighten the bolts.
20. Mount the rear body, gear shifting shaft and shif-
ting block.
(a) Before closing the transmission, mount the parts
for rear body such as limitation mechanism and oil
guide.
(b) Apply sealant on the rear body as shown in the
figure (the gluing line is sealed at the inner side of
threaded hole).
(c) Mount the shift shaft with shift lever into the rear body but not onto the proper position, and then
apply the 3rd gear of transmission.
(d) Put the shifting block in through the upper opening of rear shell, so that the shift shaft can get
through the shifting block. Do not tighten the bolt at the moment.
(e) Insert the shift lever into the groove for Gear 3/4 shifting fork shaft, and then align the Gear 5/re-
verse gear shifting fork shaft with mounting hole for rear body shell to put it into the rear body
shell.
(f) Mount and tighten the bolts for rear body shell.
(g) Mount and tighten the bolts for shifting block.

21. Mount the self locking steel balls, springs and
screw plugs.
(a) Coat sealant on the thread of screw plugs.
(b) Mount the lock balls, springs and screw plugs.
22. Check the following items after mounting the rear

shell or transmission shell.
(a) Check if the input shaft and output shaft rotate fre-
ely.
(b) Check if the gear shifting for each gear is obvious
and reliable, and if the reverse locking function
works.
23. Mount the positioning mechanism components.

Note: Separate the left one from the right one, as
the left one has smaller elastic force (looking from
the output shaft to the input shaft of transmission).
24. Mount the reverse switch seat and the reverse-gear

switch.
25. Mount the transmission control cover of transmis-
sion.
(a) Apply sealant before mounting transmission con-
trol cover (the gluing line is sealed at the inner
(b) Mount and tighten the bolt.
26. Mount the clutch casing.

(a) Mount the clutch casing.
27. Mount the external parts: oil charge/drain plug,
ventilation plug, cable clip, grounding wire, release
strut and fork cover.
28. Carry out checking.
Adjustment of Technical Conditions

Check the reserved gap δ for each gear in accordance with the table below:
Gear Gear 1/2 Gear 3/4/5
Standard clearance (mm) 1.3~1.9 1.0~1.6
Limit clearance (mm) 0.8 0.8
Check the clearance for each gear in accordance with the table below:
Gear Gear 1/2/3 Gear 5
Axial clearance (mm) 0.1~0.25 0.1~0.3
1. The dismounted oil seals, retainer rings for shaft and elastic pins can not be reused.
2. All parts must be clean and free from dust, chip, rust, oil stain and other abnormal substan-
ces.
3. All the friction surfaces which will be subject to movement relatively must be coated with lu-
bricating oil.
4. All oil seal must be pressed in vertically with its lip coated with lubricating grease.
5. In case of bearing assembly, do not use rolling elements to transmit pressure.
6. In case of synchronizer component assembly, the openings of expansion circle springs at
both sides shall be staggered.
7. A certain gear shall be applied for the assembly during transportation and installation. It is
forbidden to set it straight or make it subject to severe impact when neutral is applied.
Tightening Torque of Each Threaded Part

Tightening Tor-
Name of Fastener (Specification) Fastener No. Quantity Remarks
que (N.m)
Coat adhesive
Positioning screws for gear 1/2 shift fork ZM001A-1702034 1 13-17
sealant
Bolt with gasket at odometer bracket ZMQ150B0820 1 15-20
Bolt with gasket for reverse gear rocker Coat adhesive
ZMQ150B0850 2 17-22
bracket sealant
Coat adhesive
Cross screw for rear output bearing baffleQ2580820 4 17-22
sealant
Hexagonal-head bolt with gasket for re-
Coat adhesive
verse gear idler shaft pressure plate (at ZMQ150B0820 1 15-20
sealant
the intermediate plate)
Hexagonal-head bolt with gasket for front
ZMQ150B0825 8 15-20 Coat sealant
cover
Hexagonal-head bolt with gasket for con- Coat adhesive
ZMQ150B0825 6 15-20
trol cover sealant
Hexagonal-head bolt with gasket for clut-
ZMQ151C1045 9 30-45
ch casing
ZMQ151C1080 7 30-45
rear body
ZMQ151C10125 1 30-45
rear body
Clutch fork strut ZM001A-1601012 1 30-45
Positioning spring screw plug ZM001A-1702076 6 17-22 Coat sealant
Reverse gear switch ZM002A-1701040 1 30-50
Oil filling plug ZM001A-1701050 1 30-50
Oil drain plug ZM001A-1701051 1 30-50

Hexagonal-head bolt with gasket for oil Coat adhesive
ZMQ150B0814 1 15-20
guide sealant
Hexagonal-head bolt with gasket at oil Coat adhesive
ZMQ150B0814 2 5-10
reservoir sealant
Coat adhesive
Positioning bolt for gear shifting block ZM001B-1702059 1 15-20
sealant
Positioning mechanism components ZM001B-1701540 2 30-50
Transmission(ZMOO1M, ZMOO1MF)-1
Transmission(ZM001M, ZM001MF)
Structure drawing ............................................................. 2

Precautions ....................................................................... 3
Trouble shooting .............................................................. 3
Disassembling of the transmission ................................ 4
Input shaft assembly ........................................................ 12
Output shaft assembly ..................................................... 14
Intermediate shaft assembly and reverse gear idler
assembly ........................................................................... 22
Rear housing assembly ................................................... 25
Bearing front cover .......................................................... 28
The assembling of the transmission .............................. 29
Structure drawing
This product is manual mechanical triaxial transmission, and the control form is floor type direct con-
trol, and there are 5 forward gears with lock loop type full synchronization and 1 reverse gear with
sliding type; this product applies separation structure with complete aluminium alloy housing, and the
gear applies small module and slimness tooth; this makes this product have the following advantages:
compact structure, strong deformability, high intensity, perfect performance, low noise and light mass
etc. The drawing below is the structure drawing of the clutch.
2WD 1st shift and 2nd shift gear sleeves

3rd and 4th shift gear sleeves
Control cover
Clutch housing 2nd shift gear 5th shift gear
Shift lever
3rd shift gear 1st shift gear
Input shaft Odometer

Front cover Housing Output shaft
Reverse gear idler Rear housing
Intermediate shaft Middle coupling plate 5th shift gear sleeve
Reverse gear shaft Middle 5th shift gear
4WD
3rd and 4th shift gear sleeves 1st shift and 2nd shift gear sleeves
Control cover
Clutch housing 3rd shift gear Shift lever
5th shift gear
2nd shift gear
1st shift gear
Output shaft
Housing Rear housing

Front cover
Input shaft Reverse gear shaft Middle coupling plate
5th shift gear sleeve
Intermediate shaft th
Reverse gear idler Middle 5 shift gear
Precautions
Precautions for disassembling and assembling of the transmission
During disassembling of the transmission, pay attention to handle each part with care to avoid
knock, especially the junction plane; put each part in order so as to prevent loss and wrong ta-
king.
When assembling, except the above precautions, the following should be noticed:
1. Do not repeat using various oil seals, shaft retainers and elastic pins after they have been di-
sassembled.
2. Keep all the parts clean, dust, cut chips, rust, oil stain and other impurities must be avoided.
3. For the relative motion friction surface on the parts, lubricant must be coated.
4. Coat lubricant at the mouth of each oil seal, and press into vertically.
5. When assembling each oil seal, do not pass the pressure with rolling objects.
6. When assembling the synchronizer set, spring piston ring opening at both sides must be stag-
gered.
7. During transporting and installing of the assembly, put into a certain gear, and it is strictly for-
bidden to erect it under neutral position or make it be impacted forcibly.
Trouble shooting
Trouble type Possible causes Eliminating methods
Noise too loud Bearing damaged Replacing the bearing
or abnormal Gear tooth face knocked or eroded Repairing or replacing the gear
Gear axial position or clearance improper or inside Check, repair and adjustment
parts scratched
Lubricant level too low or lubricating insufficient Refilling to the marked position
Using inferior lubricant not complying with quality re- Replacing with specified lubricant
quirements
Damage with the inside parts of clutch Check, repair and adjustment
P u t t i n g i n t o Clutch improperly adjusted, releasing incompletely Adjustment
gear difficult Control mechanism improperly adjusted Adjustment
Synchronizer toothed ring worn severely Replacing the toothed ring
Oil leakage The oil seal worn or damaged Replacing the oil seal
Refilling oil too much, the oil level too high Check and adjustment
The sealant unevenly coated or the seal washer da- Recoating the sealant or replacing
maged the washer
The junction plane knock not repaired in time Repair
The breather plug blocked Cleaning and interpenetrating
Out of gear Gear sleeve or combination tooth severely worn Replacement
Control mechanism improperly installed or damaged Check, adjustment or replacement
Fork deformed severely or worn Replacement
Set spring or steel ball deformed severely or damagedCheck and replacement
Gear axial clearance too large Check and adjustment
Gear shifting Interlock pin lost or damaged severely Replacement
abnormal
B e a r i n g a b - Lubricating insufficient or lubricant rejected Check and replacement
normally in- Lubricant too dirty Replacement
effective
The cleaning of each part in the box not perfect Cleaning
Bearing quality rejected Replacement
Disassembling of the transmission

1. Remove the release fork and release bearing
2. Remove the backup lamp switch and odometer dri-
ven gear
3. Remove the clutch housing from the transmission
case
Remove the 9 bolts.
4. Remove the 5th gear fork shaft set spring screw

plug, set spring and the lock ball
(a) Remove the screw plug from rear cover with soc-
ket wrench.
(b) Take out the spring and the lock ball with bar mag-
net.
5. Remove the gear shift lever and control cover
(a) Remove the gear shift lever from the control cover
(b) Remove the binding bolt of the control cover.
6. Remove the set mechanism set of the gear-shifting

shaft
7. Remove the rear housing

(a) Remove binding bolt of the gear-shifting shaft
(b) Remove the nut fastening the rear housing.
(c) Gently knock out the rear housing with rubber ma-
llet, and remove the gear-shifting shaft and gear-
shifting rocker.
8. Remove the front cover

Remove the 8 bolts, and remove the front cover and
the front cover oil seal.
9. Remove the bearing stop rings of input shaft and

intermediate shaft.
10. Take apart the transmission case from the middle

coupling plate
(a) Put the transmission straight as shown in the
drawing.
(b) Gently knock out the transmission case with rub-
ber mallet.
(c) Pull out the transmission case from the middle
coupling plate as shown in the drawing.
11. Nip the middle coupling plate on the leg vice

(a) Use 2 clutch housing bolts, washers and appro-
priate nuts as shown in the drawing.
Remark: install the washer with contrary direction from
the normal; plus or minus the washer numbers to make
the bolt end align with the washer outer end face.
(b) Nip the middle coupling plate on the leg vice.
12. Remove the set spring screw plug, set spring and
lock ball
(a) Remove each set spring screw plug with torque
socket wrench.
(b) Remove 1st and 2nd, 3rd and 4th and reverse gear
fork shaft and 5th gear fork shaft set spring and
lock ball.
13. Remove the gear-shifting forked axle retainer

Gently turn and extract the gear-shifting forked axle re-
tainer with 2 screwdrivers and 1 hammer.
14. Remove the 5th gear shift fork

(a) Drift out the spring pin with drift pin and hammer.
(b) Gently knock the 5th gear shift fork until it is taken
out.
Note: pay attention to the neutral position at the
moment.
15. Remove 5th reverse gear shift guide block and 5th
reverse gear shift forked axle.
(a) Take out the interlock steel ball from the 5th rever-
se gear shift guide block.
(b) Remove 5th reverse gear shift guide block and 5th
reverse gear shift fork.
16. Take out the 5th gear shift forked axle
17. Remove the reverse gear shift fork, reverse gear

rocker, reverse gear deflector rod and block
(a) Knock out the elastic pin with tip drift pin and ham-
mer.
(b) Take out the reverse gear shift forked axle and 5th
gear shift forked axle interlock steel ball and inter-
lock guide column.
(c) Take down the reverse gear shift forked axle.
(d) Take down the reverse gear rocker and deflector
block.
18. Remove the 1st and 2nd gear shift fork.

(a) Take out the 5th reverse gear shift fork and 1st and
2nd gear shift fork interlock pin and interlock guide
column with bar magnet.
(b) Remove the 1st and 2nd gear shift fork location bolt.
(c) Remove the 1st and 2nd gear shift fork.

(d) Take out the short interlock pin between the 1st
and 2nd gear shift fork and 3rd and 4th gear shift
fork with bar magnet.
19. Remove the 3rd and 4th gear shift fork and the 1st
and 2nd gear and 3rd and 4th gear fork.
(a) Knock out the elastic pin with tip drift pin and ham-
mer.
(b) Take out the 3rd and 4th shift fork and the 1st and
2nd gear and 3rd and 4th gear fork.
20. Remove the 5th shift coupling gear, 5th gear syn-
chronizer assembly, 5th shift gear set, 5th shift gear
thrust washer and 5th gear needle bearing.
(a) Gently tap out the intermediate shaft rear shaft re-
tainer with 2 screwdrivers and 1 hammer.
(b) Take down the 5th gear synchronizer assembly, 5th

special tools shift coupling gear and 5th shift gear set.
(c) Remove the 5th gear needle bearing.
21. Remove the 5th shift gear thrust washer and lock
ball
(a) Remove the 5th shift gear thrust washer.
(b) Take out the lock ball with bar magnet.
22. Remove the reverse shift rocker bracket

Remove the 2 bolts and reverse shift rocker bracket.
23. Remove the reverse gear idler and reverse gear

idler shaft
(a) Remove the idler shaft set bolt and reverse gear
idler shaft clamping plate.
(b) Remove the reverse gear idler and reverse gear

idler shaft.
24. Remove the rear bearing baffle of the output shaft

(a) Remove 4 bolts with torque socket wrench.
(b) Remove the rear bearing baffle of the output shaft.
25. Remove the intermediate gear shaft.

(a) Prize out the rear bearing split ring of the interme-
diate gear shaft with split ring pliers.
(b) Remove the intermediate shaft rear bearing with

special tool and wrench.
special tools
(c) Remove the intermediate gear shaft.
26. Remove the input shaft

Remove the input shaft equipped with synchronizing
ring and 13 needle bearings.
27. Remove the output shaft

(a) Remove the rear bearing stop ring of the output
shaft with split ring pliers.
(b) Pull out the output shaft with hands and gently
knock the middle coupling plate with rubber mallet
at the same time, and remove the output shaft
from the middle coupling plate.
28. Inspecting backup lamp switch

As shown in the drawing, check the terminal is connec-
ted—pressing the switch indicating connecting and loo-
sening it indicating disconnecting, replace the switch if
it does not comply with the specification.
Pressing
loosening
Input shaft assembly

Part drawing
Needle bearing
Input shaft
Bearing
Bearing stop ring
Retainer
Synchronizing ring
Inspecting the synchronizing ring

1. Turn the synchronizing ring and push it into to
check its braking effect.
2. Check the clearance between the synchronizing

ring back and the gear
Standard clearance: 1.0-1.6mm
Limit clearance: 0.8mm
Replacing the bearing

1. Prize out the input shaft retainer with split ring
pliers
2. Prize out the input shaft bearing with forcing ma-

chine
3. Install the new bearing with forcing machine and

special service tools.
special tools
4. Select the retainer to achieve the min. axial clea-

rance
Remark: the clearance value should not be more than
0.1mm.
5. Install the retainer with split ring pliers

Output shaft assembly

Part drawing
3rd and 4th gear synchronizer engagement sleeve
Synchronizer sliding block 3rd shift gear needle bearing
Synchronizer
spring piston
ring
3rd shift gear set
Synchronizer ring Steel ball

Steel ball
Shaft retainer
3rd and 4th synchronizer hub
Output shaft
1st shift gear bush

st nd
1 and 2 gear synchronizer engagement sleeve
Rear bearing stop ring
of the output shaft
Synchronizer sliding block 1st shift gear set
Spring piston ring
2nd shift gear needle bearing
Output shaft rear bearing
1st shift gear needle bearing
1st and 2nd gear synchronizer ring
1st and 2nd gear synchronizer ring
2nd shift gear set

Odometer drive gear retainer
Odometer drive gear

5th shift gear
5th shift gear shaft retainer
Disassembling of the output shaft ass-

embly
1. Remove the odometer drive gear
(a) Prize out the retainers at both ends with split ring
pliers.
(b) Remove the odometer drive gear
(c) Take out the lock ball with bar magnet.
2. Remove the 5th shift gear, output shaft rear bearing,

1st shift gear set, 1st shift gear bush and 1st shift
(a) Turn and extract the 5th shift gear shaft retainer
with 2 screwdrivers and 1 hammer.
(b) Remove the output shaft rear bearing, 1st shift
gear set and 1st shift gear bush with forcing machi-
ne.
(c) Remove the 1st shift gear needle bearing
3. Remove the synchronizer
4. Remove the steel ball

Take out the steel ball with bar magnet.
5. Remove the 1st and 2nd gear synchronizer assembly,

2nd shift gear set and 2nd shift gear needle bearing
(a) Remove the 1st and 2nd gear synchronizer assem-
bly and 2nd shift gear set.
(b) Remove the 2nd shift gear needle bearing
6. Remove the engagement sleeve, sliding block and

spring from the 1st and 2nd gear synchronizer ass-
embly
Remove 3 sliding blocks and 2 springs from the syn-
chronizer assembly with 1 screwdriver.
7. Remove the 3rd and 4th gear synchronizer assembly,

3rd shift gear and needle bearing
(a) Remove the split ring with split ring pliers.
(b) Remove the 3rd and 4th gear synchronizer assem-
bly and 3rd shift gear with the forcing machine.
(c) Remove the needle bearing.
8. Remove the engagement sleeve, sliding block and

spring from the 3rd and 4th gear synchronizer ass-
embly
Remove 3 sliding blocks and springs from the engage-
ment sleeve with 1 screwdriver.
Inspection of the output shaft assembly

3 shift 1. Measure the axial clearance of each gear
Measure the axial clearance of each gear:
1st , 2nd , 3rd gear: 0.1-0.25mm
1 shift 2 shift
2. Measure the axial play of each gear

Measure the radial clearance of each gear with dial
gauge.
Allowable clearance (mm)
1st shift gear 0.009-0.032
2nd and 3rd shift gear 0.009-0.033
If the clearance exceeds the above limit, replace the
gear, needle bearing or shaft.
3. Check the output shaft and 1st shift gear bush

(a) Measure the flange thickness of the output shaft
with calipers.
Min. thickness: 4.80mm
(b) Measure the flange thickness of the 1st shift gear

bush with calipers.
Min. thickness: 3.99mm
(c) Measure the outer diameter of the output shaft jo-

urnal with micrometer.
At 2nd shift gear: 37.974mm
At 3rd shift gear: 34.974mm
(d) Measure the outer diameter of the 1st shift gear

bush with micrometer.
Min. diameter: 38.975mm
(e) Check the radial run out of the shaft with dial gau-
ge
Max. radial run out: 0.05mm
4. Inspect the synchronizing ring

Turn this ring and push it into to check its braking ac-
tion.
5. Measure the clearance between the shift fork and

engagement sleeve
Measure the clearance between the gear sleeve and
the shift fork with a clearance gauge.
Max. clearance: 1.0mm
Assembling of the output shaft assembly

1. Assemble the synchronizer
(a) The side with 45℃ step of the 3rd and 4th gear
synchronizer hub is facing the input shaft position,
and the side with big chamfer of the 3rd and 4th
gear synchronizer gear bush is facing the input
shaft position; the opening directions of two 3rd and
4th gear synchronizer spring piston rings should be
staggered.
(b) The 1st and 2nd gear synchronizer set is relative

to the installation direction of the output shaft, i.e.
the side with fork facing the middle coupling plate
position; the opening directions of two 1st and 2nd
gear synchronizer spring piston rings should be
staggered.
2. Install the 3rd shift gear set and 3rd and 4th gear syn-
chronizer on the output shaft
(a) Coat gear oil on the shaft and 3rd shift gear needle
bearing.
(b) Put the synchronizing ring on the 3rd shift gear set,
and align the synchronizing ring notch with the sli-
ding block.
(c) Encase the needle bearing into the 3rd shift gear
set.
(d) Install the 3rd shift gear set and 3rd and 4th gear
synchronizer with forcing machine.
3. Install the shaft retainer

Choose a shaft retainer that could make the min. axial
clearance (clearance value not more than 0.1mm), and
install it on the shaft.
4. Measure the axial clearance of 3rd shift gear set

Measure the axial clearance of 3rd shift gear set with
clearance gauge.
5. Install the 2nd shift gear set and 1st and 2nd gear syn-
chronizer
(a) Coat gear oil on the 2nd shift gear needle bearing.
(b) Put the synchronizing ring on this gear, and align
the ring notch with the synchronizer sliding block.
(c) Encase the needle bearing into the 2nd shift gear
set.
(d) Install the 2nd shift gear set and 1st and 2nd gear
synchronizer set with forcing machine.
6. Measure the axial clearance of 2nd shift gear set

Measure the axial clearance of 2nd shift gear set with
feeler gauge.
7. Install the lock ball and 1st shift gear set

(a) Encase the lock ball into the shaft.
(b) Coat gear oil on the 1st shift gear needle bearing.
(c) Install the 1st shift gear set, synchronizing ring,
needle bearing and 1st shift gear bush.
(d) Install the assembly on the output shaft to align
the synchronizing ring notch with the sliding block.
(e) Turn the 1st shift gear bush to align it with the lock
ball.
8. Install the output shaft rear bearing

Install the output shaft bearing on the output shaft with
special service tool and forcing machine to make the
groove of the output shaft rear bearing stop ring face
the end.
Remark: hold the 1st shift gear bush to prevent it from
special tools falling.
9. Install the 5th shift gear

Install the 5th shift gear with special service tool and
forcing machine.
special tools
10. Install the shaft retainer

(a) Choose a 5th shift gear shaft retainer that could
make the min. axial clearance, and the clearance
value should not be more than 0.1mm.
(b) Gently knock tight the 5th shift gear shaft retainer
with screwdriver and hammer.
11. Measure the axial clearance of the 1st shift gear

Measure the axial clearance of the 1st shift gear with
clearance gauge.
12. Install the odometer drive gear

(a) Install the lock ball and the drive gear.
(b) Install the odometer drive gear retainer with shaft
retainer pliers.
Intermediate shaft assembly and reverse gear idler assembly

Part drawing
Front bearing stop ring of the intermediate shaft Intermediate shaft rear bearing
Rear bearing stop ring of the intermediate shaft

Intermediate gear shaft
Steel ball
Reverse gear idler shaft
Intermediate shaft front bearing
Reverse gear idler set
Front shaft retainer of the intermediate shaft

Reverse gear idler shaft clamping plate
Synchronizer sliding block
5th gear synchronizer engagement sleeve
5th gear needle bearing
Synchronizer ring
5th shift gear thrust washer Spring piston ring

5th shift coupling gear
5th shift gear set
Disassembling, inspection and assem-

bling of the intermediate shaft assembly
1. Remove the 5th shift coupling gear, sliding block
and spring piston ring
Remove the 5th shift coupling gear, 3 sliding blocks and
2 spring piston rings with screwdriver.
2. Measure the radial clearance of the intermediate

shaft 5th gear
(a) Mount spacer, needle bearing and reverse gear
idler on the intermediate shaft.
(b) Measure the radial clearance of the reverse gear
idler with dial gauge.
Radial clearance: 0.009-0.32mm
3. Check the journal diameter at the intermediate

shaft 5th gear needle bearing installation position
Measure the needle bearing diameter with micrometer.
Allowable limit diameter: 25.975 mm
4. Inspect the synchronizing ring

Turn the shaft retainer and push it into to check its bra-
king action.
5. Measure the clearance between the shift fork and

gear sleeve
Measure the clearance between the gear sleeve and
the shift fork with a clearance gauge.
Max. clearance: 1.0 mm
6. Replace the bearing

Replace the reverse gear front bearing if necessary
(a) Prize out the shaft retainer with shaft retainer
pliers.
(b) Press out the bearing with special service tool.
special tools
(c) Press in the bearing, side ring and inner race with
socket wrench.
Socket wrench
(d) Choose a split ring that could make the min. axial
clearance, and install it on the shaft.
7. Install the 5th gear synchronizer engagement slee-

ve, sliding block and spring piston ring
(a) Encase the sliding block into the hub and then en-
case the gear sleeve.
Front (b) Install the spring piston ring under the sliding
block.
Note: the opening directions of the spring piston
ring should be staggered during installing.
The assemblage of reverse gear assem-

bly
1. Check the reverse gear idler
Measure the radial clearance of the reverse gear idler
with dial gauge.
Allowable radial clearance: 0.009-0.033mm
2. Measure the clearance between the reverse gear

idler and the shift block
Measure the clearance between the reverse gear idler
and the shift block with a clearance gauge.
Max. clearance: 1.0 mm
Rear housing assembly

Part drawing
Rear housing set
Rear housing dust cap
Limit mechanism set

Rear housing oil seal subassembly
Guide oil groove

Set spring screw plug and elastic straight pin
Reservoir
special tools
Replacing the oil seal
1. Replace the rear housing oil seal if necessary
(a) Remove the oil seal with special service tool.
(b) Press in the new oil seal with special service tool.
special tools
2. Replace the odometer driven oil seal if necesssary

(a) Prize out the oil seal with special service tool.
(b) Knock the new oil seal into the shaft bracket with
special service tool.
special tools
special tools
Replacing the bush

Replace the bush if necessary
special tools (a) Remove the oil seal and dust cap.
(b) Heat the rear housing end up to celsius 80-100
degree in the oil groove.
(c) Remove the bush and install the new bush with
special service tool.
Inspection and replacement of limit me-

chanism set
1. Remove the limit mechanism set
(a) Remove the screw plug with torque socket wren-
ch.
(b) Drift out the elastic straight pin with drift pin and
hammer.
(c) Remove the limit mechanism set
2. Check the limit mechanism set

Turn and push into the limit block with hands and it
could return automatically. Otherwise, replace it.

(a) Encase the limit mechanism set into the rear
housing.
(b) As shown in the drawing, drive in the elastic
straight pin with drift pin and hammer.
(c) Coat sealant on the screw plug thread.

(d) Fasten the screw plug with torque socket wrench.
Bearing front cover

Part drawing
★Front cover assembly
Front cover oil seal assembly
★ Pregummed components
Replacing the oil seal

Replace the bearing front cover oil seal if necessary
(a) Prize out the oil seal with screwdriver.
(b) Press in the new oil seal with special service tool.
Oil seal pressing in depth: 13±0.4mm
special tools
13±0.4mm
Oil seal pressing in depth
The assembling of the transmission

1. Encase the output shaft into the middle coupling
plate
(a) Pull out the output shaft and drive in the middle
coupling plate at the same time, and encase the
output shaft into the middle coupling plate.
(b) Encase the rear bearing stop ring of the output

Remark: the stop ring should be kept close with the
middle coupling plate surface.
2. Encase the input shaft into the output shaft

(a) Coat the grease on 13 needles bearing, and enca-
se the needles into the input shaft.
(b) Rotate the input shaft into the output shaft to align
Aligning the three grooves of the synchronizing ring with
the synchronizer sliding block
3. Encase the intermediate shaft into the middle

coupling plate
(a) Install the rear bearing stop ring of the intermedia-
te shaft on the rear bearing.
(b) Encase the intermediate gear shaft into the middle

coupling plate and hold the intermediate gear
shaft at the same time, and install the intermediate
shaft rear bearing with special service tool.
special tools
4. Install the output shaft rear bearing baffle

Install and fasten the bolt with torque socket wrench.
Tightening torque: 17-22N·m
5. Install the reverse gear idler and shaft

(a) Install the reverse gear idler and shaft
(b) Install the reverse gear idler clamping plate and

fasten the bolt.
6. Install the reverse gear rocker bracket set

Install the reverse gear rocker bracket, and fasten 2
bolts.
7. Install the steel ball and 5th shift gear thrust washer.
Lock ball
8. Install the 5th shift gear set

(a) Coat gear oil on the needle bearing.
(b) Install the 5th shift gear set
9. Install the synchronizing ring and 5th shift coupling

gear
(a) Cover the synchronizer ring on the 5 th shift
coupling gear conical surface.
(b) Remove the middle coupling plate from the leg

vice.
(c) Put the transmission straight as shown in the
drawing.
(d) Align the synchronizing ring groove with the sli-

Socket wrench ding block, and install the 5th shift coupling gear
with forcing machine.
(e) Place the middle coupling plate on the leg vice.
10. Install the split ring

(a) Choose a shaft retainer that could make the min.
axial clearance, and the clearance value should
not be more than 0.1mm.
(b) Encase the shaft retainer with bar copper and ha-
mmer.
11. Measure the axial clearance of 5th shift gear set

Measure the axial clearance of 5th shift gear set with a
feeler gauge.
Max. clearance: 0.3mm
12. Install the 3rd and 4th gear shift forked axle and 1st
and 2nd gear shift fork, 3rd and 4th gear shift fork.
(a) Install the 1st and 2nd , 3rd and 4th gear shift fork.
(b) Encase the 3rd and 4th gear shift forked axle into
the middle coupling plate and shift fork.
(c) Install the elastic straight pin of 3rd and 4th gear
shift fork.
Note: the pin opening should be in the same direc-
tion with the axle. (The same with the following)
13. Install the 1st and 2nd gear shift forked axle and 1st
and 2nd gear shift fork
(a) Coat the grease on the interlock guide column,
and install it on the 1st and 2nd gear shift forked
axle.
(b) Encase the short interlock pin into the middle

coupling plate with bar magnet.
(c) Encase the 1st and 2nd gear shift forked axle into
the 1st and 2nd gear shift fork and middle coupling
plate.
(d) Install the 1st and 2nd gear fork set bolt, and screw
down the bolt.
14. Install the reverse gear deflector rod, reverse gear

rocker and reverse gear block
(a) Assemble the reverse gear deflector rod, reverse
gear rocker and reverse gear block together.
(b) Install the reverse gear rocker on the reverse gear
rocker bracket.
(c) Coat the grease on the interlock guide column,

and install it on the reverse gear shift forked axle.
(d) Encase the long interlock pin into the middle

(e) Encase the reverse gear shift forked axle into the
reverse gear deflector rod and middle coupling
plate.
(f) Encase the elastic straight pin with drift pin and
hammer.
15. Install the 5th reverse gear shift guide block and 5th
reverse gear shift forked axle.
(a) Encase the 5th reverse gear shift guide block into
the 5th reverse gear shift forked axle.
(b) Install the 5th gear shift fork.
(c) Encase the steel ball into the 5th reverse gear shift
guide block with bar magnet.
(d) Install the 5th gear shift forked axle as shown in
the drawing.
(e) Encase the interlock steel ball into the middle

(f) Encase the 5 th gear shift forked axle into the
middle coupling plate.
(g) Encase the pin into the 5th gear shift fork with drift
pin and hammer.
(h) Encase the 5th reverse gear shift forked axle into
the 5th reverse gear shift guide block and middle
coupling plate.
(i) Encase the elastic straight pin into the 5th reverse
gear shift guide block with drift pin and hammer.
16. Install the gear shift forked axle grip ring

Encase the grip ring with steel bar and hammer.
17. Install the steel ball, set spring and set spring
screw plug
(a) Install the steel ball and set spring.
Remark: Encase the short spring into the bottom of the
middle coupling plate.
(b) Coat sealant on the screw plug thread.

(c) Install the screw plug, and fasten it with torque
socket wrench.
18. Remove the middle coupling plate from the leg

vice.
(a) Remove the middle coupling plate from the leg
vice.
(b) Remove the bolt, nut and washer.
19. Install the transmission case

(a) Coat sealing material on the transmission case
junction plane as shown in the drawing.
sealing material
(b) Put the middle coupling plate straight as shown in

the drawing.
(c) Install the transmission case on the middle
coupling plate as shown in the drawing.
20. Install the front bearing stop ring

(a) Install 2 stop rings on the input shaft bearing and
pliers.
(b) Install the front cover set coated with sealant.

(c) Coat sealant on the bolt thread.
(d) Install and fasten the bolt.
21. Install the rear housing, gear shift shaft and gear
shift block.
sealing material (a) Coat the sealing material on the rear housing as
shown in the drawing.
(b) Encase the gear shift shaft equipped with gear

shift deflector rod into the rear housing (not reach
the designated position), and put the transmission
into the 3rd gear position.
(c) Put into the gear shift deflector rod from the upper
opening of the rear housing, and continue enca-
sing the gear shift shaft to let it go through the
cross bore of the gear shift block.
Remark: the installing way of the four wheel drive is the
same with the above.
(d) Insert the gear shift deflector rod into the 3rd and
4th gear forked axle groove to align the 5th reverse
gear shift forked axle with the rear housing insta-
llation hole, and push into the rear housing.
(e) Install and fasten the rear housing bolt.
Remark: the installing way of the four wheel drive is the
same with the above.
(f) Install and fasten the gear shift block set bolt.
22. Install the steel ball, spring and screw plug

(a) Coat sealant on the screw plug thread.
(b) Install the steel ball, set spring and set spring
screw plug
23. After installing the rear housing or transmission
case, check the following items
(a) Check the rotation of the input shaft and output
shaft is stable.
(b) Check the shift of each gear is clear and reliable,
and check there is reverse gear lock function.
When installing, distinguish the left and right-less
elastic force of left limit mechanism set (seen from the
output shaft to the input shaft of the transmission)
25. Install the shift cover of the transmission
(a) Install the shift cover coated with sealant.
(b) Install 6 bolts, and fasten the bolts.
26. Install the clutch housing

(a) Install the clutch housing.
(b) Coat sealant on the bolt thread.
(c) Install and fasten 9 bolts.
27. Install the reverse gear switch

28. Install the odometer driven gear
(a) Install the odometer driven gear
(b) Install and fasten the bolt.
Transfer case(4555)-1
Transfer case(4555)
Precautions ....................................................................... 2
Trouble shooting .............................................................. 3
Product instruction and simple maintenance................ 5
Disassembling and assembling of the transfer case .... 7
Disassembling of the transfer case ................................ 9
Cleaning, inspection, repair and replacement ............... 14
The assemblage of the transfer case ............................. 22
Precautions
Precautions for disassembling and assembling of the transfer case
During disassembling of the transfer case, pay attention to handle each part with care to avoid
knock, especially the junction plane; put each part in order so as to prevent loss and wrong ta-
king.
When assembling, except the above precautions, the following should be noticed:
1. Clean all the parts before assembling (except rubber parts and liner).
2. Do not repeat using various oil seals, shaft retainers and elastic pins.
3. Coat lubricant on all friction surfaces, and coat grease on all oil seal mouths.
4. When assembling each bearing, do not pass the pressure with rolling objects.
5. When assembling mouth shape oil seal, do not tilt it.
6. When the transfer case is in operating position, there should not be lubricant leakage at each
part.
Trouble shooting
Common trouble Causes Eliminating methods
Electric shift trouble Electrical control element, electri- Refer to vehicle operation manual,
cal control module, speed sensor, and diagnose the ineffective element
electrical motor, electrical clutch or and replace it as required.
inner connection harness dama-
ged or ineffective.
Shift cam, connecting sleeve, lock Disassemble and check worn or da-
sleeve, fork or shift guide shaft maged part. Replace it as required.
damaged or worn.
Shift fork, lock sleeve or gear Disassemble and check the sliding
glued. part could move freely. Replace it as
required.
Mechanical shift not rea- Shift rocker or shift connecting bar Replace the damaged parts.
lized (when the shift han- broken or damaged.
dle is moving) Shift cam guide plate damaged; Open the transfer case rear cover,
shift fork broken. check the damaged parts and replace
them.
Mechanical shift difficult Incorrect operation. Refer to vehicle operation manual,
or putting into gear not to and operate correctly.
the specified position Lubricant improper or the amount Fill specified oil product or amount.
insufficient
Shift fork glued. Open the transfer case rear cover,
check and replace the damaged parts.
Sliding connecting sleeve, lock Open the transfer case rear cover,
sleeve or gear glued. check the sliding parts could move
freely on the shaft, disassemble and
replace the damaged parts.
Mechanical shift transfer Shift connecting bar mechanism Adjust or repair shift connecting bar
case out of gear damaged or improperly adjusted. mechanism.
Inner shift parts damaged or seve- Replace the parts severely damaged.
rely worn.
Shift fork assembly loosened on Replace loosened or worn parts.
the guide shaft or damaged.
Mechanical shift blocked Shift connecting bar mechanism Adjust or repair shift connecting bar
at a certain position improperly adjusted. parts.
Shift fork loosened too greatly on Open the transfer case and check the
the shift guide shaft. fork and guide shaft, and replace the
parts as required.
Shift fork assembly worn, inclu- Open the transfer case to check the
ding: pin and contact roller. parts are worn, replace the parts if
they are worn.
Shift cam hub and bush worn. Open the transfer case to check the
parts are worn, replace the parts if
they are worn.
Combination tooth damaged. Open the transfer case to check the
parts are worn, replace the parts if
they are worn.
Common trouble Causes Eliminating methods

No front wheel drive when Driving chain broken. Disassemble and check the damage
putting into four wheel drive condition of the inner parts, and replace
the chain.
Noise with all gears, the Incorrect lubricant or lubrica- Replace lubricant or refill the amount as
noise is from the transfer ting amount insufficient. required.
case not from the clutch, Connecting bolts loosened or Ensure that the torque of all connecting
engine, drive shaft or other other connecting parts loose- parts reaches specified value.
parts. ned.
Noise with transfer case bea- Open the transfer case to check the
ring bearing and other parts are worn or da-
maged, and replace them if damaged or
worn parts are found.
Noise with all gears, the Gear noise. Open and check there are worn or da-
noise is from the transfer maged parts (including odometer gear),
case not from the clutch, replace them if worn or damaged parts
engine, drive shaft or other are found.
parts.
Noise at high gear and low Sprocket wheel or chain da- Open and check there is abrasion or da-
gear of four wheel drive maged or worn. mage, and replace the parts if abrasion
or damage is found.
Tire pressure improper. Regulate the tire pressure to proper.
Leakage with the transfer Transfer case housing broken. Replace the housing.
case Leakage with other parts. Prove that it is actually the leakage of
transfer case. Dry it and check the lea-
king condition.
The breather pipe blocked. Open and clean, and replace it if neces-
sary.
Lubricant amount more than Use specified lubricant and regulate to
the required or the lubricant proper amount.
brand improperly chosen.
Sealing surface bolt loosened. Screw down the bolt as required.
Different brands of sealer or Use specified sealer and screw down
unusable sealer. the bolt as required.
The oil seal worn or damaged Replace the oil seal.
Product instruction and simple ma-

intenance
1. Product instruction
This company applies Borg Warner 45-55 transfer
case. It is 2-speed part-time drive, and a set of pla-
netary mechanism aims to realize decelerating, and
the power is passed to the front drive wheel through 1
high precision chain. The planetary gear pair and rear
output shaft parts of this transfer case are actively lu-
bricated through oil bath and oil pump.
Borg Warner product assembly type This transfer case has four gear positions:
• 2H-at two high gear positions, only two rear wheels
are driven, and the drive ratio of the transfer case
is 1:1.
The transfer case assembly number of the manufacturer • 4H-at four high gear positions, foul wheels are all
driven, and the drive ratio of the transfer case is 1:1.
• N–neutral position (only manual shift transfer case
Borg Warner product assembly serial number has this gear position), output shaft and input shaft
Manufacturing date
are disconnected, and no power is passed to the
wheel.
• 4L-at four low gear positions, foul wheels are all
Display: group number
driven, and the drive ratio of the transfer case is
Display: the last number of year
Display: specific manufacturing date of each month 2.48:1.
Display: month
January (A) to December (L)
The shift of mechanical shift transfer case is realized
Example indication:
through one shift rocker controlling one shift cam sha-
January 1, 1989, second group
pe guide plate.
Sign panel: fixed at the outer obvious position of the
transfer case, the detailed information of manufactu-
ring marked on it.
2. Replacing the lubricant regularly

(a) When replacing the engine lubricant or after dri-
ving 8000 km, check the transfer case oil level
and refill the lubricant according to need.
(b) Every year or every 48000km, replace with speci-
fied lubricant.
Lubricant class: Dexron III or other the same class
lubricant.
Oil drain plug oil filler plug
3. Lubricant inspection methods

(a) Clean up the oil filler plug and the area around.
(b) Screw off the oil filler plug, check the oil could flow
out.
(c) The oil not flowing out indicates the actual oil
amount lower than specified value, and refill spe-
cified lubricant to the transfer case until the oil flo-
ws out from the oil hole.
(d) Screw down the oil filler plug as required torque.
Precautions: before inspecting or replacing the
lubricant, rotate the vehicle for a while to increa-
se the oil temperature of the transfer case. Do not
open or screw down the oil drain plug and oil fi-
ller plug with hammer or other attack tool, or the
thread on the housing will be damaged.
4. Replacing the lubricant

(a) Clean up the oil drain plug and oil filler plug and
the area around.
(b) Place a container filling oil under the transfer
case.
(c) Screw off the oil drain plug.
(d) Screw off the oil filler plug.
(e) Drain off the lubricant.
(f) Install and screw down the oil drain plug as requi-
red torque.
(g) Refill lubricant from the oil hole until the oil flows
out. Install and screw down the oil filler plug as re-
quired torque.
Disassembling and assembling of the transfer case

3 4
2
1
9 8
1.Input shaft 5
2.Transfer case front housing 6.Breather valve
3.Transfer case rear cover 7.Shim
4.Flange plate 8.Transmission rear housing
5.Front output shaft flange plate 9.Bolt
1. Disassembling of the transfer case transfer case is not allowed to hang direct-
(a) Drive the vehicle to appropriate lifting jack. ly on the transmission through spline shaft,
(b) Put the transmission gear position at neu- which will cause the damage of the transfer
tral position, and shift the transfer case to case parts.
2H gear and extinguish the engine. (l) Remove the connecting nut between the
(c) Disconnect the battery cathode. transfer case and transmission, and take
(d) Lift the vehicle. down the transfer case.
(e) Place the drip pan under the transfer (m) Directly remove the transfer case bac-
case, and dismount the transfer case oil kwards until the spline connection of the
drain plug and oil filler plug to discharge transfer case input shaft and the trans-
all the lubricant, and then install two oil mission is completely uncoupled.
plugs over again. (n) Lower the transfer case lifting jack carefu-
(f) Disconnect all the wires and wire harnes- lly.
ses related to the transfer case. (o) Remove the shim between the transfer
(g) Disconnect the odometer connecting wire. case and transmission. Clean up the shim
(h) Disassemble the hose on the breather material or glue on the junction plane of
valve of the transfer case. transfer case front housing and transmis-
(i) Uncouple the connection of the front drive sion rear housing. Pay attention not to
shaft with the transfer case front flange damage the junction plane.
plate. 2. Installation of the transfer case
(j) Uncouple the connection of the rear drive (a) Use a thin sleeve (filled with grease) to
shaft with the transfer case rear flange coat grease on the transmission output
plate. shaft spline.
(k) Support the transfer case with lifting jack. (b) Install a new shim on the transfer case
Note: before removing the bolts and nuts installation surface.
connecting the transfer case and transmis- (c) Lift the transfer case lifting bracket and
sion, ensure that the transfer case is com- align on the same axial line with the trans-
pletely supported by the lifting jack. The mission.
Note: before connecting the spline, ensure the transfer case.

that the transfer case is aligned with the (k) Fill correct brand lubricant.
transmission. Do not force the transfer Note: in engine starting, not filling correct lu-
case spline to press into the transmission. bricant and appropriate lubricant amount as
Otherwise, damage may be caused. Rotate required will cause the damage of the transfer
the transfer rear output shaft if necessary case.
to make it align with the spline. Note: when filling oil to the transfer case ha-
(d) Move the transfer case forward slowly to ving been installed on the vehicle, you must
make the transmission input shaft spli- use petrol feed pump.
ne and the pin to the transfer case front Note: if the transfer case is removed to repair
housing, shim and transmission rear or check, there will be no oil in the oil duct
housing be jointed completely. lubricated through the oil pump on the up-
(e) After ensuring that the installation holes of per part of the transfer case.Controlling the
the transfer case front housing, shim and oil amount depending on the opening of the
the transmission rear housing are in align- oil filler plug will not be accurate until the oil
ment, install the bolt or nut. pump rotating oil duct is filled up.If the wheel
Tightening torque: 35-48N·m could be rotated, this could be done on the
(f) Connect the rear drive shaft and transfer vehicle lifting jack.Recheck the oil level after
case rear output flange plate. the oil pump rotating.
(g) Connect the front drive shaft and transfer (l) After inspecting the lubricant, lower the vehi-
case front output flange plate. cle and connect the battery cathode.
(h) Connect the breather valve and breather
hose.
(i) Connect the odometer cable at the trans-
fer case rear cover.
(j) Connect all the wire harnesses related to
2
4
Disassembling of the transfer case
1 1. Simple instruction
5 As to the transfer case, if only the damaged part is re-
paired, disassemble the transfer case to the extent that
3 this damaged part could be taken out. The part disas-
sembled from the transfer case could be either subas-
sembly or full group, and it is not necessary to take it
6 apart unless it contains damaged parts.
2. Disassembling of the transfer case
Place the transfer case on the work bench with rear
part or rear cover upward. Place a wooden block under
the front part to keep the transfer case level. The di-
sassembling process is as follows
1.Transfer case rear housing
2.Flange plate
(a) Fix the flange plate, screw off the nut and take
3.Oil seal down the shim, and then remove the flange plate
4.Shim and oil seal.
5.Nut
6.Oil plug (b) Take down two oil plugs from the housing.
1 For electric shift transfer case, remove the electric shift

2
parts. Disassembling steps As follows:
(a) Remove the bolt, shim, three bolts and sensor and
7 harness clips.
3 (b) Remove sensor assembly, and take off O ring
5 from speed sensor.
4
(c) Remove motor assembly.
6
1.Sensor fixing bracket

2.Bolt
3.Speed sensor
4.O ring
5.Sensor assembly
6.Bolt
7.Motor assembly
8.Transfer case rear housing
8 9
11
1.Transfer case front housing
6 2.Rear output shaft
7 3.Clutch coil assembly
5 10 4.Snap ring
4
3 5.Bearing
6.Nut
2 7.Transfer case cover assembly
8.Sign panel
12 9.Bolt
1 13
16 14
7
17
15
10.Odometer drive gear
11.Oil seal
12.Oil seal
18 13. Bearing
14.Transfer case rear cover
15.Needle bearing
16.Shift guide shaft
9 17. Return spring
18.Magnet
19.Harness clip
19
3. The process of disassembling the rear cover is as

1
follows (the above drawing):
(a) Remove 9 screws and take down harness clips
8 and sign panel at the same time. Keep well the
7 sign panel, because it contains the information re-
6 placing the substituting parts.
2
5 (b) Pry the housing gently and disconnect the surface
4 sealer, and then directly take up the transfer case
rear cover assembly upward.
3
(c) For electric shift transfer case, remove the oil seal,
bearing and 3 nuts and clutch coil assembly.
(d) Remove the snap ring, pluck out the bearing from
9 rear cover and remove the odometer gear at the
10 same time.
(e) Pluck out the needle bearing from the transfer
case rear cover.
(f) Pluck out the oil seal from the transfer case rear
cover.
1.Output shaft (g) Dismount the magnet from the transfer case front
2.Shift engagement sleeve assembly housing.
3.Lock sleeve (h) Remove the return spring from the shift guide
4.Return spring
5.Engagement sleeve shaft.
6.Snap ring (i) Clean out the sealer on the junction plane of the
7.Clutch assembly transfer case front housing and rear cover, and
8.Tightening snap ring take care not to damage the junction plane of
9.Shift guide shaft
10.Fork the two housings or let the cleanings fall into the
transfer case.
4. Dismount the connected front axle shift parts
Remove the following parts from residual transfer case housing assembly (electric shift).
(a) Electric shift assembly, remove the snap ring and sliding clutch bush from shift lock hub.
(b) Remove the shift lock hub from rear output shaft.
(c) Remove the shift engagement sleeve assembly and shift fork from rear output shaft and shift gui-
de shaft. Disconnect all assemblies and remove the shift guide shaft.
(d) Disassemble shift engagement sleeve assembly, and take down the snap ring, engagement slee-
ve, return spring and lock sleeve.
(e) One plastic fork substitutes early metal fork assembly and independent contact roller parts.
2 5. Dismount the chain driving system

Remove the following parts from residual transfer case
housing assembly.
1
(a) Remove the snap ring and washer from front
3 4 5 output shaft.
(b) Remove the drive sprocket, driven sprocket and
driving chain together from two output shafts.
7 (c) Separate the sprocket from the chain.
1.Output shaft 5.Snap ring

2.Drive sprocket 6.Driving chain
3.Driven sprocket 7.Front output shaft
4.Washer
6. Dismount the oil pump assembly

4 Remove the shaft and pump assembly from residual
7
5 transfer case housing assembly. Remove the pipe clip,
oil piper and filter.
6
3
1.Filter
2.Oil pump hose
3.Clip
4.Oil pump assembly
5.Output shaft
6.Pump pin
7.Output shaft and pump assembly
7. Disassembling of the decelerating shift parts

1 Remove the following parts from residual transfer case
2 housing assembly.
(a) Remove the decelerating hub and decelerating
shift fork assembly from the housing.
(b) Remove two plastic veneers from the decelerating
shift fork assembly.
(c) Only when replacing the damaged parts of the
decelerating shift fork assembly, disassemble the
6 3 decelerating shift fork assembly. Cut the plastic
4
5 sleeve, and take down the pin and contact roller.
7
1.Decelerating hub
2.Shift fork veneer
3.Contact roller
4.Pin
5.Pin and contact roller assembly
6.Decelerating shift fork
7.Decelerating shift fork assembly
8. Front output assembly

4
Remove the following parts from residual transfer case
housing assembly.
(a) Fix the front flange plate, screw off the nut and re-
move the shim, and pluck out the front flange plate
assembly and the seal ring.
(b) If the replacement needs, press down the dust cap
3 2 from the front flange plate
1 (c) Remove the front output shaft
6 5
7 1.Flange plate
8
2.Dust cap
3.Flange plate assembly
5.Front output shaft
6.Oil seal
7.Washer
8.Nut
9. Dismount the front housing, input shaft assembly

and planetary mechanism assembly.
7
10 Remove the following parts from residual transfer case
9
1
8 housing assembly.
6
5 (a) Remove the breather valve.
3
4 (b) Remove 6 bolts. Separate the front housing from
the transfer case housing, and take down the front
16 housing (take care not to damage the front end
cover and transfer case housing).
2 (c) Remove the front housing assembly, input shaft
11 15 assembly and planetary mechanism assembly
14
13 as groups (loosen the snap ring, and remove the
12 input shaft from the front end cover).
17
18 (d) On the work bench, hold one end of the input
shaft, and extend the long end of the snap ring
and gently press the front housing, and the front
19
20 housing assembly could be disassembled from the
1.Planetary mechanism assembly
residual assembly in this way.
2.Shim
3.Snap ring (e) Remove the snap ring and oil seal from the front
4.Thrust button housing. Remove the pin only when it needs re-
5.Sun gear placing.
6.Planet carrier
7.Input shaft assembly (f) After removing the bearing closing ring, remove
8.Input shaft the bearing and shim from the input shaft assem-
9.Needle bearing bly end. Remove the input shaft assembly from
10.Bearing shell the planetary mechanism assembly.
11.Transfer case front housing assembly
(g) Remove the needle bearing and bearing shell
12.Oil seal
13.Anchor pin from the input shaft assembly.
14.Transfer case front housing (h) Remove the snap ring, thrust button and sun gear
15.Snap ring from the planet carrier assembly.
17.Bearing (i) Do not try to disassemble the planet carrier.
18.Bearing closing ring
19.Bolt
20.Breather hole
1 10. Disassemble the shift flange parts (for electric shift

4 transfer case)
3
(a) Remove the electric shift cam set as a whole from
2 the transfer case housing.
(b) Remove the electric shift cam from the shift guide
5
shaft.
(c) Clamp the end of the shift guide shaft with soft
mouth jaw vice, and knock with a bolt driver to dis-
connect the torsion spring and remove it.

2.Shift guide shaft
3.Torsion spring
4.Electric shift
5.Shim
11. Disassemble the transfer case housing assembly

Disassemble the transfer case housing assembly in the
following way.
(a) Remove the oil seal.
(b) Remove the snap spring and pluck out the bea-
7 ring.
5
6 (c) Remove the anchor pin from the transfer case
4 front housing only when the pin is loosened or da-
3 maged.
2 1
(d) Press out the ring gear from the transfer case
housing if the ring gear needs replacing.
2.Ring gear
3.Oil seal
5.Anchor pin
6.Ball bearing
7.Snap ring
Cleaning, inspection, repair and replacement

Cleaning
1. Cleaning
Note: before cleaning, firstly check the metal chips condition, and big, small, granular or irre-
gular granular metal chips indicate the crack or similar damage. Smaller and powdery chips
indicate uneven or excessive abrasion. If metal chips are found, when inspecting the rotating
parts and corresponding matching parts, be extremely careful to check there is damage or
abrasion.
(a) General cleaning process
Clean the parts in cleaning agent, and remove the old lubricant and deposits. Wipe off the deposits
in the oil hole with hair brush For the parts that could not be cleaned with hairbrush, take care not to
scrape the metal junction plane etc when cleaning.
(b) Dry the cleaned parts
Dry the parts with compressed air of low pressure (max.137.9kPa). Mopping up with cloth may leave
strand silk. When drying the bearing, hold it with hands to prevent it from rotating.
(c) Lubricate the bearing
After cleaning, immediately lubricate the ball bearing and needle bearing with transfer case oil. When
drying, the bearing without lubricating may cause the damage. Cover the lubricated bearing to prevent
dust entering.
Inspection
1. General inspection process
Visually check all the parts (except the parts that
should be replaced by new ones such as oil pump oil
pipe, O ring and oil seal etc) are damaged or exces-
sively and unevenly worn. Abandon the damaged or
worn parts that will affect performance. The inspection
items are as follows:
• Burrs: partially protruded pointed edge of the mate-
rial.
• Chips: broken or smashed small block or grain.
• Cracks: the surface line of rent indicating part or full
separating of the material.
• Excessive abrasion: severe or obvious abrasion
exceeding the operating range.
• Shrink deformation: material sliding caused by par-
tial oppress.
• Pasting: grains of soft metal material torn up and
pasting on hard metal surface.
• Groove mark: partial crack or furrow, generally me-
aning the transfer of material not loss.
• Pitting corrosion: the breaking of metal surface un-
der contact pressure. Color change caused by the
heat produced by metallic friction can be displayed.
• Step abrasion: visual or perceivable step produced
by excessive abrasion between adjacent contact
surface and non-contact surface.
• Uneven abrasion: partial, unevenly distributed abra-
sion. Including pore space, exploring spot, uneven
polishing and other visual showings.
2. Inspection of gear or sprocket tooth

Note: do not mix the cut mark caused by machining
with the extrusion marks. Typical machining marks
are as shown in the left drawing.
Normal gear shaving mark
Normal gear grinding mark

Check the tooth contact zone form of gear or sprocket

tooth as the following way:
(a) Optimal tooth contact zone.
(b) It is allowable for contact zone deviating toward

one side.
(c) It is not allowable for contact zone deviating

toward one side, and replacement is necessary.
(d) It is allowable for contact zone deviating toward

another side.
(e) It is not allowable for contact zone deviating

toward another side, and replacement is neces-
sary.
(f) It is allowable for contact zone deviating toward

addendum.
(g) It is not allowable for contact zone deviating

toward addendum, and replacement is necessary.
(h) It is allowable for contact zone deviating toward

dedendum.
(i) It is not allowable for contact zone deviating

toward dedendum, and replacement is necessary.
4. Inspection of spline tooth

Inspect broken of flaked spline tooth. For partial small
block flaking, repair it in the same way as that of gear
tooth flaking, and you can reuse it. If any spline tooth is
broken, this part must be abandoned. The contact form
of spline tooth is different from that of gear, but the spli-
ne displaying step sliding must be abandoned.
Repair or replacement of gear and sproc-

ket tooth
1. Repair principle
(a) Repair the partial small block flaking with appro-
priate manual high-speed grinding tool.
(b) When grinding matrix metal, try your best not to
remove more metal.
(c) Revamp the closed angle or edge as sleeky form
line. The closed angle or edge may flake again
and form into cracks.
(d) Remove burrs with appropriate grinding. Take care
to remove heaved material without destroying the
matrix.
(e) Replace the unmendable parts (such as bearing),
and replace the part that you doubt about its conti-
nuous usability.
2. Several conditions for repair or replacement of

gear and sprocket tooth
(a) It is maintainable for the inbreak of both sides of
the interface addendum.
(b) It is maintainable for the inbreak of the intermedia-

te addendum of the interface.
(c) It is maintainable for the inbreak of the non-interfa-

ce side.
(d) It is maintainable for the inbreak of the middle part

of the interface side.
(e) If the middle part of the contact zone is flaked, re-

place this gear.
(f) For inbreak of two sides of the addendum, replace

this gear.
Attached list on parts inspection, repair and replacement standard

Parts (items) Inspection Accept/reject
All parts (including all Inspect cracks, contorts and co- Reject all parts with cracks
springs) rrosion Reject the parts with bends, contor-
ts and poor circle jumps
Reject all parts with pitting corrosion
or corrosion
All thread parts Inspect the dropout or other da- Reject the parts that could not be
mages with the thread screwed or without threading
Flange plate Refer to “Inspection” section to Refer to spline inspection in“Inspec-
inspect the spline tion” section
Speed sensor, motor ass- Refer to electrical equipment part Replace parts as required
embly
Parts of electric clutch
Sliding bearing Check the inner surface condition Reject if there is pitting corrosion or
of the sliding bearing damage
Transfer case housing Check the hole matching with the Abandon if there is pitting corrosion
bearing or damage

Ball bearing Visually check there is flaking, pas- Reject damaged bearing
ting, pitting corrosion or other dama- Reject damaged or loosened bea-
ges with the ball and ball race of the ring
bearing. Or check the axial clearance ex-
Be certain that the bearing has been ceeds 0.23mm
lubricated, and hold the bearing
inner race and rotate the bearing
outer race slowly at the same time
to feel whether the rotating is smoo-
th or the parts are rusted, and the
bearing should rotate stably without
play and looseness.
Needle bearing Visually check there is flaking, pas- Reject damaged bearing
ting, pitting corrosion or other dama-
ges with the needle and ball race of
the bearing.
Transfer case rear cover, Check there is burrs or other dama- Refer to “Inspection” section to re-
front housing and transfer ges obstructing sealing move the burrs or replace the dam
case front housing aged parts
Transfer case rear cover Check the bearing hole Reject if there is pitting corrosion
with the hole
Odometer gear Refer to “Inspection” section to ins- Refer to inspection of gear or
pect the gear tooth sprocket tooth in “Inspection” sec-
tion
Transfer case outer Refer to “Inspection” section to ins- Refer to spline inspection in“Ins-
housing,connecting outer pect the spline pection” section
sleeve and connecting
sleeve
Lock sleeve Check the abrasion or damage con- Reject if step slipping or damage
dition of the fork groove Refer to is found
“Inspection” section to inspect the
spline
Shift guide shaft Check the deformation condition Reject if it bends, and refer to“Ins-
Check the outer circle burrs or other pection” section to remove burrs,
damages or reject the damaged guide shaft
Check the abrasion condition of the Reject if step slipping or damage
outer circle is found
Shift fork Check the part that the fork mat- Reject if step slipping or damage
ching with the shift cam and gear is found
sleeve is worn of damaged
shift fork assembly Check the abrasion or damage con- Reject this veneer if abrasion or
dition of the fork veneer matching damage of thestep is found If the
with the gear sleeve contact roller is hard to rotate or it
Check the contact roller could rotate is damaged, use new pin, contact
freely or it is damaged roller and holder assembly
Drive and driven sprocket Refer to “Inspection” section to ins- Refer to inspection of the sprocket
pect the sprocket tooth tooth in “Inspection” section
Refer to “Inspection” section to ins- Refer to spline inspection in“Ins-
pect the sprocket spline pection” section

Driving chain Check the step slipping, loosening or Reject the drive sprocket with abrasion
the damage of the pin or connecting or damage
parts
Filter screen Check the filter screen is clean and the- Clean it if necessary; abandon if it is da-
re is hole or damage with it maged
Pump case Check there is pitting corrosion or step Abandon if the pump case is damaged
slipping with the inner diameter of the or excessively worn
pump case
Oil pump pin Check the pitting corrosion condition Abandon if there is abrasion, pitting co-
rrosion or damage with the pump case
Output shaft Refer to “Inspection” section to inspect Refer to spline inspection in “Inspection”
the spline section
Check the surface condition Reject if there is pitting corrosion or da-
mage
Reject if it bends or poor circle jump
with it
Decelerating hub Refer to “Inspection” section to inspect Refer to spline inspection in “Inspection”
the sprocket spline section
Check the abrasion or damage condi- Reject if step slipping or damage is
tion of the position matching with the found
fork
Front output shaft Check the surface condition matching Reject if there is pitting corrosion or da-
with the bearing mage
Refer to “Inspection” section to inspect
the spline
Input shaft Refer to “Inspection” section to Refer to spline inspection in“Inspection”
inspect the spline section
Check the contort condition Reject if it bends or poor circle jump
with it
Thrust plate and Check the pitting corrosion condition Reject if there is pitting corrosion or da-
thrust button mage
Sun gear Refer to “Inspection” section to inspect Refer to inspection of the gear tooth in
the gear tooth “Inspection” section
Refer to “Inspection” section to inspect Refer to spline inspection in“Inspection”
the spline section
Planetary mecha- Refer to “Inspection” section to inspect Refer to inspection of the gear tooth in
nism assembly the gear tooth “Inspection” section
Check the abrasion of the planetary Reject if step slipping or pitting corro-
shaft pin or it is loosened and the abrasion is found
sion condition of the thrust plate
Electric shift cam Check there is pitting corrosion or step Reject if pitting corrosion or step slip-
slipping ping is found
Shift guide shaft Check there is pitting corrosion or step Reject if step slipping or pitting corro-
slipping sion is found
Check the contort condition Reject if it bends
Planetary ring Check the matching condition with the Check the transfer case housing ass-
gear transfer case housing embly to see whether the ring gear is
loosenedin the housing
Refer to “Inspection” section to inspect Refer to inspection of the gear tooth in
the gear tooth “Inspection” section
The assemblage of the transfer

case
1. Overview
During assembling, please refer to specified instruction
in this chapter. In assembling, pay attention to the fo-
llowing problrms:
(a) When there is requirement for the torque of thread
parts, screw down the thread parts with torque
wrench.
(b) During installing, coat grease on small parts to
make them be fixed on the installation position.
(c) When assembling the oil seal and bearing, press
the oil seal and bearing with special tool socket
T-13-54-001. Do not directly knock the oil seal or
bearing with hammer.
2. Lubrication in assembling
Lubricate all the inner parts not yet lubricated with co-
rrect lubricant before assembling to make it easy for
assembling and provide initial lubrication.
(a) Before assembling, O ring or the oil seal of shaft
without lubrication may cause damage.
(b) Ensure the bearing or bushing could be lubricated
completely before assembling. Operating the bea-
ring or bushing without lubrication even for a short
time will cause the damage.
(c) mouth and the metalwork matching with it.
3. The assembling of the transfer case housing
7 Install the parts removed from the transfer case
6 housing, the process is as follows:
5
4 (a) If the ring gear is replaced, when pressing into
3 1 new ring gear, align the tooth shape protuberan-
2
ce of the new ring gear with corresponding gullet
1.Transfer case front housing assembly in the transfer case front housing, and press into
2.Ring gear the ring gear as shown in the lower left drawing,
3.Oil seal
and the chamfer end enters first. Ensure the ring
5.Anchor pin gear does not upwarp and it is tightly fixed in the
6.Ball bearing housing.
7.Snap ring
(b) If two anchor pins are removed, encase two new
anchor pins into the housing.
(c) Press the bearing into the transfer case front
2 3 housing and well install the snap ring.
1 (d) Place the new oil seal as shown in the lower left
drawing and press it into the housing.
4
1.Oil seal
3.Ring gear
4.Anchor pin
4. The assembling of mechanical shift flange parts (

electric shift transfer case)
2
4 For electric shift parts assembly, the installing process
is as follows:
1 3 (a) Insert the shim into the inner diameter of the tor-
sion spring and make it run through the free end
of the shift shaft.
1.Shift guide shaft

2.Torsion spring
3.Electric shift flange
4.Shim
(b) Slide the torsion spring and shim on the shift shaft
to reach the drive tongue, and put the first finger
tip of the torsion spring on the left side of the drive
1 tongue (seen from the free end of the shift shaft).
1.Torsion spring
2.Shim
3.Shift shaft
(c) Twirl the second finger tip of the torsion spring on

the shift shaft to the right end of the drive tongue.
1
3
2
1.Torsion spring 2.Shim 3.Shift shaft

(d) Try your best to push the torsion spring and shim
1 backwards together.
(e) Install the electric shift cam on the shift shaft, and
make the end with drive tongue on the cam enter
first. Fix the drive tongue of the cam under the dri-
2
ve tongue of the shift shaft and make it between
two torsion springs at the same time, and make it
enter as interior as possible.
3
(f) then encase the electric shift cam assembly into
the transfer case housing assembly.
1.Torsion spring 2.Shim 3.Shift shaft
5. The assembling of the front housing, input shaft

assembly and planet set
7
10 Install the following parts on the work bench:
9
1
8 (a) Put the planet carrier assembly on the work ben-
6
5 ch with the snap ring groove end toward upward.
3
4 (b) Encase the sun gear with the protuberant end
toward upward. Rotate the planet carrier assem-
16 bly gear until the sun gear is completely meshed.
(c) Align the protuberant teeth, and encase the thrust
2 button into the planet carrier assembly.
11 15 (d) Encase the snap ring and finish the whole planet
14
13 carrier assembly.
12
17
18
19
20
1.Planetary mechanism assembly
2.Shim
3.Snap ring
4.Thrust button
5.Sun gear
6.Planet carrier
7.Input shaft assembly
8.Input shaft
9.Needle bearing
10.Bearing shell
12.Oil seal
13.Anchor pin
15.Snap ring
17.Bearing
18.Bearing closing ring
19.Bolt
20.Breather plug
(e) If the parts are removed, place the needle bearing

1.25-1.75mm as shown in the drawing and press into the input
shaft. At the same time, press into the new sliding
bearing as shown in the drawing to finish the who-
le input shaft assembly.
(f) Lift the planetary mechanism assembly and enca-
se it into the input shaft assembly, and encase the
thrust plate and press into the bearing through the
end of the input shaft. Encase one snap ring into
1 2 3 the snap ring groove of the input shaft and fix the
bearing.
1.Needle bearing
2.Rolling bearing
3.Input shaft
(g) If the parts are removed, press new anchor pin

3 into the front housing, the pressing size is as
shown in the drawing.
12.70mm
(h) Place the oil seal as shown in the drawing and
press the oil seal into the front housing.
2 (i) Place the front housing assembly on two wooden
blocks with the housing junction plane toward
upward to make clearance between the output
1 shaft assembly and work bench. Place the ass-
embled input shaft assembly and planetary me-
chanism assembly in the front housing to make
4 the input shaft toward downward. Extend the long
end of the snap ring, and encase input shaft and
planetary mechanism assembly until the snap ring
1. Anchor pin
2.Oil seal enters into the snap ring groove of the bearing
3.Transfer case front housing outer ring.
4.Snap ring
(j) Coat sealer of 1.6mm thickness on the junction
between the front end cover and transfer case as-
sembly, and pass by the thread hole when coating
4 and continue without intermittence at the same
time.
(k) Screw down 6 bolts.
(l) Install the breather valve.
3 2
1
6. The assembling of the front output shaft
9
Assemble the following parts:
(a) If the dust cap is removed, encase it by pressing.
6 5 (b) Put the output shaft in the transfer case front
7 1. Flange plate housing, and then install the flange plate assem-
8 2. Dust cap
3. Flange plate assembly bly, seal ring, washer and nut.
4.Transfer case front housing (c) Insert into the flange plate hole with torque lever
6.Seal ring T-13-54-002 and screw it down.
7.Washer Tightening torque: 203-244N·m
8.Nut
9.Oil seal
7. The assembling of the decelerating shift parts.

2
The installing process of parts is as follows:
(a) If the disassembled parts are replaced, assemble
1 the shift fork assembly with new pin contact roller
assembly. Press the pin contact roller assembly
into the decelerating fork hole until the pin is com-
pletely through and clipped at position. Ensure the
3
contact roller could rotate freely.
(b) Install two fork veneers on the decelerating fork
assembly.
6 7 (c) Combine the decelerating fork assembly with
8
5 the decelerating gear sleeve and put them in the
4
housing, and put the decelerating gear sleeve in
1.Reduction gear
2.Output shaft the above assembled planetary mechanism ass-
3.Fork veneer embly. Install rear output shaft, and combine the
5.Pin, contact roller and bush assembly end bearings of the input shaft and output shaft
6.Decelerating shift fork with the spline of the decelerating gear sleeve.
7.Contact roller Remark: the assembling of output shaft can be dela-
8.Pin
yed after the oil pump being installed on the output
shaft. Immerse oil pump filter screen into the lubricant,
4
and rotate the output shaft clockwise (seen from the
7
5 rear end of the output shaft), and see whether there is
oil from the oil pump to check the oil pump operates
6
normally. Encase the assembled parts as an assembly
3 into the transfer case housing.
8. The assembling of the oil pump
2
Ensure the oil pump parts are lubricated completely in
assembling, and ensure the oil could flow out from the
1 tapered hole of the oil pump front cover. The installing
process of oil pump is as follows:
1.Filter
2.Oil pump hose (a) Install the pin on the rear output shaft.
3.Clip (b) The oil pump assembly is fixed on the rear output
4.Oil pump assembly
5.Output shaft
shaft through the pin.
6.Pump pin (c) Put the clip at the end of the oil pipe, and insta-
7.Output shaft and pump assembly ll the oil pipe on the pump case nozzle tip, and
screw down the clip.
9. The assembling of driving chain
2
The assembling process of parts is as follows:
(a) On the work bench, after assembling the transfer
1 case housing assembly, put the drive sprocket on
5 the rear end of rear output shaft, and put the dri-
3 4
ven sprocket on the rear end of front output shaft.
(b) Install the chain on the sprocket.
(c) Hold two sprockets and make the chain be close
7
to the sprockets, put them parallel to the transfer
case, and encase the chain and sprocket assem-
6
bly through the output shaft, and rotate the driven
sprocket gently to ensure it is meshed with the
spline of front output shaft.
1.Output shaft
5.Snap ring (d) Install the shim and snap ring on the front output
2.Drive sprocket
6.Driving chain
3.Driven sprocket shaft.
4.Washer
10. The assembling of the shift lock parts

1
The assembling process of parts is as follows (for elec-
tric shift transfer case):
8 (a) Install the return spring, engagement sleeve on
7
the lock sleeve and fix with snap ring to finish
2 6 2W-4W lock sleeve assembly.
5
(b) Encase the shift guide shaft into the blind hole of
4
the housing through the assembled decelerating
3
fork assembly.
(c) Install the shift fork on 2W-4W lock sleeve assem-
bly to make the whole assembly slip over the shift
9
guide shaft and rear output shaft.
10 (d) Joint the rear output shaft spline with 2W-4W shift
engagement sleeve.
1.Output shaft
2.Shift engagement sleeve assembly
3.Lock sleeve
4.Return spring
5.Engagement sleeve
6.Snap ring
7.Clutch assembly
8.Tightening snap ring.
9.Shift guide shaft
10.Fork
2 (e) For electric shift transfer case assembly, encase

3 4
Flange groove the above assembled electric shift cam set and
clutch housing, and the process is as follows:
• Put the electric shift cam set as shown in the
1
drawing.
• Hold the shift guide shaft toward downward,
and gently lift the fork assembly. Rotate the
electric shift cam set to position to make the
contact roller on the decelerating fork assem-
bly enter into the groove of the shift cam, and
lock the heave part of the fork at the tail end
of the shift cam. Then lower the set to make it
enter into the transfer case housing, and then
6
joint the shift shaft on the pin of the transfer
5
case housing.
1.Electric shift flange
• Put the clutch housing through shift outer
2.Torsion spring
3.Shift shaft gear sleeve, and install the snap ring.
5.Shift fork
6.Shift guide shaft
5 11. The assembling of rear cover

4 Install the parts into the rear cover, and the process is
as follows:
(a) Put the rear cover on appropriate press machine
3 with the junction plane toward upward and parallel
2
1 to the working surface of the press machine.
7
6 (b) Put the needle bearing end with mark upwards,
and press it into the rear cover until the upper end
of the needle bearing is lower (40.47-40.97)mm
than the rear cover junction plane matching with
the front housing.
1.Clutch coil assembly (c) Press the ball bearing into the rear cover, and ins-
2.Snap ring 8 tall the snap ring.
3.Ball bearing (d) Only for electric shift transfer case, encase the
4.Rear cover assembly parts as the following processes:
5.Nut
6.Oil seal • Ensure 4 O rings are all put on the position of
7.Bearing the clutch coil assembly (one on the coil, three
8.Needle bearing on the pillar bolt). Encase the clutch coil ass-
embly with the wire and pillar bolt extending
out the rear cover, and take care not to dama-
7 1
1. Bolt ge the wire, and install three nuts and screw
2. Harness clip 9
6 down.
3. Magnet
4. Return spring Tightening torque: 8-11N·m
5. Shift guide shaft 8 • Encase the motor bearing and oil seal into the
rear cover.
5 12. The assembling of rear cover
4 Install the above finished cover assembly into the
transfer case housing, and the process is as follows:
(a) Install the return spring on the transfer shift guide
3
shaft.
10 (b) Install the magnet on the groove of the housing.
(c) Coat Loctite 598 with thickness of 1.6mm on the
2 junction plane of the housing, and pass by the
1
thread hole when coating and continue without
6. Rear cover assembly intermittence at the same time.
7. Sign panel Note: in the following steps, do not try to buckle
8. Odometer drive gear
9. Oil seal
the rear cover on the transfer case front housing
10. Transfer case front housing with too much force. When the alignment conditio-
ns required are met, the rear cover can be installed
on the front housing without too much force. If it
6 could not be installed, take down the rear cover
4
3
5 assembly and check the alignment conditions.
2 (d) When the rear cover assembly is installed on the
1
transfer case front housing, all the following align-
ment conditions must be met:
• Align the pin of the housing with the pin hole
of the rear cover.
• Align the rear output shaft with the inner bea-
ring of the rear cover hole.
1.Anchor pin • Align the inner blind hole of the rear cover with
2.Front output shaft the shift guide shaft, and ensure the return
3.Shift shaft
4.Return spring spring does not upwarp. Check the hole of the
5.Shift guide shaft speed sensor on the rear cover with a pen.
6.Output shaft
• Align the shift shaft with the rear cover inner
bearing.
(e) After putting the sign panel, screw down 9 bolts.

2 Tightening torque: 27-46N·m
1 (f) Encase the odometer drive gear into the rear cover
assembly through rear output shaft spline.
(g) Press new oil seal into the rear cover assembly.
3
4
1.Harness clip
2.Motor assembly
3.Bolt
4.Sign panel
13. Installing the outer electric shift parts (electric shift

1 transfer case)
For electric shift transfer case, the installing process is
as follows:
(a) Place the motor assembly, the triangular groove
on the motor will be in alignment with the shift
shaft.
1.Motor assembly
2.Shift shaft
(b) Move the motor to combine with the shift shaft

1 2 and make it joint tightly with the rear cover. Then
rotate the motor clockwise until it is in correct po-
sition and aligned with the installation hole.
7
(c) Install O ring on the speed sensor and encase the
3 speed sensor assembly into the rear cover. Install
5
4 the clip on the upper part of the speed sensor and
install three bolts.
(d) Install the bolt and shim at the clip end of the mo-
tor.
1.Sensor fixing bracket

2.Bolt
3.Speed sensor
4.O ring 5.Sensor assembly
6.Bolt
7.Motor assembly
8.Rear cover assembly
4 14. The assembling of the flange plate parts

2 The installing process of parts is as follows:
1 (a) Install two oil plugs on the rear cover.
5 (b) Encase the flange plate, seal ring, shim and tig-
htening nut.
1.Rear cover assembly

2.Flange plate
3.Oil seal
4.Shim
5.Nut
6.Oil plug
Drive shaft-1
Drive shaft
Cautions ............................................................................ 2
Components...................................................................... 3
Disassembly of drive shaft .............................................. 4
Installation of drive shaft ................................................. 4
Drive shaft-2
Cautions
Do not clamp the drive shaft bushing too tightened by
the bench vice to avoid the deformation.
Troubleshooting
failure Possible causes Method
The spline of universal-joint fork is Replace the universal-joint fork
worn
Noise The intermediate bearing is worn Replace the intermediate bearing
The cross-axle bearing is worn or Replace the cross-axle bearing
jammed
Runout of drive shaft Replace the drive shaft
Unbalance of drive shaft Replace the drive shaft
The rear bearing bushing of trans- Replace the bushing
vibration
mission extended housing is worn
The spline of universal-joint fork is Replace the universal-joint fork
jammed
Drive shaft-3
Components
Propeller shaft assembly (2WD)
universal-joint fork
front section of rear 63±5
axle propeller shaft
rear section assembly of
circlip rear axle propeller shaft
78±5
intermediate support assembly

nut
shim cross-axle assembly
Front axle propeller shaft (4WD) assembly
flange fork
circlip
cross-axle assembly
78±5 front axle drive shaft assembly
axle tube assembly

Rear axle propeller shaft (4WD) assembly
cross-axle assembly
78-5
drive shaft axle pipe assembly
N·m :specified torque circlip flange fork

Drive shaft-4
Disassembly of drive shaft

Remove the intermediate support bolt of drive shaft
firstly (CC6460KY is without intermediate support
connecting bolt ), then remove the connecting bolt bet-
ween the drive shaft and rear axle , lastly, pull out the
drive shaft assembly from the transmission output spli-
ne shaft and remove it in integral.
transmission Installation of drive shaft

rear axle assembly
1. Firstly, check the drive shaft for damage, spline for
drive shaft assembly corrosion and connecting surface for deficiency of
damage or sand hole by itself.
2. Install the connecting spline bushing of drive shaft
on the transmission output spline shaft carefully;
then install the drive shaft intermediate support on
the intermediate support bracket of carriage.
3. Use the special drive shaft bolt, nut and spring

front axle drive shaft assembly shim to connect the drive shaft to the vehicle axle
rear axle assembly ring flange and tighten it.
Tightening torque: 78±5N·m
4. Tighten the drive shaft intermediate support nut.
(the front and rear drive shaft in CC6460KY model
rear axle drive
transmission shaft assembly are the integral and has the installation content)
Tightening torque: 63±5N·m
transfer case
Suspension and axle-1
Suspension and axle
Front wheel alignment ..................................................... 3
Front hub and steering knuckle (2WD)........................... 7

Front hub ........................................................................... 8
Steering knuckle ............................................................... 12
Front suspension (2WD) .................................................. 15
Ball pin............................................................................... 16
Torsion bar spring ............................................................ 18
Lower suspension arm .................................................... 20
Upper suspension arm..................................................... 24
Stabilizer bar ..................................................................... 28
Front hub and steering knuckle (4WD)........................... 29

Front hub ........................................................................... 30
Steering knuckle ............................................................... 34
Front suspension (4WD) .................................................. 38
Ball pin............................................................................... 39
Torsion bar spring ............................................................ 41
Lower suspension arm .................................................... 43
Upper suspension arm..................................................... 47
Stabilizer bar ..................................................................... 51
(Front axle, model 05)
Constant-speed drive shaft assembly ............................ 52
Replacement of drive gear oil seal of front reducer
assembly ........................................................................... 63
Front reducer assembly ................................................... 67
(Rear axle, model 05)
Semiaxle assembly........................................................... 97
Reducer ............................................................................. 100
Differential ......................................................................... 111
(Front axle, model 08)
Constant-speed drive shaft assembly ............................ 113
Replacement of drive gear oil seal of front reducer
assembly ........................................................................... 124
Front reducer assembly ................................................... 128
(Rear axle, model 08)
Semiaxle assembly........................................................... 158
Reducer ............................................................................. 161
Differential ......................................................................... 172
Rear suspension............................................................... 174

Troubleshooting
Failure Cause Repair content
Floating/pulling The tyre is worn or charged improperly. Charge the tyre to the proper pressure
or replace the tyre.
The front wheel alignment is incorrect. Check the condition of front wheel align-
ment.
The wheel bearing is adjusted too tightened. Adjust the wheel bearing
The front /rear suspension components is loo- Tighten or replace the suspension part
se or damaged
The steering linkage is loose or worn Tighten or replace the steering linkage
The steering device is connected unsound or Adjust or replace the steering device
worn.
Subsidence of Overload of vehicle Check the load weight
vehicle body Vibration damper is worn Replace the vibration damper
Spring is weak Replace the spring
Left-right swing/ The tyre is charged improperly Charge the tyre to the proper pressure
up-down bounce The stabilizer bar is bend or damaged Replace the stabilizer bar
The vibration damper is worn Replace the vibration damper
Front wheel vi- The tyre is worn or is charged improperly Replace the tyre or charge it to the pro-
bration per pressure.
Unbalance of each wheel Balance all wheels
The vibration damper is worn Replace the vibration damper
The front wheel alignment is incorrect Check the condition of front wheel align-
ment
The wheel bearing is worn or adjusted badly Replace or adjust the wheel bearing
The ball joint or bushing is worn Check the ball joint or bushing
The steering system is loose or worn Tighten or replace the steering linkage
The steering mechanism is adjusted badly or Adjust or repair the steering device
damaged
Abnormal abra- The tyre is charged improperly Charge the tyre to the proper pressure
sion of tyre The vibration damper is worn Replace the vibration damper
The front wheel alignment is badly Check the condition of front wheel align-
ment
The suspension part is worn Replace the suspension part
Oil leakage of High oil level or incorrect oil grade Drain the oil to the specified level or re-
differential place the oil
The oil seal is worn or damaged Replace the oil seal
The matching flange is loose or damaged Tighten or replace the flange
The axle has the The oil grade is low or incorrect Fill with the lubrication oil or replace the
noise oil according to the specification
The clearance of the pinion, ring gear or side Check the clearance
gear is large.
The ring, pinion gear or side gear is worn or Check each gear
broken
The pinion gear bearing is worn Replace the bearing
The bearing of rear axle half shaft is worn. Replace the bearing
The differential bearing is loose or worn Tighten or replace the bearing
Front wheel alignment

1. Process the following inspection and eliminate all
problems
(a) Check the wear condition of tyre and proper infla-
tion.
Tyre inflation pressure: 230kPa
(b) Check the wheel bearing of front wheel for loose.
(c) Check the front suspension for loose.
(d) Check the steering drive device for loose.
(e) Process the standard elastic test; check thefron-
tvibration damper for normal operation.
2. Adjust the height of car

Adjust the height of car to the standard value for the-
convenience of processing the front wheel alignmen-
tinspection.
B: Front fixed bolt of lower suspension arm
The standard no-load height is: the center of front
fixed boltof lower suspension arm is 295±1mm
B away form theground.
3. Install the 4-Wheel alignment instrument

Processed according to the detailed description of
equipment manufacturer.
4. Adjust the wheel angle

A B B A Remove the cover of spacing bolt of steering knuckle;
check the internal wheel’s steering angle A.
Front Internal wheel’s steering angle: ≥ 32°
Caution: The wheel should not touch the brake
hose of car body when the steering wheel is rota-
ted to limit.
The wheel angle can be adjusted by spacing bolt of

steering knuckle is the Max. steering angle does not
consist with the standard value.
It should check and replace the damaged or worn stee-
ring mechanism parts if still can not adjust the wheel
angle to within standard value range.
5. Adjust the front wheel camber and kingpin castor

kingpin castor front wheel camber: 0°±30′
front wheel camber kingpin castor : 3°30′±45′
It can add or remove the shim on the upper arm for ad-
justment when the inclination is not within the specified
value.
Shim thickness: 3.0, 1.5, 0.5mm
The Varity of wheel camber will be 7′for adding 1mm of
shim, 20′for kingpin castor.
Adjust the difference of left and right kingpin castor
within 30′.
After the wheel camber and kingpin castor are adjus-
ted, if the kingpin inclination still not reach the specified
value, then check the steering knuckle and front wheel
for curve or loose.
Adjustment of right cam If the wheel camber or kingpin castor does not consist
with the specified value, it can be adjusted through the
rear adjusting cam shaft.
decreasing increaing
Adjustment of left cam
increasing
decreasing
6. Adjust the wheel toe

Adjust the wheel toe according to the following method
(a) Shake the car upwardly and downwardly to make
the suspension reach the stable status.
(b) Push the car forwardly for 5m in flat ground when
the front wheel is in the straight forward position.
(c) Mark the center of each rear wheel; measure the

B distance “B” between the marks of left and right
tyre.
Front
(d) Push the car forwardly to move the mark on the

back of tyre to the position of front instrument.
Move the vehicle forwardly Remarks: if the tyre moves too far, repeat the procedu-
re (b).
(e) Measure the distance “A” ‘between the marks on

A front of tyre.
(f) Measure the toe of wheel.
toe =B-A
Inspection standard: 0-2mm
If the toe does not consist with the specified value, it
can be adjusted by the left and right draw-bar.
(g) Adjustment of toe: the standard value is 0~2mm.

The toe is adjusted by rotating the cross draw-
bar. When adjust the toe, it should rotate the cross
draw-bar on left and right side uniformly. After the
adjustment, tighten the lock nut, the tightening tor-
que is 60±5N·m.
(h) Check the sideslip

Sideslip: Within ±5m/km
Front hub and steering knuckle (2WD)
stabilizer bar
◆spring shim
◆ 63±5 upper suspension arm 140 brake caliper assembly
flat shim
◆split pin
connecting rod
of stabilizer bar steering knuckle
tight nut
145±15
flat shim lower suspension arm lock washer
Compress the
bushing by 1/3
disk shim screw
◆split pin
fill block
shim
fill block
disk shim 230±20
◆ 63±5
absorber ◆spring shim
23
90±10 brake cover
◆oil seal
bearing
bearing
hub and brake disc
hub cap ★ 65

Front hub
Disassembly of front hub
1. Remove the disc brake
Remove the brake caliper and hang it by steel cable.
Remarks: Do not remove the brake pipe and brake
hose.
2. Remove the hub cap

Use the inner hexagon spanner to screw off the faste-
ning blot and remove the hub cap.
3. Remove the hub and brake disc

(a) Use the Philips screwdriver to screw off the lock
screw and remove the lock washer.
(b) Use the special tools to remove the lock nut.
special tools
(c) Remove the hub and brake disc with the external
bearing.
4. Remove the oil seal and inner bearing

(a) Use the screwdriver to pry out the oil seal.
(b) Remove the inner race of inner bearing from the
hub.
Check and repair of front hub

1. Check each bearing
Wash the inner and outer race of each bearing and
check them for damage or wear.
2. Replace the bearing outer race
(a) Use the brass bar and hand hammer to knock out
the bearing outer race.
(b) Use the special tools to knock in the new bearing

outer race.
special tools
diagram of
special tools
Assembly of front hub

1. Coat the inner surface of hub and bearing outer
race with the grease.
The grease is the Jin HP-R grease or the grease
grease met the requirement in following table.
Item Typical data
Dropping point,℃ 289
Leakage amount(104℃, 6h), g 0.48
EP performance OK value, N 178
grease 2. Place in the bearing inner race; use the fill the gap
between the inner and outer race of the bearing up
with the HP-R grease.
grease
3. Install the inner bearing and oil seal

diagram of special tools
(a) Place the inner bearing in the hub.
(b) Use the special tools to knock the new oil seal into
special tools
the hub.
(c) Coat the oil seal lip with HP-R grease.
4. Install the hub on the steering knuckle

(a) Install the hub on the steering knuckle.
(b) Install the external bearing.
5. Adjust the pre-applied load

diagram of special tools (a) Use the special tools to screw on the locknut to
specified torque.
Tightening force: 80-100N·m
(b) Rotate the hub to right and left 1/3 1/4 round res-
pectively.
(c) Screw off the nut until the nut can be loosed by
hand.
special tools
(d) Use the special tools to retighten the lock nut.
Tightening force: 28N·m
(e) Use the spring tension meter to check the pre-
applied load.
Pre-applied load (for starting): 28-56N
6. Install the lock washer

Install the lock washer with the surface with counterbo-
re outwardly and fix it on the lock nut by screw.
Remarks: If the screw installation hole on the lock was-
her can not align with the screw hole on the lock nut,
then it can remove the lock washer and adjust he lock
nut slightly (rotate in the direction of Min. adjusting ran-
ge ); then install the lock washer.
7. Recheck the pre-applied load

Use the spring tension meter to recheck the pre-
applied load.
If the pre-applied load does not meet the specified va-
lue, it must remove the lock washer and adjust it by the
adjusting nut.
8. Install the hub cap

(a) Coat the silicon rubber surface sealant on the ma-
tching surface of hub and hub cap.
(b) Coat the screw of the inner hexagon bolt with the
screw lock sealant.
(c) Use the inner hexagon bolt to fix the hub cap and
ring flange on the hub; tighten the bolt to the spe-
cified torque.
Tightening force: 45±5N·m
9. Install the disc brake

Install the disc brake on the steering knuckle and tig-
hten the bolt to the specified torque.
Steering knuckle
Disassembly of steering knuckle
1. Remove the disc brake and front hub
(Refer to section “Front Hub”)
2. Remove the brake cover
3. Disconnect the steering cross rod from the stee-

ring knuckle arm
(a) Remove the split pin and nut on the ball pin.
(b) Use the special tools to disconnect the steering
cross rod from the steering knuckle arm.
special tools
4. Disconnect the connecting rod of stabilizer bar

from lower arm
Use the inner hexagon spanner to fix the ball pin; re-
move the selflocking nut.
special tools 5. Remove the steering knuckle

(a) Remove the split pin and nut on the upper ball pin
knuckle from the upper ball pin.
(c) Remove the split pin and nut on the lower ball pin.
(d) Use the special tools to disconnect the steering
knuckle from the upper ball pin.
(e) Remove the steering knuckle.
special tools
Check and replacement of steering knuc-

kle
Use the dye penetrant to check the steering knuckle for
crack.
It should replace the steering knuckle if has crack.
Installation of steering knuckle

1. Install the steering knuckle
(a) Install the lower ball pin on the steering knuckle
and install the slotted nut temporarily.
(b) Press down the upper arm and connect the upper
ball pin to the steering knuckle. Install and tighten
the nut to the specified torque.
(c) Install the new split pin.
Remarks: It should align the notch of nut with the pin-
hole when install the split pin; the nut can be tightened
but not loosed during the alignment.
(d) Install and tighten the lower ball pin nut to speci-
fied torque.
(e) Install the new split pin.
2. Connect the stabilizer bar to the lower arm

Support the lower arm by jack; use the inner hexagon
spanner to fix the ball pin and tighten the self-locking
nut to specified torque.
3. Connect the steering cross rod to the steering

knuckle arm.
(a) Tighten the slotted nut according to the specified
torque.
(b) Install the new split pin.
4. Install the brake cover

5. Install the front hub and disc brake

(see section of front hub)
Front suspension (2WD)
175±20
Fixing bolt of the upper arm shaft
★upper arm shaft shim
upper arm bush

front stabilizer bar 210±10
178-235
upper arm bush
shim
upper arm
rubber cover
63±5
upper ball pin
clip
flat shim
23±3
78±10 ◆split pin torsion bar
lower arm long bush

connecting rod of stabilizer bar 140±10
145±15
rear shaft of lower arm
flat shim
290±30 torsion bar base
front shaft of lower arm
upper adjusting block
lower arm short bush
240±20
fixed arm
eccentric shim lower arm
Compress the lower adjusting block
bushing by 1/3 disk shim ◆ 63±5
fill block shim adjusting bolt
fill block disk shim lower ball pin
140±10
◆split pin
230±20
shock absorber
90±10
front wheel hub and
steering knuckle assy

Ball pin
Inspection of ball pin
1. Check the lower ball pin for loose

(a) Raise the front of the car by jack and support it by
the frame.
(b) Ensure the front wheel is in straight advancing po-
sition and step down the brake pedal.
(c) Move the arm upwardly and downwardly; check
the clearance of lower ball pin.
Max. vertical clearance: 0mm
2. Check the upper ball pin for loose;

move the wheel upwardly and downwardly and check
the gap of upper ball pin.
3. Check the rotation of ball pin

(a) Remove the ball pin.
(b) Shown as figure, shake the ball pin stud forwardly
and backwardly for several times before install the
nut.
(c) Rotate the nut continuously by torsion meter and
2-4s for a cycle; record the readout of torsion me-
ter in the fifth cycle.
lower ball pin 1-4N·m
upper ball pin 1-4N·m
Disassembly of ball pin
1. Take down the steering knuckle and front wheel
hub assy.
(Refer to section “Front Hub and Steering Knuckle”)
2. Remove the lower ball pin form the lower arm

3. Remove the upper ball pin from the upper arm.
Installation of ball pin

1. Install the upper ball pin on the upper arm
2. Install the lower ball pin on the lower arm

3. Install the steering knuckle and front hub assembly

(Refer to section Front Hub and Steering Knuckle)
Torsion bar spring

Disassembly of torsion bar spring
1. Use the jack to raise the carriage and support it by
bracket.
2. Make the assembly mark on the torsion bar spring,
bar base and adjusting arm.
3. Shown as figure, measure the length A of exten-

sion section of bolt.
A Remarks: The measuring value is for reference when
adjust the ground clearance of chassis.
4. Loose the adjusting bolt until the torsion bar has

not tension.
5. Remove the fixed arm and torsion bar spring
Installation of torsion bar spring

Caution: There are the L and R indication marks,
which must not be exchanged on the read end of
the torsion bar spring. Mark L means the left and R
for right.
1. For reused torsion bar spring

(a) Coat thin grease on the spline of torsion bar
spring.
(b) Align the assembly mark, install the torsion bar
spring on the torsion bar.
(c) Align the assembly mark; install the adjusting arm
onthtorsion bar spring.
(d) Tighten the adjusting bolt to make the extension

length of the bolt equal to the length before remo-
ve.
2. For new torsion bar spring

(a) Remove the wheel.
(b) Coat thin grease on the spline of the torsion bar
spring.
(c) Install the torsion bar spring on the torsion bar
base.
(d) Lower the lower arm to the lower limitation po-

sition; install the adjusting arm in the torsion bar
spring with the angle that the adjusting bolt just
can be screwed on the upper adjusting block.
(e) Tighten the adjusting bolt to the specified torque.
Nut tightening limitation: A is about 30-35mm; if A>
35mm, then it is adjusted through height of adjus-
ting arm.
(f) Install the wheel; remove the bracket; bounce the
vehicle for several times to make the suspension
enters into the stable status.
(g) Rotate the adjusting bolt and adjust the ground
clearance of chassis (Refer to 4-Wheel Align-
ment).
Lower suspension arm

Removal of lower suspension arm
from the lower arm
(a) Use the jack to support the lower arm.
(b) Remove the connecting nut; disconnect the con-
necting rod of stabilizer bar form the lower arm.
2. Disconnect the vibration damper from the lower

arm.
3. Disassembly of torsion bar spring

(Refer to Section “Torsion Bar Spring”)
4. Disassembly of front hub and steering knuckle as-

sembly
(Refer to “Front Hub and Steering Knuckle”)
special tools
5. Remove the front shaft of lower arm

(a) Make the mark on the adjusting cam.
(b) Remove the nut and front shaft of lower arm.
6. Remove the rear shaft of lower arm

Screw off the nut; remove the rear shaft of lower arm
shaft; remove the lower suspension arm.
Replacement of lower suspension arm

bush
1. Removal of short bush of lower suspension arm
Use the special tools to press the short bush from the
lower arm.
special tools
2. Installation of short bush of lower suspension arm

Use the special tools to press the new short bush in
the lower arm.
Remarks: Do not coat the bush with the grease.
special tools
3. Removal of long bush of lower suspension arm

Use the special tools to remove the long bush.
special tools
4. Installation of longbushoflowersuspensionarmUse
the special tools to install the new bush.
special tools
Installation of lower suspension arm

1. Installation of lower suspension arm
(a) Install the rear shaft of lower arm and tighten the
nut to the specified torque.
(b) Install the front shaft of lower arm and screw on
the nut temporarily.
2. Installation of front hub and steering knuckle ass-

embly
3. Install the vibration damper on the lower suspen-

sion arm.
Install the vibration damper on the lower suspensio-
narm bracket.
4. Connect the stabi lizerbar to the lower suspension

arm
5. Install the torsion bar spring

(Refer to “Torsion Bar Spring”)
6. Tighten the nut of front shaft of lower arm to speci-

fied torque
(a) Install the wheel, remove the bracket and bounce
the vehicle for several times to make the vibration
damper enters into the stable status.
(b) Align the assembly mark and tighten the nut to

specified torque.
7. Check the wheel alignment parameter

(Refer to 4-Wheel Alignment)
Upper suspension arm

special tools
Disassembly of upper suspension arm
1. Disconnect the upper ball pin from the steering
knuckle
Remove the split pin and nut; use the special tools to
disconnect the upper ball pin from the steering knuckle.
2. Remove the brake oil pipe on the upper arm shaft

(a) Use the open-end wrench to screw off the oil pipe
tight nut.
(b) Pull out the brake oil pipe and plug it by the rubber
plug.
Remarks: There are two two-way valves for rear brake
oil pipe beside the right upper arm shaft ; when remove
the right upper suspension arm, it must remove four
oil pipe tight nuts in the place and plug it by the rubber
plug to prevent the brake fluid from overflowing.
3. Disconnect the brake hose form the brake caliper
Remove the hollow bolt and disconnect the brake hose
form the brake caliper
Remarks: Must not lose the copper gasket seal.
4. Disconnect the brake hose from the upper arm oil

pipe bracket.
Use the pliers to pull out the sheet steel spring clip and
disconnect the brake hose from the upper arm oil pipe
bracket.
5. Remove the upper suspension arm

Remove two bolts and remove the upper suspension
from the arm carriage.
Remarks: Keep the adjusting shim and don’t lose it.
Record the thickness of front and rear adjusting shim
for convenience of reinstalling them in the original posi-
tion.
Replacement of upper arm bush

1. Remove the bush
(a) Remove the bolt and washer.
(b) Use the special tools to push out the bush.

(c) Remove the upper arm shaft; remove another
bush in same procedure
special tools
2. Install the bush

(a) Use the special tools to press in the bush.
special tools
(b) Install the upper arm shaft; use the special tools to
press inanother bush.
special tools
3. Tighten the upper arm shaft to specified torque.

(a) Coat the screw of both ends of upper arm shaft
。 with the screw lock sealant; install the washer and
90
nut.
Remarks: Adjust the position of upper lower; make the
installation plane of ball pin is vertical to the installation
plane of upper arm shaft.
(b) Tighten the upper arm shaft nut to specified tor-

que.
Installation of upper suspension arm

1. Install the upper suspension arm on the carriage
(a) Install the upper suspension arm and camber ad-
justing shim.
(b) Tighten all bolts to the specified torque.
Remarks: Install the shim with same quantity and thick-
ness to the original position.
2. Connect the brake oil pipe of upper arm shaft

Tighten the oil pipe compression nut to specified tor-
que.
Remarks: It should tighten four connector of two two-
way valves to the specified torque if disassemble the
right upper arm.
3. Connect thebrakehosetotheupperarmoilpipebrac-
ket
(a) Thread the brake hose from the hole on upper
arm oil pipe bracket.
(b) Use the hand hammer to knock in the sheet steel
spring clip to fix the brake hose.
4. Connect the upper ball pin to the steering knuckle

torque.
5. Connect the brake hose on the brake caliper.

Connect the copper gasket seal and tighten the hollow-
bolt to specified torque.
6. Discharge the air in front brake system

(refer to relevant chapter)
Remarks: It must discharge the air in the rear brake
system if disassemble the right upper arm.
7. Check the brake fluid for leakage
8. Tighten the upper arm front shaft nut to the speci-

fied torque
Install the wheel, remove the bracket and bounce the
vehicle for several times to make the vibration damper

Stabilizer bar
Disassembly of stabilizer bar
1. Disconnect the connecting bar which supports
both ends of the stabilizer bar fromm the stabilizer
bar.
2. Remove the bush and clip of stabilizer bar; remove

the stabilizer bar
Installation of stabilizer bar

1. Install the stabilizer bar on the carriage
Place the stabilizer bar in position; install the stabilizer
bar bush and clip on the carriage. Screw on and pretig-
hten the bolt.
2. Connect the stabilizer bar to the connecting bar

Installand tighten the new nut to the specified torque
3. Tighten the clip position bolt to specified torque.

Front hub and steering knuckle (4WD)
stabilizer bar
◆spring shim
◆ 63±5 140
disc brake
◆flat shim upper suspension arm
drive shaft
connecting rod ◆split pin
of stabilizer bar
◆oil seal
steering knuckle
flat shim 145±15
lock nut
Compress the
lower suspension arm
bushing by 1/3 screw
◆needle bearing
lock washer
disk shim
◆split pin
fill block lock washer
Shim
fill block
230±20
disk shim
◆ 63±5
shock absorber
◆spring shim
23
90±10
brake cover
bearing
◆oil seal
flange
bearing circlip
★ 78
hub and brake disc adjusting washer
hub cap

Front hub
Disassembly of front hub
1. Remove the disc brake
Remove the brake caliper and hang it by steel cable.
Remarks: Do not remove the brake pipe and brake
hose.
2. Remove the hub cap and flange

(a) Use the inner hexagon spanner to screw off the
fastening bolt and remove the hub cap.
(b) Use the pliers to remove the circlip and remove
the adjusting washer.
(c) Remove the flange.
3. Remove the hub and brake disc

(a) Use the Philips screwdriver to screw off the tight
screw; remove the lock washer.
(b) Use the special tools to remove the lock nut.

special tools
diagram of
special tools
(c) Remove the hub and brake disc with the outer
bearing.
4. Remove the oil seal and inner bearing

(a) Use the screwdriver to pry out the oil seal
(b) Remove the inner race of inner bearing form the
hub.
Check and repair of front hub

1. Check all bearings
Wash the inner race and outer race of each bearing
and check them for wear and damage.
2. Replace the bearing outer race

(a) Use the brass bar and hand hammer to knock out
the bearing outer race.
(b) Use the special tools to knock in the new bearing
special tools outer race.
diagram of special tools
Assembly of front hub

1. Coat the inner surface of hub and bearing outer
race with the grease.
The grease is the Jin HP-R grease or the grease
grease met the requirement in following table.
Item Typical data
Dropping point, ℃ 289
Leakage amount (104℃,6h), g 0.48
EP performance OK value, N 178
2. Place in the bearing inner race; use the fill the gap
grease
between the inner and outer race of the bearing up
with the HP-R grease.
grease
3. Install the inner bearing and oil seal

(a) Place the inner bearing in the hub
diagram of (b) Use the special tools to knock the new oil seal into
special tools special tools
the hub.
(c) Coat the oil seal lip with HP-R grease.
4. Install the hub on the steering knuckle

(a) Install the hub on the steering knuckle
(b) Install the outer bearing.
5. Adjust the pre-applied load

diagram of (a) Use the special tools to screw on the locknut to
special tools
specified torque.
(b) Rotate the hub to right and left 1/3 1/4 round res-
pectively.
(c) Screw off the nut until the nut can be loosed by
hand.
special tools (d) Use the special tools to retighten the lock nut.
Tightening force: 28N·m
(e) Use the spring tension meter to check the pre-
applied load.
6. Install the lock washer

Install the lock washer with the surface with counterbo-
re outwardly and fix it on the lock nut by screw.
Remarks: If the screw installation hole on the lock was-
her can not align with the screw hole on the lock nut,
then it can remove the lock washer and adjust he lock
nut slightly (rotate in the direction of Min. adjusting ran-
ge ); then install the lock washer.
7. Recheck the pre-applied load

Use the spring tension meter to recheck the pre-
applied load
If the pre-applied load does not meet the specified va-
lue, it must remove the lock washer and adjust it by the
adjusting nut.
8. Install the ring flange

(a) Install the ring flange on the hub.
(b) Install the adjusting washer.
(c) Install the circlip.
9. Install the hub cap

(a) Coat the screw of the inner hexagon bolt with the
screw lock sealant.
(b) Use the inner hexagon bolt to fix the hub cap and
ring flange on the hub; tighten the bolt to the spe-
cified torque.
10. Install the disc brake

Install the disc brake on the steering knuckle; tighten
the bolt to the specified torque.
Steering knuckle
Disassembly of steering knuckle
1. Remove the disc brake and front hub
2. Remove the brake cover
3. Disconnect the steering cross rod from the stee-

ring knuckle arm
(a) Remove the split pin and nut on the ball pin.
cross rod from the steering knuckle arm.
special tools

from lower arm
move the self-locking nut.
5. Remove the steering knuckle

(a) Remove the split pin and nut on the upper ball pin
special tools
(b) Use the special tools to disconnect the upper ball
pin from the steering knuckle.
(c) Remove the split pin and nut on the lower ball pin.
(d) Use the special tools to disconnect the upper ball
pin from the steering knuckle.
special tools
(e) Use the jack to raise the lower arm; remove the
steering knuckle.
Check and replacement of steering knuc-

kle
1. Check of steering knuckle
Use the dye penetrant to check the steering knuckle for
crack.
It should replace the steering knuckle if has crack.
2. Remove the steering knuckle oil seal

Use the screwdriver to pry out the oil seal from the
steering knuckle.
3. Take out the thrust plate
4. Remove the needle bearing

Use the copper bar and hand hammer to knock out the
needle bearing.
5. Installation of needle bearing

special tools Use the special tools and hand hammer to knock in the
new needle bearing slightly.
Remarks: The thicker end of needle bearing should be
upwardly when knock in. with thicker end.
6. Installation of thrust plate

Coat the installation position of thrust plate of steering
chamfer
knuckle with the HP-R grease; place the thrust plate
with the surface with chamfer facing the steering knuc-
kle.
Remarks: It must measure the thickness of the thrust
steering knuckle
plate before the installation; it should install the new
thrust plate if the thickness is less than 1.5mm. The no-
minal thickness of the new thrust plate is 2mm.
7. Installation of steering knuckle oil seal

Use the special tools and hand hammer to knock in the
special tools new steering knuckle oil seal slightly.
Installation of steering knuckle

1. Install the steering knuckle
(a) Coat the drive shaft and inner of drive shaft dus-
tproof cove with the lithium base grease.
(b) Insert the drive shaft into the steering knuckle,

meanwhile connect the lower ball pin to the stee-
ring knuckle and install the slotted nut temporarily.
(c) Press down the upper arm and connect the upper
ball pin to the steering knuckle. Install and tighten
the nut to the specified torque.
(d) Install the new split pin.
(e) Install and tighten the lower ball pin nut to speci-
fied torque.
(f) Install the new split pin.
2. Connect the stabilizer bar to the lower arm

Support the lower arm by jack; use the inner hexagon
spanner to fix the ball pin and tighten the self-locking
nut to specified torque.

knuckle arm
torque.
4. Install the brake cover

5. Install the front hub and disc brake
Front suspension (4WD)
★ upper arm shaft

shim
upper arm bush
front stabilizer bar 210±10

178-235
upper arm bush
shim
upper arm
rubber sleeve
63±5
clip
flat shim upper ball pin
23±3
78±10
torsion bar
lower arm long bush ◆split pin
connecting rod of stabilizer bar 140±10
145±15
rear shaft of lower arm
flat shim
Torsion base
290±30
upper adjusting block
front shaft of lower arm
lower arm short bush
240±20
fixed arm
eccentric shim
lower arm
Compress the lower adjusting block
bushing by 1/3 disk shim
◆ 63±5
fill block adjusting bolt
shim
fill block disk shim lower ball pin
140±10
◆split pin
230±20
shock absorber
90±10
front hub and steering knuckle assembly

Ball pin
Check of ball pin
1. Check the lower ball pin for loose
(a) Raise the front of the car by jack and support it by
the frame.
(b) Ensure the front wheel is in straight advancing po-
sition and step down the brake pedal.
(c) Move the arm upwardly and downwardly; check
the clearance of lower ball pin.
2. Check the upper ball pin for loose move the wheel
upwardly and downwardly and check the gap of
upper ball pin.
3. Check the rotation of ball pin

(a) Remove the ball pin.
(b) Shown as figure, shake the ball pin stud forwardly
and backwardly for several times before install the
nut
(c) Rotate the nut continuously by torsion meter and
2-4s for a cycle; record the readout of torsion me-
ter in the fifth cycle.
Lower ball pin 1-4N·m
Upper ball pin 1-4N·m
Disassembly of ball pin
1. Remove the steering knuckle and front hub assem-
bly
2. Remove the lower ball pin form the lower arm
3. Remove the upper ball pin from the upper arm

Installation of ball pin

1. Install the upper ball pin on the upper arm
2. Install the lower ball pin on the lower arm

3. Install the steering knuckle and front hub assembly

Torsion bar spring

1. Make the assembly mark on the torsion bar spring,
torsion base and adjusting arm
2. Measure the length A of extension section of bolt

according to the length shown in figure.
A Remarks: The measuring value is for reference when
adjust the ground clearance of chassis.
3. Loose the adjusting bolt until the torsion bar spring

has not the tension.
4. Remove the fixed arm and torsion bar spring
Installation of torsion bar spring

Remarks: There are the L and R indication marks,
which must not be exchanged on the rear end of
the torsion bar spring. Mark L means the left while
R for right
1. For reused torsion bar spring

(a) Cost the spline of torsion bar spring with grease
thin.
(b) Align the assembly mark and install the torsion bar
spring on the torsion bar.
(c) Align the assembly mark and install the adjusting
arm on the torsion bar spring.
(d) Tighten the adjusting bolt and make the extension

length of the bolt equal to the value before disass-
embly.
2. For new torsion bar spring

(a) Remove the wheel.
(b) Coat the spline of torsion bar spring with thin grea-
se.
(c) Install the torsion bar spring on the torsion bar
base.
(d) Lower the lower arm to the lower limitation po-

sition; install the adjusting arm in the torsion bar
spring with the angle that the adjusting bolt just
can be screwed on the upper adjusting block.
Remarks: It can repeat for several times until proper
when adjust the angle.
(e) Tighten the adjusting bolt to the specified torque.
Nut tightening limitation: A is about 20-35mm; if
A>35mm, then it is adjusted through height of ad-
justing arm.
(f) Install the wheel; remove the bracket; bounce the
vehicle for several times to make the suspension
(g) Rotate the adjusting bolt and adjust the ground
clearance of chassis (Refer to 4-Wheel Align-
ment).
Lower suspension arm

Disassembly of lower suspension arm
1. The disassembly of the front hub and steering
knuckle assembly includes the removal of vibration
damper, stabilizer bar and steering cross rod.
(Refer to the section “Front Hub and SteeringKnuckle”)
2. Disassembly of torsion bar spring

(Refer to section “Torsion Bar Spring”)
3. Remove the front shaft of lower arm

(a) Make the assembly mark on the adjusting cam
(b) Remove the nut and front shaft of lower arm.
4. Screw off the rear shaft of lower arm

Screw off the nut; remove the rear shaft of lower arm
shaft and remove the lower suspension arm.
Replacement of bush of lower suspen-

sion arm
1. Remove the short bush of lower suspension arm
Use the special tools to press out the short bush form
the lower arm.
special tools
2. Installation of short bush of lower suspension arm

Use the special tools to press the new short bush into
the lower arm
special tools
3. Removal of long bush of lower suspension arm

Use the special tools to remove the long bush.
special tools
4. Install of long bush of lower suspension arm

Use the special tools to install the new bush.
special tools
Installation of lower suspension arm

1. Installation of lower suspension arm
(a) Install the rear shaft of lower arm and tighten the
screw to the specified torque.
(b) Install the front shaft of lower arm and pretighten
the nut.
2. Installation of front hub and steering knuckle ass-

embly
(Refer to section “Front Hub andSteeringKnuckle”)
3. Install the vibration damper on the lower suspen-

sion arm
Install the vibration damper on the lower suspension
arm bracket.
4. Connect the stabi lizer barto the lower suspension

arm.

knuckle arm
(a) Connect the steering cross rod to the steering
knuckle arm.
6. Install the torsion bar spring

(Refer to the section “Torsion Bar Spring”)
7. Tighten the nut of front shaft of lower arm to the

specified torque
(b) Align the assembly mark and tighten the nut to the
specified torque.

Upper suspension arm

special tools
Disassembly of upper suspension arm
1. Disconnect the upper ball pin from the steering
knuckle
Remove the split pin and nut; use the special tools to
disconnect the upper ball pin from the steering knuckle.
2. Remove the brake oil pipe on the upper arm shaft

(a) Use the open-end wrench to screw off the oil pipe
tight nut.
(b) Pull out the brake oil pipe and plug it by the rubber
plug.
Remarks: There are two two-way valves for rear brake
oil pipe beside the right upper arm shaft ; when remove
the right upper suspension arm, it must remove four
oil pipe tight nuts in the place and plug it by the rubber
plug to prevent the brake fluid from overflowing.
3. Disconnect the brake hose from the brake caliper
Remove the hollow bolt and disconnect the brake hose
form the brake caliper
Remarks: Must not lose the copper gasket seal.
4. Disconnect the brake hose from the upper arm oil

pipe bracket.
Use the pliers to pull out the sheet steel spring clip and
disconnect the brake hose from the upper arm oil pipe
bracket.
5. Remove the upper suspension arm

Remove two bolts and remove the upper suspension
from the armcarriage.
Remarks: Keep the adjusting shim and don’t lose it.
Record the thickness of front and rear adjusting shim
for convenience of reinstalling them in the original posi-
tion.
Replacement of upper arm bush

1. Remove the bush
(a) Remove the bolt and washer.
(b) Use the special tools to push out the bush.

(c) Remove the upper arm shaft; remove another
bush in same procedure.
special tools
2. Install the bush

(a) Use the special tools to press in the bush.
special tools
(b) Install the upper arm shaft; use the special tools to
press in another bush.
special tools
3. Tighten the upper arm shaft to specified torque.

(a) Coat the screw of both ends of upper arm shaft
。 with the screw lock sealant; install the washer and
90
nut.
Remarks: Adjust the position of upper lower; make the
installation plane of ball pin is vertical to the installation
plane of upper arm shaft.
(b) Tighten the upper arm shaft nut to specified tor-

que.
Installation of upper suspension arm

1. Install the upper suspension arm on the carriage
(a) Install the upper suspension arm and camber ad-
justing shim.
(b) Tighten all bolts to the specified torque.
Remarks: Install the shim with same quantity and thick-
ness to the original position.
2. Connect the brake oil pipe of upper arm shaft

Tighten the oil pipe compression nut to specified tor-
que.
Remarks: It should tighten four connectors of two two-
way valves to the specified torque if disassemble the
right upper arm.
3. Connect the brake hose to the upper arm oil pipe

bracket
(a) Thread the brake hose through the hole on upper
arm oil pipe bracket.
(b) Insert the sheet steel spring clip by the hammer to
fix the brake hose.
4. Connect the upper ball pin to the steering knuckle.

torque.
5. Connect the brake hose to the brake caliper.

Install the copper gasket seal and tighten the hollow
bolt to the specified torque.
6. Discharge the air in front brake system

(Refer to relevant chapter)
Remarks: It must discharge the air in the rear brake
system if disassembly the right upper arm.
7. Check the brake fluid for leakage
8. Tighten the upper arm front shaft nut to the speci-

fied torque
(b) Align the assembly mark and tighten the nut to the
specified torque.

Stabilizer bar
Disassembly of stabilizer bar
1. Disconnect the connecting bar which supports
both ends of the stabilizer bar form the stabilizer
bar.
2. Remove the bush and clip of stabilizer bar; remove

the stabilizer bar
Installation of stabilizer bar

1. Install the stabilizer bar on the carriage
Place the stabilizer bar in position; install the stabilizer
bar bush and clip on the carriage. Align the mark on
the stabilizer bar to keep the left and right gap of stabi-
lizer bar are same. Then install the bolt temporarily and
pretighten it.
2. Connect the stabilizer bar to the connecting rod.

Install and tighten the new nut to the specified torque.
3. Tighten the clip position bolt to specified torque.

Suspension and axle(05)-52
Constant-speed drive shaft assembly

Installation and disassembly drawing of front drive shaft assembly on
front drive axle
constant-speed drive shaft assembly
90-110 ★
hanger plank-R
universal-joint oil seal
universal-joint bearing
circlip
front reducer and electric clutch assembly
circlip
Power plug of electric clutch
23-26
circlip
universal-joint oil seal lower segment of vent tube of front drive axle
circlip
hanger plank-L
★ 90-110
constant-speed drive shaft

200-220
200-220
200-220
200-220
Disassembly of constant-speed drive

shaft assembly
1. Place the car in the middle of repair platform or
trench, support the front of the car steadily(support
on the carriage) then remove the left and right front
wheel. (make the car in 2WD status before the di-
sassembly)
2. Remove the beam on the lower of front drive axle
assembly.
3. Disconnect the connection of front drive axle flan-
ge and drive shaft and make the assembly mark
4. Drain the lubrication oil in reducer.
5. Screw off the connecting bolt of front hub cover

and remove the front hub cover.
6. Use the circlip pliers to remove the circlip from the
adjusting washer set
drive shaft and remove the washer and steering
circlip knuckle of left and right end.
★bolt
(Refer to the “Disassembly of Steering Knuckle Assem-
bly”)
flange
front hub cover
7. Disconnect the power wire connector of electric

clutch.
8. Disconnect the connecting place of front drive axle
vent tube connector assembly and rubber tube in
left hanger plank of front drive axle.
disconnect three ports in this position

9. Use the wrench to screw off the bolt which fixes

the lower segment assembly of front drive axle
vent tube on the vent tube bracket.
wrench
10. Support the front drive axle by the jack; screw off
90-110 ★ the lifting bolt of hanger plank and carriage.
11. Remove the complete drive axle.
supporting position 12. Screw off the connecting bolt of hanger plank and
front drive axle assembly.
13. Pull out the left and right front drive shaft assembly
with the oil seal, hanger plank and bearing.
14. Use the circlip pliers to remove the outside circlip

of bearing.
circlip pliers
support the lower end
15. Use the special tools pull out the bearing.

16. Use the circlip pliers to remove the circlip on ano-
ther side of bearing.
hold Caution: During the disassembly, support the lo-
special tools wer end of drive shaft and prevent the drive shaft
from sliding out from the inner jacket, meanwhile,
shim it could not damage the inner and outer jacket.

inner trumpet connector
circlip
inner jacket
three-pin section assembly
large clip of inner jacket

small clip of outer jacket
outer jacket
small clip of inner jacket
large clip of outer jacket
outer trumpet connector
dustproof cover

shaft assembly
1. Check the front drive shaft assembly
(a) Check the inner trumpet connector; it could slide
in axial direction smoothly.
(b) Check the universal-joint position; it should be
without the clear clearance in radius direction.
(c) Check the inner and outer jacket for damage.
Caution: It should use the pad when clamp the
front drive shaft to avoid the damage of it.
2. Remove the large clip of inner jacket
Caution: Do not damage the inner and outer jacket
pliers
3. Disassembly of inner trumpet connector

(a) Make the assembly mark on the inner trumpet
assembly mark connector and three-pin section assembly.
Caution: remove the grease in the connector befo-
re make the mark and don’t make the mark by the
hard object such as punch.
(b) Remove the inner trumpet connector.
4. Disassembly of three-pin section assembly

(a) Use the circlip pliers to remove the circlip.
(b) Use the adz and hand hammer to make the as-
sembly mark on the shaft and three-pin section
assembly.
assembly mark
(c) Use the cooper bar and hand hammer to remove

the three-pin section.
Caution: Remove the cooper chip on the shaft or
three-pin section assembly if has.
5. Remove the inner jacket

(a) Use the pliers to disassemble the small clip of in-
ner jacket.
(b) Pull out the inner jacket.
Caution: Remove the grease in the jacket and
maintain the clean field.
6. Use the straight screwdriver to disassemble the

large and small clip of outer jacket.
7. Remove the outer jacket

Caution: Clean the protective jacket and remove
the grease on the outer trumpet connector. Do not
disassemble the outer trumpet connector.
8. Use the screwdriver and hand hammer to remove

the dustproof cover.
Assembly of constant-speed drive shaft

assembly
1. Use the hand hammer and screwdriver to install
the dustproof cover
Caution: The dustproof cover should be replaces
when it is deformed heavily.
2. Install the large clip of outer jacket, outer jacket

and small clip of outer jacket.
Caution: The outer jacket should be replaced when
it is damaged or aged heavily and warp the end of
the shaft with the plastic band and coat with small
grease before insert it.
3. Insert the small clip of inner jacket, inner jacket

and large clip of inner jacket.
Caution: The inner jacket should be replaced when
it is damaged or aged heavily.
4. Install the three-pin section assembly on the front

drive shaft.
(a) Let the end of three-pin section assembly with
with chamfer
chamfer faces the shaft inner direction.
Caution: The three-pin section assembly should be
replaced if its needle bearing position is damaged.
(b) Align the assembly mark made before disassem-

bly.
(c) Use the hand hammer and copper bar to install

the three-pin section assembly to the front drive
shaft.
(d) Use the circlip pliers to install the new circlip.
5. Install the outer jacket on the outer trumpet con-

nector.
Fill the jacket with the grease supplied with the jacket
before install the jacket.
(Recommend used grease is CAPLEX or KY1)
Grease using amount: About 110g
6. Install the inner trumpet connector on the front dri-

ve shaft
(a) Fill the inner trumpet connector and inner jacket
with the grease supplied with the jacket
(Recommend used grease is CAPLEX or KY1).
(b) Align the assembly mark made during disassem-

assembly mark
bly; covered with inner trumpet connector.
(c) Cover the inner jacket on the inner trumpet con-
nector.
7. Use the inner and outer jacket clip pliers to clamp

outer jacket clip
the inner and outer jacket.
inner jacket clip
(a) Use the special non-ear clip pliers to lock the large
clip of inner jacket.
non-ear clip pliers
(b) Use the nutcracker to lock the small clip of inner

jacket.
Caution: Ensure the large and small connecting
place of jacket is in the corresponding groove of
trumpet connector and shaft.
nutcracker
(c) Use the special pneumatic pliers to lock the large

special tools and small clip of outer jacket.
(d) Ensure the jacket of both sides does not be pro-

longed or shortened when the front drive shaft has
the standard length.
Standard length: 400.5mm
If only need to replace the outer components of front

drive shaft assembly on car, it can remove the left and
right steering knuckle of car, then disconnect the inner
trumpet connector of front drive shaft assembly, then
take out the three-pin section assembly and shaft from
the inner trumpet connector for replacement.
Installation of constant-speed drive shaft

assembly on front drive axle
1. Insert the hanger plank into the drive shaft, inser-
circlip pliers ted with oil seal; use the circlip pliers to install the
inner circlip.
Caution: It should replace the oil seal if damaged.

2. Use the special tools to knock bearing in slightly.

Caution: Support the lower end of the drive shaft
special tools
assembly when knock the bearing in. The lower
end must not slide out.
3. Use the circlip pliers to install the outer circlip on
the front drive shaft assembly.
4. Repeat the previous method to install the hanger
plank, oil seal, circlip, bearing and circlip on ano-
support the lower end ther end.
5. Insert the spline of connecting end of drive shaft
and reducer into the differential halfaxle gear spli-
ne hole of electric clutch and reducer slowly.
6. Drip 1-2 drop of screw lock agent on the middle of
screw of connecting bolt of hanger plank and redu-
cer.
7. Use the wrench to tighten the connecting bolt of

hanger plank and drive axle to specified torque.
specified torque : 90-110N·m
Caution: It should screw on all bolts before tig-
hten them, then tighten them in diagonal direction.
Check the hanger plank for levelness after tighte-
ned the bolt to the specified torque. Remove the
hanger plank and reinstall it if is not planished.
8. Install the vent tube connector assembly; connect
all ports to front drive axle.
(Refer to “Assembly of Front Reducer Assembly”)
9. Use the jack to support the complete drive axle;

assembly mark use the hanger plank to lift the drive axle and tig-
hten the lifting bolt to the specified torque; install
steering knuckle both sides and upper and lower
ball pin; connect the connecting port of front axle
vent tube assembly and carriage; reconnect the
connector of electric clutch.
Specified torque : 200-220N·m
Caution: Drip 1-2 drop of screw lock agent on the
middle front part of the lifting bolt
10. Use the bolt to connect the front drive axle flange
and drive shaft according to the mark mage before
disassembly and tighten it to the specified torque.
specified torque: 73-83N·m
11. Install the beam under the front drive axle. Tighten
the beam connecting bolt to the specified torque.
Replacement of drive gear oil seal of front reducer assembly
front reducer assembly
washer
bearing
spacer-drive bevel gear ◆oil seal
front reducer drive gear flange, main gear

flange and dustproof cover assembly
◆ Used component which can not be used any more ◆ 140-160
1. Support the front of car; remove the left and right

assembly mark front wheel and the beam under the reducer.
2. Drain the lubricant oil in the front reducer; remove
the left and right steering knuckle
3. Disconnect the front reducer assembly flange from
the drive shaft and use the jack to remove the front
drive axle
Caution: Make the assembly mark on the reducer
and drive shaft before separate them.
4. Remove the front differential assembly

Caution: Drain the oil in front differential before the
disassembly
5. Remove the drive gear flange and dustproof cover

assembly
(a) Use the hand hammer and chisel to loose the ri-
veted part on nut.
(b) Use the special tools to clamp the drive gear flan-
ge and remove the drive gear nut.
special tools
(c) Use the cooper bar to knock down the drive gear
flange and dustproof cover assembly.
6. Remove the drive gear oil seal

Use the special tools to remove the oil seal; do not da-
mage the inner wall of reducer housing.
special tools
rotate the wrench in clockwise
7. Install the new drive gear oil seal

(a) Use the special tools to knock into the new oil
special tools seal.
(b) The top of the oil seal is level to the top of reducer
housing.
Caution: Coat the oil seal lip with the lithium base
grease and the oil seal should be in correct posi-
tion.
8. Install the drive gear flange and dustproof cover

assembly
(a) Match the drive gear flange and dustproof cover
assembly on the front drive gear.
(b) Coat the new nut with the lithium base grease.
(c) Use the special tools to clamp the flange and tig-
hten the nut to the specified torque.
Tighten torque:140-160N·m
9. Adjust the pre-applied load of the drive bevel gear

bearing
(a) Use the torque meter to measure the pre-applied
load of the gap between the drive bevel gear and
driven bevel gear.
pre-applied load: 1.2-1.7N·m
(b) Is should be replaced by the thicker washer if the
pre-applied load is more than specified value
The step of thickness of washer is 0.03mm
(c) Is should be replaced by the thinner washer if the
pre-applied load is less than specified value. Re-
peat the previous operation until meet the require-
ment.
33mm Caution: Do not reduce the load by loosing the nut.
10. Check the axial and radial run-out tolerance of flan-
ge.
(a) Use the dial indicator to measure the axial runout
of flange.
Max. axial runout: 0.1mm
(b) The max. radial run-out tolerance is 0.1mm

It should check the bearing if the radial run-out toleran-
ce is large.
11. Rivet the drive gear nut after meet the previous re-
quirements.
12. Install the reducer assembly on the front drive axle
assembly and assemble the front drive shaft ass-
embly
(refer to Assembly of Front Reducer Assembly and As-
sembly of Front Drive Shaft Assembly)
13. Install the oil drain plug; screw off the oil filling
plug and filled with the hypoid gear oil.
Tightening force of oil drain plug: 30-35N·m
Model of lubrication oil: GL-5
Filling amount: Flush to the lower edge of oil filling
open
14. Insert the oil filling plug washer and tighten the oil
filling plug to the specified torque.
15. Install the front drive axle assembly on the carria-

ge.
16. Connect the drive shaft to the flange
(a) Align the assembly mark; use four bolts and nuts
to connect the flange of drive shaft and front drive
axle.
(b) Tighten the nut to the specified torque.
Remarks: Keep the clean of the field during the mainte-
nance.
Front reducer assembly
front drive shaft assembly
★ 90-110
hanger plank-R
oil seal-front vibration damper
bearing-front vibration damper

circlip
circlip
23-26
circlip
front drive axle vent tube connector assembly

circlip
hanger plank-L
★ 90-110

1. Support the front of the car; remove two front whe-

assembly mark els and the beam under the front reducer assembly.
2. Drain the lubrication oil in the front reducer assem-
bly.
3. Remove the flange of front reducer assembly from
the drive shaft
Caution: Make the assembly mark on the flange of
front reducer assembly and drive shaft before dis-
connect them.
4. Disconnect the connector of power wire of electric
clutch
5. Disconnect three rubber connectors on the front
drive axle vent tube connector assembly.
disconnect three connectors in this place
6. Use the wrench to screw off the bolt on the vent

tube bracket, which is used to fix the vent tube
connector.
wrench
7. Disconnect the connection between the front drive

shaft assembly and steering knuckle front hub ass-
embly.
(a) Screw off the connecting bolt which is used to fix
the front hub cover; remove the front hub cover.
(b) Use the circlip pliers to remove the circlip from the
front drive shaft and remove the adjusting washer.
(c) Remove the steering knuckle of both sides and
separate it from the front drive shaft assembly.
200-220 200-220
electric clutch connector
8. Use the jack to support the front reducer assembly

9. Remove the lifting bolt of front drive axle hanger
plank and carriage.
10. Remove the front drive axle assembly
Caution: Do not damage the drive shaft and front
drive shaft jacket
11. Remove the front drive shaft assembly of both
sides from the front drive axle assembly.
12. Use the wrench to remove the bolt and nut which is
used to fix the front reducer housing.
13. Remove the clump weight assembly and clump

weight bracket welded assembly
(Refer to “Disassembly of Front Reducer Assembly”)
Replacement of oil seal and major semiaxle oil seal of front reducer ass-
embly
Replacement of front reducer assembly oil seal

(Refer to “Removal of Front Reducer Assembly”)
2. Remove the left and right front drive shaft assem-
bly from the front drive axle assembly.
3. Remove and replace the lower oil seal according to
the removal and installation procedure of front dri-
ve shaft assembly and install the new side oil seal
on the front drive shaft, then install them in the
front reducer assembly.
(Refer to “Removal and Installation of Front Drive Shaft
Assembly”)
90-110 ★
23-26
major semiaxle oil seal

circlip
major semiaxle pressing assembly
mechanical wheel of separator

Replacement of major semiaxle oil seal

1. Make the electric clutch is in the 4WD status, then
stop the engine and remove the front drive axle as-
sembly
(see the disassembly of front reducer assembly)
2. Use the wrench to screw off the bolt which fix the
front axle vent tube connector assembly on vent
wrench tube bracket bolt
3. Disconnect the connector between vent tube of

disconnect the place electric clutch housing and front drive axle vent
tube connector assembly
4. Disconnect the connector between the vent tubes

on the electric clutch and vent tube connector ass-
embly.
5. Remove the bolt which is used to fix the electric
clutch housing and front axle tube flange; use the
brass bar to open the electric clutch housing and
take out the mechanical wheel of separator.
disconnect the place Caution: The lubrication oil will flow out when se-
parate the electric clutch housing from the front
axle flange. It should use the container to hold it.

6. Use the circlip pliers to remove the circlip which

circlip clamp the major semiaxle bearing outer race.
circlip pliers
liftout bolt (3 units)
Pad
bolt pin (2 units)

special tools
7. Use the special tools to remove the major semiaxle

and bearing, circlip assembly.

oil seal.
Caution: Do not scratch the inner surface of flange.
special tools
9. Remove the sealant on the matching surface bet-

ween the flange and electric clutch housing by kni-
fe.
Caution: Do not scratch the matching surface.
10. Use the special tools to knock the new seal in the
oil seal position in flange.
Caution: Before install the new oil seal, it should
coat the lip with thin lithium base grease, and the
oil seal should be in alignment position.
special tools
11. Insert the spline of small end of major semiaxle in

the spline of front reducer half axle gear slightly,
then use the brass bar and hand hammer to knock
it in.
Caution: When knock in the major semiaxle, must
not damage the inside needle bearing of large end
spline of major semiaxle.
12. Use the circlip pliers to install the circlip in the flan-
ge and clamp the bearing outer race.
Caution: The circlip should be replaced if it has se-
rious deformation.
circlip pliers
13. Use the clean cloth to wipe the matching surface of

flange and electric clutch housing respectively.
14. Align the spline of mechanical wheel of separator

with the spline in front drive shaft and separator
shift fork sleeve, and install it in the front drive
shaft and separator shift fork sleeve.
15. Coat the flange matching surface with the 1596 si-
licon rubber plane sealant uniformly and level it by
plate.
Caution: Ensure the continuity of sealant and avoid
the sealant enter into the screw hole.
16. Align the shift fork bush with the spline on the
major semiaxle to make the mechanical wheel of
separator enters into the major semiaxle, then use
the bolt to connect the electric clutch housing and
front axle pipe flange and tighten it to the specified
torque. In which the bolt should be precoated with
the screw locking agent (drip one or two drops on
the middle of screw).
Caution: Prevent the foreign material from entering
into the front drive axle during assembly.
17. Use the wrench to tighten the bolt of vent tube
bracket to tightening torque.
18. Screw off the oil filling plug on the electric clutch
housing, remove the washer and fill it with the gear
lubrication oil until flush with the bottom of oil fi-
lling port.
Number of lubrication oil: GL-5
19. Place the washer of oil filling plug, tighten the oil
filling plug to specified torque.
Specified torque: 140-150N·m
20. Connect the vent tube on the electric clutch

housing to the front axle vent tube connector ass-
connect the place
embly.
21. Connect the electric clutch vent tube to the front
axle vent tube connector assembly.
connect the place

Disassembly and assembly of front reducer assembly and electric clutch
adjusting shim
90-115 bearing
bearing gland
★ 80-95
differential housing
pin half axle gear thrust plate
driven bevel gear half axle gear
planetary gear shaft
planetary gear
clump weight and bush assembly

bolt-clump weight bracket
front drive axle housing
★ 18-25
washer
oil filling plug clump weight bracket welded assembly
vent tube
clip
spacer-drive bevel gear
front reducer housing
adjusting washer
front drive gear flange and dustproof cover assembly
30-35
oil seal
★ 90-110
◆ 140-200
small bearing
★
front axle vents tube
23-26
connector assembly major semiaxle oil seal
major semiaxle circlip
bearing
electric clutch
needle bearing
circlip
location pin
drive bevel gear
oil filling plug big bearing
vent tube washer
adjusting washer
electric clutch housing
★ 23-26
declutch shift sleeve
disconnected in this place Disassembly of front reducer assembly

1. Remove the front drive axle and left and right front
drive shaft assembly.
disconnected in this place (Refer to “Removal of Front Reducer Assembly” and
“Removal of Front Drive Shaft Assembly”)
2. Disconnect three interface positions of front drive
disconnected in this place
3. Use the flat screwdriver to pry off the clip fixed the
vent tube connector assembly and take out the
vent tube connector assembly.
4. Screw off the bolt fixed the electric clutch and use
the brass bar to knock down the electric clutch.
5. Use the wrench to remove the oil filling plug; remo-

ve the washer and pull out the vent tube.
6. Use the wrench to remove the bolt connected to

the electric clutch housing and front axle tubeflan-
ge; take out the shift fork sleeve and mechanical
wheel of separator.
Caution: The leaked gear oil during disassembly
should be stored in the container to avoid the po-
llution for environment.
7. Use the circlip pliers to remove the circlip fixed the

major semiaxle bearing outer race.
8. Use the special tools to pull out the major semiaxle
and major semiaxle bearing with the major se-
miaxle inner race circlip.
(Refer to “Replacement of Major Semiaxle Oil Seal”)
oil seal.
10. Pull out the vent tube on the front axle tube.
11. Use the circlip pliers to remove the circlip. Fasten
the major semiaxle bearing inner race.
12. Press out the major semiaxle bearing on press ma-

chine. (Or knocked out by hand hammer)
Caution: Don’t damage the end spline of major se-
miaxle.
special tools
13. Use the special tools to pull out the needle bearing
in major semiaxle.
Caution: It should use the pad when use the vise to
clamp the major semiaxle.
14. Use the wrench to remove the bolt which is used to

fix the clump weight and axle bush assembly, take
off the clump weight and axle bush assembly.
15. Use the wrench to remove the bolt fixed the clump
weight bracket welded assembly.
16. Use the wrench to remove the bolt and nut used
to fix the front reducer assembly and front axle
housing.
17. Use the brass rod or hand hammer to knock the

front reducer housing to separate it from the front
drive axle housing.
18. Check the run-out of driven bevel gear.

Rotate the flange; use the dial indicator to measure the
run-out of driven bel gear.
Max. Runout: 0.07mm
It should replace the drive and driven bevel gear totally
if the run-out is more than 0.07mm.
19. Check the running clearance of drive and driven

bevel gear.
(a) Install the dial indicator and ensure the side axis is
vertical to contact tooth surface.
(b) Hold the drive gear flange and rotate the driven
bevel gear in clockwise and anticlockwise to mea-
sure the clearance.
Specified range of clearance: 0.15-0.25mm
Remarks: Check three average points on circumferen-
ce of driven bevel gear at least.
20. Check the engaging mark of drive and driven bevel

gear.
21. Measure the pre-applied load of drive bevel gear

bearing.
Use the torque measuring meter to measure the pre-
applied load on the gap between the drive and driven
bevel gear.
Range of pre-applied load: 1.2-1.7N·m
22. Measure the total pre-applied load of drive bevel
gear.

assembly.
veted part of drive gear nut.
(c) Use the brass rod to knock down the drive gear
24. Use the special tools to remove the drive gear oil
seal.
holding
special tools
pliers
25. Use the special tools to remove the small bearing

inner race, and then reverse the reducer to slide
out the spacer.
Remarks: The bearing should be replaced by new one
special tools
if damaged.
26. Use the wrench to remove two bearing glands.

Remarks: It should distinguish the left and right of the
bearing gland when remove it to avoid the confusion.
27. Use the brass rod to vibrate the differential assem-
bly upwardly, then take out the differential assem-
bly.
28. Remove the side bearing outer race and marked

with L and R.
left (L)
right (R)
29. Remove the left and right adjusting washer; mea-

sure its thickness; marked with left and right.
30. Remove the drive bevel gear, then take out the ad-
justing washer under spacer.
Check and replacement of reducer

1. Replace the big bearing of drive bevel gear.
(a) Use the special tools to press out the big bearing
of drive bevel gear.
Caution: It should replace the drive and driven be-
vel gear in pair before replace the big bearing if the
special tools
drive bevel gear is damaged.
(b) Install the washer on the drive bevel gear, Use the
special tools to install the new big bearing .
special tools
2. Replace the big bearing outer race of drive bevel

gear.
(a) Use the brass bar and hand hammer to knock
down the big bearing outer race.
(b) Use the special tools to press in the new big bea-
ring outer race.
special tools
3. Replace the small bearing of drive bevel gear.

(a) Use the brass rod and hand hammer to knock
down the small bearing outer race of drive bevel
gear.
(b) Use the special tools to press in the new bearing

outer race.
special tools
(c) Replace it by the new bearing inner race when
installs the small bearing..
4. Remove two side bearing inner races from the di-

fferential housing.
(a) Use the special tools to remove the side bearing
inner race on the side of differential assembly with
bolt.
(b) It should pay attention to does not damage the dri-
ven bevel gear when use the vice for clamping to
rubber pad remove the bearing inner race on another side.
5. Use the wrench to remove the bolt fastened the dri-

ven bevel gear
Caution: It should make the assembly mark on the
driven bevel gear and differential housing before
disassembly.
assembly mark
rubber pad
6. Disassembly of differential assembly

special tools
(a) Use the hand hammer and special tools to knock
out the pin after remove the driven bevel gear.
(b) Knock out the planetary gear shaft, rotate the half
axle gear to take out the planetary gear, then take
out the half axle gear and thrust plate.
7. Assembly of differential assembly.

(a) Wash the differential housing.
(b) Cover the half axle gear thrust plate with the half
axle gear, then installs it in the differential housing.
(c) Rotate the half axle gear; install the planetary gear
in rolling and insert the planetary gear shaft.
(d) Check the clearance between the half axle gear

thrust plate and differential housing.
Remarks: The rotation of half axle gear and planetary
gear should be smooth and without block; push the
planetary gear to inside, then use the dial indicator
to measure the clearance between the half axle gear
Rational clearance range: 0.4-0.75mm
It is necessary to replace the half axle gear thrust plate
if the clearance is beyond the previous range, at the
same time ensure the thrust plate in left and right side
has the same thickness.
(e) Use the special tools to hit the pin to fix the plane-
tary gear shaft, and rivet the inserted hole to pre-
vent the loose of pin.
special tools
(f) Clean the surface of differential housing; use the

brass rod to install the driven bevel gear on the
differential housing.
Caution: It should align the marked assembly mark
when install the driven bevel gear and knock it in
uniformly in circumference; it should remove the
cooper chip in time if it is adhered on the driven
bevel gear.
(g) Coat the fastening bolt of driven bevel gear with

the screw lock agent, then tighten it to the speci-
fied torque.
Specified tightening force: 80-95N·m
Caution: It should be in the diagonal sequence to
tighten the bolt and tighten it for little, then tighten
it to the specified torque uniformly.
(h) On press machine, use the special tools to press

the inner race of bearing into the bearing position
special tools
on both sides of differential housing.
special tools
(i) Place an adjusting shim in the position of front re-

bearing bearing ducer housing side bearing near exterior.
(j) Install another adjusting shim and the other side
bearing outer race in the front reducer housing
adjusting shim adjusting shim
with the differential assembly
(k) Install two bearing glands, left and right and use
the wrench to tighten the bolt to the specified tor-
que.
(l) Rotate the driven bevel gear, check the runout of

driven bevel gear.
Max. Runout: 0.07mm
Assembly of front reducer assembly

1. Install the adjusting washer in the drive bevel gear,
install the big bearing inner race of drive bevel gear
by press.
2. Clean the front reducer housing, install the outer
race of big and small bearing on the reducer
housing by press..
3. Install the drive bevel gear into the front reducer
housing, then install the washer, spacer and small
bearing inner race.
4. Use the special tools to install the drive bevel gear
oil seal.
special tools Caution: It should coat the lip with the oil seal li-
thium base grease before install it and the rear
surface of rear oil seal should flush with the top of
front reducer housing after knocked in.
assembly.
(Refer to “Replacement of Drive Bevel Gear Oil Seal”)
6. Use the special tools to tighten the drive gear nut

to the specified torque; the nut should be precoa-
ted with the lithium base grease.
7. Use the torque measuring meter to measure the

pre-applied load of big and small bearing of drive
bevel gear.
8. Place the differential assembly on the correspon-

ding position of front reducer housing.
9. Select an adjusting shim and insert it in a side of

side bearing outer race; push the differential ass-
embly to the side with adjusting shim.
10. Use the dial indicator to measure the gear side

clearance of driven bevel gear and drive bevel
gear; select out the adjusting shim in the side whi-
ch meets the rational clearance of 0.15mm.
11. Measure the thickness of the adjusting shim.
12. After select out one side adjusting shim, then se-
L1
lect theadjusting of another side according to that
L2
the theoreticthickness of the adjusting shimofa-
nother side equals to subtracting the thickness of
selected shim and oppositiondistance L2 between
outer race of two side bearings of differential as-
sembly from the opposition distance L1 between
two side bearings of front reducer housing.
13. Place an adjusting shim in the position of front re-

ducer housing side bearing and close to exterior.
14. Install the other adjusting shim and the bearing
outer race of another side with the differential ass-
embly into the front reducer housing.
Remarks: Ensure the selected adjusting shim has not
gap with front reducer housing.
15. Rotate the driven bevel gear to make the differen-

tial assembly closed to the front reducer housing.
16. Use the dial indicator to measure the tooth side
gap between the drive and driven bevel gear.
The rational range of gap is: 0.15-0.25mm.
If the measured gap is beyond the range, then adjust
it by adding or reducing the thickness of shim. (When
add in one side, the other side should be reduced with
same thickness)
Caution: Ensure the selected adjusting shim is
without clearance form front reducer housing.
17. Adjust the pre-applled axial load of side bearing.
(a) Remove two adjusting shim, remeasure the thick-
ness of two adjusting shims.
(b) Install the new adjusting shim with thickness
0.06-0.09mm more than that of removed adjusting
shim, then install it with the differential in the redu-
cer housing.
(c) Remeasure the tooth side clearance between the

drive bevel gear and driven bevel gear.
Rational range of clearance: 0.15-0.25mm
Remarks: If the measured gap is beyond the range,
then adjust it by adding or reducing the thickness of
shim. ( When add in one side, the other side should be
reduced with same thickness)
Caution: Ensure the selected adjusting shim has
not the clearance with the front reducer housing.
18. Install the bearing gland of both sides and use the
wrench to tighten it to the specified torque.
Remarks: Distinguish the left and right during assem-
bly.
19. Use the torque measuring meter to measure the to-

tal pre-applied load of front reducer.
specified torque : 1.8-2.4N·m
20. Check the meshing mark of drive and driven bevel

gear.
(a) Paint 3-4 teeth with the red lead in three different
positions of driven bevel gear.
(b) Hold the flange of drive gear; rotate the driven be-
vel gear in clockwise and anticlockwise.
(c) Check the contacting condition of gear tooth.

If the meshing mark of drive and driven bevel gear
1
4 5
4 does not consist with that shown in figure, it should se-
18～ 22
25 15～ lect the proper adjusting washer for modification accor-
5
1.2 ding to the detailed form of meshing mark.
convex of driven concave of driven bevel
large end contact

toe contact
select the adjusting washer which can make

the drive gear close to the driven bevel gear
small end contact

dedendum contact
sound contact

the drive gear away form the driven bevel gear
(d) Remove the drive bevel gear and use the special
tools to remove the large bearing of drive bevel
gear before replace the adjusting washer.
special tools
(e) Insert the new adjusting washer and use the spe-
cial tools to press in the large bearing of drive be-
vel gear.
(f) Place the adjusting washer above the large bea-
ring on the drive bevel gear, install the spacer in
the reducer housing; install the drive gear flange
andtighten the nut to the specified torque.
(g) Remeasure the pre-applied load of drive gear
bearing clearance and the total pre-applied load of
reducer; ensure it meets the requirement.
21. Use the dial indicator to measure the axial and ra-
33mm dial run-out tolerance of . Drive bevel gear flange.
Max. Axial runout : 0.1mm
Max. Radial run-out tolerance: 0.1mm

Remarks: It should check the big and small bearing of
drive bevel gear when the runout is more than 0.1mm.
22. Rivet the nut of drive bevel gear.

23. Use the bolt coated with screw lock agent tocon-
nect the clump weight bracket welded assembly to
the front reducer housing and tighten it to the spe-
cified torque.
24. Use the bolt coated with screw lock agent to con-
nect the clump weight assembly to the clump weig-
ht bracket assembly and tighten it to the specified
torque.
The amount of screw lock agent could cover the screw.
25. Use the pneumaticto screw two studs on the co-

rresponding screw hole on the front axle housing
until the limitation. (It should coat the screw of the
stud which is screwed in the front axle housing
with the screw lock agent, and the amount should
be just can cover the screw which is screw in the
front axle housing)
Caution: The position of stud should consist with
that before disassembly.
26. Coat the plane of front axle housing with the conti-
nuous 1596 silicon rubber plane sealant, scrape it
to level by plate.
Caution: Avoid the screw hole when paint the sea-
lant; prevent the sealant enters into the screw hole.
27. Install the front reducer assembly on the front drive
axle housing and screw on the hexagon bolt and
spring washer combination; cap the spring washer
on the stud, tighten the nut to the specified torque.
(The screw of all bolts should be precoated with
screw lock agent)
The specified tightening force of hexagon bolt and
spring washer combination, stud and nut should
be: 18-25N·m
Caution: The bolt should be tightened in diagonal
sequence evenly; check the reducer housing and
axle housing contacting surface for gap; check the
sealant from break. It should remove the reducer
for reinstallation if has the gap or break.
28. Screw the oil filling plug with washer on the front
drive axle.
Caution: Do not tighten it.
29. Screw the oil drain plug on the front drive axle.
30. Use the special tools to install the major semiaxle

oil seal in the front axle tube.
Caution: Precoat the lip of oil seal with thin lithium
base grease and the oil seal should be installed in
position.
31. Use the special tools to install the needle bearing

in the major semiaxle.
special tools

bearing by press.
special tools
33. Use the circlip pliers to install the circlip to clamp
the bearing inner race of major semiaxle.
special tools
34. Insert the spline on small end of major semiaxle

into the spline of front reducer half axle gear; use
the brass rod and hand hammer to knock the major
semiaxle into the front reducer.
Caution: Does not damage the inside needle bea-
ring. On spline of large end of major semiaxle when
knock in the major semiaxle.
35. Use the circlip pliers to install the circlip in the

flange and clamp the major semiaxle bearing outer
race.
36. Push the mechanical wheel of separator into the

needle bearing inner race in major semiaxle until
can not move.
37. Detect the electric clutch assembly .

(a) Measure the clearance between the shift fork and
shift fork sleeve.
Range of clearance : 0.2-0.4mm
It should replace the electric clutch assembly and shift
fork sleeve when the clearance is not in the range.
(b) Connect the electric clutch assembly to the elec-
tric clutch detector and power the electric clutch
detector with 220V power supply to test the elec-
tric clutch (Before the test, adjustthe test controller
status to make the motor starting time is 3s ,the
time form found the actuator is not in position to
restarting is 2.5s and the time of controller to redri-
ve the electric clutch is 2s) The motor starts for 3s
when the gear switch is shifted form 2WD to 4WD,
the lamp flashes at the same time, the clutch is
electric clutch detector in 4WD status, the indicator lamp is light always.
If does not reach the 4WD status in the first time,
then the controller restarts it for 2s after 2.5s de-
lay, the lamp flashes at the same time; if it is still
not in position, then the indicator lamp flashes
twice continuously, the indicator lamp is extinguis-
hed for 1s, the motor is stopped. That means the
electric clutch is unqualified and should be repla-
ced by the qualified product. The motor starts for
3s normally when the clutch is shifted form 4WD
to 2WD, the lamp flashes at the same time, when
the clutch is in 2WD status, the indicator lamp is
extinguished always. If does not reach the 2WD
status in the first time, then the controller restarts
it for 2s after 2.5s delay, the lamp flashes at the
same time; if it is still not in 2WD status, then the
indicator lamp flashes twice continuously, the indi-
cator lamp is extinguished for 1s, the motor is sto-
pped. That means the electric clutch is unqualified
and should be replaced by the qualified product.
38. Cover the shift fork sleeve on the major semiaxle

spline.
39. Install the separator housing on the front axle tube
flange and use the bolt to tighten it to the speci-
fied torque (The bolt should be precoated with the
screw lock agent and the amount should be just
can cover the complete screw)
Caution: Before installation, remove the foreign
material on two matching surfaces of separator
housing and front axle tube flange; and precoat the
1596 silicon rubber plane sealant on the front axle
tube flange. Caution: Prevent the sealant from en-
tering into the screw hole.
40. Press in the plastic vent tube on the electric clutch

housing and front axle tube.
41. Install two location pins in the location pin hole of
electric clutch housing respectively.
42. Coat the connecting surface of electric clutch
housing and electric clutch with 1596 silicon rub-
ber sealant uniformly; level it by plate.
Caution: The connecting surface should be clea-
ned and must not have the oil and other foreign
matters. The sealant must not enter into the elec-
tric clutch housing and screw hole.
43. Install the electric clutch assembly on the electric

clutch housing.
(a) Make the shift fork cross on the shift fork sleeve.
(b) Align the location pin hole of electric clutch with
two location pins, and tighten it by bolt; tighten the
bolt to the specified torque. (Precoat the medium
screw of bolt with one or two drop of screw lock
agent)
44. Insert the clip into the vent tube bracket.

45. Clamp the vent tube clip on the front drive axle
vent tube connecting tube assembly.
46. Connect the front drive axle vent tube connecting

tube assembly to three ports, the front axle tube,
electric clutch and electric clutch housing.
47. Screw off the oil filling plug of front drive axle
housing, then fill the axle housing with the hypoid
gear oil; then tighten the oil filling plug to the spe-
cified torque.
Gear oil number: GL-5
Filling amount: The oil level is flush with the lower
edge of oil filling port.
48. Fill the electric clutch housing with the gear oil;
then tighten the oil filling plug to the specified tor-
que.
Installation of front reducer assembly
1. Install the front drive shaft assembly on the redu-

cer assembly
(Refer to “Assembly of Front Drive Shaft”)
2. Use the jack to support the front drive axle, insert

the hanger plank bolt with washer and tighten it to
the specified torque.
Remarks: Do not insert the previous two bolts in rever-
se direction.

to the drive shaft according to the mark made be-
assembly mark fore disassembly, and tightens it to the specified
torque.
4. Install the beam under the front drive axle; tighten
the connecting bolt of the beam to the specified
torque.
5. Connect the power sire connector of the electric
clutch to the power output wire of the car.
Semiaxle assembly
oil seal pressing block 95-105
◆oil seal brake caliper assembly
bearing parking brake assembly
◆circlip
oil seal base

brake disc
rear axle
9
pull-wire assembly

Removal of semiaxle
1. Remove the wheel.
2. Disconnect the manual brake pull-wire from the ca-
rriage; loose the small bracket.
3. Remove the brake caliper; remove the brake disc .
4. Remove the rear halfaxle assembly from the rear

axle housing
(a) Use the bolt to connect the special tools to the se-
miaxle flange surface.
(b) Use the hammer of special tools to remove the
rear axle.
5. Remove the circlip from the halfaxle assembly.

Use the circlip pliers to remove the circlip.
Check and repair of rear axle compo-

limitation limitation
2.0mm 0.2mm nents
1. Check the rear axle and flange for wear, damage
and run-out.
Max. Run-out of axle: 2mm
Max. Run-out of flange: 0.2mm
It should replace the rear axle if the rear axle or flange
is worn or damaged, or the measured run-out is be-
yond the specified value.
2. Check the external oil seal
(a) Check for the wear or damage; especially for the
lip of oil seal.
(b) Replace it if necessary.
3. Check the bearing and oil seal holder
Check for wear and damage, replace it if necessary.
4. Remove the bearing and oil seal holder
(a) Move the brake and oil seal pressing block to the
limit position along flange direction; move the ex-
ternal oil seal to the limit position of oil seal.
(b) Place the hook of the special tools in sequence,
the position is shown as figure; make the hook
holds the bearing tightly; then use the bolt to
connect the hook to the hammer fixedly; at last,
place it on the pad with halfaxle spline end facing
ground.
(c) Hold the hammer to beat downwardly with force
for several times to remove the bearing and oil
seal holder.
Caution: Do not damage the oil seal .
5. Install the new external oil seal
(a) Clean the semiaxle.
(b) Coat the lip of external oil seal with proper HP-R
grease.
Caution: When install the oil seal, the lip of oil seal
must not contact the semishaft to avoid scratching
the oil seal .
6. Replace the bearing and oil seal holder
(a) Heat the oil seal pressing block in 22# engine oil
to 100 ℃.
Caution: The end of oil seal pressing block with
larger chamfer faces the halfaxle spline. Install it
immediately after taken out.
(b) Use the hydraulic press to install the new bearing
and new oil seal pressing block by press.
7. Install the circlip
Use the circlip pliers to install the new circlip in the slot
of semiaxle.
8. Check the inner oil seal for wear or damage.

9. Remove the inner oil seal
special tools Use the special tools to remove the inner oil seal.
10. Install the new inner oil seal

special tools (a) Coat the lip of oil seal with proper HP-R grease.
(b) Use the special tools to knock in the new oil seal.
Installation of rear axle

1. Install the halfaxle assembly in the axle housing
(a) Use the kerosene to clean the semiaxle and inner
oil seal holder.
(b) Assemble the halfaxle spline and halfaxle gear
spline firstly, then use the brass rod to beat knock
the halfaxle assembly into the axle housing.
Caution: Protect the lip of inner external oil seal
and pull-wire assembly during assembly; do not
damage the oil sleeve assembly; align the brake
bolt with the flange bolt of rear axle.
axle housing flange 2. Install the rear brake disc
brake disc
halfaxle assembly
3. Install the brake caliper

4. Connect the manual brake wire.
5. Install the wheel.
6. Discharge the air of brake system by test.
Reducer
adjusting ring
side bearing driven bevel gear

adjusting washer
◆locking plate
drive bevel gear
rear bearing
65-95
◆bearing spacer
78-115
lock washer with double ears
oil baffle disc
dustproof cover
flange
plain washer
18-25
◆nut
front bearing stop plate
bearing gland
◆oil seal

Replace the oil seal on the car

assembly mark 1. Disconnect the reducer from the drive shaft.
(a) Make the assembly mark on two flanges.
(b) Remove four bolts and nuts.
2. Remove the flange and dustproof cover assembly

3. Remove the oil seal
Use the special tools to remove the oil seal.
4. Install the new oil seal

(a) Coat the lip of oil seal with the HP-R grease.
Insertion depth of oil seal: 1.0mm
5. Install the flange and dustproof cover assembly
special tools
insertion depth: 1mm
6. Rivet the drive bevel gear nut.
7. Connect the drive shaft flange to the reducer flan-

ge.
assembly mark
Align the assembly mark ; then connect them by bolt.
8. Check the oil level of reducer.

Replace the hyperbolic gear oil if necessary.
Oil number : GL-5 hyperbolic gear
Viscosity : SAE80W/90
Amount: Filled with oil until the oil flows out form
oil filling port.
Removal of reducer
assembly mark 1. Remove the oil drain plug; drain the oil from the re-
ducer
2. Remove the rear axle
(Refer to Step 2 in “Disassembly of Rear Axle”)
3. Disconnect the drive shaft from the reducer
(Refer to step 1 in “Replace the Oil Seal on Car”)
4. Remove the assembly of reducer.
Disassembly of reducer
Remarks: If the noise of differential is loud, process the
following inspection before disassembles the differen-
tial to determine its reason. When the differential has
serious problems, it can be disassembled for repair if
necessary.
1. Check the internal clearance of driven bevel gear.

If the clearance is beyond the specified range; adjust
the preapplied load of bearing or repair if necessary.
(Refer to step 13 “Assembly of Reducer”)
Standard internal clearance: 0.15-0.25mm
2. Check the intertooth contact of drive bevel gear
and driven bevel gear.
(Refer to Step 14 in “Assembly of Reducer”)
Record the contact position of tooth.
3. Check the clearance between the thrust plate of
axle shaft gear and differential housing.
Use the feeler to measure the clearance between the
thrust plate of axle shaft gear and differential housing.
It should be replaced by the proper thrust washer if the
clearance is beyond the specified range.
(Refer to Step 2 in “Replacement of Differential Com-
ponents”)

Use the torsion meter to measure the pre-applied load
on the internal clearance between the drive small gear
Pre-applied load: 0.4-0.6N·m
5. Total pre-applied load
Use the torsion meter to measure the total pre-applied
load.
Pre-applied load : 0.9-1.3N·m
6. Remove the differential and driven bevel gear

(a) Make the assembly mark on the differential bea-
ring gland and reducer housing.
(b) Remove two stop plates.
(c) Remove two bearing glands and two adjusting
rings.
(d) Remove the bearing outer race.
(e) Remove the differential from the reducer housing.
Remarks: Mark the label on the removed components

to indicate the position of reassembly.
left right

(a) Use the hammer and chisel to loose the riveted
special tools part of nut.
(b) Use the special tools to clamps the flange; then
remove the nut.
Caution: The used nut can not be used any more.
(c) Remove the flange and dustproof cover assembly.
Use the tools to pry out the oil seal.
9. Remove the drive bevel gear and spacer

special tools
Remove the drive bevel gear, bearing and spacer from
the reducer housing.
10. Remove the oil baffle disc and front bearing inner
race
11. Replace the rear bearing of drive bevel gear

(a) Use the press machine and special tools to pull
out the rear bearing from the drive bevel gear.
special tools
(b) Use the press machine and special tools to install

the reused adjusting washer and new rear bearing
on the drive bevel gear.
special tools
12. Replacement of front and rear bearing outer race of

drive bevel gear.
(a) Use the hammer and brass bar to knock out the
front and rear bearing.
the new bearing outer race by press.
13. Remove the side bearing form the differential

housing.
Use the special tools to pull out the side bearing from
the differ ential housing.
14. Remove the driven bevel gear

(a) Remove the connecting bolt and lock plate of dri-
ven bevel gear.
(b) Make the assembly mark on the driven bevel gear
and differential housing.
(c) Use the rubber hammer or brass rod to knock
down the driven bevel gear.
Assembly of reducer
1. Install the bearing outer race of drive bevel gear.
(Refer to Step 12 in “Disassembly of Reducer”)
2. Install the rear bearing of drive bevel gear and ad-

justing washer
special tools
(a) Select the proper adjusting washer according to
“Meshing Condition of Drive Bevel Gear and Dri-
ven Bevel Gear”.
(b) Install the rear bearing and selected adjusting
washer by press machine.
3. Install the spacer.

(a) Select the adjusting washer between the rear bea-
ring and spacer based on the experience.
spacer
(b) Install the spacer.
4. Install the front bearing inner race, oil baffle disc

and oil seal of drive bevel gear
special tools
(a) Place the front bearing inner race in the reducer
housing; place the oil baffle disc.
(b) Coat the position of reducer housing oil seal and
lip of oilseal with grease uniformly; place the oil
seal in position. Start the press machine for insta-
llation.
5. Install the drive bevel gear, flange and dustproof

level
cover assembly
(a) Install the flange and dustproof cover assembly in
the reducer housing, Press it to level by hand.
(b) Insert the drive bevel gear installed with the spa-
cer, rear bearing and adjusting washer into the
flange through the spline; screw on the nut.
(c) Use the nut to tighten the flange, plain washer and
drive gear.
6. Use the special tools to clamp the flange; use the

torque wrench to tighten the nut.
special tools Tightening force: 140-160N·m
7. Measure the rotation pretightening force of bearing

For new bearing : 1.2-1.7N·m
For reused bearing : 0.4-0.6N·m
If does not meet the requirement, replace the adjusting
washer under the spacer until meet the requirement.
Tightening torque : 0-3.5N·m
(a) Reduce the thickness of adjusting washer if the
measured value is less than standard value;
(b) Increase the thickness of adjusting washer if the
measured value is more than standard value.
8. Install the driven bevel gear on the differential
housing.
(a) Use the bolt and lock plate to connect the driven
bevel gear to the differential housing.
(b) Screw on for three rounds at least by hand; then
use the pneumatic wrench to tighten it properly.
(c) Use the torque wrench to tighten it.

Caution: Tighten the bolt in diagonal .
Use the hand hammer and flat head punch to lock the
lock plate.
9. Install the differential side bearing by press.

Use the press machine and special tools to install the
special tools
side bearing on the differential housing by press.
special tools
10. Install the differential assembly

(a) Remove the bearing gland. Do not mix the left up
with right.
(b) Install the differential assembly in the reducer
housing.
11. Install the adjusting ring

Use the adjusting ring to press the bearing outer race
in position; tighten it properly. Adjust the clearance
between the drive and driven gear to the proper dimen-
sion.
12. Install the bearing gland

(a) Align the assembly mark on the bearing cover with
that on reducer housing; Press down the press
cover by hand.
(b) Install the lock washer with double ears and nut;
tighten the hexagon nut by pneumatic wrench pro-
perly.
assembly mark
13. Adjust the engagement clearance between the dri-

ve and driven gear.
(a) Use the torque wrench to tighten four bolts on
bearing cover by torque wrench.
(b) Adhere the measuring meter base on the end

surface of reducer housing; the measuring head
contacts the tooth surface; rotate the driven gear
by hand and measure the engagement clearance
between the drive and driven gear.
(c) If the engagement clearance does not meet the

requirement, use the special tools to adjust the left
and right adjusting ring until it meets the require-
ment.
(d)Recheck the engagement clearance between the

drive and driven gear.
Engagement clearance: 0.13-0.18mm

gear.
(b) Rotate the driven bevel gear in clockwise and
anticlockwise by hand.Check the engagement of
gear.
large end contact toe contact
select the shim which can make the small

drive gear close to the driven bevel gear
small end contact

dedendum contact
sound contact
select the shim which can make the small drive gear away from the driven bevel gear
Select the proper washer from the table for correction

rear bearing if the intertooth contacting status is bad. The thickness
washer tolerance of washer is ±0.01mm.
Set NO. Thickness Set NO. Thickness
1 1.60 7 1.90
2 1.65 8 1.95
3 1.70 9 2.00
4 1.75 10 2.05
5 1.80 11 2.10
6 1.85 12 2.15
15. Install the stop washer and stop plate
(a) If the drive and driven gear engagement mark
meets the requirement, then use the hand ham-
mer and punch to lock the stop washer.
(b) Install the stop plate, spring shim and bolt; tighten
the bolt.
(c) Use the punch and hand hammer to knock the lo-
wer end of stop plate in the adjusting ring hole.
16. Measure the total pre-applied load

If the pre-applied load is beyond the specified; it should
replace the shim between the spacer and rear bearing
until meet the requirement.
(a) It should replace the adjusting washer if the pre-
applied load is more than specified value.
(b) If the pre-applied load is less than specified va-
lue, it can retighten the nut slowly and the torque
should be no more than 160N·m.
Caution: When tighten the nut, if is beyond the
Max. torque, replace the adjusting washer and re-
peat the pre-applied load process. Do not reduce
the pre-applied load by the method of screw off the
drive gear nut to loose.
17. Check and adjust the run-out of flange.

(a) Adhere the dial indicator base on the reducer
housing; make the probe of dial indicator contact
with the end surface of flange; rotate the flange
and watch the rotation range of the dial.
Full run-out tolerance of end surface: 0.10mm
(b) Adhere the dial indicator base on the reducer

housing; make the probe of the dial indicator con-
tact with the inner diameter of flange; rotate the
flange by hand , and watch the rotation range of
the dial.
Radial full run-out tolerance: 0.10mm
18. Rivet the nut of drive bevel gear
Installation of reducer and differential

assembly mark
assembly
1. Install the new stiffening ring
2. Install the reducer and differential assembly
Install the reducer and differential assembly in the rear
axle housing; place the washer and nut. Tighten the
3. Install the reducer and differential assembly flange
on the drive shaft flange and align the assembly
mark; use four bolts and nuts to connect them.
Tighten the bolt and nut to the specified torque.
4. Install the oil drain plug; fill the differential with the
gear oil
oil number : GL-5 hyperbolic gear oil
Viscosity: SAE80W/90
Amount: Filled with oil until the oil flow out from
the oil filling port.
Tighten the oil filling plug.
Differential
thrust plate
straight pin lock washer
half axle gear planetary gear

differential housing planetary gear shaft
half axle gear
planetary gear thrust plate
lock washer
Differential
1. Remove the reducer and differential assembly
(Refer to “Removal of reducer”)
2. Remove the differential from the reducer and diffe-
rential assembly.
(Refer to “Disassembly of reducer”)
Replacement of differential components
1. Disassembly of differential
Use the hammer and punch to knock out the pin. Re-
move the planetary gear shaft, two half axle gears, two
planetary gears and two lock washers, two thrust pla-
tes.
2. Assembly of differential
(a) Install the half axle gear and thrust plate of axle
shaft gear
(Unit: mm)
Set NO. 1 2
Thickness 1.2 1.5
(b) Install the planetary gear and planetary gear lock

washer in the differential by rolling.
(Unit: mm)
Set NO. 1 2
Thickness 0.8 1.0
(c) Use the feeler to measure the clearance between

feeler the thrust plate and differential housing; it can be
replaced by the thrust plate with different thick-
ness if the clearance is beyond the specified ran-
ge.
(d) Install the straight pin

Use the hammer and punch to knock in the pin through
the hole on the differential housing and planetary gear
shaft. Rivet the pin with the differential housing.
Installation of differential
1. Install the differential assembly in the reducer
housing
(Refer to “Assembly of Reducer”)
2. Install the differential
(Refer to “Installation of Reducer and Differential Ass-
embly”)

Installation and disassembly drawing of front drive shaft assembly on
front drive axle
constant-speed drive shaft assembly
90-110 ★
hanger plank-R
universal-joint oil seal
circlip
circlip
23-26
circlip
universal-joint oil seal lower segment of vent tube of front drive axle
hanger plank-L circlip
★ 90-110
constant-speed drive shaft

200-220 200-220
200-220
200-220

shaft assembly
1. Place the car in the middle of repair platform or
trench, support the front of the car steadily(support
on the carriage) then remove the left and right front
wheel. (make the car in 2WD status before the di-
sassembly)
2. Remove the beam on the lower of front drive axle
assembly.
3. Disconnect the connection of front drive axle flan-
ge and drive shaft and make the assembly mark
4. Drain the lubrication oil in reducer.
5. Screw off the connecting bolt of front hub cover

and remove the front hub cover.
6. Use the circlip pliers to remove the circlip from the
adjusting washer set
drive shaft and remove the washer and steering
circlip knuckle of left and right end.
(Refer to the “Disassembly of Steering Knuckle Assem-
★bolt
bly”)
flange
front hub cover
7. Disconnect the power wire connector of electric

clutch.
8. Disconnect the connecting place of front drive axle
vent tube connector assembly and rubber tube in
left hanger plank of front drive axle.
disconnect three ports in this position

9. Use the wrench to screw off the bolt which fixes

the lower segment assembly of front drive axle
vent tube on the vent tube bracket.
wrench
10. Support the front drive axle by the jack; screw off
90-110 ★
the lifting bolt of hanger plank and carriage.
11. Remove the complete drive axle.
supporting position 12. Screw off the connecting bolt of hanger plank and
front drive axle assembly.
13. Pull out the left and right front drive shaft assembly
with the oil seal, hanger plank and bearing.
14. Use the circlip pliers to remove the outside circlip

of bearing.
circlip pliers
15. Use the special tools pull out the bearing.

16. Use the circlip pliers to remove the circlip on ano-
ther side of bearing.
hold
Caution: During the disassembly, support the lo-
special tools wer end of drive shaft and prevent the drive shaft
from sliding out from the inner jacket, meanwhile,
it could not damage the inner and outer jacket.
shim

inner trumpet connector
circlip
inner jacket
three-pin section assembly
large clip of inner jacket

small clip of outer jacket
small clip of inner jacket
outer jacket
large clip of outer jacket
outer trumpet connector
dustproof cover

shaft assembly
1. Check the front drive shaft assembly
(a) Check the inner trumpet connector; it could slide
in axial direction smoothly.
(b) Check the universal-joint position; it should be
without the clear clearance in radius direction.
(c) Check the inner and outer jacket for damage.
Caution: It should use the pad when clamp the
front drive shaft to avoid the damage of it.
2. Remove the large clip of inner jacket
Caution: Do not damage the inner and outer jacket
pliers
3. Disassembly of inner trumpet connector

(a) Make the assembly mark on the inner trumpet
assembly mark connector and three-pin section assembly.
Caution: remove the grease in the connector befo-
re make the mark and don’t make the mark by the
hard object such as punch.
(b) Remove the inner trumpet connector.
4. Disassembly of three-pin section assembly

(a) Use the circlip pliers to remove the circlip.
(b) Use the adz and hand hammer to make the as-
sembly mark on the shaft and three-pin section
assembly.
assembly mark
(c) Use the cooper bar and hand hammer to remove

the three-pin section.
Caution: Remove the cooper chip on the shaft or
three-pin section assembly if has.
5. Remove the inner jacket

(a) Use the pliers to disassemble the small clip of in-
ner jacket.
(b) Pull out the inner jacket.
Caution: Remove the grease in the jacket and
maintain the clean field.
6. Use the straight screwdriver to disassemble the

large and small clip of outer jacket.
7. Remove the outer jacket

Caution: Clean the protective jacket and remove
the grease on the outer trumpet connector. Do not
disassemble the outer trumpet connector.
8. Use the screwdriver and hand hammer to remove

the dustproof cover.
Assembly of constant-speed drive shaft

assembly
1. Use the hand hammer and screwdriver to install
the dustproof cover
Caution: The dustproof cover should be replaces
when it is deformed heavily.
2. Install the large clip of outer jacket, outer jacket

and small clip of outer jacket.
Caution: The outer jacket should be replaced when
it is damaged or aged heavily and warp the end of
the shaft with the plastic band and coat with small
grease before insert it.
3. Insert the small clip of inner jacket, inner jacket

and large clip of inner jacket.
Caution: The inner jacket should be replaced when
it is damaged or aged heavily.
4. Install the three-pin section assembly on the front

drive shaft.
(a) Let the end of three-pin section assembly with
with chamfer
chamfer faces the shaft inner direction.
Caution: The three-pin section assembly should be
replaced if its needle bearing position is damaged.
(b) Align the assembly mark made before disassem-

bly.
(c) Use the hand hammer and copper bar to install

the three-pin section assembly to the front drive
shaft.
(d) Use the circlip pliers to install the new circlip.
5. Install the outer jacket on the outer trumpet con-

nector.
Fill the jacket with the grease supplied with the jacket
before install the jacket.
(Recommend used grease is CAPLEX or KY1)
6. Install the inner trumpet connector on the front dri-

ve shaft
(a) Fill the inner trumpet connector and inner jacket
with the grease supplied with the jacket
(Recommend used grease is CAPLEX or KY1).
(b) Align the assembly mark made during disassem-

assembly mark
bly; covered with inner trumpet connector.
(c) Cover the inner jacket on the inner trumpet con-
nector.
7. Use the inner and outer jacket clip pliers to clamp

outer jacket clip
the inner and outer jacket.
inner jacket clip
(a) Use the special non-ear clip pliers to lock the large
clip of inner jacket.
non-ear clip pliers
(b) Use the nutcracker to lock the small clip of inner

jacket.
Caution: Ensure the large and small connecting
place of jacket is in the corresponding groove of
trumpet connector and shaft.
nutcracker
(c) Use the special pneumatic pliers to lock the large

special tools and small clip of outer jacket.
(d) Ensure the jacket of both sides does not be pro-

longed or shortened when the front drive shaft has
the standard length.
Standard length: 400.5mm
If only need to replace the outer components of front

drive shaft assembly on car, it can remove the left and
right steering knuckle of car, then disconnect the inner
trumpet connector of front drive shaft assembly, then
take out the three-pin section assembly and shaft from
the inner trumpet connector for replacement.
Installation of constant-speed drive shaft

assembly on front drive axle
1. Insert the hanger plank into the drive shaft, inser-
circlip pliers ted with oil seal; use the circlip pliers to install the
inner circlip.
Caution: It should replace the oil seal if damaged.

2. Use the special tools to knock bearing in slightly.

special tools
Caution: Support the lower end of the drive shaft
assembly when knock the bearing in. The lower
end must not slide out.
3. Use the circlip pliers to install the outer circlip on
the front drive shaft assembly.
4. Repeat the previous method to install the hanger
plank, oil seal, circlip, bearing and circlip on ano-
support the lower end ther end.
5. Insert the spline of connecting end of drive shaft
and reducer into the differential halfaxle gear spli-
ne hole of electric clutch and reducer slowly.
6. Drip 1-2 drop of screw lock agent on the middle of
screw of connecting bolt of hanger plank and redu-
cer.
7. Use the wrench to tighten the connecting bolt of

hanger plank and drive axle to specified torque.
Caution: It should screw on all bolts before tig-
hten them, then tighten them in diagonal direction.
Check the hanger plank for levelness after tighte-
ned the bolt to the specified torque. Remove the
hanger plank and reinstall it if is not planished.
8. Install the vent tube connector assembly; connect
all ports to front drive axle.
9. Use the jack to support the complete drive axle;

use the hanger plank to lift the drive axle and tig-
assembly mark
hten the lifting bolt to the specified torque; install
steering knuckle both sides and upper and lower
ball pin; connect the connecting port of front axle
vent tube assembly and carriage; reconnect the
connector of electric clutch.
Caution: Drip 1-2 drop of screw lock agent on the
middle front part of the lifting bolt
and drive shaft according to the mark mage before
disassembly and tighten it to the specified torque.
11. Install the beam under the front drive axle. Tighten
the beam connecting bolt to the specified torque.
Replacement of drive gear oil seal of front reducer assembly
front reducer assembly
washer
bearing
spacer-drive bevel gear ◆oil seal
front reducer drive gear flange, main gear

flange and dustproof cover assembly

◆ Used component which can not be used any more ◆ 140-160
assembly mark
1. Support the front of car; remove the left and right
front wheel and the beam under the reducer.
2. Drain the lubricant oil in the front reducer; remove
the left and right steering knuckle
3. Disconnect the front reducer assembly flange from
the drive shaft and use the jack to remove the front
drive axle
Caution: Make the assembly mark on the reducer
and drive shaft before separate them.
4. Remove the front differential assembly

Caution: Drain the oil in front differential before the
disassembly

assembly
veted part on nut.
special tools
(c) Use the cooper bar to knock down the drive gear
6. Remove the drive gear oil seal

Use the special tools to remove the oil seal; do not da-
mage the inner wall of reducer housing.
special tools
7. Install the new drive gear oil seal

(a) Use the special tools to knock into the new oil
special tools seal.
(b) The top of the oil seal is level to the top of reducer
housing.
Caution: Coat the oil seal lip with the lithium base
grease and the oil seal should be in correct posi-
tion.

assembly
(a) Match the drive gear flange and dustproof cover
assembly on the front drive gear.
(b) Coat the new nut with the lithium base grease.
(c) Use the special tools to clamp the flange and tig-
hten the nut to the specified torque.
Tighten torque:140-160N·m
9. Adjust the pre-applied load of the drive bevel gear

bearing
(a) Use the torque meter to measure the pre-applied
load of the gap between the drive bevel gear and
driven bevel gear.
pre-applied load: 1.2-1.7N·m
(b) Is should be replaced by the thicker washer if the
pre-applied load is more than specified value
The step of thickness of washer is 0.03mm
(c) Is should be replaced by the thinner washer if the
pre-applied load is less than specified value. Re-
peat the previous operation until meet the require-
ment.
33mm Caution: Do not reduce the load by loosing the nut.
10. Check the axial and radial run-out tolerance of flan-
ge.
(a) Use the dial indicator to measure the axial runout
of flange.
Max. axial runout: 0.1mm
(b) The max. radial run-out tolerance is 0.1mm

It should check the bearing if the radial run-out toleran-
ce is large.
11. Rivet the drive gear nut after meet the previous re-
quirements.
12. Install the reducer assembly on the front drive axle
assembly and assemble the front drive shaft ass-
embly
(refer to Assembly of Front Reducer Assembly and As-
sembly of Front Drive Shaft Assembly)
13. Install the oil drain plug; screw off the oil filling
plug and filled with the hypoid gear oil.
Tightening force of oil drain plug: 30-35N·m
Model of lubrication oil: GL-5
Filling amount: Flush to the lower edge of oil filling
open
14. Insert the oil filling plug washer and tighten the oil
filling plug to the specified torque.
15. Install the front drive axle assembly on the carria-

ge.
16. Connect the drive shaft to the flange
(a) Align the assembly mark; use four bolts and nuts
to connect the flange of drive shaft and front drive
axle.
(b) Tighten the nut to the specified torque.
Remarks: Keep the clean of the field during the mainte-
nance.
Front reducer assembly
★ 90-110
hanger plank-R

circlip
circlip
23-26
circlip

front drive axle vent tube connector assembly
hanger plank-L circlip
★ 90-110

1. Support the front of the car; remove two front whe-

assembly mark els and the beam under the front reducer assembly.
2. Drain the lubrication oil in the front reducer assem-
bly.
3. Remove the flange of front reducer assembly from
the drive shaft
Caution: Make the assembly mark on the flange of
front reducer assembly and drive shaft before dis-
connect them.
4. Disconnect the connector of power wire of electric
clutch
5. Disconnect three rubber connectors on the front
drive axle vent tube connector assembly.
disconnect three connectors in this place
6. Use the wrench to screw off the bolt on the vent

tube bracket, which is used to fix the vent tube
connector.
wrench
7. Disconnect the connection between the front drive

shaft assembly and steering knuckle front hub ass-
embly.
(a) Screw off the connecting bolt which is used to fix
the front hub cover; remove the front hub cover.
(b) Use the circlip pliers to remove the circlip from the
front drive shaft and remove the adjusting washer.
(c) Remove the steering knuckle of both sides and
separate it from the front drive shaft assembly.
200-220 200-220
electric clutch connector
8. Use the jack to support the front reducer assembly

9. Remove the lifting bolt of front drive axle hanger
plank and carriage.
Caution: Do not damage the drive shaft and front
drive shaft jacket
11. Remove the front drive shaft assembly of both
sides from the front drive axle assembly.
12. Use the wrench to remove the bolt and nut which is
used to fix the front reducer housing.
Replacement of oil seal and major semiaxle oil seal of front reducer ass-
embly
Replacement of front reducer assembly oil seal

(Refer to “Removal of Front Reducer Assembly”)
2. Remove the left and right front drive shaft assem-
bly from the front drive axle assembly.
3. Remove and replace the lower oil seal according to
the removal and installation procedure of front dri-
ve shaft assembly and install the new side oil seal
on the front drive shaft, then install them in the
front reducer assembly.
(Refer to “Removal and Installation of Front Drive Shaft
Assembly”)
90-110 ★
23-26

circlip
major semiaxle pressing assembly

Replacement of major semiaxle oil seal

1. Make the electric clutch is in the 4WD status, then
stop the engine and remove the front drive axle as-
sembly
(see the disassembly of front reducer assembly)
2. Use the wrench to screw off the bolt which fix the
front axle vent tube connector assembly on vent
wrench tube bracket bolt
3. Disconnect the connector between vent tube of

disconnect the place electric clutch housing and front drive axle vent
tube connector assembly
4. Disconnect the connector between the vent tubes

on the electric clutch and vent tube connector ass-
embly.
5. Remove the bolt which is used to fix the electric
clutch housing and front axle tube flange; use the
brass bar to open the electric clutch housing and
take out the mechanical wheel of separator.
disconnect the place Caution: The lubrication oil will flow out when se-
parate the electric clutch housing from the front
axle flange. It should use the container to hold it.

6. Use the circlip pliers to remove the circlip which

circlip clamp the major semiaxle bearing outer race.
circlip pliers
liftout bolt (3 units)
bolt pin (2 units) Pad

special tools

and bearing, circlip assembly.

oil seal.
Caution: Do not scratch the inner surface of flange.
special tools
9. Remove the sealant on the matching surface bet-

ween the flange and electric clutch housing by kni-
fe.
Caution: Do not scratch the matching surface.
10. Use the special tools to knock the new seal in the
oil seal position in flange.
Caution: Before install the new oil seal, it should
coat the lip with thin lithium base grease, and the
oil seal should be in alignment position.
special tools
11. Insert the spline of small end of major semiaxle in

the spline of front reducer half axle gear slightly,
then use the brass bar and hand hammer to knock
it in.
Caution: When knock in the major semiaxle, must
not damage the inside needle bearing of large end
spline of major semiaxle.
12. Use the circlip pliers to install the circlip in the flan-
ge and clamp the bearing outer race.
Caution: The circlip should be replaced if it has se-
rious deformation.
circlip pliers
13. Use the clean cloth to wipe the matching surface of

flange and electric clutch housing respectively.
14. Align the spline of mechanical wheel of separator

with the spline in front drive shaft and separator
shift fork sleeve, and install it in the front drive
shaft and separator shift fork sleeve.
15. Coat the flange matching surface with the 1596 si-
licon rubber plane sealant uniformly and level it by
plate.
Caution: Ensure the continuity of sealant and avoid
the sealant enter into the screw hole.
16. Align the shift fork bush with the spline on the
major semiaxle to make the mechanical wheel of
separator enters into the major semiaxle, then use
the bolt to connect the electric clutch housing and
front axle pipe flange and tighten it to the specified
torque. In which the bolt should be precoated with
the screw locking agent (drip one or two drops on
the middle of screw).
Caution: Prevent the foreign material from entering
into the front drive axle during assembly.
17. Use the wrench to tighten the bolt of vent tube
bracket to tightening torque.
18. Screw off the oil filling plug on the electric clutch
housing, remove the washer and fill it with the gear
lubrication oil until flush with the bottom of oil fi-
lling port.
Number of lubrication oil: GL-5
19. Place the washer of oil filling plug, tighten the oil
filling plug to specified torque.
20. Connect the vent tube on the electric clutch

housing to the front axle vent tube connector ass-
connect the place
embly.
21. Connect the electric clutch vent tube to the front
connect the place

Disassembly and assembly of front reducer assembly and electric clutch
adjusting shim
90-115
bearing
bearing gland
★ 80-95
pin half axle gear thrust plate
half axle gear

driven bevel gear
planetary gear shaft
planetary gear
front drive axle housing

★ 18-25
washer
oil filling plug
vent tube
spacer-drive bevel gear
adjusting washer
30-35
oil seal
front drive gear flange and dustproof cover assembly

★ 90-110
◆ 140-200
small bearing
front reducer housing
★
front axle vents tube
23-26
connector assembly
major semiaxle circlip
bearing
electric clutch
needle bearing
circlip
location pin
drive bevel gear
oil filling plug
big bearing
vent tube washer
electric clutch housing adjusting washer
★ 23-26
declutch shift sleeve

disconnected in this place Disassembly of front reducer assembly

1. Remove the front drive axle and left and right front
drive shaft assembly.
(Refer to “Removal of Front Reducer Assembly” and
“Removal of Front Drive Shaft Assembly”)
2. Disconnect three interface positions of front drive
3. Use the flat screwdriver to pry off the clip fixed the
vent tube connector assembly and take out the
vent tube connector assembly.
4. Screw off the bolt fixed the electric clutch and use
the brass bar to knock down the electric clutch.
5. Use the wrench to remove the oil filling plug; remo-

ve the washer and pull out the vent tube.
6. Use the wrench to remove the bolt connected to

the electric clutch housing and front axle tubeflan-
ge; take out the shift fork sleeve and mechanical
wheel of separator.
Caution: The leaked gear oil during disassembly
should be stored in the container to avoid the po-
llution for environment.
7. Use the circlip pliers to remove the circlip fixed the

major semiaxle bearing outer race.
8. Use the special tools to pull out the major semiaxle
and major semiaxle bearing with the major se-
miaxle inner race circlip.
oil seal.
10. Pull out the vent tube on the front axle tube.
11. Use the circlip pliers to remove the circlip. Fasten
the major semiaxle bearing inner race.
12. Press out the major semiaxle bearing on press ma-

chine. (Or knocked out by hand hammer)
Caution: Don’t damage the end spline of major se-
miaxle.
special tools
13. Use the special tools to pull out the needle bearing
in major semiaxle.
Caution: It should use the pad when use the vise to
clamp the major semiaxle.
14. Use the wrench to remove the bolt and nut used
to fix the front reducer assembly and front axle
housing.
15. Use the brass rod or hand hammer to knock the

front reducer housing to separate it from the front
drive axle housing.
16. Check the run-out of driven bevel gear.

Rotate the flange; use the dial indicator to measure the
run-out of driven bel gear.
Max. Runout: 0.07mm
It should replace the drive and driven bevel gear totally
if the run-out is more than 0.07mm.
17. Check the running clearance of drive and driven

bevel gear.
(a) Install the dial indicator and ensure the side axis is
vertical to contact tooth surface.
(b) Hold the drive gear flange and rotate the driven
bevel gear in clockwise and anticlockwise to mea-
sure the clearance.
Specified range of clearance: 0.15-0.25mm
Remarks: Check three average points on circumferen-
ce of driven bevel gear at least.
18. Check the engaging mark of drive and driven bevel
gear.

bearing.
Use the torque measuring meter to measure the pre-
applied load on the gap between the drive and driven
bevel gear.
20. Measure the total pre-applied load of drive bevel
gear.

assembly.
veted part of drive gear nut.
(c) Use the brass rod to knock down the drive gear
22. Use the special tools to remove the drive gear oil
seal.
holding
special tools
pliers
23. Use the special tools to remove the small bearing

inner race, and then reverse the reducer to slide
out the spacer.
Remarks: The bearing should be replaced by new one
special tools
if damaged.
24. Use the wrench to remove two bearing glands.

Remarks: It should distinguish the left and right of the
bearing gland when remove it to avoid the confusion.
25. Use the brass rod to vibrate the differential assem-
bly upwardly, then take out the differential assem-
bly.
26. Remove the side bearing outer race and marked

with L and R.
left (L)
right (R)
27. Remove the left and right adjusting washer; mea-

sure its thickness; marked with left and right.
28. Remove the drive bevel gear, then take out the ad-
justing washer under spacer.
Check and replacement of reducer

1. Replace the big bearing of drive bevel gear.
(a) Use the special tools to press out the big bearing
of drive bevel gear.
Caution: It should replace the drive and driven be-
vel gear in pair before replace the big bearing if the
special tools
drive bevel gear is damaged.
(b) Install the washer on the drive bevel gear, Use the
special tools to install the new big bearing .
special tools
2. Replace the big bearing outer race of drive bevel

gear.
(a) Use the brass bar and hand hammer to knock
down the big bearing outer race.
(b) Use the special tools to press in the new big bea-
ring outer race.
special tools
3. Replace the small bearing of drive bevel gear.

(a) Use the brass rod and hand hammer to knock
down the small bearing outer race of drive bevel
gear.
(b) Use the special tools to press in the new bearing

outer race.
special tools (c) Replace it by the new bearing inner race when
installs the small bearing..
4. Remove two side bearing inner races from the di-

fferential housing.
(a) Use the special tools to remove the side bearing
inner race on the side of differential assembly with
bolt.
(b) It should pay attention to does not damage the dri-
ven bevel gear when use the vice for clamping to
rubber pad remove the bearing inner race on another side.
5. Use the wrench to remove the bolt fastened the dri-

ven bevel gear
Caution: It should make the assembly mark on the
driven bevel gear and differential housing before
disassembly.
assembly mark
rubber pad
6. Disassembly of differential assembly

special tools
(a) Use the hand hammer and special tools to knock
out the pin after remove the driven bevel gear.
(b) Knock out the planetary gear shaft, rotate the half
axle gear to take out the planetary gear, then take
out the half axle gear and thrust plate.
7. Assembly of differential assembly.

(a) Wash the differential housing.
(b) Cover the half axle gear thrust plate with the half
axle gear, then installs it in the differential housing.
(c) Rotate the half axle gear; install the planetary gear
in rolling and insert the planetary gear shaft.
(d) Check the clearance between the half axle gear

Remarks: The rotation of half axle gear and planetary
gear should be smooth and without block; push the
planetary gear to inside, then use the dial indicator
to measure the clearance between the half axle gear
Rational clearance range: 0.4-0.75mm
It is necessary to replace the half axle gear thrust plate
if the clearance is beyond the previous range, at the
same time ensure the thrust plate in left and right side
has the same thickness.
(e) Use the special tools to hit the pin to fix the plane-
tary gear shaft, and rivet the inserted hole to pre-
special tools vent the loose of pin.
(f) Clean the surface of differential housing; use the

brass rod to install the driven bevel gear on the
differential housing.
Caution: It should align the marked assembly mark
when install the driven bevel gear and knock it in
uniformly in circumference; it should remove the
cooper chip in time if it is adhered on the driven
bevel gear.
(g) Coat the fastening bolt of driven bevel gear with

the screw lock agent, then tighten it to the speci-
fied torque.
Specified tightening force: 80-95N·m
Caution: It should be in the diagonal sequence to
tighten the bolt and tighten it for little, then tighten
it to the specified torque uniformly.
(h) On press machine, use the special tools to press

the inner race of bearing into the bearing position
special tools
on both sides of differential housing.
special tools
(i) Place an adjusting shim in the position of front re-

bearing ducer housing side bearing near exterior.
bearing
(j) Install another adjusting shim and the other side
bearing outer race in the front reducer housing
adjusting shim adjusting shim
with the differential assembly
(k) Install two bearing glands, left and right and use
the wrench to tighten the bolt to the specified tor-
que.
(l) Rotate the driven bevel gear, check the runout of

driven bevel gear.
Max. Runout: 0.07mm
Assembly of front reducer assembly

1. Install the adjusting washer in the drive bevel gear,
install the big bearing inner race of drive bevel gear
by press.
2. Clean the front reducer housing, install the outer
race of big and small bearing on the reducer
housing by press..
3. Install the drive bevel gear into the front reducer
housing, then install the washer, spacer and small
bearing inner race.
4. Use the special tools to install the drive bevel gear

oil seal.
special tools Caution: It should coat the lip with the oil seal li-
thium base grease before install it and the rear
surface of rear oil seal should flush with the top of
front reducer housing after knocked in.
assembly.
(Refer to “Replacement of Drive Bevel Gear Oil Seal”)
6. Use the special tools to tighten the drive gear nut

to the specified torque; the nut should be precoa-
ted with the lithium base grease.
7. Use the torque measuring meter to measure the

pre-applied load of big and small bearing of drive
bevel gear.
8. Place the differential assembly on the correspon-

ding position of front reducer housing.
9. Select an adjusting shim and insert it in a side of

side bearing outer race; push the differential ass-
embly to the side with adjusting shim.
10. Use the dial indicator to measure the gear side

clearance of driven bevel gear and drive bevel
gear; select out the adjusting shim in the side whi-
ch meets the rational clearance of 0.15mm.
11. Measure the thickness of the adjusting shim.
12. After select out one side adjusting shim, then se-
L1 L2 lect theadjusting of another side according to that
the theoreticthickness of the adjusting shimofa-
nother side equals to subtracting the thickness of
selected shim and oppositiondistance L2 between
outer race of two side bearings of differential as-
sembly from the opposition distance L1 between
two side bearings of front reducer housing.
13. Place an adjusting shim in the position of front re-

ducer housing side bearing and close to exterior.
14. Install the other adjusting shim and the bearing
outer race of another side with the differential ass-
embly into the front reducer housing.
Remarks: Ensure the selected adjusting shim has not
gap with front reducer housing.
15. Rotate the driven bevel gear to make the differen-

tial assembly closed to the front reducer housing.
16. Use the dial indicator to measure the tooth side
gap between the drive and driven bevel gear.
The rational range of gap is: 0.15-0.25mm.
If the measured gap is beyond the range, then adjust
it by adding or reducing the thickness of shim. (When
add in one side, the other side should be reduced with
same thickness)
Caution: Ensure the selected adjusting shim is
without clearance form front reducer housing.
17. Adjust the pre-applled axial load of side bearing.

(a) Remove two adjusting shim, remeasure the thick-
ness of two adjusting shims.
(b) Install the new adjusting shim with thickness
0.06-0.09mm more than that of removed adjusting
shim, then install it with the differential in the redu-
cer housing.
(c) Remeasure the tooth side clearance between the

drive bevel gear and driven bevel gear.
Rational range of clearance: 0.15-0.25mm
Remarks: If the measured gap is beyond the range,
then adjust it by adding or reducing the thickness of
shim. ( When add in one side, the other side should be
reduced with same thickness)
Caution: Ensure the selected adjusting shim has
not the clearance with the front reducer housing.
18. Install the bearing gland of both sides and use the
wrench to tighten it to the specified torque.
Remarks: Distinguish the left and right during assem-
bly.
19. Use the torque measuring meter to measure the to-

tal pre-applied load of front reducer.
specified torque : 1.8-2.4N·m

gear.
(b) Hold the flange of drive gear; rotate the driven be-
vel gear in clockwise and anticlockwise.
(c) Check the contacting condition of gear tooth.
ht H≥4
of gear m the top
Away from the small end 5≤A≤10 If the meshing mark of drive and driven bevel gear
nt heig
does not consist with that shown in figure, it should se-
B≥1
Away fr
o Away from the small
end 3≤A≤10
Footpri
lect the proper adjusting washer for modification accor-
ht H≥4
Footprint length 13≤L≤20
ding to the detailed form of meshing mark.
Away from the

root of gear C≥1
nt heig
Footpri
↓↓ Away from
the top of
↑ gear B≥1
↑
convex of driven concave of driven bevel

the drive gear close to the driven bevel gear
small end contact

dedendum contact
sound contact

the drive gear away form the driven bevel gear
(d) Remove the drive bevel gear and use the special
tools to remove the large bearing of drive bevel
gear before replace the adjusting washer.
special tools
(e) Insert the new adjusting washer and use the spe-
cial tools to press in the large bearing of drive be-
vel gear.
(f) Place the adjusting washer above the large bea-
ring on the drive bevel gear, install the spacer in
the reducer housing; install the drive gear flange
andtighten the nut to the specified torque.
(g) Remeasure the pre-applied load of drive gear
bearing clearance and the total pre-applied load of
reducer; ensure it meets the requirement.
21. Use the dial indicator to measure the axial and ra-
dial run-out tolerance of . Drive bevel gear flange.
33mm
Max. Axial runout : 0.1mm
Max. Radial run-out tolerance: 0.1mm

Remarks: It should check the big and small bearing of
drive bevel gear when the runout is more than 0.1mm.
22. Rivet the nut of drive bevel gear.
23. Use the pneumaticto screw two studs on the co-

rresponding screw hole on the front axle housing
until the limitation. (It should coat the screw of the
stud which is screwed in the front axle housing
with the screw lock agent, and the amount should
be just can cover the screw which is screw in the
front axle housing)
Caution: The position of stud should consist with
that before disassembly.
24. Coat the plane of front axle housing with the conti-
nuous 1596 silicon rubber plane sealant, scrape it
to level by plate.
Caution: Avoid the screw hole when paint the sea-
lant; prevent the sealant enters into the screw hole.
25. Install the front reducer assembly on the front drive
axle housing and screw on the hexagon bolt and
spring washer combination; cap the spring washer
on the stud, tighten the nut to the specified torque.
(The screw of all bolts should be precoated with
screw lock agent)
The specified tightening force of hexagon bolt and

spring washer combination, stud and nut should
be: 18-25N·m
Caution: The bolt should be tightened in diagonal
sequence evenly; check the reducer housing and
axle housing contacting surface for gap; check the
sealant from break. It should remove the reducer
for reinstallation if has the gap or break.
26. Screw the oil filling plug with washer on the front
drive axle.
Caution: Do not tighten it.
27. Screw the oil drain plug on the front drive axle.

oil seal in the front axle tube.
Caution: Precoat the lip of oil seal with thin lithium
base grease and the oil seal should be installed in
position.
29. Use the special tools to install the needle bearing

in the major semiaxle.
special tools

bearing by press.
special tools 31. Use the circlip pliers to install the circlip to clamp
the bearing inner race of major semiaxle.
special tools
32. Insert the spline on small end of major semiaxle

into the spline of front reducer half axle gear; use
the brass rod and hand hammer to knock the major
semiaxle into the front reducer.
Caution: Does not damage the inside needle bea-
ring. On spline of large end of major semiaxle when
knock in the major semiaxle.
33. Use the circlip pliers to install the circlip in the

flange and clamp the major semiaxle bearing outer
race.
34. Push the mechanical wheel of separator into the

needle bearing inner race in major semiaxle until
can not move.
35. Detect the electric clutch assembly .

(a) Measure the clearance between the shift fork and
shift fork sleeve.
Range of clearance : 0.2-0.4mm
It should replace the electric clutch assembly and shift
fork sleeve when the clearance is not in the range.
(b) Connect the electric clutch assembly to the elec-
tric clutch detector and power the electric clutch
detector with 220V power supply to test the elec-
tric clutch (Before the test, adjustthe test controller
status to make the motor starting time is 3s ,the
time form found the actuator is not in position to
restarting is 2.5s and the time of controller to redri-
ve the electric clutch is 2s) The motor starts for 3s
when the gear switch is shifted form 2WD to 4WD,
the lamp flashes at the same time, the clutch is
electric clutch detector in 4WD status, the indicator lamp is light always.
If does not reach the 4WD status in the first time,
then the controller restarts it for 2s after 2.5s de-
lay, the lamp flashes at the same time; if it is still
not in position, then the indicator lamp flashes

twice continuously, the indicator lamp is extinguis-
hed for 1s, the motor is stopped. That means the
electric clutch is unqualified and should be repla-
ced by the qualified product. The motor starts for
3s normally when the clutch is shifted form 4WD
to 2WD, the lamp flashes at the same time, when
the clutch is in 2WD status, the indicator lamp is
extinguished always. If does not reach the 2WD
status in the first time, then the controller restarts
it for 2s after 2.5s delay, the lamp flashes at the
same time; if it is still not in 2WD status, then the
indicator lamp flashes twice continuously, the indi-
cator lamp is extinguished for 1s, the motor is sto-
pped. That means the electric clutch is unqualified
and should be replaced by the qualified product.
36. Cover the shift fork sleeve on the major semiaxle

spline.
37. Install the separator housing on the front axle tube
flange and use the bolt to tighten it to the speci-
fied torque (The bolt should be precoated with the
screw lock agent and the amount should be just
can cover the complete screw)
Caution: Before installation, remove the foreign
material on two matching surfaces of separator
housing and front axle tube flange; and precoat the
1596 silicon rubber plane sealant on the front axle
tube flange. Caution: Prevent the sealant from en-
tering into the screw hole.
38. Press in the plastic vent tube on the electric clutch

housing and front axle tube.
39. Install two location pins in the location pin hole of
electric clutch housing respectively.
40. Coat the connecting surface of electric clutch
housing and electric clutch with 1596 silicon rub-
ber sealant uniformly; level it by plate.
Caution: The connecting surface should be clea-
ned and must not have the oil and other foreign
matters. The sealant must not enter into the elec-
tric clutch housing and screw hole.
41. Install the electric clutch assembly on the electric

clutch housing.
(a) Make the shift fork cross on the shift fork sleeve.
(b) Align the location pin hole of electric clutch with
two location pins, and tighten it by bolt; tighten the
bolt to the specified torque. (Precoat the medium
screw of bolt with one or two drop of screw lock
agent)
42. Insert the clip into the vent tube bracket.
43. Clamp the vent tube clip on the front drive axle
vent tube connecting tube assembly.
44. Connect the front drive axle vent tube connecting

tube assembly to three ports, the front axle tube,
electric clutch and electric clutch housing.
45. Screw off the oil filling plug of front drive axle
housing, then fill the axle housing with the hypoid
gear oil; then tighten the oil filling plug to the spe-
cified torque.
46. Fill the electric clutch housing with the gear oil;
then tighten the oil filling plug to the specified tor-
que.

Installation of front reducer assembly
1. Install the front drive shaft assembly on the redu-

cer assembly
(Refer to “Assembly of Front Drive Shaft”)
2. Use the jack to support the front drive axle, insert

the hanger plank bolt with washer and tighten it to
the specified torque.
Remarks: Do not insert the previous two bolts in rever-
se direction.

to the drive shaft according to the mark made be-
assembly mark
fore disassembly, and tightens it to the specified
torque.
4. Install the beam under the front drive axle; tighten
the connecting bolt of the beam to the specified
torque.
5. Connect the power sire connector of the electric
clutch to the power output wire of the car.
Semiaxle assembly
oil seal pressing block 95-105
◆oil seal
brake caliper assembly
bearing parking brake assembly
◆circlip
oil seal base brake disc

rear axle
pull-wire assembly

Removal of semiaxle
1. Remove the wheel.
2. Disconnect the manual brake pull-wire from the ca-
rriage; loose the small bracket.
3. Remove the brake caliper with the brake disc.
4. Remove the rear halfaxle assembly from the rear

axle housing
(a) Use the bolt to connect the special tools to the se-
miaxle flange surface.
(b) Use the hammer of special tools to remove the
rear axle.
5. Remove the circlip from the halfaxle assembly.

Use the circlip pliers to remove the circlip.
Check and repair of rear axle compo-

limitation limitation
2.0mm 0.2mm nents
1. Check the rear axle and flange for wear, damage
and run-out.
Max. Run-out of axle: 2mm
Max. Run-out of flange: 0.2mm
It should replace the rear axle if the rear axle or flange
is worn or damaged, or the measured run-out is be-
yond the specified value.
2. Check the external oil seal
(a) Check for the wear or damage; especially for the
lip of oil seal.
(b) Replace it if necessary.
3. Check the bearing and oil seal holder
Check for wear and damage, replace it if necessary.
4. Remove the bearing and oil seal holder
(a) Move the brake and oil seal pressing block to the
limit position along flange direction; move the ex-
ternal oil seal to the limit position of oil seal.
(b) Place the hook of the special tools in sequence,
the position is shown as figure; make the hook
holds the bearing tightly; then use the bolt to
connect the hook to the hammer fixedly; at last,
place it on the pad with halfaxle spline end facing
ground.
(c) Hold the hammer to beat downwardly with force
for several times to remove the bearing and oil
seal holder.
Caution: Do not damage the oil seal .
5. Install the new external oil seal
(a) Clean the semiaxle.
(b) Coat the lip of external oil seal with proper HP-R
grease.
Caution: When install the oil seal, the lip of oil seal
must not contact the semishaft to avoid scratching
the oil seal .
6. Replace the bearing and oil seal holder
(a) Heat the oil seal pressing block in 22# engine oil
to 100 ℃.
Caution: The end of oil seal pressing block with
larger chamfer faces the halfaxle spline. Install it
immediately after taken out.
(b) Use the hydraulic press to install the new bearing
and new oil seal pressing block by press.
7. Install the circlip
Use the circlip pliers to install the new circlip in the slot
of semiaxle.
8. Check the inner oil seal for wear or damage.

9. Remove the inner oil seal
special tools Use the special tools to remove the inner oil seal.
10. Install the new inner oil seal

special tools (a) Coat the lip of oil seal with proper HP-R grease.
Installation of rear axle

1. Install the halfaxle assembly in the axle housing
(a) Use the kerosene to clean the semiaxle and inner
oil seal holder.
(b) Assemble the halfaxle spline and halfaxle gear
spline firstly, then use the brass rod to beat knock
the halfaxle assembly into the axle housing.
Caution: Protect the lip of inner external oil seal
and pull-wire assembly during assembly, align the
brake bolt with the flange bolt hole of the rear axle.
axle housing flange 2. Install the rear brake disc
brake disc
halfaxle assembly
3. Install the brake caliper

4. Connect the manual brake wire.
5. Install the wheel.
6. Discharge the air of brake system by test.
Reducer
adjusting ring
side bearing
driven bevel gear
adjusting washer
◆locking plate
drive bevel gear
rear bearing
65-95
◆bearing spacer
78-115
oil baffle disc
dustproof cover
flange
plain washer
18-25
◆nut front bearing stop plate
bearing gland
◆oil seal

Replace the oil seal on the car

assembly mark 1. Disconnect the reducer from the drive shaft.
(a) Make the assembly mark on two flanges.
(b) Remove four bolts and nuts.

Use the special tools to remove the oil seal.
4. Install the new oil seal

(a) Coat the lip of oil seal with the HP-R grease.
Insertion depth of oil seal: 1.0mm
5. Install the flange and dustproof cover assembly
special tools
insertion depth: 1mm
6. Apply some adhesive to the upper and lower sur-

faces of the plain washer, install the plain washer,
then rivet the nuts of the drive bevel gear.
Nut tightening torque: 150±10N·m
7. Connect the drive shaft flange to the reducer flan-

ge.
assembly mark
Align the assembly mark ; then connect them by bolt.
8. Check the oil level of reducer.

Replace the hyperbolic gear oil if necessary.
Oil number : GL-5 hyperbolic gear
Viscosity : SAE80W/90
Amount: Filled with oil until the oil flows out form
oil filling port.
Removal of reducer
assembly mark 1. Remove the oil drain plug; drain the oil from the re-
ducer
2. Remove the rear axle
(Refer to Step 2 in “Disassembly of Rear Axle”)
3. Disconnect the drive shaft from the reducer
(Refer to step 1 in “Replace the Oil Seal on Car”)
4. Remove the assembly of reducer.
Disassembly of reducer
Remarks: If the noise of differential is loud, process the
following inspection before disassembles the differen-
tial to determine its reason. When the differential has
serious problems, it can be disassembled for repair if
necessary.
1. Check the internal clearance of driven bevel gear.

If the clearance is beyond the specified range; adjust
the preapplied load of bearing or repair if necessary.
(Refer to step 13 “Assembly of Reducer”)
Backlash: 0.13-0.21mm
Clearance differences among three points≤0.08mm
2. Check the intertooth contact of drive bevel gear
(Refer to Step 14 in “Assembly of Reducer”)
Record the contact position of tooth.
3. Check the clearance between the thrust plate of
axle shaft gear and differential housing.
Use the feeler to measure the clearance between the
thrust plate of axle shaft gear and differential housing.
Standard clearance≤0.35mm
If the backlash is not within the specified extent, repla-
ce with an appropriate thrust washer. It shall turn flexi-
bly after the assembling.
(Refer to Step 2 in “Replacement of Differential Com-
ponents”)

Use the torsion meter to measure the pre-applied load
on the internal clearance between the drive small gear
5. Total pre-applied load
Use the torsion meter to measure the total pre-applied
load.
6. Remove the differential and driven bevel gear

(a) Make the assembly mark on the differential bea-
ring gland and reducer housing.
(b) Remove two stop plates.
(c) Remove two bearing glands and two adjusting
rings.
(d) Remove the bearing outer race.
(e) Remove the differential from the reducer housing.
Remarks: Mark the label on the removed components

to indicate the position of reassembly.
left right

(a) Use the hammer and chisel to loose the riveted
special tools part of nut.
(b) Use the special tools to clamps the flange; then
remove the nut.
Caution: The used nut can not be used any more.
(c) Remove the flange and dustproof cover assembly.
Use the tools to pry out the oil seal.
9. Remove the drive bevel gear and spacer

special tools
Remove the drive bevel gear, bearing and spacer from
the reducer housing.
10. Remove the oil baffle disc and front bearing inner
race
11. Replace the rear bearing of drive bevel gear

(a) Use the press machine and special tools to pull
out the rear bearing from the drive bevel gear.
special tools

the reused adjusting washer and new rear bearing
on the drive bevel gear.
special tools
12. Replacement of front and rear bearing outer race of

drive bevel gear.
(a) Use the hammer and brass bar to knock out the
front and rear bearing.
the new bearing outer race by press.
13. Remove the side bearing form the differential

housing.
Use the special tools to pull out the side bearing from
the differ ential housing.
14. Remove the driven bevel gear

(a) Remove the connecting bolt and lock plate of dri-
ven bevel gear.
(b) Make the assembly mark on the driven bevel gear
and differential housing.
(c) Use the rubber hammer or brass rod to knock
down the driven bevel gear.
Assembly of reducer
1. Install the bearing outer race of drive bevel gear.
(Refer to Step 12 in “Disassembly of Reducer”)
2. Install the rear bearing of drive bevel gear and ad-

justing washer
special tools
(a) Select the proper adjusting washer according to
“Meshing Condition of Drive Bevel Gear and Dri-
ven Bevel Gear”.
(b) Install the rear bearing and selected adjusting
washer by press machine.
3. Install the spacer.

(a) Select the adjusting washer between the rear bea-
ring and spacer based on the experience.
spacer
(b) Install the spacer.
4. Install the front bearing inner race, oil baffle disc

and oil seal of drive bevel gear
special tools
(a) Place the front bearing inner race in the reducer
housing; place the oil baffle disc.
(b) Coat the position of reducer housing oil seal and
lip of oilseal with grease uniformly; place the oil
seal in position. Start the press machine for insta-
llation.
5. Install the drive bevel gear, flange and dustproof

level
cover assembly
(a) Install the flange and dustproof cover assembly in
the reducer housing, Press it to level by hand.
(b) Insert the drive bevel gear installed with the spa-
cer, rear bearing and adjusting washer into the
flange through the spline; screw on the nut.
(c) Use the nut to tighten the flange, plain washer and
drive gear.
6. Use the special tools to clamp the flange; use the

torque wrench to tighten the nut.
special tools Tightening force: 140-160N·m
7. Measure the rotation pretightening force of bearing

For new bearing : 1.2-1.7N·m
For reused bearing : 0.4-0.6N·m
If does not meet the requirement, replace the adjusting
washer under the spacer until meet the requirement.
Tightening torque : 0-3.5N·m
(a) Reduce the thickness of adjusting washer if the
measured value is less than standard value;
(b) Increase the thickness of adjusting washer if the
measured value is more than standard value.
8. Install the driven bevel gear on the differential
housing.
(a) Use the bolt and lock plate to connect the driven
bevel gear to the differential housing.
(b) Screw on for three rounds at least by hand; then
use the pneumatic wrench to tighten it properly.
(c) Use the torque wrench to tighten it.

Caution: Tighten the bolt in diagonal .
Use the hand hammer and flat head punch to lock the
lock plate.
9. Install the differential side bearing by press.

Use the press machine and special tools to install the
special tools
side bearing on the differential housing by press.
special tools
10. Install the differential assembly

(a) Remove the bearing gland. Do not mix the left up
with right.
(b) Install the differential assembly in the reducer
housing.
11. Install the adjusting ring

Use the adjusting ring to press the bearing outer race
in position; tighten it properly. Adjust the clearance
between the drive and driven gear to the proper dimen-
sion.
12. Install the bearing gland

(a) Align the assembly mark on the bearing cover with
that on reducer housing; Press down the press
cover by hand.
assembly mark
13. Adjust the engagement clearance between the dri-

ve and driven gear.
(a) Use the torque wrench to tighten four bolts on
bearing cover by torque wrench.
(b) Adhere the measuring meter base on the end

surface of reducer housing; the measuring head
contacts the tooth surface; rotate the driven gear
by hand and measure the engagement clearance
between the drive and driven gear.
(c) If the engagement clearance does not meet the

requirement, use the special tools to adjust the left
and right adjusting ring until it meets the require-
ment.
(d)Recheck the engagement clearance between the

drive and driven gear.
Engagement clearance: 0.13-0.18mm

gear.
(b) Rotate the driven bevel gear in clockwise and
anticlockwise by hand.Check the engagement of
gear.
select the shim which can make the small

drive gear close to the driven bevel gear
small end contact

dedendum contact
sound contact
select the shim which can make the small drive gear away from the driven bevel gear
Select the proper washer from the table for correction

rear bearing if the intertooth contacting status is bad. The thickness
washer tolerance of washer is ±0.01mm.
Set NO. Thickness Set NO. Thickness
1 1.60 7 1.90
2 1.65 8 1.95
3 1.70 9 2.00
4 1.75 10 2.05
5 1.80 11 2.10
6 1.85 12 2.15
15. Install the stop washer and stop plate
(a) If the drive and driven gear engagement mark
meets the requirement, then use the hand ham-
mer and punch to lock the stop washer.
(b) Install the stop plate, spring shim and bolt; tighten
the bolt.
(c) Use the punch and hand hammer to knock the lo-
wer end of stop plate in the adjusting ring hole.
16. Measure the total pre-applied load

If the pre-applied load is beyond the specified; it should
replace the shim between the spacer and rear bearing
until meet the requirement.
(a) It should replace the adjusting washer if the pre-
applied load is more than specified value.
(b) If the pre-applied load is less than specified va-
lue, it can retighten the nut slowly and the torque
should be no more than 160N·m.
Caution: When tighten the nut, if is beyond the
Max. torque, replace the adjusting washer and re-
peat the pre-applied load process. Do not reduce
the pre-applied load by the method of screw off the
drive gear nut to loose.
17. Check and adjust the run-out of flange.

(a) Adhere the dial indicator base on the reducer
housing; make the probe of dial indicator contact
with the end surface of flange; rotate the flange
and watch the rotation range of the dial.
Full run-out tolerance of end surface: 0.10mm
(b) Adhere the dial indicator base on the reducer

housing; make the probe of the dial indicator con-
tact with the inner diameter of flange; rotate the
flange by hand , and watch the rotation range of
the dial.
Radial full run-out tolerance: 0.10mm
18. Rivet the nut of drive bevel gear
Installation of reducer and differential

assembly mark
assembly
1. Install the new stiffening ring
2. Install the reducer and differential assembly
Install the reducer and differential assembly in the rear
axle housing; place the washer and nut. Tighten the
3. Install the reducer and differential assembly flange
on the drive shaft flange and align the assembly
mark; use four bolts and nuts to connect them.
Tighten the bolt and nut to the specified torque.
4. Install the oil drain plug; fill the differential with the
gear oil
oil number : GL-5 hyperbolic gear oil
Viscosity: SAE80W/90
Amount: Filled with oil until the oil flow out from
the oil filling port.
Tighten the oil filling plug.
Differential
thrust plate
straight pin lock washer
half axle gear planetary gear
differential housing planetary gear shaft
half axle gear
planetary gear thrust plate
lock washer
Differential
1. Remove the reducer and differential assembly
(Refer to “Removal of reducer”)
2. Remove the differential from the reducer and diffe-
rential assembly.
(Refer to “Disassembly of reducer”)
Replacement of differential components
1. Disassembly of differential
Use the hammer and punch to knock out the pin. Re-
move the planetary gear shaft, two half axle gears, two
planetary gears and two lock washers, two thrust pla-
tes.
2. Assembly of differential
(a) Install the half axle gear and thrust plate of axle
shaft gear
(Unit: mm)
Set NO. 1 2
Thickness 1.2 1.5
(b) Install the planetary gear and planetary gear lock

washer in the differential by rolling.
(Unit: mm)
Set NO. 1 2
Thickness 0.8 1.0
(c) Use the feeler to measure the clearance between

feeler the thrust plate and differential housing; it can be
replaced by the thrust plate with different thick-
ness if the clearance is beyond the specified ran-
ge.
Standard clearance≤0.35mm
(d) Install the straight pin

Use the hammer and punch to knock in the pin through
the hole on the differential housing and planetary gear
shaft. Rivet the pin with the differential housing.
Installation of differential
1. Install the differential assembly in the reducer
housing
(Refer to “Assembly of Reducer”)
2. Install the differential
(Refer to “Installation of Reducer and Differential Ass-
embly”)
Rear suspension
upper support pad of coil spring
coil spring
long longitudinal
pull-rod assembly
rear axle assembly
short longitudinal pull-rod assembly
short longitudinal pull-rod fixed bolt
short longitudinal cross pull-rod
long longitudinal rubber pad pull-rod assembly short longitudinal connecting bolt
pull-rod fixed bolt pull-rod fixed bolt
180±15 rubber pad Compress the

180±15 180±15
bushing by 1/3
long longitudinal
pull-rod assembly
cross pull-rod assembly
180±15
rear vibration
damper
long longitudinal pull-rod fixed bolt
180±15
170±15
rear stabilizer bar

rear connecting rod of stabilizer bar assembly
bush
23±3 63±5
plain washer
bush clip

Removal of vibration damper

1. Use the lifter to raise the car firstly, then support
the rear axle by bracket.
2. Remove the upper and lower fixing nut which is
used to fix the vibration damper; compress the
vibration damper by hand. Remove the upper end
firstly, then the lower end; take out the vibration
damper.
Installation of vibration damper
1. Lower tightening force of vibration damper: 170±
15N·m.
Upper tightening torque: Compress the bushing by
1/3 as a standard.
Caution: If the fixing nut of vibration damper is the
lock nut, it should be replaced by the new lock nut
after replace the vibration damper.
Removal of coil spring

1. Remove the vibration damper (As previous )
2. Use the special tools to clamp the coil spring.
3. Place the car in the bounce status, take out the
coilspring
4. Remove the special tools from the coil spring.
special tools
Installation of coil spring

1. Firstly, use the special tools to clamp the coil
spring to certain height (height when car is in
bounce status).
2. Cautions for installation: Adjust the rubber gasket
on the spring to ensure the spring in flat status.
3. Remove the special tools.
Removal of connecting rod of stabilizer

bar
1. Shown as figure, firstly screw off the nut in the
connecting place between the connecting rod of
stabilizer bar and carriage. (Need the inner hexa-
gon spanner ).
2. Screw off the nut connected to stabilizer bar in
same method; screw off the connecting rod.
Installation of connecting rod of stabili-

zer bar
Tighten it to the specified torque during installa-
tion: 63±5N·m
Wheels and Tyres-1
Wheels and Tyres
Tyres ................................................................................................ 2
Wheels ............................................................................................. 7
Tools ................................................................................................ 9
Wheels and Tyres-2
Wheels and Tyres

Tyres
Instructions
This type of vehicles is equipped with tyres without inner tubes. They can achieve their best design
status when the inflation pressure reaches the recommended valve and the tyre load reaches the full
load state. The proper tyre pressure and the correct driving habit can greatly influence the service life
of tyres. This can realize the traveling comfort, stability and operability, reduce the tyre tread wear,
extend the service life of tyres and avoid damage to tyres. Furthermore, the phenomenon such as
overload, overspeed and unnecessary emergency braking will speed up the wear of tyres.
High tyre pressure and the Low tyre pressure and

Normal tyre pressure the tyre shoulder worn
middle of the tyre tread worn
Measurement of the tyre pressure shall be carried out under the normal temperature. The tyre
pressure will be increased due to the tyre heating when the vehicle is traveling, and get back
to the original condition when the tyre is cold. Do not deflate when the pressure is increasing.
Its pressure will reduce naturally and slowly even when the tyre is used under the normal
condition, so the periodic check for the tyre pressure is necessary (once per month is proper).
You should check the tyre pressure under the cold tyre state and adjust it to the specified
value. It is recommended that you should check the tyre pressure, including the spare tyre, at
least once per month or before a long trip.
Tyre Inflation
In the initial usage period of a new tyre, its tyre size
will be increased due to the tyre heating with curvature
movement, according making the relative pressure
reduced. So, the pressure shall be added when
the tyre is used for 24h and the vehicle travels for
2000-3000km.
1. Check whether the tyre inflation pressure is normal
or not. Cold tyre inflation pressure:
P235/65 R17 104H Front 230kPa (2.3 kgf/cm2, 33.35psi)
P235/65 R17 104T Rear 230kPa (2.3 kgf/cm2, 33.35psi)
P235/70 R16 104S Spare

230kPa (2.3 kgf/cm2, 33.35psi)
tyre
Wheels and Tyres-3
Precautions for Tyre Inflation

1. Be sure to keep safety in inflation. Check the pressure with the tyre pressure gauge at any time
to avoid tyre cracking due to over inflation.
2. Carry out the inflation only after the tyre is cold when the vehicle stops traveling, for the tyre
temperature will increase and then influence the pressure.
3. Check the tyre valve and valve core. It is inconvenient for the inflation and pressure
measurement if the tyre valve and valve core aren’t matched well and if there are defects such
as projection and recess.
4. Be sure to keep clear in inflation. Do not interfuse water and fuel into the inflated air to prevent
the rubber air-retaining liner from going bad and being damaged
5. During carrying out the inflation, do not inflate only after the pressure exceeds the standard
one greatly, and do not over inflate because the tyre is lack of inflation when you go out for a
long time. Exceeding the standard pressure greatly will make the cord over extend, reduce its
high-strength and influence the service life of tyres.
6. Clear away the dust on the tyre valve before inflation, and do not loose the valve core. Coat the
tyre valve with soapy water after inflation, check leakage (the bubbles will generate if the tyre
valve is leaky), then complete and screw the valve cap to prevent mug and sand from entering
into the tyre valve.
7. Calibrate the tyre pressure gauge which is with the vehicle or used in the tyre workshop
periodically to make sure the accuracy of the pressure check.
Possible Malfunction Caused by Tyre Pressure

Higher than the The same axle with a different
Lower than the recommended pressure
recommended pressure pressure
Possible 1. Traveling bumped 1. Tyre makes noise in steering 1. Unbalanced braking
malfunction 2. Ty r e s c r a t c h e d o r 2. Inconvenient steering 2. Over steering
carcass broken 3. Ty r e t r e a d e d g e w o r n q u i c k l y a n d 3. Operation failure
3. Tyre middle tread irregularly 4. Operation failure
worn quickly 4. Tyre wheel rim snagged and broken
5. Tyre cord broken
6. Higher tyre temperature
7. Operation failure
Assembly Instructions
The radial hard part of the tyre (high point) shall be aligned with the least radius position (low point)
when assembling the tyre. The high point of the tyre is marked by the paint spot, which will be washed
away, on the outside sidewall of the tyre, and the low point is marked by the paint spot on the wheel
flange first. The dynamic balance for the tyre and wheel shall be reached again to make sure the
smooth driving whenever removing the tyre. If you can not find out the position of the paint spot,
please mark a line on the tyre and wheel before removing to ensure they are refitted at the same
place. Pay attention to the following points for the general tyre assembly:
1. Pay attention to the size match of the tyre and wheel rim. The defects such as deformation,
rust, crack and aufreissen should not exist on the wheel rim, or they may lead to the tyre
damage.
2. Pay attention to keep clear when install the wheel rim to the type, and it will lead to tyre local
heating if any granular hard materials such as sand and iron chip are installed into tyre.
3. The same vehicle equipped with tyres of different sizes or patterns is not allowed, or it will
lead to irregular wear. Pay attention to the balance of the wear rate of the two tyres installed
together. The large diameter discrepancy between the two tyres due to the tyre wear will speed
up the tyre damage.
4. Pay attention to the protection of the tyre valve and the completion and clean of the valve core
when removing and installing the tyre.
5. Clear away the materials on the tyre tread such as horse, hard materials or other sharp
materials timely to reduce the tyre damage.
Wheels and Tyres-4
6. Retread and repair the tyre crown worn or the

break and cut on the tyre tread and sidewall. The
tyre damage would be speeded up if you do not
repair the damaged parts timely.
7. Pad the lining belt to the relative part in the broken
or scratched tyre, and reinstall it to the driving axle
wheel for use after balancing. However, you can not
install it on the steering wheel to prevent the steering
wheel from shimmy. At the same time, pay attention
to do not drive a vehicle under the overload and
overspeed status to make sure the safe traveling.
If you use the tyres of other sizes or types, these
elements such as traveling comfort, operability,
speedometer calibration, vehicle ground clearance,
and the clearance between tyre or snow antiskid
chain and body & chassis will be influenced. You had
better install a new pair of tyres on the same axle.
Install a most similar tyre, compared to the original
one, to balance the brake force and traction force
when only one tyre needs to be replaced.
Warning:
Do not install the tyres in different types such as
the radial tyre, bias tyre and belt-bias tyre to the
same vehicle unless there is emergency situation.
It will influence the vehicle operability and stability,
even lead to the vehicle out of control, if the tyres
of different types are used together.
Abnormal Wear of Tyres
1. Abnormal wear of tyres involves irregular wear and
quick tyre wear. There are a lot of reasons such
as incorrect tyre pressure, lack of periodic tyre
rotation, bad driving habit and the abnormal front
wheel alignment.
Please replace the tyre if:
1. The wear rate of the front and rear tyres are
different.
2. There exists irregular wear on any tyre tread.
3. The wear rate of the left and right front tyre is
different.
4. The wear rate of the left and right rear tyre is
different.
5. There is scallop abnormal wear on the tyre tread
and the tyre grounding point is flat.
A
Please check the front wheel alignment if
1. The wear rates of the left and right tyres are different.
2. There exists irregular wear on any tyre tread.
3. The tread pattern strip or block on one side of the
B front tyre wears seriously.
A. Hard steering, insufficient pressure or lack of
periodic tyre rotation.
B. The front wheel alignment is abnormal and the
structure of the tyre or wheel is not uniform.
Wheels and Tyres-5
Wear Mark
There are some tyre tread wear marks in the tyre tread
pattern groove (as shown as A in the left figure). Such
marks show that the tyre must be replaced right away.
The tyre will reach its ultimate usage when remained
A
tread pattern depth reaches 1.6mm (it is parallel to the
projection of the tread pattern groove). Replace the
tyre before this for making sure your safety. The tyre
shall be left unused when serous eccentric wear leads
to the partial cord ply exposure, or the external object
wear depth reaches the cord ply or the steel belt layer.
Runout of the Radial Tyre
Such runout refers to the front part, rear part or the
front and rear part of the vehicle shakes to both sides
at the same time. The runout of the tyre is caused
by the out-of-straight steel breaker belt in the tyre.
It behaves the most evident when traveling at the
speed of (8~48)km/h, and you can find out the tyres
with malfunction through the road test. The wigwag
motion (also called runout) will appear on the rear of
the vehicle if there is malfunction. By now the driver on
the seat will feel as if someone pushes the vehicle on
one side of the vehicle. This will become more obvious
when it occurs on the front of the tyre. The metal plate
in the front looks like doing the frontward and backward
movement and the driver feels as if he is on the rotary
centre point of the vehicle.
Road Test Method of the Vehicle
1. Find out whether the runout exists on the front wheel
or on the rear wheel. Install the known fine wheel,
which is verified at other vehicles of the same type,
to the place where the vehicle runout occurs.
2. Replace the rear wheel if you can not distinguish
the wheel with runout. Keep on testing, and if
the condition improves greatly just reinstall the
original wheels one by one until you find out the
runout wheel.
3. If there is not obvious improvement, you can install
four known fine tyres first, and install the original
tyres one by one and check it with the above method.
Transposition of Tyres
1. Carry out the tyre transposition in time according
to the principle shown in the left figure to let the
Front
前
wear uniform.Carry out the transposition for the
radial tyre periodically and inflate the pressure
in accordance with the provisions. Attention: the
tyre shoulder of the radial tyre (especially for the
front tyre) may wear quickly due to the structure.
The service life of tyres will extend by 20% if
carrying out the tyre rotation once after the vehicle
travels for 8000 to 12000km. So, the periodic tyre
transposition is very important.
Wheels and Tyres-6
Adjust the tyre pressure to

the recommended one
Test the vehicle on the horizontal

and straight road back and forth
Carry out the above test after interchange

the left and right front tyres
Deviate to the Obtain the calibration and Deviate to

same direction replace the tyre if works another direction
Deviate to another Install the “New tyre” on

direction one side of the front part
Do not obtain the calibration,

Obtain the calibration and install the “New tyre” on
and replace the tyre another side of the front part
Do not obtain the calibration,

Obtain the calibration this means the “New tyre”
and replace the tyre is not good actually
Offtracking refers to: The vehicle does not travel along a straight line on the horizontal road when not
operating the steering wheel.
Reasons for offracking
1. Incorrect tyre and front wheel alignment.
2. Brake force is inconsistent.
3. The structure problem of tyres:
The manufacturing way, such as the arrangement of the steel breaker belt in the tyre, will lead
to the offtracking. The steel breaker belt of the offtracking tyre center line in the radial tyre will
generate lateral force when the tyre rolls along a straight line. The tyre will roll inclining to one
side if the tyre diameter is longer than that on the other side. This will generate lateral force
and lead to vehicle offtracking. The above procedures will also be suitable for judging the tyre
offtracking in the case of correct front wheel alignment. Furthermore, the rear tyre will not lead
to the offtracking.
Fitting and Removal of Tyres
1. Use a tyre changer to install and remove the tyre. Operate the machine in accordance with the
instruction of the manufacturing factory. Do not replace the tyre with manual tools or a tyre
removing lever because this will damage the tyre bead or the wheel rim.
2. Use the steel wire brush or the steel wool to clear away the lubrication grease, old rubber and
light rust on the wheel rim bead seat. Fully lubricate the bead with the specified tyre lubrication
before fitting or removing the tyres.
3. Inflate the tyre to the specified pressure and check whether the tyre bead completely sets on
the seat or not after fitting the tyre.
Wheels and Tyres-7
Warning:
Do not over inflate the tyre. The tyre bead may
break and this may lead to the serious physical
injury when the bead expansion exceeds the safety
rate of the wheel rim. Do not exceed the specified
pressure in inflation. Deflate, re-lubricate and re-
inflate if the specified pressure can not properly
set the tyre bead on the seat.
Usage of Spare Tyre
1. The standard inflation pressure is 230kPa.
2. Measure the pressure of the spare tyre under the
normal temperature.
3. Test whether the valve core leaks or not with soapy
water and lock the cap of valve core after the
inflation for spare tyre.
4. Make sure the spare tyre is on the usable condition
at any time and check its tyre pressure at least
once per month.
5. The spare tyre can reach its ultimate usage when

its remained tread pattern depth reaches 1.6mm
(it is parallel to the projection of the tread pattern
groove). Do not use such spare tyre for making
sure your safety.
Attention:
Use “△’ to indicate the setting position of the
wearing index on the spare tyre bead (as shown in
the figure).
Wheel
General Balancing Procedures
Clear away the soil accumulated in the inner side of
the wheel rim.
Warning: Clear away the pebbles on the tyre tread,
or the operator will be injured by the flying pebbles
when the wheel revolves. Check the situation of the
tyre damage carefully, and carry out the balance
operation according to the advice of the balance
device manufacturer.
Off-car Balancing
Most of the off-car balancers, which are more precise
than the on-car rotary balancers, are simple and
convenient and can carry out the dynamic (two sides)
balancing. Although they can not correct the unbalance
of brake drum or brake disc like the on-car balancing,
they can overcome such shortcoming by their accuracy.
On-car Balancing
The on-car balancing varies with the different device
and tool manufacturing factories. So, do carry out the
balancing operation according to the instructions of the
different manufacturers.
Wheels and Tyres-8
Warning:
Limit the wheel rotary speed within 55km/h which
is shown on the speedometer. This limitation is
necessary because the speedometer only displays
a half of the real wheel speed when a driving wheel
is slipping while another one is in motionless. Be
careful when the wheel is slipping because the
slipping wheel will achieve a high speed. This may
lead to the tyre peeling or the differential damage
and the serious physical injury or vehicle damage.
Dynamic and Static Balance
1. The wheel balance consists of two modes: dynamic
[A] [B] 2
and static balance. The Fig.1 is the static balance
while the Fig.2 is the dynamic balance. Static
balance refers to the weight distribution around the
vehicle is equal. It will lead to fierce upward and
3 downward runout which is called as bounce. This
1 situation may lead to the irregular tyre wear finally,
Fig.1 as shown in the Fig.1.
1. Wheel runout focus point [A]：Do not add the balance weight
2. The place where added [B]：Added the balance weight
the balance weight
3. Axle center
2. Dynamic balance refers to the weight distribution

[C] [D] 2 on the both sides of the wheel center is equal.
The tyre assembly will not lean to the other side
from the wheel center side in rotation. The wheel
dynamic unbalance may lead to the shimmy, as
shown in the Fig.1.
1. Wheel runout focus point [C]：Do not add the balance weight
3
2. The place where added [D]：Added the balance weight
1 the balance weight
Fig.2
3. Axle center
Detection method of the wheel dynamic

balance:
1. Clear the wheel to be detected, clear away the soil
and sand, and remove the old balance weight.
2. Inflate the tyre to the specified pressure valve.
3. Install the wheel on the balancer and lock it.
4. Open the electric switch and check whether the
indicating device is correct or not.
5. Key in the wheel rim diameter and width, and
measure and key in the distance between wheel
rim edge and the case.
6. Take off the protective cover and press the starting
key for measurement.
7. Read the dynamic unbalancing weight and position
inside and outside of the wheel from the indicating
device when the wheel stops rotating automatically.
8. Rotate the wheel slowly and manually, stop rotating
it when the indicating device on the dynamic
balancer sets out a signal.
Wheels and Tyres-9
9. Put the dynamic unbalance weight displayed on the

dynamic balancer to the wheel rim edge on the twelve o’
clock position according to inner and outer position.
10. Restart the dynamic balance to carry out the balance
test until the dynamic unbalance weight is smaller
than 10g and the machine displays that it is qualified.
11. Take off the wheel and shut off the power supply,
at this moment, the measurement completes. Read
the instruction carefully before using the dynamic
balancer because the operation method is different
due to the different models and brands.
Repair of Wheels
Do not use the methods of welding, heating or
hamming when you repair the wheel. All the damaged
wheels must be replaced. Replace the wheel which
owns the defects of distortion, hollow, over large
horizontal and radial runout, leakage from the welled
position, bolt hole prolonged, unlocking nut with cap
and serious dust. The over wheel runout will lead to
the bad vibration. The load capability, diameter, wheel
rim width, offset distance, and installing structure of the
wheel to be replaced should be accordance with the
original wheel. The unsuitable wheel size will influence
the service life of the wheel and the bearing, braking
cooling effect, the calibration of the speedometer,
vehicle ground clearance and the clearance between
the tyre and the body/chassis.
Removal of Wheels
1. Unscrew the nut; one to two cycles are suitable.
2. Lift the vehicle.
3. Unscrew off the nut and remove the wheel.
The nut tightening torque is (135±15) N•m.
Note: Do not unscrew the fastened wheel with the
method of heating, or this will reduce the wheel
service life and damage the hub bearing when the
wheel is heated.
Installation of Wheels
Mount the wheel in reverse order and in accordance with
the following requirements: To avoid wheel and brake disc
deformation, tight the wheel nut to the specified torque
according to the order. Align the wheel arch gap with the
tyre valve when installing the wheel arch.
Screwing order: diagonal screwing.
Note: Clear away the corrosion on the mounting surface
of the wheel and the brake drum or brake disc with the
tools such as wire brush before mounting wheel. So,
the metal on the mounting surface will contact well
when mounting the wheel, or the wheel nut may loosen
and the wheel may fall in the traveling.
Tools
Tyre pressure Dial measuring gauge Wheel balancer
gauge with a magnetic seat
Brake-1
Brake
Cautions ............................................................................ 2
Check and adjustment ..................................................... 5
Brake pedal ....................................................................... 7
Parking brake .................................................................... 8
Front brake ........................................................................ 9
Rear brake (Disk-and-drum type) .................................... 16
Rear parking brake ........................................................... 22
Load-sensing proportional valve .................................... 29
Antilock Braking System (ABS) ...................................... 31
Brake-2
Cautions
1. It should be carefully when replace each part. For any mistake may affect the performance of
brake system and cause the accident and danger during driving. The replaced components
must be the component with same component number or equivalent.
2. It is very important that maintain the clean of component and each place when repair the brake
system.
Troubleshooting
Failure cause Inspection content
brake pad is worn Replace the brake shoe
brake block is worn Replace the brake block
brake system is leaked Repair the leakage
Pedal is low or soft master pump has failure Repair or replace the master pump
Brake system has air Drain the air from brake system
Brake pump has failure Replace the brake pump
Auto adjuster of rear brake has failure Repair or replace the adjuster
Parking brake is adjusted badly. Adjust the parking brake
Pull wire of parking brake is locked Repair if necessary
Assist push rod is adjust badly Adjust the push rod
Extension spring or return spring has Replace the extension spring
fault
Lag of brake
Pipeline is blocked Repair if necessary
brake pad is broken or deformed Replace the brake shoe
brake block is broken or deformed Replace the brake block
Auto adjuster is damaged Replace the adjuster
Master pump has failure. Replace the master pump
Improper inflation of tyre Charge the tyre to the proper pressure.
There is grease spot or lubricant oil on Find out the cause. Replace the brake
the brake shoe or brake block. shoe or block.
The brake shoe is deformed ; the brake Replace the brake shoe
pad is worn or smoothed
The brake block is deformed, worn or Replace the brake block
smoothed
Brake is stagnant
The brake drum or brake disc is defor- Replace the brake drum or brake disc
med
Extension spring or return spring has fa- Replace the spring
ilure
Wheel pump has failure Repair the wheel pump
Pump has failure Replace
Brake block is blocked Replace the brake block
There is the grease spot or lubrication Find out the cause. Replace the brake
oil on the brake disc or brake block. shoe or brake block
The brake shoe is deformed; the brake Replace the brake shoe
pad is worn or smoothed
Brake wheel is worn Replace
brake pedal is hard The brake block is deformed, worn or Replace the brake block
smoothed
Brake pump has failure. Replace
Brake assist has failure Replace the assist
Improper vacuum degree Repair if necessary
The brake pipeline is blocked. Repair if necessary
Brake-3
failure cause Inspection content

(drum brake)
The brake shoe is blocked in the rear Filled with lubricated oil
apron flange
The rear apron flange is worn Replace the lubricant flange
The brake genera-
The brake shoe pull-out piece spring is Replace
tes the crack clatter
loose or lost
during operation.
The fixed bolt of rear apron is loose Tighten
(disc brake )
Brake block support plate is loose or lost Replace
Installation bolt is loose Tighten
The brake shoe gasket or brake block is Replace, if the scratch is heavy, then fine
worn machine the brake drum or rotor again
The brake caliper and wheel or rotor are Replace it according to requirement
disturbed mutually
It has the rustle or The dustproof cover and rotor, rear Correct or replace
rattler when use the apron and brake drum are disturbed
brake mutually
Failure of other brake system compo- Repair or replace it according to require-
nent ment
Tyre generates the abrasion with the Check or maintain
tyre and chassis
It has the squeak, The brake drum and brake shoe gasket, Check, repair or replace
continuous scream, rotor and brake block is worn or scrat-
rattler or vibration ched.
noise when use the The brake pad or block is dirty, with oil Clean or replace
brake . or smoothed.
Caution: The abra- The brake pad or block is not used pro- Check, replace
sion material in the perly
brake will generate The brake pedal or assistor push bar is Check and adjust
the inherent noise adjusted incorrectly
and heat during the (disc brake )
abrasion, then emit The brake block silencing plate is lost or Replace
the heat. So it is damaged.
normal that gene- The abrasion of the brake block makes Replace
rate the squeak by the brake block abrasion indication plate
accident. The con- contacts the rotor
dition will be serious The brake caliper has burr or is corrosi- Clean or remove the flash
in extreme environ- ve
ment, such as cold, (drum brake)
hot, high humidity, The pull-out piece spring of brake shoe Check, repair or replace
snowing, saliferous is soft, damaged or improper. The pull-
and mud. The acci- out piece spring pin and spring of brake
dent squeak will not shoe is loose or damaged; and rear
cause the fatal failu- apron flange has crack
re of the brake, and
will not reduce the
effective performan-
ce of the brake.
Brake-4
failure cause Inspection content

The brake pedal or assist push bar is Check and adjust
adjusted incorrectly
The return of brake assist or master Check, repair or replace
pump or wheel pump is bad
(disc brake )
The piston is corrosive or blocked Check and fill with lubrication oil if neces-
sary.
The brake block in brake caliper is in im- Repair or replacement
proper position
Shell abrasion of rotor and brake caliper Repair or replacement
The brake block support plate in disc Repair or replacement
brake is installed improperly
The brake block abrasion indication pla- Replace
te contacts the rotor for the abrasion of
It has the continuous brake block
scream and squeak (drum brake)
when does not use The press spring of brake shoe is soft, Replace
the brake damaged or improper.
The flange of rear back rear apron is Repair or replacement
cracked
The rear apron interfere with the brake Repair or replacement
drum mutually after bent or warp
Improper machining of brake drum, cau- Replace the brake drum
se the mutual interference of rear apron
and brake shoe
Components of other brake system: Check, maintain and replace if neces-
Brake system has loose or redundant sary.
components
The brake pad is smoothed for the rear
brake drum is adjusted too tight
The wheel bearing is worn damaged or
under lubricated
The stone or foreign enters into the insi- Remove the foreign materials such as
de of wheel protecting hood the stone
The hub nut is loose Tighten it to the specified torque, it
should be replaced if the bolt hole is en-
larged
The brake pedal or assistor push bar is Check and adjust
adjusted improperly
The wheel bearing is worn, damaged or Check, lubricate or replace
It still has the rattler,
lubricated insufficiently
click or cackle noise
(disc brake )
when does not use
The muffler spring is soft or lost; the Repair or replacement
the brake.
brake block support plate or external
end of brake block is coiled
Silencing plate is unsound Check and replace if necessary
The slide bush is worn Check and replace if necessary
The installation bolt is loose Check and tighten if necessary
Piston returns unsoundly Check , repair or replace
(drum brake)
Have loose or redundant component Check, take out or repair
Brake-5
Check and adjustment

Check and adjustment of brake pedal
1. Check the correctness of height of pedal
Distance from pedal to lower front apron: 152mm.
parking lamp switch 2. Adjust the pedal height if necessary

pedal push rod (a) Disconnect the brake lamp switch wire connector;
loose the tightened nut; rotate the brake switch to
the position not contacted to limit block of brake
pedal
pedal level
(b) Loose the lock nut of operating connecting rod;

use the thinnose pliers to rotate the operating con-
necting rod to adjust the height of brake pedal to
the standard value; lock the block nut tightenedly
when reach the standard value.
(c) Rotate the brake lamp switch to contact with the

limit block of brake pedal; then rotate 1/2~1 round
continuously; tighten the block nut;
(d) Connect the wire connector of brake lamp switch;
(e) The brake lamp should not be light when the
brake pedal is released.
pedal push rod 3. Check the free stroke of pedal

Free stroke of pedal: 4-6mm
In the status of engine is stop, step on the brake pedal
for 2~3 times after eliminate effect of the brake assist,
push down the brake pedal by hand to just with the re-
sistance, then measure its displacement (free stroke).
It should be in accordance with the standard value.
free stroke of pedal

Brake-6
4. Adjust the stroke of pedal if necessary

(a) Rotate the pedal push bar to adjust the free stroke
if the stroke length is improper.
(b) Start the engine to confirm the free stroke of pe-
dal.
(c) Check the height of pedal after adjusts the free
stroke of pedal.
(d) The height difference of brake pedal and clutch
pedal to front apron is 0~8mm.
(e) The height difference of brake pedal and accele-
rator pedal to the front apron is 30±5mm.
Vacuum assist
Remarks:
Use the vacuum assist tester to check the operation of
vacuum assist if possible.
1. Operation inspection
(a) Step on the brake pedal for several times before
start the engine and check the reserved distance
which should not be changed.
(b) Step down the brake pedal and start the engine. If
the pedal moves downwardly a little, then it means
the normal operation; if the brake pedal moves
upwardly, then it means the brake assist is dama-
ged.
2. Air tightness inspection

(a) Start the engine and shut off it after 1-2 minutes.
ok not well Step down the brake pedal slowly for several ti-
mes. If the pedal moves downwardly all long at
the first time, but moves upwardly little by little
after second or third times, then it means the va-
the 3rd time cuum assist has the sound air tightness. If the
the 2nd time pedal height is without variety, then it means the
the 1st time
brake assist is damaged.
(b) Step down the brake pedal when the engine is
operating; then shut off the engine but step down
the pedal, if the pedal keeps the stroke without va-
riety within 30s, then it means the vacuum assist
has the sound tightness; if the brake pedal moves
upwardly, then it means the brake pedal assist is
damaged.
Brake-7
Air discharge of brake system

Remarks:
It should discharge the air if operate on the brake sys-
tem or assume the brake system pipeline has the air.
Caution:
Must not keep the brake fluid on the paint surface,
wipe off it if has.
1. Fill the liquid reservoir up with the brake fluid.
Check the liquid level in liquid reservoir after discharge
the air of each wheel pump. Filled with the brake fluid if
necessary.
2. Connect the polyethylene resin pipe to the over-

flow hole plug of wheel pump, insert the other end
of pipe into the container with half of brake fluid.
Remarks:
When discharge the air of wheel brake pump, it should
begin from the longest pipeline.
3. Air discharge of brake system pipe
(a) Step down the brake pedal slowly for several ti-
mes.
(b) Let the assistant presses down the pedal, at the
same time screw off the overflow hole plug until
the brake fluid flows out. Then switch off the over-
flow hole plug.
(c) Repeat the procedure until the liquid is without air
bubble.
Tightening torque of overflow hole plug: 11N·m
4. Process the same procedure for each wheel pump.
Brake pedal
return spring
brake bracket welded assembly support sleeve
衬套
screw bar
bush
pin shaft
pedal cover block
hexagon flange nut
rocker arm welded assembly

Brake-8
fork pin shaft

Replacement of pin shaft
Remarks:
When the connecting fork pin shaft and pin hole is over
worn, it should replace the pin shaft bush.
Remarks:
lock nut When the clearance between the brake pedal shaft and
push bar bush is large, it should remove the pedal and replace
inner distance
the bush.
Parking brake
rear parking brake pull wire (R)
parking handle assembly
brake pull wire clip
switch assembly
rear parking brake pull wire (L)
1. Adjust the parking handle assembly in position, 7-9

teeth.
2. When parking the vehicle, the controlling power of

the parking handle shall not exceed 400N.
Brake-9
Front brake
25-35 50±5
front brake oil pipe
guide pin copper
washer
guide pin rubber cover tong
guide pin dustproof cover
25-35
Piston
piston dustproof cover air-bleed
bolt cover
7-10
location pin
square seal ring
guide pin dustproof cover
upper circlip of brake block (I) upper circlip of brake block (II)
lnner silencing plate combination
caliper bracket Inner brake block

silencing plate
wear limitation alarm plate of brake block

outer silencing plate combination
lower circlip of brake block
lower circlip of brake block
N·m :specified torque brake block assembly
Replacement of brake block

Remarks:
When brake during the travel process, if the front whe-
el has the continuous screams noise, then it should
check the wear limitation alarm plate of brake block. If
the alarm plate has the abrasion mark with brake disc,
then it should replace the brake block .
1. Remove the front wheel
2. Check the thickness of abrasion material of brake

block.
Check the thickness of abrasion material of brake block
by the watch hole on the tong, Replace it if is not within
specified range.
Min. thickness : 2.0mm
Brake-10
3. Lift the main body of brake caliper.

(a) Remove the hexagon flange bolt.
(b) Lift the brake pump and hang it by rope to protect

the brake oil pipe.
Remarks: Do not screw off the brake oil pipe and bleed
plug.
4. Remove the following components

(a) Two pieces of brake block
(b) One piece of silencing plate
(c) Two piece of silencing plate combination
(d) One wear limitation alarm plate of brake block
(e) Four brake block circlip plates
5. Measure the thickness of brake disc

(Refer to step 2 of “ Inspection of component of front
brake” )
6. Measure the circular runout of brake disc.
(Refer to step 3 of “Inspection of component of front
brake”)
7. Install the brake block circlip plate

Brake-11
8. Install the new brake block

(a) Install a wear limitation alarm plate of brake block
on the inner brake block.
(b) Install a silencing plate and a silencing plate com-
bination on the inner brake block.
(c) Install a silencing plate combination on the on the
outer brake block.
(d) Install two brake blocks; let the wear limitation

alarm plate is in the inside of brake caliper.
Caution: It is unallowable that the operating surfa-
ce of brake block and brake disc is polluted by the
grease and paint.
(e) Suck a few of brake fluid form the liquid reservoir

(prevent the brake fluid from overflowing from li-
quid reservoir).
(f) Use the special tools to press the piston .
9. Install the brake pump

Install and tighten the hexagon flange bolt.
Tightening force: 25-35N m
Remarks: Only can replace the brake block on a wheel
in one time to avoid the piston on another wheel is pus-
hed out.
10. Install the front wheel
Tightening force of the wheel fixing nut is 135±15
N·m
11. Check whether the brake fluid level is in the speci-

fied position.
Brake-12
Removal of brake pump

1. Remove the brake pipeline
Remove the brake pipeline. Use a container to contain
the brake fluid.
2. Remove the brake pump from the clamp bracket

(a) Remove the hexagon flange bolt, location pin and
guide pin.
(b) Remove the brake pump.
3. Remove the brake block

(a) Two brake blocks
(b) One silencing plate
(c) Two silencing plate combinations
(d) One wear limitation alarm plate of brake block
(e) Four brake block circlips
Disassembly of brake pump

1. Remove the piston form the tong
(a) Place the wood block between the tong bracket
and tong body .
(b) Use the air gun or air pipe to aim at the brake oil
pipe hole; remove the piston form the tong.
(c) Use the clean rag or soft cloth to take out the pis-
ton.
Warning: It must not place the finger in front of the
piston when use the compressed air.
2. Remove the piston gasket from the tong body.
Use the paper clip to remove the piston gasket.
Caution: The used tools must not be sharp to pre-
vent from scratching the piston gasket.
Brake-13
Check the component of front brake

1. Measure the thickness of the brake block bush.
standard thickness: 9.0mm
minimum thickness: 2.0mm
It should replace the brake block if less than minimum
thickness or has uneven abrasion.
2. Measure the thickness of the brake disc.

It should repair or replace the brake disc if the brake
disc is damaged or worn or its thickness is less than
minimum thickness.
3. Measure the circular runout of the brake disc.

Remarks: It should ensure that the bearing is adjusted
correctly before the measurement .
maximum circular runout : 0.11mm
4. Replace the brake disc if necessary.

(a) Remove the tong bracket form the steering knuc-
kle.
(b) Remove the hub and brake disc. (Refer to section
“Front hub”)
(c) Install the new brake disc; tighten the connecting
bolt to the specified torque.
Tightening force: 90-100N·m.
(d) Install the hub and brake disassembly. (Refer to
section “Front hub”)
(e) Install the tong bracket on the steering knuckle;
tighten the connecting bolt to the specified torque.
Tightening torque 140±10N·m.
Brake-14
Assembly of brake pump

1. Preparation work
All components should be washed, dried by wind and
without foreign material before the assembly. During
the assembly, cost the guide pin and location pin with
proper vacuum silicon based grease; coat the working
surface of piston and square gasket with proper rubber
lubricant.
2. Install the piston gasket in the tong body.

(a) Screw the bleed screw into the bleed hole;
Tightening torque 7-10N·m.
(b) Install the square gasket in the sealing groove of
two cylinders of pump respectively after coat its
working surface with proper rubber lubricant.
3. Install the piston with dustproof cover in the tong

(a) Cover the dustproof cover on the piston.
(b) Lengthen the dustproof cover to expose the bo-
ttom of piston from the dustproof cover clip ring;
use the tool (for example: steel wire about 2mm )
to assist insert the clip ring into the cylinder hole
clip ring groove.
Caution: The used tools must not be sharp to pre-
vent the damage of dustproof cover.
(c) Press the piston to the bottom of cylinder hole by
hand.
4. Pre Install the guide pin and location pin on the
tong bracket.
(a) Install the guide pin dustproof cover on the guide
pin and location pin respectively.
(b) Screw the guide pin and location pin in the tong
bracket respectively.
Caution: Do not damage the guide pin dustproof
cover.
Brake-15
piston dustproof cover Installation of brake caliper

brake block Note: before installing the brake block, make sure
that the piston is installed properly, at the same
Piston
time, observe whether there is a interference the
brake block with the piston dustproof cover or not,
so avoiding interference can prevent failure of pis-
ton dustproof cover from occuring.
1. Install the brake block
2. Install the brake pump

(a) Install the brake pump.
(b) Install and tighten the hexagon flange bolt.
3. Connect the brake pipeline

Connect the brake oil pipe to the tong body.
4. Fill up the brake liquid reservoir with the brake

fluid and dis charge the air in brake system.
5. Check for the leakage of brake fluid.
Caution: Discharge the air after the completion of
replacement.
Brake-16
Rear brake (Disk-and-drum type)

55
25-30 brake oil pipe fastening bolt
guide pin
copper washer
rectangle seal ring
bleed screw dustproof cover

rear brake oil pipeline bleed screw
cylinder hole
piston dustproof cover
location pin tong body (left)
wire clip
25-30
pin rubber cover

brake block circlip
inside brake block
outside brake block
silencing plate
tong bracket silencing plate

combination
brake block wearing indication plate
brake caliper locking bolt

N·m :specified torque 100
Replacement of brake block

Remarks: if the rear wheel generates the cheep during
the braking, it should check the abrasion indication pla-
te of brake block. If the indication plate has the abra-
sion mark with brake disc, then it should replace the
brake block.
1. Remove the rear wheel
2. Check the thickness of brake block bush.

Measure the thickness of the brake block bush (abra-
sion material) from the eyehole of tong. If the thickness
is not within the specified range, then it should replace
the brake block.
minimum thickness: 2.0mm.
peephole
Brake-17
3. Uplift the brake pump

(a) Remove the location pin.
(b)Uplift the brake pump and hang it with a rope to

protect the brake oil pipe.
Remarks: do not remove the brake oil pipe.
4. Remove the following components:

(a) Two brake blocks
(b) Two silencing plates
(c) Two silencing plate combinations
(d) One brake block bush wearing indication plate
(e) Two brake block circlips
5. Measuring the depth of brake discs

(refer to the step 2 of measuring the components of
rear brake)
6. Measuring the brake disc circular runout
(Refer to step 3 of measuring the components of rear
brake)
7. Install the brake block Circlip

Brake-18
8. Install new brake block

(a) Install a brake block bush wearing indication plate
on the internal brake block.
(b) Install one silencing plate and one silencing plate
combination on each brake block.
Remarks: Coat the two sides of silencing plate with
disc brake oil (which cannot be replaced with oil of
other models).
(c) Install two brake blocks, make the wearing indica-

tion plate in the lower position (near the tank cylin-
der).
Remarks: The working surface of the brake block and
brake disc are not allowed to be contaminated by grea-
se and paint.
9. Install the sub pump

(a) Unscrew the release screw, absorb some of the
brake fluid.
(b) Press the plunger with hammer beam or similar
tools, and unscrew the release screw at the same
time.
Remarks: Only the brake block of one wheel can be
replaced for once, lest the plunger on the opposite side
be bounced.
(c) Install and tighten the location pin.

10. Install the rear wheel

11. Fill up with the brake fluid and drain the air in the
brake system after the completion of replacement.
Brake-19
Removal of brake pump

1. Remove the brake pipeline
Remove the brake pipeline. Use a container to contain
the brake fluid.
2. Remove the pump form the bracket

(a) Remove the location pin and guide pin.
(b) Remove the tong.
3. Remove the brake block

(a) Two pieces of brake block
(b) Two pieces of silencing plate
(c) Two pieces of silencing plate combination
(d) One piece of brake block bush abrasion indicating
plate
(e) Two brake block circlips
Disassembly of brake pump

1. Remove the piston form the tong
(a) Insert the cleaning cloth or other soft cloth into the
place between piston and tong.
(b) Use the compressed air to remove the piston and
cylinder hole dustproof cover from the tong.
Warning: it must not place the finger in front of the
piston when use the compressed air.
2. Remove the piston gasket form the tong

Use the screwer to remove the piston gasket.
Brake-20
Check the components of rear brake

1. Measure the thickness of the brake block bush.
Standard thickness: 8.0mm
Minimum thickness: 2.0mm
It should replace the brake block if less than minimum
thickness or has uneven abrasion.
2. Measure the thickness of brake disc.

It should repair or replacement brake disc if it is scrat-
ched or worn or its thickness is less than minimum thic-
kness.
3. Measure the circular runout of brake disc.

Remarks: It should ensure that the rear bearing is ad-
justed correctly before the measurement.
Maximum circular runout : 0.11mm
4. Replace the brake disc if necessary.

(a) Remove the bracket form the rear axle flange.
(b) Remove the rear brake disc and install the new
brake disc .
(c) Install the bracket and tighten the fastening brake
caliper bolt.
Brake-21
Assembly of pump
1. During the assembly, coat the guide pin with the
proper vacuum sili con based grease; coat the
operating surface of piston and square gasket with
proper rubber lubricant.
2. Install the piston gasket and piston in the tong
3. Install the cylinder hole dustproof cover and wire

clip in the tong.
4. Install the rubber pin cover on the tong bracket.
Installation of brake caliper

1. Install the brake block
Brake-22
2. Install pump.
(a) Install the pump;
(b) Install and tighten the location pin and guide pin.
Tightening torque: 25-30N·m.
3. Connect the brake pipeline

Connect the brake oil pipe to the tong.
4. Fill up the brake system with the brake fluid and

drain the air in the brake system.
5. Check for leakage of brake fluid.
Rear parking brake

pull-out piece
spring draw bar stopper
upper release spring

push pedal release spring
push pedal
◆saddle type washer
brake shoe pulling arm
rear brake shoe rear brake disc
hand brake stay wire pulling arm pin

pull-out piece spring
front brake shoe
lower tension spring pull-out piece spring seat
clearance-adjusting bolt clearance-adjusting bolt head
clearance-adjusting gear
Removal of rear brake

Remarks: When the brake torque of the hand brake
cannot meet the brake requirement, the thickness of
the brake shoe gasket shall be tested. If it is less than
the minimum value of brake show gasket, the brake
shoe shall be replaced.
Minimum thickness: 1.0mm
Brake-23
1. Remove the rear wheel

2. Remove the rear brake caliper
3. Remove the rear brake disc
Remarks: If the brake disc is difficult to remove, remo-
ve the adjust ment spout plug, insert the screwdriver
into the adjust ment spout of the rear brake bedplate,
Release the brake shoe adjustment device through
twisting the clearance-adjusting gear.
4. Remove the shoe plate, pull-out the piece spring,

pull-out piece spring seat, pull-out piece spring
draw bar
5. Remove the lower tension spring and clearance-

adjusting device
Use clipper to remove the extension spring, release the
clearance adjusting device and remove it.
6. Remove the two upper extension springs
7. Remove the brake shoe

(a) Remove the brake shoe, baffle, baffle return
spring.
(b) Remove the band brake stay wire from the stay
and brake pulling arm.
Brake-24
8. Remove the parking brake pulling arm

Use the screw driver to remove the parking brake pu-
lling arm
Check and maintain the components of

brake
1. Check the dismantled components
Check to see whether the dismantled components are
wearing, rusted or damaged.
2. Measure the internal diameter of the brake disc

Standard inter diameter: 210mm
maximum internal diameter: 212mm
3. Measure the thickness of the brake shoe

If the thickness of the brake shoe is less than the mini-
mum value, or there is uneven wearing, the brake shoe
shall be replaced.
Remarks: If any one of the brake shoes needs to be
replaced, all the brake shoes need to be replaced to
keep the even brake performance.
4. Check whether the contact between the brake shoe

gasket and brake disc is sound.
If the contact between the brake shoe gasket and
brake disc is bad, it should use the brake shoe grinding
device to repair or replace the brake shoe assembly.
Brake-25
Assembly of rear parking brake

Remarks: Assemble the component according to the direction shown in figure;
It is prohibited strictly that the working surface of brake drum and abrasion disk is polluted by
the paint and grease. It should be removed by the fine abrasive paper if the abrasion disk has
little dirty. The brake shoe should be replaced when the polluted area is large, otherwise it will
cause the serious effect of insufficient brake force.
left wheel right wheel
front
front
1. Install the clearance-adjusting device assembly

Insert the clearance-adjusting shaft head into the clea-
rance-adjusting wheel; screw the clearance-adjusting
screw rod into the clearance adjusting wheel.
Remarks: The screw direction of left clearance-
adjusting screw rod is the left hand.
The screw direction of right clearance-adjusting
screw rod is the right hand.
2. Coat the following components with the proper

anti-high tem perature grease
(a) Contact position of brake soleplate and brake
shoe.
(b) Contacting surface of push plate and shoe plate;

contacting surface of clearance-adjusting device
assembly and shoe plate.
Brake-26
2. Install the parking brake pulling arm

Install the parking brake pulling arm and use a new
saddle washer.
3. Install the rear brake shoe

(a) Install the parking brake pull wire on the parking
brake pulling arm.
(b) Insert the end of rear brake shoe into the support
pin of brake soleplate. Insert the pull-out piece
spring pull bar into the brake soleplate and brake
shoe assembly, then insert the pull-out piece
spring and pullout piece spring base. Use the pull-
out piece spring fork to rotate the pull-out piece
spring base in position.
4. Install the front brake shoe

Install the front shoe plate; insert one of its ends into
the fixed pin of soleplate. Insert the pull-out piece
spring pull bar into the brake soleplate and brake shoe
assembly, then insert the pull-out piece spring and pu-
llout piece spring base. Use the pull-out piece spring
fork to rotate the pull-out piece spring base in position.
5. Install the brake push plate

Insert the push plate release spring into the push plate;
then install the push plate on the place between the
front and rear brake shoe assemblies.
Brake-27
6. Install the lower tension spring

Install the lower tension spring between the front and
rear shoe plate.
7. Install the clearance-adjusting device.

Install the clearance-adjusting device after poke the
brake shoe by screwer.
8. Install two upper release springs

Insert the block into the support pin, then install the
upper release spring on the place between two brake
assemblies.
9. Check the operating process of automatic adjus-

ting mechanism.
(a) Pull the manual brake pill-wire, then release it.
Check the clearance-adjusting gear for rotation. If
can not rotate, check the rear brake and find the
problem.
(b) Adjust the clearance-adjuster to the length as

short as possible.
(c) Install the rear brake disc.
Brake-28
10. Adjust the clearance between the brake drum and

brake shoe.
Poke the adjusting hole plug on the brake drum, insert
the screwdriver into the clearance-adjusting hole; ro-
tate the clearance-adjusting gear to expand the brake
shoe until the brake disc can not be rotated by hand.
Then rotate it for 3-5 teeth in anticlockwise, rotate the
brake disc by hand at the same time, it is proper that it
can rotate freely and without the contact between the
abrasion and disc. It is allowable that the non-running-
in brake shoe has the slight abrasion sensing. When
adjust the clearance, the left and right wheel must be
adjust at the same, install the adjusting hole plug after
the completion of adjusting.
11. Rear brake caliper assembly

12. Rear wheel assembly
Tighten torque :135±15N·m
Brake-29
Load-sensing proportional valve
The action of load-sensing proportional valve is to pre-

vent the rear wheel is braked before the front wheel is
braked by adjusting the distribution of front and rear
brake force according to the difference of vehicle rear
shaft load, then avoid the risk of vehicle rotation.
The adjustment of proportional valve is
shown as follows
(a) The rear shaft load can be 820Kg after adjustment
(including driver).
(b) Install the brake pressure measuring meter and
drain the air.
(c) Increase the front brake pressure to 12Mpa, the
rear brake pressure should be within 8~9 Mpa.
(d) If necessary, adjust the hydraulic pressure.
1. Move the sensing spring bracket on the rear axle,
the right hook of sensing spring moves to right;
the rear brake pressure is increased .
2. Vice versa, the rear brake pressure decreases, the
adjustment scope of the frame is 20mm.
3. The extension amount of spring of load sensing
proportional valve is controlled within 84~95mm.
Brake-30
main cylinder
output manometer input manometer
hydraulic load
Replace of load-sensing proportional

valve
1. Removal
Disconnect the brake pipeline form the valve; remove
the lock nut and remove the adjusting bolt from the
suspension arm bracket; remove the installation bolt
and take off the load-sensing proportional valve ass-
embly.
2. Installation
(a) Use two installation bolts to fix the load-sensing
proportional valve.
The bolt tightening torque is 23N·m
(b) Tighten the adjusting bolt locking nut,
(c) Connect each brake pipeline.
The tightening torque of the connector is 16N·m,
(d) Filled with the brake fluid, discharge the air from
the brake system; check the brake pressure and
leakage.
Brake-31
Antilock Braking System (ABS)

Cautions
1. It must not remove or install the electric elements and wire bunch plug when the ignition swit-
ch is in ON to avoid the damage of ECU. It should turn off the ignition switch if needs disass-
embly.
2. Pay attention to do not knock or impact the ABS ECU during the maintenance and repair, for it
will damage the ABS ECU easily.
3. The wheel speed sensor and hydraulic unit (integrated with ECU) of BOSCH ABS8.0 can not be
repaired, it should be replaced in integral if damaged.
4. After the brake system is maintained, the brake pedal maybe soft. Discharge the air according
to the normal brake system.
5. It must use the brake fluid from original manufacturer; the brake fluid of different number can-
not be used in mixed, otherwise it will cause the failure of brake system. Select the tyre of ori-
ginal type as most as possible
Repair of Antilock Braking System (ABS)
1. It should process the failure diagnosis for the brake system before process the ABS failure
diagnosis. It can diagnose out the failure rapidly by using Table 1. In Table 1, the small number
means the failure which occurs most possibly. Check each element according to the sequence
and maintain or replace it if necessary.
2. Check the following elements for normal operation before the diagnosis
• Brake fluid level and brake fluid quality
• Pressure of tyre, size of tyre, shape and depth of tyre figure
• Other brake component
These components will affect the brake effect of the ABS. Check the system sensor, connecting wire
and connector for correct installation, arrangement and connection. Ensure the completeness of fuse,
repair or replace it if necessary.
3. Process the analysis and diagnosis according to the ABS advanced by owner. Use the diagno-
sis instrument (Annex 1) for final check and confirmation. It must process the run inspection
after the competition of all ABS maintenance. The test condition is shown as follows
(a) Confirm the tyre complies with the requirement, the tyre pressure is normal.
(b) The brake system (including brake light ) is normal
(c) The brake system is without leakage.
(d) The position and installation of wheel speed sensor is correct.
(e) All fuses are normal.
4. test method:
Run for 1 min at least when the vehicle speed is beyond 40Km/h, process a proper brake. Then read
out the failure code to ensure the ABS is without failure code.
Brake-32
Table 1
The brake
Brake is
Name of element Lag of Block of is very hard
low or Brake noise
(failure) brake brake but has
soft
bad effect
Brake system (leakage of
1 1
brake fluid)
Brake system (with air) 2 2
brake shoe (worn) 3
Piston oil seal (worn or da-
3
maged)
brake pedal (small free
1
stroke)
Brake main pump (failure) 4 11
parking brake (brake shoe is
4
out of round)
parking brake (improper ad-
2
justment)
parking brake pull-wire (lag) 3
Assist push bar (improper
5 9 8
adjustment)
Tension or release spring (fa-
8 8
ilure)
brake shoe (crack or defor-
5 5 4 1
mation)
Piston (lag) 6 1
brake shoe (with oil) 2 5
Piston (block) 7 3
assist system (vacuum
10 9
leakage)
brake shoe support plate
4
(loose)
fixed bolt (loose) 2
Slide pin (worn) 5
brake drum (crack) 4 7 3
brake shoe (with foreign ma-
6 6
terial)
brake shoe (harden ) 7
Noise reduction plate (worn) 9
Press spring (damaged) 10
Brake-33
Testing of ABS System

Connect the diagnostic port, turn the ignition key to ON
position, open the diagnostic equipment and operate
according to the prompts in the diagnostic equipment
interface.
Main Functions of ABS Diagnosis Sys-

tem
1. Read Malfunction Code
2. Clear Malfunction Code
3. Read Dataflow
4. Action Test
5. Version Information
6. Bleeding Mode
Read Malfunction Code

In the menu of functions, click the “Read Malfunction
Code” function, and the X431 will begin the malfunction
code testing. Upon the completion, the test results will
be shown on the screen. Troubleshoot the malfunctio-
ns according to the shown codes.
Clear Malfunction Code

The following conditions must be met:
1. All shown malfunctions have been eliminated;
2. The engine is not running;
3. Ignition switch is placed to the position of “ON”.
Read Dataflow
Click the “Read Dataflow” option from the main menu
to read the dataflow.
The dataflow items may occupy more than one page.

Use the “Page Up” and “Page Down” buttons to view
up and down.
Brake-34
Action Test
Click the “Action Test” option, and click the correspon-
ding testing option to view if any action has been done
to the selected item. If no, then check the element mal-
function of the selected item.
Bleeding Mode
Bleed in the order indicated in the detector. Work in
pairs after clicking the “Left Rear Wheel”, with one
pressing down the brake pedal, and the other staying
outside the vehicle and bleeding the wheel until the air
is drained. Then bleed the other wheels in turn.
Steering System-1
Steering System
Steering System ............................................................................. 1

Precautions ..................................................................................... 2
Malfunction and Troubleshooting ................................................. 2
On-vehicle Inspection .................................................................... 3
Steering Transmission Device (2005) ........................................... 5
Steering Transmission Device (2006) ........................................... 6
Steering Transmission Device (2008-Petrol)................................ 15
Steering Transmission Device (2008-Diesel) ............................... 21
Steering Transmission Device (2.5TCI Right-hand drive)........... 27
Steering System-2
Precautions
Be careful and carry it out correctly when you are
replacing parts. Any mistake may influence the
performance of steering system and cause accident or
danger during driving.
Malfunction Cause Troubleshooting
Poor 1. Insufficient tyre pressure 1. Inflate tyre according to the standard pressure.
returnability 2. Deflection of the front wheel after align- 2. Re-measure and adjust the front wheel
ment alignment parameters.
3. Seizure of the steering valve 3. Check and replace components of the steering gear.
4. Decreases for performance of the steering 4. Replace the steering gear.
valve torque rod
Hard steering 1. The tyre with low air pressure 1. Inflate tyre according to the standard pressure.
2. The steering knuckle is too tight. 2. Check and adjust the clearance of the steering
knuckle, then lubricate it.
3. The steering gear clearance is small. 3. Check and adjust the clearance between gear
and cog rack.
4. The alignment of the front wheel is not accurate. 4. Adjust the front wheel alignment.
5. The hydraulic system is lack of oil. 5. Check the level of the power steering oil tank and
add steering fluid according to the specification.
6. The hydraulic system with air in. 6. Check the tightness of each oil pipe joints. Ex-
haust and check the level of fluid.
7. Insufficient oil supply of steering pump 7. The oil pump is seriously leaky due to serious
leakage. Replace the steering pump.
The oil viscosity is so low that leakage happens.
Replace it with qualified steering fluid.
8. The track-rod ball pin is lack of oil or damaged. 8. Replace the track-rod ball
One-way 1. Insufficient air pressure of the unilateral tyre 1. Inflate tyre according to the standard air pressure
hard steering 2. The steering gear valve is not in the inter- 2. Repair or replace the steering gear.
mediate position.
3. Left or right fixed pressure can not be 3. Replace the seals.
accumulated.
The steering 1. The clearance between the gear and cog 1. Adjust the clearance. Replace the steering gear
wheel with rack is too big. assembly when the adjustment is no use.
too large free 2. The interior and exterior ball pin of the 2. Replace the ball pin as required after examina-
play / abnor- track-rod is damaged too much. tion or verification.
mal sound
3. Abnormal damage of the steering universal 3. Replace the steering pipe column or lower
joint transmission shaft as required after examination
or verification.
4. The connection point of the steering 4. Check whether the connecting bolt of the lower
transmission shaft and steering gear steering transmission shaft and steering gear is
becomes flexible. loose.
5. The connection point of the steering wheel 5. Check whether the connecting bolt of the
and pipe column becomes flexible. steering wheel and pipe column is loose.
6. The mounting bolt of the steering gear is 6. Check whether the mounting bolt of the steering
loose. gear is loose.
7. The rubber disc of the lower transmission 7. Check whether the connecting bolt of the lower
shaft is loose. Rubber is aging. transmission shaft rubber disc is loose and the
rubber of the rubber disc is aging.
Poor steering 1. Insufficient tyre pressure 1. Inflate tyre according to standard pressure
returnability 2. The dynamic balance of the wheel is out 2. Re-correct the dynamic balance of the wheel
and poor of tolerance caused by the wheel balance
stability weight’s falling and other factors.
of straight 3. The rubber bushing of the lower swing arm 3. Replace the lower swing arm.
traveling is aging. The difference of the right and left
wheel rigidity is big.
4. Four-wheel alignment parameters are not 4. Re-measure and adjust the four-wheel
correct. alignment parameters.
5. Deterioration of the meshing between the 5. Replace the power steering gear.
gear and cog rack of the steering gear with
big reverse resistance.
6. The performance of the interior control 6. Replace the power steering gear.
valve of power steering gear has reduced.
Steering System-3
On-vehicle Inspection
Inspection of the steering wheel
1. Check whether the steering wheel has clearance or
“click” sound.
The play “a” of the steering wheel : (0-30)mm.
2. Check whether the bolt and nut are screwed down.
Screw them down accordingly. If necessary, please
repair or replace the damaged parts.
3. Fixation of the steering wheel centering: first,
make the front wheel right ahead. Then take off the
steering wheel without changing the position of the
steering rod and install it with alignment. The right
and left spoke plate of the steering wheel should
be in alignment and the “Great Wall” mark on the
steering wheel should be in driver’s orthophoria
position. Screw down the nut with a tightening
torque of 25-35 N•m.
4. Inspection for free travel of the steering wheel
Make the vehicle right ahead and stop the engine. Then
apply 5N with the circle direction to turn left the steering
wheel. In this process, you will feel the resistance and
stop your operation with the resistance increasing.
Repeat this operation but turn right the steering wheel
and stop it with the resistance increasing. The outer
turning angle of the steering wheel is the free travel of
the steering wheel. The standard value should be less
than 20°and the left and right turning angle from the
intermediate position should not be more than 10°.
Inspection for tension of the transmission

belt
The tension of the transmission belt: when applying
the force of 98N
New belt: (5-7)mm
Old belt: (7-9)mm
Remarks:
● “New belt” means that the belt is used in
machine for no more than five minutes.
● “Old belt” means that the belt is used in
machine for more than five minutes.
Inspection and filling of power steering
fluid
1. Stop the vehicle on the level ground.
2. Check the level of the power steering oil tank,
which should be in the range of the upper and
lower index.
3. Check and add the hydraulic oil every traveling for
6000Km or three month.
Steering System-4
4. Replacement and exhaust of the hydraulic oil:

(a) Open the oil tank cover of power steering.
(b) Jack up the front side of the vehicle and support it
by a bracket.
(c) Loosen the connecting bolt of the inlet oil return pipe
stack of power steering gear and steering gear.
(d) After stopping the engine, turn the steering wheel
right and left to the limit position for several times
when discharging oil fluid. Stop the operation until
the oil in the steering system is fully discharged.
(e) Well connect the inlet oil return pipe stack of
power steering gear. Fill the fresh hydraulic oil into
the power steering oil tank.
(f) Re-start up the engine to make it run at idle
speed. Turn the steering wheel right and left to the
limit position for several times. Simultaneously,
fill fresh hydraulic oil into the power steering oil
tank until no bubble or opacity appears in it. And
the level of the power steering oil tank should be
in the range of the upper and lower index when
shutting down the engine.
(g) Screw down the oil tank cover of power steering
Note: During steering or changing hydraulic oil,
when turning the steering wheel of the vehicle
to the limit position, the station time should not
exceed five seconds to prevent the steering system
from being damaged.
Steering System-5
Steering Transmission Device (2005)

Components Diagram
Steering wheel
Supporting
rubber pad
Steering
pipe column
70±10 Steering transmission shaft

Steering reservoir tank
Auxiliary steering transmission shaft PS pump
70±10
Hollow
hexagon bolt
Sealing washer
Hose
25±3
Fixing bolt
Disassembly and installation of power steering pipeline
Fixing bolt High/low pressure pipeline

■O rubber sealing ring
Assembly of power
steering gear with tie rod
90±10
N•m : specified torque
■ Disposable parts
Steering System-6
Steering System and Power Steering

Principle
1. The power steering system consists of the steering oil pump,
the reservoir tank, the power steering gear and the oil pipe.
2. The engine drives the steering oil pump by belt
transmission to create hydraulic pressure, which takes
effect on the piston of the power steering gear. Then the
piston pushes the cog rack of the steering gear and applies
an auxiliary force on it, which is related with the pressure
on the piston. The variation of the pressure is fulfilled by
the control valve of the steering gear.
Valve Oil return

Straight Traveling
plug port During straight traveling, the control valve plug of the power
steering gear is in the intermediate position without movement.
Torsion bar The hydraulic oil supplied by the oil pump does not flow into the
oil tank but directly flow back to the power steering oil tank by
Valve
sleeve the return pipeline from the control valve. At this time, the two
sides’ pressures of the steering gear piston are equal. Thus, the
One chamber piston will not return.
of oil drain
Oil return of the other Pressure-oil Turning Process
chamber of oil drain oil inlet port When turning the steering wheel, the torsion bar in the control
valve is torsional deflection, which causes the control valve core
connected with the torsion bar to rotate accordingly. One oil
Oil return
port passage is opened and the other is closed simultaneously. The
Valve
plug hydraulic oil is sent to one side of the oil tank piston and pushes
the piston to move, accordingly driving the cog rack to fulfill the
Torsion
bar front wheel turning.
Valve
sleeve Returning Process
After turning, the applied force on the steering wheel disappears.
One chamber The torsion bar with distortion shape recovers, along which the
of oil drain control valve plug returns to the middle position. The hydraulic
Oil return of the other Pressure-oil oil supplied by the oil pump does not flow to the oil tank but
chamber of oil drain oil inlet port
directly flows back to the power steering oil tank by the return
pipeline from the control valve. At this time, the two sides’
pressures of the steering gear piston are equal. For the effects
of the front wheel alignment parameters, the vehicle recovers
straight traveling automatically. In the process of recovery, the
piston moves and the oil in one side of the piston flows into the
other side through the control valve passage.
Road Feel Effect
Road feel effect means driver’s feel about resistance from
ground in turning. When drivers apply force on the steering
wheel, the torsion bar will deform. The bigger the steering
resistance from ground is, the more serious the torsion bar
deformation is. To protect the torsion bar from being damaged,
the stop gear is set. When the deformation of the torsion bar
reaches a certain degree, the stop gear takes effect. The
torsion force on the steering wheel is transmitted to the gear
directly by the valve plug but not by the torsion bar any more.
Then the force is transmitted to the cog rack. In this situation,
the resistance from ground is transmitted to drivers not by the
torsion bar. Therefore, drivers could judge the variation of the
steering resistance by the resistance on the steering wheel.
Steering System-7
Steering Transmission Device (2006)

Components Diagram
Right-hand drive
Cover plate assembly
of steering wheel
Fixing screw of
cover plate
25±3
Steering pipe Steering wheel
column assembly body assembly
25±3
25±3
50±5 Lower transmission shaft assembly
Angle transmission 25±3

pair assembly
Flexible universal joint assembly
70±10
90±10 120±10
25±3
Power steering oil

tank assembly Fuel intake hose
Power steering oil pump

with bracket assembly
4PK1100
Power steering
oil tank bracket 27.5±2.5 Inlet oil pipe stack of
assembly power steering gear 17.5±2.5

Steering System-8
Left-hand drive

of steering wheel
Fixing screw of
cover plate
Steering wheel
25±3 body assembly
Steering pipe
column assembly
25±3
25±3
50±5 Lower transmission shaft assembly
Angle transmission
pair assembly 25±3

70±10 120±10
90±10
25±3
Fuel intake hose

Power steering oil
tank assembly

4PK1100
27.5±2.5
17.5±2.5
Power steering oil tank

bracket assembly
Inlet oil pipe stack of

power steering gear

Steering System-9
Disassembly and Installation of Steering Pipe Column

Hexagon-head bolt,
spring washer and large
washers assemblies
Q1460825FD(Q40208)
Hexagon flange bolt

Q1840835 Hexagon flange bolt
Lower transmission Q32008FD
shaft assembly
Steering pipe
column assembly
1. Disassembly
(a) Remove the hexagon flange nut (Q1840835) for connecting the steering pipe column and lower
transmission shaft assembly by a M10 socket wrench to disconnect them.
(b) Remove the hexagon-head bolt, spring washer and large washers assemblies for (Q1460825FD)
connecting the steering pipe column and front wall and the hexagon flange nut (Q32008FD) for connecting
the steering pipe column and front wall collision prevention beam by a M13 socket wrench.
(c) Draw out the pipe column upward along the axial line of the upper shaft of pipe column.
2. Installation
(a) Insert downwards the pipe column assembly along the axial line of the upper shaft of pipe column.
(b) Connect the steering pipe column to the lower transmission shaft. Install the hexagon flange
bolt (Q1840835) for connecting the steering pipe column and lower transmission shaft by a M10
socket wrench.
(c) Install the hexagon-head bolt, spring washer and large washers assemblies (Q1460825FD) for connecting
the steering pipe column and front wall and the hexagon flange nut (Q32008FD) for connecting the
steering pipe column and front wall collision prevention beam by a M13 socket wrench.
Disassembly of Steering Angle Transmission Pair
Hexagon flange bolt
Hexagon flange bolt Q1840830
Q1841090FD
Gasket
Lower transmission
Angle transmission shaft assembly
pair assembly
Hexagon flange bolt

Q18410105FD Flexible universal joint assembly
Hexagon flange bolt

Q1840830
1. Disassembly
(a) Remove the two hexagon flange bolts (Q1841090FD) and one hexagon flange bolt
(Q18410105FD) connecting the angle transmission pair assembly and vehicle frame by a M13
socket wrench.
Steering System-10
(b) Remove the hexagon flange bolt (Q1840830) connecting the angle transmission pair assembly
and lower transmission shaft assembly by a M10 open end wrench.
(c) Remove the hexagon flange bolt (Q1840830) connecting the angle transmission pair assembly
and flexible universal joint assembly by a M10 socket wrench.
(d) Take out the angle transmission pair assembly.
2. Installation
(a) Insert downwards the angle transmission pair assembly and flexible universal joint assembly
along the axial line of the lower transmission shaft assembly and axial line of the flexible
universal joint assembly.
(b) Install the hexagon flange bolt (Q1840830) connecting the angle transmission pair assembly and
steering lower transmission shaft by a M10 open end wrench.
(c) Install the hexagon flange bolt (Q1840830) connecting the angle transmission pair assembly and
flexible universal joint by a M10 socket wrench.
(d) Install the three hexagon flange bolts (Q1841090FD) connecting the angle transmission pair
assembly and vehicle frame by a socket wrench.
Disassembly of Steering Gear
Inlet oil return pipe stack
of power steering
Hexagon flange bolt
Q1840830
Flexible universal
joint assembly
Split pin
Hexagon slotted nut
I-shaped hexagon nut

Q341B14 Ball head assembly
Hexagon flange bolt

Hexagon flange bolt-oversized series Q32012FD(M12×1.25)
Q1861225FD(M12×1.25)
1. Disassembly
(a) Remove the hexagon flange bolt (Q1840830) for connecting the flexible universal joint assembly
and steering gear by a M10 open end wrench.
(b) Remove the high/low pressure fuel pipe for connecting the steering gear and inlet oil return pipe
stack of power steering and completely discharge the steering power-assistance oil in it.
(c) Remove the three hexagon flange bolts-oversized series (Q1861225FD) and one hexagon flange
nut (Q32012FD) for connecting the steering gear and vehicle frame by a M18 socket wrench.
(d) When only removing the steering gear assembly, loosen the I-shaped hexagon nut (Q341B14) by a M14
open end wrench and M21 open end wrench and then remove the steering tie rod from the ball head.
(e) About removing the ball head assembly, first remove the split pin by pliers, and then remove it by
a M21 socket wrench.
(f) Take off the steering gear assembly.
2. Installation
(a) Install the hexagon flange bolt (Q1840830) for connecting the steering gear and flexible universal joint
assembly by a M10 open end wrench when installing the steering gear assembly to the vehicle frame.
(b) Install the three hexagon flange bolts-oversized series (Q1861225FD) and one hexagon flange
(c) Install the high/low pressure fuel pipe for connecting the steering gear and inlet oil return pipe
stack of power steering by a M17 open end wrench and fill it with steering fluid.
(d) When only installing the steering gear assembly, screw the steering tie rod into the ball head and
then install the I-shaped hexagon nut by a M14 open end wrench and M21 open end wrench.
(e) When installing the ball head assembly, first install it by a M21 socket wrench, then install the
split pin by pliers.
(f) After accomplishing the above installation procedures, carry out the exhaust of the steering
hydraulic system. Then re-check the four-wheel parameters of complete vehicle on the four-
wheel alignment instrument and align the steering wheel.
Steering System-11
Disassembly and Installation of Steering Lower Transmission Shaft
Hexagon flange bolt

Hexagon flange bolt Q1840835
Q1840830
Steering pipe
column assembly
Lower transmission
shaft assembly
Angle transmission pair assembly
1. Disassembly
(a) Remove the hexagon flange bolt (Q1840835) for connecting the steering pipe column and lower
transmission shaft by a M10 socket wrench to disconnect them.
(b) Remove the hexagon flange bolts (Q1840830) for connecting the lower transmission shaft
assembly and angle transmission pair assembly by a M10 open end wrench.
(c) Draw out the steering lower transmission shaft upwards along the axial line of the lower
transmission shaft.
2. Installation
(a) Insert downwards the lower transmission shaft assembly along the axial line of the lower
transmission shaft.
(b) Connect the lower transmission shaft to the steering pipe column. Install the hexagon flange bolt
(Q1840835) for connecting the steering pipe column and lower shaft by a M10 socket wrench.
(c) Install the hexagon flange bolt (Q1840830) for connecting the lower transmission shaft assembly
and angle transmission pair assembly by a M10 open end wrench.
Disassembly and Installation of Steering Oil Pump
Hexagon-head bolt and plain
Right-hand drive gasket sub-assembly
Q1400820FD
4PK1100
Power steering oil
pump bracket
Hexagon flange bolt

Q18408105
Power steering oil

pump assembly
Steel-strip elastic
clamping ring
Fuel intake hose

Steering System-12
Hexagon-head bolt and plain

Left-hand drive gasket sub-assembly
Q1400820FD
4PK1100
Power steering oil
pump bracket
Hexagon flange bolt

Q18408105
Power steering oil
pump assembly
Steel-strip elastic
clamping ring
Fuel intake hose
1. Disassembly
(a) Remove the high pressure fuel pipe for connecting the power steering gear and inlet oil return
pipe stack of steering gear by a M17 open end wrench and completely discharge steering power-
assistance oil.
(b) Remove the fuel intake hose from the steering oil pump.
(c) Remove the tension bolt (Q1400820FD) at the oil pump by a M13 socket wrench or M13 open
end wrench.
(d) Remove the fastening bolt (Q18408105) at the oil pump by a M10 socket wrench or M10 open
end wrench.
(e) Take off the 4PK1100 belt.
(f) Take off the power steering oil pump.
(g) Remove the fastening bolt for connecting the oil pump bracket and engine by a M13 socket
wrench.
(h) Take off the power steering oil pump bracket.
2. Installation
(a) Fasten the fastening bolt (Q1400820FD) for connecting the oil pump bracket and engine by a
M13 socket wrench.
(b) Install the oil pump to the correct position according to the loading position. Install the tension
bolt (Q1400820FD) and fastening bolt (Q18408105) but do not screw them down.
(c) Install the 4PK1100 belt.
(d) Tension the belt by the required tension force. Simultaneously, fasten the tension bolt
(Q1400820FD) and fastening bolt (Q18408105) of the oil pump by a M13 open end wrench and
M10 socket wrench.
(e) Install the fuel intake hose.
(f) Fasten the high pressure oil pipe of inlet oil return pipe stack of steering gear to the power
steering oil pump by a M17 open end wrench.
(g) Fill the hydraulic system with steering power-assistance fluid as required and completely
discharge air in it.
Steering System-13
Disassembly and Installation of Steering Oil Pipe
Right-hand drive
Steel-strip elastic clamping ring
Fuel intake hose
Power steering oil pump with bracket assembly
Power steering oil Power steering gear assembly

tank assembly
Hexagon flange bolt

Q1840616FD Hexagon flange bolt
Q1840616FD
Inlet oil return pipe

stack of power steering
Left-hand drive
Steel-strip elastic
clamping ring Steel-strip elastic clamping ring

Power steering oil Power steering gear assembly

tank assembly
Steel-strip elastic
clamping ring

of power steering Hexagon flange bolt
Q1840616FD
Hexagon flange bolt

Q1840616FD
1. Disassembly
(a) Loosen the mounting position of the high/low pressure oil pipe and steering gear by a M17 open end wrench.
(b) Completely discharge oil fluid.
(c) Remove the two hexagon flange bolts (Q1840616) for connecting the inlet oil return pipe stack of power steering
and vehicle frame by a M8 socket wrench.
(d) Loosen the bolt for connecting the inlet oil pipe of power steering gear and power steering oil pump by a M17
open end wrench.
(e) Remove the fuel intake hose (connecting the steering oil pump and power steering oil tank) and oil return pipe of
steering gear (connecting the power steering oil tank).
(f) Remove the inlet oil return pipe stack of power steering and fuel intake hose.
2. Installation
(a) Tighten the mounting point of the high/low pressure oil pipe and steering gear according to the required torque by
a M17 open end wrench.
(b) Tighten the two hexagon flange bolts (Q1840616) for connecting the inlet oil return pipe stack of power steering
and vehicle frame by a M8 socket wrench.
(c) Tighten the bolt connecting the inlet oil pipe of power steering gear and power steering oil pump according to the
required torque by a M17 open end wrench.
(d) Connect the oil return hose of power steering to the power steering oil tank. Connect the power steering oil pump
to the power steering oil tank by the fuel intake hose.
(e) Install the fuel intake hose (for connecting the steering oil pump and power steering oil tank) and oil return hose
of steering gear (connected with the power steering oil tank).
(f) Fill fresh oil fluid into the power steering oil tank and completely discharge air in hydraulic system.
Steering System-14
Disassembly and Installation of Steering Oil Tank

Right-hand drive
Hexagon flange bolt
Steel-strip elastic clamping ring Q1840616FD
Power steering oil tank bracket assembly
Fuel intake hose Inlet oil return tube stack of power steering
Left-hand drive
Hexagon flange bolt
Steel-strip elastic clamping ring Q1840616FD
Power steering oil tank bracket assembly
Fuel intake hose Inlet oil return pipe stack of power steering
1. Disassembly
(a) Remove the fuel intake hose.
(b) Completely discharge power steering fluid.
(c) Remove the oil return hose of inlet oil return pipe stack of power steering.
(d) Draw out the power steering oil tank assembly upward along the center line of the steering oil
tank.
(e) Remove the hexagon flange bolt (Q1840616FD) for connecting the power steering oil tank
bracket and vehicle body by a M8 socket wrench.
(f) Take off the power steering oil tank bracket assembly.
2. Installation
(a) Install the power steering oil tank bracket assembly ant tighten the hexagon flange bolt
(Q1840616FD) for connecting the power steering oil tank bracket assembly and vehicle body.
(b) Insert downwards the power steering oil tank assembly along the center line of steering oil tank.
(c) Install the fuel intake hose.
(d) Install the oil return hose of inlet oil return pipe stack of power steering.
(e) Fill power steering fluid as required and completely discharge air.
Steering System-15
Steering Drive Device (2008-Petrol)

Components Diagram
Fixing screw of cover plate
25±3
Steering pipe
column assembly
25±3
25±3 Cover plate assembly

of steering wheel
Steering wheel body assembly
4PK ribbed belt
Lower transmission shaft assembly
Fuel intake hose
25±3
Power steering oil
tank assembly

17.5±2.5
27.5±2.5

of power steering
120±10
bracket assembly Assembly of power
Ball head
assembly
90±10 160±10

Steering System-16

Hexagon-head bolt,
washer assemblies
Q1460825FD(Q40208)
Hexagon flange bolt

Q1840835 Hexagon flange bolt
Q32008FD
Lower transmission
shaft assembly
Steering pipe column assembly
1. Disassembly
(b) Remove the hexagon-head bolt, spring washer and large washer assemblies (Q1460825FD) for
connecting the steering pipe column and front wall and the hexagon flange nut (Q32008FD) for
connecting the steering pipe column and front wall collision prevention beam by a M13 socket
wrench.
(c) Draw out the pipe column upwards along the axial line of the upper shaft of pipe column.
2. Installation
socket wrench.
(c) Install the hexagon-head bolt, spring washer and large washer assemblies (Q1460825FD) for
wrench.
Disassembly and Installation of Steering Gear
Spring washer
Q40308
Hexagon-head bolt
Q150B0832
Steering lower transmission

shaft assembly
I-shaped hexagon nut Split pin

Assembly of power
steering gear with tie rod Q341B16
Hexagon slotted nut
Ball head assembly
Hexagon flange bolt-

oversized series Plain washer
Q1861225FD Hexagon-head bolt-
fine pitch thread
Q151B16190
Inlet oil return pipe stack of power steering

Steering System-17
1. Disassembly
(a) Remove the hexagon-head bolt and spring washer for connecting the steering lower transmission
shaft and steering gear by a M13 open end wrench.
stack of power steering gear and completely discharge steering power-assistance oil.
(c) Remove the two hexagon flange bolts-oversized series for connecting the steering gear and
vehicle frame by a M18 socket wrench.
(d) Remove the two I-shaped hexagon nuts (Q341B16) for connecting the steering gear and vehicle
frame by a M24 socket wrench.
(e) When only disassembling the steering gear assembly, loosen the I-shaped hexagon nut
(Q341B14) by a M14 open end wrench and M21 open end wrench and remove the steering tie
rod from the ball head.
(f) About disassembling the ball head assembly, first remove the split pin by pliers, and then remove
the ball head assembly by a M21 socket wrench.
(g) Take off the steering gear assembly.
2. Installation
(a) Install the steering gear assembly to the vehicle frame. Simultaneously, install the hexagon-head
bolt and spring washer for connecting the steering gear and lower transmission shaft assembly
by a M13 open end wrench or socket wrench.
(b) Install the two hexagon flange bolts-oversized series for connecting the steering gear and vehicle
(c) Install the two I-shaped hexagon nuts (Q341B16) for connecting the steering gear and vehicle
(d) Install the high/low pressure fuel pipe for connecting the steering gear and inlet oil return pipe
stack of power steering and fill it with steering power-assistance oil.
(e) When only installing the steering gear assembly, screw the steering tie rod into the ball head and
(f) About installing the ball head assembly, first install it by a M21 socket wrench, then install the
(g) After accomplishing the above installation, carry out the exhaust of the steering hydraulic system.
Then re-check the four-wheel parameters of complete vehicle on the four-wheel alignment
instrument and align the steering wheel.
Hexagon flange bolt
Q1840835
Hexagon-head bolt
Q150B0832
Spring washer
Assembly of power Q40308
Steering pipe
column assembly
1. Disassembly
(b) Remove the hexagon-head bolt and spring washer for connecting the lower transmission shaft
assembly and assembly of power steering gear with tie rod by a M13 socket wrench.
(c) Draw out the lower transmission shaft assembly upward along the axial line of the lower
transmission shaft.
Steering System-18
2. Installation
transmission shaft.
for connecting the steering pipe column and lower shaft by a M10 socket wrench.
(c) Install the hexagon-head bolt and spring washer for connecting the lower transmission shaft
Power steering Hexagon-head bolt and plain gasket

oil pump bracket sub-assemblyQ1400820FD
Hexagon flange bolt

Q18408105 Ribbed belt4PK1100
Power steering oil return assembly

1. Disassembly
(a) Remove the high pressure fuel pipe for connecting the inlet oil return pipe stack of power steering and
steering oil pump by a M17 open end wrench and completely discharge steering power-assistance oil.
(b) Remove the fuel intake hose from the steering oil pump.
(c) Remove the tension bolt (Q1400820FD) at the oil pump by a M13 socket wrench or M13 open end wrench.
(d) Remove the fastening bolt (Q18408105) at the oil pump by a M10 socket wrench or M10 open end wrench.
(e) Take off the 4PK1100 ribbed belt.
(g) Remove the fastening bolt for connecting the oil pump bracket and engine by a M13 socket wrench.
(h) Take off the power steering oil pump bracket.
2. Installation
(a) Fasten the fastening bolt (Q1400820FD) for connecting the oil pump bracket and engine by a
M13 socket wrench.
(b) Install the oil pump to the correct position according to the loading position. Install the tension
bolt (Q1400820FD) and fastening bolt (Q18408105) but not screw them down.
(c) Install the 4PK1100 ribbed belt.
(d) Tension the belt by the required tension force. Simultaneously, fasten the tension bolt (Q1400820FD)
and fastening bolt (Q18408105) of the oil pump by a M13 open end wrench and M10 socket wrench.
(e) Install the fuel intake hose.
(f) Fasten the high pressure oil pipe of inlet oil return pipe stack of power steering to the power
steering oil pump by a M17 open end wrench.
(g) Fill steering power-assistance fluid as required and completely discharge air in the hydraulic system.
Steering System-19
Assembly of power
Fuel intake hose steering gear with tie rod
Power steering oil with bracket assembly
tank assembly
Hexagon flange bolt Inlet oil return pipe stack of power steering
Q1840616FD
1. Disassembly
(a) Loosen the mounting position of the high/low pressure oil pipe and steering gear by a M17 open
end wrench.
(b) Completely discharge oil fluid.
(c) Remove the two hexagon flange bolts (Q1840616) for connecting the inlet oil return pipe stack of
power steering and vehicle frame by a M8 socket wrench.
(d) Loosen the bolt for connecting the inlet oil pipe of power steering gear and power steering oil
pump by a M17 open end wrench.
(e) Remove the fuel intake hose (for connecting the steering oil pump and power steering oil tank)
and oil return pipe of steering gear (connected with the power steering oil tank).
(f) Remove the inlet oil return pipe stack of power steering and fuel intake hose.
2. Installation
(a) Tighten the mounting point of the high/low pressure oil pipe and steering gear according to the
required torque by a M17 open end wrench.
(b) Tighten the two hexagon flange bolts (Q1840616) for connecting the inlet oil return pipe stack of
(c) Tighten the bolt for connecting the inlet oil pipe of power steering gear and power steering oil
pump according to the required torque by a M17 open end wrench.
(d) Connect the power steering oil return hose to the power steering oil tank. Connect the power
steering oil pump to the power steering oil tank by the fuel intake hose.
(e) Install the fuel intake hose (for connecting the steering oil pump and power steering oil tank) and
oil return pipe of steering gear (for connecting the power steering oil tank).
(f) Fill fresh oil fluid into the power steering oil tank and completely discharge air in the hydraulic
system.
Steering System-20
Removal of Steering Oil Tank and Steering Oil Tank Bracket
Hexagon flange bolt

Q1840616FD
Steel-strip elastic
clamping ring
bracket assembly
Fuel intake hose
1. Disassembly
(a) Remove the fuel intake hose.
(b) Completely discharge the power steering fluid.
(c) Remove the oil return hose of inlet oil return pipe stack of power steering.
(d) Draw out the power steering oil tank assembly upward along the center line of the steering oil
tank.
(e) Remove the hexagon flange bolt (Q1840616FD) for connecting the power steering oil tank and
vehicle body by a M8 socket wrench.
(f) Take off the power steering oil tank bracket assembly.
2. Installation
(a) Install the power steering oil tank bracket assembly. Fasten the hexagon flange bolts
(Q1840616FD) for connecting the power steering oil tank bracket assembly and vehicle body by
a M8 socket wrench.
(b) Insert downwards the power steering oil tank assembly along the center line of the steering oil
tank.
(c) Install the fuel intake hose.
(d) Install the oil return hose of the inlet oil return pipe stack of power steering.
(e) Fill the power steering fluid as required and completely discharge air in it.
Steering System-21
Steering Drive Device (2008-Diesel)

Components Diagram
Steering wheel cover

plate assembly
Fixing screw
of cover plate
Steering wheel
25±3 body assembly
25±3
25±3

50±5
Angle transmission 25±3

pair assembly

70±10 120±10
90±10
25±3
Power steering oil

pump assembly
Hollow bolt 30±5

6KP ribbed belt
17.5±2.5

Steering System-22
Hexagon-head bolt, spring washer

and large washer assemblies
Q1460825FD(Q40208)
Hexagon flange bolt Hexagon

Q1840835 flange bolt
Lower transmission Q32008FD
shaft assembly
Steering pipe
column assembly
1. Disassembly
(b) Remove the hexagon-head bolt, spring washer and large washer assemblies (Q1460825FD) for
wrench.
(c) Draw out the pipe column upward along the axial line of the upper shaft of pipe column.
2. Installation
socket wrench.
(c) Install the hexagon-head bolt, spring washer and large washer assemblies (Q1460825FD) for
wrench.
Disassembly of Steering Angle Transmission Pair
Hexagon flange nut

Hexagon flange nut Q1840830
Q1841090FD
Gasket
Lower transmission
shaft assembly
Angle transmission
pair assembly
Hexagon flange nut

Q18410105FD Flexible universal joint assembly
Hexagon flange nut

Q1840830
Steering System-23
1. Disassembly
(a) Remove the two hexagon flange bolts (Q1841090FD) and one hexagon flange bolt
(Q18410105FD) for connecting angle transmission pair assembly and vehicle frame by a M13
socket wrench.
(b) Remove the hexagon flange bolt (Q1840830) for connecting the angle transmission pair
assembly and lower transmission shaft assembly by a M10 open end wrench.
(c) Remove the hexagon flange bolt (Q1840830) for connecting angle transmission pair assembly
and flexible universal joint assembly by a M10 socket wrench.
(d) Take out the angle transmission pair assembly.
2. Installation
(a) Insert downwards the angle transmission pair assembly and flexible universal joint assembly
along the axial line of the lower transmission shaft assembly and axial line of the flexible
universal joint assembly.
(b) Install the hexagon flange bolt (Q1840830) for connecting the angle transmission pair assembly
and steering lower transmission shaft by a M10 open end wrench.
(c) Install the hexagon flange bolt (Q1840830) for connecting the angle transmission pair assembly
and flexible universal joint by a M10 socket wrench.
(d) Install the three hexagon flange bolts (Q1841090FD) (Q18410105FD) for connecting the angle
transmission pair assembly and vehicle frame by a socket wrench.
Disassembly of Steering Gear
Hexagon flange bolt
Q1840830
Flexible universal
joint assembly
Split pin
Hexagon slotted nut

Q341B14 Ball head assembly
Hexagon flange nut

H e x a g o n f l a n g e b o l t - Q32012FD(M12×1.25)
oversized series
Q1861225FD(M12×1.25)
1. Disassembly
(a) Remove the hexagon flange bolt (Q1840830) for connecting the flexible universal joint assembly
and steering gear by a M10 open end wrench.
(b) Remove the high/low pressure fuel pipe for connecting steering gear and inlet oil return pipe
stack of power steering and completely discharge the steering power-assistance oil.
(c) Remove the three hexagon flange bolts-oversized series (Q1861225FD) and one hexagon flange
(d) When only disassembling the steering gear assembly, loosen the I-shaped hexagon nut
(Q341B14) by a M14 open end wrench and M21 open end wrench and then remove the steering
tie rod from the ball head.
(e) About disassembling the ball head assembly, first remove the split pin by pliers, and then remove
it by a M21 socket wrench.
(f) Take off the steering gear assembly.
2. Installation
(a) Install the steering gear assembly to the vehicle frame. Simultaneously, install the hexagon flange
bolts (Q1840830) for connecting the steering gear and flexible universal joint assembly by a M10
open end wrench.
Steering System-24
(b) Install the three hexagon flange bolts-oversized series (Q1861225FD) and one hexagon flange
(c) Install the high/low pressure fuel pipe for connecting the steering gear and inlet oil return pipe
stack of power steering by a M17 open end wrench and fill it with steering fluid.
(d) When only installing the steering gear assembly, screw the steering tie rod into ball head and
(e) About installing the ball head assembly, first install it by a M21 socket wrench, then install the
(f) After accomplishing the above installation, carry out the exhaust of the steering hydraulic system.
Hexagon flange bolt Hexagon flange bolt
Q1840830 Q1840835
Angle transmission pair assembly
1. Disassembly
(b) Remove the hexagon flange bolt (Q1840830) for connecting the lower transmission shaft
assembly and angle transmission pair assembly by a M10 open end wrench.
(c) Draw out the steering lower transmission shaft upward along the axial line of the lower
transmission shaft.
2. Installation
transmission shaft.
(b) Connect the lower transmission shaft to steering pipe column. Install the hexagon flange bolt
(c) Install the hexagon flange bolt (Q1840830) for connecting the lower transmission shaft assembly
and angle transmission pair assembly by a M10 open end wrench.
Removal and Installation of Steering Oil Pump

Hexagon-head bolt
Q150B1055 B worm drive hose clamping ring
Hollow bolt

of power steering
Hexagon-head bolt, spring
Hexagon-head bolt, washer and large washer
spring washer and large assembliesQ1461030
washer assemblies
Steering System-25
1. Disassembly
(a) Loosen the hexagon-head bolt (Q1461030) for connecting the power steering oil pump and
power steering oil pump bracket and the tension bolt (Q150B1055) at the steering oil pump by a
M16 socket wrench.
(b) Take off the 6KB ribbed belt.
(c) Loosen the B worm drive hose clamping ring for connecting the oil return hose of the inlet oil
return pipe stack of power steering and steering oil tank by a flat head screwdriver and cross
head screwdriver.
(d) Draw out the oil return hose of the inlet oil return pipe stack of power steering and completely
discharge the oil fluid in it.
(e) Remove the hollow bolt of the high pressure oil pipe of inlet oil return pipe stack of power steering
by a M20 open end wrench or M20 socket wrench.
2. Installation
(a) Install the power steering oil pump to the correct position.
(b) Install the 6KB ribbed belt.
(c) Install the hexagon-head bolt (Q1461030) for connecting the power steering oil pump and power
steering oil pump bracket and the tension bolt (Q150B1055) at the steering oil pump by a M16
socket wrench to make the 6KB ribbed belt reach the specified tension
(d) Screw down the hollow bolt of the high pressure oil pipe of the inlet oil return pipe stack of power
steering by a M20 open end wrench or M20 socket wrench.
(e) Insert downwards the oil return hose of inlet oil return pipe stack of power steering.
(f) Screw down the B worm drive hose clamping ring for connecting the oil return hose of the inlet
oil return pipe stack of power steering and steering oil tank by a flat head screwdriver and cross
head screwdriver.
(g) Fill the steering fluid as required and completely discharge air in it.
Removal and Installation of Steering Oil Pipe
Power steering oil
pump assembly
B worm drive hose clamping ring
Hollow bolt

6KP ribbed belt
Assembly of power Hexagon flange bolt

steering gear with tie rod Q1840616FD
Steering System-26
1. Disassembly
end wrench.
(b) Completely discharge the oil fluid.
(c) Remove the hexagon flange bolt (Q1840616) for connecting the inlet oil return pipe stack of
(d) Loosen the hollow bolt for connecting the inlet oil pipe of power steering gear and power steering
oil pump by a M20 open end wrench.
(e) Loosen the B worm drive hose clamping ring by a flat head screwdriver and cross head
screwdriver.
(f) Remove the inlet oil return pipe stack of power steering.
2. Installation
(a) Tighten the mounting point of the high/low pressure oil pipe and power steering gear according to
the required torque by a M17 open end wrench.
(b) Tighten the hexagon flange bolt (Q1840616) for connecting the inlet oil return pipe stack of power
steering and vehicle frame by a M8 socket wrench.
(c) Tighten the hollow bolt for connecting the inlet oil pipe of power steering gear and power steering
oil pump according to the required torque by a M20 open end wrench.
(d) Insert downwards the oil return hose of the inlet oil return pipe stack of power steering.
(e) Screw down the B worm drive hose clamping ring by a flat head screwdriver and cross head
screwdriver.
(f) Fill fresh oil fluid into the power steering oil tank and discharge air in it as required.
Steering System-27
Steering Drive Device (2.5TCI Right-hand Drive)

Components Diagram
Hexagon nut and conic elastic
Fixing screw of cover plate washer subassembly
25±3
Steering pipe
column assembly
25±3
25±3
of steering wheel
Steering wheel body assembly
Lower transmission
shaft assembly
Split pin
25±3 Hexagon
slotted nut
Hexagon-head bolt-
fine pitch thread
Q151B16190
Assembly of power
Ball head assembly
Plain washer
Q341B16
Hexagon flange bolt-
oversized series
Q1861225FD Power steering oil
pump assembly
Hexagon-head bolt
Q150B1055 Hollow bolt
30±5
Hexagon-head bolt,
spring washer and plain B worm drive hose
washer assemblies clamping ring
Q1461030
6KP ribbed belt Assembly of power
17.5±2.5
Hexagon flange bolt

N•m : specified torque Inlet oil return pipe stack Q1840616FD
of power steering
Steering System-28
Steering pipe Hexagon nut and conic elastic

column assembly Fixing screw washer subassembly
of cover plate
Hexagon flange nut
Q32008FD
Hexagon-head bolt,
washer assembliesQ1
460825FD(Q40208)
Hexagon flange bolt

Q1840835 Cover plate assembly
of steering wheel
Steering wheel
body assembly
Lower transmission
shaft assembly
1. Disassembly
(a) Loosen the fixing screw of cover plate by an inner hexagonal wrench only for the steering wheel,
then remove the cover plate assembly of steering wheel.
(b) After disassembling the hexagon nut and conic elastic washer subassembly by a M18 socket
wrench, take off the steering wheel body assembly.
(c) Remove the hexagon flange bolt (Q1840835) for connecting the steering pipe column and lower
(d) Remove the hexagon-head bolt (Q1460825FD) for connecting the steering pipe column and front
wall and the hexagon flange nut (Q32008FD) for connecting the steering pipe column and front
wall collision prevention beam by a M13 socket wrench.
(e) Draw out the pipe column upward along the axial line of the upper shaft of pipe column.
2. Installation
(a) Insert downwards the pipe column assembly along the axial line of the upper shaft of pipe
column.
socket wrench.
Tightening Torque: 25±3N•m
(c) Install the hexagon flange bolt (Q1460825FD) for connecting the steering pipe column and front
wall and the hexagon flange nut (Q32008FD) for connecting the steering pipe column and front
wall collision prevention beam by a M13 socket wrench.
Steering System-29
Disassembly and Installation of Steering Gear

Hexagon-head bolt Steering lower

transmission
Q150B0832 shaft assembly
Spring
Hexagon-head bolt- washer
fine pitch thread Q40308
Q151B16190
Split pin
Hexagon slotted nut
Assembly of power
Ball head assembly
Plain washer

Hexagon flange bolt- Q341B16
oversized series
Q1861225FD
1. Disassembly
(a) Remove the hexagon-head bolt and spring washer for connecting the steering lower transmission
shaft and steering gear by a M13 open end wrench.
stack of power steering and completely discharge steering power-assistance oil.
(c) Remove the two hexagon flange bolts-oversized series for connecting the steering gear and
vehicle frame by a M18 socket wrench.
(d) Remove the two I-shaped hexagon nuts (Q341B16) for connecting the steering gear and vehicle
(e) When only disassembling the steering gear assembly, loosen the I-shaped hexagon nut (Q341B14) by a
M14 open end wrench and M21 open end wrench and remove the steering tie rod from the ball head.
(f) About disassembling the ball head assembly, first remove the split pin by pliers, and then remove
the ball head assembly by a M21 socket wrench.
(g) Take off the steering gear assembly.
2. Installation
(a) Install the steering gear assembly to vehicle frame. Simultaneously, install the hexagon-head bolt
and spring washer for connecting the steering gear and lower transmission shaft assembly by a
M13 open end wrench.
(b) Install the two hexagon flange bolts-oversized series for connecting the steering gear and vehicle
(c) Install the two I-shaped hexagon nuts (Q341B16) for connecting the steering gear and vehicle
(d) Install the high/low pressure fuel pipe for connecting the steering gear and inlet oil return pipe
stack of power steering and fill it with steering power-assistance oil.
Tightening Torque: 17.5±2.5N•m
(e) When only installing the steering gear assembly, screw the steering tie rod into the ball head and
(f) About installing the ball head assembly, first install it by a M21 socket wrench, then install the
(g) After accomplishing the above installation, carry out the exhaust of the steering hydraulic system.
Steering System-30

Hexagon flange bolt
Hexagon-head bolt Q1840835
Q150B0832
Spring washer
Q40308
Assembly of power
Steering pipe
column assembly
Lower transmission
shaft assembly
1. Disassembly
(b) Remove the hexagon-head bolt and spring washer for connecting the lower transmission shaft
(c) Draw out upwards along the axial line of the lower transmission shaft.
2. Installation
transmission shaft.
(c) Install the hexagon-head bolt and spring washer for connecting the lower transmission shaft
Hexagon-head
boltQ150B1055 Power steering oil pump assembly
Hollow bolt
Ribbed belt 6PK1525 Hexagon-head bolt, spring

washer and large washer
assembliesQ1461030
B worm drive hose

clamping ring

Steering System-31
1. Disassembly
(a) Loosen the hexagon-head bolt (Q1461030) for connecting the power steering oil pump and
power steering oil pump bracket and the tension bolt (Q150B1055) at the steering oil pump by a
M16 socket wrench.
(b) Take off the ribbed belt 6PK1525 belt.
(c) Loosen the B worm drive hose clamping ring for connecting the oil return hose of the inlet oil
return pipe stack of power steering and the steering oil tank by a flat head screwdriver and cross
head screwdriver.
(d) Draw out the oil return hose of the inlet oil return pipe stack of power steering and completely
discharge the oil fluid in it.
(e) Remove the hollow bolt of the high pressure oil pipe of the inlet oil return pipe stack of power
2. Installation
(a) Install the power steering oil pump to the correct position.
(b) Install the ribbed belt 6PK1525 belt.
(c) Install the hexagon-head bolt (Q1461030) for connecting the power steering oil pump and power
steering oil pump bracket and the tension bolt (Q150B1055) at the steering oil pump by a M16
socket wrench to make the 6KB ribbed belt reach the specified tension
Tightening torque of the hexagon-head bolt (Q1461030): 65±5N•m
(d) Screw down the hollow bolt of the high pressure oil pipe of the inlet oil return pipe stack of power
(e) Insert downwards the oil return hose of the inlet oil return pipe stack of power steering.
(f) Screw down the B worm drive hose clamping ring for connecting the oil return hose of the inlet oil
return pipe stack of power steering and the steering oil tank by a flat head screwdriver and cross
head screwdriver.
(g) Fill the steering fluid as required and completely discharge air in it.
Power steering oil pump assembly
Hollow bolt
30±5
Assembly of power
steering gear with tie rod Inlet oil return pipe
17.5±2.5
Hexagon flange bolt

Q1840616FD
1. Disassembly
end wrench.
(b) Completely discharge the oil fluid.
(c) Remove the hexagon flange bolt (Q1840616FD) for connecting the inlet oil return pipe stack of
Steering System-32
(d) Loosen the hollow bolt for connecting the inlet oil pipe of power steering gear and power steering
oil pump by a M20 open end wrench.
(e) Loosen the B worm drive hose clamping ring by a flat head screwdriver and cross head
screwdriver.
(f) Remove the inlet oil return pipe stack of power steering.
2. Installation
(a) Tighten the mounting point of the high/low pressure oil pipe and power steering gear according to
the required torque by a M17 open end wrench.
(b) Tighten the two hexagon flange bolts (Q1840616FD) for connecting the inlet oil return pipe stack
of power steering and vehicle frame by a M8 socket wrench.
(c) Tighten the hollow bolt for connecting the inlet oil pipe of power steering gear and power steering
oil pump according to the required torque by a M20 open end wrench.
(d) Insert downwards the oil return hose of the inlet oil return pipe stack of power steering.
(e) Screw down the B worm drive hose clamping ring by a flat head screwdriver and cross head
screwdriver.
(f) Fill fresh oil fluid into the power steering oil tank and discharge air in it as required.
Body Electrical Appliance (2005)-1
Body Electrical Appliance (2005)
Maintenance of Electrical Appliance System .............................. 2

Harness ........................................................................................... 3
Fuse Box ......................................................................................... 11
Basic Diagram of the Complete Vehicle Electrical Appliance .... 13
Central Door Lock Controller ........................................................ 25
Maintenance of Electrical Appliance System

For the circuit basic diagram and partial breakdown drawings of Hover CUV vehicle, please see the
Diagram-4.1~4.12. Among which, the electronic instruments are basically as same as that of the
“Saiying” and “Saifu”. However, the ceiling lamp delay switch is controlled by the Central Control Door
Lock. A new function is added, which automatically locks the five doors when the speed is over 15 km/h.
The headlamps are changed to 4 upper beam lamps. Power clutch is added for 4WD vehicles, and
more new changes.
Power sunroof and airbag are optional for this vehicle.
For continence of the users to read this chapter, in addition to the circuit basic diagram of this vehicle,
the connection diagrams among the harnesses, relative plugs, and junction boxes are also provided.
Among which, the junction box inside the engine room is numbered as 2, and the junction box inside
the instrument panel as 1. Decomposition introductions of the circuits are made one-by-one by
systems, as follows.
Instructions
1. A special plug symbol is added to the harness connection diagram, as shown in Diagram VIII-1.1
2. To reduce the special plug symbols used, all the plugs between the harness and the load are
described in characters.
3. The representations of the wire plugs on the sleeve are shown in Diagram VIII-1.2, in which the
upper numbers are the wire number, while the lower letters are wire color.
The letter symbols of the wire colors are shown as follows
B-Black Br-Brown G-Green Gr-Grey L-Blue Lg-Light green
Or-Orange P-Pink R-Red V-Violet W-White Y-Yellow
Additionally, the two-color wire is expressed by adding a slash (/) between the two letters representing
the two colors. The letter before the (/) represents the color of the wire, while the letter after the (/)
represents the color of the other fine wire on this wire. For example, L/R presents a blue wire with a
red fine wire. Br/Gr presents a brown wire with a grey fine wire.
4. The plug pin numbering follows the direction in which the wire and the plug are inserted into
the sleeve. The plug parts are numbered from left to right, while the jack parts are numbered
from right to left, as shown in Diagram VIII-1.3.
Wire number
Jack end Plug end

Wire color
Diagram VIII-1.1 Diagram VIII-1.2
Number of pins at Number of pins at the

the positive plug end negative plug end
Sleeve view
Sleeve view direction direction
Diagram VIII-1.3
Harness
Schematic Diagram of Harness Mid-Connection Numbering and Pin
Functions 1
Connecting the Connecting the engine

instrument harness 2 room harness 2
Diagram VIII-2.2-1

Functions 2
Connecting the instrument Connecting the engine

harness 1 room harness 1
Connecting the floor Connecting the engine

harness room harness
Connecting the floor Connecting the instrument

harness 2 harness 2
Diagram VIII-2.2-2

Functions 3
Connecting the engine

Connecting the instrument room harness 3
harness 3
Connecting the instrument Connecting the engine

harness 4 room harness 4
Connecting the floor Connecting the instrument

harness 1 harness 1
Diagram VIII-2.2-3

Functions 4
Connecting the ceiling Connecting the floor

harness harness
Connecting the right front Connecting the floor

door harness harness
Connecting the chassis Connecting the floor

harness harness
Connecting the right-left Connecting the floor

front door harness harness 1
Diagram VIII-2.2-4

Functions 5
Connecting the floor

Connecting the left front
harness 2
door harness 2
Connecting the right rear Connecting the floor


Connecting the right rear harness
door harness
Connecting the left rear Connecting the floor

Diagram VIII-2.2-5

Functions 6
Connecting the tail-gate Connecting the floor

transition harness harness

Connecting the tail-gate
harness
transition harness

Connecting the tail gate transition harness
Connecting the tail gate Connecting the tail-gate

transition harness
Diagram VIII-2.2-6
Horn Right front

A/C cold and warm air A/C mode actuator Horn fog lamp
actuator Left front Left turn
fog lamp signal lamp Right turn
signal lamp
Internal and external

Evaporator temperature
circulation actuator
Combined Motor for condenser Side turn signal sensor
lamp fan lamp
Right combined Blower motor
Engine room harness

lamp
Speed governing module
Side turn Engine hood Front wiper
Outdoor temperature
signal lamp warning switch
Brake fluid level A/C pressure switch (Tri-state switch) Rear washer motor
alarm
sensor
Front washer motor
Connecting the
distribution box
Connecting the
electric control clutch
Connecting the
Diagnostic equipment
distribution box
Connecting the
distribution box
Connecting the
distribution box
No. 1 junction box
Connecting the ECM
Schematic Diagram of Harness Relationship and Plug Connection Numbering

harness
Engine
Power rear-view mirror switch Central control door
lock
Electric control
clutch ECU
Rear fog lamp switch Warning switch

Diagram VIII-2.1
Indoor temperature
sensor
Front fog lamp switch
Rear wiper control switch
Instrument harness
Connecting the antenna
Stop lamp switch Antenna interface

Charging power CD player
supply
CD player
Instrument dimming interface
Grounding switch
point
A/C ECU
Cigar lighter Cigar lighter illumination
Combined Ignition switch

Combined
switch 1 switch 2
Ash tray
illumination A/C ECU
CD player
No. 2 junction box
Speedometer sensor
4WD control
Floor harness
Reversing switch
Power seat
Handbrake
Water
Seat belt switch
pipe
Middle ceiling lamp
High tone speaker Power rear-view mirror
High tone
speaker
CD player
interface
Driver's side sun visor
Power rear-view
mirror
Right front door

Regulator (rocker
Speaker
Speaker
type)
Regulator
harness
chassis harness
Connecting the
Regulator switch
Oil pump
Front ceiling lamp
lamp
Door
Left front door
lamp
Door
left front door lamp

Connecting the
mechanism assembly
Left front door locking
Connecting the right

harness
Right front door integrated door

front lamp switch
lock assembly (locking mechanism

switch
assembly)
Rear fog lamp
left rear door lamp
Rear fog lamp

Connecting the
switch
Assistant driver’s side
Ceiling harness
sun visor
Sunroof ECU
Backup
power
Left tail lamp

lower
Speaker
Left tail lamp
the right rear

upper
lamp switch
Speaker
Connecting
Sunroof switch
Right tail lamp

High tone speaker
lower
High tone
speaker
Right rear door

Door lamp
Regulator switch
transition
Tail-gate
harness
Regulator
harness
Rear ceiling lamp
switch
Right tail lamp
upper
lock assembly (locking mechanism

assembly (locking mechanism assembly)
Regulator (rocker type)
Regulator (rocker
Right rear door integrated door

Right front door integrated door lock
Rear liftgate
type)
assembly)
harness
Left rear door
harness
mounted stop lamp

Outdoor high-
Door lamp
Rear wiper motor

switch
Water pipe
Licence lamp Licence lamp Negative

pole of rear
High-mounted stop Positive pole of windscreen
lamp rear windscreen defroster
defroster Tail-gate integrated door lock assembly
(locking mechanism assembly)
Connecting the central control door
lock
Connecting the central control door
Storage battery
lock and power seat

Connecting the ignition Connecting the instrument power
switch IGI supply, generator excitation
Red
Red Red
Green/Yellow
Green/Yellow
Blue/White
Green
Black/
White
Red/
Connecting the tachometer sensor

Connecting the speedometer sensor
White/Black
Charcoal canister cleaning control solenoid switch
Connecting A/C tri-state switch

Ignition plug
(normally closed )
Oil pump relay
Red/Yellow
Grey
Malfunction indicator lamp

Black/Green
Compressor relay
Idle control valve

Yellow
Black/Green
Fuel pump
Main relay
Pink/Brown
Fuel injector 1
Fuel injector 2
Fuel injector 3
Fuel injector 4
Green/Yellow
Green/Yellow
Connecting the A/C ECU
Black/
Yellow
Black/
Blue
Black/White
Black/Red
electromagnetic clutch
Brown/Red
Green
Compressor for
Yellow/Red
Red
Brown/Blue
Violet/Red
Red/Blue
Blue/Red
Sensor pool 1 Sensor pool 2
Green/
Yellow
Violet/
Black
Red/
Red
Red
Blue/Red
Green/
Green/
Green
Green
Red
Red
Grey/White
Green/
Green/
White
Yellow
Yellow
Black/
Blue/
White
Violet
White
Grey/
Grey
Blue
Diagnostic plug
Front oxygen sensor Crankshaft position Coolant temperature Knock sensor Throttle valve position Intake manifold pressure
sensor sensor sensor and temperature sensor
Connecting the ignition Connecting the water Connecting the front oxygen
coil temperature sensor sensor
Connecting the engine room
harness
Connecting the water Connecting Connecting the Connecting the Connecting the
Connecting the idle control Connecting the charcoal
temperature sensor Connecting the intake the A/C engine oil pressure knock sensor Throttle valve crankshaft position canister control valve
valve
temperature and clutch switch position sensor sensor
pressure sensor
Connecting the ECM
Fuse Box
Front Pin Diagram of No. 1 Fuse Box
Intermittent relay
Flash relay
Defroster relay A/C
Stop lamp switch Central control

door lock
Flash relay Charging power

supply for power
seat
Door lamp
Interior lamp Generator

Unloading
(ACC)
Engine
Rear wiper motor Rear fog lamp
Front wiper motor Power clutch
Power rear-view Reversing switch

mirror Cigar
lighter
Sunroof
Rear defroster relay
Unloading relay
Diagram VIII-3.1
F19 compressor relay
F16 electronic fan relay
F25 front fog lamp relay
Compressor relay Electronic fan relay
F1 unloading relay F2 to the junction

box 2
F3 to the ignition F0 to the storage

switch battery
Front fog lamp relay

Horn relay
Small lamp relay
F24 small lamp relay
50
(grounding)
Blower relay F28 horn relay
F31 right window F30 left window

power supply F21 oil pump relay
power supply
Diagram VIII-3.2
F23 headlamp relay
F22 headlamp relay

Front Pin Diagram of No. 2 Fuse Box
Fuel pump relay Headlamp relay Main relay

F4 sunroof power supply
F20 Main relay
F17 Blower
Backup
50
(grounding)
Dimming relay
Basic Diagram of the Complete Vehicle Electrical Appliance

Power Supply and Engine Peripheral Circuit
To No. 1 fuse box
To the central control

door lock ECU
Key
pulled
out Main relay
Ignition switch
A/C compressor
relay
Starting
motor
Storage battery
Diagnostic
interface
A/C compressor
To the A/C tri-state

pressure switch
Fuel pump relay
Generator
To the interface
instrument
Compressor Main relay control
A/C switch Main relay
relay signal
Engine oil Water Engine rotation

Ignition switch pressure Detection Oil pump relay
temperature Odometer speed
sensor lamp
Fuel pump sensor
To the
instrument
Generator

harness
Connecting the fuel

pump Connecting the Connecting the
ignition switch generator
Diagram VIII-4.1
Instrument System
To No. 1 fuse box
To the small lamp relay Upper beam
Dimming switch
Connecting the CD
power supply
Lighting lamp
Combination instrument
Tachometer Odometer Water

temperature Fuel gauge
gauge
To the clutch ECU
To the central control

door lock ECU
To the engine
To the seat
belt switch
To the detection lamp sensor of engine
To the engine speed sensor
To the engine odometer
Brake fluid level alarm switch

Odometer sensor
To the engine water

temperature sensor
To the generator
Front engine hood switch

Fuel sensor
Tail-gate lamp switch

Parking switch
Connecting the
instrument
Connecting the Connecting the brake

Connecting the speedometer sensor Connecting the tail-
fuel pump fluid level alarm
Connecting the gate lamp switch
dimming switch

hood warning switch
Diagram VIII-4.2
Headlamp System
Small lamp relay
Headlamp relay
Connecting the small lamp

Left Right
headlamp headlamp
To No.1 fuse box
Dimming switch
Light switch
Upper-beam
indicator lamp
Turn off Overtaking
Small
lamp
Lower
beam
Dimming relay
Headlamp Upper
beam
Connecting the Connecting the left Connecting the right

combined switch combined lamp combined lamp
Diagram VIII-4.3
Steering and Alarm System
Danger
alarm switch
Left turn
Right turn
Turn switch
To the central control door lock
Left turn Right turn

signal lamp signal lamp
Indicator
Indicator
lamp
lamp
Front Side Rear Front Side Rear
Connecting the
Connecting the
combined switch
warning switch
Diagram VIII-4.4
Front & Rear Wiper and Washer System
F7-15A F8-10A
Rear wiper switch
Washer switch
Intermittent relay
Washing
Wiper
Front wiper switch
Rear washer motor

Front washer motor
Wiper Rear wiper motor
Connecting the
Connecting the
combined switch
rear wiper switch
Connecting the Connecting the front Connecting the rear Connecting the
front wiper motor water spray motor water spray motor rear wiper motor
Diagram VIII-4.5
Small Lamp and Fog Lamp
To the lighting system

Small lamp relay of CD player etc.
To the instrument
lighting system
Rear fog
lamp switch
Front small lamp
Rear small lamp
Small lamp
indication
To the headlamp
controlling system
Indicator lamp Rear fog

lamp Indicator lamp
Turn off
Small lamp
Headlamp
Light switch
Front fog lamp
Connecting the
combined switch
Connecting the front Connecting the rear

fog lamp switch fog lamp switch
Diagram VIII-4.6
Central Control Door Lock and Window Regulator System
To No.1 fuse box
To No.1 fuse box
F15-10A F13-5A
To the ignition
lock
To the door
switch
Left front Left rear Right front Right rear

Central control door lock controller
window switch window switch window switch window switch
Connecting the
turn signal lamp
Power regulator Power regulator Power regulator Power regulator motor

motor motor motor
Locking mechanism
assembly of left front door Locking Locking Locking Locking
mechanism mechanism mechanism mechanism
assembly assembly of assembly
To the speedometer of right left rear door of right
assembly of
rear door
rear door front door
Connecting the central Connecting the Connecting the right Connecting the locking
control door lock window motor front door switch mechanism assembly
Connecting the locking

Connecting the left Connecting the left mechanism assembly Connecting the right
front door switch rear door switch of left front door rear door switch
Diagram VIII-4.7
A/C System
To No. 1 fuse box
To No. 1 fuse box
F15-10A
F14-10A
Indoor temperature Outdoor Evaporator Blower

sensor temperature sensor temperature sensor
Compressor
relay
Defroster
High-speed relay
relay for blower
To the rear-view
mirror system
(Connecting the A/C ECU
CD player)
Tri-state Speed governing

pressure switch module
Condenser relay
To the engine ECU

Rear windscreen
defroster
Defroster
indicator
Cold and Internal and Mode actuator lamp
warm air external circulation To the engine ECU Condenser motor
actuator actuator
Connecting the A/C ECU Connecting the A/C ECU Connecting the external
Connecting the tri-

Connecting the outdoor
state pressure switch
temperature sensor
Connecting the Connecting the
mode actuator engine harness
Connecting the evaporator

temperature sensor
Connecting the A/C speed

Connecting the cold and
governing module
Connecting the indoor warm air actuator
temperature sensor
Diagram VIII-4.8
Audio, Sunroof and Power Clutch System
To No. 1 fuse box

To No. 1 fuse box
From the small lamp relay
To the A/C ECU
CD player
Turn off Turn on
Sunroof
Power clutch controller

indication (instrument)
Connecting the 4WD
Left front Right front Left rear Right rear

Clutch motor
Speaker
Connecting the Connecting the Connecting the Connecting the

sunroof ECU sunroof switch electric drive switch sunroof ECU
Connecting the Connecting the power Connecting the

CD player clutch controller clutch motor
Diagram VIII-4.9
Interior Lamp System
To No.1 fuse box
supply of CD instrument
Connecting the power
Front ceiling lamp Front ceiling lamp Middle Rear ceiling lamp
ceiling lamp
Door
lamp
To the
instrument
To the central
control door lock
To the
instrument
Rear door
switch
Four door lamp switches
Connecting the
Connecting Connecting the Connecting the
door switch
the door lamp rear door switch rear door switch
Diagram VIII-4.10
Power Rear-view Mirror
Switch Function Instructions

1 K1, K2, and K3 are the rear-view mirror
To No.1 fuse box function switches. K4 is the rear-view
mirror selector switch.
2 When K4 selects the right rear-view
mirror (R) and K1 is connected to b, the
positive current would be connected
Rear-view
to the negative pole of power supply
mirror switch
through K2 (R), drive motor Mc, and
To the defroster relay

then K1. The current goes bottom-up.
3 When K4 selects the right rear-
view mirror (R), and K2 and K3 are
connected to b (while K1 is connected
to a), the positive current would be
K4 connected to the negative pole of power
supply through K1, drive motor Mc, and
then K2. The current goes top-down.
4 When K4 selects the right rear-view
mirror (R) and K3 is connected to b, the
positive current would be connected
to the negative pole of power supply
through K2 (R), drive motor Md, and
then K3. The current goes bottom-up.
Power rear-view mirror
Left rear-view mirror

5 When K4 selects the right rear-
view mirror (R), and K1 and K2 are
connected to b, the positive current
would be connected to the negative
pole of power supply through K3 (R),
drive motor Md, and then K3. The
Right rear-view mirror
current goes top-down.

6 When K4 selects the left rear-view
mirror (L), the drive motors Ma and Mb
would do the same as Mc and Md.
Connecting the rear-view

mirror of right front door

rear-view mirror switch
Connecting the rear-view
mirror of left front door
Diagram VIII-4.11
Reversing Lamp, Stop Lamp and Aid System
To No.1 fuse box
To No.1 fuse box
To No.1 fuse box
Horn relay Power
Braking switch
Cigar lighter seat
Reversing switch Power socket

Electric horn
High-mounted
Reversing lamp
Stop lamp
Horn button
stop lamp
Connecting Connecting the

the horn power seat

combined switch braking switch
Connecting the
reversing switch
Diagram VIII-4.12
Central Door Lock Controller

1. The positive pole of power supply (12 V) is connected to the positive pole of the vehicle battery
via a 15A fuse. The voltage shall not be less than 10 V when the starting motor works.
2. Unlocking output of the central control door lock: The unlocking wire connected to the
actuator of the central control door lock, which is generally grounded via the normally closed
contact point of the interior relay; when unlocking by hand or remote controller, the public
contact point of the relay is connected to the normally open contact point, and the wire will
generate an output voltage of 12 V.
3. Locking output of the central control door lock: The locking wire connected to the actuator
of the central control door lock, which is generally grounded via the normally closed contact
point of the interior relay; when locking by hand or remote controller, the public contact point
of the relay is connected to the normally open contact point, and the wire will generate an
output voltage of 12 V.
4. Key detection wire: The wire is connected to the vehicle’s ignition lock. Connect it to the
grounding when the key is plugged in. (Negative input)
5. Right turn signal lamp: The wire is connected to the positive wire of the right turn signal lamp
of the vehicle. It generates an output voltage of 12 V when working.
6. Left turn signal lamp: The wire is connected to the positive wire of the left turn signal lamp of
the vehicle. It generates an output voltage of 12 V when working.
7. Door switch negative input: is connected to the door switch and grounded when the door is
open. (The interior lamp would be on)
(a) Open the door and then close it when the reading lamp is on for 10 seconds. If the key inserting
or door locking is detected during the 10 seconds, the reading lamp would be off.
(b) When the key is pulled out of the ignition lock, the reading lamp is on. If insert the key again, the
reading lamp is off; the reading lamp would be off 1minute later after closing the door without any
subsequent operation.
8. ON power supply detection wire: A wire that is connected to the ON gear of the ignition switch.
(When the key is turned to ON, there will be an output voltage of 12 V)
9. Connected to the speedometer detection wire. (When the speed rises up to 15 km/h, the
instrument would transfer a rectangular positive pulse of 500mS to the central door lock
controller which would manipulate the central lock to lock the doors after detection of such
pulse signal.)
10. Window closer signal output: When locking the door with remote controller, this wire would
provide an output voltage of 12 V for 1 second, and then cut it off. (No output)
11. Locking signal: Connected to the locking signal wire of the left front door central control door
lock of the vehicle and connected with the grounding when working.(Grounding)
12. Unlocking signal: Connected to the unlocking signal wire of the left front door central control
door lock of the vehicle and connected with the grounding when working.(Grounding)
13. Negative pole of the power supply: Connecting the body (grounding), and as short as possible
to prevent interference. Functions of the central door lock controller.
Functions of the Central Door Lock Controller
1. Locking: After all the doors are closed, press the LOCK button on the remote controller once.
The turn signal lamp would flash once, and the central control door lock is locked.
2. Unlocking: In the state of locking, press the UNLOCK button on the remote controller once.
The turn signal lamp would flash twice, and the central control door lock is opened.
3. In the state of locking, press the LOCK button on the remote controller once. The turn signal
lamp would flash quickly ten times. Press the UNLOCK button on the remote controller to quit
the positioning function.
4. Automatic locking protection function: In the state of locking, press the UNLOCK button on the
remote controller for unlocking purpose, the door would be automatically locked 30 seconds
later if it is not opened.
5. Automatic locking in traveling: When the speed rises up to 15 km/h, the central control door
lock is automatically locked. When the IG gear of the ignition switch is cut off, the door would
be unlocked automatically. When JP1 is connected to H, the function is started; when JP1 is
connected to L, the function is closed.
6. Automatic window-shutdown function (optional) (not set up)
7. Suspension of remote control function: When the vehicle key is inserted into the ignition lock,
the remote controller would be unable to operate, but the main unit works normally.
8. Manual locking and unlocking: The locking and unlocking can be operated with manual
control.
9. Clearing and registration of remote controller
Open the door, insert the vehicle key into the ignition lock and turn it continuously and quickly from
OFF to ON five times, and then stop at ON. The lamps would flash once, which means the learning
function is activated. Press any button on the remote controller within 10 seconds. The lamps would
flash twice, which means the remote controller is successfully registered. Such operation can be
repeated and up to two remote controllers can be registered: the system would exit from the learning
function if no remote controller is pressed in 10 seconds. The first registered remote controller would
be cleaned when registering a new one after four remote controllers are registered.
10. Delay Function of Reading Lamp
(a) Open the door and then close it. The vehicle amp is on for 10 seconds. If the vehicle key is
inserted into the ignition lock within 10 seconds, the reading lamp would be off at once.
(b) Open the door and then close. The vehicle lamp is on for 10 seconds. If the door is locked within
10 seconds, the reading lamp would be off at once.
(c) When the vehicle key is pulled out of the ignition lock, the vehicle lamp is on for 1 minute. If the
key is inserted into the ignition lock again, the reading lamp would be off at once.
(d) When the vehicle key is pulled out of the ignition lock, the vehicle lamp is on for 1 minute. If the
door is locked, the reading lamp would be off at once.
Body Electrical Appliance (2005 Top model)-1
Body Electrical Appliance (2005

Top model)
Schematic Diagram of Harness Mid-Connection Numbering and
Pin Functions .................................................................................. 2
Power Supply System .................................................................... 6
Engine System ................................................................................ 7
Instrument System ......................................................................... 8
Light System ................................................................................... 9
Front & Rear Wiper and Power Rear-view Mirror System .......... 10
A/C and CD Player System ............................................................ 11
Central Control Door Lock and Interior Lamp System ............... 12
Airbag and ABS System ................................................................ 13
Auto & Manual Gear System ......................................................... 14
Power Clutch and Power Seat System ......................................... 15
Harness Connecting Diagram ....................................................... 16
Schematic Diagram of Harness Mid-Connection Numbering and

Pin Functions
Connecting the
Connecting the
engine harness 1
engine harness 2
Connecting the positive Sleeve:
harness A of engine
Holder:
402 403 390A 401
0.5 0.5
Terminal:
46 47 0.5 0.5
0.5 0.5 W/B R G/Y L
W/R Y/B
173 404 409 405
390 199 0.5
1.5 0.5 0.5
0.5 3.0
G/Y R R/W Br P/Br Br/W
406 407 97
651 652
0.5 0.5 0.5
0.5 0.5
L/W L/Y W/R
G/W G/B
63 410 174 408 437 436
0.5 0.85 1.25 0.5 Br/R Br/B
Br/Gr B/L Gr/B Lg 0.5 0.5
47 46
0.5 0.5
Y/B W/R
652 651
199 390 0.5 0.5
G/B G/W
3.0 0.5
401 390 403 402 436 437
R G/Y Br/B Br/R
4 L G/Y R W/B 1 0.5 0.5
0.5 0.5 0.5 0.5
405 409 404 173
Br/W P/Br Br B/Y Connecting the
0.5 0.5 0.5 1.5
engine harness 2
Connecting the engine 97 407 406
0.5 L/Y L/W
room harness 1 W/R 0.5 0.5 Sleeve:
408 174 410 63 Holder:
16
L/G Gr/B
0.5 1.0
B/L Br/Gr
0.5 0.5 13
Terminal:
Connecting the main
Connecting the main harness CT2
harness CT2
Connecting the
Connecting the instrument harness 2
instrument harness 1
42
42A
604 603 33
84 0.5 0.5 0.5
88 306
0.5 0.5 0.5 78 Br/B Br/R R/B
Y/B R/W L/B 78A
81 80 90 31
86 89 79 0.5 0.5 0.5 0.5
0.5 0.5 0.5 60 P W L/Y G/Y
Y G L 60A 83 82 182
183
305C 0.5 0.5 1.25
1.25
0.5 W/L W/B Y
L/W
L/R
50P 85 76 191 380 184A
Connecting the positive 2.0 0.5 0.5 0.85
G/R
1.25 1.25
P/Y L/Y Gr/B
harness B of engine B G/B
1
3 B/R
33 603 604
1
305 0.85 0.5 0.5
3 B/R 0.5 R/B Br/R Br/B
L/R
Connecting the engine 60C
31 90 80 81
79D 89 86 0.5 0.5 0.5
room harness B 0.85 0.5 0.5 0.5
1.25
L/Y W P
Y
O/L
G/R L G
182 183 82 83
78 84 306 88
1.25 1.25 0.5 0.5
78A 0.5 0.5 0.5
W/B W/L
Y/B Y L/W
L/B R/W
184A 380 191 76 85 50G
42C 1.25 1.25 0.85 0.5 0.5 2.0
0.85 Gr/B L/Y G/R G/B P/Y B
G/V
Connecting the engine Connecting the engine

room harness 1 room harness 2
Connecting the instrument Connecting the instrument Connecting the

harness 3 harness 4 floor harness
452 451 488 405

0.5 0.5 155 B/W Br/W
R/L R/W 3.0 0.5 0.5
W/R 71B 47 402 46
310 164 436 437 0.5 0.5 0.5 0.5 615 50A 609 610 611 612
0.5 0.5 Br/R R/B Y/B W/B W/R 0.5 2.0 0.5 0.5 0.5 0.5
Br/B
L L/B 4 150 0.5 0.5 401 63 41 44 311 281 Br/R B G/B G/R G/L G/Br
3.0 0.5 0.5 0.85 0.5 0.5 0.5
300
3.0 302 L Br/Gr G/Y R/L R/Y G/Y
614 613
301 R/L 29 0.5 0.5
1.25 1.25 R/G 0.5 1.25 390 116 151 75 282 Br/B
Gr/Br
L/W Y/W 0.5 0.5 0.5 0.5
L/R L/Y 0.5
35 44
G/Y R/W G/W L/R G/L
99
1.25 0.5
311 95 404 403B 79
0.5
Y R/L
0.5 0.5 0.5 0.5 0.5
R/Y L/O Br R L G/B 29 135
1.25 1.25
L/Y L/W
46 402 47 71
135 29
0.5 0.5 0.5 0.5
0.85 1.25
W/R W/B Y/B R/B
29 302 301 300 L/W L/Y
0.5 0.5 1.25 1.25 281 311 44 63 401 44 35
150 4 0.5 41 0.5
L/Y Y/W L/R L/W 0.5 0.5 0.5 0.5 1.25
3.0 3.0 0.85
G/Y R/Y R/L Br/Gr L R/L Y
R/L R/G 164 310 O 613 614
437Br/R 436Br/B
0.5 0.5 151 0.5 0.5
0.5 0.5 282 75 116 390A
L/B 0.5 Br/B Gr/Br
155 L 0.5 0.5 0.5 0.5
G/L L/R G/W G/Y 612 611 610 609 50Y 615
3.0 451 452 R/W 2.0 0.5
405Br/W 488B/W 0.5 0.5 0.5 0.5
W/R 0.5 0.5 99 403 404 B Br/R
0.5 0.5 79 95 311
R/W R/L 0.5
G/B
0.5
L
0.5
R
0.5
Br
0.5
L/O
0.5
R/Y Connecting the
Connecting the engine Connecting the engine engine room harness
room harness 3 room harness 4

floor harness 1 floor harness 2
Airbag (yellow)
30 8 20
0.85
33
T02 T01
Sleeve:
0.85 0.85 0.85 261 37
Y/L O/G Y/W R/B 0.5 0.5 2 0.85
26 260 24 21 503 504
Br Br/L R
G/W Terminal:
0.85 2 0.85 0.85 0.5 0.5 T41 T42 162 6 7 12
Y/R R/G B/G G V/Y V/L 0.5 0.5 0.5 0.85 0.85 0.85
Br/R Br/W B/Y W/G B/W Gr/B
70 32 22 48
0.5 0.85 0.85 0.5 T32 T31 375 69
R/W O R/Y W/G 0.5 0.5 0.5 69B
Br/Gr Br/Y G/B
163 60 34A 162 5 36
1.25 0.85 0.5 0.5 0.5 0.5 T51 T52 315A 13 5 42 480 482 405 488
L/R G/R W B/Y W/L Y/R 0.5 0.5 2.0 0.85 0.5 0.85 0.85 0.5 0.5 0.5
Br/G Br/B Br Gr/R W/L G/V R R/W Br/W B/W
1 2 3 4
20 30 37 261 T01 T02

33 8 0.5
0.85 0.5 2.0 0.5
0.85 0.85 0.85 Br/L
Y/L G/W R Br
R/B Y/W O/G
6 T42 T41
504 503
0.5
21 24 260B 26
0.85
12
0.5
7
0.85 0.85
162E
0.5 0.5 0.5
1 2 3 4
0.5 0.85 0.85 2.0 Gr/B W/G
V/Y B/W B/Y Br/W Br/R 482 405 488
W/L G B/G R/G Y/R 480
69 T31 T32 0.85 0.5 0.5 0.5
48 22 32 70 375
Br/W Br/B
0.85 0.5 0.5 0.5 R W/L
0.5 0.85 0.85 0.5
W/G G/Y G/B Br/Y Br/Gr
R/Y O R/W
42 5 13 315 T52 T51
36 5 162 60 163
34 0.85 0.5 0.5 2.0 0.5 0.5
0.5 0.5 0.5 0.85 1.25 Br
34A G/V W/L Gr/R Br/B Br/G
Y/R W/L B/Y G/R L/R
Connecting the Connecting the Connecting the instrument

instrument harness 1 instrument harness 2 panel harness (yellow)
Connecting the MT/AT Connecting the

harness assembly ceiling harness
457Bl /R Bl /W 458 38 R/B 33 R/Bl 44

0.5 0.5 0.85 0.5 1.0 504 163 135
Y/G 0.5 1.25 0.85
W/V 459 B/G 460 436Br/ B 437Br/R
0.5 0.5 0.5 V/L L/R L/W
0.5 37
0.85
503 34 50X 44
67 R/L 452
R/G 461 462 R G/W 0.5 0.5 0.85 0.5
0.5 0.5 0.5 0.5
L/G V/Y W B R/L
50 B
Y /R 463 B/W 456 0.85 B/R 455 Br/W 405
0.5 0.5 0.5 0.5
Br404 39
0.5 G/Y 390
0.5 0.5
Br/G 135 163 504
0.85 0.5 0.5
L/W L/R V/L
44 50 34 503
0.5 0.85 0.5 0.5
38
R/L B W V/Y
0.85
Y/G Connecting the
floor harness
37
0.85 67 50
G/W 0.5 B
50 L/G 0.5
B
0.85
39 390
0.5 G/Y
Br/G 0.5
Connecting the Connecting the instrument

接仪表线束
instrument harness harness assembly
DJ7211-6.3/2-10
Connecting the Connecting the left Connecting the left

chassis harness front door harness 1 front door harness 2
69 36 35 7 T01 T02
0.85 0.5 1.25 0.85 0.5 0.5 S 260B 18 50U
G/Y Y/R Y
B/W Br/L Br
50L 612 611 610 609 2.0 0.85 2.0
1.25 0.5 0.5 0.5 0.5 6 29 504 34 R/G R/L B
G/B
B G/Br G/L G/R 0.85 0.85 0.5 0.5 12 13 22 21 20
W/G L/Y V/L W 0.5 0.5 0.85 0.85
21A
Gr/B Gr/R R/Y Y/W
7
35 36 69 T02 T01 0.85 50 18 260
1.25 0.5 0.85 T12 T11
B/W 2.0 0.85 2.0
Y Y/R G/Y 6
34 504 29 B R/L R/G
609 610 611 612 50 0.5 0.5 0.85 0.85
0.5 0.5 0.5 20 21 22 13 12
0.5 1.25 W V/L L/Y W/G
G/B G/R G/L G/Br 0.85 0.85 0.85 0.85 0.85
B Gr/R Gr/B
Y/W G R/Y
Connecting the Connecting the Connecting the

floor harness floor harness floor harness
Connecting the right Connecting the right Connecting the right

front door harness front door harness rear door harness
12 T41 21A 18A 261A

0.5 0.5 0.85 6E 7E 24
0.85 2.0
Gr/B Br/R G 0.85 0.85 0.85
W/G R/L R
B/W B/G
13 34 504 T42 6B 50N 7B
0.5 0.5 0.5 0.5 29B 50M 26 18C 261
0.85 0.85 2.0 0.85 2.0 0.85
Gr/R W V/L Br/W 0.85 2.0
L/Y B Y/R R/L R W/G B B/W
18 261
12 21 2.0
T41 6 7 24 0.85
0.85
S
0.5 T41A 0.85 0.85 0.85 R/L R
Gr/B G
W/G B/W B/G 6 50 7
13 34 504 T42 0.85 2.0 0.85
29 50 26 18 261
0.5 0.5 0.5 T42A B
0.85 2.0 0.85 0.85 2.0 W/G B/W
Gr/R W V/L L/Y B Y/R R/L R

floor harness Connecting the floor harness
floor harness
Connecting the left Connecting the tail-

rear door harness gate transition harness
rear door harness
6C 7C 50B 260A 33C 44C

0.85 0.85 2.0 2.0 T31 504
0.5 0.5 0.85 0.5
W/G B/W B R/G
Br/Y V/L R/B R/L
T51 T52 34 504 18B
0.5 0.5 0.5 0.5 0.85 T32 34 70 32 34A
W V/L R/L 0.5 0.5
Br/G Br/B
Br/Gr W 0.5 0.85 0.5
R/W W
O
260 50 7 6
2.0 2.0 0.85 0.85
R/G B/W W/G 44 33
B 504 T31
18 504 0.5 0.5 0.85
34 T52 T51 T31A
0.85 0.5 0.5 T51A V/L R/L R/B
V/L T52A 34
R/L W T32 34 32
0.5 70
Connecting the
T32A 0.5 0.85
W 70A
W O
floor harness Connecting the

Connecting the
floor harness floor harness
Connecting the tail- Connecting Connecting the tail-gate

gate transition harness the tail gate transition harness 1
29A 30
1.25 0.85
L/Y Y/L
6D 7D 8 50H
0.85 0.85 0.85 1.25
W/G B/W O/G B
30 29
0.85 1 25
Y/L L/Y
50 8 7 6
1.25 0.85 0.85 0.85
B O/G B/W W/G
Connecting the
floor harness Connecting Connecting the tail-gate
the tail gate transition harness 2
Red
White/Red
Red/Blue
Storage battery
Red/Green
Red
the switch of the key

Status of Position
Outgoing
terminal
Ignition switch
Key pulled out
Key plugged in
Red/Yellow Red/Yellow
Starter
Red
Directly grounded manual transmission Red/Yellow
Red/Black
Starting relay
Blue/White
Yellow
Connecting the central
control door lock
Yellow
Red/Blue
Yellow
Unloading relay
Black/Red Black/Red
Generator
Black/White Green/Yellow
>
Power Supply System

White/Red
Yellow/White
Fuel pump
Yellow
Red
Pink/Brown Green/Yellow
Oil pump relay

pressure sensor
Starter control
Black/Blue
Engine oil
Red/Yellow Red
0.5
199
47
Y/B
R
3.0
Main relay
Green/Yellow Blue/White
Blue/Yellow Green/Yellow
Grey/Black Red
room harness B
Compressor relay
Generator
G/Y
0.5
390
Red Red/Green
3 B/R
1
High-speed fan relay

0.5
W/R
46
Green/Black Green/Yellow
Green/White
Black/Red
room harness 1
Cooling fan
Green/White
199
R
3.0
0.5
47
Y/B
Logical circuit for
Red/Grey
indicator lamp
Manual mode
of AT gear
G/Y
0.5
390
0.5
W/R
46
Low-speed fan relay Green/Yellow
Red/Green
Connecting the central door lock controller
Green/Yellow
R/L
3.0
150C
G
0.5
112
Ignition switch
Red/Black
1.25
L/W
106
B
0.5
50R
1.25
R
40
R/G
3.0
4B
Red/Black
R
0.5
453
R/B
2.0
298
Connecting the regulator switch and windshield wiper

Red/Blue
Unloading relay
Red/Blue
Red
White/Red
Red/Blue
ignition coil CT5

Storage battery
Connecting the
0.75 1.0 0.75
P/W B/Y P/B
412 173E 411
C Red/Green
Red
the switch
the terminal
Leading out
Status of the key
Ignition switch
B
Position of
Red/Yellow
Key pulled out
A
Connecting the front and

rear door window switch
Key plugged in
Red/ Red/
White Yellow
Starter
Starting relay
Red/Blue
Directly grounded manual transmission
Connecting the front
oxygen sensor CT7
Red/Black
423
0.5
A
Blue/White
Connecting the steering,

Green
G/R
422
CD player and A/C

0.5
B
Black/Red
No such wire for engine Red/Blue
Connecting the central

R/Y B/Y
424 173H
control door lock

0.5 0.5
Red
C
Green/Yellow
>
Connecting
the M88AT
White/Red
D
White/Red
Generator Charging indicator lamp Unloading relay
the CD player
Yellow
Connecting
canister control valve CT11
Connecting the charcoal
Black/Red
Fuel pump
Yellow
A
Green/Yellow
Green/
173F
B/Y
0.5
Red
OSP front oxygen
Red
Pink/Brown
sensor
Violet Green/Yellow
R/W
417
0.5
Oil pump relay

Black/
Blue
B
Red/
Yellow Black/ Red/Yellow Red
Yellow
Brown Main relay
Idle control valve
Brown/ Pink/Black
Black
Connecting the idle
control valve CT16
W/R W/B
418 419
Pink/
0.5 0.5
D
White/Black White
Grey/Green
C
White/Red Fuel injector

420
0.5
Br
B
Grey/Brown
Black/
Br/B
Ignition
421
0.5
Yellow
A
coil
Fuel injector
position sensor
Engine System
Grey/White
Crankshaft
White
Fuel injector
Black
Throttle valve position
Grey/Red
B
sensor CT18
Coolant temperature
428E 431
B/W L/R A
0.5 0.5
Violet/ Fuel injector Ignition plug

L/W C
430
0.5
Black
sensor
Sensor grounding 1
Red/White
Black/ Charcoal canister cleaning control solenoid valve

White
Green/Yellow Blue/White
Knock sensor
Blue/Yellow Green/Yellow
Blue
Connecting the
Grey/Black Red airbag ECU
Electromagnetic clutch
Black/
Connecting the crankshaft
ECU
Compressor Compressor relay
White
position sensor CT19
Black/White Red
position sensor
Throttle valve
425
Red/Green
0.5
Red
W
A
Blue/White
White/Black White/Black
426
0.5
B
Blue/Red
B
Brown Brown
B/W
0.5
50
Blue Black/White Green/Yellow

C

Red/Yellow
Intake manifold pressure
and temperature sensor
Brown/Black
Sensor grounding 2
White
Brown/Red
Black/Red
Blue/White Blue/White
Connecting the intake temperature
High-speed fan relay White/Red White/Red

Connecting the M88 (AT) CAN-H
Blue/Black
and pressure sensor CT20
M88 AT CAN-H
Green/Black Green/Yellow
B/R
434
0.5
D
Red/White
435
L/B
0.5
C
Blue/Green
Red Black/Red
R/Y
432
0.5
B
Connecting the tachometer
speedometer
Connecting the
Connecting
Cooling fan
the airbag
Green/White Red
Diagnostic
ECU
Connecting the A/C tri-

A/C ECU assembly
state switch (ground)

433
0.5
W
plug
A
Connecting the M88 (AT)
A/C tri-state switch

Connecting the
Red/Grey
M88 AT
Brown/White
Low-speed fan relay
Red
Connecting the airbag

ECU, ABS, M88AT
Connecting the
13
1 W/B
ECM CT1
Br/Gr
L/W
173
B/Y
406
402
1.5
0.5
0.5
0.5
63
room harness 1
410 174 408
407 97
404 409 405
403 390 401

L/Y 0.5
B/L Gr/B L/G
0.5 1.0
0.5 W/R
0.5 0.5 0.5
0.5 0.5 0.5

Br P/Br Br/W
R G/Y
419 418 413 415 410 424 422 417 651 429 414 416
0.5
53 W/B W/R Gr/G Gr/W B/L R/Y G/R R/W 0.5 L Gr/Br Gr/R 72
L
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 G/W 0.5 0.5 0.5
420 421 406 433 427 402 407 409 652 412
16
33 Br Br/B L/W W V/B W/B L/Y P/Br 0.5 P/W 52

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 G/B 0.75
Terminal

Connecting the main
Sleeve
Holder
403A 403B 431 434 430 435 426 408 401 411
room harness 2
17 R R L/R B/R L/W L/B B L/G L P/B 32

harness CT2
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.75 50A 2.0
：
：
：
Br/B
0.5
436
390 404 432 428 423 97 405 425 436 437 B 73

1 G/Y Br R/Y B/W V 0.5 Br/W W Br/B Br/R 16
Br/R
0.5
437
0.5 0.5 0.5 0.5 0.5 W/R 0.5 0.5 0.5 0.5
G/B
0.5
652
G/W
0.5
651
room harness 4
46 402 47 71
0.5 0.5 0.5 0.5
W/R W/B Y/B R/B
281 311 44 63 401
41
Red/Green 4
0.5 0.5 0.5 0.5 0.5

Brown
0.85
White/Black
Green/Yellow
G/Y R/Y R/L O Br/Gr L

Green/Yellow
Green/Yellow
Green/Yellow
282 75 151 116 390 A

Turn signal 0.5 0.5 0.5 0.5 0.5
switch G/L L/R G/W R/W G/Y
Connecting the 99 79 403 404 95 311
Left 0.5 0.5 0.5
接顶灯
ceiling lamp
G/B L
0.5 0.5
Br
0.5
L/O R/Y
R
Black/White
CD-H097 Connecting the

White
Right
engine room harness 3
Warning lamp of airbag
Green/
Yellow
AT gear indicator lamp——

combination instrument 29 302 300
301
0.5 0.5 1.25 1.25
L/Y Y/W 150 4
L/R L/W
3.0 3.0
R/L R/G 164 310
437Br/R 436Br/ B
0.5 0.5
0.5 0.5
L/B
155 L
WD indicator lamp
Fuel alarm lamp

3.0
Instrument System
Green/Red
Green/Violet
Instrument lighting lamp
452
Green
405Br/W 488B/W 451
W/R 0.5 0.5
Alarm lamp
Alarm lamp
Logical circuit 0.5 0.5

Manual R/W R/L
for indicator
Water temperature gauge

Engine oil pressure indicator lamp
Brake malfunction indicator lamp
Parking brake indicator lamp
lamp in
Engine hood indicator lamp

Tail-gate indicator lamp
Safety belt indicator lamp

manual mode
Power Snow
Blue/White
Door indicator lamp
Speedometer
Indicator lamp of right turn signal

Indicator lamp of left turn signal
Tachometer
room harness 2
Green/
Blue
Blue
Brown
White/Black
Fuel gauge
Brown/Red
33 603 604
Brown/
Black
0.85 0.5 0.5

R/B Br/R Br/B
Yellow
Blue/Red
31 90 80 81
Yellow/
Black/
White/
Black/
Green
Green
White
Black/
White
Violet
Blue/
Red
Red/
Red
Red
Connecting the door switch
0.5 0.5 0.5

Rear liftgate switch
1.25
O/L L/Y W P
Yellow/
Brown/
Yellow/
Brown/
White/
White/
Green
Green
Engine hood warning switch Green
Black
Black
Green/
83
Blue/
Yellow
Light
82
Grey
Blue
182 183
Red
1.25 1.25 0.5 0.5
Y L/W W/B W/L
Airbag 184 A 380 191 76 85 50G
Brake malfunction switch
Engine oil pressure switch
Water temperature sensor

Parking brake switch
1.25 1.25 0.85 0.5 0.5 2.0
Safety belt switch

Gr/B L/Y G/R G/B P/Y B
Speed sensor
WD power clutch
Dimmer assembly
Fuel sensor
Connecting the
floor harness 2
Combination
instrument A T02 T01 261 37
0.5 0.5 2 0.85
Br Br/L R
G/W
T41 T42 162 6 7 12
0.5 0.5 0.85
Connecting the MT/
0.5 0.85 0.85
Br/W
Connecting the
Br/R B/Y W/G B/W Gr/B
room harness 1
AT harness assembly
T32 T31 375 69
floor harness 1
0.5 0.5 0.5 69B
Br/Gr Br/Y G/B
20 10 1
34B 50J 390 295 44R 404 39 402 63 36 29 69 B 41B 60A T51 T52 315A 13 5 42
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 2.0 0.85 0.5 0.85
W B G/Y G/L R/L Br Br/G W/B Br/Gr Y/R L/Y G/Y O G/R Br/G Br/B Br Gr/R W/L G/V
164 303 44L 46 482 603 390 48 604 47 70 5 375 401 75 42A
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
457Bl/R W/Bl 458 R/B 33 R/Bl 44
L/B Y R/L W/R L/W Br/R G/Y W/G Br/B Y/B W/L G/B L L/R G/V 38 305
R/W 0.5 0.5 0.5 1.0 30 8 20 33
40 30 21 0.85 0.5 0.85
0.85 0.85 0.85
Y/G L/R
Combination W/V 459
0.5
B/G 460
0.5 37
436Br/B
0.5
437Br/R
0.5 60 C 79D 89 86
26
Y/L O/G
260 24 21
Y/W
503
R/B
504
0.85 0.85 0.5 0.5 0.5
instrument B R/G 461 462 R 67 2 0.85 0.85
G/W R/L452 Y 0.85 0.5 0.5
0.5 0.5
0.5
0.5
G/R L G
Y/R
R/G
B/G G V/Y V/L
Airbag (yellow)
L/G
50 B
78 84 306 88
32
Y/R 463 B/W 456 0.85 B/R 455 Br/W405 70 22 48
78A 0.5 0.5 0.5
0.85
0.5 0.5 0.5 Y/B 0.5 0.85 0.5
0.5 L/B R/W
： R/W O R/Y W/G
Sleeve Br404
0.5
39
0.5 G/Y 390 42C
0.85
163 60 34A 162 5 36
： Br/G 0.5 1.25 0.5
0.85 0.5 0.5 0.5
Terminal G/V L/R G/R W B/Y W/L Y/R
462 R 461 R/G 460 B/G 459 W/V 458 Bl/W 457 Bl/R
0.5 0.5 0.5 0.5 0.5 0.5
480 482 405 488
0.85 0.5 0.5 0.5 50H
R R/W Br/W B/W 463 Y/R 455 B/R 456 B/W
0.5
0.5 0.5
1 2 3 4 0.5 B
Combined switch
1 (green)
Connecting Connecting the central
the ABS-ECU 60E 42 E 157A 50
control door lock
0.85 0.85 0.85 0.5
G/R G/V G B
281 282 254 254 151 50Q
0.5 0.5 0.5 0.5 0.5 0.5
G/Y G/L G/L G/L G/W B
Green/Red
Red/Blue
Red/Black
Red/Black
Green/Violet
Red/Blue
Red
Red/Blue
Red
Green
Red/Blue
Red
Red/
Turn signal switch Left combined Right combined Left front
lamp lamp fog lamp
Upper beam relay
Left
50 50Y 41
Lower beam relay
50 73B 44B 73D 44A
Yellow
1.25
Brown
1.25 0.5 1.25 1.25 0.5 1.25
Red/
Red/
1.25 L/R
B B
Warning lamp L/R R/L L/R R/L
73A 74A 73C 74B
switch 50 1.25 1.25

50
1.25 1.25
1.25
1.25 L/R L/W L/R L/W
Turn Right
off
Right front
Turn
on fog lamp
Assistant driver's side sun visor & make-up lamp
Position lamp relay

Driver's side sun visor & make-up lamp
41
Green/Violet
50U
Green/Red
1.25
Left turn lamp Right turn lamp
1.25
Green/Yellow
Green
Red/Yellow
B G/Y
Green
Blue/
50X 60
1.25 50T 42
0.85
White
1.25 0.85
Blue/
B G/R
Light System
B G/V
Blue/
Green/White
Red
Green/Blue
Flasher
Red/White
Left tail Left tail

lamp upper lamp lower
Green/White
Left front
turn lamp
Blue/Red
Left headlamp
Right headlamp
Left front 50G 60 50F
Upper-beam indicator lamp
Left side turn lamp

position lamp 0.85 0.85 0.5
B G/R
Stop lamp switch

B
Green/Yellow
33A 44A 37
Rear fog lamp switch
0.85 0.5 0.5

Right front R/B R/L G/W
Green/White
Left rear turn lamp
position lamp
Right tail Right tail
Yellow/Blue
Left rear Indicator lamp of lamp lower lamp upper
position lamp left turn signal
Green/Yellow
Red/Black
Flashing Turn off
Lower Clearance Right front
Right rear 50R 50S 42
beam lamp turn lamp
position lamp 0.5 0.85 0.85
Upper B B G/V
Electric horn
Headlamp 44B 37A
beam 33D
0.5 0.5 0.85
R/L G/W
High-mounted stop lamp

Dimming Light switch Left license R/B
Right side
switch plate lamp turn lamp
Right stop lamp

Left stop lamp
Dimmer assembly
Front fog lamp indicator lamp
Rear fog lamp indicator lamp

Right rear
Right rear fog lamp

Right front fog lamp
Right license
Left rear fog lamp

Left front fog lamp
plate lamp turn lamp

Licence Licence
plate lamp plate lamp
Green/
Blue Indicator lamp of
right turn signal
Instrument
lighting lamp
Connecting the IG
Connecting the
position lamp relay
unloading relay
Yellow Yellow
Combined switch
Front & Rear Wiper and Power Rear-view Mirror System
Rear wiper motor

2 (white)
Red/Yellow
Red/Blue
Orange/Blue
116 190 187 31B
0.5 0.5 1.25 1.25
G/R
Orange/Green
Blue/White R/W L/W O/L
184 182 380 186 187 31C
1.25 1.25 1.25 1.25 1.25 1.25
Gr/B Y L/Y Lg L/W O/L
Black/Yellow
Yellow
Front wiper switch

Front wiper
Power rear- Power rear-view mirror
Rear wiper switch

view mirror
Rear washing
50AD 380 182
29 50E
50D 29
0.85 0.85 1.25 1.25 1.25 0.85 0.85
Middle B L/Y B L/Y Y L/Y B
26 24 21 31 183 21 20 22
0.85 0.85 0.85 0.85
Left 1.25 1.25 0.85 0.85
Y/R B/G G
O/L L/W G Y/W R/Y
Rear wiping
Right
Red/White
Power rear-view mirror switch
Yellow
Green/Red
Light Green
Upper
Blue/Yellow
Lower
Middle
Yellow/Blue
Green/Red
Orange
Power rear-view
Wiping intermittent relay

Left
Turn
off Right
mirror switch
Front washer switch
Rear washer motor

Upper
Lower
Cigar lighter
Middle
26 22 21 24 20 101 50M
Left Intermittent 0.85 0.85 0.85 0.85 0.85 0.85 0.85
circuit Y/R R/Y G B/G Y/W B/Y B
Right
Grey/Black
Orange/Blue
Upper
Lower
Yellow/White
Black/Green
Rear wiper
Green
Red/Yellow
Yellow/Red
Blue/Red
control switch
44M 50N
0.5 0.85
Rear wiper motor

R/L B
Front washer motor

30 32 8A 191
Vertical
Front wiper motor

Vertical

0.85 0.85 0.85 0.85

Y/L O O/G G/R
Horizontal
Horizontal
A/C cold and

warm air actuator
Connecting
the sunroof
Connecting the engine ECU
Connecting the 50AB 79A
Connecting the door lamp engine ECU 0.5 0.5
B L
Connecting the position lamp relay 82 81 80C 83
0.5 0.5 0.5 0.5
W/B P W W/L
Red/Blue
Blue/White
Blue/Red
White/Red
Yellow
White
Red
Blue
Black
Blue
Red/
Red
Red
A/C mode
Audio and A/C
actuator
integrated display
Tri-state pressure switch

Outdoor temperature sensor
Indoor temperature sensor
assembly
Temperature sensor
50AC 79B
0.5 0.5
Evaporator
Dedicated communication cable
Blue
B L
Blue/Red
Right front speaker
84 90 80A 85
Red/Black
0.5 0.5 0.5 0.5
Blower relay
Left front speaker
L/B L/Y W P/Y

Brown
Green/Black
Blue
Blue/Red
A/C and CD Player System
Green
Black/Yellow
Brown
Brown/
Brown/
Brown/
White
Blue
Red
Blower
Green 50M 79C
Plug B (12-pin) 0.5 0.5
Integrated Radio Red B L
306 88 80B 86
Shielding ground Black 0.5 0.5 0.5 0.5
and CD unit A/C ECU assembly
R/W Y/B W Y
Red/Black
Plug C (8-pin) Outdoor temperature
Speed Green
sensor
governing
Brown/
Brown/
Brown/
Brown/
Green
Yellow
Black
Grey
Blue
module 78A 310

Left rear speaker
Right rear speaker
Yellow/Black
White/Black
Blue/Orange
0.5
White/Blue
0.5
Blue/Black
Red/White
Blue/Yellow
Green/Black
Pink/Red
Pink/Red/Yellow
Yellow
White
Br L
Blue

Signal feed line
89 72A
High-speed relay
Indoor temperature
0.5 1.25
Defrosting relay
G B/Y
Blower
71A 50N
1.25
R/B
1.25
B
sensor
Blower motor
Internal and external circulation actuator

Cold and warm air actuator
Mode actuator
Blue/Yellow
6CD disk box
77 78A 50V 79C
Right rear-view mirror defroster

assembly
Left rear-view mirror defroster

0.5 0.5 0.5
Overhead antenna
0.5
Rear windshield defroster
Defroster indicator lamp

G Br B L
72B
2.0
B/Y
71C Evaporator
temperature sensor
2.0
R/B
78 76
0.5 0.5
Br G/B
CD player
A/C ECU A/C ECU
A/C pressure switch
S01 S02 A44 T01 T02 T41 T42 406
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
50 79 99 305 95 G R R/L Br/L Br L/W
82 83 84 306 S02 S01 S03 Br/R Br/W 50 97
0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5 S03 400 163 B50 34C T51 T52 T31 T32 B
R/W B L G/B L/R L/O 0.85 0.85 0.5
W/R
W/B W/L L/B R G B 0.5 0.5 1.25 0.5 0.5 0.5 305A
86 76 78 A 50 A 79 403A 89 71 B L L/R B W Br/G Br/B Br/YBr/Gr 0.5
81 85 90 88 80 310 77 L/R
0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
B L R G R/B
P P/Y L/Y Y/B Y W G/B L G Br
Central Control Door Lock and Interior Lamp System
Connecting 106
Key detection
switch
Connecting the turn lamp
Connecting the power clutch

Black
Red/
Blue
Red/
Green
Red/
Yellow
Green/
Yellow
Violet/
Green
Yellow
Black/
Yellow
Black/Yellow
Violet/Yellow
IG unloading relay
White
Green
Red/
Red/Green
White
Green
Black/Yellow
Green/Red
Green/Red
Green/Yellow
Left front door lamp
Right front door lamp
Left rear door lamp
Right rear door lamp
White
Green
Red/
Central door
Red
Red/Blue
lock controller Grey/Red
Violet/Yellow
Black/Yellow
Left front door Left rear door Right front door Right rear door
Black/White
White/Green
Middle ceiling lamp
Rear ceiling lamp

Front reading lamp
Grey/Black
White
Blue/
White
Blue/
White
Red/
White
Red/
White
Blue/
White
Red/
White
Blue/
White
Red/

Door indicator lamp
Left front door
Violet/Blue
fastener
Right front Left front Right front Left rear Right rear
door fastener
White
Red/
door motor door motor door motor door motor
Left rear door Reading lamp switch

fastener
Blue
White/
Right rear
door fastener
Left front door switch
Right front door switch
Left rear door switch
Right rear door switch
Rear liftgate switch

Tail-gate fastener
Harness connecting Harness 1 connecting

Harness connecting right Harness connecting right
ceiling and floor Harness 2 connecting left front door and floor
front door and floor front door and floor
left front door and floor
135 163 504 7

50 18 260
0.85 0.5 0.5 12 T41
21
6
0.85
7
0.85
24
0.85 2.0 0.85 2.0
T02
T12
T01
T11
0.85
L/W 0.85 R/G B/W
L/R V/L 0.5
Gr/B
T41A
G
W/G B/W B/G B
20
R/L
21 22 13 34 504 29 6
26 261 12
44 50 34 503 13 34 504 T42
29
0.85
50
2.0 0.85
18
0.85 2.0 0.85 0.85 0.85 0.85 0.85 0.5 0.5 0.85 0.85
0.5 0.5 Gr/R Gr/B W V/L L/Y W/G
0.5 0.85 0.5 0.5 Gr/R W
0.5
V/L
T42A L/Y B Y/R R/L R Y/W G R/Y
R/L B W V/Y
Harness connecting left Right rear regulator switch

Left front regulator switch Regulator switch Left rear regulator switch
rear door and floor
18 18
260 50 7 6 18 9 260 10 50B 9 50B 261 10 0.85 0.85
2.0 2.0 0.85 0.85 0.85 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 R/L R/L
R/G B/W W/G L/W L/W B R R/W 9 10 9 50 261 10
B R/L R/G R/W B 50C 260
12B 13 50C 50C 12 13 18 2.0 2.0 2.0 2.0
18 504 34 T52 T51 2.0 0.5 0.5 2.0 2.0 2.0 2.0 R/W
0.85 0.85 2.0 0.85 L/W B R
0.85 0.5 0.5 T51A B B Gr/B Gr/R R/L L/W B R/G R/W
V/L T52A Gr/B Gr/R
R/L W
Left front door Right front door Left rear door Right rear door Tail-gate lock
Right rear Right rear lock assembly lock assembly assembly Sun visor of
door harness door harness lock assembly lock assembly driver’s seat
18 261 6 7 70 50B
504 T31 0.85 6 6 7
0.85 2.0 0.85 7 0.5 0.5
0.5 T31A W/G B/W
6 7 0.85 0.85 0.85 0.85
R/L R 0.85 0.85 W/G R/W B
V/L W/G B/W B/W
6 50 7 34
12A
0.85
50A
0.85
W/G B/W 6 7 44 50D
0.85 2.0 0.85 T32 0.85 0.85
W/G B B/W
0.5 T32A Gr/B B
W/G B/W 0.5 0.5
W
R/L B
Front ceiling Middle ceiling

lamp lamp
50C 503 34D 504 34A

0.5 0.5 0.5 0.5 0.5
B V/Y W V/L W
Airbag and ABS System

ABS, EBD electronic control system
Diagnostic
interface Connecting the stop
lamp and AT
Brown/White
Red/Black
Yellow
Green/
Brown/White
Black/White
Yellow
Green/
Green/Yellow
Red Red
Diagnostic Acceleration
interface sensor (4WD)
Alarm lamp
Alarm lamp
Black/White
Brown/Black
Red
Green/Brown
Brown/Red
Blue/White
Brown/White
Red/Green
Red/Black
Red/Black
Brown/Red
Brown/Black
Airbag ECU
Oil pump motor

Blue/Red
Blue/Yellow
Yellow/Red
Yellow/Black
Yellow/Black
Yellow/Red
Yellow/Blue
Yellow/Brown
Green/Black
Green/Red
Green/Blue
Green/Brown
Clock spring
Control solenoid
valve
Integrated ABS control

module assembly

Driver’s side airbag Assistant driver’s side airbag
Wheel speed sensor
ABS-RF sensor
1 2
607 608
1 2 3 4 16 26 0.5 0.5
YB YR
50C 601 602 50B

606
0.5
609
0.5
390
0.5
616
0.5
33
0.5 0.5
614 604
0.5
613
0.5
615
0.5
4.0 4.0 2.5 2.5 605

YR
610
G/B
618
G/Y
617
G/L
608
RB GBr
607 405
Br/B
603
BrB BrR
B R/B R/G B 0.5

Y/B
0.5
G/R
0.5
G/Y
0.5
G/Br
0.5
Y/Br
0.5
Y/L
0.5
BrW
0.5
Br/R
5 15
Auto & Manual Gear System

Connecting the
starting relay Diagnostic plug and
airbag ECU
Odometer and MT20U

Connecting the stop lamp and ABS-ECU
Connecting the Connecting power supply 106 via 15A fuse
position lamp relay
Red/Blue
Red/Black
Brown/White
Brown/Black
Brown/Red
Brown
Yellow
Green/
Yellow/Green
AT control AT gear indicator lamp -
Blue/White
Red/Blue
mechanism combination instrument

Yellow/Green
P gear switch Snow
Manual mode
electromagnetic lock
Control lever
Lighting
Standard Logical circuit for
indicator lamp
Green
Yellow/
Blue/Red
Blue/White
White/Violet
Black/Green
Red/Green
Red
Yellow/Red
Black/Red
Black/Red
Black
Blue/
Yellow
Brown/
Green
Brown/
White
Brown/
Yellow
Grey/
Grey/Red
Grey/White
Brown/Red
Brown/Black
Green/Black
Green
Brown
White/
Blue
White/
White
Green/
Reversing lamp
AT control solenoid valve,

oil temperature sensor
AT gear sensor, control switch
TCU 1
Connecting the instrument harness
IL-AG5-30S-D3C1 接仪表线束
Terminal Connecting the instrument
DJ7211-6.3/2-10 harness assembly
38
0.85
Y/G
TCU 2 Control mechanism
操纵机构 37
IL-AG5-14S-D3C1-A DJ7131-2.3-20
0.85
G/W
67 50
0.5 B
Terminal
50 L/G 0.5
B
0.85
39 390
0.5 G/Y
Br/G 0.5
Transmission Speedometer sensor AT gear sensor, control switch

车速里程传感器 AT档位传感器、控制开关 Speedometer sensor
position controller
变速箱位置控制器 Sleeve m22541 Terminal 172280-1
282191-1 Rubber plug DJ90115
Sleeve
390 50C 39
0.5 0.5 0.5
Terminal Br/G
390 50C 39 G/Y B
G/Y B Br/G
Rubber plug 0.5
0.5 0.5
Connecting 155 via ACC unloading relay

Connecting 291 and the
CD player via 10A fuse
Connecting 106 via 10A fuse
Connecting 105 via IG unloading relay
Green/Yellow
Blue/Red
Yellow Red
Indicator lamp for power clutch
Yellow
Power Clutch and Power Seat System
Blue/Red
Orange
Yellow
Middle
Sunroof
Brown Turn on switch
Turn off
4WD front axle
Front power
power clutch Fore-and-aft adjusting switch Reclining switch for
Grey/Blue
socket
Black/Blue
controller for driver’s power seat driver’s power seat
Rear power
Sunroof ECU
Blue/White
Blue/Red
Yellow/White
Blue/Green socket
assembly
Sunroof assembly
Clutch motor
Switch
Fore-and-aft adjustment Reclining adjustment
electric motor electric motor
Sunroof ECU
Sunroof switch
Electric control Electric control
clutch ECU clutch 4WD control
Power seat 1 3 5
135 50B 2
0.85 0.85 0.5
303 300 301 299 L/W B B/L
50A 55 163 2
0.5 1.25 1.25 1.25 50C 302 67 50Z 55 163
Y L/W L/R O 1.25 0.5
315B 50J 0.5 0.5 0.5 0.5
302
B Y/W
0.5 0.5 2.0 2.0 0.5 0.5 L/R B/L
50AC 67 300 301
B Gr/L
1.25 0.85 0.5
Y/W
1.25
L/W
1.25
L/R L/G B Br B Gr/L L/R
B
1
L/G
2 4 6 5
Left combined lamp
Right combined lamp
Left front fog lamp Right turn lamp
Left turn lamp Right front fog lamp
B B D A
1.25 0.5 1.25 0.5 T
1.25
L/R R /L Y U B L/R R /L 1.25 0.85
A A 1.25 1.25 1.25 1.25 C B B G/V
X 1.25 1.25 B L/R B G/Y 1.25 1.25
1.25 0.85 1.25 L/R L/W L/R L/W
B G/R
Right side turn lamp
Q A
0.50 0.5
Outdoor temperature sensor B G/V
A
0.5 0.5
Br L
Left side turn lamp Tianhai Tianhai

Left electric horn Right electric horn
Diagnostic equipment 1.25 1.25
E A B O/L 1.25 1.25 Front wiper
0.5 0.5
B O/L
B G/R
403A 3.0
0.5 B
Front washing water pipe
AD
R 1.25
1.25 1.25
gnidnuorG
B S L/Y Y
A/C pressure switch B
0.5 W 0.5 0.5 0.5 Grounding
Lg B B Br/W 1.25 1.25
O/L L/W
Seal ring 406

0.5
L/W
R C
Terminal 0 .5 0.5 3.0 4.0
B W/R
305A B B
3 2 3
0.5 ABS
B R /Gr R /W
Sleeve L/R
Radiator fan
A/C cooling and heating air A/C mode actuator

actuator Speed governing module
Front washing water pipe
Rear washer motor
AB A AC B 0.85
0.5 0.5 0.5 0.5 G/R
B L B L J B A
C A 0.85 2.0 0.5 1.25
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 B B/Y G B/Y
W/B P W W/L L/B L/Y W P/Y 3 B/R 3R C A N
410 451 452 2.0 1.25 1.25
0.85 0.5 0.5 0.5 Connecting No. 2 fuse R /B R /B B
R /W R /L 1.25
3R 2R B/L G/Y
409 2.0 407 Gr/B
0.5 R /Y R /W R /B R /G
box A I
1.25 0.5 1.25 0.5 1.5
0.5 0.5 0.5 0.5 P/Br 1.25
Blower motor
Y G/Y L/W L/Y Gr/B
G/B G/Y G/W G/Y B
3 2 Front washer motor

R /W R /Gr
0.5 0.5
G/Br G/L
M C
0.5 0.5
0.5 0.5 0.5 B L
G/Y G/Br G/L
D B
95 A
0 .5 0.5 0.5 0.5
0.5 0.5 1.25 0.5
E R /W Y/B W Y
B/R L/O O/L L
3.0 2.0 2.0 2.0 2WD 2WD/4WD conversion
R /G B/Y L/R L/R
4WD converter
No. 3 fuse box 0.5 Connecting No. 2 fuse
D Internal and external circulation actuator
0.5 0.5 G/Y converter socket
0.5 0.5 box B
B L/B
G/W G/B
Brake fluid level alarm B
0.5 0.5
Br G/B
Connecting No. 2 fuse box D

Evaporator temperature sensor
1.25
0.5 0.5 G
G/B L/Y
YB YR 3.0 2.0
D
R /Y W/R B
0.5 0.85 1.25 0.5 0.5
Sensor R /Y G/Y R /L YB YR
C
ABS-FR sensor
1 .25 0 .5
B Y /W
46
1 .25 1 .25 0 .5 0 .5
L /W L /R W/R Y/B
Body Electrical Appliance (05 Top Model)-16
1 99
Connecting the positive
3 B/R 0 .5 3 .0
harness B of engine G/Y R
Electric control clutch Connecting the positive Connecting No. 2 fuse box G Connecting the fuse box
Connecting the engine 1
3 B/R harness A of engine
room harness B 0.5
G/W
2.0 2.0
R /B
R
46 L/W 0.5
A
16.0
0.5 0.5 R /W
Y/B W/R
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
199 YR G/B G/Y G/L RB GBr Br/B BrB BrR
Negative battery connector K1-F20M Connecting the engine 4.0 4.0 2.5 2.5
3.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Negative protecting sleeve K1-F-BHT R G/Y room harness 1 B R/B R/G B Y/B G/R G /Y G/Br Y/Br Y/L BrW Br/R
Connecting the negative

20.0 pole of storage battery
B
402 403 A 401

0.5 0.5 0.5 0.5
Connecting the engine W/B R G/Y L
404 409 405
harness 2 1.5 0.5 0.5 0.5
R /W Br P/Br Br/W
Sleeve 406 407

0.5 0.5 0.5
L/W L/Y W/R
410 174
Connecting the engine Engine oil pressure sensor
Holder 0.5 0.85 1.25 0.5
Br/Gr B/L Gr/B Lg
harness 1
0.5 0.5
G/W G/B
Terminal B 0.5
Y/B
Connecting the engine Connecting the positive
harness 2 pole of storage battery 0.5 0.5
G/Y W/R
0.5 0.5
Generator
Sleeve G/B G/W
Fuse box model
Holder B
Terminal
Connecting
main harness
A
16.0 16.0
B/R B/R
B
20.0 Generator
R
Connecting the front oxygen sensor
Engine grounding
20.0
B
Connecting the single fuse box
B/Y
20.0
3.0 R Rubber cap
R
Starter control Starter Grounding
Connecting the ECM CT1 Water

temperature
plug
Connecting ignition coil

Connecting the instrument
harness 3 Connecting
Connecting the A/C clutch No.1 nozzle
Water temperature sensor CT12 blue
Connecting the harness 2
Connecting the floor instrument harness 4
harness
452 451
0.5 0.5 W W
Connecting
B 402 R/L R/W 3.0 No. 2 nozzle
0 .5 0.5 0.5 0.5
R /B Y/B W/B W/R W/R
CT13 42A
401 0.5 0.5
0.5
B
0.5 0.85 0.5 L
0.5 0.5 L/B 0.5 0.5 0.5
L Br/Gr G/Y R /L
50A R /Y G/Y 0.5 Br/B Br/R
0.5 0.5 0.5 0.5
3.0 0.5 0.5 R/B
0.5 2.0 3.0
Br/R G/B G/R G/L G /Br 0.5 0.5 R/L Y/B R/W L/B 78A
B 0.5 0.5 R/G
R /W G/W 1.25 1.25 0.5 1.25
G/Y L/R G/L L/W L/R Y/W L/Y 0.5 0.5 0.5
0.5 0.5 404 403B Connecting the idle Connecting the instrument 0.5
Br/B 0 .5 0.5 0.5
0.5 0.5 0.5 P G/Y
Gr/Br 0.5 Knock sensor W L/Y
R /Y L/O Br R L G/B control valve Y G L 60A
harness 1
1.25 0.5
Y R/L C 0.5 0.5 1.25
1.25
B/Y 0.5 W/L W/B Y
1.25 1.25
L/W
L /R
L/Y L/W A
P
2.0 0.5 0.5 0.85 1.25 1.25
Connecting the charcoal canister control valve P/Y G/R L/Y Gr/B
B G/B
0.85 1.25
L/W L/Y
0.5 1.25
Connecting
R/L Y No.3 nozzle
Connecting the crankshaft
Throttle valve position
0.5 0.5 position sensor CT19 Combination instrument A CT14 blue
Br/B Gr/Br
50Y sensor
0.5 0.5 0.5 2.0 0.5
0.5 Power rear-view mirror
B Br/R Connecting No.
switch
CD-H097 connecting the engine room Rear wiper control switch 4 nozzle CT15
Connecting the engine room Connecting the antenna
Connecting the engine room harness 4 harness 3
harness
Central control door lock Electric control clutch ECU
Connecting the intake Black plastics-based tape Connecting the engine room
temperature and harness 1
pressure sensor CT20 Connecting the Connecting the engine room
antenna harness 2
Warning switch
Combination instrument B

Indoor temperature sensor Connecting the floor CD
player interface
Front fog lamp switch (white) Reading lamp switch (black)
Connecting the floor harness 2

Connecting the floor harness 1
Stop lamp switch

T01 T02
0.5 2.0 0.5 0.5
0.85 G/W R Br/L Br
0.85 0.85 0.85 Connecting the instrument
R/B Y/W O/G Y/L T42
E T41
0.5 0.85 0.85 0.5 harness 2
260B 0.5 0.5
G r/B B/W W/G
0.5 0.5 0.85 0.85 2.0 0.85 Airbag (yellow) B/Y Br/W Br/R
V/Y G B/G Y/R
W/L R/G T31 T32
Grounding point 0.85 0.5 0.5 0.5
0.5 0.85 0.85 0.5 G/Y G/B B r/Y B r/Gr
W/G R/Y O R/W
Sleeve T52 T51
0.85 0.5 0.5 2.0 0.5 0.5
0.5 G/V W/L G r/R Br Br/B Br/G
0.5 0.5 0.85
Y/R W/L B/Y 34A G /R L /R Terminal
Antenna interface
Electric horn
Instrument dimming
harness 1
0.5 CD player
R/W
Charging power Connecting the instrument panel
supply harness (yellow)
Combined switch 1 (green)
Connecting the ceiling harness
IC unloading relay
Ignition switch
Intermittent relay
0.5 1.25 0.85
V/L L/R L/W
Cigar lighter Cigar lighter
X
0.5 0.5 0.85 0.5 Combined switch 2 (white) A/C ECU illumination Washing
Ash tray illumination Connecting the instrument
V/Y W B R/L Connecting the clock spring
(yellow) CD player interface
Water pipe
Standby fuse
Connecting the ACC unloading relay
floor harness 0.85 0.5 0.5 Flash relay
L/W L/R V/L
Connecting the right front
Harness Connecting Diagram
0.5 0.85 0.5 0.5 No. 1 fuse box Grounding point door harness
Where to paste the Connecting the MT/AT harness
R/L B W V/Y
trademark assembly
A/C ECU CD player front door harness
Connecting the airbag ECU (yellow)
T41 A
0.5 0.5 0.85
G r/B E E
Connecting the B r/R G
0.85 0.85 0.85
T42 W/G
instrument harness B/W B/G
0.5 0.5 0.5
G r/R W V/L B M C
B r/W
TCU 1 操纵机构接仪表线束 0.85 0.85
2.0 0.85 2.0
L/Y YB/R R/L R
IL-AG5-30S-D3C1 DJ7131-2.3-20 DJ7211-6.3/2-10
Terminal 0.85
Y/G
T41
Connecting the floor 0.5 0.85
Connecting the T41A 0.85 0.85 0.85
Gr/B G
0.85 Connecting the PAB generator harness W/G B/W B/G
Connecting the left front instrument wire harness T42 261
G/W 0.5 (yellow) 0.5
door harness 2 0.5 T42A 0.85 2.0 0.85 0.85 2.0
L/G
assembly Gr/R W V/L L/Y B Y/R R/L R
Connecting the
floor harness
Connecting the left front 0.5 G/Y
Br/G High tone speaker T41A
T01 T02 door harness 1
260B U 0.5 0.5
0.85 0.5
2.0 0.85 2.0 Br/L Br Br/R
R/G B/W T42A
R/L B 0.5
0.85 0.85 0.5 Br/W
0.5 0.5 0.85 0.85
21A W/G L/Y V/L W
G r/B G r/R R/Y Y/W
Power seat
Power rear-view D
Connecting the acceleration 0 .85 0 .85
Safety belt switch B L /Y
Connecting the floor sensor mirror
260 0 .85 0 .85 0 .85
2.0 0.85 2.0 T02 T01
0.85 harness
TCU 2 Y /R B /G G
R/L R/G T12 T11 Sleeve

B 0.5 0.5
B/W 0.5
IL-AG5-14S-D3C1-A Br/B Gr/Br Br/R Connecting the handbrake
0.85 0.85 0.85 0.85 0.85 0.5 0.85
0.85
Y/W R/Y Gr/R Gr/B Terminal Speaker
G W V/L L/Y W/G B J Terminal
K
0.5 0.5 2.0 2.0
B W/G Br B 0.5
Connecting the G/B
floor harness T11 High tone speaker
0.5
Br/L T41
T12 2.0 0.5
0.5 L/W Br/R
Br Speedometer sensor T42
车速里程传感器 2.0 0.5
R/W Br/W
282191-1 Regulator (rocker
Middle ceiling lamp
type)
Regulator switch
E Power rear-
0.85 0.85
D A L/Y B view mirror
0.5 0.5 0.5 0.5 0.85 0.85 0.85
V/L W G Y/W R/Y
R/L B Speaker
B
Sun visor of driver’s 0.5 2.0 2.0 2.0 2.0
V/L W L/W B R R/W
seat C
Door lamp 2.0 0.5 0.5 0.85
B Gr/B Gr/R R/L
T01
2.0 0.5
L/W Br/L
Connecting the
0 .85 0 .5 1 .25 AT gear sensor, control switch
T02 G/Y
3.0
chassis harness Y /R Y AT档位传感器、控制开关
0.5 Connecting the left front door Reversing switch B
2.0 Br L
0.5 0.5 0.5 0.5
1 .25 P Terminal
R/W lamp switch B G/Br G/L G/R G/B Sleeve
3.0 Y6-6 CD player interface
Regulator (rocker B Rubber plug
type) 0.5 0.5
Regulator Y6-6 Y/G G/W 0.85 0.85
switch Connecting the W/G B/W
C C
floor harness 1.25 0.5 0.85 Connecting the right front
0.5 0.5
Y Y /R G/Y
A A B/Y W/L door lamp switch
0.5 0.5 0.5 0.5 0.5 0.5 1.25
B B/Y W/L G/ B G/R G/L G /Br C
0.5 B
0.85 2.0 2.0 2.0 2.0 0.5
V/L W R/L L/W R/G R/W B A Right front door integrated door lock
B C
B
Door lamp 0.85 0.85 2.0 0.5 assembly (locking mechanism assembly)
Gr/B Gr/R B B
0.85 0.85
W/G B/W Transmission position
Front ceiling lamp A A
Connecting the left rear
0.85 0.85 controller
变速箱位置控制器 Connecting the right rear
Gr/B B
door harness Oil pump Connecting the right rear
door harness A A T31
Sleeve 0.85 2.0 0.5 0.5 door harness
Z R/L R Br/Y V/L
Left front door integrated door lock B N B T32
Terminal 0.5 0.5 0.85 2.0 0.85 0.5
C D
assembly (locking mechanism B W/G B B/W Br/Gr W
Rubber plug L/G
assembly) CD-E046 6C 7C B 260A
0.5 0.5 0.5 0.85 0.85 2.0 2.0
B A
W/G B/W B R/G 1 .25 0 .5 0 .5 1 .25 4WD control
B V/Y W Y Y /R B
T51 T52 B B
0.5 0.5 0.5 0.5 0.85

B r/G B r/B W V/L R /L Connecting the floor
Sunroof ECU Connecting the 261 T31
2.0 0.5
0.85 T31A harness
floor harness R V/L
Connecting the right rear R/L
6 7 T32
260 lamp switch 0.85 2.0 0.85 T32A
2.0 0.85 0.85 W/G B B/W W
2.0
1 3 5 R/G B B/W W/G
B T52 T51 ABS left rear
0.85 0.5 E
0.85 0.85 0.5 0.5 T52A T51A sensor
R/L V/L 0.5
L/W W
B B/L W/L
Connecting the floor Connecting the left rear door

0.5 0.5 C
harness lamp switch 0.5 0.5 0.5
Gr/L L/R G/Y B Br/G Speaker
B
2 4 6 0.5
0.5 0.5
W/L
G/B G/R
Speaker T31A
0.5
Left tail lamp lower B r/Y
Sunroof switch T32A
0.5 High tone speaker
Speedometer sensor B r/Gr
F R T31
T51A C
High tone speaker 2.0 0.5 0.5 0.5
0.5 Br B B r/Y
A E
B T32
Br/G A B A
0.5 0.5 2.0 0.5
0.5 0.5 T52A B 0.5 0.5 0.5 0.5
Door lamp
B r/Gr
B Gr/L L/R B/L 0.5 R/L G/W R/L G/W
Backup power
Br/B
5 1 Right tail lamp lower
T51 0.85
0.5 R/L
Regulator switch 0.5
Br/G V/L W
2.0 2.0 2.0 2.0
Door lamp T52 L /W B R R/W
0.5
E Br/B 0.5 0.5 Regulator switch
0.5 0.5 G/L G/Br
R/L B ABS right rear sensor
Sun visor of assistant Left tail lamp upper
0.85
driver’s seat R/L
C D A
2.0 2.0 E B
2.0 2.0 0.85 0.85
0.5 0.5 0.85 0.85
L/W B R/G R/W
V/L W B G/Y
B G/Y
G
0.85 0.85 Rear fog lamp Rear fog lamp
B G/R
A
0.85
R/B S
0.85 0.85
2.0 B G/V
L/W D
Tail-gate integrated door lock assembly 0.85
2.0 R/B
Rear wiper motor (locking mechanism assembly)
R/W
Rear ceiling lamp Right tail lamp upper 2.0
Regulator (rocker type) Connecting the tail-gate transition L/W
harness 2.0
R/W
High-mounted stop lamp Regulator (rocker type)

Negative pole of rear
windscreen defroster
Positive pole of rear T B
0.85 0.85 0.85 0.85
C C
W/G B/W 0.85 0.5 A Connecting the tail-gate transition windscreen defroster B R/B
0.85 0.85
R/B R/L 1.25 0.85 harness W/G B/W
L/Y Y/L
A Connecting the tail gate
D D H Connecting the tail-gate Outdoor high-mounted stop
0.5 0.85 0.5
0.85 0.85 0.85 1.25 transition harness 1
R/W O W B/W
lamp
W/G O/G B
Right rear door integrated door lock

Left rear door integrated door lock assembly (locking
Connecting the floor assembly (locking mechanism assembly)
mechanism assembly)
harness
A

harness
Licence lamp Licence lamp

transition harness 2
Connecting the tail gate

Schematic Diagram of Harness Mid-Connection

Numbering and Pin Functions ...................................................... 2
Storage Battery/Starter/Generator ................................................ 9
Engine Electronic Control System................................................ 10
Reversing Radar System ............................................................... 11
ABS EBD Electronic Control System (38-pin) ............................. 12
ABS EBD Electronic Control System (26-pin) ............................. 13
AWD Electronic Control System/4WD Power Clutch .................. 14
Lighting System.............................................................................. 15
Electric Horn/Brake Lamp/Cigar Lighter/Power
Rear-View Mirror ............................................................................. 16
Ceiling lamp/Reading lamp/Combination instrument ................. 17
Windshield wiper/Washer .............................................................. 18
CD Player/A/C/Defroster (Right steering) ..................................... 19
Integrated CD and A/C Unit ........................................................... 20
DVD Player/A/C/Defroster .............................................................. 21
Airbag/Seat Belt Alarm ................................................................... 22
Central control door lock/Power Windows (with Anti-Pinch) ..... 23
Central control door lock/Power Windows (without Anti-Pinch).... 24
Power Electric Heating Seat/Power Socket/Sunroof................... 25
Schematic Diagram of Harness Relationship and Plug
Connection Numbering .................................................................. 26
Schematic Diagram of Harness Mid-Connection

Numbering and Pin Functions
C01
46
0.5 0.5
G/Y W/R
199
3.0 0.5
R Y/B
Connecting the power Connecting the engine

supply harness 1 room harness 1
C02

supply harness B room harness 2
C03

engine harness 1 room harness 1
C04

engine harness 2 room harness 2
C05

Connecting the
room harness 2
C06
Connecting the
instrument harness
1 1 room harness 11
C07

C08

Connecting the
room harness 3
C09
0.85 1.25
L/W L/Y
0.5 1.25
R/L Y
0.5 0.5
Br/B Gr/Br
50Y
0.5 0.5 0.5 0.5 2.0 0.5
B Br/R
Connecting the floor Connecting the

harness engine room harness
C10
T01 T02
0.5 2.0 0.5 0.5
G/W R Br/L Br
E T42 T41
0.5 0.85 0.85 0.5
0.5 0.5
Gr/B B/W W/G Br/W
B/Y Br/R
T31 T32
0.85 0.5 0.5 0.5
G/Y G/B Br/Y Br/Gr
T52 T51
0.85 0.5 0.5 2.0 0.5 0.5
G/V W/L Gr/R Br Br/B Br/G
Connecting the
Connecting the floor instrument harness 2
harness 2
C11
0.85 0.85 0.85 0.85

R/B Y/W O/G Y/L
260B
0.5 0.85 0.85 2.0 0.85
V/Y G B/G Y/R
R/G
0.5 0.85 0.85 0.5

W/G R/Y O R/W
0.5 0.5 0.5 0.85

Y/R W/L B/Y 34A G/R L/R
Connecting the floor Connecting the

harness 1 instrument harness 1
C13
517
C/O
0.5
Connecting the MT Connecting the

harness assembly instrument harness
C14
5
0.5 1.25 0.85
V/L L/R L/W
50X
0.5 0.5 0.85 0.5
V/Y W B R/L
Connecting the Connecting the floor

ceiling harness harness
C15
T41
A T41 0.5 0.85
T41A
0.85 0.5 0.5 Gr/B G
G Br/R Gr/B
T42 5 0.5 T42
0.5
0.5 0.5 0.5 Gr/R T42A
W V/L
Br/W V/L W Gr/R

harness 1
front door harness 1
C16
E E
0.85 0.85 0.85 0.85 0.85 0.85
B/G B/W W/G W/G B/W B/G
C M B 261
2.0 0.85 0.85 2.0 0.85 0.85 2.0 0.85 0.85 2.0
R R/L Y/R B L/Y L/Y B Y/R R/L R
Connecting the right Connecting the floor

front door harness 2 harness 2
C17
0.85 0.5 1.25

G/Y Y/R Y 1.25 0.5 0.85
Y Y/R G/Y
L 612 611 610 609
1.25 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 1.25
B G/Br G/L G/R G/B G/B G/L G/Br
G/R B
Connecting the chassis
harness Connecting the floor harness
C18
T01 T02
0.85 0.5 0.5 T02 T01
0.85
Br/L Br T12 T11
B/W B/W
5
0.5 0.85 0.85
0.85 0.85 0.5 W V/L L/Y W/G
W/G L/Y V/L W
Connecting the left front Connecting the floor

door harness 1 harness 1
C19
260
260B U 2.0 0.85 2.0
R/G R/L B B R/L R/G
0.85 0.85 0.85 0.85 0.85

Gr/B Gr/R R/Y G Y/W Y/W G R/Y Gr/R Gr/B

Connecting the left front harness 2
door harness 2
C20
A
2.0
R
B N B
0.85 2.0 0.85
W/G B B/W

Connecting the right harness
rear door harness
C21
T31 5
0.5 0.5 T31
Br/Y V/L W/L T31A
T32 A
0.5 0.85
0.85
T32
Br/Gr W R/L R/L W T32A
rear door harness Connecting the floor
harness
C22
6C B 260A
0.85 2.0 2.0
W/G B R/G
T51 T52 7C 5 B
0.5 0.5 0.85 0.5 0.5 0.85
B/W W V/L R/L
Br/G Br/B
Connecting the floor harness
Connecting the left rear door harness
C23
A
L/Y Y/L Y/L L/Y
D D H
W/G B/W O/G B B O/G B/W W/G

harness
transition harness
C24
C C
0.85 0.5
R/B R/L
A
0.5 0.85 0.5
R/W O W
Connecting the tail-gate Connecting the floor

transition harness harness
C25

C26

C27
Connecting the cabin

Connecting the reversing harness
radar transition harness
C28
Connecting the reversing

Connecting the transition radar harness 1
harness 1
C29

Connecting the transition radar harness 2
harness 2
Yellow
Unloading relay
White/Red Generator
Charging indicator lamp
White/Red
Green/Yellow
From ECU fuse
No such wire for engine Green/Yellow
>
Storage Battery/Starter/Generator
Black/Red Black/Red
Red/Blue
Green
Blue/White
Starting relay
Red/Black Starter
Ignition switch
Red/White
Red
Red/Yellow
Red/Yellow
Key plugged in
Ignition switch
Key pulled out
Red
Position of
Status
Outgoing switch
of the
the key
terminal
Red/Green
Storage battery
Red/Blue
White/Red Black
Red
From ECU
Normal From low From mid- normal
From From From airbag
Normal power power From From ECU pressure power supply
From ECU fuse pressure From ECU fuse Normal power TCU pin 9 ECU pin 37
From IG1 supply tachometer speedometer fuse fuse
supply switch switch supply
Red
Red
Red
Red
Red Black/Yellow
Brown
Black/Red
White/Red
Blue/White
Black/White
Red/Green
Blue/White
Brown/Red
Connecting the water
Brown/White
Brown/White
Brown/Black
White/Black
Connecting the
Green/Yellow
Green/Yellow
From ECU fuse ECU normal power
Green/Yellow
Green/Yellow
Green/Yellow
Black/Yellow
supply fuse
temperature plug
temperature sensor
To be used in case of no anti-theft function

Red
Oil pump relay

Red/Yellow
Ignition plug
Red
To be cancelled in case of no anti-theft function

Yellow
Pink/Black
Connecting the
PCP ignition coil
Connecting the ignition compressor
Main Relay
Pink/Brown
coil
Compressor relay
Fuel pump
Maintenance indicator lamp
Low-speed fan relay
Pink/White
Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4
Red/Grey
Grey/Black
Red/White
Green/Yellow
Green/Black
Green/White
Charcoal canister cleaning control solenoid valve
Black/Blue
Red/White
Black/Yellow
Green/Yellow
Blue
Brown
Green
White/Red
Blue/White
Brown/Red
Brown/Black
White/Black
Compressor
Cooling fan
Connecting the idle Connecting the front
control valve
oxygen sensor
Grey/Red
Grey/White
Grey/Green
Grey/Brown
Red
Red/Blue
Connecting the
Connecting the knock
Red/Yellow
Green/White
Brown/White
Connecting the throttle charcoal canister

sensor
Red
Violet
valve position sensor control valve
Blue
Green/
Blue/Green
White
Brown
Blue/Red
Blue/Red
Black/Red
Violet/Black
Blue/Black
Black/White
Black/White
Black/White
Blue/White
Red/Yellow
Black/White
White/Black
White/Red
White/Black
Black
White
Brown/Black
Diagnosis plug
Connecting the Connecting the intake

crankshaft position temperature and
Crankshaft position Coolant temperature Throttle valve Intake manifold pressure and Low acceleration sensor
OSP front oxygen OSP rear oxygen Idle control valve Knock sensor pressure sensor
sensor sensor position sensor temperature sensor sensor
sensor sensor
Engine Electronic Control System
Connecting the fuel Connecting the fuel Connecting the fuel Connecting the fuel
Connecting the injection nozzle I injection nozzle II
Connecting the engine injection nozzle III injection nozzle IV
diagnostic equipment
room harness 2
B A
1.25 0.5 0.5 1.25
Y Y/R B B
Connecting the engine Connecting the radiator

Connecting the
room harness 1 fan Connecting the fuel
acceleration sensor
pump
Connecting ECU
engine
Reversing Radar System
From IG1
Yellow/Green
Yellow/White
Reversing lamp fuse
Speaker
Brown/Red
Brown/Black
White
Green/
Reversing radar
ECU
Brown
Green/
Green/Red
Green/Brown
Green/Blue
Yellow/Black
Yellow/Blue
Yellow/Black
Yellow/Red
White
Green/
Reversing lamp
Left Right
Left side Right side
middle middle
Ultrasonic sensor

Connecting the buzzer cabin harness
ECU

left side probe left middle probe right middle probe right side probe
ABS EBD Electronic Control System (38-pin)

To the diagnosis From the brake Normal power Normal power From ECU fuse
connector lamp switch From ECU fuse supply supply
Brown/White
Red/Black
Green/Yellow
Red
Yellow
Green/
Red
Acceleration
sensor (4WD)
Alarm lamp
Alarm lamp
Brown/Black
Green/Brown
Brown/Red
Brown/White
Red/Black
Red/Green
Red/Black
Brown/Red
Brown/Black
Oil pump motor
Brown
Green/
Brown
Green/
Blue
Green/
Brown
Green/
Blue
Yellow/
Brown
Yellow/
Red
Green/
Blue
Green/
Black
Green/
Brown
Green/
Black
Yellow/
Black
Yellow/
Red
Yellow/
Red
Yellow/
Control solenoid
valve
Integrated ABS control

module assembly
Left front Left front

Right front Left rear Right rear
(2WD) (4WD)
Wheel speed
sensor
0.5 0.5 0.5 0.5

G/L G/Br G/B G/R
Left front ABS-FL Right front ABS-FR

ABS right rear ABS left rear
sensor sensor
sensor sensor
Leading out
from this side
ABS EBD Electronic Control System (26-pin)

To the diagnosis From the brake Normal power Normal power From ECU fuse
connector lamp switch From ECU fuse supply supply
Brown/White
Red/Black
Green/Yellow
Red
Yellow
Green/
Red
Acceleration
sensor (4WD)
Alarm lamp
Alarm lamp
Green/Brown
Brown/Red
Brown/Black
Brown/White
Red/Green
Red/Black
Red/Black
Brown/Black
Brown/Red
Oil pump motor
Red
Yellow/
Black
Green/
Blue
Yellow/
Brown
Green/
Red
Green/
Blue
Green/
Brown
Yellow/
Black
Yellow/
Control solenoid
valve
Integrated ABS control module

assembly
Wheel speed sensor

AWD Electronic Control System/4WD Power Clutch

From the position From IG unloading
To the diagnosis From the reversing lamp relay relay
Normal power supply From ECU fuse
connector lamp fuse
Red
Yellow/Green
Brown White
Yellow
Yellow
Green/
Red/Blue
Power clutch indicator lamp

端口
Port Working lamp
Orange
Position of
the switch
2H
4L
4H
Yellow
Green
Blue/
Green
Blue/
Green
Blue/
4WD front axle power
clutch controller
Blue/White
Blue/Red
White
Yellow/
White
Green/
Power clutch
Clutch motor
Speed sensor
4WD motor unit

From the From the
From the position From the position Normal From the position Normal
From the position Normal From the ignition central central
lamp relay Normal power supply From F35 lamp relay power lamp relay power From
lamp relay power switch control box control box
supply supply IG2
supply pin 8 pin 2
Red
Red
Red/
Green
Green
Red/Blue
Red
Red/Black
Red/Blue
Red/Blue
Red/Blue
Red/White
Turn signal
Green/Red
Green/Violet
switch
Left
Red/
Warning lamp
Yellow
switch
Red/Brown
Lower beam relay

Turn Right
Upper beam relay

off
Turn
on

Green
Blue/
Electric levelling
Green
Green/Red
headlamp switch
Key detection
Green/Violet
Green/White
Red/Yellow
Green/Yellow
Position lamp relay
Working lamp
Port
Flasher
Red/Blue
Blue/
Position
Blue/White
Yellow
Green/Blue
Blue/Red
Automatic light ECU Left front turn lamp
White
Driver's side sun visor & make-up lamp
Red/Blue
Yellow/

Assistant driver's side sun visor & make-up lamp
Yellow/Red
Left headlamp
Left front position Left side turn lamp
levelling motor
Blue/Red
lamp
Right headlamp
Left headlamp
Orange
Right front position Left rear turn lamp
Green/Red
Yellow/Blue
lamp
Green/Black
Green/Yellow
Right headlamp Yellow/Blue
levelling motor
Green/White
Upper-beam indicator lamp

Left rear position Indicator lamp of
lamp left turn signal
Flashing Automatic light

Turn off
Lower Right rear position Right front turn
Green/Yellow
beam Width lamp lamp lamp
Upper
beam Photoelectric Headlamp
sensor
Dimming switch Light switch Left license plate Right side turn
lamp lamp
Right license plate Right rear turn

lamp
Lighting System
lamp
Dimmer assembly
Green/
Blue Indicator lamp of
Left rear fog lamp
Left front fog lamp

Right rear fog lamp

right turn signal
Instrument lighting
Front fog lamp indicator lamp

lamp
Front fog lamp switch Reading lamp switch Connecting the Connecting Right side turn Left side turn
前雾灯开关（白）
(white) (black) Rear fog lamp switch the automatic lamp lamp
photo-sensitive
sensor headlamp ECU
E B E B
0.85 0.85 0.85 0.85
B G/Y B G/Y
Left front fog Right front fog Right rear fog Left rear fog Right turn Left turn
Door lamp Left combined Right combined
lamp lamp lamp lamp lamp lamp
lamp lamp
Electric Horn/Brake Lamp/Cigar Lighter/Power Rear-View Mirror
Right power rear-view

mirror
Power rear-view mirror switch Vertical Horizontal
Yellow/Red
Red/Yellow
switch
Green
Black/Green
Yellow/White
Left power rear-view

From IG2
Red/Yellow Black/Yellow
Vertical Horizontal
Middle
Middle
Middle
Upper
Lower
Upper
Lower
Upper
Lower
Right
Right
Right
Left
Left
Left
mirror
Turn off
unloading relay

From ACC
Cigar lighter
Yellow Red/White
Red/Blue
position lamp
From the
relay
Right electric
horn
High brake lamp
Red/Black
Red/White Right brake lamp
Normal power
Red/Blue Red/White Left brake lamp

Red/Black
supply
Electric horn
Brake lamp switch
Left electric
horn
Orange/Blue
Normal power
Red Red/White
supply
Horn switch
Horn relay
To ECU pin 45
White/Black
D
Tachometer
0.5
W
Front ceiling
Speed sensor
Red/Green
lamp
To ECU pin 3
V/Y
0.5
Brown Brown/Green
Ceiling lamp/Reading lamp/Combination instrument
Speedometer
C
0.5
B
Water temperature gauge
Middle ceiling
Brown/Grey
A
Fuel alarm lamp
0.5
W
lamp
Combination instrument
Fuel gauge Fuel sensor

Yellow/Red
V/L
0.5
Engine oil pressure indicator lamp Engine oil pressure switch
Yellow/Black
From ECU
Connecting the
Red/Green
Green/Yellow
fuse
left rear door

lamp switch
Brake malfunction indicator lamp Brake fluid level switch
Blue/Black
W/L
B
0.5
Parking brake indicator lamp Parking brake switch
White/Blue
Seat belt switch
Seat belt indicator lamp
Violet White/Green
Combination
instrument A
Connecting the
right rear lamp
switch
W/L
E
0.5
Door indicator lamp
Normal power
supply
front door lamp switch

Red/Green White

Rear ceiling lamp
W/L
C
0.5
Liftgate switch
White Red/White
C
0.5
Left rear door lamp
B
Middle ceiling lamp
C
White/Blue
B/Y
Right rear door switch
0.5
Left rear door lamp
For right-hand drive
Left rear door switch
Front reading lamp
Right front door lamp
Right front door switch
front door lamp switch

W/L
Connecting the left

A
0.5
Left front door lamp
Front reading lamp
Reading lamp
A
0.5
switch
B
Violet/Blue
A
To the central To the central
control door
lock pin 9
B/Y
0.5
Violet/Yellow
Violet/Yellow
control door
Black/Yellow
lock pin 21
Black/Yellow
Rear wiper motor
Rear wiper switch
Blue/Yellow
automatic wiper ECU

Orange
unloading relay
Connecting the
Yellow Orange/Green
From IG
Rear washer motor

Green/Red
Windshield Wiper/Washer
Wiping intermittent relay

Rear washer Rear wiper Blue/Red
Front wiper motor
Front wiper switch
Intermittent
circuit
Green/Red
Cancel automatic wiper
Yellow
Blue/White
Rear wiper control

Orange/Blue
Blue/Yellow
switch
Light green
Front washer switch
Front washer motor
unloading relay
Yellow
Grey/Black
From IG
Orange/Blue
Light green
Grey/Black
Blue/White
Front wiper
Automatic wiper ECU
Blue/Red
Orange/Blue
Blue/Yellow
Rear washer motor

Yellow
Rain sensor
CD Player/A/C/Defroster (Right Steering)
From the water From the
From IG2
From the From ACC From the ceiling From the temperature speedometer From ECU normal power To ECU pin 39
position unloading position lamp supply fuse To ECU pin 9 From the A/C
lamp fuse sensor Normal power
relay fuse Normal power
lamp relay relay supply
supply
Yellow White
Red
Red
Blue
Red
Blue
Red/
Black
Brown
Radio fuse
Red/Blue
Blue/Red
A/C fuse
Red/Blue
White/Red
Blue/White
Brown/Grey
Integrated Audio
and A/C display Connecting the A/C clod and Connecting the A/C mode
assembly warm air actuator actuator
Blue
Blower relay
Evaporator
Speed sensor
Blue/Red
Red/Black
Temperature sensor
Left front speaker

Right front speaker

Red
Blue
Blue/Red
White

Brown
Black/Yellow
Small lamp signal

Brown/
Brown/
Brown/
Plug B (12-pin)
Blower
Radio CD player (right steering)
A/C ECU assembly (right-hand
Green Connecting the internal and
drive) Connecting the A/C pressure external circulation actuator
Plug C (8-pin) switch
Red/Black
Blue/
Orange
Grey
Blue
Black
Green
Yellow
Brown/
Brown/
Brown/
Brown/
White
Blower
Yellow
Pink/Red
Red/White
Blue/Black
White/Blue
Blue
White/Black
Blue/Yellow
Yellow/Black
High-speed relay
Pink/Red/Yellow
Defroster
Connecting the
Left rear speaker

Connecting the

Right rear speaker
switch negative pole of Connecting the
Green/
Blue
positive pole of
Time-delay circuit Black rear windscreen
rear windscreen heater
Signal feed line

Red/ defroster
Defrosting relay
Blue defroster
6CD disk box

Blue/Yellow
assembly
actuator
Mode actuator
actuator
Cold and warm air
Overhead antenna
Internal and external circulation
Connecting the indoor

Rear windscreen defroster
Connecting the outdoor

temperature sensor temperature sensor
Connecting the
Connecting the evaporator
speed governing Connecting the
temperature sensor
module blower motor
Connecting the A/C Connecting the A/C
ECU C2A ECU C2B
A/C ECUI
Integrated CD and A/C Unit
A/C ECU
Green
Black
Red
Shielding ground
Right front speaker Right rear speaker Overhead antenna

Brown/White Brown/Grey
Blue/Red
Brown/
Brown/Red Yellow
From ACC From the ceiling
lamp fuse
White Blue
Integrated CD and A/C Unit

Blue/Red Signal feed line
Yellow
position lamp unloading
relay
Red/Blue
From the
relay
Brown/
Brown/Blue Green
Brown Brown/Black
6CD disk box

assembly
A/C ECU
CD player
Left front speaker
Left rear speaker
Plug C (8-pin)
Display assembly
Plug B (12-pin)

Blower/relay
Blower
the antenna
Normal
supply
Red/Black
power
Connecting the Connecting

Red Black/Yellow
From the
A/C fuse
Blue
Green
Blower
High-speed relay
power supply
Red Red/Black
Normal
left rear speaker right rear speaker

White/Red
To ECU pin To ECU pin
White/Red Blue/Orange
9

Blue/White Blue/Red
Br/Gr
Br/Y
Defroster relay
T32
T31
0.5
39
0.5
Blue/Yellow
Red
normal power
supply fuse
From ECU
Evaporator Rear windscreen defroster

Temperature sensor Green/Black
Connecting the
Mode actuator
Green/Black
Br/G
Br/B
Pink/Red/Yellow
T52
T51
0.5
0.5
Blue/Yellow
A/C ECU assembly
Blue/Black
Internal and external circulation

actuator
White
Blue
Yellow
left front speaker right front speaker

Yellow/Black
Connecting the
Brown
White/Blue
DVD Player/A/C/Defroster
Br/W
Br/R
T42
Green
T41
0.5
0.5
Blue
Cold and warm air actuator
White/Blue
Pink/Red
Blue
Red/Black
From IG2
White/Black
Connecting the
Electric heater relay
Green/Red
Red
Red/Yellow Yellow
T02
Br/L
T01
0.5
0.5
Br
Heater
tachometer
From the
White/Black Speed sensor Fuel heater Reserved
Water temperature
Brown/Grey sensor
From the water
temperature
sensor
Blue
Connecting A/C
Green
Black
Red
panel
Shielding ground
Brown/ Brown/
White Grey
Blue/Red Brown/ Brown/

Red Yellow
position unloading ceiling lamp
From the From ACC From the
White
fuse
Blue
Blue/Red Signal feed line

Yellow
relay
Red/Blue Small lamp signal

lamp relay
Brown/ Brown/
Blue/Red
Blue Green
Integrated DVD and A/C unit
Brown/
Brown Black
DVD player B
Connecting
Left front speaker Left rear speaker

display
Plug E (20-pin)
DVD
Green/Blue
Silence detection
Ignition detection Dedicated communication cable
From brake From reversing
Brightness adjustment
lamp fuse
Green/White Reversing detection

Red/Black Brake detection
lamp switch
Power amplifier control

Key-control grounding
key-control switch
Steering wheel
Key-control input B
Key-control input A
Rear-row
display
DVD player A
Connecting
Plug F (16-pin)

reversing lamp
From the
fuse
Positive pole of video
Negative pole of video

Airbag/Seat Belt Alarm

To the diagnosis
To the diagnosis
connector From IG1 From ECU fuse
connector
From the
From the seat belt From the Normal From the From the From the
From position power speed
seat belt indicator ignition door lamp
IG1 lamp relay supply sensor
switch lamp switch switch
Black/White
Brown/White
Green/Yellow
Blue/White

Red
Blue/White
Black/Yellow
Brown/Green
Green
Red/Blue
Red
Green
White/
Violet
Blue/White
Seat belt switch detection
lamp
Connecting the seat belt indicator
Small lamp detection
Blue/Red
Airbag ECU
Door lamp detection

Key detection
Speed detection
Safety belt alarm
ECU
Blue/Red
Blue/Yellow
Yellow/Red
Yellow/Black
Clock spring
Driver airbag Assistant driver’s

side airbag
Safety belt alarm

indicating system
Connecting PAB Connecting the clock

generator (yellow) spring (yellow)
Connecting ECU
Central control door lock/Power Windows (with Anti-Pinch)

From the From the Normal From ECU From the To the left To the
door lamp ignition power fuse door lamp side turn right side From IG1 Normal Normal
switch supply switch lamp turn lamp power power
switch
supply supply
Green/Violet
Red/Black
Red/Blue
Yellow
Red/Green
Violet/Yellow
White/Red
Green/Red
Green
Black/Yellow
Green/Yellow
IG unloading relay
Red/Green
Red/Green
Red
Central door lock controller
Grey/Red
Violet
Left front door window Left rear door window Right front door Right rear door window
Black/White
White/Green
switch switch window switch switch
Grey/Black
Blue/White
Red/White
Blue/White
Red/White
Blue/White
Red/White
Red/
Blue

mechanism assembly
Anti-pinch Anti-pinch Anti-pinch Anti-pinch

Right front door locking
ECU I ECU II ECU III ECU IV
mechanism assembly
Left rear door locking

mechanism assembly
Right rear door locking

mechanism assembly
Left front door motor Left rear door motor Right front door motor Right rear door motor
Tail-gate locking
mechanism assembly
B
2.0 2.0 2.0 2.0 2.0 2.0
L/W B R R/W L/W L/W
C
2.0 0.5 0.5 0.85 2.0 2.0
B Gr/R Gr/B R/L R/W R/W
Left rear regulator (rocker Right rear regulator (rocker

Left front regulator Right front regulator type)
switch type)
switch
0.85 0.85 2.0 2.0

0.85 0.85 L/W L/W
W/G B/W
W/G B/W
2.0
R/W
2.0
R/W
Right front regulator (rocker Left front regulator (rocker
type) type)
Right front door integrated door lock Left rear door integrated door lock assembly
assembly (locking mechanism assembly) (locking mechanism assembly)
0.85 0.85
R/L R/L
C
0.85 0.85 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
W/G B/W L/W B R/G R/W L/W B R R/W
Left rear regulator switch Right rear regulator switch
Right rear door integrated door lock assembly Left front door integrated door lock assembly
(locking mechanism assembly) (locking mechanism assembly)
Central control door lock/Power Windows (without Anti-Pinch)

From the From the Normal From ECU From the To the left To the
door lamp ignition power fuse door lamp side turn right side
switch turn lamp From Normal power
switch switch supply lamp
IG1 supply
Red/Blue
Black
Red/
Green/Violet
Green
Red/
Black/Yellow
Green/Red
Violet/Yellow
Green
Yellow
Green/Yellow
IG unloading relay
Red/Green
Black/Yellow
White
Green/Red
Green
Green/Yellow
Green/Violet
Green
Red/
Red
Central door lock controller Red/Blue
Grey/Red
Right rear door window

Left front door window Left rear door window Right front door window
White
Black/
Green
White/
switch
switch switch switch
Grey/Black
White
Blue/
White
Blue/
Red/White
White
Blue/
White
Blue/
White
Red/
White
Red/

mechanism assembly
Right front door locking Left front door motor Left rear door motor Right rear door motor
mechanism assembly Right front door motor

mechanism assembly

mechanism assembly
Tail-gate locking
mechanism assembly
From the central
control door lock Normal power From the radio
fuse supply fuse
From IG1
Red
Yellow
Blue/Red
Red/Green
Red
Middle
For left steering
Brown
Turn on
Turn off
Sunroof switch
Front power
Driver seat heating switch Assistant driver seat Fore-and-aft adjusting switch Reclining switch for driver socket
heating switch for driver power seat power seat
Grey/Blue
Black/Blue
Rear power
socket
Sunroof ECU
assembly
Sunroof assembly
Driver seat heating Assistant driver seat

heating resistance Fore-and-aft adjustment Reclining adjustment
resistance electric motor electric motor
166 315D 168 315E 166

B J 167 B 50D 169 B 50Z 167
2.0 2.0 2.0 2.0 2.0
2.0 2.0 2.0 2.0 B 2.0 2.0 B B2.0
G Br BL Br G
Br B
Heating switch for driver and assistant
Driver seat heating Assistant driver seat driver seats
Power seat heating
Electric Heating Power Seat/Power Socket/Sunroof
Right rear door

Engine room Instrument Floor Right front
harness
harness harness harness door harness
Water pipe
Right front door integrated lock assembly

Speaker
Speaker Regulator switch Door lamp
C16
Regulator switch
C05 C12 Right rear door integrated lock assembly
player interface
Connecting CD
to instrument
Connecting the
C06 C15 C20
antenna
CD-Z020

circulation actuator C10 Connecting the right front lamp switch
Speed governing
High tone speaker

Regulator (rocker
module
C21 Regulator switch Regulator (rocker type)

type) Door lamp Connecting the right
rear lamp switch
Evaporator temperature
Connecting the acceleration

sensor Water pipe
A/C ECU
sensor
Assistant driver’s seat heating
A/C ECU
2WD/4WD
conversion
Electric control
socket
clutch ECU
Engine oil
Blower motor
Body grounding Generator Outdoor high-

pressure sensor
mounted stop lamp
Handbrake
Connecting the positive
DVD player A
pole of storage battery
Front wiper
Frame harness
Connecting the negative pole
ABS-FR sensor of storage battery Right tail
lamp lower
Rear liftgate
Generator Heating switch for driver’s seat and assistant driver’s seat Right tail harness
DVD player B
lamp lower
Right side turn lamp
Central control
Connecting
Frame harness
door lock
Engine grounding
the starter
pole of rear
windscreen
Y6-6 ABS left rear sensor
C13
Negative
defroster
Rear washer motor
interface
Antenna
Levelling devices Starter control CD player interface
Warning switch
for right headlamp 16
ABS right rear sensor
B
R
Right combined
Front washer motor
C02
Right turn
License plate
C01
Cigar lighter
illumination
lamp
lamp
Tail-gate integrated door lock assembly

Oil pump
lamp

Rear fog lamp
4WD control
Rear fog lamp
Connecting the
switch
CD player
illumination
crankshaft position
Ash tray
Sensor CT19
Grounding for
Safety belt switch
Rear wiper motor

Connecting
electronic fan
Motor for condenser
the power
C17
L
distribution
Right electric horn

box
Indoor temperature
Rear liftgate
Charging power
A/C pressure switch (Tri-state
Left tail lamp upper

Engine
distribution box
Cigar lighter
supply
Rear fog lamp
transition harness
fan
sensor
No. 1 junction
harness
License plate
Connecting No.1 Connecting No. Connecting Connecting No. 4
lamp
box
switch)
Levelling devices
No.3 nozzle nozzle CT15

for left headlamp
nozzle CT12 blue 2 nozzle CT13
Where to paste
Power seat
the trademark
Combination
instrument A
CT14 blue Left tail lamp lower
rear windscreen
Positive pole of
Connecting
distribution
the power
Connecting
Combined
distribution
Connecting
the power
distribution
the power
defroster
box
Instrument dimming
box
lamp
box
Connecting
Headlamp control
A/C clutch Connecting the left rear
CT8 Knock sensor door lamp switch
switch
C23 C25
Left turn
No. 1 fuse box

lamp
Left electric
Reversing switch
horn
Outdoor temperature
Fog lamp switch Reading lamp
Horn
sensor Driver’s seat heating
High brake lamp

C03
switch
Diode component
Left front
fog lamp
C24 C26
The protector is
clutch Brake fluid level
Connecting the
A/C mode actuator
Connecting the
yellow
left front door lamp Backup power
雾灯开关
acceleration
alarm
Water temperature sensor CT9 switch

Left side turn
C04
0.85
sensor Connecting the idle

B
接怠速控制阀 0.85
R/B
Rear ceiling lamp

lamp
control valve Clutch switch
Brake lamp
Photo-sensitive
Combined switch 3 The outer of video connector

Connecting the
electric control
switch
Ignition switch
Connecting the charcoal
接碳罐控制阀 is covered with foam strip
C18
Throttle valve Automatic wiper Right front door integrated door lock
sensor
canister control valve

Connecting ignition coil position sensor ECU Speaker assembly (locking mechanism assembly)
CT5 Regulator switch Door lamp
ABS-FL sensor Grounding Electric horn
C22
Connecting the rear

oxygen sensor CT7
Water temperature
switch
plug
A/C cooling and heating
Combined switch 2
Connecting the intake temperature
C19
air actuator
Connecting the 接进气温度压力传感器

and pressure sensor
front oxygen Automatic
接ECM
Connecting ECM sensor CT7 headlamp ECU Regulator switch
Left front door Regulator (rocker type)
Regulator Door lamp locking mechanism Speaker
assembly
AB
Left rear door

2.0
Left front door

Grounding point
B
High tone speaker
Combined switch 1
High tone
Anti-theft module
speaker Power rear-
view mirror harness harness
Speedometer sensor
Connecting the buzzer
Sunroof ECU
Reversing radar
Middle ceiling lamp
transition wire
C07
Front ceiling lamp
C27
C14
Connecting rain sensor (black)
2 4 6
Connecting ECU
C08
C28
C29
C11 Sunroof switch
Connecting the probe

Connecting the wiper control box (red)
Sun visor of driver’s seat Sun visor of assistant driver’s seat
Reversing radar
C09 harness
Ceiling harness
Connecting the probe Connecting the probeConnecting the probe

Harness ........................................................................................... 2
Front View and Pin Diagram of No. 1 Fuse Box .......................... 9
Front & Back Pin Diagram of No. 2 Fuse Box .............................. 10
Storage Battery/Starter/Generator ................................................ 11
Engine Electronic Control System (4G64 or 4G69) ..................... 12
Engine Electronic Control System (2.8TC) .................................. 13
Engine Anti-theft System ............................................................... 15
TCS Electronic Control System .................................................... 16
Cigar Lighter and Power Rear-view Mirror................................... 17
Central Control Door Lock and Power Windows......................... 18
Reversing Radar System ............................................................... 19
Integrated DVD and A/C Unit ......................................................... 20
Seat Belt Alarm System ................................................................. 21
Reversing Display .......................................................................... 21
PTC System..................................................................................... 22
Schematic Diagram of Harness Relationship and Plug
Connection Numbering .................................................................. 23
Harness
Schematic Diagram of Harness Mid-Connection Numbering and Pin Function 1
C01
46
0.5 0.5
G/Y W/R
199
3.0 0.5
R Y/B

supply harness 1 C02 room harness 1
3 B/R

supply harness B C03 room harness 2

engine harness 1 C04 room harness 1
Connecting the
engine harness 2 Connecting the engine
C05 room harness 2

C06

C09
0.85 1.25
L/W L/Y
0.5 1.25
R/L Y
0.5 0.5
Br/B Gr/Br
50Y
0.5 0.5 0.5 0.5 2.0 0.5
B Br/R
Connecting the
Connecting the
floor harness
engine room harness
C10
T01 T02
0.5 2.0 0.5 0.5
G/W R Br/L Br
E T42 T41
0.5 0.85 0.85 0.5
0.5 0.5
Gr/B B/W W/G Br/W
B/Y Br/R
T31 T32
0.85 0.5 0.5 0.5
G/Y G/B Br/Y Br/Gr
T52 T51
0.85 0.5 0.5 2.0 0.5 0.5
G/V W/L Gr/R Br Br/B Br/G

floor harness 2 instrument harness 2
C13
517
C/O
0.5
Connecting MT harness assembly Connecting the instrument harness


C07

C08

Connecting the
room harness 3
C11
0.85 0.85 0.85 0.85

R/B Y/L
Y/W O/G
260B
0.5 0.85 0.85 2.0 0.85
V/Y G B/G R/G Y/R
0.5 0.85 0.85 0.5

W/G R/Y O R/W
0.5 0.5 0.5 0.85

Y/R W/L B/Y 34A G/R L/R

floor harness 1 instrument harness 1
C12
Connecting the instrument harness Connecting the floor harness

DJ7031-6.3-11 DJ7031-6.3-21
C14
5
0.5 1.25 0.85
V/L L/R L/W
50X
0.5 0.5 0.85 0.5
V/Y W B R/L
Connecting the
Connecting the
ceiling harness
floor harness
C15
A T41 T41
0.5 0.5 0.85
0.85 0.5 T41A
Gr/B Gr/B G
G Br/R
T42 5 T42
0.5 0.5 0.5
0.5 0.5 T42A
Gr/R Gr/R W V/L
Br/W V/L W
Connecting the right Connecting the

front door harness 1 floor harness 1
C16
E E
0.85 0.85 0.85 0.85 0.85 0.85
B/G B/W W/G W/G B/W B/G
C M B 261
2.0 0.85 0.85 2.0 0.85 0.85 2.0 0.85 0.85 2.0
R R/L Y/R B L/Y L/Y B Y/R R/L R

C17
0.85 0.5 1.25

G/Y Y/R Y 1.25 0.5 0.85
Y Y/R G/Y
L 612 611 610 609
609 610 611 612
1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25
G/L G/Br
B G/Br G/L G/R G/B G/B G/R B

chassis harness floor harness
C18
T01 T02
0.85 0.5 0.5 T02
T12
T01
0.85
T11
B/W Br/L Br B/W
5
0.5 0.85 0.85
0.85 0.85 0.5 W V/L L/Y W/G
W/G L/Y V/L W
Connecting the
Connecting the left
floor harness 1
front door harness 1
C19
260
260B U 2.0 0.85 2.0
R/G R/L B B R/L R/G
0.85 0.85 0.85 0.85 0.85

Gr/B Gr/R R/Y G Y/W Y/W G R/Y Gr/R Gr/B
Connecting the left Connecting the

C20
A
2.0
R
B N B
0.85 2.0 0.85
W/G B B/W

rear door harness floor harness
C21
T31 5 T31
0.5
Br/Y
0.5
V/L
W/L T31A
T32
0.5
A
0.85 0.85
T32
Br/Gr W R/L R/L W T32A
rear door harness Connecting the
floor harness
C22
6C B 260A
0.85 2.0 2.0
W/G B R/G
T51 T52 7C 5 B
0.5 0.5 0.85 0.5 0.5 0.85
B/W W V/L R/L
Br/G Br/B
Connecting the left Connecting the

rear door harness floor harness
C23
A
L/Y Y/L Y/L L/Y
D D H
W/G B/W O/G B B O/G B/W W/G
Connecting the
Connecting the tail- floor harness
gate transition harness
C24
C C
0.85 0.5
R/B R/L
A
0.5 0.85 0.5 RW
R/W O W
Connecting the
Connecting the tail-gate floor harness
transition harness
C25
Connecting
the tail gate Connecting the tail-
C26
Connecting the tail-

Connecting
the tail gate
C27

reversing radar cabin harness
transition harness
C28
Connecting the Connecting the reversing

transition harness 1 radar harness 1
C29
Connecting the Connecting the reversing

transition harness 2 radar harness 2
StBrake Steering Rear- Rear Front Right- Left-
Starter lamparter view A/C wiper wiper Power side side
mirror motor motor clutch power power
window window IC unloading relay
Intermittent relay
IntermDo not install
this relayittent relay
IntermiReserved
linettent relay Ceiling Central Warning Reversing Combination Cigar Radio Power
lamp Normal control switch lamp instrument lighter sunroof seat
power door
supply lock
Airbag
Spare fuse
ACC unloading relay

Front View and Pin Diagram of No. 1 Fuse Box
Flash relay
Sunroof Compressor relay
Seat belt alarm Oil pump relay
0.5
Y/R Main relay of engine
Oil pump relay

Compressor relay Starting relay
Start 1# fuse box
Backup Blower
Main relay of engine

Upper beam relay
Upper-beam indicator
Electric horn
Electric horn relay

Lower beam Lower beam relay
Left upper beam Backup
Backup
Blower relay
Right upper beam
Connecting No. 2 fuse box G Backup Backup
Backup
Small lamp
Front fog lamp
Connecting No. 2 fuse box D Front fog lamp relay Small lamp relay Backup High-speed relay for main blower
Fuse of 1# fuse box Fuse of 1# fuse box
Backup
Front & Back Pin Diagram of No. 2 Fuse Box
Rear defroster
Null
Rear defroster relay

Storage Battery/Starter/Generator
From ECU fuse
Red White R e d / Red/ Ignition switch Red/ Black/

B l u e / Green Green/ White/ Green
/Red Blue Green Position of K e y Key plugged in Black White Red Yellow Red
the key pulled
out
Status of
Outgoing the switch
terminal
Red
Unloading relay
Red/
Yellow
No such wire for engine
Charging indicator lamp

Red/
White
Red
Starting relay
Black/ Green/ White/

Red Yellow Red
Storage battery
Red/
Yellow
Generator
Red/
Blue
>
Starter
Black
Ignition switch
CD-H005
airbag ECU37
From the
Black/White
pin
Brown/White
From the
TCU9 pin
Brown/White
Diagnostic plug
Red Low-speed fan relay Red
From the ECU
normal power
supply fuse
Green/Black
Brown/White
Green/White
Cooling fan
Blue/Green
Black/Red Red
Red/Grey
From ECU fuse
Blue/Red
Low acceleration
Green/Yellow Red/Grey
White/Black
sensor
low pressure mid-pressure
From the
switch
White/Red Black/White
White/Red
Blue/White Blue/White
From the
switch
Blue/Black
sensor for air intake manifold

Pressure and temperature
Brown/Red Brown/Red
Brown/Black Brown/Black Black/Red

From ECU fuse
To be cancelled in case of no anti-theft function Green

White
Engine Electronic Control System (4G64 or 4G69)
Maintenance indicator lamp

Green/Yellow Blue Red/Yellow

tachometer speedometer
Brown Brown
From the
White/Black White/Black Blue/Red
position sensor
Throttle valve
From the
Blue/White
ECU normal power
supply fuse
Red/Green Red
Normal power
发动机电子控制系统(4G64或4G69)
Black/White
supply
Red
Knock sensorsensor
Black/White
Compressor relay Compressor
Normal power
Red Grey/Black
supply
Blue
Green/Yellow Blue/Yellow
ECU fuse
Coolant temperature
Black/White
From IG1
Blue/White Green/Yellow
sensor
Violet/Black
Red/White Black
position sensor
Crankshaft
White
Fuel injector 3 Fuel injector 4
Ignition plug
Grey/Red
Grey/White
Black/Yellow
White/Red
PCP ignition coil
Grey/Brown White/Black
Brown/Black Idle control valve
Brown
Grey/Green
Pink/White
Red/Blue
OSP rear oxygen sensor
Pink/Black
Green/White
Black/Yellow
Main relay
Red Red/Yellow Black/Yellow

Red/Yellow
OSP front oxygen sensor
Green/Yellow Black/Blue
Violet
From ECU fuse
Green/Yellow Pink/Brown
Green/Red
Red
Yellow
Fuel/pump
Oil pump relay
Connecting ECU engine

Engine Electronic Control System (2.8TC)
Normal Normal Normal Normal

From the From the To the Normal From the airbag Normal
power power power power From the low From the mid- From the From the power
pressure switch pressure switch speedometer tachometer power From TCU9 pin
supply supply supply main relay main relay From IG1 supply main relay supply ECU37 pin supply
Black/ Brown White/ Brown/ Brown/ Red

Black/ Red/ Red/ Blue/White Green/ Red Blue/ White/ Brown/ Red
Yellow Red Brown/
Red
Black Black
Red
Red
Yellow Blue Black Black/ Yellow White Red
Yellow White
Red/Green
Black/White
Red/
Yellow Red/ Black/ Red
White Red
EGR
controller Compressor
Main relay
relay
Black/ Brake
switch Red
Yellow
Red/
White
Clutch switch
Low-speed fan relay
Preheating relay
Oil/water separator
Blue/ Grey/
Indicator lamp
Red/ Green/ Green/
Preheating indicator lamp

Black/ Red/
Yellow Yellow Black Grey White White Black
Air quality sensor

Diagnostic
Brown White/ Brown Brown plug
Blue/ White/
Blue
Glow plug
Engine malfunction indicator lamp
Black/
White Red Black /Black /Red
clutch
Cooling fan
Brown/
Blue
White
Oil/water separator indicator lamp

Compressor for electromagnetic
Electronic High-pressure pump Phase sensor Fuel rail pressure sensor Coolant temperature
Fuel injector 1# Fuel injector 2# Fuel injector 3# Fuel injector 4# Crankshaft position
accelerator pedal sensor
sensor
sensor
BODY PLUG(K)
Connecting AFS (air flow sensor)

侧侧侧侧侧侧侧侧
Vacuum regulator
侧侧侧侧侧
ECM-A
Water temperature sensor High-pressure pump

侧侧侧侧侧侧侧侧
Connecting No. 2 nozzle
侧2侧侧侧
Connecting No. 4 nozzle
侧4侧侧侧
pressure sensorozzle
侧侧侧侧侧侧侧
Connecting No. 1 nozzle Connecting the camshaft position Connecting the crankshaft position
侧1侧侧侧 Connecting No. 3 nozzle
侧3侧侧侧侧侧侧侧侧侧侧侧侧
sensor 侧侧侧侧侧侧侧侧 sensor
Engine Anti-theft System

Normal Normal
IG1 relay
power power
circuit
supply supply
Brown/ Blue/ Red/ Red/

White White Green Green
Anti-theft indicator lamp

Green/ Red White
Yellow
Green/
Red
Anti-theft ECU assembly
Key detection
Connecting the anti-

theft module
Connecting the
combination instrument
TCS Electronic Control System
Brown/ Red/ Red Red Green/

Green/
White Black Yellow
Yellow
Acceleration sensor
(4WD)
Switch Alarm Alarm

Indicator
lamp lamp
lamp
Brown/ Green/ Brown/

Black Brown Red
Brown/
White Red/ Red/ Red/
Green/ Black Black Green
White
Brown/ Brown/ Green/
Red Black Yellow
Oil pump motor
Brown/ Green/ Green/ Green/

Black Brown Brown Yellow
Yellow/ Yellow/ Green/ Green/ Green/ Green/

Blue Brown Black Red Blue Brown
Yellow/ Yellow/ Yellow/ Yellow/

Black Red Black Red
Control solenoid valve
Integrated TCS control module assembly
Left front (2WD) Left front (4WD) Right front rearront Right rear
Wheel speed sensor
TCS-ECU
1 928 D00 981
Cigar Lighter and Power Rear-view Mirror

From the From ACC From IG2
position unloading
lamp relay relay
Red/ Yellow Red/

Blue Yellow
Black/
Yellow
Red/
White
Middle
Left
Right
Upper
Power rear-view mirror switch

Lower
Middle
Left
Turn Right
off
Upper
Lower
Middle
Left
Cigar
lighter Right
Upper
Lower
Yellow/White
Black/Green
Yellow/Red
Red/Yellow
Green
Vertical
Vertical

Horizontal
Horizontal
Power rear-view Left power rear- Right power rear-

侧侧侧侧侧侧侧
mirror switch 侧侧侧侧侧侧
view mirror 侧侧侧侧侧侧
view mirror
Central Control Door Lock and Power Windows

From the From the Normal From ECU From the To the left To the right From IG1 Normal
door lamp ignition power fuse door lamp side turn side turn power
switch switch supply switch signal lamp signal lamp supply
Red/ Red/ White/ Yellow

Violet/ Green Red/ Green/ Black/ Green Green/ Black Blue Red
Yellow Green Yellow Yellow /Red Violet
IG unloading relay
Red/
Green
Red/ Red
Green
Grey/
Red
Violet Left front window Left rear window Right front Right rear
White/ Black/
switch switch window switch window switch
Green White
Grey/
Black
Blue/ Red/ Blue/ Red/ Blue/ Red/
White White White White White White
Red/
Blue
mechanism assembly
Anti-pinch Anti-pinch Anti-pinch Anti-pinch

Right front door locking ECU I ECU II ECU III ECU IV
mechanism assembly

mechanism assembly

mechanism assembly
Left front door Left rear door Right front Right rear
motor motor door motor door motor
Tail-gate locking
mechanism assembly
Right rear regulator Left front regulator

Left front regulator switch 侧侧侧侧侧(侧侧) 侧侧侧侧侧(侧侧)
(rocker type) (rocker type)
CD-H033
Right rear regulator Right front regulator Left rear regulator switch
侧侧侧侧侧侧侧侧侧侧侧侧(侧侧) CD-H034
switch (rocker type)
Reversing Radar System

Relay
circuit for
reversing
lamp Speaker
Brown Brown
/Red /Black
Green
White
Reversing radar ECU
Yellow Yellow/ Yellow/ Yellow/ Green/ Green/ Green Green/

/Red Black Blue Black Red Brown /Blue Brown
Left side Left middle Right middle Right side
Ultrasonic sensor
Connecting ECU
Connecting the buzzer Connecting the cabin

harness
Connecting the left side Connecting the left Connecting the right Connecting the right
probe middle probe middle probe side probe
Connecting MT harness
assembly
Speed governing
module
Blower relay
Blower
Normal
supply
From A/C power
Red Black/Yellow Red/Black
fuse Blue
Green
Blower
High-speed relay
Normal
supply
Red Red/Black
power

To ECU pin To ECU
pin 9
White/Red
Blue/ Orange
Blue/White Blue/Red
Defroster relay
39

Blue/ Yellow
normal power
Red
supply fuse
From ECU
Evaporator Rear windshield defroster

Temperature sensor Green/Black
Mode actuator
/Black
Green
Pink/Red/ Yellow
Blue/Yellow
Blue/Black

A/C ECU assembly
Blue
Yellow/Black
Brown
Integrated DVD and A/C Unit
Red/White
Green
Blue Cooling and heating air actuator
White/Blue
Pink/Red
Red/Black Blue
From IG2
White/Black
Electric heating relay
Green/Red
Red Red/Yellow Yellow
Heater
tachometer
From the
White/Black Speed sensor Fuel heater Reserved
Brown/Grey Water temperature sensor

From the water
temperature
sensor
Blue
Black
Green
Red
Shielding ground
Brown/
Brown/White Grey
Blue/Red Brown/
Brown/Red Yellow
ceiling lamp
From the
White
fuse
Blue
101-06002-0(侧侧)
Signal feed line

From the From ACC
position unloading
101-06001-0 (yellow)101-06002-0 (green)
Yellow Blue/Red
relay
Red/Blue Small lamp signal

lamp relay
Brown/
Brown/Blue Green
Blue/
Red
DVD and AC all-in-one unit
Brown/
Brown Black
Left rear speaker

DVD
Silence detection
Plug E (20-pin)
display
DVD
Silence detection
侧DVD
Ignition detection Dedicated communication cable

Connecting
Green
/Blue
Brightness adjustment
lamp fuse
brake lamp reversing
From the From the
Green/White Reversing detection

101-06001-0(侧侧)
Red/Black Power amplifier Brake detectioncontrol

switch
Power amplifier control

Key-control switch for
Key-control grounding
steering wheel
Key-control input B
Key-control input A
Rear-row
display
Plug F (16-pin)
From the reversing

lamp fuse
Positive pole of
video
Negative pole of
video
From DVD
自DVD
Reversing Display
From DVD
自DVD

Reversing display
H:MG610159
camera
To DVDc1-4 pin
To DVDc1-1 pin 到DVDc1-4引脚
Positive pole of video

Negative pole of video
到DVDc1-1引脚
Door lamp detection Black/Yellow

Seat Belt Alarm System
Key detection
Green
Speed detection
Brown/Green
Connecting the seat belt

Seat belt alarm ECU
Blue/Red
Normal power supply
Red
alarm
Small lamp detection Red/Blue
IG1 relay circuit Blue/White
Connecting the seat belt indicator lamp Violet
Detection of seat belt switch
White/Green
PTC System
Normal
Normal
supply
Normal power
power
Speed sensor
Normal
Engine
Engine
power supply
Blue
Red Blue power supply
Relay
circuit supply
Red
Red/
Black
Blue/ White/ Red
Red/Yellow
White Red

Red/
Green
Electric heater relay
Temperature sensor
Blue
Blower relay
Evaporator
Red/
Black
Brown/Grey
White/Black
Red
Heater
Green/Red
Heater
Brown Blue
Green
Yellow
Green/
Blue/Red
Black/Yellow
Black
Blower
CD
Green
Red
player Shielding
ground Black
A/C ECU assembly
Red/Black
Green
Fuel heater
Blue/ Orange
White/Black
Yellow/Black
Green/Black
Blue/Black
Yellow
White/Blue
Blue/Yellow
Red/White
White
Pink/Red
Pink/Red/ Yellow
Blue

High-speed relay
Blower
Defroster relay
Reserved
Cooling and heating air actuator
Blue/ Yellow
Mode actuator

Connecting the A/C ECU Connecting the A/C ECU
Connecting the indoor temperature sensor

Connecting the outdoor temperature sensor
Connecting the A/C pressure switch

Connecting the A/C cooling and heating Connecting the A/C mode actuator Connecting the internal and external Connecting the speed Connecting the blower motor
air actuator circulation actuator governing module Connecting the evaporator temperature Connecting the heater
sensor
Connecting the combination instrument
Connecting the left power rear-view

mirror Connecting the right power Connecting the positive pole of
rear-view mirror Connecting the negative pole of
rear windscreen defroster rear windscreen defroster
Engine compartment Instrument harness Floor harness Right front door Right rear door
harness harness harness
Water pipe
assembly(locking mechanism assembly)

Integrated right front door
Regulator (rocker
type)
Anti-nip
防夹功能 Speaker
function Speaker High tone speaker Door lamp
C16
Regulator switch
C05 C12
T01
0.5
B r/L
T02
0.5
Br
0.85
R/L
B
2.0
L /W
2.0
R/G
2.0
R/W
B
2.0
B
C
T31A
0.5
B r/Y
T32A
0.5
T31
0.5
B r/Y
T32
0.5
B r/Gr
0.5
V/L W
Integrated right rear lock
assembly(locking mechanism
assembly)
0.85 0.85 2.0 B r/Gr
G r/B G r/R B
GPS signal line
interface with the instrument

Connecting the
Connecting the CD player

antenna
C06 C15 T11
0.85 0.85
W/G B/W
A A
0.85 0.85
G r/B B
C20 C D-Z020
0.85
W/G
0.85
B/W

C10
0.5
B r/L
T12
0.5
Br 2.0 Connecting the right front lamp switch
Speed-regulating
L /W
High tone
0.85 2.0
Connecting the
2.0 R/L L /W
R/W
C C
speaker 2.0 2.0 2.0 2.0 2.0
0.5 0.5 0.5
Regulator (rocker right rear lamp L /W B R R/W R/W
module
Regulator (rocker
V/L W B/Y W/L
Door lamp
C21 Regulator
E
type) P
switch Anti-nip riser (rocker
0.5
0.5
switch type)
B W/L
type)
Power rear-view
temperature sensor
Connecting the mirror

Water pipe
Evaporator
acceleration sensor
A/C ECU
0.5
W/B
0.5
P
Assistant driver seat
A/C ECU
W/L
0.5
P/Y
0.5
2WD/4WD 0.5 0.5 0.5
heating
G/B
L/Y
0.5
0.5
L/B
Br/B Gr/Br Br/R
Electric clutch
conversion
Br
Y/B
0.5
R/W
A
0.5
0.5
0.5
315D
B
1.25
Y/W
B
50D
socket
0.5
20.0
O
2.0
0.5
A
Connecting the negative R
0.5
2.0 B
0.5
ECU
T B
Y
Outdoor high -mounted
1.25
0.85
L
L /R
Body grounding
L
Br
L/G
Generator
0.85 0.85
pole of storage battery
Blower
0.5
Connecting the positive pole of storage battery
W
motor
A B R/B
168
stop lamp
Handbrake
Front wiper
20.0
G/B
0.5
169 B
B 2.0
1.25
L /W
0.5 0.5 2.0
403A
BL
S02
0.5
0.5
0.5
0.5
20.0 W/R
DVD player A
G/Y
R
AC
L
1.25
0.5
Y/B
Y
B 0.5
S01
0.5
0.5
G/B
B/Y
0.5
R/B
Connecting the negative pole of
G
315E
G
G/B
Right tail lamp
50Z
Transmission harness
storage battery
S
ABS-FR sensor 2.0 R
S03
0.5
0.5
2.0 B
L/R
Br
0.5
0.5
B
0.85
G
Br 0.5 0.85
B B G/V upper
R/B
0.5
0.5
L/O
95
Rear liftgate harness
B A D
166
ALT 20.0 16.0
B/R 2.0
167 0.5 0.5 0.85
100A R G
B2.0 R/L G/W R/B
3.0
Generator
B Driver and assistant driver Right tail lamp
Central control
16.0 seats heating switch lower
DVD player B
B/R
door lock
Frame harness
Connecting
Engine grounding 20.0
R the starter
GPS interface antenna interface
windscreen
pole of rear
Y6-6
20.0
windscreen defroster Integrated tail-gate lock assembly (locking defroster

Negative
C13
Leveling
B
ABS left rear sensor
Rear washer motor
1.25
3.0
A
P
devices
B
R
3.0 0.5 0.5
CD player connector
Alarm switch
B G/L G/Br
for right Starter control
Right combination
headlamp
0.5 0.5 ABS right rear sensor
B
Front washer motor
16 G/ B G/R
Left side turn
C02
License lamp
signal lamp
Cigar lighter
C01
illumination
lamp
Oil pump
point reversing camera

H
R/L
0.5
F
0.5
connecting
B
B
Electric 4WD switch

E
mechanism assembly)
0.85 0.85
B G/Y
G
B A
1 .25 0 .5 0 .5
TCS switch
1 .25
Rear fog lamp

Right front fog
BrW
Y /R
B
Y B B
3
Connecting the
CD player
illumination
Ash tray
crankshaft position
lamp
motor Grounding
Sensor CT19
G
0.5
R/L
D
0.5
Grounding for electronic fan
B
Electric fan Grounding for
Seat belt switch
Charging power
0.5
special ground electronic fan
C17
L
Right-side K
Rear wiper
Engine harness
Indoor temperature
D A
Condenser fan
No. 1 junction box
0.5 0.5
Rear iftgate transition

electric horn
A/C pressure switch (Tri-
0.85 0.85
C
Left tail lamp
0.5
W/G B
supply
B G/Y
Instrument dimmer Cigar lighter

L
0 .85
Y /L
0 .85
G
B
upper
motor
O/G
0 .85
0 .85
O
sensor
V
Rear fog lamp
0.5
harness
License lamp
B
state switch)
Connecting Connecting Connecting Connecting

for left headlamp
Leveling devices
A
G
0.5
No. 1 nozzle No. 2 nozzle
Br
No. 3 nozzle nozzle
Where to paste
0.85 0.85
the trademark
B G/R
CT12(blue) CT12(blue) Power seat Left tail lamp
Grounding for
Ct15(4)
electronic fan
0.5
CT13
Combination instrument A
A
G
Grounding for
electronic fan
Grounding for
electronic fan
0.85
Positive pole of rear

Combined
lower R/B
ACC unloading relay

IG unloading relay
lamp
Connecting B J Connecting the left rear
Headlamp regulating switch
1 .25
L /Y
A/C clutch
2.0 2.0
Br B door lamp switch F
CT8 Knock sensor 0.5

signal lamp
C23 C25
B
Left turn
No. 1 fuse box

0.5 0.5
electric horn
B R/L G/W
Left-side
Spare fuse
166 0.5
167 B W/L
2.0
2.0
G
Outdoor temperature
Driver’s seat
Horn
sensor
1 .25
O/L
High-mounted
C03 Diode components heating
Left front fog
stop lamp
C24 C26
lamp
Brake fluid level
Do not install this relay
The protector is yellow

Intermittent relay
Connecting the left front
Reserved line
Flash relay
A/C mode actuator
Connecting the Backup power
Stop lamp switch

Fog lamp switch door lamp switch C
acceleration sensor Water temperature sensor CT9 雾灯开关
B
alarm
Light-sensitive sensor
2.0
electric control clutch
C04
0 .85
Connecting the idle Br

B
Anti-pinch regulator
接怠速控制阀
Combined
0 .85
speed control valve

Connecting the
E
Rear ceiling lamp
R /B
Speedometer sensor
Clutch switch 2.0
switch 3 Video outer connector
Ignition switch
A A
Connecting the charcoal 0.5 0.5 B
wrapped with foam piece
接碳罐控制阀
Automatic
B/Y W/L
C18
canister control valve
Throttle valve
0 .85
Speaker
R /B
R /W
0 .85
A
Connecting the ignition coil CT5
wiper ECU
Electric rear-view mirror switch
position sensor Anti-nip riser 0.5 Integrated right front door

Regulator switch B Door lamp
assembly(locking mechanism assembly)
T01
Grounding
Connecting the rear

oxygen sensor CT7
ABS-FL sensor Electric horn
0.5
B
Br/L 0.85 2.0 2.0 2.0 2.0
T02 0.5 0.5
C22
R/L L /W R/G R/W B
Water temperature plug
Anti-pinch
0.5 W/L W/B
B C 0.85 0.85
防夹
Br
0.85 0.85 2.0 W/G B/W
G r/B G r/R B
Combined switch 2
A/C cold and warm
Connecting the intake air

接进气温度压力传感器
Regulator (rocker type)
air actuator
C19
0.85 0.85
temperature pressure sensor

0.85
W/G B/W R/L
Connecting the front

A A 2.0
C L/W
0.85 0.85 2.0 2.0
2.0 2.0
G r/B B
Automatic
L/W B R/G R/W
2.0
oxygen sensor CT7 Door lamp Regulator switch

R/W
接ECM
Connecting ECM headlamp ECU
L/W
2.0
R/W
0.5
V/L W
Left front door locking Regulator (rocker type)
T11
Regulator mechanism assembly Speaker
0.5
Left rear door

Br/L
Grounding point
AB
High tone speaker

2.0
T12
CT1 Left front door

B 0.5
Combined switch 1
Br T52A
0.5
High tone speaker
Gearshift actuator
Br/B
T51A
harness
0.5
Br/G
Power rear-view
harness
T52
0.5
Br/B
mirror
T51
Anti-thief module 0.5

Br/G
Connecting the buzzer
Medium ceiling
Reversing radar
lamp transition wire
C07
Front ceiling Sun roof ECU
lamp
C27
and speed sensor

A A
Connecting the rain
C14
0.5 0.5
B/Y W sensor (black) 1 3 5
2 4 6
Connecting ECU
C08
C28
C29
C11 Sunroof switch
Connecting the probe

Connecting the wiper Sun visor of driver’s
control box (red) seat Sun visor of assistant
driver’s seat
Reversing radar
C09 Ceiling harness
wire
Connecting the probe Connecting the probe Connecting the probe

Body Electrical Appliance (K1-NCAP)-1
Body Electrical Appliance (K1-

NCAP)
Schematic Diagram of PAB Switch ............................................... 2
Schematic Diagram of Seat Belt Alarm System .......................... 2
Electrical Schematic Diagram and Connector Arrangement of
Airbag .............................................................................................. 3
Schematic Diagram of Central Control Door Lock and Motor
Door Window .................................................................................. 5
Schematic Diagram of Fuel Cut-off in Impact for Petrol Vehicle .... 6
Schematic Diagram of Fuel Cut-off in Impact for Diesel Vehicle ... 7
Seat Belt Alarm ............................................................................... 8
Central Door Lock Controller ........................................................ 9
Airbag (Bosch) ................................................................................ 11
PAB indicator lamp of
alarm lamp
C2 passenger seat belt

indicator lamp
PAB switch
of PAB Switch
Connecting PAB switch

Schematic Diagram
Seat belt switch detection
IG1 relay circuit
Blue/White
Red/Blue Small lamp detection
Blue/Red Red Normal power supply
Brown/Green Speed detection

Seat belt alarm ECU
Green Key detection

Belt Alarm System
Black/Yellow Door lamp detection
Connecting the seat belt alarm

Schematic Diagram of Seat
Electrical Schematic Diagram and Connector Arrangement of Airbag
Clock spring
Horn button
Driver airbag assembly
Diver’s pretensioning force- Red Blue/White

limiting seat belt /D P/T
Driver seat belt switch
Assistant driver airbag

assembly PAB
Passenger’s pretensioning
force-limiting seat belt P P/T
K diagnostic instrument linker
Brown /White
IEE - seat sensor (front-

row passenger) Passenger seat belt switch
Passenger seat belt
indicator lamp
乘员安全带指示灯
Impact output unlocking signal
PAB indicator lamp

PAB指示灯
A warning lamp
C1 driver seat belt indicator lamp
PAB开关 PAB switch
Seat belt alarm output

Combination instrument A
CD-H009
Connecting the PAB Connecting the clock Drive seat Passenger seat
generator (yellow) spring transition belt switch belt switch
line (yellow)
Ground Seat sensor Connecting PAB switch Connecting the

instrument panel and
the console harness
Pretensioning Pretensioning Connecting the

seat belt seat belt airbag ECU
Schematic Diagram of Central Control Door

Lock and Power Door Window
From the From the From the Normal From ECU From the To the left To the Normal Normal
airbag ECU door lamp ignition power fuse door lamp turn lamp right turn From IG1 power power
switch switch supply switch lamp
supply supply
Black
Red/
Blue
Red/
Green /Violet
Green
Red/Green
Black /Yellow
Yellow
Violet/Yellow
Green /Red
White/Red
Green /Yellow
IG unloading relay
Red/Green
Green
Red/
Red
Grey/Red
Right rear door

Violet
Left front door Left rear door Right front door

White
Black/
Green
White/
Grey/
Black
Blue/White
Red/White
Blue/White
Red/White
Red/White
Blue/White
Red/
Blue
mechanism assembly
Anti-pinch ECU Anti-pinch Anti-pinch ECU Anti-pinch ECU

Right front door locking I ECU II III IV
mechanism assembly

mechanism assembly

mechanism assembly
Left front door Left rear door Right front door Right rear door
motor motor motor motor
Tail-gate locking
mechanism assembly
Central control door lock controller

Schematic Diagram of Fuel Cut-off in Impact for Petrol Vehicle
Crankshaft position
Red/White Black
sensor
White
Spark plug
Grey/Red
Grey/
White
Green/Yellow
White/
Red
PCP ignition coil
Idle control valve

Grey/ White/
Brown Black
Brown/
Black
Engine ECU
Grey/ Brown
Green
Pink/
Brown
Red/Blue
OSP rear oxygen

Pink/Black
sensor
Green/
White
Green/Yellow
Main relay
Red Red/Yellow Green/Yellow
Red/
OSP front oxygen

Green/Yellow Black/Blue Yellow
sensor
Violet
Yellow
Pink/Brown
Green/
Red Red
Fuel pump
Switch for fuel
Oil pump relay cut-off in impact
Schematic Diagram of Fuel Cut-off in Impact for Diesel Vehicle
Red
Black/Red
Red/Yellow
Main relay
EGR controller
Switch for fuel cut-off in impact
Red/ Black/Red
White
Black/
Yellow
Black/Blue
Engine ECU
Seat Belt Alarm

External View of Seat Belt Alarm
Schematic Diagram of Pin Positions and Pin Functions

Pin Pin
Function Function
number number
1 Power supply positive pole 7 Speed signal input
2 Power supply negative pole 8 Key detection signal input
3 To SRS ECU 9 Combination switch input
5569-12MA 4 Empty 10 Door switch signal input
“ON” gear detection signal

Schematic Diagram of 5 Empty 11
input
Pin Positions
6 Empty 12 Lighting control signal input
1. Rated voltage: 12V DC; working voltage DC 9V~16V
2. Static current: less than 5mA;
3. Working temperature: -40℃~+85℃;
4. Connectors used: 5569-12MA (module end), 5557-12P (harness end);
Functional Descriptions
1. Alarm function description of front-row seat belt
(a) If the driver or front-row passenger does not wear seat belt when the ignition switch is at ON
position, the seat belt alarm will send a tone for ten times continuously (every 0.5s), and the
driver or front-row passenger seat belt indicator lamp (controlled by SRS ECU) will be always on
until the seat belt is pulled on.
(b) If the driver or front-row passenger does not wear seat belt when the speed is up to 20km/h, the
seat belt alarm shall send a tone continuously (every 15s), and the driver or front-row passenger
seat belt indicator lamp will be on until the seat belt is pulled on.
2. When the door is opened with the key in the ignition lock but not at ON position, the tone for
"key not pulled out” will be sent until you pull out the key or close the door;
3. There will be no alarm for “light not turned off” when the combination switch is at AUTO position
with the key not in the ignition lock; when the combination switch is not at AUTO position with one
lamp in the lighting system (position lamp) turned on and a door opened, there will be a tone for
“light not turned off” until you turn off the lighting switch or close the door.
Malfunctions and Measures
Malfunction Measures
1. No tone for “seat belt not fastened” 1. Check harness connection;
2. No tone for “light not turned off” 2. Check whether there is an input to the signal for “seat belt not
3. No tone for “key not pulled out” fastened";
3. Check whether there is an input to the signal for “light not turned off ";
4. Check whether there is an input to the signal for “key not pulled out ";
5. Have the malfunction been solved by replacing the seat belt alarm
assembly?
Central Door Lock Controller

Terminal number and connecting wire arrangement
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10
Terminal Terminal
Connecting wire arrangement Connecting wire arrangement
number number
1 Empty 12 ON power supply detection(12V)
2 Right turn lamp output (12V) 13 Power supply negative pole
3 Empty 14 Empty
4 Empty 15 Empty
5 Central control door lock positive (12V) output for unlocking 16 Power supply positive pole(12V)
6 Central control door lock unlock positive (12V) output for locking 17 Airbag signal detection (impulse)
7 Key insertion detection (-) 18 Empty
8 Left turn lamp output (12V) 19 Manual locking signal
9 Reading lamp output 20 Manual unlocking signal
10 Automatic window shutdown signal 21 Door detection
11 Speedometer detection (impulse) 22 Empty
Technical parameter
1. Working voltage: DC12V±3V;
2. Working current: ≤10mA (standby);
3. Control current: 15A max;
4. Working temperature: -40℃~+85℃;
5. Receiving frequency: 433.92MHz±250KHz;
Functional specification
1. Locking
Press the LOCK key on the remote controller after getting off and closing the door, and then the
vehicle lamp will flash once and the central control door lock is activated to lock the doors;
2. Unlocking
Press the UNLOCK key on the remote controller when the doors are locked, and then the vehicle
lamp will flash twice and the central control door lock is activated to unlock the doors;
3. Positioning function
At night or in a parking yard, if you press the UNLOCK key on the remote controller once when the
doors are in locked state, the vehicle lamp will flash ten times quickly so that you can find you car
easily. Press the UNLOCK key on the remote controller to exit the positioning function.
4. Automatic locking protection function

If the owner accidentally presses the UNLOCK key on the remote controller when the doors
are at locked state, and he does not open any door after this operation, the doors will be locked
automatically in 30s;
5. Automatic locking in traveling (optional)
When the vehicle speed is up to 15km/h, the central control door lock will make a locking command
after receiving the speed signal sent by the relevant instrument, and the doors will unlock
automatically after the vehicle is stopped with its engine turned off.
6. Suspension of remote control function
The remote controller will not work after the key is inserted into the ignition lock, but the main unit can
work normally.
7. Manual locking or unlocking
The doors can be locked or unlocked by the manual switch;
If the original remote controller is lost, it should be cleared from the main unit to avoid illegal operation.
At most another remote controller can be added onto the original remote controller.
9. When the reading lamp is conducted
Stop the ve- The ceiling lamp is The ceil- The ceiling lamp is
hicle and turn →
Pull out
→ on and the delay
→ Open the → ing lamp is → Close → on and the delay
the key door the door
off the engine time comes normally on time comes
The ceiling lamp will be off automatically when the main unit of
→ central control door lock does not receive any signal within 60s.
The locking lamp of remote The remote controller works
→ controller is off (the turn lamp→ to unlock (the turn lamp→ Open the door → Close the door
flashes once) flashes twice)
→ The signal lamp will be off automatically when the main unit of central control door lock does not receive any signal
within 30s.
→ The lamp will be off after locking or inserting the key
→ The signal lamp will be off automatically when the main unit of central control door lock does
not receive any signal within 30s.
10. When the reading lamp is turned off
Stop the ve- The ceiling lamp is The signal lamp will be off automatically when the
Pull out Open the
hicle and turn → → on and the delay → → main unit of central control door lock does not re-
the key door
off the engine time comes ceive any signal within 30s.
The ceiling lamp will be off automatically when the main unit of
→ central control door lock does not receive any signal within 60s.
The ceiling lamp is

Close the → The remote controller works to lock The remote controller works to
→ on and the delay time and the ceiling lamp is off (the turn → unlock (the turn lamp flashes →
door
comes lamp flashes once) twice)
The signal lamp will be off automatically when the main unit of central control
→ door lock does not receive any signal within 30s.
Open the The ceiling lamp is on and the → The lamp will be off after locking or insert-
→ Close the door →
door delay time comes ing the key
The signal lamp will be off automatically when
→ the main unit of central control door lock does
not receive any signal within 30s.
11. Automatic window shutdown signal output
The locking function will be activated and the system will send the automatic window shutdown signal
after pulling out the key, closing the door and pressing the LOCK key on the remote controller when
the door is at unlocked state.
12. Impact unlocking function
Airbag (Bosch)
Precautions for Maintenance
Read the precautions for maintenance for safety before operation.
1. The SRS airbag maintenance should be pursuant to the procedures and items stated in this
chapter.
2. The operation should be performed by using the experimental device and special tools
pursuant to the requirement stated in this chapter.
3. The following components should be replaced in maintenance when failures occur with them:
(a) SRS airbag control elements (SRS-ECU)
(b) Clock spring module
(c) Front airbag module at driver’s side
(d) Front airbag module at passenger’s side
(e) Airbag harness
(f) Pretensioning seat belt
(g) PAB control switch
4. For the electrical basic diagram and connector definition of airbag, see Pages 3, 4); for SRS-
ECU pin definition, see the diagram below; for the position and shape of airbag malfunction
indicator lamp, see Page 12.
A cavity pin arrangement
1 K-Line 13 PAB indicator lamp

2 NC 14 Driver seat belt indicator lamp
3 Seat belt alarm output 15 DAB negative pole
A seat
4 NC 16 DAB positive pole

5 Impact output 17 PAB positive pole
6 Passenger seat belt indicator lamp 18 PAB negative pole
Negative pole of driver seat belt
7 Simulative ground 19
pretensioner
Positive pole of driver seat belt
8 Driver seat belt latch switch 20
B seat
pretensioner
Positive pole of passenger seat
9 NC 21
belt pretensioner
Negative pole of passenger
10 PABswitch 22
seat belt pretensioner
Passenger seat belt latch switch
11 23 Negative pole
Passenger seat sensor
12 Positive pole 24 Malfunction indicator lamp
5. Disconnect the battery negative pole and hold on for 60s before maintenance. The
disconnected negative pole should be wrapped with the insulating tape for insulation purpose.
There is a condenser in the SRS-ECU which should store enough energy to deploy the airbag in
certain time after the battery is disconnected. It may deploy airbag accidentally and lead serious
accident without waiting a certain time before maintenance.
6. The SRS-ECU, airbag module, clock spring and other parts should be removed and placed
properly when it is too hot and they may be influenced during painting. (Above 93℃)
You should use the diagnostic scanner to clear the malfunction code to make alarm lamp work
normally after maintaining the SRS airbag system.
Malfunction alarm lamp

of airbag system
Driver seat charge Passenger seat charge

element and airbag element and airbag
Impact sensor and
diagnosis module
Insulating tape
Battery
Wire
Testing instrument
Instrument Name Utility
Inspect the SRS airbag system for

X-431 Diagnostic detection instrument system malfunction and clear the ECU
malfunction code.
Troubleshooting
Basic Process for Troubleshooting
The current malfunction code DTC may coexist with the historical malfunction code DTC.
Note
• The malfunction alarm lamp of airbag system will be normally on for 4s and then off
permanently when the ignition switch is at ON state after the electronic control unit
of new SRS airbag system is installed, which means the SRS airbag system works
well, and in this case, the system needs no inspection; or else, the system should be
diagnosed and maintained.
• If the airbag system alarm lamp is always on when the ignition switch is at ON state,
check the circuit related to the alarm lamp, and operate again to make it enter working
condition.
Alarm lamp is always on
Use the scanner connected with K-line to scan ECU
Find out the malfunction
Solve the malfunction
Clear the malfunction code
Inspection of SRS airbag alarm lamp

(a) Place the ignition switch at ON position and check if the SRS alarm lamp is on.
(b) Make sure the alarm lamp is off permanently after being on for 4s.
(c) It needs diagnosis inspection besides what is mentioned above.
Malfunction alarm lamp

of airbag system
System Diagnosis
The SRS-ECU will perform a series of circular diagnosis tests to check if the performance of airbag
system is ready. This test can prevent the restraint system from deploying accidentally and ensure it
will deploy in impact. When a malfunction is found, the SRS-ECU will store a proper malfunction code
and open the alarm lamp to show there is a malfunction to be maintained.
Diagnosis interface 405 is for SRS diagnosis wire.
Malfunction code list

DTC Description GWM DTC Bosch DTC
ECU Internal Malfunction B1000 $9000
Configuration Error B1001 $9001
Open Circuit of Driver Airbag B0026 $8026
Low Resistance of Driver Airbag B0022 $8022
Short Circuit to Ground or Cross Coupling of Driver Airbag B0024 $8024
Short Circuit to Battery of Driver Airbag B0025 $8025
Open Circuit of Passenger Airbag B0017 $8017
Low Resistance of Passenger Airbag B0016 $8016
Short Circuit to Ground or Cross Coupling of Passenger Airbag B0018 $8018
Short Circuit to Battery of Passenger Airbag B0019 $8019
Open Circuit of Driver Seat Belt Pretensioner B0065 $8065
Low Resistance of Driver Seat Belt Pretensioner B0064 $8064
Short Circuit to Ground or Cross Coupling of Driver Seat Belt Pretensioner B0066 $8066
Short Circuit to Battery of Driver Seat Belt Pretensioner B0067 $8067
Open Circuit of Passenger Seat Belt Pretensioner B0058 $8058
Low Resistance of Passenger Seat Belt Pretensioner B0057 $8057
Short Circuit to Ground or Cross Coupling of Passenger Seat Belt Pretensioner B0059 $8059
Short Circuit to Battery of Passenger Seat Belt Pretensioner B0060 $8060
* Open Circuit of the Airbag at Driver’s Side B0041 $8041
* Low Resistance of the Airbag at Driver’s Side B0040 $8040
* Short Circuit to Ground or Cross Coupling of the Airbag at Driver’s Side B0045 $8045
* Short Circuit to Battery of the Airbag at Driver’s Side B0046 $8046
* Open Circuit of the Airbag at Passenger’s Side B0029 $8029
* Low Resistance of the Airbag at Passenger’s Side B0028 $8028
* Short Circuit to Ground or Cross Coupling of the Airbag at Passenger’s Side B0030 $8030
* Short Circuit to Battery of the Airbag at Passenger’s Side B0032 $8032
* Open Circuit of Driver Air Curtain B0062 $8062
* Low Resistance of Driver Air Curtain B0061 $8061
* Short Circuit to Ground or Cross Coupling of Driver Air Curtain B0068 $8068
* Short Circuit to Battery of Driver Air Curtain B0063 $8063
* Open Circuit of Passenger Air Curtain B0070 $8070
* Low Resistance of Passenger Air Curtain B0069 $8069
* Short Circuit to Ground or Cross Coupling of Passenger Air Curtain B0071 $8071
* Short Circuit to Battery of Passenger Air Curtain B0076 $8076
DTC Description GWM DTC Bosch DTC

* Open Circuit of Knee Airbag B102E $902E
* Short Circuit to Battery of Knee Airbag B102D $902D
* Short Circuit to Ground of Knee Airbag B102C $902C
* Low Resistance of Knee Airbag B102F $902F
* Performance Malfunction or Cross Coupling of the Outer Wall Throttle Sensor at
B0077 $8077
Driver’s Side
* Incorrect Installation of the Outer Wall Sensor at Driver’s Side B0079 $8079
* Breakage or Security Malfunction of the Outer Wall Sensor at Driver’s Side B0080 $8080
* Performance Malfunction or Cross Coupling of the Outer Wall Throttle Sensor at
B0078 $8078
Passenger’s Side
* Incorrect Installation of the Outer Wall Sensor at Passenger’s Side B0081 $8081
* Breakage or Security Malfunction of the Outer Wall Sensor at Passenger’s Side B0082 $8082
High Battery Voltage B1328 $9328
Low Battery Voltage B1327 $9327
Short Circuit to Battery of Driver Seat Belt Latch B0097 $8097
*Short Circuit to Battery of Passenger Seat Belt Latch B0096 $8096
PAB Switch Malfunction B0090 $8090
Incorrect Set of PAB Switch Resistance B0091 $8091
Short Circuit to Ground or Open Circuit of System Malfunction Lamp B0671 $8671
Short Circuit to Battery of System Malfunction Lamp B0673 $8673
Short Circuit to Ground or Open Circuit of PAB Indicator Lamp B0681 $8681
Short Circuit to Battery of PAB Indicator Lamp B0683 $8683
Malfunction of Passenger Seat Belt Indicator Lamp B059A $859A
Malfunction of Driver Seat Belt Indicator Lamp B0595 $8595
Short Circuit to Battery of Seat Belt Alarm Circuit B0883 $8883
Short Circuit to Ground or Open Circuit of Seat Belt Alarm Circuit B0882 $8882
Front Airbag Deployment Commanded B0051 $8051
* Side Airbag or Air Curtain Deployment Commanded B0034 $8034
The airbag controller reaches its maximum usage, and can not be reused B0052 $8052
Short Circuit to Battery of Impact Output Circuit B0049 $8052
Short Circuit to Ground or Open Circuit of Impact Output Circuit B0048 $8048
Note:
DTC with * means only for 9-loop ABM.
Clearing of malfunction codes
After ECU receives a command to clear the malfunction code which is sent by the diagnosis tester
through a serial interface, the malfunction code will be cleared, but if an internal malfunction code or
an impact is recorded, the clearing command will not be performed.
Troubleshooting
The alarm lamp is always on or off
No. Malfunction Description
1 The airbag system alarm lamp doesn’t display. Alarm circuit malfunction of airbag system
2 The airbag system alarm lamp is always on. Alarm circuit malfunction of airbag system or external malfunction
1. The airbag system alarm lamp doesn’t display.

1 The airbag system alarm lamp doesn’t display.
Inspection state Alarm circuit malfunction of airbag system
Possible Vo l t a g e d i s a p p e a r a n c e ( f u s e b r e a k a g e ) ,
reasons combination instrument malfunction or malfunction
of the harness between instrument group and ECU
Diagnosis procedures
It is recommended to shake the harness and connector before the malfunction detection at the first
time to see if there is any discontinuous failure in contact. If so, you should check the connector,
terminal and harness connection to see if there is any breakage; if there is no malfunction mentioned
above, you should perform the following procedures.
Step Detection Operation item

Inspect other harnesses and instrument group indicator Place the ignition switch at LOCK po-
lamps. Yes
sition, and then turn to next step.
1  Place the ignition switch at ON position. Inspect the instrument group power
 Are the other alarm lamps and indicator lamps on? No supply system and grounding system
(fuse), then turn to the step 5.
Inspect the bulb
Warning:
Improper handling of airbag system elements may deploy
the airbag or pretensioning seat belt accidentally, which Yes Turn to the next step.
may lead serious accident. Please read the airbag system
maintenance warnings before operation.
2  Place the ignition switch at LOCK position.
 Cut off battery negative pole wire and hold on for at
least 60s.
 Remove the combination instrument. No Replace the alarm lamp bulb.
 Measure the two relevant pins of airbag alarm lamp
to see if they are conducted.
Inspect the harness connection between ECU and
instrument group. Yes Turn to the next step.
 Place the ignition switch at LOCK position.
3  Cut off the battery negative pole wire.
 Cut off the instrument group connector. Replace the harness and then turn to
 Inspect the relevant parts of alarm lamp circuit to see NO the step 5.
if they are conducted.
2. The airbag system alarm lamp is always on
2 The airbag system alarm lamp is always on
Inspection state The airbag system alarm lamp is always on
Possible reason Battery power supply insufficiency.
ECU internal malfunction.
Malfunction of airbag alarm lamp at the combination instrument
Improper connection of ECU plug
Combination instrument connector failure in contact
Broken circuit or failure in contact of ECU power supply fuse
Improper connection of ECU connector terminal
Improper connection of harness between ECU connector terminal and ground
Airbag circuit malfunction at driver’s side or passenger’s side
Pretensioning seat belt malfunction
PAB control switch circuit malfunction
Central door lock controller malfunction
Seat belt alarm malfunction
Diagnosis Procedures
Use a special diagnosis tester (X-431 diagnosis tester) to establish the communication with ECU
to find out the reason of malfunction. Conduct the following inspection if the communication is
impossible.
Step Detection Operation
Inspect battery Yes Turn to the next step.
Inspect battery voltage Battery power supply insufficiency.
1 Is the voltage above 9V? NO Inspect the charge/discharge
system, and then turn to the step 5.
Inspect the conductivity of the harness between ECU and
combination instrument.
Place the ignition switch at LOCK position. Yes Turn to the next step.
Cut off the battery negative pole wire.
Open the central passage protecting board.
2 Cut off the instrument group connector.
Connect the battery negative pole.
Place the ignition switch at ON position. Inspect the circuit and turn to the
Inspect the voltage between relevant connector terminals NO
step 5 after it is repaired.
of instrument to see if it is 12V (connecting wire between
power supply and instrument).
Place the ignition switch at LOCK position. Yes Turn to the next step.
Inspect the relevant terminals of instrument connector and
3 Repair or replace the harness and
diagnosis connector to see if they are conducted (the two NO
ends of diagnosis K-line). then turn to the step 5.
Step Detection Operation

Cut off the battery negative pole wire and hold on for at least Yes Turn to the next step.
1 min.
Cut off the ECU connector.
3
Cut off the instrument group connector. Replace the harness and then turn
Is the circuit between the ECU connector terminal 24 and No
to the step 5.
instrument connector conducted?
Yes Replace ECU
Remove the ECU to see if the terminal is complete, or if the
4 Reconnect ECU connector and then
short-circuit rod is broken. No
turn to the next step.
Make sure the malfunction doesn’t recur after repairing. Solve the malfunction and then ex-
Place the ignition switch at LOCK position. Yes plain the maintenance procedures
Cut off battery negative pole wire and hold on for at least 1 to the customer.
min.
Connect all the ECU connectors.
Connect the airbag component connectors at driver’s side
Connect the airbag assembly connector at passenger’s side
Connect the driver and passenger pretensioning seat belt
5 connectors.
(Vehicle with pretensioning seat belt) Inspect again, and start from the
Connect the clock spring connector No
first step if the malfunction recurs.
Connect the central door lock controller connector;
Connect the seat belt alarm connector
Connect the PAB control switch connector;
Connect the battery negative pole wire
Place the ignition switch at ON position.
Does the airbag alarm lamp work properly?
Internal malfunction
Malfunction
Internal malfunction of SRS airbag system unit
code B1000
Warning
The inspection condition of this malfunction is that there is no possible past malfunction code before
Inspection
inspection by DTC. The incorrect operation for this malfunction inspection may lead personnel injury
conditions
or system damage, so preparation should be made before inspection.
Internal circuit malfunction of SRS airbag system ECU
Possible reason Internal malfunction of SRS airbag system unit
Operation
Replace the SRS airbag system unit. Refer to the “Disassembling and assembling of airbag system unit” under the “SRS
airbag system unit” section.
Power Supply
Malfunction
code Low power supply voltage of SRS airbag system ECU
B1327
Warning
The inspection conditions of this malfunction is that there is no possible past malfunction code before
Inspection inspection by DTC. The incorrect operation for this malfunction inspection may lead personnel injury or
condition system damage, so preparation should be made before inspection.
The voltage between the pins 12 and 23 of SRS airbag system unit connector is lower than 9V.
Possible Low battery power supply or malfunction of harness between the battery and SRS airbag system ECU.
reason
Step Inspection Operation
Inspect the battery Yes Turn to the next step.
1 Measure the battery voltage Low battery power supply; inspect the
Is the voltage above 9V? No
charge and discharge system
Inspect the harness between battery and fuse box.
Yes Turn to the next step.
Remove the fuse box without loosening the
connector
2
Measure the voltage between two relevant No Inspect the harness
terminals of fuse box to see if it is above 9V?
Malfunction
code Low power supply voltage of SRS airbag system ECU
B1327
Inspect the harness between fuse box and
connector of SRS airbag system unit
Warning:
Improper handling may deploy or tension
the airbag module or pretensioning seat belt
accidentally, which may lead serious personnel Yes Turn to the next step.
injury. Please read the airbag system maintenance
warnings carefully before operation. Refer to the
“Airbag system maintenance warnings” section.
Place the ignition switch at LOCK position.
Remove the steering column shell and loosen the
3
clock spring connector at least 1min after cutting
off the battery negative pole wire.
Remove the PAB trim cover and glove box
(passenger’s side airbag is under the trim cover).
Loosen the airbag module connector at passenger’
s side. No Replace the harness
Loosen all the connectors of SRS airbag system.
Install the battery negative pole wire and place the
ignition switch at ON position, then measure the
voltage between connector pin 12 and 23 (ground)
of SRS airbag system unit to see if it is above 9V.
Place the ignition switch at LOCK position. [Current malfunction code]
Loosen the battery negative pole terminal and hold Replace the SRS airbag system unit. Refer
on for at least 1min. to the “Disassembling and assembling of
Remove left inner trim board Yes airbag system unit” under the “SRS airbag
4 Cut off the connector of SRS airbag system unit system unit” section.
Install the battery negative pole wire and place [Historical malfunction code ]
the ignition switch at ON position, then measure The malfunction diagnosis is over.
the voltage between relevant pin and (ground) of
connector to see if it is above 9V. No Replace the harness
Driver’s Side Airbag Malfunction

Malfunction Driver’s side airbag malfunction (high resistance, low resistance, short-circuit or grounding etc.)
code
B0026
B0022
B0024
B0025
Warning
Improper handling may deploy or tension the airbag module or pretensioning seat belt accidentally,
which may lead serious personnel injury. Please read the airbag system maintenance warnings carefully
Inspection before operation. Refer to the “Airbag system maintenance warnings” section.
condition If there is driver’s side airbag
The resistance between the connector terminals of SRS airbag system unit is out of the required range.
Relevant harness breakage or short-circuit of driver airbag in SRS airbag system
Driver’s side airbag module malfunction
Internal malfunction of clock spring
Possible Connector malfunction of circuit between clock spring and SRS airbag system ECU
reason Broken circuit or short circuit of harness between the clock spring and SRS airbag system ECU
Improper insertion of connector of driver airbag generator
Inspect the clock spring Normal Turn to the next step.
Warning Replace the clock spring.
Improper handling of airbag system elements Refer to the “Disassembling and
may deploy the airbag module accidentally, which assembling of clock spring” under
may lead personnel injury. Please read the airbag the “Airbag system” section.
system maintenance warnings before operation.
1 Refer to the “Airbag system maintenance
warnings” section. Abnormal
Are all the relevant parts of clock spring normal?
(Is the relationship between pins normal? Is there
any short circuit or broken circuit) Replace the
clock spring if necessary.
code
B0026
B0022
B0024
B0025
Confirm whether the malfunction occurs on the Replace the driver's side airbag
airbag module at drive’s side or other parts. module.
Replace the DAB with a good one. Refer to the “Disassembling and
Yes
2 Install the battery negative pole wire assembling of drive’s side airbag
Place the ignition switch at ON position. module” under the “Airbag system”
Is malfunction code displayed or can it be cleared? section.
No Turn to the next step.
Inspect the clock spring harness connector Normal Turn to the next step.
Place the ignition switch at LOCK position.
Loosen the battery negative pole terminal and
3 hold on for at least 1min
Remove the steering column shell Abnormal Replace the harness
Loosen the clock spring connector
Is the clock spring connector normal?
Confirm whether the malfunction occurs on the Yes Turn to the next step.
clock spring at drive’s side or other parts. Replace the clock spring.
Set the special tools, fuel and temperature Refer to the “Disassembling and
4 inspection instrument at the position of 2 ohm. assembling of clock spring” under
Install the battery negative pole wire No the “Airbag system” section.
Is malfunction code displayed?
Inspect the harness between the clock spring and Replace the SRS airbag system unit.
SRS airbag system ECU Refer to the “Disassembling and
Place the ignition switch at LOCK position. Normal assembling of airbag system unit”
Loosen battery negative pole wire and hold on for under the “SRS airbag system unit”
at least 1min section.
Remove the PAB trim cover and glove box Replace the harness
(passenger’s side airbag is under the trim cover)
Loosen the airbag module connector at
5 passenger’s side
Loosen all the connectors of SRS airbag system.
Inspect the harness between connector terminals
Abnormal
of SRS airbag system unit and clock spring to see
if there is the following malfunction:
● Ground
● Short circuit to power supply
● Broken circuit
Are the harnesses above normal?
Inspect the clock spring connector Normal Turn to the next step.
Remove the steering column shell
6 Loosen the clock spring connector Abnormal Replace the harness or connector
Is the clock spring connector normal?
Inspect the clock spring Normal Turn to the next step.
Remove the clock spring
Replace the clock spring.
Refer to the “Disassembling and assembling of
Refer to the “Disassembling and
clock spring” under the “Airbag system” section..
7 assembling of clock spring” under
Inspect the clock spring Abnormal the “Airbag system” section..
Refer to the “Inspection of clock spring” under the
“Airbag system” section..
Is the clock spring normal?
code
B0026
B0022
B0024
B0025
Inspect the harness between the clock spring and Normal Turn to the next step.
SRS airbag system ECU. Replace the clock spring.
Place the ignition switch at LOCK position Refer to the “Disassembling and as-
Loosen battery negative pole wire and hold on for sembling of clock spring” under the
at least 1min “Airbag system” section..
Remove the PAB trim cover and glove box
(passenger’s side airbag is under the trim cover)
Loosen the passenger’s side airbag module
8 connector
Loosen all the connectors of SRS airbag system. Abnormal
Inspect the harness between connector terminals
of SRS airbag system unit and clock spring to see
if there is the following malfunction:
● Ground
● Broken circuit
Passenger’s Side Airbag Malfunction

Malfunction Airbag module malfunction at the passenger’s side (high resistance, low resistance, short circuit or
code grounding etc.)
B0017
B0016
B0018
B0019
Warning
Improper handling of airbag system elements may deploy or tension the airbag module and pretension-
ing seat belt accidentally, which may lead serious personnel injury. Please read the airbag system main-
tenance warnings carefully before operation.
Inspection Refer to the “Airbag system maintenance warnings” section.
condition If there is passenger’s side airbag
The resistance between the pins 17 and 18 of SRS airbag system unit connector is out of the required range.
Short circuit of harness between the pins 17 and 18 of SRS airbag system unit
Open circuit of harness between the pin 17 and 18 of SRS airbag system unit, if there is no passenger’s
side airbag.
Passenger’s side airbag malfunction
Malfunction of the connector between passenger’s side airbag module and SRS airbag system ECU
Possible Malfunction of the connector between SRS airbag system ECU and grounding point
reason Broken circuit or short circuit between passenger’s side airbag module and SRS airbag system ECU
Broken circuit or short circuit between SRS airbag system ECU and grounding point
SRS airbag system unit malfunction
Has the vehicle been equipped with a passenger’s side Yes Turn to the next step.
1 airbag module?
No Turn to the step 5.
Inspect the passenger’s side airbag module [Current malfunction code]
Warning Turn to the next step.
Normal
Improper handling of airbag system elements may Historical malfunction code
deploy the airbag module and pretensioning seat belt Turn to the next step.
accidentally, which may lead serious personnel injury.
Replace the harness
Please read the airbag system maintenance warnings
carefully before operation.
Refer to the "Airbag system maintenance warnings”
2
section.
Place the ignition switch at LOCK position
Loosen the battery negative pole terminal and hold on for Abnormal
at least 1min
Remove the PAB trim cover and glove box (passenger’s
side airbag is under the trim cover)
Loosen the airbag module connector at passenger’s side
Is the passenger’s side airbag module normal?
Malfunction Airbag module malfunction at the passenger’s side (high resistance, low resistance, short circuit or
code grounding etc.)
B0017
B0016
B0018
B0019
Confirm whether the malfunction occurs on the airbag Yes Turn to the next step.
module at passenger’s side or other parts.
Replace the passenger's side
Connect a good module with the terminal A and B of the
airbag module.
3 airbag module at passenger’s side
Refer to the “Disassembling
Connect the battery negative pole wire No
and assembling of passenger’s
Place the ignition switch at ON position
side airbag module” under the
Is the malfunction code displayed?
“Airbag system” section.
Inspect the harness between airbag module at the [Current malfunction code]
passenger’s side and SRS airbag system ECU Replace the SRS airbag sys-
Place the ignition switch at LOCK position tem unit. Refer to the “Disas-
Loosen the battery negative pole terminal and hold on for sembling and assembling of
at least 1min. airbag system unit” under the
Normal
Remove the steering column shell “SRS airbag system unit” sec-
Loosen the clock spring connector tion.
Loosen the airbag module connectors at driver and [Historical malfunction code ]
4 passenger’ side The malfunction diagnosis is
Loosen all the connectors of SRS airbag system. over.
Inspect the harness between connector terminals of SRS
Replace the relevant harness
airbag system unit and clock spring to see if there is the
following malfunction:
● Ground Abnormal
● Broken circuit
Malfunction of Pretensioning Force-limiting Seat Belt

Malfunction The circuit of the seat belt pretensioner of driver is open
code The resistance of the seat belt pretensioner of driver is too low
B0065 The circuit of the seat belt pretensioner of driver is short to the ground
B0066 The circuit of the seat belt pretensioner of driver is short to the power supply
B0058 The circuit of the seat belt pretensioner of passenger is open
B0059 The resistance of the seat belt pretensioner of passenger is too low
B0064 The circuit of the seat belt pretensioner of passenger is short to the ground
B0067 The circuit of the seat belt pretensioner of passenger is short to the power supply
B0057
B0060
Warning
Inspection
Refer to the “Airbag system maintenance warnings” section.
conditions
The resistances of pins 19, 20, 21 and 22 of the SRS airbag system unit connector don’t lie in the speci-
fied range.
A short circuit occurs in the harnesses among pins 19, 20, 21 and 22 of the SRS airbag system unit.
An open circuit occurs among the pins 19, 20, 21 and 22 of the SRS airbag system unit connector.
Malfunction of pretensioning force-limiting seat belt
Malfunction of the connector between the pretensioning force-limiting seat belt and the SRS airbag sys-
tem ECU
Possible Malfunction of the connector between the SRS airbag system unit and the grounding point
reason Broken circuit or short circuit between the pretensioning force-limiting seat belt and the SRS airbag sys-
tem ECU
Broken circuit or short circuit between the SRS airbag system unit and the grounding point
Malfunction of the SRS airbag system unit
Step Inspection Operate
Is the vehicle equipped with any pretensioning Yes Turn to the next step
1 force-limiting seat belt?
No To Step 5
Malfunction The circuit of the seat belt pretensioner of driver is open

code The resistance of the seat belt pretensioner of driver is too low
B0065 The circuit of the seat belt pretensioner of driver is short to the ground
B0066 The circuit of the seat belt pretensioner of driver is short to the power supply
B0058 The circuit of the seat belt pretensioner of passenger is open
B0059 The resistance of the seat belt pretensioner of passenger is too low
B0064 The circuit of the seat belt pretensioner of passenger is short to the ground
B0067 The circuit of the seat belt pretensioner of passenger is short to the power supply
B0057
B0060
Check the warnings for the connector of the [Current malfunction code]
pretensioning force-limiting seat belt. Turn to the next step
Normal
Improper handling of airbag system elements [Historical malfunction code]
may deploy or tension the airbag module and Turn to the next step
pretensioning seat belt accidentally, which may
lead serious personnel injury. Please read the
airbag system maintenance warnings carefully
before operation.
Refer to the “Airbag system maintenance
2
warnings” section.
Place the ignition switch at “LOCK” position.
Loosen the battery negative pole terminal and Abnormal Replace the harness
hold on for at least 1min.
Remove the protective board of pillar B.
Loosen the connector of the pretensioning
force-limiting seat belt
Is the connector of the pretensioning force-
limiting seat belt normal?
Confirm whether the malfunction: occurs on Normal Turn to the next step
the pretensioning force-limiting seat belt or
Replace the pretensioning force-limiting
3 other parts?
Abnormal seat belt.
Is the pretensioning force-limiting seat belt
normal?
Check the harnesses between the [Current malfunction code]
pretensioning force-limiting seat belt and the Replace the airbag system unit
SRS airbag system ECU Refer to the “Disassembling and assem-
Turn the ignition switch to “LOCK” Normal bling of airbag system unit” under the
Loosen the negative pole wire of the battery “SRS airbag system unit” section.
and wait for more than 1 minute [Historical malfunction code]
Remove the protective plate of the B column The malfunction diagnosis is over.
Loosen the connector of the pretensioning
Replace
force-limiting seat belt
the relevant harness
Loosen all the connectors of the SRS airbag
4 system unit
Check the connector terminals between
the SRS airbag system ECU and the circuit
between the connector terminals of the
pretensioning force-limiting seat belt Abnormal
Determine whether there is any situation in the
circuit as follows:
● Grounding
● Short to the power supply
● Broken circuit
Are these harnesses foresaid normal?
Malfunction of Seat Belt Alarm

Malfunction The seat belt warning circuit is short to the power supply
codes The seat belt warning circuit is short or open to the ground
B0883
B0882
Warning
Inspection
conditions
The voltage of pin 3 in the SRS airbag system unit connector is 12V
The voltage of pin 3 in the SRS airbag system unit connector is 0V or without voltage
Malfunction of SRS airbag system unit
Possible Malfunction of the connector between seat belt alarm and SRS airbag system ECU
reason Malfunction of the connector between SRS airbag system unit and grounding point
Broken circuit or short circuit between the seat belt alarm and the SRS airbag system ECU
Steps Inspection Operation item
Is the vehicle equipped with any seat belt Yes Turn to the next step
1 alarm?
No Turn to Step 5
Check the warning of the connector of the seat [Current malfunction code]
belt alarm. Turn to the next step
Normal
2 before operation.
warnings” section. Abnormal Replace the harness
wait for at least 1 min.
Loosen the seat belt alarm connector.
Is the seat belt alarm connector normal?
Confirm whether the malfunction: occurs on the Normal Turn to the next step
3 seat belt alarm or other parts?
Is the seat belt alarm normal? Abnormal Replace the seat belt alarm.
Check the harness between the seat belt alarm [Current malfunction code]
and the SRS airbag system ECU Replace the airbag system unit。
Place the ignition switch at “LOCK” position. Refer to the “Disassembling and as-
Loosen the battery negative pole terminal and Normal sembling of airbag system unit” under
wait for at least 1 min. the “SRS airbag system unit” section.
Loosen the seat belt alarm connector [Historical malfunction code]
Loosen all the connectors of the SRS airbag The malfunction diagnosis is over.
system unit
Check the connector terminals between
4 the SRS airbag system ECU and the circuit
between the seat belt alarm connector
terminals
Determine whether there are any situations in
Abnormal Replace the relevant harness
the circuit as follows:
● Grounding
● Broken circuit
Malfunction of Central Door Lock Controller

Malfunction The impact output circuit is short to the power supply
code The impact output circuit is short or open to the ground
B0049
B0048
Warning
Inspection
conditions
The voltage of pin 5 in the SRS airbag system unit connector is 12V
The voltage of pin 5 in the SRS airbag system unit connector is 0V or without voltage
Possible Malfunction of the connector between the central door lock controller and the SRS airbag system ECU
reason Malfunction of the connector between the SRS airbag system unit and the grounding point
Broken circuit or short circuit between the central door lock controller and the SRS airbag system ECU
Is the vehicle equipped with any central door Yes Turn to the next step
1
lock controller? No To Step 5
Check the warning of the connector of central [Current malfunction code]
door lock controller Turn to the next step
Normal
before operation.
2 Refer to the “Airbag system maintenance
warnings” section.
Place the ignition switch at “LOCK” position. Abnormal Replace the harness
wait for at lease 1 min.
Loosen the central door lock controller
connector
Is the central door lock controller connector
normal?
Confirm whether the malfunction occurs on the Normal Turn to the next step
central door lock controller connector or other
3
parts Abnormal Replace the central door lock controller
Is the central door lock controller normal?
Check the harness between the central door [Current malfunction codes]
lock controller and the SRS airbag system ECU Replace the airbag system unit.
Place the ignition switch at “LOCK” position. Refer to the “Disassembling and as-
Loosen the battery negative pole terminal and Normal sembling of airbag system unit” under
wait for at least 1 min。 the “SRS airbag system unit” section.
Loosen the central door lock controller connec- [Historical malfunction code]
tor The malfunction diagnosis is over.
Loosen all the connectors of the SRS airbag
system unit
4 Check the connector terminals between the
SRS airbag system ECU and the circuit be-
tween the central door lock controller connector
terminals
Determine whether there are any situations in Abnormal Replace the relevant harness
the circuit as follows:
● Grounding
● Broken circuit
Malfunction of PAB Switch

Malfunction Malfunction of PAB switch
codes Switch resistance setting error
B0090
B0091
Warning
Inspection ing seat belt accidentally, which may lead serious personnel injury. Please read the airbag system main-
conditions tenance warnings carefully before operation.
Check the switch resistance varies between 100 Ω and 400 Ω (“OFF” and “ON”)
Possible Malfunction of the connector between the PAB switch and the SRS airbag system ECU
reason Malfunction of the connector between the SRS airbag system unit and the grounding point
Broken circuit or short circuit between the PAB switch and the SRS airbag system ECU
Is there any PAB switch readily-equipped? Yes Turn to the next step
1
No To Step 5
Check the warning of the connector of the PAB [Current malfunction code]
switch Turn to the next step
Normal
2 before operation.
warnings” section. Abnormal Replace the harness
wait for at least 1 min.
Loosen the PAB switch connector
Is the PAB switch connector normal?
Confirm whether the malfunction occurs on the Normal Turn to the next step
3 PAB switch or other parts
Is the PAB switch normal? Abnormal Replace the PAB switch
Check the harness between the PAB switch [Current malfunction code]
and the SRS airbag system ECU Replace the airbag system unit.
Place the ignition switch at “LOCK” position. Refer to the “Disassembling and
Loosen the battery negative pole terminal and Normal assembling of airbag system unit” under
wait for at least 1 min. the “SRS airbag system unit” section.
Loosen the PAB switch connector [Historical malfunction code]
Loosen all the connectors of the SRS airbag The malfunction diagnosis is over.
system unit
4 Check the connector terminals between
the SRS airbag system ECU and the circuit
between the PAB switch connector terminals
Determine whether there are any situations in
the circuit as follows: Abnormal Replace the relevant harness
● Grounding
● Broken circuit
Malfunction of PAB Indication Lamp/ Malfunction of Seat Belt Indication Lamp

Malfunction The PAB indication lamp is short or open to the ground
codes The PAB indication lamp is short to the power supply
B0681 B0683 Malfunction of the passenger seat belt indication lamp
B059A Malfunction of the driver seat belt indication lamp
B0595
Warning
Inspection ing seat belt accidentally, which may lead serious personnel injury. Please read the airbag system main-
conditions tenance warnings carefully before operation.
The same as the inspection method to the trouble lamp of airbag system
Possible
The same as the malfunction occurring in the system trouble lamp
reason
Please refer to the inspection method to the system malfunction lamp.
Diagnosis to Vehicle Impact

Inspection and maintenance to the vehicle impact should be implemented in the following sequence,
whether the airbag is deployed or not:
Check the SRS-ECU diagnosis signal.
1. Connect (X-431diagnosis tester) the diagnosis connector.
2. Use (X-431diagnosis tester) to read the diagnosis report.
Maintenance sequence
1. When the airbag deploys,
The following spare parts should be replaced with new ones:
(a) Passenger’s side airbag module
(b) SRS-ECU
(c) Driver’s side airbag module
(d) Pretensioning seat belt
2. Check the following spare parts. Replace it with a new one if it is abnormal
(a) Clock spring
(b) Steering wheel, steering column, steering lower shaft subassembly
(c) Harness
(d) PAB switch
(e) Central door lock controller
(f) Warning device of seat belt
3. The installation status of the driver’s side airbag module with reference to the steering wheel
(a) Check to see whether there is any abnormal sound in the steering wheel, the steering wheel
moves soundly or the clearance is within the normal value.
(b) Check to see whether there is any damage to the harness connector or any deformation to the
terminal.
Note: Due to impact, when the battery supply is insufficient, the tester can’t communicate with
the SRS-ECU. Therefore it is necessary to check and maintain the instrument panel harness or
use the external power supply.
SRS-ECU
1. Check whether there is any pit, crack, deformation,
etc. on the SRS-ECU casing bracket.
2. Check whether there is any damage to the
connectors or any deformation to the terminals.
3. Check the installation status of the SRS-ECU bracket.
(a) Check whether there is any pit, crack, deformation,
etc. on the cover.
(b) Check whether there is any damage to the
connector, any deformation to the terminal or the
harness is seized.
(c) Check whether there is any pit, crack, deformation,
etc. on the gas generator casing.
(d) Check to ensure the direction of arrow is the same
as the front direction of the vehicle.
4. Check the installation status of the airbag module
Driver’s side
Driver’s side airbag module
Generator
Bracket
Clock spring
the horn 1. Check to see whether there is any damage to
driver module
the connector and the protective pipe or any
deformation to the terminal.
2. Check to see whether there is any deformation to
the casing.
Steering wheel, steering column, lower shaft

subassembly
1. Check the installation status of the driver’s side
airbag module.
2. Check to see whether there is any abnormal sound
on the steering wheel or the clearance is within the
normal value.
Passenger’s side airbag (PAB) Passenger’s side airbag module
1. Check the installation status of the passenger’s
side airbag module
2. Check to see whether there is any deformation to
the casing.
Inspection to harness connectors (instrument

panel harnesses)
Check to see whether the harnesses are installed
firmly, there is any damage to the connectors, or any
deformation to the terminals.
Warning Sign
The precautions for using and maintaining SRS airbags
are as shown in the figure. When maintaining, operate
as the documented situations by the label.
Steering wheel
Warning Sign
Clock spring
Warning Sign
SRS-ECU
SRS-ECU
Sun visor
Passenger’s side airbag module Passenger’s side airbag module
Warning label
Method for Removing Each Parts

Airbag ECU (SRS-ECU)
Note:
1. Remove the (-) negative pole of battery, and then wait for
60s before operation. Enlace the removed (-) negative
pole with adhesive tape for the sake of insulation.
2. As for SRS-ECU, no disassembling or repairing is
allowed. Please replace it with a new SRS-ECU in
case of any malfunction itself.
3. Do not get SRS-ECU impacted or vibrated. Be sure
to replace it with a new SRS-ECU in the event of
any pit, crack, deformation or other defects found.
4. Be sure to replace it with a new SRS-ECU in case
of any airbag deployment.
5. Take care and prevent yourself from touching
the SRS-ECU when removing or repairing the
peripheral parts of the SRS-ECU.
1. Operation before disassembling
(a) Set the ignition switch to “LOCK”.
(b) Remove the (-) negative pole of the battery
and put it in a proper position or enlace it with
adhesive tape
2. Sequence of removing
SRS-ECU (a) The cover plate at the central passage side (or
remove the auxiliary instrument panel)
(b) Remove the connector connected with the airbag
ECU
(c) Remove the SRS-ECU
3. Sequence of installing
(a) SRS-ECU; SRS-ECU;
(b) Install the connector connected with the airbag
ECU
(c) Connect the earth wire

(d) The cover plate at the central passage side (or
install the auxiliary instrument panel)
4. Essentials of installing
(a) Install the SRS-ECU
(b) Inspecting after installing
• Set the ignition switch to “ON”.
• The SRS warning lamp goes off after 4s from the
moment it is lighted
(c) the lamp doesn’t go off, do the malfunction
inspection and troubleshooting.
5. Inspection
(a) Check to see whether there is any pit, crack,
deformation, etc. on the SRS-ECU casing
(b) or whether there is any damage or deformation to
the connector.
Note:
Any incorrect installation of the SRS-ECU would
make the SRS airbag actuate improper.
Do replace it with a new SRS-ECU in the event of
any pit, crack or deformation found.
Besides the foresaid inspection to the SRS-ECU, refer
to the corresponding contents of troubleshooting.
Driver ’s side & passenger ’s side airbag

modules (DAB, PAB), clock spring
Note:
1. Remove the (-) negative pole of battery, and then
wait for 60s before operation. Enlace the removed
(-) negative pole with adhesive tape for the sake of
insulation.
2. As for the airbag module, no disassembling or
repairing is allowed. Please replace it with a new
one in case of any malfunction itself.
3. Pay high attention to the use of the airbag module
and the clock spring. Never drop them onto the
floor or get them immersed into the water or oil.
More still, replace them with new ones in case of
any pit, crack or deformation, etc. found.
4. The deployed airbag module should be placed in a
flat place, with its deployment surface upwards. No
other articles are allowed to be laid on it.
5. Never put the airbag module into the position with
a temperature of 93℃ above.
6. Replace the airbag module with a new one after
deploying it. At the same time, inspect the clock
spring and replace it with a new one, if it is
abnormal.
7. Do wear gloves and protective glasses when
operating the deployed airbag.
8. Do deploy the airbag and then discard it if you
want to discard an airbag that doesn’t deploy.
Note:
In removing, to avoid the static interference
which would trigger detonating by accident, do
remove the harness connectors of DAB and PAB
modules first, and then remove the other harness
connectors; do the installation inversely.
1. Disassembling and assembling
Driver’s side airbag module, passenger’s side airbag
module and clock spring
2. Operation before disassembling
(a) Fetch out the key of the ignition switch with the
steering wheel and the front wheels in a status of
straightforward direction.
(b) Disconnect the (-) negative pole of the battery.
3. Sequence for removing the driver’s side airbag
module
(a) Loosen the screws at both sides;
(b) Disconnect the harness connector;

(c) Remove the airbag module components;
(d) Remove the steering wheel;
4. Sequence for removing the passenger’s side airbag
module (PAB)
(a) Remove all the covers and the glove boxes of
instrument panel; separate the airbag harness
connector of PAB module from the connector at
the PAB side of the airbag harness.
(b) Remove the M6 bolts to separate the PAB module
from the stiffening beam of instrument panel.
(c) Remove the instrument panel body
(d) Remove the four M5 bolts at both sides of PAB
module.
5. Sequence for removing the clock spring
(a) Remove the DAB module (disconnect the
connector)
(b) Remove the steering wheel slowly and gently (see
the precautions)
(c) Open the upper cover of combination switch, find
and disconnect the harness connector at the lower
end.
(d) Remove the clock spring in the combination
switch.
6. D r i v e r ’s s i d e a i r b a g m o d u l e ( D A B ) a n d i t s
installation sequence
(a) Inspection before installing
• Steering wheel
• Connecting harness
• Driver’s side airbag module
• Screw down the mounting screws at both sides.
(b) Connecting of the (-) terminal of the battery
(c) Inspection after installation
7. Passenger’s side airbag module (PAB) and its
installation sequence
• Take up the PAB module gently, align the four M5
bolts of trim cover bracket with the mounting holes at
both sides of the module, and then plug them in.
• Well assemble the module, trim cover bracket and
the mounting bracket of instrument panel with four
M5 nuts
• After installing the entire instrument panel onto
the vehicle body, fasten the PAB module onto the
cross beam at the glove box of vehicle body with
two M6 bolts with gaskets.
• Well fit the airbag harness connector of the PAB
module and the connector at the PAB side of the
airbag harness. Now the PAB module is installed
completely.
(b) Connecting of the (-) terminal of the battery
8. Sequence for installing the clock spring
• Fit the wire at the upper end of clock spring
through the hole at the steering wheel body.
• Fix the connection between the clock spring and
the steering wheel
• Install the upper cover of combination switch
• Install the steering wheel
• Steering wheel and airbag module components
(b) Connect the (-) terminal of the battery
Use a hexagon Removing of steering wheel

socket sleeve (a) Remove the mounting screw from the center and
take out the steering wheel
Note:
Due to the tight meshing between the spline and
the steering column, it is difficult to separate it
from the steering column. So, it is recommended
to fasten the screw on the steering column by
several circles and then pull up the steering wheel,
rather than forcedly removing the steering wheel
(Because the steering wheel is connected with the
clock spring at the lower side, forced removal may
damage the clock spring).
Note
Diagnose the circuit of airbag module with
electronic measuring instrument instead of
decomposing it.
Get the removed driver’s side airbag module with
its bottom upwards and put it in a clean and dry
place for safekeeping.
Put the removed clock spring in a clean and dry
place for safekeeping.
9. Installing operation essentials
• Inspect the new airbag or the clock spring before
installing them.
Note:
Deploy the airbag as the specified sequence and
then discard it when discarding an airbag module.
• Connect the (-) negative pole of the battery

• Connect the K-431 diagnosis tester to the diagnosis
interface (16-pin)
Note:
Set the ignition switch to “LOCK” when connecting
or disconnecting the K-431 diagnosis tester.

• Read the circuit diagnosis results to see whether
the other parts of the airbag module except the
ones of malfunction are in normal condition.
• Set the ignition switch to “LOCK”
• Enlace the removed (-) negative pole with the
adhesive tape for the sake of insulation.
Note:
Disconnect the (-) negative pole of battery and
operate after 60s.
Get the clock spring aligned and then install it onto
the steering wheel.
(b) Get the center of the clock spring aligned: refer to
the description in the label on the clock spring.
Note:
In case of failure to get the center of the clock
spring aligned, you would be unable to turn the
steering wheel on the road or the clock spring
circuit may get poor performance, thus impairing
the normal working of the SRS airbag.
Do take out the positioning clip after replacing the
used clock spring with a new one, or the clock
spring will be damaged.
(c) Installing of the steering wheel and airbag module
subassembly
• Install the steering wheel and airbag module
subassembly after getting the center of the clock
spring aligned.
Note:　
Don’t clamp the clock spring harnesses when
installing the steering wheel and airbag module
subassembly.
• After installing, turn the steering wheel leftwards
and rightwards as properly as possible to see
whether there is any abnormality.
(d) Inspection after installing
• Turn the steering wheel leftwards and rightwards
gently to see whether there is any abnormality or
noise. (Driver’s side airbag module, clock spring)
Malfunction warning • The SRS warning lamp goes off after it is on for 4s.
lamp of airbag
module system • Conduct troubleshooting if it goes off and then
persists to go on (or persists to go off, persists to
go on) after it is on for 4s
10. Inspection
(a) Inspection to the driver’s side airbag module
Inspect the following items. Replace the used airbag
module components with the new and corresponding
ones in case of any badness found.
Deploy the used components as the specified
sequence and then discard them.
Note:
Never measure the circuit resistance of the airbag
module (detonator) with a meter, even the specified
measuring instrument.
When measuring the resistance with a tester ,
owing to the current flowing in the detonator, the
airbag sometimes will be deployed mistakenly by
static electricity, thus causing a severe damaging
accident.
• Whether there is any pit, crack or deformation on

the cover.
• Whether there is any damage to the harness
connectors or any deformation of the terminals.
• Whether there is any pit, crack or deformation on
the casing of gas generator.
• The installation status of the airbag module
Note:
Please change the used airbag module with a new
one in case of any pit, crack, deformation, etc.
spotted. Do discard the used one after deploying it.
(b) Inspection to clock spring

Inspect the following items. Replace the used clock
spring with the new and corresponding ones in case of
Casing any badness found.
• Whether there is any damage to the connectors
and protective pipes and there is any deformation
3 to the terminals.
• Whether there is any damage to the casing.
Protective pipe • Check to see whether the circuit is normal
2
between the upper connector terminal of the clock
spring and the lower counterpart.
• Insert a fine probe from the backside of the 3#
connector of the clock spring.
Note:
Don’t insert the probe directly from the underside
of the connector.
• As shown in the figure, insert the fine probe into
the current tester to check the conduction between
the terminals.
Essentials of discarding airbag modules

When discarding the airbag modules or the vehicles
equipped with the SRS airbags, at first, deploy the airbags
in the following sequence and then do the next operation.
Discarding before deployment of airbags
Note:
Deploy the airbag at first before discarding it.
When replacing the airbag, please deploy it outside
the vehicle.
There will be smoke when deploying the airbag. So,
please do it near a smoke detector.
There will be loud sound when deploying the
airbag. So, please remind nearby persons of
jamming their ears. Avoid doing it in the resident
area as possible as you can.
Remove the positive and negative poles of
battery and remove the battery from the vehicle
Note:
Operate till 60s later after removing the positive
and negative poles of battery.
Deploy the airbag in the following sequence
1. Driver’s side airbag module
(a) Remove the locking lever of column
(b) Remove the 2# connector of the clock spring and
the harness connectors of instrument panel (yellow).
Casing
Note:
Take off the connector of clock spring from the
instrument panel harness and the clock spring will
3 be involved with short circuit itself, thus preventing
the fatal accident due to static electricity in the
Protective pipe deployment of the driver’s side airbag module.
2
(c) Connect the switchover harness of SRS airbag

Short circuit position
to two 6m above long harnesses for deployment.
Harness for deployment Enlace the connecting position with insulating tape
for insulating.
SRS switchover 6m above long Connect other ends of the harnesses for deployment
harness with each other (to form a short circuit) to prevent any
mistaken deployment caused by static electricity.
(d) Lead the switchover harness for connecting SRS

Clock spring airbag from the 2# connector of clock spring
Clock spring outside the vehicle.
connector
SRS switchover
harness
Harness for
deployment
(e) Close all the windows and doors, and apply the
vehicle covering to damp the noise,
Note:
The glass is fragile if there is some crack in it. So
the vehicle covering must be applied.
(f) Disconnect the harness for deployment of the

driver’s side airbag module in a place far away
Vehicle covering from the vehicle, connect the two terminals of the
battery removed from the vehicle and then get it
deployed.
Note:
Harness for At first, confirm whether there is any person in and
deployment
near the vehicle. If not, do the further operation.
The gas generator is of high temperature after the
driver’s side airbag gets deployed. Put it for more
than 30min. Use it only after it becomes cool
Consult with the local authorized service station of
Great Wall Motor Company Limited if the driver’s
side airbag module is unable to be deployed.
(g) Discard the deployed driver’s side airbag module
in accordance with the relevant essentials.
2. Deployment outside the vehicle
Note:
Deploy the airbag in a vast and plain place more
than 6m away from the barrier or people
Avoid the strong wind when deploying the airbag

module in open air. Ignite windward if it is breezy.
(a) Disconnect the (-) negative pole and the (-)
positive pole of battery and remove them from the
battery
Note:
Operate 60s later after removing the battery.
(b) Deploy the airbag module in the following
sequence
• Driver’s side airbag module
• Remove the driver’s side airbag module from the
vehicle
Note:
The both ends of the terminal will be involved with
short circuit automatically when the connector of
the driver’s side airbag module is disconnected,
thus avoiding any mistaken deployment caused
by static electricity. Get the deployment surface
upwards and put it in a flat place with no other
articles laid on it if any mistaken deployment
occurs.
• Prepare two 6m above long harnesses for
Harness for deployment deployment and connect the other ends of them
Short circuit position with each other (to form a short circuit) to avoid any
deployment due to static electricity.
6m above long
• Touch the vehicle body to eliminate all the static

electricity.
Note:
Operating in the foresaid sequence can avoid any
mistaken deployment caused by static electricity.
Do perform it strictly.
Driver’s side Harness for deployment • Disconnect the harness of driver’s side airbag
airbag module module and then connect it with the foresaid two
harnesses for deployment. Enlace the connecting
position with the insulating tape for the sake of
Short insulating.
circuit
position
Insulating tape
• Apply the unused bolts into the bolt holes at the

inner side of the driver’s side airbag module. Tie
the thick metal wire for fixing purpose to the hub.
• Get the harnesses for deployment connected

with the driver’s side airbag module through the
used tyre with hub. Fasten the driver’s side airbag
module upwards with the metal wire connected to
Harness for the bolt.
deployment
• Put three used tyres without hub onto the tyre fixing
the driver’s side airbag module.
Used tyre without hub
Harness for deployment
• Disconnect the connection of the harnesses for

deployment of the driver’s side airbag module at
a place far away from the vehicle. Connect the
harnesses with the two terminals of the battery
removed from the vehicle and get the airbag
module deployed.
Note:
Harness for deployment Deploy the airbag module after ensuring there is
nobody nearby.
The gas generator is in a status of high temperature
after the driver’s side airbag gets deployed. Put it
for more than 30min. Use it only after it becomes
cool.
• Discard the deployed driver’s side airbag module in

accordance with the essentials of discarding.
Body Electrical Appliance (TK)-1
Body Electrical Appliance (TK)
Schematic Diagram of Front and Rear Fog Lamp System ......... 2

Schematic Diagram of Reversing Radar System ........................ 3
Front Fog Lamp Assembly ............................................................ 4
Rear Fog Lamp Assembly ............................................................. 4
Reversing Radar ............................................................................. 5
Blue/White
Blue/Red
Schematic Diagram of Front and Rear Fog Lamp System
Left front fog lamp Right front fog lamp Right rear fog lamp Left rear fog lamp
DJ7022-2.2-20
Red/Blue
Green/
A
0.85
G/Y
Yellow
D
0.85
Right rear fog lamp
B
Left rear fog lamp
Logic control
Red Red/Pink
DJ7022-2.2-20
circuit
B
0.85
G/Y
E
0.85
B
Rear fog lamp relay
Green/
Pink
DJ7021-1.8-11
Red/Blue Front fog lamp indicator lamp
Front fog lamp relay Close Open Right front fog lamp
Green/ Rear fog lamp switch Left front fog lamp

Red Orange
Red/Blue Red/Yellow
DJ7021-1.8-11
Red/Blue
Close Open
Schematic Diagram of Reversing Radar System
Display signal
Display power supply

Reversing lamp
Speaker
relay circuit
Red
Brown/
Black
Brown/
White
Green/
Reversing radar
ECU
Brown
Green/
Brown
Green/
Blue
Green/
Red
Ye l l o w /
Black
Yellow/
Left side Left middle Right middle Right side
Connecting ECU Connecting the horn
H：AMP 1-967642-1 H：AMP 1-967642-1 H：AMP 1-967642-1 H：AMP 1-967642-1

T：AMP 962885-1 T：AMP 962885-1 T：AMP 962885-1 T：AMP 962885-1
W：HWS-0157-8-140 W：HWS-0157-8-140 W：HWS-0157-8-140 W：HWS-0157-8-140
left-side probe middle-left-side probe middle-right- right-side probe
side probe
Front Fog Lamp Assembly

Note: The front fog lamps are white, 55w, with one on
the left, one on the right.
Replacement
1. Detach the negative wire connector of the storage
battery.
2. Remove the front bumper, detach the front fog
lamp wire connector.
3. Screw off the 3 fixed nuts and the washer of the

front fog lamp, and remove the front fog lamp from
Q32006 the front bumper.
Q40206
4. Remove the front fog lamp bulb

(a) Revolve anticlockwise the seal cover of the lamp
body.
(b) Pull off the plug.
(c) Press the circlip fixing the bulb, and remove the
bulb.
5. Install the front fog lamp assembly
Installation is in the reverse order of removal.
Rear Fog Lamp Assembly

Note: The rear flog lamps are red, 21W, with one on
the left, one on the right.
Replacement
1. Detach the negative wire connector of the storage
battery.
2. Remove the rear bumper, detach the rear fog lamp
wire connector.
3. Screw off the 3 fixing screws of the rear fog

Q2714819FD
lamp, and remove the rear fog lamp from the rear
bumper.
4. Remove the rear fog lamp bulb

(a) Revolve anticlockwise the bulb of the rear fog
lamp.
(b) Press the bulb and revolve anticlockwise, then
remove the bulb from the bulb holder.
5. Install the rear fog lamp assembly
Installation is in the reverse order of removal.
Reversing Radar
System Functions
The reversing radar system consists of several sensors and a group of microcomputer controllers
and buzzers, and the principle is that the ultrasonic signals are applied, directed and controlled by the
microcomputer and the distance to the detected object is calculated through comparing the returning
time in course of the signal sending and receiving of the sensor, and then different warning sounds
will be given out by the alarm buzzer.
Test and Adjustment
The power supply cable of this device is connected with the reversing lamp wire. Once shifted to
reversing gear, the system starts immediately and enters into the detection working state.
There shall be an opening sound of ”beep” indicating that the system works normally.
The system sensitivity has been pre-adjusted to the optimum condition, and typically no need to be
readjusted while installing.
System Overview Diagram
Main Unit Connector Definitions
SA-16AWDL SA/16AWD Connector Arrangement
Pin Arrangement Remarks
1 +12V Main Unit power supply cable
2 Buzzer- Reserved alarm signal wire
3 DISPLAY Reserved display signal wire
4 +8V Probe power supply cable
5 L(sensor)
6 CR(sensor)
Probe signal wire (four probes)
7 CL(sensor)
8 R(sensor)
9 10 11 NC
Empty
12 13 NC
14 +5V Reserved display power supply cable
15 Buzzer+ Reserved alarm power supply cable
16 GND Main unit power supply grounding wire
Note: The main unit power supply and the sensors
share the same grounding wire.
Arrangement of sensor connector
Sensor signal
Negative pole of Positive pole of

power supply power supply
Detecting area
The system is a supplemental reversing system, and shall not be totally depended on. It can only
detect all the obstacles within the minimum area, but will not react to those beyond its limit.
The area that the rear detecting area must cover includes: The car width with 20cm added on each side.
The area that the rear detecting area may cover includes: The car width with 30cm added on each side.
When an obstacle comes near to some side area, it is able to give indications within 40cm away from
behind the car.
This system will be activated within one second when shifted to reversing gear, with a sound of “beep”
indicating that the system operates normally.
This system is supported by a 12v (refers to the positive pole) power supply system. If the power
supply of the reversing lamp is cut off, the system enters into the closed state.
When the distance of the obstacle detected is <25cm in the side -rear area, and/or <40cm in the
middle, the sound signal will become continuous lest the obstacle hits the bumper.
Working state of reversing radar
The system shall have three different states:
Activated state: when the vehicle is shifted to reversing gear as the engine running or the ignition
switch placed at working gear, the system enters into the activated state, and sends a signal indicating
its working status.
Closed state: when the vehicle is shifted off the reversing gear and the ignition switch is away from
the working gear (whether at the reversing gear or not), the system changes to the closed state.
Error state: When the system has been activated but has not sent the sound signal, the system is
in the error state. After the elimination of the error, it needs to shift again to reversing gear, thus the
system will return to the activated state.
While the vehicle is shifted to reversing gear and kept at that gear as the engine running, the system
enters into the activated state.
In this state, should the car be approaching or leaving the obstacle, or kept still, the system will make
an indication to the driver.
The system may be interfered by a same system or a similar one from other vendors quipped on a car
nearby (which system has been activated), but will still work normally.
If the relative moving speed between the obstacle and the vehicle is less than 1m/s, the system shall
work normally.
The system is only a driving aid apparatus, and the drivers shall be responsible for all safety issues.
While reversing too fast, the detecting precision of the reversing radar system decreases. Slow speed
is suggested: 6km/h.
When the warning sound lasts long, stop the car, for there is an obstacle within 40cm.
Sensors have a high precision, and are hard to back to normal if dismantled by yourself.
Specifications:
Detecting distance to 1.5m
Precision of detecting distance ±5cm
Optimal detecting range An area within 0.9m around
Supersonic frequency 48KHz±2KHz
Detecting range of sensors Horizontal angle ≈120° Vertical angle ≈60°
Working voltage DC9V~16V
Range of working temperature -30℃~80℃
Sound 100~115dB/10CM/12VDC
Note
For differences in object location, angle, size and
reflective material, the reflected signal may not
be received. Besides, the signal rejected from a
complicated environment may be wrong. Please pay
attention to following examples.
1. The driver can not receive any warning indication
from the reversing image ///even can not see the
minor objects from the side mirror
2. B and C will be detected sooner or later, but A will

never be detected.
3. A is first detected, however, when the car reverses

to the limit distance, the radar indicates the
distance of B.
It may misjudge the nearest distance which shown as
the distance from B but not A. It only happens when
the nearest obstacle enters into the blind area.
4. A glass wall or other smooth surface which is

almost vertical to the car may not be detected.
5. When approaching a smooth slope, it may not be

detected.
6. A small smooth column pole may not be detected.

7. When hard raining, the raindrops form a rain

screen, and then become an obstacle to the radar
sensors, which may give sound indication when
detected the obstacle.
8. Foreign stuff (chewing gum, mud etc.) on the

detecting surface of the sensors will lead the
sensors to alarm for a detection of foreign objects.
Get rid of that stuff, and the system recovers to
operate normally.
9. In thunderstorms, when driving reversely, the radar

Thunderstorm sensors may give wrong indications as interfered
by the strong wave interference from the thunder.
The system recovers to operate normally after the
thunderstorms.
10. The systems will interfere with each other as the

two cars put back-to-back within 4m and with
the reversing radars started simultaneously. The
When the distance ≈4m buzzer makes sounds occasionally, which will not
influence the detection of normal obstacles.
11. The systems will interfere with each other as

the two cars put parallelly aside each other
within 2m and with the reversing radars started
s i m u l t a n e o u s l y. T h e b u z z e r m a k e s s o u n d s
occasionally, which will not influence the detection
≈2m
of the normal obstacles.

12. The sensors may not detect such obstacles as the

steel wire with minor diameter shown in the left
picture,
13. When driving reversely by shifting to reversing

gear on an undulating bumpy road or a complicated
gravel road, the system may occasionally give
sound indications as detecting the obstacles on
the ground.
Road
surface
14. Radars measure distance by sending and receiving

wave, which is radar's operating principle. Thus,
radars may not detect such obstacles such as
sponge that with a strong sound deadening effect
or other similar obstacles.
15. In daily road traffic, there will be different ultrasonic

sources, such as the air compressor, construction
machinery, vehicles with reversing radars on
simultaneously, which may slightly influence the
reversing radar’s function or even make it loss the
function temporarily.
When interfered, the system may buzz occasionally,
which has no influence to its normal operation.
16. Detection range: 0~1.5m, it takes some time for the

driver to respond to the alarm heard and then step
on the brake pedal and the car stops due to inertia.
Low speed is suggested when reversing. ≤1m/s
Slow
17. Sensors have a high precision, and are hard to

back to normal if dismantled by yourself.
18. As the sensors are of high precision, the detecting

distance of the sensors may increase or decrease
in response to the temperature changes of its
interior electronics and mechanical components.
However, this will not influence the normal
operation of the system.
Troubleshooting
Malfunction
Malfunction Causes Solution
Phenomenon
1. Check whether the storage battery
1. No power supply or insufficient voltage of the has a normal voltage and whether
After shifted to
power supply the wiring for getting power from
reversing gear, the
2. Poor connection among various connecting wire the vehicle is correct.
reversing radar
3. While reversing, no obstacle has been detected. 2. Check whether all the connecting
system fails to react.
4. The control unit doesn’t work. wire is properly inserted.
3. Replace the controller.
After shifted to re-
versing gear, and
with systematic 1. Incorrect plug-in position of the socket which
1. Reconnect all the sockets correctly.
power supplied, the results in the sensor malfunction.
system still can not
work normally.
1. Wrong installation of the sensor or falling-off of the
sensor connector pair. 1. Please check it periodically.
2. The sensor has been damaged. 2. Timely replace the damaged sen-
versing gear, the
3. The system may detect an obstacle on the ground sor.
buzzer makes a
when driving on an uneven road. 3. Remove the foreign materials on
long sound.
4. Mud, ice, chewing gum or other obstacles stuck on the detection surface of the sensor.
the sensor.
1. Check whether the storage battery
has a normal voltage.
2. Turn off the system, correctly con-
1. Abnormal voltage of the storage battery.
nect all the sockets again.
2. Incorrect location of the socket.
After shifted to re- 3. Check whether the connecting
3. When the interfering wave from an audio inter-
versing gear, the wire of sensors contacts with such
ference source received by the radar, the buzzer
buzzer is not able to audio interference source as the
makes an incorrect warning.
make correct warn- exhaust pipe, silencer and etc.
4. Too fast when reporting on reverse.
ing. 4. Low speed is suggested when re-
5. There are other vehicles reversing nearby with the
versing (≤6 km/h).
reversing radar on.
5. The buzzer return to normal alarm
after the leaving of the other ve-
hicle.
1. The buzzer makes one sound as the opening indi-
cation, which means the system works normally.
2. The buzzer makes two sounds indicating that one 1. Check whether the connectors are
versing gear, the
sensor does not work. correctly inserted, or whether any
buzzer makes differ-
3. The buzzer makes three sounds indicating that two of the connector pairs fall off.
ent times of sound
sensors do not work. 2. Replace the corresponding number
indications when
4. The buzzer makes four sounds indicating that of sensors according to the num-
there is no obsta-
three sensors do not work. ber of times the buzzer sounds.
cles in the rear.
5. The buzzer makes five sounds indicating that four
sensors do not work.
Electric Appliance-1
Electric Appliance
Illumination ..................................................................................... 2
Central Control Door Lock System ............................................... 12
Power Regulator ............................................................................. 15
Electric Horn System ..................................................................... 16
Combination instrument ................................................................ 17
Combined Switch ........................................................................... 20
Ignition Switch ................................................................................ 21
Wiper and Washer System ............................................................ 22
Automatic Windshield Wiper System ........................................... 32
Automatic lighting system............................................................. 38
Electric Levelling Headlamp System ............................................ 43
Front & Rear Fog Lamps System .................................................. 45
Power Window ................................................................................ 46
CD Player......................................................................................... 49
Reversing Radar ............................................................................. 51
Reversing Camera System ............................................................ 55
DVD Player ...................................................................................... 57
On-board Navigation GPS ............................................................. 62
Engine Anti-theft System ............................................................... 65
Illumination
Precautions
1. Precautions for Replacement of Headlamp Bulb
(a) If the surface of the halogen bulb (headlamp) is with oil, the heat generated from using the bulb
will reduce the service life of bulb.
(b) Be careful in operating the halogen bulb (headlamp) for its high internal pressure. It may burst if
the bulb drops.
(c) Do not try to touch the lens with fingers when replacing the bulb for this may lead to smudge or
damping. Do prepare the bulb required for replacement.
(d) Do replace the bulb with the same wattage.
(e) Prevent the lens from being stained with water fog or water.
(f) Refasten the bulb holder after replacing the bulb to prevent the lens from being stained with
water fog or water.
Malfunction Phenomenon List

Tips:
The suspected parts are organized in numeral order for defining the malfunction causes in this
list. Check, repair and replace the spare parts in accordance with the following listed procedures if
necessary.
1. Headlamp and Rear Position Lamp
Malfunction Phenomenon Suspected Parts Reference Page
1. Bulb -
“Lower beam lamp” off (One side)
2. Harness -
1. Lower beam lamp fuse -
2. Lower beam lamp relay -
“Lower beam lamp” off (All) 3. Left combination switch assembly -
4. Bulb -
5. Harness -
1. Bulb -
”Upper beam lamp” off (One side)
2. Harness -
1. Upper beam lamp fuse -
2. Upper beam lamp relay -
”Upper beam lamp” off (All) 3. Left combination switch assembly -
4. Bulb -
5. Harness -
1. Fuse -
“Flash lamp” off (All) 2. Left combination switch assembly -
3. Harness -
1. Bulb -
Dark headlamp light
2. Harness -
1. Bulb -
Only one rear position lamp on
2. Harness -
1. Bulb -
Both rear position lamps off (Headlamp normal)
2. Harness -
1. Position lamp fuse -
2. Position lamp relay -
Both rear position lamps off (Headlamp off) 3. Left combination switch assembly -
4. Bulb -
5. Harness -
2. Fog Lamp

1. Fog lamp fuse -
2. Fog lamp relay -
All fog lamps off 3. Fog lamp switch assembly -
4. Bulb -
5. Harness -
1. Fog lamp switch assembly -
Fog lamp on continually
2. Harness -
1. Bulb -
Fog lamp off (One side)
2. Harness -
3. Turn Signal Lamp and Hazard Warning System

1. Hazard warning lamp fuse -
2. Turn signal lamp fuse -
“Hazard warning lamp” and “Turn signal lamp” off
3. Flash relay -
4. Harness -
1. Hazard warning lamp fuse -
Hazard warning lamp off (Turn signal lamp normal)
2. Harness -
1. Turn signal lamp switch -
Turn signal lamp off ( Hazard warning lamp normal)
2. Harness -
1. Turn signal lamp switch -
2. Flash relay -
Turn signal lamp on one direction off
3. Bulb -
4. Harness -
1. Bulb -
Only one lamp on
2. Harness -
4. Brake Lamp System

1. Brake lamp fuse -
Both brake lamps off 2. Brake lamp switch assembly -Electric appliance-5
3. Harness -
1. Brake lamp switch assembly -Electric appliance-5
Brake lamp on continually
2. Harness -
1. Bulb -
Brake lamp off (One side)
2. Harness -
5. Reversing Lamp System

1. Bulb -
2. Fuse -
Reversing lamp off
3. Reversing lamp switch assembly -
4. Harness -
1. Reversing lamp switch assembly -
Reversing lamp on continually
2. Harness -
6. Ceiling Lamp System

1. Bulb -
Ceiling lamp off 2. Fuse -
3. Harness -
1. Bulb -
Reading lamp off 2. Fuse -
3. Harness -
Ceiling lamp and reading lamp off (All) 1. Fuse -
Check:
1. Upper Beam Lamp Relay
(a) Remove the headlamp relay from the relay box.
3 3
5 (b) Check the on-state between the terminals of the
5 relay.
1 2 (c) Measure the resistance in accordance with the
2 1
valve in the following list.
Standard:
Detector
Specified State
Connection
3-5 10 kΩ or more
Less than 1Ω
3-5 (When applying battery voltage between
the terminal 1 and terminal 2)
Replace the relay if necessary.
2. Lower Beam Lamp Relay (The checking and
judging procedures are the same as those of the
upper beam lamp relay.)
3. Hazard Warning Lamp Switch

(a) Separate the negative (-) wire connector of the
battery.
(b) Separate the wire connector of the hazard warning
lamp switch, and remove the hazard warning lamp
switch.
(c) Check the on-state between the terminals with an
ohmer. The definition for on-state: the resistance
Rear View of Hazard Warning Lamp of the two pins is less than 1 Ω.
On/Off State State Description
Off Pin 1 to pin 3 on, pin 7 and pin 8 on
Pin 1 to pin 3 on, pin 4, pin 5 and
On
pin 6 on, pin 2 to pin 7 on
Press Note: Press down and the switch will under

turned- on state.
4. Press
(a) Remove the flash relay from the relay box.
(b) Connect the positive (+) and negative (-) poles of
the battery to terminal 2 and terminal 3 of the flash
relay respectively.
(c) Connect the turn signal lamp between terminal
1 and terminal 2 of the flash relay, and check
the working status of the flash relay. Judging
standard: normally, the flicker frequency of the
turn signal lamp is 60~120 times per minute. If
one of the front turn signal lamps is broken, the
flicker frequency will come up to more than 120
times per minute. Replace the flash relay if the
Unscrew Push in 2 1
flicker frequency exceeds the normal valve when
the turn signal lamp is in good condition.
5. Brake Lamp Switch
(a) Check the on-state of the brake lamp switch
assembly.
(b) Measure the resistance in accordance with the
Standard:
On/Off Operation Detector Connection Specified State

ON
Push in the switch pin
1-2 10 kΩ or more
OFF (Release the pedal)
Release the switch pin
1-2 Less than 1Ω
(Step on the pedal)
Replace the switch if necessary.

6. Door Lamp Control Switch
(a) Check the on-state of the door lamp control switch
assembly.
Standard:
ON Body grounding Less than 1Ω
OFF Body grounding 10 kΩ or more

7. Ceiling Lamp Assembly
(a) Check the on-state of the ceiling lamp assembly.
Standard:
ON 1-2 Less than 1Ω
DOOR 1-2 Less than 1Ω
OFF 1-2 10 kΩ or more

Combination Headlamp Assembly
Replacement
1. Separate the negative (-) wire connector of the battery.
2. Unscrew the three fixing bolts of the combination

headlamp, separate the wire connector of
the combination headlamp, and remove the
combination headlamp assembly.
3. Remove the upper/lower beam lamp bulb.
(a) Anti-clockwise rotate the seal cover (see note 2 in
the figure).
(b) Pull out the plug.
bulb.
4. Remove the auxiliary upper beam bulb.
(a) Anti-clockwise rotate the seal cover (see note 3 in
the figure).
On (c) Press the circlip fixing the bulb, and remove the
Off
bulb.
On 5. Remove the front position lamp bulb.
Off (a) Pull out the seal rubber plug of the front position
lamp (see note 4 in the figure).
(b) Take off the bulb from the bulb holder.
6. Remove the front turn signal lamp bulb.
Front turn signal lamp bulb
a) Anti-clockwise rotate the front turn signal lamp
Front position
bulb (see note 1 in the figure).
lamp bulb (b) Press and anti-clockwise rotate the bulb, and take
off the bulb from the bulb holder.
7. Install the combination headlamp assembly.
The installation order is reverse to that for removal.
Upper/lower
beam lamp bulb
Auxiliary upper beam lamp bulb
Adjustment
Adjustment of the headlamp: adjust the adjusting
bolt of the headlamp to adjust the lighting point of
headlamp.
Upper beam lamp Adjustment Description:
1. A is the up and down adjusting screw hole of the
Reflector
upper beam lamp. Clockwise rotate the upper beam
universal Reflector
joint universal joint
with a crosshead screwdriver until the upper beam
is downward, or vice versa.
Upper/lower
beam lamp 2. B is the left and right adjusting screw hole of the
upper beam lamp. Clockwise rotate the upper beam
with a crosshead screwdriver until the upper beam
is leftward, or vice versa.
3. C is the up and down adjusting screw hole of the
upper/lower beam lamp. Clockwise rotate the upper
beam with a crosshead screwdriver until the upper
beam is upward, or vice versa.
4. D is the left and right adjusting screw hole of the
upper/lower beam lamp. Clockwise rotate the upper
beam with a crosshead screwdriver until the upper
beam is rightward, or vice versa.
The procedures for adjusting the lower beam are as

Central line
follow:
Vertical center line Vertical center line
of left headlamp of vehicle
of right headlamp 1. Prepare for a piece of thick and white paper (and
Horizontal center
draw a baseline).
line of headlamp
Line V (the centre position of the vehicle): Draw a
Dividing line vertical line along the middle of the paper to align with
Dividing line the center of the vehicle.
Ground Line H (the height of the headlamp): Draw a horizontal
line
line, whose distance to the earth is equal to that to the
center mark of the upper beam lamp, on the paper.
2. Make the distance between the headlamp and the
paper be 3m (9.84ft), put the paper on the wall, and
make the height of the line H be equal to that of the
center mark.
3. Turn on the headlamp, and check and make sure
the beam focusing is within the specified valve as
Replacement of Front Fog Lamp Assembly
1. Separate the negative (-) wire connector of the
battery.
2. Remove the front bumper, and separate the wire
connector of the front fog lamp.
Q2734816FD
3. Unscrew three fixing screws of the front fog lamp,
and remove the front fog lamp from the front
bumper.
4. Remove the front fog lamp bulb.
(a) Anti-clockwise rotate the seal cover of the lamp
body.
bulb.
5. Install the front fog lamp assembly.
Replacement of Side Turn Signal Lamp Bulb

1. Remove the lamp body through pulling the face
shield towards the direction of vehicle traveling.
(Fix the side turn signal lamp by a clamp.)
2. Remove the side turn signal bulb.
(a) Anti-clockwise rotate the bulb holder, and take off
the bulb from the bulb holder.
3. Install the side turn signal lamp.
Remarks: The side turn signal lamp (2008) is integrated

with the outside rear-view mirror, so please remove the
side turn signal lamp together with the outside rear-
view mirror.
Combination Rear Lamp Assembly
Replacement
battery.
2. Unscrew the four fixing bolts of the combination

rear lamp, separate the wire connector of
the combination rear lamp, and remove the
combination rear lamp assembly.
3. Remove the brake lamp bulb and the rear turn

signal lamp bulb.
Brake lamp
bulb (a) Anti-clockwise rotate and take off the bulb holder,
pull and anti-clockwise rotate the bulb, and take
off the bulb.
Rear turn signal lamp bulb
Reversing 4. Remove the reversing lamp bulb and the rear

lamp bulb position lamp bulb.
(a) Anti-clockwise rotate and take off the bulb holder,
pull and anti-clockwise rotate the bulb, and take
off the bulb.
5. Install the combination rear lamp assembly.
Rear position
lamp bulb
License plate Lamp (2006)

Replacement
battery.
2. Remove the rear bumper, and separate the wire
connector of the rear fog lamp.
3. Unscrew the three fixing screws of the rear fog lamp,

and remove the rear fog lamp from the rear bumper.
Replace the whole lamp if the light source is broken
because the light source of the rear fog lamp is LED.
4. Install the rear fog lamp assembly.
High Mount Brake Lamp Assembly

Replacement
battery.
2. Remove the liftgate cover, and separate the wire
connector of the indoor high mount stop lamp.
3. Unscrew the two fixing screws of the high mount

stop lamp, and remove the high mount brake lamp.
4. Remove the high mount brake lamp bulb.

(a) Anti-clockwise rotate the bulb holder, take off the
bulb from the bulb holder, and replace the bulb.
5. Install the high mount brake lamp assembly.
License plate Lamp (2006)
Replacement
battery.
2. Unscrew the two fixing screws of the license plate

lamp, separate the wire connector of the license
plate lamp, and remove the license lamp.
Replace the whole lamp if the light source is

broken because the light source of the license
plate lamp (2006) is LED.
4. Install the license plate lamp.
License Plate Lamp (2008)
Replacement
battery.
2. Plug the screwdriver into the rabbet of the lamp
assembly, and lightly prize up the lamp body.
Attention: Wrap the head of the screwdriver
with cloth to prevent the lamp shade from being
scratched.
3. Separate the connector of the license plate lamp,
and remove the license plate lamp.
4. Remove the license plate lamp bulb.
(a) Anti-clockwise rotate the bulb holder, take off the
bulb from the bulb holder, and replace the bulb.
5. Install the license plate lamp bulb.
Reading Lamp
Replacement
1. Remove the reading lamp.
(a) Plug the screwdriver into the rabbet of the lamp
assembly, lightly prize up the lamp shade, and
take off the bulb from the bulb holder.
Note: Wrap the head of the screwdriver with cloth
to prevent the lamp shade from being scratched.
2. Install the reading lamp.
Ceiling Lamp
Replacement
1. Remove the ceiling lamp bulb.
Attention: Wrap the head of the screwdriver
with cloth to prevent the lamp shade from being
scratched.
2. Install the ceiling lamp.
Rear Ceiling Lamp

Replacement
1. Remove the rear ceiling lamp bulb.
2. Install the rear ceiling lamp.
Door Lamp
Replacement
1. Remove the door lamp bulb.
2. Install the door lamp.
Electrical Accessories-12
Central Control Door Lock System

Component of Central Control Door Lock System
Central control door lock system is mainly composed of lock body assembly, locking mechanism
assembly, central control box, remote controller, key and relative harness.
Central
control box
Remote
controller
Lock body
locking mechanism
assembly
Key
Function Information of Central Control Door Lock

1. Locking
After all the doors are closed, press the LOCK button on the remote controller once. The turn signal
lamp would flash once, and the central control door lock is locked.
2. Unlocking
In the state of locking, press the UNLOCK button on the remote controller once. The turn signal lamp
would flash twice, and the central control door lock is opened.
3. Positioning Function
In the state of locking, press the LOCK button on the remote controller once. The turn signal
lamp would flash quickly ten times. Press the UNLOCK button on the remote controller to quit the
positioning function.
4. Automatic Locking Protection Function
In the state of locking, press the UNLOCK button on the remote controller for unlocking purpose, the
door would be automatically locked 30 seconds later if it is not opened.
5. Automatic Locking in Traveling
When the speed rises up to 15 km/h, the central control door lock is automatically locked. When the
IG gear of the ignition switch is cut off, the door would be unlocked automatically.
6. Automatic Window Shutdown Signal Output
Pull out the key and close the door. Under the unlocking state, press down the LOCK button on the
remote controller to lock the door, and at the same time the system delivers the automatic window
shutdown signal to make the anti-pinch regulator close the window automatically. (Note: only for anti-
pinch window regulator)
7. Suspension of Remote-control Function
When the key of vehicle is inserted into the ignition lock, the remote controller would be unable to
operate but the main unit works normally.
8. Manual Locking and Unlocking
The locking and unlocking can be operated with manual switch.

Open the door and turn the key continuously and quickly from LOCK position to ON position 5 times
and finally turn it to ON position, and at this time the turn signal lamp flash once, which means the
learning function is activated. Press any button on the remote controller within 10 seconds, and the
turn signal lamp would flash twice, which means that the remote controller is successfully registered.
Such operation can be repeated and up to two remote controllers can be registered; the system would
exit from the learning function if no remote controller is pressed in 10 seconds. The first registered
remote controller would be cleaned when registering a new one after two remote controllers are
registered.（05 model）
10. Delay Function of Ceiling Lamp
(a) Open the door and at this time the ceiling lamp would be on for 30 seconds, and if the key is
inserted again into the ignition lock within 30 seconds, the ceiling lamp would go out immediately;
(b) Open the door and then close it, and at this time the ceiling lamp would be on for 30 seconds,
and if the door is locked within 30 seconds, the ceiling lamp would go out immediately;
(c) When the key is pulled out from the ignition lock, the ceiling lamp would be on for 1 minute, and if
the key is inserted into the ignition lock again, the ceiling lamp would go out immediately;
(d) When the key is pulled out from the ignition lock, the ceiling lamp would be on for 1 minute, and if
the door is locked, the ceiling lamp would go out immediately.
Common Malfunctions and Troubleshooting of Central Control Door Lock
System
No. Malfunction Troubleshooting
1.Check whether the remote controller is electrified.
Remote controller failed to lock and 2.Check for any error in the central control box.
1
unlock 3.Check whether the harness between the locking mechanism
assembly and central control box is in good contact.
1.Check whether the locking mechanism assembly of failed door is
A door can not be locked or unlocked out of service
2
remotely 2.Check whether the harness connected with locking mechanism
assembly is in good contact.
1.Shedding of inside cable and lock body
3 Failure of lock inside handle 2.Check whether the child lock is locked (only for the rear door
lock)
1.Shedding of inside fuse cable and lock body
4 Failure of inside fuse
2.Serious distortion of fuse cable
Part Maintenance
1. Steps for replacing the battery of remote controller:
(a) Remove the fastening bolt of key to open the
upper cover;
(b) Disassemble the shell of remote controller.
(c) Replace the battery of remote controller. (Model:

CR2016)
2. Replacement or maintenance of lock body

(a) Remove the power window switch and core board
etc., (see section of trim)
(b) Remove the fixing bolts of lock body and inside
handle bracket.
(c) Disconnect the clips between the lock body, lock

core and outside handle to remove the lock body.
(d) Maintain or replace the corresponding parts
according to the failed position of lock body.
3. Replacement or maintenance of lock catch

Remove the bolt and door lock catch.
4. Up-down or in-out adjustment of lock catch

It is necessary to carry out the up-down or in-
out adjustment for lock catch under the following
conditions:
(a) Damage of frame due to the crash.
(b) Installation of the weather strip of new door.
(c) Serious wind noise reported by user.
(d) Difficulty to open/close the door.
Power Regulator
Common Malfunction and Diagnosis of Regulator System

No. Malfunction Troubleshooting
1.Check whether the steel wire rope of regulator has come off;
1 Glass failed to rise and decline 2.Check whether the electrode is out of service;
3.Check whether the harness and switch are out of service.
Vibration or incline during the 1.Check whether the groove is abraded abnormally;
2
regulation of glass 2.Check whether the regulator is distorted.
1.Check whether the regulator motor failed;
2.Check whether the glass groove is abraded seriously;
3 Difficulty to regulate the glass
3.Check whether the mating clearance between the inside and
outside weather strips is too small.
Removing Process of Regulator

1. Remove the core board (see the section of trim)
2. Remove the door glass (see the section of glass and rearview mirror)
3. Disconnect the electrical linker
4. Remove the nut and window regulator
5. Check the relative parts and repair or replace the failed parts according to the malfunction of
regulator system.
Electric Horn System

1. Malfunction Table
Malfunction Suspected Position

1.Button switch of electric horn
2.High-tone electric horn assembly
Silence of 3.Low-tone electric horn assembly
electric horn 4.Electric horn fuse
5.Electric horn relay
6.Harness
2. Check
Connect the voltage of battery to the electric horn and
check the operation of the electric horn. If the electric
horn is silent, replace the electric horn.
3. Replacement of electric horn assembly
(a) Open the engine hood
(b) Pull out the connector
(c) Remove the fastening bolt and electric horn.
(d) Replace the electric horn and fix it on the horn
bracket with bolt
(e) Plug in the connector
(f) Lay down the engine hood
Combination Instrument
Schematic Diagram of Instrument
Combination Instrument Indicator Lamp Malfunction Table and Indication

Check
Malfunction Suspected Position Reference Page
Failure of front fog lamp indicator lamp1.Harness -
2.Front fog lamp switch -
3.Combination instrument -
Failure of rear fog lamp indicator lamp 1.Harness -
2.Rear fog lamp switch -
Failure of high beam indicator lamp 1.Harness -
2.Combination switch -
Failure of turn indicator lamp 1.Harness -
2.Turn signal and alarm system -
Failure of door open alarm indicator 1.Harness -
lamp 2.Control switch of door lamp Electric Accessories-5
Failure of charging indicator lamp 1.Harness -
2.Generator -
Failure of parking brake indicator lamp 1.Harness -
2.Parking brake switch -
Failure of airbag indicator lamp 1.Harness -
2.Control unit of airbag -
Failure of seat belt indicator lamp 1.Harness -
2.Lock catch switch of seat belt -
Failure of brake malfunction indicator 1.Harness -
lamp 2.Combination instrument -
Failure of ABS indicator lamp 1.Harness -
3.ABS control unit -
Failure of engine oil pressure alarm 1.Harness -
indicator lamp 2.Oil pressure switch -
Failure of fuel alarm indicator lamp 1.Harness -
2.Fuel sensor -
Failure of engine malfunction indicator 1.Harness -

lamp 2.ECM -
Failure of engine maintenance indicator 1.Harness -
lamp 2.ECM -
Failure of EBD indicator lamp 1.Harness -
2.ABS control unit -
Failure of engine preheating indicator 1.Harness -
lamp 2.ECM -
Failure of master lighting switch 1.Harness -
indicator lamp 2.Combination switch -
Failure of rear frost removal indicator 1.Harness -
lamp 2.Rear frost removal switch -
Failure of oil/water separator indicator 1.Harness -
lamp 2.Oil/water separator -
Failure of liftgate indicator lamp 1.Harness -
2.Liftgate switch -
Failure of 4WD indicator lamp 1.Harness -
3.Front axle power clutch controller -
Failure of TCS indicator lamp 1.Harness -
3.TCS control unit -
Failure of braking fluid level alarm 1.Harness -
indicator lamp 2.Combination instrument -
3.Brake fluid level switch -
Failure of anti-theft indicator lamp 1.Combination instrument -
2.Anti-theft controller -
3.Harness -
Failure of speed alarm indicator lamp 1.1.Combination instrument -
Check of Instrument Indication

1. Check of speedometer
Check the allowable indicating error of speedometer with the function signal generator and check the
operation of odometer.
Checkpoint（km/h） Input Frequency（Hz） Allowable Error（km/h） Remarks
40 52.4 0~+5 Gasoline
100 131.1 0~+5 Gasoline
160 209.8 0~+8 Gasoline
40 55.5 0~+5 Diesel
100 138.7 0~+5 Diesel
160 221.9 0~+8 Diesel
2. Check of tachometer
Check the allowable indicating error of tachometer with function generator.
Checkpoint（r/min） Input Frequency（Hz） Allowable Error（r/min）
1000 33.3 ±100
3000 100 ±150
6000 200 ±240
3. Check of fuel gauge

Check the allowable indicating error of fuel gauge with potentiometer.
Checkpoint Input Resistance（Ω） Indicating Angle（°）
E 95 0±3
1/2 32.5 40±3
F 7 80±3
4. Check of water thermometer

Check the allowable indicating error of water thermometer with potentiometer.
Checkpoint Input Resistance（Ω） Indicating Angle（°） Remarks
C(50) 146.5 0±3 Gasoline
80-100℃ 27.8-51.1 40±3 Gasoline
Alarm Point 120℃ 16.1 70±3 Gasoline
C(50℃) 226 0±3 Diesel
80-100℃ 40.4-75.8 40±3 Diesel
Alarm Point 110℃ 32.5 70±3 Diesel
Combination Switch
Q2360516FD
Combination switch
top panel cover
Combination switch
assembly
Q2204816FD
Q2300416FD Combination switch

bottom panel cover
Replacement
Hint:
The installing steps are reverse to the removing steps.
1. Remove the airbag of driver
2. Remove the steering wheel
3. Remove the bottom and top panel covers of
combination switch
(a)Remove 7 standard pieces.
(b)Remove the bottom and top panel covers of
combination switch.
4. Disconnect the linker and remove the combination
switch assembly
Lgnition Switch
Replacement
Hint:
The installing steps are reverse to the removing steps.
1. Remove the airbag of driver
2. Remove the steering wheel
3. Combination switch
4. Remove the ignition switch assembly
(a) Disconnect the ignition switch linker.
LOCK
(b) Remove the clip.
ACC
(c) Remove 2 screws and ignition switch.
ON
Check
START 1. check the ignition switch assembly
(a) Check the switch resistance.
3 2 1 Standard:
6 5 4
If the results are not in line with the regulation, replace
the switch assembly.
Connection
Switch State Specified State
of Tester
1-3 ACC
1-2
1-3 ON
5-6 Less than 1 Ω
1-2
4-5 START
5-6
Wiper and Washer System

Component of Wiper System
The front windshield wiper system is mainly composed of front wiper motor assembly, front wiper
connecting rod assembly and left/right front wiper arm assembly.
Right front wiper
arm assembly Left front wiper arm assembly
Front wiper connecting rod assembly

Front wiper motor assembly (bracket sprayed with plastic)
Function Information of Wiper System

The main function of wiper system is to provide the
OFF good visual field for vehicle driver and passenger to
ensure the safety.
The wiper system of Hover model has 3 wiper
LO frequencies of (intermittent) , low speed (LO) and
HI high speed (HI) and a stop gear (OFF). The wiper
Combination switch handle located frequency can be controlled by the combination switch.
at different position corresponds
Remarks: the combination switch with automatic wiper
to different wiping frequency.
has an automatic gear.
1. Intermittent position
when the combination switch is at intermittent gear,
the wiper system can operate according to the preset
frequency.
2. LO Position
When the combination switch is turned to LO position, the
wiper system would operate at the rather low frequency.
3. HI Position
When the combination switch is turned to HI position, the
wiper system would operate at the rather high frequency.
4. OFF Position
When the combination switch is turned to OFF position,
and the wiper system would stop operating.
Malfunction Table of Wiper and Washer
System
Malfunction Suspected Position Reference Page

1. Wiper fuse －
2. Windshield wiper switch assembly －
Failure of front wiper
3. Front wiper motor assembly －
4. Harness －

Front wiper failed at LO and HI
positions
3. harness －

Front wiper failed at intermittent
position
3. Harness －
1. Wiper fuse
－
2. Windshield wiper switch assembly
Front washing motor failed －
3. Front washer motor
－
4. Harness
1. Wiper fuse －
Rear wiper and washer motor failed 2. Rear wiper switch －
3. Harness －
1. Washer fuse －
2. Rear washer motor －
Rear washer motor failed
3. Rear washer switch －
4. Harness －
Check of front windshield wiper motor

Blue-low speed Green-high speed (left figure is the motor plug)
1. Check of operation at low speed position
Connect the positive cable of battery to the positive
Black terminal of linker and the negative cable to the negative
cathode terminal. Check and confirm the operation of motor at
low speed position (LO).
2. Check of operation at high speed position
Red-positive White-return
terminal of linker and the negative cable to the negative
terminal. Check and confirm the operation of motor at
high speed position (HI).
3. Check of automatic stop
terminal of linker and the negative cable to the positive
terminal. When the motor is operating at low speed
(LO), disconnect the positive terminal to make the
Basic Wiring diagram (positive control) [B] wiper motor operate any position except the Automatic
Sleeve model Connector
model
Stop Position.
4. Basic Wiring diagram of wiper motor
Negative Black
Positive Red
Green
White
Blue
Negative
Positive pole–red
pole–black
White
Malfunction Diagnosis Process of Front Windshield Glass Wiper and

Washer
1. Front windshield glass wiper failed at any speed
Steps Operation Value Yes No
Check whether the front wiper motor fuse is burned

1 — To step 2 To step 3
out.
1. Check for the short circuit and complete the
necessary repair.
2 — Normal —
2. Replace the fuse.
Has the repair been finished?
Check whether the voltage of wiper motor fuse is
3 11-14V To step 5 To step 4
equivalent to the specified value.
Repair the open circuit of fuse supply.

4 — Normal —
1. Disconnect the wiper motor linker.

2. Connect the ignition switch.
3. Turn the wiper switch to HI (high speed) position.
4. Check the voltage of wiper motor linker terminal
(high speed).
Is the voltage equivalent to specified value?
Replace the wiper motor.

6 — Normal —
1. Keep the wiper switch open.

7 3. Check the battery voltage of wiper switch linker 11-14V To step 9 To step 8
terminal.
Is the voltage equivalent to the specified value?
Repair the open circuit between the wiper switch linker

8 terminal and the fuse. — Normal —
1. Keep the wiper switch disconnected.

2. Turn the wiper switch to the HI(high speed)
position.
9 3. Check whether the wiper switch terminals are ≈0Ω To step 11 To step 10
connected with the resistance gauge.
Is the resistance value displayed on the resistance
gauge in line with the regulation?
Replace the wiper switch.

10 — Normal —
Repair the open circuit between the wiper switch and

11 wiper motor. — Normal —
2. The wiper is out of service at high speed but normal at low speed.

1 3. Check the voltage on the wiper motor linker 11-14V To step 2 To step 3
terminal.
2 — Normal —
1. Disconnect the wiper switch.
3. Check whether the wiper switch terminals are
3 ≈0Ω To step 5 To step 4
4 — Normal —

5 terminal and wiper motor linker. — Normal —
3. The wiper is out of service at low speed but normal at high speed
2. Turn the wiper switch to the LO (low speed)
1 position. 11-14V To step 2 To step 3
3. Check the voltage on the wiper motor linker.
2 — Normal —
1. Disconnect the wiper switch.
2. Turn the wiper switch to the LO (low speed)
position.
3 3. Check whether the wiper switch terminals are ≈0Ω To step 5 To step 4
4 — Normal —

5 terminal and wiper motor linker. — Normal —
4. The wiper is out of service at intermittent (INT) but normal at other speeds.
2. Turn the wiper switch to the INT (intermittent)
position.
1 3. Check the voltage on the wiper motor linker 11-14V To step 5 To step 4
terminal.
Is the voltage displayed on the voltage meter
equivalent to the specified value?
Check whether the circuit between the wiper switch
linker terminal and the wiper motor linker terminal is
open.
Is there a open circuit malfunction?

3 — Normal —

4 terminal and wiper motor linker terminal. — Normal —

2. Turn the wiper switch to the INT (intermittent)
position.
5 3. Check the pulsating voltage on the wiper motor 11-14V To step 7 To step 6
linker terminal.
Is the pulsating voltage displayed on the voltage meter
equivalent to the specified value?

6 — Normal —

2. Check the voltage on the wiper switch linker
7 terminal. 11-14V To step 8 To step 9
Is the voltage pulsating according to the specified
value?

8 — Normal —
Repair the open circuit between the wiper switch and

9 wiper motor. — Normal —
5. Front windshield glass wiper failed to return to the “stop” position

2. Check the voltage on the wiper motor linker
terminal.
Repair the open circuit between the wiper motor linker

2 terminal and the fuse. — Normal —

3 — Normal —
6. Front windshield glass washer is out of service but wiper is normal
Start the front windshield glass washer switch.

1 Does the front windshield glass wiper operate after the — To step 4 To step 2
washer switch activates?
2. While starting the washer switch, check the
2 voltage on the front windshield glass wiper switch 11-14V To step 8 To step 3
linker terminal.
Replace the front windshield glass wiper switch.
3 — Normal —
Check the front windshield glass washing liquid tank.

Is there washing liquid in the tank?
Add the washing liquid of front windshield glass.

5 — Normal —
Check the front windshield glass washing liquid hose

and nozzle.
Are the washing liquid hose and the nozzle of the front
windshield glass blocked or damaged?
Repair the front windshield glass washing liquid hose
7 and nozzle. — Normal —
2. While starting the front windshield glass washer
8 switch, check the voltage on the front windshield 11-14V To step 10 To step 9
glass washer pump.
Repair the open circuit between the front windshield

glass washer pump and front windshield glass wiper
9 — Normal —
switch.
Measure the resistance between the ground and front

windshield glass washer pump linker terminal with
10 ≈0Ω To step 12 To step 11
resistance gauge.
Is the resistance equivalent to the specified value?
Repair the grounding circuit of front windshield glass

11 washer pump. — Normal —
Replace the front windshield glass washer pump.

12 — Normal —
Right front wiper arm assembly Left front wiper arm assembly
Front wiper trim cap Front wiper

Right front wiper arm trim cap
Right wiper blade 2 type Left front wiper arm
hexagon nut 2 type
hexagon nut
Left wiper blade
Front wiper connecting rod assembly
Front wiper motor assembly

(bracket sprayed with plastic)
Front Windshield Wiper Assembly

Removal
1. R e m o v e t h e l e f t a n d r i g h t f r o n t w i p e r a r m
assemblies of front windshield glass
(a) Open the engine hood to take off the trim cap of
wiper arm nut;
(b) Remove the 2 types of hexagon nuts from the
wiper arm;
(c) Take off the wiper arm assembly.
2. Remove the front wiper motor assembly
(a) Disconnect the electrical connectors of front wiper
motor assembly;
(b) Remove the fixing bolt from the front wiper motor
assembly.
3. Remove the front wiper connecting rod assembly
(a) Remove the cover plate of front window ventilator
(see the section of Interior and exterior trimmings);
(b) Remove the fixing nut from the front wiper
connecting rod assembly.
Precautions: the direct contact among the different
kinds of metal would lead to the rusty. Be sure to
use the fastener correctly to avoid the premature
corrosion.
4. Install the front windshield wiper assembly
The installing sequence is reverse to the removal.
Rear nozzle assembly of

the windshield washer
Rear water pipe fixing seat

assembly of the windshield Front water pipe
washer assembly of the
windshield washer
Windshield washer pipe Windshield washer two-way clip

assembly (6780) Front pipe fixing seat assembly
Lace (rear washer of the windshield washer
pipe clip) Windshield washer hose
Windshield washer
Windshield washer nozzle connector
one-way assembly Windshield washer
three-way clip Front nozzle
Windshield washer pipe assembly of the
bracket assembly windshield washer
Fluid refill pipe seal ring of the windshield washer
Fluid refill pipe cover of the windshield washer
Grounding bolt (M6)
Fluid refill pipe assembly of the windshield washer
Two-way connector of the windshield washer pipe
Seal ring of the spraying motor
Washer spraying motor assembly
Windshield washer body assembly
Front Windshield Washer Assembly

Removal
1. Disconnect the negative cable of battery.
2. Remove the left front wheel. See the section of “tyre
and wheel”.
3. Remove the bolt, screw and front wheel mudguard.
4. Remove the washer hose from the washer pump.
5. Disconnect the electrical linker of hydraulic pump.
6. Remove the nut and reservoir tank.
Installation
1. Install the reservoir tank with nut and fasten the
washing liquid reservoir tank bolt.
2. Connect the electrical linker of reservoir tank.
3. Connect the washer hose to the washer pump.
4. Install the mudguard of front wheel with bolt and
screw and fasten the front wheel mudguard bolt.
5. Install the left front wheel. See the section of tyre
and wheel.
6. Connect the negative cable of battery.
Front windshield washer nozzle
Removal
1. Remove the ventilation grille of front cover plate.

See the section of interior and exterior trimmings.
2. Disconnect the washer hose from the nozzle.
3. Remove the nozzle from the ventilation grille of
front cover plate.
Installation
1. Install the nozzle onto the ventilation grille of front
cover plate.
2. Connect the washer hose to the nozzle.
3. Install the ventilation grille of front cover plate. See
the section of interior and exterior trimmings.
Front windshield glass washer hose
Removal
1. Remove the ventilation grille of front cover plate.
See the section of "Front End of Vehicle Body".
2. Disconnect the front windshield glass washer hose
from the washer nozzle.
3. Remove the left front wheel. See the section of
"Tyres and Wheels".
4. Remove the bolt, screw and front wheel mudguard.
5. Disconnect the washer hose from the washer
reservoir tank.
6. Remove the washer hose.
Installation
1. Install the washer hose.
2. Connect the washer hose to the washer pump.
3. Install the front wheel mudguard with bolt and
screw and fasten the bolts of wheel mudguard.
4. Install the left front wheel. See the section of "Tyres
and Wheels".
5. Connect the front windshield glass washer hose to
the washer nozzle.
6. Install the ventilation grille of front cover plate. See
the section of "Front End of Vehicle Body".
Electric Appliances－32
Automatic Windshield Wiper System
Wiper Sensor Cover

Interior rear-view mirror
Glass Cover
Left & right

Clasps
direction limiters
Cover
Sensor
Mounting
blocks Upper & lower
direction limiters
Clasp: to fix the cover onto the mounting blocks.
Mounting blocks: fixed on and by the front windshield.
For installation, first fit the interior rear-view mirror

through the round hole of the cover and have it fixed
on the mounting support of the rear-view mirror, then
apply the cover onto the other three clasps on the
glass and fix it firmly through the limiters of itself.
For removal or maintenance, make the cover tilt along
the round hole and the peripheral to come off from the
mounting blocks, and then the parts can be taken off.
How to clean the windshield in case of
sensor damaged
1. Unplug the connectors.
2. Remove the protective cover.
3. Tear off the damaged sensor.
4. Spray some 3M cleaner on the glue residue on
the glass surface, wait for 1 minute and then wipe
it with clean cotton cloth, and finally make the
windshield glass surface as clear and fresh as
before.
Assembling of automatic wiper control

system
1. Ambient requirements : temperature 20-30°C;
relative humidity 0-60%.
3M467 2. Wipe the glass surface for assembly with a cotton
Peel (tear) cloth soaked with alcohol; no stains, dirt or moister
off
are allowed to remain.
3. Take a new sensor, and peel off the liner of the
3M467 adhesive tape on its facade (all black).
Note: do not touch the adhesive tape
surface with hands or other objects,
to avoid affecting the adhesion.
4. Keep the adhesive tape parallel to the mounting
surface, use a scraper to apply the tape by
pushing, starting from the initial side; make sure
3M no bubbles are generated between the adhesive
tape and the part to be mounted.
Note: it will take 72 hours for the adhesive tape to
mature to its final strength. During this period, do
Scraper not apply any force on it, which might cause its
peeling-off.
5. Tear off the protective paper of the white 3M

adhesive tape, align the sensor cover with the
sensor edges, then stick it on the 3M adhesive tape
and press to secure its position.
6. Insert the sensor communication cable plug into

the sensor socket (beware the direction), and make
Sensor communication
cable connector sure the plug is fully inserted in place.
7. Put the internal rear-view mirror into the trim cover,
then mount it on the glass and fix it with screws;
then fix the trim cover onto the three mounting
bases. Shake it by hand to make sure it is installed
firmly in place.
8. Fix the main unit on the bracket with screws, then
insert the other plug of the sensor communication
cable & the main unit plug into the main unit, and
make sure the connection is fully in place and firm.
Troubleshooting for the automatic wiper

control system
In case of abnormal working of the automatic control,
check the working condition of the controller first.
• If the switch is set to automatic control and the
wiper has no motion at all, or it remains idle even
in water spraying, and it failed to move after
repeated operation several times, then follow the
steps 2-5 for troubleshooting.
• If such phenomena happen as: the wiper
constantly moves without stop, or the wiper moves
intermittently at high speed and low speed, or the
wiper doesn’t move while spraying, or it moves
without stop after the spraying is ended, etc., then
follow the steps 3-5 for troubleshooting.
Unplug the controller and carry out the following
inspections.
1. If the wiper works at high speed or low speed
accordingly when it is set to high speed or low
speed respectively, then it indicates that the
wiper is in good working condition. If the wiper
is set to low or high speed and the wiper doesn’
t work accordingly, first check whether the fuse
5 6 7 8 controlling the wiper in the distributor is melted; if
so, change the fuse, and then re-check if the wiper
1 2 3 4
can work properly in manual mode; if the wiper
1-BKT 2-WT 3-GND 4-BAT
still doesn’t work properly, check the wiper circuit
5-BKO 6-LO 7-HO 8-AUT and the working condition of the wiper motor; if
it’s all right, re-install the controller and test if it
works properly; if at this time the controller can
work properly, the diagnosis is completed; or else,
unplug the controller and enter the next step.
2. Check the power supply harness connecters, using
a universal meter set to 2.0V DC measuring range.
The harness wiring order is described as follows.
3. The harness terminal 3 is to be connected to the
universal meter COM terminal, and terminal 4 is
to be connected to the universal meter measuring
terminal. The voltage between terminals 3 & 4
should be the power supply voltage (approximately
+12V). If no voltage is detected, the verdict is that
there is a broken circuit at the connection between
either terminals 3 or 4 and the power supply
harness; in this case, re-connect where the broken
circuit occurs and re-measure to make sure the
voltage is right.
4. Set the wiper to low speed, and the wiper should

move accordingly, the voltage with terminal 1
should be jumping back and forth between 0-12V,
and that with terminal 6 should be approximately
+12V. If no voltage is detected with terminal 1, then
the verdict lies with that there is a broken circuit at
the connection between terminal 1 and the power
supply harness; in this case re-connect where the
broken circuit occurs; if no voltage is detected with
terminal 6 then the verdict is that there is a broken
circuit at the connection between terminal 6 and
the power supply harness; in this case, re-connect
where the broken circuit occurs.
5. Set the wiper to spraying mode, and the wiper
will wipe with a few strokes intermittently, and the
voltage with terminal 2 should be approximately
+12V. If no voltage is detected with terminal 2,
then the verdict is that there is a broken circuit at
the connection between terminal 2 and the power
supply harness; in this case, re-connect where the
broken circuit occurs.
6. Set the wiper to high speed, and the wiper should
move with high speed accordingly, and the voltage
with terminal 7 should be approximately +12V. If
no voltage is detected with terminal 7, the verdict
is that there is a broken circuit between terminal
7 and the power supply harness; in this case, re-
connect where the broken circuit occurs.
7. Set the switch to automatic control, and the wiper
will not move, the voltage with terminal 8 should
be approximately +12V. If no voltage is detected
with terminal 8, the verdict is that there is a broken
circuit between terminal 8 and the power supply
harness; in this case, re-connect where the broken
circuit occurs and measure again for confirmation.
• If the above mentioned working conditions are all
normal, the controller should be replaced.
• If the replaced controller still doesn’t work
properly, use a new sensor communication cable
to directly connect the controller and the sensor
from outside; if the controller works fine with the
outside connection, it shows that the original
communication cable is damaged; in this case,
take out the original one and replace it with a new
one.
• If the controller still doesn’t work properly even
after the outside communication cable connection
is used, it can be confirmed that the sensor itself
is damaged; in this case, replace it with a new one
and re-check to verify that the controller works
properly.
Testing of the automatic wiper control

sensor
1. Ambient requirements: temperature 20-40°C;
relative humidity: less than 80%.
2. Measuring instrument: capacitance tester, with a
precision >0.05 pF.
3. Te s t i n g c o n d i t i o n : t h e 2 t e s t i n g w i r e s o f
capacitance tester and the sensor must be
suspended during the testing, and no other objects
are allowed to be present within a 30 cm vicinity.
Testing content:
(a) Terminal 1 is the capacitor common terminal
(COM), terminal 3 is the testing terminal of
capacitor A, and terminal 2 is the testing terminal
of capacitor B.
(b) Measure the capacitance A between terminals
3 & 1, and the value should be > 1.5 pF; if the
measured value is negative, it indicates that there
is a short circuit between these two terminals and
the capacitor should be judged as unqualified.
(c) Measure the capacitance B between terminals 2 &
1, and the value should be >1pF; if the measured
value is negative, it indicates that there is a short
circuit between these two terminals and it should
be judged as unqualified.
(d) When A-B> 0.4 pF, and the capacitance values of
A & B are not negative, the sensor is judged as be
qualified.
In the above mentioned functional tests, a sensor
passing all the testing items are judged as qualified,
otherwise it is unqualified.
Schematic Diagram of Automatic Wiper
184
Front washer motor Gray/Black
183
Motor-end resuming control Blue/Red
automatic wiper ECU

380
Automatic wiper ECU
Low speed motor Blue/Yellow
Rain sensor
Connecting the
Dedicated
High speed motor 182 Yellow communication cable
186
Switch-end resuming control Light green
187
Automatic wiper control Blue/White
31
Orange/
IC relay output 655, yellow Blue
System
Automatic lighting system

Assembling of automatic lighting control
Sensor
Plugging
cover
system
1. Take off the plugging cover on the upper left side
of instrument panel.
2. Mount the sensor into the mounting hole and make
sure it’s firm and fully in place.
3. Insert the sensor plug into the instrument harness,
and make sure the connection is fully in place and
firm.
4. Fix the main unit on the bracket with screws, then
guide the corresponding wiring plugs through into
the main unit and make sure the connection is fully
in place and firm.
Matching between the main unit and the

sensor (using this function only when
replacing the main unit or sensor)
1. Mask the system sensor with an opaque object
(making the sensor in a dark environment).
Note: beware the sensor surface wearing while
performing this operation.
2. Perform the following operations within 20
seconds.
(a) Under the status that the vehicle power supply
is on, the lighting switch is off, and the key is
pulled out, turn the automatic lighting switch
OFF→ON→OFF→ON.
(b) Insert the ignition key and then pull it out from
the key hole, repeat this operation 5 times (i.e.
inserting → pulling out → inserting → pulling
out → inserting → pulling out → inserting →
pulling out → inserting → pulling out).
3. If this operation is successful, then the vehicle
small lamp will flash 2 times (f=400 ms), which
indicates that the system has entered into the
automatic data storage stage.
4. Wait for another 3 seconds, and the vehicle small
lamp flashes another 3 times (f=400 ms), which
indicates that the system has completed its
normal data storage.
If the vehicle small lamp slowly flashes 2 times (f=800
ms), which indicates the data which the system has
learned are abnormal, exit the learning mode and re-
enter to re-learn.
5. Turn off the system automatic lighting switch,
and the system then exits this mode, and the
operation is completed.
Testing of the automatic lighting control

sensor
Check to verify that the photodiode works properly by
using an analog universal meter.
1. Set the universal meter to R × 1K Ohms resistance
measuring range, use its red & black probes to
touch randomly with the photodiode pins; if the
reading is approximately a few thousand ohms,
then the pin in contact with the black probe is
the positive pole, while that in contact with the
red probe is the negative pole; this is the forward
resistance, which does not change along with the
luminous intensity.
2. Then swap the 2 probes and connect them with
the 2 photodiode pins, and now what the universal
meter measures is the reverse resistance, and
the universal meter dial pointer should only show
slight deflection. Normally the reading is above
200K Ohms (Beware that the photodiode should not
face an illuminant directly during the measuring).
3. Subsequently, use a flashlight to illuminate the top
end of the photodiode; at this moment, the dial
pointer deflection should increase. The higher the
luminous density is, the smaller the photodiode
reverse resistance should be, and even it could be
as low as just a few hundred Ohms. Turn off the
flashlight, and the dial pointer should resume to its
original position immediately.
Troubleshooting of Automatic Lighting Control System

1. System out of work
In the circumstance of no natural lighting,

the system doesn’t work after started.
Check to verify that there is 12V voltage No

between the main unit terminals 5 & 6.
Yes
The malfunction
Harness malfunction
persists.
occurs; replace the harness
and restart the system.
While inserting the key into the

No
ignition key hole, check to verify that
the voltage with terminal 8 is 0.
Yes
The malfunction
persists. Replace the switch,
and restart the system
While the lighting switch is set to

No
automatic control, check to verify that
the voltage with terminal 8 is 0.
Yes
The malfunction
persists. Replace the switch,
and restart the system
The main unit is

damaged; replace
the main unit
The system
works properly.
2. Mis-operation in the system
Under high intensity light,

both the system headlamp
and small lamp are lit.
Check whether the connection between No

the main unit terminal and the sensor is
all right (including the connectors).
Yes
The malfunction
still exists.
Replace or re-connect,
then restart the system.
Replace the sensor.
Restart the system.
Does the system No

work properly?
Yes
Replace the
main unit.
The system
works properly.
Schematic Diagram of Automatic Lighting System
Connecting the automatic

headlamp ECU
254
Upper & lower beam control Yellow/Blue
Automatic lighting control 892 Orange
Automatic lighting ECU
Photoelectric sensor
151 896 Green/Black
Position lamp control Green/White
photosensitive sensor
Normal power supply 263
150 Red/Blue Red/White 895 Red/Green
Connecting the
Testing the key functioning 112 Green
Electric Levelling Headlamp System

System Malfunction Diagnosis & Maintenance
Height adjustment can not be
realized through operating
the dimmer switch.
Is there any running Yes The motor is seized and the lamp
noise with the
reflector is in a extreme position.
dimmer motor?
Use a screwdriver to adjust the

lamp reflector to its correct position.
No
The malfunction
still exists.
Internal problems with regard

to the lamp; replace the lamp.
Check to verify that there is 12V No Check the power supply

voltage with dimmer switch pin 1. circuit of the switch.
Yes
Shift the dimmer switch to check whether there is No Replace the

continuously changeable resistance output with pins 4 & 5. dimmer switch.
Yes
Replace the
dimmer motor.
Schematic Diagram of Electric Levelling Headlamp System
lamp voltage
Position
44 Red/Blue
Connecting the left

headlamp levelling device
Electric levelling
headlamp switch
Working lamp
Port
Position
Yellow/White
28
Yellow/Red
27

Left levelling headlamp levelling device
motor
Right levelling
motor
Connecting the headlamp

adjustment switch
Front & Rear Fog Lamps System

Logic Control
1. The front fog lamp can be turned on only after the position lamp is on.
2. There are 2 ways to turn on the rear fog lamp.
(a) The rear fog lamp can be turned on only after both the position lamp and the front fog lamp are
turned on.
(b) The rear fog lamp can be turned on after the upper or lower beam lamp is turned on.
Basic Diagram of Front & Rear Fog Lamps System
44 Red/Blue
44 Red/Blue
0 Red
44 Red/Blue
0 Red
44 Red/Blue
45 Red/Pink
Green/Orange
41
311 Red/Yellow
/Orange
41 Green
Rear fog lamp reply
74 Blue/White
75 Blue/Red
52 Green/Pink
On On Logic control
circuit
Off Off
69 Green/Yellow
Indicator lamp for rear fog lamp
Left rear fog lamp
Right rear fog lamp

Indicator lamp for front fog lamp
Left front fog lamp

Electric Accessories－46
Power Window
The Hover power window anti-pinch regulator is composed of a motor and a control module and is
provided with such functions as anti-pinch, automatic shutdown of four windows, soft stop and power-
saving mode, and it features convenient operation, power saving and long service life.
Description on Function
1. Anti-pinch Function
After initialization, the motor will automatically lower the window (for a distance of about 200mm) as
long as an obstacle is compressed in the course of automatic raising. Thus, the function of anti-pinch
is activated (with an anti-pinch force lower than 100N) to prevent the user from being pinched. Such
anti-pinch function can be available unlimitedly and the applicable range is from 4mm to (200~300)
mm below the top of window rubber strip. When the anti-pinch function works, the automatic and
manual raising input is ineffective from the beginning to the end of lowering process.
4mm
Max: 300mm
Min: 200mm
2. Automatic Shutdown of Four Windows

When the four doors are completely closed, the key locking button shall be pressed, and the central
door latch controller will provide the master switch of regulator with four successive 20ms impulse
signals with a pulse width of 20ms and a voltage of (9~16)V.
After that, the master switch of regulator will send a command of shutting-down to the regulator
controllers of four windows. The motors of four windows will successively raise the window in the
order of left front, right front, left rear and right rear. The startup interval of motor is 100ms, so as to
avoid current shock occurring when starting at a time.
Note: If the four doors are not closed completely, this function will not work.
3. Soft Stop Function:
When the window is raised to the top or lowered to the bottom, the motor is easy to be affected by the
impact due to blockage, which will shorten the service life of the regulator. To avoid this, it is required
to activate the soft stop function and this function shall be available during automatic/manual raising or
lowering. In this way, when opening or closing the power window, the window will stop at 3mm away
from the upper/lower mechanical stopper, instead of touching the mechanical stopper and stopping
due to blockage.
4. Zero Calibration Function
The mechanical stopper of window will be changed over time, resulting in deterioration of sealing of
window glass. In this case, it is required to calibrate the mechanical stopper.
Manual zero calibration: when the window is raised to the top, the window will stop at the electronic
stopper. Once the raising button is pressed again for more than 5s, the window will be raised to the
limit position. Thus, the zero calibration is done.
Automatic calibration: when the regulator has been operated for 20 raising and lowering cycles, a
single zero calibration will be conducted automatically. During this process, the soft stop function will
not work.
5. Self-diagnosis Protective Function
To ensure the reliability of system and improve the mean time to failure (MTTF) of system, the self-
diagnosis protection has been taken:
(a) The operation voltage of regulator is 9V-5%~16V+3%; when the voltage is lower or higher than
this value, the regulator is out of function, and it can be operated again when the voltage is within
the range of operation voltage.
(b) Conglutination of relay contacts: the regulator motor is controlled by two relays. When one
of them is with malfunction and always being connected, the system will send a command to
connect the other one, so as to ensure the power supply of motor can be cut off.
(c) Motor protection for Hall element malfunction:
If there is malfunction of Hall element, the control module can not receive any signal from the Hall
element and the regulator will be in degradation mode. In this case, only the manual operation works,
and the automatic operation will be out of function.
6. Method and Time for Initialization
When the anti-pinch regulator is mounted on the vehicle for the first time or the overhaul of regulator
is completed, the regulator itself will be in degradation mode or in a condition that the electronic
stopper runs off. In this case, the regulator is without automatic raising and lowering function or having
defects such as failure in raising the window to the top. Thus, it is required to conduct initialization to
the regulator for learning purpose, so as to let the controller recover the total travel of window.
The method for initialization is to pull up the switch button again after the window is raised to the top
and keep it for more than 5s. As long as the window moves upwards sharply, the initialization is done,
and all functions of regulator are available.
Schematic Diagram of Window Regulator Wiring

IG (connected when the key
is turned to ON position)
+12V normal
power supply
Earthing
Earthing Earthing
Raising
Central door latch controller
Raising Raising
Automatic Unlocking
shutdown
(connecting the
central controller) Locking
Earthing Earthing
Earthing Earthing Lowering Lowering

Incorrect output
(reserved)
Lowering
Unlocking
Locking
Left front window

regulator motor Right front window Left rear window
and controller regulator motor regulator motor
and controller and controller
Right rear window

regulator motor
and controller
The left front door switch sends a LIN-BUS communication instruction to the window regulators of four
doors to realize various functions of the regulators. The switches of the other three doors send high
level signal to the regulators to realize various functions of the regulators.
Note: As the communication between the left front window regulator and its switch is
controlled by the LIN-BUS, when the left front window regulator fails to raise or lower the
window as a result of malfunction, it is required to disassemble the regulator assembly for
inspection in case of maintenance.
Pin Assignment and Functions

Pin assignment for window regulator assemblies used in four doors are the same.
Pins Functions & Assignment

1 +12V (normal power supply)
2 Empty pin
3 LIN-BUS
4 Earthing
5 Raising
6 Lowering
Pin Assignment for Left Front Pin Assignment for Rear Pin Assignment for Right Front
Window Control Switch Window Control Switch Window Control Switch
(LIN signal, reserved)

CD Player
Function Overview
This product is a vehicle audio system with such functions as PLL electronic tuner radio, CD playing
and vehicle A/C control, and equipped with VFD multiple information integrated display. It can receive
AM, FM and FM stereo broadcasting, play CD disc and control the A/C electronically. The integrated
display can show the information about the radio, the CD player, the operation status and mode of A/C,
the equalizer, the clock as well as the temperature inside/outside the vehicle.
Illustration on Wiring (See the Figure)

1. Connection Between Main Unit and Speaker: The power amplifier of the main unit in this
system applies four-track BTL output. Each speaker shall have independent wiring. The phase
and position of each speaker shall be connected correctly. Before connection, please cut off
the power of radio cassette and avoid short-circuit in wiring.
2. Connection Between Main unit and Integrated Display:

Use special 12-pin plug cable to connect the VFD integrated display and the main unit.
3. Connection of Power Supply, Output and Communication Cables of the Main Unit:
First, connect the communication cable of 20-pin plug with the ECU of A/C, and connect the outgoing
cables of speaker with other cables, and then directly connect the yellow memory power supply cable
(10A fuse tube) with the positive pole of battery. When all the above connections are done, connect
the red power supply cable (1A fuse tube) with the positive terminal of power supply for ignition key.
4. Connection Between Main Unit and Antenna:
(a) Ordinary antenna: insert the coaxial cable plug of vehicle antenna in the antenna socket of main
unit.
(b) Automatic antenna: insert the coaxial cable plug of vehicle antenna in the antenna socket of
main unit, and then connect the blue antenna control cable of the 20-pin plug to the control
end of automatic antenna. The positive pole of the power supply cable of automatic antenna is
connected with the positive pole of battery and its negative pole shall be grounded.
5. Connection Between Main Unit and CD Changer Box
Connect the CD player and CD changer box with a signal cable.
6. Before installation, please do remove the three protective screws on the CD changer box and
stick a piece of dust-proof paper. Otherwise, the disc can not be displayed normally.
Note: Incorrect wiring may result in damage to the CD player!
20-pin Antenna plug

12-pin plug cable
plug cable
Integrated display
Terminal
Main unit
box
Signal sensor
Wiring Diagram
A-direction View
Position of 20-pin Plug Cable
Position Position
Color Function Color Function
Code Code
Shielding
1 White Sending data TX 11 Data cable earthing
cable
2 Red Receiving data RX 12 — —
3 Brown Telephone mute TEL 13 Blue Automatic antenna ANT
Ignition power supply
4 Orange Illumination LAMP 14 Red
ACC
5 — — 15 Black Earth wire
6 — — 16 Yellow Memory power supplyB+
White/ Green/
7 Left front speaker - FL- 17 Left rear speaker – RL –
Black Black
8 White Left front speaker + FL+ 18 Green Left rear speaker + RL +
Grey/ Right rear speaker – RR
9 Right front speaker - FR- 19 Violet/Black
Black –
Right front speaker – Right rear speaker + RR
10 Grey 20 Violet
FR+ +
Check and Analysis for Possible Malfunctions of CD Player

Malfunction Phenomenon Possible Cause and Check Method
Failure in receiving any channel Check if the antenna is pulled
by AM and FM tuning out or the socket is loose.
Impure tone after automatic
Manually tune the channel.
channel search
Check the speaker and its socket, and make
A certain speaker not working
the front, rear, left and right sides balanced.
Check the power supply or cut off the
Failure in startup power supply and connect to the power
supply again before the second startup.
Check the fusible link and output plug for
No power
looseness and the fuse for burned-out.
Only one audio track Check the speaker for open-circuit
works when playing and check the plug of speaker.
Check the type of disc and check if it is
Failure in disc reading
placed reversely or is with scratch, etc.
Check the connecting cable of display
Poor display
or try to turn up the brightness.
Failure in starting A/C Check the A/C ECU and air conditioning system.
Failure in operation of A/C button Check the A/C ECU and air conditioning system.
Reversing Radar
System Function
The reversing radar system consists of several sensors and a group of microcomputer controllers
and buzzers, and the principle is that the ultrasonic signals are applied, directed and controlled by the
microcomputer and the distance to the detected object is calculated through comparing the returning
time in course of the signal sending and receiving of the sensor, and then different warning sounds
will be given out by the alarm buzzer.
Testing and Adjusting
The power supply cable and reversing lamp wire of this device are connected to each other, and the
system will start and enter the sensing state when it is shifted to the reverse gear.
Moreover, two “beeps” of starting prompt sound indicate that the system operates normally.
The system sensitivity has been preset as the optimum matching state, and generally speaking, it is
unnecessary to readjust it in installation.
System Schematic Diagram
Pin
Position
Definition Remarks
1 GND Ground
power
wire of main unit
2 Buzzer- Buzzer ground wire
3 DATA Reserved display data wire
4 GND Reserved display ground wire

5 L (sensor)
6 CL(sensor) Sensor signal wire
(four sensors)
7 CR(sensor)
8 R (sensor)
9 GND ECU controller
10 GND Sensor ground wire
(four sensors)
11 GND
12 GND
13 GND
14 Vcc
15 Buzzer+ Buzzer power supply cable
Power supply cable of
16 +12v main unit
Power supply cable
Power supply cable

Connecting to reversing lamp
Buzzer
+
SA-16AWD: 6:1
Sensor
(built in the rear bumper)
L CL CR R
Detecting Area
Range to be covered in rear detecting area: car width plus 20 cm on each side
Range possibly covered in rear detecting area: car width plus 30 cm on each side
When an obstacle approaches to some side area, it may be directed starting from 40 cm away from
the rear area of the vehicle.
This system will be activated within one second after the shift of reverse gear, and it will beep twice as
the starting prompt tone to show the system operates normally.
This system is powered by a power system of 12V (referring to the positive pole of power supply), and
if the power supply of reversing lamp is cut off, this system will enter the off state.
When the detected distance is less than 25 cm on the side area or less than 40 cm in the middle area,
the audible signal will become the sustained sound to warn against collision of bumper.
Operating State of Reversing Radar
This system has 3 different states:
Activation state: if it is shifted to the reverse gear when the engine operates or the ignition switch is on
the operation gear, the system will enter the activation state and the signal indicating service state will
also be sent out.
Off state: after the reverse gear is disengaged or the ignition switch is off the operation gear (no
matter whether it is shifted to the reverse gear), the system will enter the off state.
Error state: if the system is activated but no audible signal is sent out, the system is in the error state.
After the error is eliminated, it is required to shift to the reverse gear again to enable the system to re-
enter the activation state.
If it is shifted to the reverse gear and remains on the reverse gear when the engine operates, the
system enters the activation state.
In this state, the system will give a prompt to the driver no matter whether the vehicle approaches to
or leave the obstacle or stays put.
The system may be interfered but its normal operation will not be influenced in case of a nearby
vehicle equipped with a same system or similar system (being activated) of other suppliers.
If the relative moving speed between the obstacle and vehicle is less than 1m/s, the system is
supposed to operate normally.
In case of a high reversing speed, the sensing accuracy of the reversing radar system will be
decreased and a low speed of 6 km/h is recommended.
If the alarm tone is long, the vehicle must stop immediately as some obstacle has been within 40 cm
at this point.
The sensor has a high precision and it shall not be disassembled without permission, otherwise it is
hard to resume it.
Specifications
Sensing distance Up to 1.5m
Exact value of sensing distance ±4cm
Optimal sensing coverage Within 0.9m
Ultrasonic frequency 48KHz±2KHz
Horizontal angle ≈120°
Sensing range of sensor
Vertical angle ≈60°
Operating voltage DC9V～16V
Operating temperature range -30℃～80℃
Sound 85～115dB/10cm
Note
Owing to the position, angle and size of the object as
well as the relation between reflection and material,
the reflection signal may not be received. In addition,
the signal reflected in a complex environment may be
wrong. See the following examples:
1.The driver cannot get any warning from the
reversing image - or even seeing from the exterior
rear-view mirror.
2. B and C will be detected sooner or later, however A

will never be detected.
3. A is first sensed but when the vehicle is reversed

to a due location, the distance of B is displayed.
Maybe the nearest distance is judged wrongly to
display the distance of B but not that of A. However, it
happens only when the object of the nearest distance
enters the blind area.
4. In case of glass wall or any other smooth surface

nearly vertical to the vehicle, it possibly cannot be
sensed.
5. If approaching to a smooth slope, the slope

possibly cannot be sensed.
6. A small and smooth cylindrical rod possibly cannot

be sensed.
Troubleshooting
Phenomenon Cause Resolution
1. No power supply or 1. Check the battery voltage to
insufficient supply voltage make sure it is normal and the
ignition switch is properly wired.
The reversing radar
2. Poor connection of various 2. Check the various connecting
system doesn’t respond.
connecting wires wires to make sure they are
3. Failure to sense the connected or plugged properly.
obstacle in reversing
The system power is supplied, Improper socket position makes

Correctly connect all the sockets again.
but it cannot operate normally. the sensor unable to operate.
1. The sensor is improperly 1. Correctly install the sensor

installed or falls. and check it regularly.
2. The sensor is damaged. 2. The damaged sensor should
The buzzer gives a long sound.
3. The system detects the be timely replaced.
body or ground.
1. The battery voltage is abnormal. 1. Check the battery to make

sure it operates normally.
It cannot give a correct prompt 2. The socket position is improper. 2. Shut off the system and reconnect
for the distance to the obstacle. all the sockets correctly.
3. The sensor connecting 3. Check the sensor connecting wire for
wire is damaged. touching the exhaust pipe and muffler.
Reversing Camera System

Functions of Reversing Camera System
The camera lens takes the image behind the vehicle and the image signal will be sent to the DVD for
display, which helps driver in reversing.
Note: The ignition switch is turned “ON”, the DVD is in a starting state, and it is shifted to the reverse
gear.
Composition of Reversing Camera System
DVD display
camera lens
Reversing
system
Definition of camera lens interface

NO. Name of Pin Position
1 Video negative pole
2 Video negative pole
Power supply negative pole (drawn
3
from DVD)
Power supply positive pole (drawn
4
from DVD)
Harness Connection and Interface Definition
Video negative pole

Reversing camera lens
DVD and AC all-in-one unit
Video positive pole
Power supply negative pole
Power supply positive pole
Reversing lamp positive pole
Connecting to reversing
Connecting to DVD camera lens
Precautions for Operation

1. The dust and other foreign material affixed to the
surface of camera lens should be timely removed
to get a good image effect. It is recommended to
use soft and wet cloth to gently clean the lens.
2. No water blast gun is allowed to directly spray over
the camera lens.
3. No water blast gun is allowed to directly spray over
the camera lens.
Operating voltage (9～16)V DC
Current consumption 100mA/MAX
Operating temp. range (-30～80)℃
Storage temp. range (-40～85)℃
Image pixel 30×104 pixels (color image)
Signal amplitude (1.0±20%)Vpp
TV system NTSC
Camera lens
Video output amplitude 1.0Vpp/75Ω
Video range V：(88±5)°
H: (115±5)°
Minimum illumination Less than 1.51ux
Chrominance subcarrier frequency 3.579545MHz±200Hz
Image stabilization time 2Sec/MAX
Image resolution ≥300
DVD Player
Outside View of Complete DVD Player and its LCD
Overview of DVD Player Functions

This product consists of the DVD main unit and a LCD (6.5”), which are connected to each other
by the dedicated harness. It is designed with FM/AM stereo broadcasting, and it supports the
disks of CD, VCD, DVD, and MP3. It adopts 4-channel output and a rated output power of 4×25W.
General Diagram for Device Connection
Hole Wiring Wiring Label

Label in Chinese
Position Color Route Content
A1
A2 Brown 20# MUTE Mute testing
A3
A4 Red 20# ACC Ignition testing
A5 Blue 20# P.ANT Control of radio antenna power supply
A6 Orange 20# ILLUMI Headlamp testing
A7 Yellow 16# BATT+ Power supply+
A8 Black 16# GND Connecting the grounding
Pin A Definition
Hole Wiring Wiring Label Hole Label in

Label in Chinese Remarks
Position Color Route Content Position Chinese
B1 Violet 20# RR+ C3-1 NC Empty
Right rear audio output
B2 Violet/black 20# RR- C3-2 NC Empty
B3 Grey 20# FR+ C3-3 NC Empty
Right front audio output
B4 Grey/black 20# FR- C3-4 NC Empty
B5 White 20# FL+ C3-5 NC Empty
Left front audio output
B6 White/black 20# FL- C3-6 NC Empty
B7 Green 20# RL+ C3-7 NC Empty
Left rear audio output
B8 Green/black 20# RL- C3-8 NC Empty
Pin B Definition Pin C3 Definition

Hole Wiring Wiring
Label Content Label in Chinese
Position Color Route
C1-1 Black 22# CAMERA-VIDEO Rear-view mirror video input
C1-4 Yellow 22# CAMERA-VIDEO Rear-view mirror video input +
C1-2
C1-5
C1-3 Black 20# CAMERA-GND Rear-view mirror power supply ground wire
C1-6 Red 20# CAMERA-B+ Rear-view mirror power supply
Pin C1 Definition
Hole Wiring
Wiring Color Label Content Label in Chinese
Position Route
C2-7 Pink 20# REVERSE Reverse detecting
C2-8 Blue/white 20# P.CONT Power amplifier control
C2-9 Orange/white 20# KEY A Keying input A
C2-10 Green/white 20# BRAKE Brake detecting
C2-11 Brown/black 20# KEY GND Keying grounding
C2-12 White/brown 20# KEY B Keying input B
Pin C2 Definition
№ Function Color
Socket Interface G 1 RX Grey
2 TX White
3 ACC+ start power Red
10 4 4 B+ main power supply+ Yellow
9 3 5 NC Empty
8 6 Ground wire Violet
7 7 Ground wire Back
6 2 8 NC Empty
5 1 9 NC Empty
10 ILL+ illuminating wire Orange
Wiring Description
1. Connection between DVD Main Unit and Speaker
The DVD main unit and speaker are connected with each other by an 8-pin connector. Each door of
the vehicle is respectively provided with a low tone speaker and a high tone speaker, and the two
speakers are paralleled and then connected to the corresponding channel of the DVD; be noted that
the speaker phases should be correct, and wrong phase connection will affect the tone quality.
2. DVD main unit power
The ground wire and DVD main unit power supply cable shall be connected with the dedicated
connector.
3. Connection between DVD Main unit and Antenna
(a) Common antenna Directly plug the antenna plug into the antenna socket of the main unit.
(b) Automatic antenna connection Plug the antenna plug into the antenna socket of the main unit ,
and connect the power supply cable of antenna amplifier with the power supply of antenna in the
slot at the rear part of DVD main unit.
Precautions for Control Wire Connection

1 This device is designed for the vehicle with a battery system of 12V and its negative pole
connecting to the ground wire; and if this device is to be installed on the vehicle with a battery
system of 24V, a voltage reducing device is required.
2 Before installation, the connection of the battery negative pole shall be cut off to avoid a short
circuit of the electrical system.
3 The connecting wires are supposed to be arranged in fixable places where it makes them
impossible to touch any movable parts such as hand brake, gear lever, and seat retaining rail;
the connecting wires should not be arranged within the heat source area, for instance, places
around the hot air discharge outlet, otherwise the heat source will cause the connecting wire
insulating layer to melt or wear to further bring the short circuit between the connecting wire
and vehicle body.
4 Do not connect the battery with the yellow power supply cable going through the mounting
hole to the engine compartment, otherwise the power supply cable may be damaged to further
cause the short circuit between the power supply cable and vehicle body.
5 The fuse of given specifications (10A) shall be applied in fuse replacing, and the application of
the fuse unmatchable with the given specifications may cause the failure to normal operation
or even damage to this device or fire accident.
6 No other equipment is allowed to share the power supply with this device, otherwise it may
cause malfunction due to overload.
7 Any exposed wire port shall be well bound using the insulating tape so as to avoid
touching with the metal part of the vehicle body, which may cause the short circuit and then
consequently bring malfunction or fire accident.
8 When the power supply of this device is switched on, the external power amplifier control
signal is given out by means of the down-lead P.CONT; if this device is connected with the
external power amplifier, the down-lead P.CONT shall not be connected to the power end of the
power amplifier, otherwise it will cause malfunction.
9 The output terminals of the speakers of this device shall not be grounded; otherwise the power
amplifier will be burnt out. The 3-wire type speaker system sharing a ground wire shall not be
used, and the speaker wire shall not be connected to the vehicle body either.
Guide to Common Troubleshooting

General problems
Phenomenon Cause Measures
Replace the fuse with the new fuse
The fuse of this device is burnt out. with same specifications.
Device unable to start The fuse of the vehicle battery is burnt out. Replace the fuse of the battery.
Illegal operation or other factors Press the RESET button to reset the system.
Insufficient power of the Replace the remote controller battery.
Remote controller remote controller battery
unable to operate The polarity of the remote controller Correctly mount the battery.
battery is incorrectly handled.
The audio output wire is Correct the connecting error in accordance with
connected incorrectly. the General Diagram for Device Connection.
The volume of the main unit or the part Raise the volume of the main unit
connected with it is tuned too low. or the part to be connected.
Correct the connecting error in accordance with
No sound or too The “MUTE” wire is connected incorrectly. the General Diagram for Device Connection.
low tone
The speaker may be damaged. Check the speaker.
The sound tracks are not balanced. Balance the sound tracks.
Connect the speaker with insulated
The connecting wire of speaker conductor, and bind the exposed on-
touches the vehicle body. line parts by insulating tape.
The disk is illegal. Use the legal disks.
The speaker power is not Replace the speaker.
Relatively poor matchable with this device.
acoustic quality or Correct the connecting error in accordance with
distortion of sound The speaker is connected incorrectly. the General Diagram for Device Connection.
The connecting wire of speaker Check the connecting wire of speaker.
touches the vehicle body.
Phone mute or The “MUTE” wire touches the Make sure the phone MUTE control wire is
distortion of sound metal part of the vehicle body. insulated with the vehicle body.
User configuration The ignition wire ACC and the Correct the connecting error in accordance with
information completely positive pole power supply cable
lost after the ignition the General Diagram for Device Connection.
“BATT” is connected incorrectly.
switch is off
Radio Receiving Problem and Its Measures

Check the radio receiving automatic antenna
The automatic antenna of vehicle is not control wire ANT.CONT to make sure it is
stuck out. connected correctly, in accordance with the
General Diagram for Device Connection.
Bad channel-locking effect Correctly connect the radio antenna in
The radio receiving antenna is connected
accordance with the General Diagram for
improperly.
Device Connection.
The function of local search (LOCAL) is Turn off the function of local search
turned on. (LOCAL).
DVD Playing Problem and Its Measures

Take the disk out of the tray and
Unable to load the disk There has been a disk in the tray.
insert a new disk into the tray.
The disk is scratched, unable to be read. Replace the disk.
The disk is too dirty or
Clean up the disk and wipe it with soft cloth.
moistened by water.
Use the laser-lens cleaner to
The laser lens is smeared.
clean up the laser lens.
Unable to read the disk This device does not support the disk. Check the disk type.
The child lock is of too high grade. Change the configuration of child lock.
The disk is reversely Insert the disk into the tray, with
inserted into the tray. the marked surface upwards .
The region code of the disk does Use the disk containing the same
not agree with that of this device. region code as this device.
Unable to display the subtitle This disk contains no subtitle file. Use the disk containing a subtitle file.
Sound/subtitle This disk contains only one Use the disk containing multiple
switch disabled language / subtitle. sounds / subtitle files.
Use the disk supporting multi-
This disk has only one viewing angle.
Multi-viewing angle viewing angle playing.
switching disabled The fragment being played does not Select in the disk the fragment supporting
support the multi-viewing angle playing. multi-viewing angle playing to play.
This device is compatible with the system,
The disk contains information of and if the disk contains the information of
Fuzzy, and distorted image
guarantee on copy prohibition. copy prohibition, it may not play normally,
which is not machine malfunction.
PBC program list unable to
The disk has no PBC function. Use the disk supporting the PBC function.
be called in playing VCD disk
Unable to replay a
disk or perform the The PBC function is activated. Inactivate the PBC function.
track / time search
TFT Display Problems and Its Measures

No image on the display Correct the connecting error in
The parking control wire “PRK
screen, but warning being accordance with the General
SW” is connected incorrectly.
displayed all the time Diagram for Device Connection.
The DVD output image system is not matchable
Set the display system as AUTOMATIC.
with the display system of the display screen.
The image display system of some illegal
Abnormal display such Use legal disks.
disks is inconsistent with the labeled system.
as bouncing stripe
occurring in the image The video wire is damaged. Replace the video wire.
Correct the connecting error in
Incorrect connection of video connecting wire accordance with the General
Diagram for Device Connection.
Character display Turn off the unit and then restart
disorder or error display Operation mistake it, or switch to other playing
on the display screen source and then return.
Meanings of Common Characters and Malfunctions to be Displayed

Message Cause Measures
The disk is extremely smeared. Clean up the disk or replace it.
Insert the disk into the tray, with
No Disc The disk is reversely inserted.
the marked surface upwards .
The tray contains no disk. Put in the disk.
The disk is extremely smeared. Clean up the disk or replace it.
Bad Disc Insert the disk into the tray, with
The disk is reversely inserted.
the marked surface upwards .
Unknown Disc This device is unable to identify the disk. Use the disk supported by this device.
DVDThe region code of this DVD disk Use the disk whose region code is
Region Error
does not agree with that of this device. consistent with that of this device.
MP3 Playing Problems and Its Measures

The disk is scratched or smeared. Clean up the disk and wipe it with soft cloth.
Use the laser-lens cleaner to clean up the
The laser lens is smeared.
laser lens.
Unable to play MP3
This device does not support the disk. Use the disk supported by this device.
Insert the disk into the tray, with the marked
The disk is reversely inserted.
surface upwards .
The disk is too dirty or scratched. Clean up the disk or replace it.
Not fluent sound in playing MP3 Part of the content is damaged. Replace the disk.
Recording condition is not good. Record the disk again.
Unable to normally display the
The file naming is irregular. Avoid using Chinese file names.
MP3 file name
Vehicle Navigation System GPS

General Description of Vehicle Navigation System
The navigation system consists of four parts, namely, the main unit (Satellite Positioning Navigation
Control Box Assembly), DVD main unit, LCD display and antenna; and the navigation system
displays the relevant information by means of the LCD display. The GPS antenna is connected to the
navigation control box by a dedicated plug.
Satellite Signal
The navigation system needs the global positioning system (GPS) to determine the vehicle position.
First of all, the GPS needs to know the longitude and latitude of the vehicle. Under some special
circumstances, the GPS also needs to know the altitude for precise positioning. With the said three
kinds of data, the positioning accuracy of GPS can often reach up to (2~3) m. The GPS will not work
before the vehicle navigation system is located within the direct sight of the synchronous satellite,
and therefore, the tunnel, bridge, or high-rise building all may block off the direct sight to disable
the navigation system from operating. In addition, the navigation system uses the trigonometrical
and geometrical methods to calculate the vehicle position, and generally speaking, this system can
precisely calculate the position of the vehicle as long as it receives the signals from 4 satellites (the
GPS navigation needs at least 4 satellite signals, of which, three are used to determine the latitude,
longitude and altitude of the GPS receiver, and the fourth is used to offer the synchronous correction
time). The more synchronous satellites there are within the direct sight of the navigation system, the
more precise the positioning will be; the system can display the number of the satellites in the signal
state.
Signal Receiving
The operational principle of the GPS is to analyze the signals received from the synchronous
satellites. Projected on the vertical plane, those signals can be visually expressed as lots of inverted
funnels. If the lower parts of these “funnels” are overlapped to a certain extent, the analyzing program
of the GPS can calculate the coordinates of the vehicle location. In course of the traveling of the
vehicle, a device similar to the gyroscope used by a plane or ship can provide the locations of the
vehicle continuously. In case of interruption of the satellite signal, the data provided by the speed
counter will be used to fill its blank and record the traveling time.
Map Database
When the coordinate information provided by the GPS is overlapped on the electronic map, the driver
can see his present location and future directions. The last step is called mapping, which is the most
important step of the vehicle navigation system, without such step, the navigation system will lose its
direction.
Composition and External View of GPS
DVD Main unit

LCD Display
Satellite Positioning Navigation

Control Box Assembly
Connection Diagram of
DVD Main unit
DVD Main unit

See the “DVD player” section for the definitions of pins A, B, C1, C2, C3, and connection description
of the DVD player and its troubleshooting.
GPS Technical Parameters of GPS
Category Item Description
Power supply voltage (9－16)V
Current consumption < 500mA
Operation temp. -10°C―60°C
Size of main body 142(L)×95(W)×25(H)mm
Satellite receiving channel number 16channels
Receiving sensitivity -150dB
Main unit
Positioning accuracy 10m
Positioning time Cold start < 50s warm start < 35s
hot start < 3s
Refreshing frequency 1HZ
Memory 32MByte
Display screen 480×242
GPS antenna Center frequency 1575.42MHZ
GPS Troubleshooting
Phenomenon Possible cause Solution
1. The connecting wire to the main unit is 1. Make sure the main unit is well connected, and
Unable to start the not well plugged. fix it with screws.
navigator 2. An overheating GPS navigator may cause 2. First shut down the navigator for some time,
it unable to start normally. and restart it after it cools.
1. The navigator and the satellite receiving 1. Check the navigator antenna to make sure it is
antenna are connected improperly. well connected.
2. It shows no signal within some time after 2. After the navigator is just started, there will
it is started. be a short period in which the signal cannot
be received, and after a while, it will enter the
Unable to receive
normal operation state. This is normal and just
the satellite signals
be patient.
3. The vehicle is located “under the bridge, 3. Drive the vehicle away from those obstacles to
in the tunnel or around the high-rise recover the normal signal receiving.
building” where the signal receiving is
definitely affected.
The software gets lagged as the user enters Press the RESET button on the navigator to reset
Failure in the course too many instructions into the navigator within the navigation and restart the navigator.
of operation a short time or for other causes.
Software prompt: The SD card becomes loose, or the SD card Shut down the navigator and tightly insert the SD
please insert the SD is forgotten. card. Prompt: Try best not to insert and pull out the
card SD card frequently.
1. This information point is relatively small or 1. Search the relatively big or famous information
a newly-built structure, and the navigation points in the annex.
Unable to search the electronic map of the navigator has no
information point sub-information point.
2. The name entered by the user is 2. Enter the full name of the information point
incorrect.
1. The vehicle runs under the interchange 1. It will all resume normal after the vehicle comes
Deviation occurring
or overpass, and the satellite signals are out of this area.
between the
interfered to cause positioning deviation.
navigation and actual
2. The actual road conditions have changed, 2. Keep up driving, and the navigator will re-plan
situation
and the road on the map is not completely a new route for you to reach your destination.
matched with the real road.
1. It occurs after the route is re-planned. 1. The navigator is re-planning and it is normal,
2. The actual road conditions are changed. and just be patient.
No sound prompt,
3. The vehicle runs under the interchange 2. Keep up driving, and the navigator will re-plan a
lag occurring, and
or overpass, and the satellite signals are new route for you to reach your destination.
navigation image
interfered to cause positioning deviation. 3. Drive the vehicle away from those obstacles to
error
Using the navigator behind the overpass recover the normal signal receiving.
or around the high-rise building makes the
satellite signals become discontinuous.
Engine Anti-theft System

Constitution of Engine Anti-theft System
This engine is equipped with a DELPHI anti-theft control system, composed of anti-theft controller,
password responsers and anti-theft coil.
Note: Each vehicle has been equipped with two keys, each key provided with an embedded
password responser.
1. Since the password responser requires the specific magnetic field intensity, the anti-theft
coil must be axially fixed on the ignition switch. The anti-theft controller may be installed
on the proper position of vehicle body, but the anti-theft controller for this vehicle is located
on the brake pedal. The anti-theft coil cable is connected with the anti-theft controller via
the terminals. The engine control module (ECM) communicates with the anti-theft controller
through the K line.
2. When you insert the key to the lock core and then turn the key to the position “ON”, the anti-
theft controller respectively establishes the communication with the password responser
and ECM, and then verifies their passwords. If the password verification is successful, it is
allowed to start the engine. Or else, the fuel cutoff mode will be actuated; at this time, the anti-
theft controller and password responser are subject to the password verification. After the
password verification on anti-theft controller and password responser succeeds, the anti-theft
controller and ECM will be exposed to the subsequent password verification.
3. Steps for Password Verification:
(a) Once the ignition switch is turned to the position “ON”, the anti-theft controller shall be activated.
(b) When the ignition switch is turned to the position “ON”, the ECM shall begin initialization.
(c) The password verification is carried out on the anti-theft controller and password responser.
(d) After the password verification on anti-theft controller and password responser succeeds, the
anti-theft controller and ECM shall be exposed to the subsequent password verification.
It is not allowed to start the engine Password Responser The front end encryption is composed of the
unless password verifications protocol between anti-theft repeater and anti-
1# and #2 are successful! theft controller and the encrypted functions.
Front End Encryption

Password
Verification #1
Password
Password Verification
Verification #2
ECM Anti-theft Diagnosis
Controller Device
Final End Maintenance

Encryption End Encryption
The final end encryption is composed of the Since the communication protocol between anti-theft
specific communication protocol between controller and diagnosis device usually follows some
anti-theft controller and ECU and the public protocols for complete vehicle, many special
encrypted functions in ECM and ECU. strategies are applied to this vehicle to effectively
prevent the malicious attack of skilled thief.
Precautions:
1 Once the ignition switch is turned to the position “ON”, the alarm lamp will light for 2s±50ms.
2 When the sleep mode is activated, the alarm lamp will flicker with the following frequency: it
constantly lights for 50ms every 2±10%s.
3 If the password verification is unsuccessful, the alarm lamp will flicker with the 1Hz frequency
and 50% duty ratio.
4 If the password verification is successful, the alarm lamp will be off.
5 When the diagnosis is carried out, the alarm lamp will be off.
It is hereby explained that: once a Great Wall vehicle equipped with the anti-theft system goes off
the production line, the off-line matching equipment will automatically engender a 4-digital user
authorization code (a.k.a. PIN code) according to the VIN code, and the system will automatically
print this 4-digital code into the password envelope (confidential document) as shown in the following
figure.
VIN code PIN code
This 4-digit user authorization code directly affects the replacement of anti-theft controller and ECU
and other operations (such as clearing key list, resetting anti-theft controller and clearing malfunction
codes) conducted by after-sales service station. If a user authorization code has been erroneously
entered for several times, the anti-theft system will be automatically delayed till the password lock is
closed. Please pay especial attention to this!
Schematic Circuit Diagram of Anti-theft Controller

Constant Constant voltage of
Diagnosis From voltage instrumentvoltage
K line IG1 of ECU of ECU
Brown/White
Green/Yellow
Red
Whiteindication lamp
Status
Green/Red
Anti-theft ECU
assembly
Yellow/Red
Yellow/Black
Key detection
Black
Structure of Anti-theft System
Anti-theft controller
The connecting cable for

coil and anti-theft controller
shall be shorter than 90cm
Coil
Password Bolt
responser
Designations for Anti-theft Controller Terminals

Positive
B1 Alarm lamp A1
pole of coil
B2 Grounding A2 Blank pin
Negative
B3 Ignition switch A3
pole of coil
Positive pole
B4
of battery
B5 Blank pin
B6 Blank pin
Diagnosis
B7
communication port
B8 Blank pin
Treatment for Malfunction Codes

1. Detection and Treatment for Malfunction Codes
Once the ignition switch is turned to the position “ON”, the anti-theft system will begin self-checking.
If a malfunction happens, its corresponding malfunction code will be saved into EEPROM, and the
system malfunction status will turn to “Malfunction Code Detected and Saved”, and the reading of
malfunction code counter will be 15.
If the same malfunction no longer occurs in next ignition cycle, the system malfunction status will turn
to “Malfunction Code Saved but Unfound Yet”. If the reading of malfunction code counter descends to 0,
the malfunction will be deleted from the EEPROM, and the system malfunction status will return to “No
Malfunction Code Found Yet”.
11 kinds of different malfunction codes may be saved.
2. Clearing of Malfunction Codes

It is available to clear the malfunction codes by the diagnosis device. If the anti-theft controller is
deenergized, the existing malfunction code and the reading of malfunction code counter will be saved
in EEPROM.
3. Malfunction Code List
Malfunction Code
No. Malfunction Description
(Hexadecimal)
1 B1001 The anti-theft controller malfunction RAM/ROM or the EEPROM is at fault.
The user authorization codes have not been programmed, or all user authorization codes
2 B1002
in EEPROM are 00H or FFH.
The non-password responser modulation signal has not received the password responser
identification code; when the ignition switch is turned on, there is no key, or the present
key is merely a mechanical key, or no password responser in the key, or the password
3 B1003 responser is damaged; when the ignition switch is turned on, the password responser
fails to read the information (i.e. the password verification by password responser takes a
time beyond 1s.); the password responser is at fault; or the reading circuit hardware is at
fault.
4 B1004 The keys have not been programmed, or the values of all keys are “0” or “1”.
5 B1005 The K line short-circuits to ground lasting over 450ms.
6 B1006 The password verification on ECM is unsuccessful, or the verification result is NG.
No request or confirmation information from ECM has been received; the K line is
exposed to open circuit; the ECM is damaged; no request information from ECM has
7 B1007
been received within 2s; for a password verification cycle, no conformation information
from ECM has been received within 3.5s after the first request from ECM is received.
The password verification on password responser is unsuccessful; the identification code

8 B1008
from password responser dose not match that in EEPROM; or the key is wrong.
The identification code list of password responser is blank, or no password responser

9 B1009
identification code is saved in EEPROM.
The format of received password responser data is wrong (inconsistent with the
10 B1010
predefined format).
The alarm lamp fails to output, or short-circuits to the battery, or suffers from the drive
11 B1017
malfunction.
Replacing Anti-theft Controller Program in Maintenance Station

During the use of vehicle, if the anti-theft controller module gets damaged due to the accident or
other factors, the anti-theft controller will be unable to work normally, and the key can not activate the
vehicle. The anti-theft controller shall be replaced once it has been confirmed as damaged one.
If a new anti-theft controller is used, it is required to match the anti-theft controller with the ECM and
key. The anti-theft controller can not be used as usual and the vehicle shall not be started, unless the
matching between them is successful.
During the course of replacing anti-theft controller, the following tasks shall be completed for
programming:
- Write the key saved in ECM into the new anti-theft controller;
- Write the password responser identification code into the new anti-theft controller;
- Write the user authorization code into the new anti-theft controller;
Connect the diagnosis device with the vehicle diagnosis port;
Insert the key to the lock core;
Turn the ignition switch to the position “ON”;
Wait for at least 4s; and
Establish the communication between ECM and diagnosis device.
Replace anti-theft controller 1. Confirm to replace the functions of anti-theft

controller.
Do you want to replace the anti-theft controller?
At first, the diagnosis device asks whether it is
necessary to replace the functions of anti-theft
controller. Only after the user clicks “Yes” can he
proceed to the following functions.
Yes No
Enter
Reading Key 2. Insert the key to be learned, turn the ignition switch
to the position “ON”, and then click the button
“ENTER”.
Please insert the key to be learned and turn the
ignition switch to the position “ON”.
Enter Print
Enter
Reading Key 3. Input the user authorization code.

The diagnosis reads the key from the engine system,
and then writes this key into the anti-theft controller.
Input a 4-digital hexadecimal user authorization
code
After the successful writing, the matching for key will

be carried out.
Enter
Matching
Replacing Key
Anti-theft Controller
4. Match the key
Now
Please insert thethe key is key
second matching…
to be learned, turn
on ignition switch, and then click the button [Enter]
Diagnosis Homepage
Enter
Enter
Replacing Anti-theft Controller

5. Insert the second key to be learned
Please insert the second key to be learned, turn

on ignition switch, and then click the button [Enter]
Enter
Enter
Programming VIN
6. Input the VIN code
Since the present anti-theft controller is a new one,
Please input a 17-digital VIN code.
you have to set the VIN code. In consideration of the

importance of VIN code for anti-theft function, make
sure that the VIN code you input shall be consistent
with that of present vehicle and such a VIN code shall
be unique.
Enter
Programming VIN 7. Confirm the VIN code

After you input the VIN code, it will be displayed on the
The VIN code you just input is:
LGB32AE3472003443
diagnosis device for your confirmation. If the VIN code
Is it right?
If it is right, click “Yes”; or else, click “No”. you input is right, you can proceed to the following
functions; or else, you may click the button “No” to
input the right VIN code.
Yes No
8. After the VIN code is successfully written, the

Enter
diagnosis device will write the authorization code
into the anti-theft controller, and this course does
not need to be inputted by user.
9. Turn the key to the position “OFF”, and then click
Replacing Anti-theft Controller
the button “Enter”.
10. Turn the key to the position “ON”, and then click
the button “Enter”. If you can proceed to this step,
Programming for replacing anti-theft controller
has been successfully completed!
this means that the anti-theft controller has been
successfully replaced.
After replacing the anti-theft controller, try starting the
vehicle by the key. If your try fails, you shall search for
Enter
Enter
the reason and then conduct the proper matching.
Replacing ECM Programming in Maintenance Station

When the ECM needs replacing, you have to match the new ECM with the anti-theft controller. Only
after the matching gets successful can the anti-theft controller and key work normally.
During the course of replacing ECM, the following tasks shall be completed for programming:
- Write the user authorization code to the new ECM;
- Write the key saved in anti-theft controller into the new ECM.
Replacing ECM 1. Confirm to replace the ECM according to the

prompt.
2. Turn the key to the position “ON”, and the click the
Do you want to replace the ECM?
button “Enter”.
Yes No
Enter
Reading Key 3. Insert the key to be learned, and then click the
button “Enter”.
Insert the key to be learned, and turn the ignition

switch to the position “ON”.
Enter Print
Enter
Reading Key 4. Input the user authorization code

Please input a 4-digital hexadecimal user
Only after you input the right user authorization code
authorization code.
can you proceed to the following functions.
Enter
Programming VIN
5. Input the VIN code
The diagnosis device will write the key read from anti-
Please input a 17-digital VIN code.
theft controller into the ECM of the engine. After the
successful writing, the engine system VIN code shall
be written.
Enter
Programming VIN 6. Confirm the VIN code

After you input the VIN code, it will be displayed on the
The VIN code you just input is:
diagnosis device for your confirmation. If the VIN code
you input is right, you can proceed to the following
LGB32AE3472003443
Is it right?
If it is right, click “Yes”; or else, click “No”.
functions; or else, you may input the right VIN code

instead.
Yes No
Enter
7. After the VIN code is successfully written, the

Replacing ECM diagnosis device will begin to set the user
authorization code of engine system. During
this course, the diagnosis device dose not need
Turn the key to the position “ON”, and then click
the button [Enter].
the input by user, it just directly call the user
authorization code and keep this code consistent
with that of anti-controller.
With the authorization code properly set, the ECM, on
the whole, has been successfully matched..
Enter
Enter the button “Enter”.
9. Turn the switch to the position “ON”, and then click
Malfunction Code 10. Read the malfunction code.

Read the malfunction to judge whether the matching is
B1001: The anti-theft controller is at fault.
B1002: The user authorization has not been

programmed.
B1003: No password responser modulation signal is
found. successful.
Previous Page Next Page
Diagnosis
Homepage Back Print Help
Enter
Replacing ECM
11. If any malfunction code appears, record it.
After the ECM is matched, try starting the vehicle by
the key. If your try fails, you shall search for the reason
If anyone of malfunction code B1005, B1006 and
B1007 appears, the programming is unsuccessful;
or else, the programming is successful. and properly re-match the ECM (if necessary).
Enter Print
Enter
Matching Key Re-matching of key

Complete the re-matching of key and turn the ignition
Please insert the first key to be learned, and turn
the ignition switch to the position “ON”.
switch to the position “OFF” (It is forbidden to cut off
the power supply or start the vehicle).
1. Insert the first key to be learned.
Enter Print
Enter
Inputting User Authorization Code

2. Input the user authorization code to verify the va-
Input a 4-digital hexadecimal user authorization
lidity of user identity. If the authorization code is
wrongly input, the user will be unable to access the
code.
key matching function.

3. After the user input the right user authorization
code, the diagnosis device will ask the user wheth-
er to clear the key list. If you select “Yes”, all of
previous keys can not be used, and they need re-
matching; or else, the previous keys will not be
Enter
cleared.
4. Matching Key
Matching Key 5. Turn the key to the position “OFF”, and then click
6. Insert the second key, insert the key to position
Do you want to match the second key? (It is
recommended that you match two keys.)
“ON”, and then click the button “Enter”.
7. Make sure that the second key are properly
matched (it is suggested that the user keep two
available key)
Yes No
Enter
Matching Key 8. Turn the key to the position “OFF”, and then click
9. Turn the key to the position “ON”, and then click
Now the key is matching… the button “Enter”.
10. Match the key.
Diagnosis Homepage
Enter
Malfunction Code
11. If any malfunction code is found, the content of
B1001: The anti-theft controller is at fault.
malfunction code will be displayed on the interface
as shown in the left figure; or else, no malfunction
B1002: The user authorization has not been
programmed.
B1003: No password responser modulation signal is
code will be displayed. If any malfunction code is

found.
found, please record it; or else, click “BACK”.
Previous Page Next Page
Diagnosis
Homepage Back Print Help
Enter
Matching Key
12. Now, the key function has been completely added.
Check whether the key can be used normally. If the
result is negative, you shall re-match the key.
If anyone of malfunction code B1003, B1008,
B1009 and B1010 appears, the programming
is unsuccessful; or else, the programming is
successful.
Enter Print
Enter
Air Conditioning System-1
Air Conditioning System
Components...................................................................... 2
PTC electric heating system (Optional PTC electric
heating by Hover diesel vehicle A/C system) ................ 4
Trouble Diagnosis and Repair of Automatic Air
Conditioning System........................................................ 6
Trouble Diagnosis and Troubleshooting of Air
Conditioning System........................................................ 11
Volume of Refrigeration Oil Addition and its Methods . 14
Pumping Out of Air Conditioning System to the
Vacuum and Addition of Refrigeration Oil ..................... 14
Daily Maintenance of Air Conditioning System ............. 17
Components
Fluorin intake hose of compressor
Heater water tank assembly

Fluorin outtake hose of compressor
evaporator assembly condenser assembly
blower assembly Inner low pressure

pipe of engine room
compressor assembly
Reservoir tank
Right high pressure pipe of engine room Front high pressure

hose of condenser
Composition of Air Conditioning control System

Air conditioning system mainly consists of air conditioner control unit, display unit, sensors and execu-
tor elements.
1 outside temperature sensor

10
fresh air damper executor
5
inside temperature sensor

9
4
mode damper executor integrated display screen
temperature sensor of the evaporator

8
2
temperature damper executor
3
7
ECU of the air conditioner
speed-adjusting module
CD Player
outside temperature sensor

10
11 DVD player
fresh air damper executor
5
inside temperature sensor

9
4
mode damper executor
⑹ ⑶ ⑴⑵
11 ① temperature sensor of the evaporator
⑷
⑨ ②
8
temperature damper executor
3
④ ⑤ ⑥ ⑦ ③ ⑧ ⑩
7
12 air conditioner control panel ECU of the air conditioner
speed-adjusting module
1. Integrated display screen 2. CD player 3. Air conditioner ECU 4. Temperature sensor the evapo-
rator 5. Inside temperature sensor 6. Outside temperature sensor 7. Speed-adjusting module
8. Temperature damper executor 9. Mode damper executor 10. Fresh air damper executor 11. DVD
player 12. Air conditioner control panel
Definitions of A/C control buttons on the CD player control panel and A/C control panel
[1] Button to increase the temperature [7] wind conveying mode button
[2] Button to decrease the temperature [8] button to start air conditioner
[3] automatic operation button [9] button to decrease the wind amount
[4] front-defrost button [10] power-off button of air conditioner
[5] rear-defrost button [11] button to increase the wind amount
[6] external circulation button
Definitions of the control buttons in the A/C display area on the integrated display and
the A/C control panel
[1] display of inside temperature setting of air conditioner
[2] display of automatic operation of air conditioner
[3] display zone of wind conveying mode of air conditioner
[4] display zone of wind amount of air conditioner
[5] switch button of outside temperature display
[6] display zone of outside temperature
[7] clock display zone
Control and display unit:
The A/C control and display units mainly include:
A/C ECU: The CC6460K-type vehicle adopts an independent A/C ECU installed below the CD player
or DVD player, to control the whole A/C system. When the vehicle is fitted with CD player, the A/C
control panel is integrated in the CD player control panel. When the vehicle is fitted with DVD player,
the A/C control panel is independent of the DVD player control panel. The A/C control panel is used to
adjust, control, and set the operation of A/C system.
The integrated display or A/C control panel shows the operation of vehicle’s A/C system. The relative
functions of A/C system are displayed in different areas on the integrated display.
The sensor
Sensors of CC6460K Model automatic air conditioning system include: inside temperature sensor,
outside temperature sensor, temperature sensor executor of the evaporator. Executor components
include: mode selection executor motor, cold & hot executor motor, internal & external circulation exe-
cutor motor.
PTC electric heating system (Optional PTC electric heating by
Hover diesel vehicle A/C system)
Heater assembly
PTC electric heater
PTC, the electric heating ceramics, is equipped on vehicle to heat and warm for passenger space at
the primary stage after cold start in extremely cold area. When ambient temperature is 25 ℃, the two
lead pins' resistance value of PTC connector assembly is 0.36 Ω ± 20％; The value varies a little with
the changing of ambient temperature. The self-diagnostic methods and steps of relative A/C control
unit are to extend the existing process, i.e. to add the inspection steps 12 and 13.
Basic Diagram of PTC Electric Heating System Circuit
Normal power supply

Normal power supply
Normal power supply
Normal power supply

Engine
Engine
IG2
Speed sensor
Blue
Blue
Red
Evaporator of temperature sensor
Blue White
White Red
Red
Red Black
Red
Red Green
Red
Yellow
Blower relay
Relay Blue
Red Black
Brown Grey
White Black
Green Red
Red
Blue Red
Brown Blue
Yellow
Green
Black Yellow
Green
Black
Blower
Green
CD player
Red
Shield ground Black
A/C ECU assembly

Red Black
Green
Yellow Black
Red White
White Blue
White Black
Pink Red
Blue Yellow
Blue Black
Green Black
Blue Orange
Yellow
White
Pink red Yellow
Blue
High-speed relay blower
defroster relay
Windscreen
Cooling and heating air actuator
Mode actuator
Blue Yellow
Windscreen defroster indicator lamp

Defroster of right rear-view mirror
Defroster of left rear-view mirror

Connecting the ECU C2A Connecting the ECU C2B Connecting the
outdoor temperature
sensor
Connecting the Connecting

Connecting the Connecting the internal Connecting
A/C pressure Connecting Connecting
A/C cooling the A/C mode and external the Speed
switch the evaporator the blower
and heating air actuator circulation governing
temperature motor
actuator actuator module
sensor
Connecting the combination instrument

left rear-view right rear-view
mirror mirror

Connecting the indoor negative pole of positive pole of
temperature sensor rear windscreen Connecting rear windscreen
defroster the PTC defroster
Definition of A/C Control Unit Ports
Plug No. Plug Function Plug No. Plug Function

A-1 GND B-1 Negative pole of temperature actuator
A-2 IG2 B-2 Feedback of temperature actuator
A-3 Null B-3 Negative pole of mode actuator
Negative pole of internal and external
A-4 PTC electric heater B-4
A-5 Water temperature sensor (WT) B-5 Null
A-6 Rear windscreen defroster B-6 Null
A-7 Compressor request B-7 Null
A-8 High-speed blower relay B-8 Display interface input
A-9 GND B-9 Display interface output
A - 10 IG2 B - 10 Display interface ground
A - 11 Engine rotation speed (RS) B - 11 Positive pole of temperature actuator
A - 12 Null B - 12 Feedback of mode actuator
A - 13 Positive pole of storage battery B - 13 Positive pole of mode actuator
Positive pole of internal and external
A - 14 Self-diagnosis B - 14
Feedback of internal and external cir-
A - 15 Speed governing module B - 15
culation actuator
A - 16 Feedback of speed governing module B - 16 5V Power supply
B - 17 Evaporator temperature sensor
B - 18 Outdoor temperature sensor
B - 19 Indoor temperature sensor
B - 20 Sensor GND
Trouble Diagnosis and Repair of Automatic Air Conditioning

System
1. Self-diagnosis of the system
CC6460K air conditioning system is designed with the system self-diagnosis function. When the air
conditioning system fails to work, the self-diagnosis function designed for the car can be activated for
the initial trouble diagnosis.
Operating directions:
At first, start the engine (turn the ignition switch from OFF to ON) and press OFF, A U TO, RR and
MODE successively and the pressing of MODE switch shall last at least 2 seconds. The button must
be pressed down within 10 seconds when the engine is started (the ignition switch is turned to ON po-
sition).If the system is supposed to be released, then press A U TO switch or turn off the ignition swit-
ch (OFF) .If one step is supposed to switch to another step, then press TEMP (HOT) or TEMP (COLD)
switch based on the needs.
The inspection procedures:
Turn the ignition switch from OFF to ON
During the period of 10 seconds after the engine is started(turn the ignition switch from OFF to ON), press OF F, A U TO,
RR and MODE once more, and the pressing of MODE switch shall last at least 2 seconds .
NO
The display symbols all light up failure of the switch or display tune
Press down “Temp+” switch
Enter into self-diagnosis procedur1? NO

“ Temp +” switch failure
Step 1: Display “01” (set the temperature zone)
all other display symbols turn off
All sensors are good.

Step 2: Display “02”(set the temperature zone) Display “000”
(outside temperature)
Sensor failure
Code of
Sensor failure
failure
100 Open circuit of outside temperature sensor
The code of the sensor with failure 200 Short circuit of outside temperature sensor
is showed on the display screen.
010 Open circuit of inside temperature sensor
020 short circuit of inside temperature sensor
Open circuit of temperature sensor of the
001
evaporator
Short circuit of temperature sensor of the
002
evaporator
Step 3: Display “03”(set the temperature zone) Display the outside temperature value
Step 4: Display “04”(set the temperature zone) Display the inside temperature value
Step 5: Display “05” (set the temperature zone) Display the temperature value of the evaporator
B
Step 6: Display “06”(set the temperature zone)
Code
Code Meaning
number
Temperature damper executor works
Display the detection code of mode/ 0x0
temperature damper executor normally
Detection for temperature damper exe-
0x1
cutor is in progress.
0x2 Temperature damper executor failure
00x Mode damper executor works normally
Press down “Temp+” switch Detection for mode damper executor is
01x
in progress.
02x Mode damper executor failure
Note: X is a digital number without specific meaning;

Step 7: display “07”(set the temperature zone) the code number is displayed in the outside temperature
display zone.
Action of the executor mechanism:

Mode damper: wind to the person
Circulation damper: internal circulation
Temperature damper: cold end
Wind amount: the maximum
Compressor: enabled
Step 8: display “08”
C

Mode damper: wind to the person and the feet
Circulation damper: internal circulation
Temperature damper: in the middle
Wind amount: bigger
Compressor: enabled
Step 9: display “09”

Mode damper: wind to the person and the feet
Circulation damper: external circulation
Temperature damper: hot end
Wind amount: medium
Compressor: enabled
Step 10: display “10” (set the temperature zone)

Mode damper: wind to the feet and defrost
Temperature damper: in the middle Wind
amount: small
Compressor: off
Step 11: display “11”(set the temperature zone)

Mode damper: defrost
Temperature damper: cold end
Wind amount: the minimum
Compressor: off
Car inside and outside temperature display area indicates: “000” PTC is started normally.
Car inside and outside temperature display area indicates: “111” PTC can not be started.
Car inside and outside temperature display area indicates: “000” PTC is shut down normally.
Car inside and outside temperature display area indicates: “111” PTC can not be shut down.
Note: During checking step 7 to step 11, the controller will forcibly transmit output signal to
the controlled actuator according to the codes shown on the integrated display. Do the chec-
king by visual inspection, listening to the abnormal sounds, or touching the air outlet by hand,
to decide if there is any improper operation.
Step 12 and 13 are only applicable to the A/C fitted with the optional PTC electric heating func-
tion.
Trouble Diagnosis and Troubleshooting of Air Conditioning Sys-

tem
1. Air cooling system
(a) Refrigeration of air conditioner failed
Descrip-
Trouble Analysis of the Cause
tions
1. fuse burned down, compressor’ s relay damaged
2. pressure switch contact disconnected, short circuit or open circuit of the
routing
3. open circuit of clutch’s winding
4. switch burned down
5. master relay burned down
1.No pick-
6. slide of the clutch
up of com-
7. belt of the compressor broke or too loose
pressor
8. compressor failure
9. sensor failure(judged by reading the failure code)
R efrigera-
10. insufficient cold media, lower system pressure(< 0.196MPa)
tion of air
11. system pressure above 3.14MPa
conditioning
12. water temperature of the engine too high
system failed
13. V oltage of the clutch below 7.5V
2. Pick-up 1. normally-open contact of the compressor’ s relay stuck and serious leakage
of Com- of system cold media, systemrunning short of cold media
pressor 2. no wind fromthe blower
1. fuse burned down
2. motor brush of the blower damaged
3. no wind
3. switch of the blower damaged
from the
4. coming off of distribution wire connectors or circuit disconnected
blower
5. speed-adjusting module damaged
6. no wind fromthe blower when at high speed, high-speed relay damaged
(b) Insufficient refrigeration output

Trouble Descriptions Analysis of the Cause
1. compressor works normally
a. low-level pressure at high-pressure and low-pressure sides
• block of expansion valve
• openness of expansion valve too narrow
• Insufficient refrigerant
b. high-level pressure at high-pressure and low-pressure sides
• failure to high-voltage pipeline, flow not smooth
• malfunction of thermo resistor
• openness of expansion valve too wide
• too much refrigeration oil
• too much refrigerant
• poor heat dissipation of the condenser
c. pressure at high-voltage side too low
• low-pressure pipeline damaged
• block of low-pressure pipeline
d. pressure at low-pressure side too low
• the evaporator frosted
• block of expansion valve
• low-pressure pipeline not smooth
• malfunction of thermo resistor
e. pressure at low-pressure side sometime normal, sometimes with ne-
gative pressure, moisture and ice block in air cooling system
f. negative pressure at low-pressure side, pressure at high-pressure
1.wind amount side too low, block of air cooling system
is normal g. pressure at low-pressure side too low, pressure at high-pressure
side too high
Inadequate • internal block of drier of fluid reservoir
refrigera- • block of high-pressure pipeline
tion h. pressure at low-pressure side too high, pressure at high-pressure
side too low
• leakage of the compressor
• damaged valve of compressor
i. poor heat radiation of condenser due to small wind amount fromthe
condensing blower
2. compressor works improperly
a. internal malfunction of compressor
b. belt of compressor too loose or sliding
c. failure of electromagnetic clutch
• low voltage of power supply
• Poor fitting of the suction cup (armature) with the belt wheel at-
traction surface
• Faulty engine ECU
• circuit disconnected, coming off of the joints
• poor operation of the switch and relay
• short circuit and open circuit of the routing
• poor earthing
3. other causes
bad sealing of wagon
1. fan of the blower works normally
a. air supply pipe damaged
2 . s m a l l w i n d 2. Abnormal blower
amount a. switch of the blower is abnormal
b. low voltage of power supply
c. speed-adjusting module damaged
(c) The cooling system sometimes works while sometimes refuses to work.
The cooling 1. ice block in the cooling system
s y s t e m compressor works nor- 2. failure of thermal resistor or temperature sensing bulb
sometimes mally 3. poor contact of A /C switch
produces 4. condensing blower damaged
refrigeration
effect while compressor works im-
2. coming off of the clutch’ s winding
sometimes properly
3. poor earthing of clutch’ s winding
not.
(d) Noise of the air cooling system
1. belt too loose or worn too much
2. fastening screw of mounting holder of the compressor loose-
ned
3. mounting holder of the compressor damaged
Noise of
4. internal parts of the compressor damaged
the air
5. too much refrigeration oil or none
c o o l i n g Noise too loud
system too
7. Bearing of the clutch running short of oil or damaged
loud
8. motor bearing of the blower damaged
9. holder of the blower broken or loosened
10. blade of the blower broken or loosened
11. Friction of the blower’ s blade with other components
(e) Precautions for the overhaul of air cooling system
When the air cooling system encounters the trouble, the cause for such trouble shall be analyzed in-
lightof trouble varieties, followed with the examination and report work.
2. air heating system
Trouble Causes of the trouble
1. blower of air conditioner failure 2. relay of the blower damaged
Heating not supplied or
3. heating water pipe blocked 4. cooling water pipe blocked
not sufficiently supplied
5. cold/hot damper executor damaged 6. insufficient cooling liquid
1. fuse burned down or poor contact of the switch
2. motor of the blower burned down
No rotation of blower 3. open circuit of high-speed relay of the blower
4. speed-adjusting module damaged
5. short circuit
leakage of water Water pipe of air heating aged, insecure joint
1. speed-adjusting resistor of the fan damaged
Overheat
2. cold/hot damper executor damaged
1. mode executor damaged
2. falling off of the drive rod
3. damper not in position
Insufficient hot air volume
4. air vent blocked
for defrosting
5. inadequate heating supply
6. installation of wind tunnel not fit
7. circuit disconnected
Volume of Refrigeration Oil Addition and its Methods

1. CC6460K air conditioning system is designed with SD7V16 compressor, whose refrigeration oil
type as specified is SP-10PAG; hence application of other type of refrigeration oil may damage
the parts and components of the compressor. When the air conditioning system goes through
maintenance and replacement of parts, it should be added with new refrigeration oil, whose
volume is listed as follows: the evaporator and condenser: 30ml; the drier: 20ml; the pipeline:
10ml.
Addition of refrigeration oil can be available with two methods: The direct addition and the vacuum
suction
2. Direct addition method
(a) remove the oil filler plug and fill with the specified SP-10PAG refrigeration oil.
(b) observe through the hole of oil filter plug and rotate front plate of clutch to make the piston con-
necting rod right position in the center of the hole of oil filter plug.
(c) insert the dipstick along the right side of piston connecting rod till the top of dipstick touches the
case of the compressor
(d) pull out the dipstick and examine the graduations (grooves) of refrigeration oil, the readings shall
be within the range of 4-6 scales.
(e) screw firmly the oil filter plug with the fastening torque of 14.7± 4.9N·m
3. Vacuum suction method
Firstly pump out the refrigerating system to the vacuum of 0.2x105Pa, and then fill with the specified
0.2x105 Pa refrigeration oil; the detailed steps are as follows:
(a) switch off the high-pressure manual valve and the auxiliary valve.
(b) dismantle the high-pressure side hose from the manifold pressure gauge and insert it into the oil
cup
(c) open the auxiliary valve and have the refrigeration oil sucked into the refrigerating system from
the oil cup.
(d) when the refrigeration oil in the oil cup is almost pumped out to the vacuum, then immediately
turn off the auxiliary valve to prevent the air from being sucked into the system.
(e) secure the hose adapter at high-pressure side to the manifold pressure gauge, start the vacuum
pump and turn on the highpressure manual valve, then turn on the auxiliary valve to pump the
system to the vacuum state of 0.2x105Pa, keep such state for 15mins so as to discharge out the
air flowing into the system along with the oil.
Attention:
when a new compressor is used to substitute for the old one, the oil must be released to some
extent that its oil volume is the same as that of old compressor so as to avoid the influence
over the refrigeration effect due to too much oil.
when an old or repaired compressor is employed, the volume of the refrigeration oil in the
compressor must be kept the same as that of the replaced compressor.
Pumping Out of Air Conditioning System to the Vacuum and
Addition of Refrigeration Oil
Connect the manifold pressure gauge with the pipe of air conditioner (compressor) and the multi-pur-
pose adapter of the vacuum pump for the purpose of pumping out of the system to the vacuum state.
Before pumping out to the vacuum, turn on the high-pressure and low-pressure valve of the manifold
pressure gauge and the end valve (if provided) of the vacuum pump, then press the button ON to start
the vacuum pump, the duration shall be more than 20 minutes. When the reading of manifold pressu-
re gauge is -760mmHg or below, turn off the high-pressure and low-pressure valve (if opened), and
press the switch to turn off the vacuum pump.
low pressure
manifold pressure gauge
manifold pressure gauge high pressure
low pressure gauge high pressure gauge
blue
quick coupler red
quick coupler
low-pressure pipe
high-pressure pipe
quick coupler
yellow
vacuum pump blue yellow Red
1. check the air tightness

Continue to check the pressure reading of the manifold pressure gauge after turning off the
vacuum pump.
If the pressure reading remains unchanged within 20 minutes after the vacuum pump stops running,
then it indicates that the refrigerating system has no leakage, the operator can proceed with next
work; while change of the reading indicates that the system has the leakage. Launch the examination
and pump out to the vacuum after the leakage is fixed.
2. Injection of the refrigerant
When the air tightness of the system is verified correct, connect the refrigerant reservoir (or gas bottle)
with one end of the yellow air-charging hose, while other end of yellow air-charging hose is connected
with the liquid injection port in the middle of the manifold pressure gauge. Ensure that the refrigerant
reservoir is connected firmly with the nut of air-charging hose, then turn on the valve of refrigerant re-
servoir; at this time, the high-pressure and low-pressure is closed, use a tip screw driver or other simi-
lar tools and press the by-pass valve spool for 1~2 seconds to discharge out the air in the air-charging
hose and the manifold pressure gauge.
low-pressure
high-pressure
off off on
air washing off
blue
red red
blue yellow yellow

tip screw driver low-pressure pipe
high-pressure pipe
refrigerant reservoir
refrigerant reservoir
Turn on the high-pressure valve on the manifold pressure gauge and inject the refrigerant to the sys-
tem from high-pressure pipeline. At this time, the attention shall be given to the readings of high-pres-
sure meter and low-pressure meter, and make sure that these two pressure all go up. If the refrigerant
is being injected while the pressure does not go up, then the joints of the pipeline may be loosened or
the seals damaged, inject the refrigerant once more after finding out the cause and the fixing. When
the increase of pressure stops, turn off the high-pressure valve of the manifold pressure gauge and
then start the engine.
Operate the switch in a way as follows:
Turn the switch of air conditioner to “ON”
Regulate the temperature controller to the coolest position,

Enable the air conveying to the maximum,
Select the internal air circulation between the internal/external air circulation,
During this process, the door and windows will be all opened.
Adjust the engine’s speed to the specified free running speed.
Erect the refrigerant reservoir or gas bottle (have the refrigerant injected into the refrigerating system
in a gas state), turn on the low-pressure valve of the manifold pressure gauge.
When the compressor is at work, please do not turn on the high-pressure valve.
Before checking the refrigeration level, please confirm the injection volume of the refrigerant specified
for air conditioning system.
When injecting the refrigerant, carefully observe the high-pressure side of the manifold pressure
gauge and the flow condition of the refrigerant (clear, foaming or turbid), all these could be viewed
through the inspection window, by which the moment of stop injecting the refrigerant can be reasona-
bly judged(turning off the low-pressure valve).
low pressure
high pressure
Pressure at high-pressure side
on
on
(MPa)
blue
red
(The appropriate pressure)
low-pressure pipe high-pressure pipe yellow (The overdue injection)

(The appropriate injection)
refrigerant reservoir Injection volume of the refrigerant (g)
When judging the injection volume of the refrigerant, please make the settings based on the following
working conditions:
Water tank temperature of the engine: stable
Speed of the engine: normal free running speed
Switch of air conditioner: ON
Switch of the fan: “High” gear
Temperature controller: air return temperature inside the car is between 25℃ and 30℃ .
Fresh air control: internal circulation
Door: all opened
Window: all opened
Repair and replacement of pipeline
1. Before installation of parts and components, the negative pole of the accumulator must be dis-
connected.
cut off
2. When the air entries of the refrigerating system, water tank of the engine and the air conditio-
ner are opened, please make sure that all openings are capped to prevent the penetration of
the dust, foreign matters or water.
protective cap
protective cap
protective cap must be installed.
3. At ends of each pipe the protective caps should be installed till the pipe is connected to the re-
frigerating system.
fasten it by using two wrenches at the same time

compressor oil
4. When connecting the pipe, apply little compressor oil to the O-ring and fasten the nut with two
wrenches. Attention: never spatter the compressor oil to the painted parts or the plastic com-
ponents to avoid the corrosion. If these components are spattered with the oil, please clean it
immediately.
5. When connecting the pipe, please follow the torque listed in the following table to fasten the
screws or the nuts:
Diameter of Pipe Fastening Torque (N·m)
￠8mm 12-15
￠16mm 30-35
Daily Maintenance of Air Conditioning System

In order to ensure normal operation of air conditioning system, maintenance and care services shall
be frequently performed for the air conditioning system. The daily maintenance of air conditioning sys-
tem is illustrated as follows:
1. Inspect, wash and clean the condenser of air conditioning system, requiring that radiator pins
are clean and there is no dirt between the pins. After the car runs in the rain or on the muddy
road, the fan of the condenser should be inspected to find whether it bears the earth, sand,
stone and etc, and remove them if any.
2. Check the quantity of the working media of the refrigerating system; when the compressor set
works normally, observe the liquid viewing glass, under the normal circumstance, there shall
be not air bubbles in the glass.
3. Inspect the drive belt. The belt between the compressor and the engine should be tensioned.
4. Check if there is any abnormal noise or odor in the air conditioning system.
5. Check if the temperature difference between the air inlet and outlet of the compressor is nor-
mal.
6. Check if the hose of the refrigerating system is in an apparent good condition and connections
of all joints are secure.
7. Check if the pipeline of the refrigerating system collides with other parts and components, and
if there is any oil leakage trace left at each joint.
8. Check if the circuit connection of the refrigerating system is secure and if there is an occu-
rrence of short circuit and falling off
9. Check if fastening bolts of the compressor are firmly secured or broken.
Safety airbag(Siemens)-1
Safety airbag(Siemens)
Instructions for maintenance .......................................... 2

Test instrument ................................................................. 5
Failure handing ................................................................. 5
Impact-vehicle diagnosis ................................................. 18
Warning signs ................................................................... 20
Removal methods for all the parts.................................. 21
Safety airbag module abandoning instruction .............. 27
Instructions for maintenance

For your safe operation, please read the following instructions prior to your operation.
1. The maintenance of SRS safety airbag must be operated under the procedure and directions
instructed in this chapter.
2. The operation must be done with the test instruments and special tools designated by the
chapter.
3. The following parts must be replaced by new ones providing something wrong with them.
(a) SRS safety airbag control unit (SRS-ECU)
(b) Clock spring module
(c) The driver’s side safety airbag module
(d) The passengers’ side safety airbag module.
(e) Safety airbag wiring harness.
4. The safety airbag electric principles figure and definitions of connector clips are in Figure
1,SRS-ECU stitch definition in Table 1 and the position and form of safety airbag failures indi-
cator lamp in combined instrument in Figure 2.
Table 1 SRS-ECU stitch description
No Wire# Name Description

5 480 IGN Battery voltage
6 50 GND Grounding jumper
7 481 WL Safety airbag alarm lamp
9 405 K Diagnosis of serial data I/O (K-line)
10 484 DAB Hi The driver’s side safety airbag, high position
11 485 DAB Lo The driver’s side safety airbag, low position
13 486 PAB Hi Passengers’ side safety airbag, high position
14 487 PAB Lo Passengers’ side safety airbag, low position
37 488 DUAG REQ Diagnosis request
5. The maintenance operation must be started after 60 seconds following the removal of negative
connection of accumulator, wrap the negative with insulating tape for insulation.
Due to the capacitance in SRS-ECU to maintain certain power to make the safety airbag release
within a certain time after the power-off of accumulator, the operation must be started after a while to
avoid any possible major damaging accident caused by the safety airbag’s improper release.
6. The parts such as SRS-ECU, safety airbag module as well as clock spring should be removed
off and well preserved providing the temperature is high enough to cause any damage(above
93℃) in the painting operation.
The failure codes must be debugged with the diagnostic scanner following the repairing of SRS safety
airbag system so as to make alarm lamp work functionally.
K-line diagnosis
brown white green yellow

blue white
diagnosis
request
connecting clock spring (yellow) connecting PAB generator (yellow)

black white
red
safety airbag siren

blue white
Safety airbag ECU grounding jumper

connecting instrument panel wiring harness
blue red blue yellow
yellow red yellow black
clock spring
connecting SRS ECU
driver side airbag co-driver side airbag
Figure 1 Safety airbag principles figure and connector clips definition

safety airbag system alarm lamp
Figure 2
impact sensor and diagnosis module

passengers’ side inflation elements and airbag
driver’ s side inflation elements and airbag
insulating tape
battery
wire
Test instrument
Instrument Name Utility
Test the systematic failures in SRS

X-431 diagnostic scanner safety airbag system, debug ECU.
failure codes.
Failure handing
The basic failure diagnosis process
The failure code DTC of both present and history-accumulated failures may co-exist.
Caution
The safety airbag alarm lamp flashes for 6 times and then extinguishes when the ignition swit-
ch is in ON position after the installation of new safety airbag system electronic control unit,
which demonstrates the normal function of SRS safety airbag system. In this case the system
does not need to be tested, otherwise it should be diagnosed and repaired.
If the alarm lamp does not illuminate when the ignition switch is in ON position, repair the
alarm lamp relevant circuit and, then further operate to get it into work.
The alarm lamp keeps illuminating.
Scan the ECU by connecting the scanner with k-line
Failure detection
Failure handling
Debug the failure codes
The test for SRS safety airbag alarm lamp

1. Place the ignition switch in ON position and confirm whether the alarm lamp is lighted.
2. Check whether the alarm lamp permanently extinguishes after flashing for 6 times.
3. The diagnosis and test is also required besides the previous measures.
safety airbag system alarm lamp
System diagnosis
SRS-ECU will execute a series of diagnosis and test to check whether the function of airbag system
is prepares. The check can prevent the restriction system from mis-explosion and ensure the neces-
sary explosion during collision. If found the failure, SRS-ECU will save a proper failure code and light
the alarm lamp to indicate a failure status for the convenience of maintenance.
If connect the pin 2# wire 488# (diagnosis request wire) on the diagnosis port to the ground (wire 50#)
for more than 2s, the safety airbag alarm lamp will flash the code. For detailed position refer to follo-
wing figure.
brown white red
blue green black white
diagnosis plug
black
Failure judgment
1. Failure record (failure code storage)
When ECU determines the error through the cyclic diagnosis and test, SRS-ECU should saves the
corresponding code, first judgment time, final judgment time and number of occurrence in EEPROM.
SRS-ECU can stores 6 failures at most, under voltage failure and two collision records (front and
side).
Failure code approved by SRS-ECU
Serial
Failure description Debugging
No.
1 Ignition loop 1 (driver’s front airbag), resistance is too high or open-circuit. Can
2 Ignition loop 1 (driver’s side front airbag), resistance is too low or short-circuit Can
3 Ignition loop 1 (driver’s side front airbag), grounding Can
4 Ignition loop 1 (driver’s side front airbag), connected to power supply Can
5 Ignition loop 2 (passenger side front airbag), resistance is too high or open-circuit. Can
6 Ignition loop 2 (passenger side front airbag), resistance is too low or short-circuit Can
7 Ignition loop 2 (passenger side front airbag), connected to power supply Can
8 Ignition loop 2 (passenger side front airbag), connected to power supply Can
9 Power voltage is high Can
10 Power voltage is low Can
11 Alarm light failure, connected to power supply or lamp is short-circuit Can
12 Alarm lamp is failure- grounding or filament is open-circuit. Can
Cannot (re-
13 Shortage/failure of algorithm parameter place the
SRS-ECU)
Cannot (re-
14 The front collision is recorded place the
SRS-ECU)
15 Communication failure Can
Cannot (re-
16 Internal failure (refer to following table) place the
SRS-ECU)
The failure code transmission is completed by SRS-ECU’s input to the defined diagnostic scanner
through the maintenance system’s serial data interface. (X-431 diagnostic scanner) Failure code of
diagnosis
2. Failure code of diagnosis

Description of flash code
Serial No. Failure Failure code Flash code
1 No storage error $12
2 Front Airbag Driver, resistance too high B1021 $21
3 Front Airbag Driver, resistance too low B1022 $22
4 Front Airbag Driver, short to GND B1024 $24
5 Front Airbag Driver, short to VBATT B1025 $25
6 Front Airbag Passenger, resistance too high B1015 $15
7 Front Airbag Passenger, resistance too low B1016 $16
8 Front Airbag Passenger, short to GND B1018 $18
9 Front Airbag Passenger, short to VBATT B1019 $19
10 Battery Voltage too high B1031 $31
11 Battery Voltage too low B1032 $32
12 Warning lamp failure B1061 $61
13 Internal Fault (replace SDM) B1071 $71
14 Crash Frontal recorded B1051 $51
15 Crash Side Driver recorded B1056 $56
16 Crash Side Passenger recorded B1057 $57
17 Crash Beltpretensioner B1058 $58
18 Max. Reuse Number exceeded B1054 $54
3. Interior failure
The micro controller can test the following items not only in starting detection but also in cyclic diagno-
sis detection.
(a) Ignition circuit triggers the transistor: The high-side transistor is detected not only in the starting
detection but also in the circulation diagnosis. But for the low-side transistor is opened when is
connected to power supply directly, so the low-side transistor only can be detected in the starting
detection to avoid the misexplosion.
(b) The ignition voltage is provided by the booster transformer.
(c) The acceleration sensor is detected by itself when start the detection.
(d) Allowable deviation scope of acceleration sensor in circulation diagnosis.
(e) Micro controller includes (AD converter, ROM, RAM etc.)
(f) Status of safety sensor
Cautions:
Connector of explosion tube circuit has the short-circuit bar. When the connector is not con-
nected, the end (+) of explosion tube is connected to end (-) directly to prevent the failure
outspread caused by static. When the connector is bas and short-circuit bar is connected, the
failure may not be eliminated.
An external watch dog can detect the operating status of micro controller. It can trigger the watchdog
when the micro controller has failure. The watch dog will reset the micro-controller and light the alarm
lamp.
Internal failure determined by SRS-ECU

Serial
List of failure Description of failure
No.
AD converter or EEPROM is faulty (the micro con-
1 Micro-controller troller will be reset and alarm lamp is light when the
RAM has failure.)
Enable the failure
2 Driver’s front airbag ignition loop Measure the failure of loop
Passenger front airbag ignition loop (if rea- Enable the failure
3
lized) Measure the failure of loop
Seat safety belt preloaded ignition loop (if Enable the failure
4
realized) Measure the failure of loop
Passenger side safety belt preloaded Enable the failure
5
ignition loop (if realized) Measure the failure of loop
Driver’s side airbag ignition loop (if reali- Enable the failure
6
zed) Measure the failure of loop
Passenger side airbag ignition loop (if rea- Enable the failure
7
lized ) Measure the failure of loop
Maximum times of explosion of safety belt Reach the maximum value 6
8
pre-tightener
Holding time of ECU energy (self-supply Too short
9
time)
Deviation range
10 Accelerometer Sensor not in constant, stable model
Sensor tests the failure itself
The measurement of ignition loop is rejec- No cycling diagnosis test (duplicated calculation)
11
ted continuously
Calculate the safety sensor open-loop using the me-
12 Safety sensor thod that power-off for 2 or more than 2 seconds is
considered as passing
All initial firing current in normal status when the front
13 Initial firing current
airbag releases.
Though SRS-ECU has received ignition information
The ignition of side airbag is not determi-
14 for 5 times during HSIS cycling ignition, the ignition
ned.
can not be determined due to the side safety..
Debug the failure codes
Approach 1. The failure codes will be debugged following the ECU’s receipt from the X-431 diagnostic
tester of the debugging failure codes order through the serial interface, however, if an internal failure
code is recorded or one impact is recorded, the debugging will not be executed.
Approach 2. Ground 488# line for 5 times in 10 seconds to debug the failure codes.
Failure status display (alarm lamp keeps illuminating).
1. Bulb test
SRS-ECU will light the alarm lamp in order to test the bulb after working voltage is provided to it
through the battery. The lamp will flash for 6 times and then extinguish at 1HZ in the initial phase. The
alarm lamp will keep illuminating after the working voltage is provided in order to inform the driver’s
system failures. The alarm lamp will keep illuminating for 6 seconds after the ignition on and then be
extinguished if the history-accumulated failures are less than five times. In the initial phase, SRS-ECU
will not prepare to test impact and stop release till the circuit is stable. Therefore, alarm lamp’s display
manner will be one of following projects in the initial phase. (Table 4.9).
Project 1. If the impact is recorded or the number of history accumulated failures is or more than 5,the
alarm lamp will keep illuminating, simultaneously, it will also keep illuminating if there is a possible ex-
plosion failure.
Project 2. The number of history- accumulated failures is or more than one and less than 5. (The case
of low power is excluded)
Project 3 functional working (neither possible explosion failure or historical failure).
Table 4.9 indicator lamp’s activities after ignition
2. Failure indication
The alarm lamp will indicate it in case any failure arises. If the external failure is a historical one, the
indication will be called off. If the number of history-accumulated failures is or more than 5, the alarm
lamp will keep illuminating albeit no failure emerges. The case of low power will be excluded.
A displayed or historical failure can but only be reconfigured by the service personnel. An internal fa-
ilure or impact record can not be reconfigured, in these cases, SRS-ECU must be replaced.
3. Micro controller-independent alarm lamp illumination
The micro-controller in clear failure status can not work therefore can not control the alarm lamp. In
this case, the alarm lamp will be directly lighted via suitable circuit despite of the micro-controller. As
following:
(a) The battery for SRS-ECU fails, the alarm lamp will be continuously lighted through the lamp drive
function.
(b) No internal working voltage, the alarm lamp keeps illuminating
(c) Reconfiguration caused by watchdog’s trigging failure, the alarm lamp flashes.
(d) No work of micro-controller, the alarm lamp keeps illuminating
(e) Incomplete plugging-in of SRS-ECU connector, the alarm lamp keeps illuminating via shoring bar
Next explain the diagnostic
procedure by taking some examples:
If the alarm lamp is found keeping illuminating, please test it according to the following procedure
even it extinguishes finally. First test the failure region with the scanner followed by the test in the fa-
ilure region with the corresponding approaches and steps.
(a) If an internal failure or the explosion of safety airbag is scanned, replace the SRS-ECU
(b) Troubleshooting
Troubleshooting
Extinguishments or normal-light of alarm lamp
No. Troubleshooting item Description
The warning lamp of safety airbag system is not
1 Safety airbag system warns circuit failure
displayed.
The warning lamp of safety airbag system is light Safety airbag system warns circuit failure or ex-
2
normally. ternal failure.
1. Extinguishments of safety airbag system alarm lamp
1 Extinguishments of safety airbag system alarm lamp
Test status Safety airbag system warns circuit failure.
No voltage (fuse shutoff)
Possible causes Combined instrument failure
Failure of wiring harness between instrument cluster and ECU unit
Diagnostic procedure
When first carry out failure test, joggle the wiring harness and plug to test whether there is periodical
bad contact in the circuit, if it so, please confirm whether the plug, terminal and wiring harness well
connected and in good condition. If it is not any of previous cases, operate according to the following
steps.
Proce-
Test Operation
dure
Place the ignition switch in LOCK posi-

Yes
Test other wiring harness and instrument clus- tion followed by next step
ter indicator lamp
1
• place the ignition switch in ON position Test the instrument cluster power-supply
• light other alarm and indicator lamps No system and grounding system (fuse),
then go to step 5.
Bulb test
Warning:
Incorrect handling with the safety airbag sys- Yes Next step
tem units will cause the safety airbag’s impro-
per release and pretension of safety belt, whi-
ch will lead to serene accidents. Please read
safety airbag service warning before handling
2 the safety airbag units.
• Place the ignition switch in LOCK position.
• Shut off accumulator negative line and
keep the status for at least 60 seconds. No Replace the bulb of alarm lamp.
• Remove the combined instrument.
• Test the connection between the two co-
rresponding stitches of safety airbag alarm
lamp
Test the wiring harness connection between
ECU unit and instrument cluster. Yes Next procedure.
• Place the ignition switch in LOCK position.
3 • shut off accumulator negative line
• shut off the instrument cluster plug Replace the wiring harness and get into
No
• test the connection between alarm lamp step 5
circuitand its relative circuits
2. Normal-light of safety airbag system indicator lamp

2 Normal-light of safety airbag system alarm lamp
Test status Normal-light of safety airbag system alarm lamp
Insufficient battery voltage
ECU internal failure
Combined instrument safety airbag alarm lamp failure
ECU plug misconnects
Possible causes Combined instrument plug bad-contact
ECU power-supply fuse shutoff or bad contact
Misconnection of ECU plug terminal
Bad contact between ECU plug terminal and grounding wiring harness.
Driver’s or passengers’ side safety airbag circuit failure.
Diagnostic procedure
Begin the test with diagnostic communication with special diagnostic device (X-431 diagnostic tester)
and ECU to find out the failure causes, do the next test providing communication is not successful.
Pro-
ce- Test Operation
dure
Test the battery Yes Next procedure
Test the battery voltage Insufficient battery supply.
1
Is the voltage higher 9V? No Test the charging/discharging system,
then go to step 5.
Test the wiring harness connection between Yes Next step
ECU and combined instrument.
Place the ignition switch in LOCK position.
Shut off the battery negative.
Open the central channel guard plate.
2 Shut off the instrument combined connector clip Check the circuit and continue the opera-
No
Connect the negative of battery tion according to step 5.
Place the ignition switch in ON position.
Check whether the instrument connector clip
terminal voltage is 12V(power supply and instru-
ment line)
Place the ignition switch in LOCK position. Yes Next step
Check the connection of corresponding terminals
3 Repair or replace the wiring harness and
between instrument connector clip and diagnos- No
continue according to step 5
tic interface (diagnose the two ends of K-line)
Make sure the shutoff of accumulator negative Yes Next step
line and keep the status for at least 1 minute.
Shut off ECU connector clip.
3
Shut off the instrument cluster plug. No Replace the wiring harness and step 5
Connect the ECU plug terminal 5,7,9 and instru-
ment cluster plug?
Remove ECU to check the condition of terminal Yes Replace ECU
4 and whether the shorting bar is broken.
Reconnect ECU connector clip and next
No
step.
Make sure that the failure will never reoccur after Troubleshooting followed by the expla-
repairing. Yes nations to customers upon the repairing
Place the ignition switch in LOCK position. procedure.
Shut off accumulator negative line and keep the
status for at least 1 minute.
Connect all ECU plugs
Connect the driver’s side safety airbag combined
instrument plug
Connect the passengers’ side safety airbag com-
5
bined instrument plug
Retest the failure symptoms; repeat from
Connect the driver and passengers’ side preten- No
step 1 if the failure reoccurs.
sion safety belts plugs.
(Vehicles with pretension safety-belts)
Connect clock spring plug
Connect the accumulator negative line
Place the ignition switch in ON position
Does the safety airbag alarm lamp work functio-
nally?
Internal failure
Failure code
SRS safety airbag system unit internal failure
B1071
Warning
The test condition of this failure is the failure code that may not emerge before the test,
DTC conducts the test, and the preparatory work must be done before the test because
Test condition
the damage to working personnel or system may be caused by the incorrect operation
during the test.
SRS safety airbag system electronic-control unit internal circuit failure.
Possible cau- SRS safety airbag system unit internal failure
ses
Operation
With regard to replacing SRS safety airbag system unit, take references in the removal/installation of
safety airbag system
Power-supply
Failure
code Low power-supply voltage for SRS safety airbag system electronic-control unit
B1032
Warning
Test The test condition of this failure is the failure code that may not emerge before the test, DTC
condi- conducts the test, and the preparatory work must be done before the test because the damage
tion to working personnel or system may be caused by the incorrect operation during the test.
The voltage for SRS safety airbag system unit connector clip is stitch 5 and 6 is under 9V
Pos- Accumulator low voltage
sible Failure with the wiring harness between accumulator and SRS safety airbag system electronic-
causes control unit
Proce-
Test Operation
dure
Yes Next step
Check accumulator
Accumulator low volta-
1 Test accumulator voltage
No ge, test the recharging/
Is the voltage above 9V
discharging system
Check the wiring harness between accumulator and fuse panel Yes Next step
Remove fuse panel without releasing the connector clips
2 Place the ignition switch in ON position Check the wiring har-
No
Test the potential of two fuse corresponding contactors, the poten- ness
tial above 9V?
Check the wiring harness between fuse panel and SRS safety air- Yes Next step
bag system unit connector clip
Warning:
If not correctly handled, the safety airbag module as well as pre-
tension safety belt may possibly be trigged, released and tensio-
ned, thus make serene damage to people. Therefore, please ca-
refully read the repairing warning before trouble handling. Please
take references in safety airbag system repairing warning
Place the ignition switch in LOCK position
3 Release accumulator negative wire and wait for 1 minute plus
No Replace wiring harness
Remove steering pillar shell
Release the clock spring connection clips
Remove the PAB trim cover, glove box (passengers’ side safety
airbag is under the trim cover)
Release passengers’ side safety airbag module connector clips
Release all SRS safety airbag system unit connector clips
Install back the accumulator negative wire, Place the ignition swit-
ch in ON position. Is the potential of SRS safety airbag system
unit connector clips stitch 5,6(grounding) above 9V?
Present failure codes
Replace SRS safety air-
Place the ignition switch in L OC K position
bag system unit
Release accumulator negative wire and wait for 1 minute plus
See he removal/insta-
Remove the left trim cover
llation of SRS safety
Shut off SRS safety airbag system unit translation connector clips Yes
4 airbag system unit
Install back the accumulator negative wire, place the ignition swit-
History accumulated fa-
ch in ON position
ilure codes
Is the potential of SR S safety airbag system unit connector clips
The end of failure diag-
stitch 5,6(grounding) above 9V ?
nosis
No Replace wiring harness
Drive side failure

Failure
code
B1021
Driver’s side safety airbag failure (high or low resistance, shorting grounding, etc.)
B1022
B1024
B1025
Warning
If not correctly handled, the safety airbag module as well as pretension safety belt may possibly
be trigged, released and tensioned, thus make serene damage to people. Therefore, please
carefully read the repairing warning before trouble handling. Please take references in safety
Test
airbag system repairing warning
condition
Driver’s side safety airbag
The resistance between the SRS safety airbag system connector clips connectors not within
the designated scope
SRS safety airbag system driver’s side airbag relative wiring harness shorting or shutoff
Driver’s side safety airbag module failure
Clock spring internal failure
Failure of circuit connector clips between clock spring and SRS safety airbag system electro-
Possible
nic-control unit
causes
Shutoff or shorting of wiring harness between clock spring and SRS safety airbag system elec-
tronic-control unit.
Misconnection of SRS safety airbag system driver’s side airbag generator connector clip
Proce-
Test Operation
dure
Check the clock spring Normal Next step
Warning
If not correctly handled, the safety airbag module may pos-
sibly be trigged and released thus make serene damage to
Replace the clock spring
people. Therefore, please carefully read the repairing war-
Take references in the re-
1 ning before trouble handling. Abnor-
moval/installation for safety
Please take references in safety airbag system repairing mal
airbag system and clock
warning.
spring
Are the relative parts of clock spring normal? (The relation
between stitches, unnecessary shutoff or shorting?) if the
present clock spring can be replaced by a better one.
Replace the driver’s side
Confirm the failure in driver’s side safety airbag module or
safety airbag module
other parts.
Replace the DAB module with a better one Can
2 moval/installation for driver’
Install back accumulator negative wire
s side safety airbag in safe-
ty airbag system
Is the failure code still in display or can be debugged?
No Next step
Check clock spring wiring harness connector clip Normal Next step
Release accumulator negative wire and wait for 1 minute
3 plus Abnor-
Remove steering pillar shell Replace the wiring harness
mal
Release the clock spring connector clip, is it in normal con-
dition?
Confirm the failure in clock spring or other parts Yes Next step
configure the special tools fuel and temperature diagnostic Replace clock spring
instrument at 2Ω position Take references in the re-
4
Install back the accumulator negative wire No moval and installation for
Place the ignition switch in ON place safety airbag system and
Any failure code in display? clock spring.
Check the wiring harness between clock spring and SRS Replace SRS safety airbag
safety airbag system electronic-control unit system unit;
Place the ignition switch in LOCK position Normal take references in removal/
Release accumulator negative wire and wait for 1 minute installation of SRS safety
plus airbag system unit.
Remove PAB trim cover, glove box (passengers’ side safe-
ty airbag is under the trim cover)
Release the passengers’ side safety airbag module con-
5 nector clip
Release all SRS safety airbag system unit connector clips
Check whether the following troubles are with the harness Abnor-
Replace the wire harness
between connector clips terminals of SRS safety airbag mal
system unit and clock spring
• Grounding
• Power-supply shorting
• Shutoff
Is the previous wiring harness normal?
Check the clock spring connector clip Normal Next step
Remove the steering pillar shell
6 Abnor- Replace the wiring harness
Release the clock spring connector clip
mal or connector clips
Is the clock spring connector clip normal?
Check clock spring Normal Next step
Remove clock spring
Take references in removal/installation of safety airbag Replace clock spring
system as well as clock spring Take references in the re-
7 Abnor-
Check clock spring moval/installation of safety
mal
Take references in the test for safety airbag system and airbag system and clock
clock spring. spring.
Is the clock spring normal?
Check the wiring harness between clock spring and SRS Normal Next step
safety airbag system electronic-control unit
Release accumulator negative wire and wait for 1 minute
plus
Remove PAB trim cover, glove box (passengers’ side safe-
ty airbag is under the trim cover)
Replace clock spring
Release the passengers’ side safety airbag module con-
8 nector clip Abnor-
moval/installation of safety
Release all SRS safety airbag system unit connector clips. mal
airbag system, and clock
Check whether the following troubles are with the harness
spring
between connector clips terminals of SRS safety airbag
system unit and spring clock.
• Grounding
• Shutoff
Is the previous harness normal?
Passengers’ side failure

Failure
code
B1015
Passengers’ side safety airbag module (high or low resistance or shorting grounding)
B1016
B1018
B1019
Warning
If not correctly handled, the safety airbag module as well as pretension safety belt may possi-
bly be trigged, released and tensioned, thus make serene damage to people. Therefore, plea-
se carefully read the repairing warning before trouble handling.
Test con- Please take references in safety airbag system repairing warning
dition If with passengers’ side safety airbag failure
The resistance between SRS safety airbag system unit connector clip stitch 13 and stitch 14
not within the designated scope.
The wiring harness shorting between safety airbag system unit stitch 13 and stitch 14
Open loop between SRS safety airbag system unit connector clip stitch 13 and stitch 14.
Passengers’ side safety airbag module failure
The failure of connector clip between passengers’ side safety airbag module and SRS safety
airbag system electronic-control unit
Possible The failure of connector clip between SRS safety airbag system unit and grounding jumper.
causes The circuit shutoff or shorting between passengers’ side safety airbag module and SRS safety
airbag system electronic-control unit
The circuit shutoff or shorting between SRS safety airbag system unit and grounding jumper
SRS safety airbag system unit failure
Proce-
Test Operation
dure
Is the vehicle with passengers’ side safety air- Yes Next step
1
bag module No Step 5
Check passengers’ side safety airbag connec- Present failure code
tor clips Next step
Normal
Warning History- accumulated failure codes
If not correctly handled, the safety airbag mo- Next step
dule may possibly be trigged and released
thus cause serene damage to people, therefo-
re, please carefully read the maintenance war-
ning.
Take references in safety airbag maintenance
2 warning.
Abnor-
Release accumulator negative wire and wait Replace the wiring harness
mal
for about 1 minute plus
Remove the PAB trim cover, glove box (pas-
sengers’ side safety airbag is under the trim
cover)
Release passengers’ side safety airbag modu-
le connector clip
Is the previous connector clip normal?
Confirm whether the failure cause is with pas- Yes Next step
sengers’ side safety airbag module or some
other parts
Replace passengers’ side safety air-
Connect a better module to the terminal A and
bag module
3 B of passengers’ side safety airbag connector
No Take references in the removal/insta-
clip
llation of passengers’ side safety air-
Connect the accumulator negative wire
bag module in safety airbag system.
Any failure code in display?
Check the wiring harness between passengers’ Present failure code
side safety airbag module and SRS safety air- Replace SRS safety airbag system
bag system electronic-control unit unit
Place the ignition switch in LOCK position Take references in removal/installa-
Normal
Release accumulator negative wire and then tion of SRS safety airbag system unit
wait for about 1 minute plus in safety airbag system.
Remove steering pillar shell History-accumulated failure codes
Release clock spring connector clip The end of failure diagnosis
Release driver’s and passengers’ side safety
airbag module connector clips
4 Release all SRS safety airbag system unit con-
nector clips
Check whether the following troubles are with
the circuit of the connector clips terminals bet-
Abnor-
ween SRS safety airbag system electronic- Replace the relative wiring harness
mal
control unit and passengers’ side safety airbag
module
• Grounding
• Shutoff
Is the previous circuit normal?
Impact-vehicle diagnosis
The test and maintenance for the impact vehicle must be carried out according to following procedure
no matter the safety airbag is released or not.
Test SRS-ECU diagnostic signals
1. Connect the (X-431 diagnostic test’s) diagnostic joint
2. Read the diagnostic results with X-431 diagnostic tester
Repairing procedure
1. When safety airbag is released.
The following parts should be replaced with new ones
(a) Passengers’ side safety airbag module
(b) SRS-ECU
(c) Driver’s side safety airbag module
2. Check the following parts; replace them with new ones providing something wrong with them.
(a) Clock spring
(b) Steering-wheel, steering column, bottom steering shaft module
3. Driver’s side safety airbag module’s installation status towards the steering wheel.
(a) Check whether abnormal knocking is with the steering wheel, its activity is in good condition and
its clearance is normal.
(b) Check whether the wiring harness joint is broken and its terminal is deformed.
Caution: Due to the impact, the diagnostic instrument cannot communicate with SRS-ECU
when accumulator is lack of power, in this case, check and maintain the instrument panel
wiring harness or utilize the extension power supply.
SRS-ECU
1. Check whether depression, crack or deformation is with the SRS-ECU bracket.

2. Check whether the joint is broken and terminal is deformed
3. Check SRS-ECU bracket’s installation status
(a) Check whether depression, crack or deformation is with the shroud
(b) Check whether the joint is broken, terminal is deformed and wiring harness is meshed.
(c) Check whether depression, crack or deformation is with the gas generator shield.
(d) Make sure the direction of the arrow is straightforward
4. Check the installation status of safety airbag module.
Driver’s side safety airbag module (the following Figure)
driver’s side connect the horn connect the driver’s

generator side module
bracket
Clock spring (right Figure)

1. Check whether the joint and protecting tube are broken and the terminal is deformed.
2. Check whether the shield is deformed.
Steering wheel, steering column and bottom steering shaft module
1. Check the installation status of driver’s side safety airbag module
2. Check whether abnormal knocking is with the steering wheel and its clearance is normal
Passengers’ side safety airbag module (the following Figure)
1. Check the installation status of passengers’ side safety airbag module
2. Check whether the shield is deformed
Passenger side airbag (PAB)

Wiring harness joint (instrument cluster wiring harness)

Check whether the wiring harness is well installed, the joint is broken and the terminal is deformed.
Warning signs
The attentions for use and maintenance for SRS safety airbag are displayed in the Figure. Operate
according to the sign and, the destructed and dirty sign must be replaced with a new one .
Steering wheel in Figure 6-1
Driver’s side safety airbag module in Figure 6-2
Clock spring in Figure 6-3
SRS-ECU in Figure 6-4
Sun visor in Figure 6-5
Passengers’ side safety airbag module in Figure 6-6
warning signs
Figure 6-1 Figure 6-2
warning signs
Figure 6-4
Figure 6-3
passengers’ side safety airbag module
warning signs
Figure 6-5
Figure 6-6
Removal methods for all the parts

Safety airbag electronic-control unit (SRS-ECU)
Caution
• Continue the operation 60 seconds after the removal of accumulator negative. Wrap the re-
moved negative with insulating tape for insulation.
• The SRS-ECU must not be separated nor repaired replace the failed SRS-ECU with a new
one.
• Prevent the SRS-ECU from shock and vibration, replace the SRS-ECU with depression,
crack or deformation with a new one.
• Do replace the SRS-ECU with a new one after the safety airbag is released.
• Do not damage the SRS-ECU when removing or maintaining the parts next to it.
1. Operations before removal
(a) Place the ignition switch in OFF position.
(b) Remove the accumulator negative and well preserve it somewhere or wrap it with tape.
2. Removal procedure.
(a) Central channel’s side panel (or remove the co-instrument panel)
(b) Remove the connector clip connecting with the safety airbag ECU
(c) Remove the SRS-ECU
3. Installation sequence
(a) SRS-ECU;
(b) Install the connector clip connecting with the safety airbag ECU
(c) Central channel’s side panel (or remove the co instrument panel)
(d) Connect the grounding jumper.
4. Some points for installation
(a) SRS-ECU installation
(b) Post-installation test
• Place the ignition switch in ON position
• SRS alarm lamp flashes in 6 seconds and extinguishes.
(c) If not extinguishes, the failure test and troubleshooting must be done.
5. Test
(a) Whether the depression, crack or deformation is with the SRS-ECU shield.
(b) Whether the terminal is broken or deformed.
Caution: The SRS-ECU safety airbag will not work normally if the SRS-ECU is not correctly ins-
talled.
Caution: The SRS-ECU with depression, crack or deformation must be replaced with a new
one.
For the inspection of SRS-ECU besides the previous refer to related item of troubleshooting
Driver’s and passengers’ side safety airbag module (DAB, PAB), clock
spring
Caution
• Continue the operation 60 seconds after the removal of accumulator negative. Wrap the ne-
gative with insulating tape for insulation.
• Safety airbag module and clock spring must not be separated nor repaired, replace the fai-
led ones with new ones.
• Please pay high attention when using the safety airbag module and clock spring, do not let
them fall on the ground nor fall into water or oil. Moreover, replace the depressed, crack or
deformed ones with new ones.
• After the safety airbag module is released, keep the released side up, store it somewhere
flat and do not lay anything on it.
• The safety airbag module must not be stored in a place with the temperature above 93 .
• The released safety airbag module must be replaced with a new one, at the same time test
the clock spring, replace it with a new one if something unusual with it.
• Use gloves and protection glasses during operating the released safety airbag.
• The unreleased safety airbag must be abandoned after its release.
Caution
During the removal, the wring harness connector clip must be removed before the removal of
other wring harness connector clips in order to avoid the possible improper release caused by
static interferences, which is reversal to the case of installation.
1. Removal and installation
Driver’s side safety airbag module, passengers’ side safety airbag module, clock spring.
2. Operations before removal.
(a) Take out the ignition switch key after the steering wheel and front wheel in straightforward direc-
tion.
(b) Remove the connections of accumulator negative
3. Driver’s side safety airbag module removal procedure
(a) Screw off the bolts of two sides, as showed in Figure 8-1
(b) Shut off the wiring harness connector clip
(c) Remove the safety airbag module assembly
(d) Remove the steering wheel
4. Passengers’ side safety airbag module removal procedure
(a) Remove all the trim covers and glove boxes of instrument panel separate the PAB module’s air-
bag wiring harness connector clip from the safety airbag’s PAB side one.
(b) Remove M6 bolts and separate PAB module from instrument panel armed beam.
(c) Remove the instrument panel itself.
(d) Remove the M5bolts of two sides of four PAB modules.
5. Clock spring removal procedure
(a) Remove DAB module (shut off the connecting connector clip)
(b) Carefully remove the steer
(c) Open the combined switch upper shield, find and shut off the bottom wring harness connector
clip
(d) Remove the clock spring from the steer
6. Driver’s side safety airbag module (DAB) and its installation procedure
(a) Test before installation
• Steering wheel
• Connect wiring harness
• Driver’s side safety airbag module
• Screw home the bolts of the two sides
(b) The connection of accumulator terminal
(c) Post-installation test
7. Passengers’ side safety airbag module (PAB) and its installation procedure.
• Carefully take PAB module, justify both of them and plug four trim cover M5bolt into the mounting
holes of the module’s both sides
• Well install together the module with trim cover bracket and instrument panel mounting bracket
with four M5 bolts.
• After the installation of the entire instrument assembly to the vehicle, tightly fix the PAB module to
the vehicle transverse beam with 2 matted M6 bolts at the glove box site.
• Well mutually plug the PAB module airbag wiring harness connector clip and safety airbag wiring
harness PAB side connector clip it is the end of PAB module installation.
(b) Connection of accumulator terminal
8. Clock spring installation procedure
• Cross the line of upper clock spring through the hole in steer.
• connect and fix the clock spring and steer
• install the combined switch upper cover
• install the steering wheel
• steering wheel and safety module assembly
(b) Connect accumulator’s terminal
Figure 8-1
The removal of steering wheel (Figure 8-2)
use the socket head barrel
Figure 8-2
(d) Remove the steering wheel by removing the mounting screw from the mid-position. (Shut off the
horn connector)
Caution
It is difficult to separate the steer from steering column due to the over meshing between spli-
ne and steering column, in this case, do not forcibly remove the steer but screw off the bolt
on the steering column and lift up the steer instead (the forced removal will damage the clock
spring since the connection between the steer and the spring)
Caution
Diagnose the safety airbag module circuit with electric diagnostic instrument without separa-
ting it.
Let the removed driver’s side safety airbag module bottom-side up and store it at a clean and
dry place.
Store the clock spring in a clean and dry place.
9. Installation operation instructions
(a) The test before installation
• The new safety airbag or clock spring must be tested before installation.
Caution
The safety airbag module must be abandoned after its release according to the procedure
• Connect the accumulator negative
• Connect the K-431 diagnostic instrument with the diagnostic interface (16 plug)
Caution
Place the ignition switch in OFF place when connect or shut off the K-431 diagnostic instru-
ment.
• Place the ignition switch in ON position
• Read the diagnostic circuit, check whether the safety airbag module is in normal condition except
the failure regions.
• Place the ignition switch in OFF position
• Remove accumulator negative and wrap it with the tape for insulation.
Caution
Continue the operation 60 seconds after the removal of accumulator negative
Install the clock spring to the steer after its involution
(b) Clock spring’s central involution.Rotate anticlockwise until tight.Then rotate in opposite direction
roughly 3 turns and align arrows.
Figure 8-3
Caution
If without the clock spring central involution, the steering wheel will not be able to rotate at
midway, or the clock spring circuit will be damaged so that jeopardize SRS safety airbag’s nor-
mal activities.
The spacer must be removed after replacing a clock spring with a new one, otherwise it will
damage the clock spring.
(c) Steering wheel and safety airbag module assembly installation.
• Install the steering wheel and safety airbag module assembly after clock spring’s central involu-
tion.
Caution
Do not jam the clock spring wiring harness during the steering wheel and safety airbag modu-
le assembly installation.
• After the installation, rotate the steering wheel to left and right positions as enough as possible to
confirm whether something abnormal is with it.
(d) Post-installation test.
• lightly rotate the steering wheel to the left and right to confirm whether something abnormal and
noises will arise.(Driver’s side safety airbag module, clock spring)
• Place the ignition switch in ON place.
• SRS alarm lamp flashes in 6 seconds and then extinguishes.
safety airbag system failure alarm lamp
Figure 8-4
• Do the troubleshooting if the alarm lamp re-illuminates after its extinguishments following the 6-se-
cond-flashing (or it keeps illuminating from the very beginning)
10. Test
(a) Driver’s side airbag module test (Figure8-3)
Check the following items and replace the corresponding safety airbag module part with anything ab-
normal with a new one.
Abandon the safety airbag’s old parts after its release according to the instructed procedure.
Caution
The safety airbag module (squib) circuit resistance can even not be tested by the designated
tester.
When testing the resistance with an experimental instrument, sometimes the improper release
will be caused by the static interference because of the current in explosion pipe and cause
some major damaging accidents.
• Whether depression, crack or deformation is with the shroud.
• Whether the joint is broken and the terminal is deformed.
• Whether depression, crack or deformation is with the gas generator shield.
• Safety airbag module. Installation status.
Caution
Replace the safety airbag with depression, crack or deformation with a new one. Its old parts
must be abandoned after its release.
(b) Clock spring test (figure 8-5,figure 8-6)

Check the following items and replace the clock spring with anything abnormal (even it is quite tiny)
with a new one
• Whether the joint and protection tube are broken and the terminal is deformed.
• Whether the shield is damaged.
• Check the connection between clock spring’s upper joint terminal and it’s corresponding bottom
terminal.
• Plug in a thin probe from the 3# joint of clock spring.
Figure 8-5
Caution
Do not directly plug in the probe from the bottom of the joint.
• Figure 8-5 As showed in Figure 8.5,Plug a thin probe into the current tester to check the connec-
tion of the terminal.
Safety airbag module abandoning instruction

Carry out the operation according to the following procedure to abandon a safety airbag module or a
vehicle with the SRS safety airbag. First of all, release the safety airbag.
Unreleased safety airbag module abandoning
Caution
First release the SRS safety airbag when abdbdon it.
Release the safety airbag outside the vehicle to replace the safety airbag module.
Conduct the operation somewhere next to a smoke tester due to the smoke during the safety
airbag’s release.
Tell the people to cover their ears and try to conduct the operation somewhere far away from
the residential area due to the big noise during the safety airbag’s release.
Remove the accumulator positive and negative and remove the accumu-
lator off the vehicle.
Caution
Continue the operation 60 seconds after the removal of accumulator positive and negative.
Release the safety airbag module according to the following procedure.
1. Driver’s side safety airbag module
(a) Remove the blocking lever
(b) Remove the clock spring 2# joint and instrument panel wiring harness joint (yellow)(figure 8-6)
the shroud
protection tube
2
Caution
The clock spring joint will short automatically after the removal of clock spring from the instru-
ment wiring harness, which can prevent any possible major accident caused by the incorrect
release of driver’s side safety airbag module duo to the static interference from happening.
(c) Connect the SRS safety airbag translation wring harness with 2 6m plus release wiring harnes-
ses, wrap the joint part with insulating tape for insulation.
shorting site
releases wring harness

6m plus
SRS translation wiring harness

Mutually connect (short) the other end of release wring harness to avoid the possible incorrect release
caused by the static interference.
(d) At the clock spring’s 2# joint, tract the translation wiring harness out of the vehicle with the relea-
se wiring harness (Figure 9-2)
clock spring
clock spring connector clip
SRS translation wiring harness
release wiring harness
(e) Close all the windows and doors and wear the guard to reduce the noises.
Caution
The guard should be worn because the glass with cracks is very fragile.
(f) Shut off the joint of driver’s side safety airbag release wiring harness somewhere far from the ve-
hicle, and connects the joint with the accumulator and makes the safety airbag release.
auto body outer panel.
releases wring harness.
Caution
Continue the operation after the confirmation of nobody is in or next to the vehicle.
Its gas generator is quite hot after the driver’s side safety airbag’s release, it can be used after
its cooling down for more than 30 minutes.
Contact with the local service station of the Great Wall Auto Stock Corporation if the driver’s
side safety airbag module cannot be released.
(g) Abandon the released driver’s side safety airbag module according to the instructions.
auto body outer panel.

2. Release outside the vehicle

Caution
Release the safety airbag somewhere open and plain as well as 6m plus from the obstacles
and people
When release the safety airbag outdoors, try to avoid the strong wind and ignite windward in
the breeze.
(a) Remove the accumulator negative and positive and remove the accumulator.
Caution
Continue the operation 60 seconds after the removal of the accumulator.
(b) Release the safety airbag module according to following procedure
• driver’s side safety airbag module
• remove the driver’s side safety airbag module off the vehicle.
Caution
The two ends of the terminal will short automatically without the joint connection of driver’
s safety airbag module, therefore the possible improper release caused by static interference
can be avoided; if it improperly releases, keep the released side up and store it somewhere
plain, do not lay anything on it.
Prepare 2 6m plus release wiring harnesses and mutually connect the other ends(short-circuit) of
them to avoid the possible improper release caused by static interference.( refer to figure 9-4)
wiring harness for release
shorting site
6m plus
• Touch the vehicle with your hands to eliminate the static electricity.
Caution
Strictly execute the previous procedure for it can prevent the possible incorrect release cau-
sed by the static interference from happening.
• Shut off the driver’s side safety airbag module wiring harness and connect it with two release
wiring harnesses( refer to figure 9-5)

passengers’ side safety airbag module
shoring site
insulating tape
• Installed the stand-by bolts on the driver’s side safety airbag module’s inside bolt and fasten a
thick wire to the wheel rim to fix it.
• Connect the release wiring harness connecting with the driver’s side safety airbag module with the
low part of an old tire loading the wheel rim. ( refer to figure 9-6)
driver’s side safety airbag module
• Lay three wheel-hub-free old tires on the tire fixing the driver’s side safety airbag module (Figure
9-7).
wheel-hub-free old tires
• Shut off the joint of driver’s side safety airbag release wiring harness somewhere far from the ve-
hicle, and connect the joint with the accumulator and make the safety airbag release (Figure9-8).
release wiring harness.
Caution
Release the driver’s side safety airbag module after the confirmation of nobody close to it.
Its gas generator is quite hot after the driver’s side safety airbag’s release, it can be used after
its cooling down for more than 30 minutes.
Contact with the local service station of the Great Wall Auto Stock Corporation if the driver’s
side safety airbag module cannot be released.
• Abandon the released driver’s side safety airbag module according to the abandoning instructions.
Interior and Exterior Trims of Vehicle Body-
Interior and Exterior Trims of

Vehicle Body
Instrumental Panel ......................................................................... 2
outside rear-view mirror ................................................................ 8
Front Windshield Glass ................................................................. 9
Rear Windshield Glass................................................................... 0
Sunroof ............................................................................................
Front Door ....................................................................................... 2
Rear Door ........................................................................................ 4
Rear liftgate ..................................................................................... 6
Inner Facing Cover of Roof ........................................................... 7
Roof Cover Trimming ..................................................................... 8
Inner Facing Cover of Side Wall .................................................... 9
Front Bumper .................................................................................. 2
Rear Bumper ................................................................................... 22
Seat Belt .......................................................................................... 23
Seat .................................................................................................. 26
Interior and Exterior Trims of Vehicle Body-2
Instrumental Panel
Left-hand drive
Instrument panel stiffening Instrument panel stiffening rib right bracket assembly
rib left bracket assembly
Instrument panel stiffening rib assembly
Defrosting ventilation duct
Upper main duct inside instrumental panel
Right front pillar upper

trim board assembly
Middle delivery conduit Instrument panel

right vent assembly
Left front pillar upper
trim board assembly
Instrument panel
upper cover
Instrument panel
body assembly
Passenger airbag module
Rear row air conditioner duct
Driver airbag module
Steering wheel assembly

Left-hand drive
Instrument panel body assembly
Sundries box assembly

Instrument panel
left vent assembly Instrument brightness Instrument
adjustment switch Upper cover of instrument panel sundries
panel middle face shield box lock
TCS switch Alarm lamp
Instrument panel switch assembly
face shield assembly
Instrument panel middle
face shield
Headlamp Right vent assembly
adjusting switch
Instrument panel middle face
Front fog lamp switch shield
Cigar lighter Left vent assembly
Instrument panel left lower Combination
face shield assembly instrument assembly
CD player assembly
Combination switch
upper face shield
Instrument panel fuse A/C control unit
box face shield plate Wire stay handle of
engine hood lock

face shield
Right cover assembly
Combination switch
lower face shield
Front section assembly of Shift lever trim cover

transmission trim hood
Rear section assembly of

Left cover assembly of instrument transmission trim hood
panel middle face shield
Right-hand drive Instrument panel stiffening rib right bracket assembly

Instrument panel stiffening
rib left bracket assembly
Instrument panel stiffening rib assembly
Upper main duct inside instrumental panel
Middle delivery conduit
Defrosting ventilation duct

trim board assembly
trim board assembly
Instrument panel
upper cover
Instrument panel left

vent assembly
Instrument panel
body assembly
Driver airbag module

Steering wheel assembly
Rear row air conditioner duct

Passenger airbag module
Right-hand drive
Instrument panel
left vent assembly
Combination
instrument assembly
Instrument panel
body assembly
Instrument panel
right vent assembly
Upper cover of instrument Instrument panel face shield assembly

panel middle face shield Instrument panel middle face
shield Right vent assembly Front fog
Alarm lamp lamp switch
switch assembly
Sundries box Instrument panel middle
assembly face shield
Left vent assembly
Headlamp
Blank cover
Instrument brightness adjusting switch
adjustment switch
CD player assembly Instrument panel right
lower face shield assembly
Instrument panel inner water
Instrument panel cup bracket assembly Bracket assembly for instrumental
sundries box lock panel right lower face shield
Instrument panel fuse

Instrument panel middle box face shield plate
A/C control unit
Combination switch Bracket assembly for Wire stay handle of
upper face shield instrumental panel right lower engine hood lock
face shield (in new condition)
Instrument panel
middle face shield
Right cover assembly
Shift lever trim cover
Combination switch
lower face shield
Front section assembly of
Front power
Left cover assembly of instrument supply socket
panel middle face shield
Cigar lighter
Ash tray
Rear section assembly of

Removal and Installation of Instrument Panel (Left-hand drive )

1. Remove the instrument panel middle face shield assembly.
(a) Remove the upper cover of instrument panel middle face shield.
(b) Remove the ash tray.
(c) Remove the three tapping screws at the upper part, two tapping screws at the middle part and
one tapping screw at the lower part.
(d) Dismount the instrument panel middle face shield assembly.
(e) Remove the four tapping screws fixing the CD player, and disconnect the harness connectors.
(f) Dismount the CD player.
(g) Remove the four tapping screws fixing A/C panel, and disconnect the harness connectors.
(h) Take down the A/C panel.
2. Remove the auxiliary facia console.
(a) Remove the rear section assembly of transmission trim hood.
(1)Remove the two tapping screws;
(2)Take down the rear section assembly of transmission trim hood.
(b) Remove the front section assembly of transmission trim hood.
(1)Remove the left/right cover assembly of instrument panel middle face shield.
(2)Dismount the two tapping screws at left and right sides of the front section of transmission trim
hood.
(3)Remove the hand ball head.
(4)Remove the two tapping screws at both left and right sides of the front section of transmission
trim hood.
(5)Disconnect the electrical appliance harness connectors of 4WD switch.
(6)Dismount the front section assembly of transmission trim hood.
3. Remove the instrument panel left lower face shield assembly.
(a) Remove the two tapping screws fixing the wire stay handle of engine hood lock.
(b) Remove the tapping screw at the right lower part.
(c) Dismount the instrument panel left lower face shield assembly.
4. Remove the bracket assembly for instrument panel left lower face shield.
(a) Remove the six bolts.
(b) Dismount the bracket assembly for instrument panel left lower face shield.
5. Remove the instrument panel assembly.
(a) Remove the six tapping screws that fix the instrument panel face shield assembly.
(b) Remove the instrument panel face shield assembly.
6. Remove the sundries box assembly.
(a) Remove the two tapping screws fixing the sundries box.
(b) Dismount the sundries box assembly.
7. Remove the combination switch cover assembly.
(a) Remove the seven screws.
(b) Prize up the upper and lower covers and take down the two covers of combination switch.
8. Remove the instrument panel body assembly.
(a) Prize up the three upper covers of instrument panel.
(b) Remove the three bolts.
(c) Remove the four bolts at the lower part of instrument panel body.
(d) Remove the two internal (four if for airbag fitting) bolts of sundries box.
(e) Dismount the instrument panel body assembly.
9. Remove the bracket assembly for instrument panel cross beam.
(a) Remove the two hexagon flange nuts and the subassembly of two hexagon bolts, spring washer
and large washer.
(b) Remove the left bracket assembly for instrument panel cross beam.
(c) Remove the two hexagon flange nuts and dismount the subassembly of two hexagon bolts and
large washer.
(d) Remove the right bracket assembly for instrument panel cross beam.
10. Remove instrument panel stiffening rib assembly.
(a) Remove the subassembly of four hexagon nuts and taper elastic washer and the single
hexagonal flange auto chip flow nut.
(b) Remove the subassembly of two hexagon bolts, spring washer and large washer, the single
hexagonal flange auto chip flow nut and the single hexagon flange bolt.
(c) Remove the instrument panel stiffening rib assembly.
11. Remove the mounting bracket assembly for instrument panel stiffening rib.
(a) Remove the subassembly of three hexagon bolts, spring washer and plain washer.
(b) Dismount the left mounting bracket assembly for instrument panel stiffening rib.
(c) Remove the subassembly of three hexagon bolts, spring washer and plain washer.
(d) Dismount the right mounting bracket assembly for instrument panel stiffening rib.
12. Install the instrument panel in reverse order of its removal.
Removal and Installation of Instrument Panel (Right-hand drive)
1. Remove instrument panel middle face shield assembly.
(a) Remove the upper cover of instrument panel middle face shield.
(b) Remove the three tapping screws at the upper part, two tapping screws at the middle part and
one tapping screw at the lower part.
(c) Dismount the instrument panel middle face shield assembly.
(d) Remove the four tapping screws fixing CD player, and disconnect the harness connectors.
(e) Dismount the CD player.
(f) Remove the four tapping screws fixing A/C panel, and disconnect the harness connectors.
(g) Take down the A/C panel.
2. Remove auxiliary facia console.
(a) Remove the rear section assembly of transmission trim hood.
(1)Remove the two tapping screws;
(2)Take down the rear section assembly of transmission trim hood.
(b) Remove the front section assembly of transmission trim hood.
(1)Remove the left/right cover assembly of instrument panel middle face shield.
(2)Dismount the two tapping screws at left and right sides of the front section of transmission trim
hood.
(3)Remove the hand ball head.
(4)Remove the two tapping screws at both left and right sides of the front section of transmission
trim hood.
(5)Disconnect the electrical appliance harness connectors of 4WD switch.
(6)Dismount the front section assembly of transmission trim hood.
3. Remove instrument panel left lower face shield assembly.
(a) Remove the two tapping screws fixing the wire stay handle of engine hood lock.
(b) Remove the tapping screw at the right lower part.
(c) Dismount the instrument panel left lower face shield assembly.
4. Remove bracket assembly for instrument panel left lower face shield.
(a) Remove the six bolts.
(b) Dismount the bracket assembly for instrument panel left lower face shield.
5. Remove instrument panel assembly.
(a) Remove the six tapping screws that fix the instrument panel face shield assembly.
(b) Dismount the instrument panel face shield assembly.
6. Remove sundries box assembly.
(a) Remove the two tapping screws fixing the sundries box.
(b) Dismount the sundries box assembly.
7. Remove combination switch cover assembly.
(a) Remove the seven screws.
(b) Prize up the upper and lower covers and take down the two covers of combination switch.
8. Remove instrument panel body assembly.

(a) Prize up the three upper covers of instrument panel.
(b) Remove the three bolts.
(c) Remove the four bolts at the lower part of instrument panel body.
(d) Remove the two internal (four if for airbag fitting) bolts of sundries box.
(e) Dismount the instrument panel body assembly.
9. Remove bracket assembly for instrument panel cross beam.
(a) Remove the two hexagon flange nuts and the subassembly of two hexagon bolts, spring washer
and large washer.
(b) Remove the left bracket assembly for instrument panel cross beam.
(c) Remove the two hexagon flange nuts and dismount the subassembly of two hexagons and large
washer.
(d) Dismount the right bracket assembly for instrument panel cross beam.
10. Remove mounting bracket assembly for instrument panel stiffening rib.
(a) Remove the subassembly of four hexagon nuts and taper elastic washer and the single
hexagonal flange auto chip flow nut.
(b) Remove the subassembly of two hexagon bolts, spring washer and large washer, the single
hexagonal flange auto chip flow nut and the single hexagon flange bolt.
(c) Remove the instrument panel stiffening rib assembly.
11. Remove mounting bracket assembly for instrument panel stiffening rib.
(a) Remove the subassembly of three hexagon bolts, spring washer and plain washer.
(b) Dismount the left mounting bracket assembly for instrument panel stiffening rib.
(c) Remove the subassembly of three hexagon bolts, spring washer and plain washer.
(d) Dismount the right mounting bracket assembly for instrument panel stiffening rib.
12. Install the instrument panel in reverse order of its removal.
Outside rear-view mirror
Right outside rear-view mirror assembly
Left outside rear-view mirror assembly
Removal of Outside Rear-view Mirror Assembly

1. Insert a clip screwdriver into gap between the clip and the triangular plate of outside rear-view
mirror and prize it up.
Attention: Wrap the clip head with tape before using it.
2. Dismount the triangular plate of outside rear-view.
3. Remove the three hexagonal flange auto chip flow nuts and disconnect the electrical heating
defrosting connectors.
4. Dismount the outside rear-view mirror.
Install in the reverse order of removal.
Front Windshield Glass

Upper trim strip of front
windshield glass
Left trim strip of front
windshield glass
Front windshield glass assembly
Right trim strip of front

windshield glass
Buffer rubber block of

Front windshield front windshield glass
Clamp of cover plate glass bracket
of front ventilator
Clip seat of cover plate

of front ventilator Cover plate body
of front ventilator
Mounting hole cover plate of
cover plate of front ventilator
Expansion buckle of cover
plate of front ventilator
Right front wiper arm

Lower rubber strip of cover
plate of front ventilator
Left front wiper arm
Front wiper trim cap

Right wiper blade
Left wiper blade
Removal of Cover Plate of Front Ventilator

1. Remove the front wiper arm (see the section of electrical appliance).
2. Remove the 6 mounting hole cover plates of cover plate of front ventilator.
3. Remove the 6 tapping screws and expansion buckles of cover plate of front ventilator.
4. Remove the 5 clamps and clip seats of cover plate of front ventilator.
5. Remove the cover plate of front ventilator.
Removal of Front Windshield Glass
1. Remove the tapping screw and take off the interior rear-view mirror.
2. Remove the trim strip of front windshield glass from the vehicle.
3. Cut off the glass glue around the front windshield glass with steel wire.
4. Clear off the glass glue on the inner edge of glass with blade.
5. Eliminate the glass glue on the window frame with the polishing machine.
Installation of Front Windshield Glass

1. Apply the primer to the frame of front windshield glass and the edge of front windshield glass.
2. Apply the glass glue (10±2mm in height) on the front windshield glass with coating pistol.
3. Install the front windshield glass.
4. Fix the windshield glass by pasting the adhesive tape on the front windshield glass and the
sheet metal around front windshield glass.
5. Remove the adhesive tape after 24h when the glass glue is solidified.
6. Install the front windshield glass trim strip onto the front windshield glass.
Rear Windshield Glass
Rear liftgate glass
Rear liftgate ventilator

expansion port
Rear liftgate ventilator
Removal of Rear Liftgate Trim Board

1. Remove the lower trim board of rear liftgate.
2. Remove the trim board of upper cross beam of rear liftgate.
3. Remove the left and right trim boards of rear liftgate.
Removal of Rear Windshield Glass
1. Remove the rear wiper arm.
2. Remove the tail.
3. Disconnect the electrical connector of rear windshield defroster.
4. Cut off the glass glue around the rear liftgate glass with steel wire.
5. Remove the rear liftgate glass from the vehicle.
6. Eliminate the glass glue on the glass with the blade.
7. Eliminate the glass glue on the window frame with the polishing machine.
Installation of Rear Windshield Glass
1. Apply the glass glue primer on the rear liftgate sheet metal rabbet and glass.
2. Apply the glass glue (10±2mm in height) on the rear liftgate glass.
3. Install the rear liftgate glass on the leftgate.
4. Fix the rear liftgate glass by pasting the adhesive tape on the rear liftgate and its glass.
5. Connect the electric connectors of rear windshield defroster.
6. Remove the adhesive tape after 24h when the glass glue is solidified.
Sunroof
Roof cover ventilator

glass assembly
Fixing pressure ring of

roof cover ventilator
Fixing screw of roof

cover ventilator
Sun visor assembly of

Fixing screw Ⅱ of
Roof cover ventilator motor assembly

Fixing screw of roof
cover ventilator motor
Removal of Sunroof Assembly

1. Remove the roof.
2. Remove the 4 screws.
3. Remove the roof cover ventilator motor assembly.
4. Remove the 4 fixing screws of roof cover ventilator.
5. Remove the sun visor assembly of roof cover ventilator.
6. Remove the 14 fixing screws of roof cover ventilator.
7. Remove the fixing pressure ring of roof cover ventilator.
8. Take off upwards the roof cover ventilator glass assembly.
Note: after removing the sunroof glass plate, be sure not to turn the sunroof switch to “open”
position, because the glass plate no longer presses the water groove at this time, and the
water groove may incline into the sunroof.
Install it in reverse order of removal.
Front Door
Left front side door glass assembly
Left outside rear-view mirror triangle
Left front side door

outside weather strip
Left front side door glass groove
Sticking film of front

side door inner panel
weather strip

interior cover cloth Left front side door interior
trim board assembly
Window regulator
Left large speaker

Left side door interior armrest Front door high tone speaker
Left front side door and window switch and panel assembly
Left front side door and window switch and panel assembly
1. Remove the front door interior trim board.
(a) Remove the interior armrest screw and armrest.
(b) Remove the door inner buckle screw and inner buckle.
(c) Remove the electric switch and pull out the harness.
(d) Insert the clip screwdriver between the fixing clamp and door interior trim board to loosen it.
Note: it is necessary to use the adhesive tape to wrap the head of screwdriver before using it.
(e) Take off the interior trim board of door and disconnect the door lamp terminal.
(f) Take off the cover cloth of door.
2. Remove the front door outside weather strip.
Adjust the glass downwards, remove the front fixing screw and pull up the weather strip to remove it.
3. Remove the front door glass assembly.
(a) Align the fixing screw of glass bracket with the mounting hole of door inner panel by adjusting the
glass and remove the 2 fixing bolts of glass bracket.
(b) Pull up the glass and then tilt it to remove it.
4. Remove the front door glass groove.
5. Remove the front door glass guide assembly.
6. Replace the front door glass assembly.
(a) Adjust the front door glass to align the fixing bolt of glass bracket with the mounting hole of door
inner panel.
(b) Remove the fixing bolt of glass bracket to take off the glass for replacement.
Assembly of Front Door
1. Application of lubricating grease.
It is necessary to coat the MP lubricating grease before installing the parts.
(a) Apply the MP lubricating grease on the sliding face and the gear of window regulator.
Note: be sure not to coat the MP lubricating grease on the window regulator spring.
(b) Apply the MP lubricating grease on the sliding face of door lock.
2. Install the door outside handle and lock with core.
3. Install the button of door inner lock.
4. Install the window regulator.
5. Install the front door glass guide assembly.
Install the guide and bolt.
6. Install the front door glass groove.
7. Install the front door glass assembly.
Install the glass into the door cavity, and then fix the glass on the window regulator with 2 bolts.
8. Install the front door outside weather strip.
Adjust the glass downwards to insert the outside weather strip into the door outer panel rabbet and
then fasten the screw.
9. Install the cover cloth of door.
10. Install the interior trim board of door.
Rear Door
Left rear side door triangular window groove

Left rear side door triangular window glass
Left rear side door
Left rear side door glass groove
outside weather strip
Left rear side door Left rear side

dustproof rubber strip door glass
Left rear side door

interior cover cloth
Left rear side door Window regulator

weather strip
Left rear side door interior trim board assembly
Left side door

interior armrest Left large speaker
Left rear side door high tone speaker

Left rear side door and window
switch and panel assembly
Disassembly of Rear Door

1. Remove the rear door interior trim board.
(a) Remove the rear door armrest screw and armrest.
(b) Remove the inner buckle screw and inner buckle.
(c) Remove the electric switch and pull out the harness, as well as the electric window switch of rear
door.
(d) Remove the rear door inside weather strip.
(e) Insert the clip screwdriver between the fixing clamp and interior trim board to loosen it.
Note: it is necessary to use the adhesive tape to wrap the head of screwdriver before using it.
(g) Take off the interior trim board of door and disconnect the door lamp terminal.
(h) Take off the cover cloth of door.
2. Remove the rear door outside weather strip.

Adjust the glass downwards to remove the fixing screw and pull up the outside weather strip manually
to remove it.
3. Remove the rear door glass assembly.
(a) Lower the regulator of rear door to the place where the rocker arm can rotate freely and take off
the rocker arm from the slide rail at the lower part of glass.
(b) Pull up the glass and then tilt the glass to remove it.
4. Remove the rear door glass groove.
5. Remove the rear door glass guide assembly.
6. Remove the window regulator.
7. Remove the door inner lock button.
8. Replace the rear door glass assembly.
(a) Adjust the rear door glass to align the fixing bolt of glass bracket with the mounting hole of inner
panel.
(b) Remove the fixing bolt of glass bracket and take off the glass for replacement.
Assembly of Rear Door
1. Apply the lubricating grease.
It is necessary to apply the MP lubricating grease on the parts before installing them.
(a) Apply the MP lubricating grease on the sliding surface and the gear of window regulator.
Note: be sure not to apply the MP lubricating grease on the spring of window regulator.
(b) Apply the MP lubricating grease on the sliding surface of door lock.
2. Install the outside handle and lock with core (see the section of electric appliance).
3. Install the inner lock button and connect the control rod (see the section of electric appliance).
4. Install the window regulator (see the section of electric appliance).
5. Install the rear door glass guide assembly, guide and bolt.
6. Install the rear door glass groove.
7. Install the rear door glass assembly.
Lower the regulator rocker arm to the free position to install the glass inside the door cavity to get the
window regulator rocker arm into the slide track at the lower part of the glass.
8. Install the rear door outside weather strip.
Adjust the glass downwards and insert the outside weather strip into the outer panel rabbet and fasten
the screw.
9. Install the cover cloth of door.
10. Install the interior trim board of door.
Rear Liftgate
Upper cross beam trim board

Upper cross beam right cover assembly of rear liftgate
plate assembly of rear liftgate
Upper cross beam left cover
plate assembly of rear liftgate
Right trim board

assembly of rear liftgate
Left trim board assembly

of rear liftgate
Rear liftgate weather strip
Lower trim board

assembly of rear liftgate
Rear liftgate lock service cover plate
Lower buckle of rear liftgate
Rear liftgate doorsill
Removal and Installation of Rear Liftgate

1. Remove the interior trim board of door.
(a) Remove the inner buckle.
(b) Insert the clip screwdriver between the fixing clamp and interior trim board to loosen it.
Note: it is necessary to wrap the head of clip screwdriver before using it.
(c) Remove the interior trim board of door.
(d) Take off the rear liftgate dustproof film.
2. Remove the door inner lock button.
3. Remove the rear wiper arm assembly.
4. Install it in reverse order of its removal.
Removal and Installation of Rear Liftgate Air Spring (see the section of
vehicle body)
Inner Facing Cover of Roof

Subassembly of roof Rear wall cross
Roof armrest beam trim board
Rear wall cross beam
trim board clip
Right sun visor assembly
Fixing clip of roof

Interior rear-view Ceiling lamp
mirror assembly assembly
Left sun visor assembly

Rear ceiling lamp assembly
Fixing support of sun visor Fixing clip Ⅱ of roof
Reading lamp assembly
Inner Facing Cover of Roof Cover

1. Remove the left sun visor.
(a) Remove the 2 screws with screwdriver.
(b) Take off the left sun visor.
(c) Remove the single screw with screwdriver and take off the fixing support of sun visor.
2. Remove the right sun visor.
(a) Remove the 2 screws with screwdriver.
(b) Take off the right sun visor.
(c) Remove the single screw with screwdriver and take off the fixing support of sun visor.
3. Remove the reading lamp, ceiling lamp and rear ceiling lamp.
4. Remove the 2 fixing clips of roof.
Note: after this step, another employee shall provide assistance to support the unfixed roof to
avoid the breakage of roof.
5. Remove the 6 screws and take off the 3 roof armrests.
6. Remove the 8 fixing clips of roof.
9. Remove the rear wall cross beam trim board.
(a) Insert the clip screwdriver between the fixing clip and trim board to loosen it.
(b) Take off rear wall cross beam trim board.
10. Remove the roof.
Raise the rear liftgate by two persons and take it off from the rear liftgate.
Roof Cover Trimming
Right rear section body of luggage rack
Right regulating block assembly

of luggage rack cross beam
Tail
Upper rubber strip
Left rear section body
of luggage rack
Front upper rubber strip
Tail shim plate
M8 non-standard bolt
Right front section Right guide body of
body of luggage rack luggage rack
Pad
M6 non-
standard bolt Luggage rack cross
beam assembly
Front upper rubber strip
Left front section Left guide body of luggage rack
body of luggage rack
Sliding block
Right trim strip

of roof cover
Left trim strip of roof cover
Removal of Luggage Rack

1. Raise the regulating block cover of luggage rack cross beam to move the luggage rack cross
beam to the wider position of opening of guide and take off the luggage rack cross beam;
2. Screw off the M6 non-standard bolt at the front section body of luggage rack with No. 4
hexagon socket head tool;
3. Move the rubber strip on the luggage rack guide to expose the M8 non-standard fixing bolt,
and screw off the fixing bolt with No.5 hexagon socket head tool;
4. Raise the front section and rear section bodies of luggage rack and take off the luggage rack.
Removal of Roof Cover Trim Strip
1. Insert the screwdriver between the fixing clip and trim strip to loosen it.
Note: it is necessary to wrap the head of clip screwdriver before using it.
2. Take off the roof cover trim strip.
Install it in the reverse order of removal
Inner Facing Cover of Side Wall
U-shape strip of right

Middle pillar upper rear side door Right seat belt
trim board cover plate guide ring hood
Right middle pillar upper Right rear side wall rear
trim board assembly trim board assembly
Seat belt height
adjuster assembly
U-shape strip of
right front side door
trim board assembly
Right rear side wall front

trim board assembly
Right front
side doorsill
Right rear side wall lower
trim board assembly
Right rear side

doorsill assembly
Right middle pillar
Right front pillar lower lower trim board
trim board assembly
Left seat belt Left rear side Left rear side wall rear
guide ring hood wall front trim trim board assembly
board assembly
Middle pillar upper
trim board cover plate
U-shape strip of left

front side door
trim board assembly
U-shape strip of
left rear side door
Left middle pillar upper Left rear side

trim board assembly doorsill assembly
Left front pillar lower Left rear side wall lower

trim board assembly trim board assembly
Left front side doorsill
Left middle pillar

lower trim board
Removal of Inner Facing Cover of Side Wall

1. Remove the left front side doorsill.
(a) Insert the clip screwdriver between the fixing clip and doorsill to loosen it.
(b) Take off the left front side doorsill.
2. Remove the left rear side doorsill.
(a) Insert the clip screwdriver between the fixing clip and doorsill to loosen it.
(b) Take off the left rear side doorsill.
3. Remove the left front pillar lower trim board.
(b) Take off the left front pillar lower trim board.
4. Remove the left middle pillar lower trim board.
(a) Remove the lower fixing bolts of the left front seat belt and the seat belt guide ring (see the
section of seat belt).
(b) Insert the clip screwdriver between the fixing clip and trim board to loosen it.
(c) Take off the left middle pillar lower trim board of left center pillar.
5. Remove the left rear side wall lower trim board.
(a) Remove the lower fixing bolts of the left rear seat belt and the seat belt guide ring (see the
section of seat belt).
(b) Remove the 3 hooks of luggage compartment.
(c) Remove the shielding curtain.
(d) Insert the clip screwdriver between the fixing clip and trim board to loosen it.
(e) Take off the left rear side wall lower trim board.
Note: it is necessary to wrap the head of clip screwdriver with adhesive tape before using it.
6. Remove the weather strip of door.
(a) Remove the U-shape strip of left front side door.
(b) Remove the U-shape strip of left rear side door.
7. Remove the left front pillar upper trim board.
(b) Take off the left front pillar upper trim board.
8. Remove the left middle pillar upper trim board.
(b) Take off left middle pillar upper trim board.
9. Left rear side wall front trim board
(b) Take off the left rear side wall front trim board.
10. Remove the left rear side wall rear trim board.
(b) Take off the left rear side wall front trim board.
Tips:
The operation procedure for right side is in the same as that of left side.
Install it in the reverse order of removal.
Front Bumper
Radiator guard iron clip
Radiator guard
Front bumper upper

fixing clamp seat
Radiator guard rubber blocks
Front bumper body
Towing hook
cover iron clip
Towing hook cover
Front bumper protective screen
Front license plate mounting panel
Disassembly of Front Bumper

1. Disassemble the bumper expansion buckle.
Use screwdriver to disassemble the bumper expansion buckle from the upper part of the bumper,
then disassemble the bumper expansion buckle connecting the lower part of the bumper and the anti-
splashing pad.
2. Remove the tapping screws on the two sides.
Use screwdriver to disassemble the subassembly of cross recessed hexagon head tapping screws
and large washer connecting the 2 sides of bumper and the fender.
3. Disassemble the bumper mounting bolts.
Screw out the hexagon bolts connecting the bumper and its brackets.
4. Pull out the front bumper body from the left/right front bumper mounting bracket.
5. Unplug the left/right fog lamp connecting harness.
6. Take off the bumper accessories.
Take off the front bumper plastic brackets from the vehicle body respectively.
Rear Bumper
Right lower mounting bracket Right supporting plate of rear bumper

assembly of rear bumper
Left lower mounting bracket
assembly of rear bumper Rear bumper pallet assembly
Left supporting plate
of rear bumper Spring clamp
Rear bumper upper

fixing clamp seat
Rear bumper body
Right upper fixing bracket
assembly of rear bumper pallet
Left upper fixing bracket Small cover plate
assembly of rear bumper pallet
Bumper
expansion buckle
Rear bumper expansion buckle

Right lower mudguard
of rear bumper
Left lower mudguard of rear bumper
Disassembly of Rear Bumper

1. Disassemble the bumper expansion buckle.
Use screwdriver to disassemble the bumper expansion buckle from the upper part of the bumper.
2. Remove the tapping screws on both sides.
Use screwdriver to disassemble the subassembly of cross recessed hexagon head tapping screws
and large washer connecting the 2 sides of bumper and the side wall.
3. Disassemble the nut connecting the lower part of rear bumper and the anti-splash pad.
4. Disassemble the bumper fixing bolts.
Unscrew the rear bumper fixing bolts connecting the left/right upper sides of rear bumper and the
vehicle body.
5. Pull out the bumper.
Pull out the rear bumper from the rear bumper left/right bracket.
6. Unplug the left/right fog lamp connecting harness.
7. Disassemble the plastic brackets.
Unscrew the subassembly of cross recessed hexagon head tapping screw and large washer mounted
on the rear bumper bracket, and take off the rear bumper plastic brackets.
Seat Belt
Front trim board assembly of right rear side wall

Right seat belt guide ring hood
Seat belt height
adjuster assembly Seat belt height
adjuster assembly
Right middle pillar upper Right seat belt
trim board assembly guide ring hood
Lower trim board assembly
of right rear side wall
42
42
42
42 Seat belt height

adjuster assembly Left seat belt
Right rear seat belt assembly guide ring hood
Right front seat belt assembly
42
Rear-row seat
belt assembly
Right middle pillar

lower trim board 42
42 42
Right front seat belt lock assembly

Rear-row seat belt Left rear seat
lock assembly 42 belt assembly
Left front seat belt lock assembly Seat belt height adjustor assembly
Left seat belt

guide ring hood
42
Left front seat belt assembly
42
42
N•m : rated torque

Disassembly of Front-row Seat Belt

1. Disassemble the end piece hood.
Lift the hood at the lower part of seat belt to unveil the seat belt lower fixing bolts.
2. Disassemble the seat belt lower fixing bolts and the middle pillar lower trim board.
3. Disassemble the guide ring hood.
Disassemble the seat belt guide ring hood to unveil the seat belt upper fixing bolts.
4. Disassemble the seal belt guide ring.
Disassemble the seat belt upper fixing bolts and the middle pillar upper trim board to unveil the seat
belt height adjustor.
5. Disassemble the height adjustor.
Disassemble the seat belt height adjustor fixing bolts, in the order from bottom to top.
6. Disassemble the seat belt retractor upper fixing screws.
7. Disassemble the seat belt retractor lower fixing bolts.
Assembly of Front-row Seat Belt
1. Assemble the seat belt height adjustor.
(a) Tighten the seat belt height adjustor fixing bolts.
(b) Check the tightening torque of the seat belt height adjustor fixing bolts.
The torque of the seat belt height adjustor fixing bolts is (42±5) N•m.
2. Assemble the middle pillar upper trim board.
3. Assemble the retractor lower fixing bolts.
Tighten the seat belt retractor fixing bolts. The rated value is (42±5) N•m.
4. Assemble the retractor upper fixing bolts.
Tighten the seat belt retractor upper fixing bolts.
5. Assemble the seat belt guide ring
Fix the seat belt upper fixing bolts on the seat belt height adjustor.
The rated tightening torque for the seat belt upper fixing bolts is (42±5)N•m.
6. Assemble the middle pillar lower trim board.
7. Assemble the seat belt fixing end piece.
Fix the seat belt lower fixing bolts on the side wall of vehicle body. The rated tightening torque
for the lower fixing bolt is (42±5)N•m.
8. Assemble the seat belt guide ring hood.
Assemble the seat belt guide ring hood on the seat belt guide ring.
Disassembly of Rear-row Three-point Seat Belt
1. Lift the seat belt lower hood to unveil the seat belt lower fixing bolts.
2. Disassemble the seat belt lower fixing bolts.
2. Disassemble the rear side wall guard board.
3. Disassemble the guide ring hood.
Disassemble the seat belt guide ring hood to unveil the seat belt guide ring fixing bolts.
4. Disassemble the seat belt guide ring fixing bolts and the retractor lower fixing bolts.
5. Disassemble the seat belt height adjustor fixing bolts, in the order from bottom to top.
Assembly of Rear-row There-point Seat Belt
1. Assemble the seat belt height adjustor
(a) Tighten the seat belt height adjustor fixing bolts.
(b) Check the tightening torque for fixing bolt of seat belt height adjuster.
The rated value is (42±5)N•m.
2. Assemble the retractor.
Tighten the seat belt retractor lower fixing bolts. The rated tightening torque value is (42±5)N•m.
3. Assemble the guide ring.
Tighten the seat belt guide ring fixing bolts. The rated tightening torque value is (42±5)N•m.
4. Assemble the seat belt guide ring hood.
Assemble the seat belt guide ring hood on the seat belt guide ring.
General Description & system operation of Seat Belt

Warning on front passenger seat belt not fastened:
The front-row driver’s seat belt is equipped with a seat belt warning lamp, which is on the instrument
panel. Once the ignition switch is turned on and the driver’s seat belt is not fastened, the warning
lamp will alarm the driver.
Precautions for Operation & Functional Checks
Precautions:
1. If the seat belt retractor is not correctly assembled, the seat belt will be out of function in case
of accident, leading to failure in providing proper protection to the passengers!
2. The contact between the seat belt and sharp objects or hazardous materials should be
avoided.
3. The bending or damage of the seat belt latch and lock should be avoided.
4. it is forbidden to bleach wash the seat belt textile. It is only permissible to wash it with neutral
liquid soap and clean water.
5. While assembling the seat belt fixing bolts, first use hands then use a torque wrench for the
tightening.
6. It is forbidden to repair the seat belt retractor and seat belt lock. If the seat belt is damaged, it
is required to replace the whole seat belt assembly.
7. Replace the broken or damaged seat belt.
Functional Checks:
1. Check if all the seat belt fixing bolts are properly tightened.
2. Check the seat belt lock. The lock should be easily unlocked and locked.
3. Once the seat belt is locked, the latch should not get loosened.
4. Pull out the whole length of the seat belt, no knotted or fractured phenomenon are allowed
with the seat belt.
5. The retraction of the shoulder strap should be easy and smooth, and without sluggish feeling
seizure.
Warning: the interaction between different kinds of metal pieces can accelerate the corrosion.
It’s imperative to use correct fastener to avoid early corrosion!
Seat
Driver’s Seat
Driver’s seat
headrest assembly
Headrest guide
Driver’s seat inner- sleeve free end
Headrest guide
side lateral plate sleeve locking end
Seat belt lock

fixing bolt Driver’s seat inner-
side angle adjustor Driver’s seat
backrest assembly
Driver’s seat waistrest
adjustor hand wheel
Front seat right

Driving rod rear cover plate
Driver’s seat right
rear cover plate
Left front seat belt
lock assembly
Angle adjustor Driver’s seat left
Front seat right fixing bolt rear cover plate
front cover plate
Front seat left

rear cover plate
Q1401025FD(M10X1.25) Q1401025FD(M10X1.25)
Front seat left
front cover plate Driver’s seat angle
Driver’s seat outer- adjustor button
side lateral plate
Driver’s seat angle
Driver’s seat adjustor handle cover Driver’s seat slide button
slide assembly
Assistant Driver’s Seat
Driver’s seat headrest assembly
Headrest guide Headrest guide sleeve locking end Assistant driver’s seat
sleeve free end inner-side lateral plate
Seat belt lock fixing bolt
Assistant driver’s seat
Driver’s seat waistrest backrest assembly
adjustor hand wheel Assistant driver’s seat
inner-side angle adjustor
Right front seat belt
lock assembly
Front seat right
rear cover plate
Driving rod
Angel adjustor Assistant driver’s seat

fixing bolt cushion assembly
Q1401025FD(M10X1.25)
Assistant driver’s seat
right rear cover plate
Front seat left rear cover plate
Lateral plate
mounting screw
Front seat right
Assistant driver’s seat front cover plate
left rear cover plate
Q1401025FD(M10X1.25) Assistant driver’s
seat slide assembly
Assistant driver’s seat Front seat left
angle adjustor button Driver’s seat Assistant driver’s seat
outer-side lateral plate front cover plate
slide button
Assistant driver’s seat angle
adjustor handle cover
Precautions:
1. Take care during the process of disassembling, handling and assembling the seat, and avoid
scratch and crushing injuries by the seat.
2. Pay attention to protect the interior trimmngs during the assembly and handling of the seat,
and avoid scatch of lateral plate.
3. After the assembly, check the tightening torque for the mounting bolts against the rated value,
(38± 5) N•m.
4. The order for disassembly is just opposite to that of the assembly.
Disassembly and Assembly of Front-row Seat
Disassembly
1. Disconnect the seat belt terminal connecting wire (which is located at the bottom of seat).
2. Disassemble the rear foundation cover plate and its fixing bolts.
3. Disassemble the front foundation cover plate and its fixing bolts.
4. Disassemble the seat.
Assembly
Important precautions: the interaction between pieces made of different kind of metals can
accelerate the corrosion. It's imperative to use correct fastener to avoid early corrosion.
1. Assemble the seat.
2. Connect the seat belt terminal connecting wire.
3. Tightening the rear foundation bolts and assemble the rear foundation cover plate.
4. Tightening the front foundation bolts and assemble the front foundation cover plate.
Remarks: It should be symmetrical between the left and right front-row seats.
Rear-row Seat
Rear-row seat right cushion assembly Rear-row seat left cushion assembly
40% foamed seat cushion & its skin
Rear-row seat
belt assembly Rear seat belt
lock assembly
60% foamed seat

cushion & its skin
Rear-row Rear-row left lock assembly

seat belt lock
assembly Rear-row seat left
Rear-row seat right seat pan assembly
seat pan assembly
Foundation bolts 8 x 1.25
Foundation bolts 8 x 1.25
Rear-row seat foundation assembly Rear-row seat foundation assembly
Q1401025FD(M10X1.25)
Rear-row seat front foot cover plate
Headrest guide Belt outlet shield assembly

sleeve locking end
Tapping screw ST 4.8 x
Headrest guide 13
sleeve free end Rear-row seat headrest assembly
Rear-row seat backrest
skeleton assembly
Right rear seat Driver’s seat headrest assembly
backrest lock cover Rear backrest lock assembly-left
Unlock button Rear-row seat backrest
Q2140520F31 assembly skeleton assembly
Rear backrest Unlock button
lock assembly- assembly
right
Q2140520F31
Q2714895F31
Q2714895F31
Screw M8 x 1.25
Q2140520F31
Screw M8 x 1.25
Left rear seat
backrest lock cover
60% foamed Q2140520F31
backrest & its skin
40% foamed backrest & its skin
Right connecting plate
Left connecting plate
Bolt 10 x 1.25
Middle
Q32010FD(M10×1.25) connecting plate
Q32010FD(M10×1.25)
Q1401025FD(M10X1.25)
Disassembly & Assembly of Rear-row Seat

Disassembly
1. Disassemble the rear seat foundation cover plate and its fixing bolts.
2. Disassemble the rear seat 40% foamed cushion.
3. Disassemble the rear seat 60% foamed cushion.
4. Disassemble the nuts and bolts fixing the rear seat backrest.
5. Unlock the seat backrest lock and disassemble the rear seat backrest.
Assembly
Important precautions: direct interaction between pieces made of different kinds of metals can
accelerate the corrosion. It’s imperative to use correct fastener to avoid early corrosion.
1. Assemble the fastening bolts and nuts for the rear seat backrest.
2. Assemble the fastening bolts for the rear seat 60% foamed cushion.
3. Assemble the fastening bolts for the rear seat 40% foamed cushion.
4. Assemble the rear foundation cover plate.
Body & Stamping Parts-1
Body & Stamping Parts
Front Body Stamping Parts ........................................................... 2

Stamping Parts for Rear Carriage ................................................. 3
Instrument Panel Stiffener ............................................................. 4
Fuel Tank Door................................................................................ 6
Engine hood .................................................................................... 7
Front Door Stamping Parts............................................................ 9
Rear Door Stamping Parts ............................................................. 10
Rear Liftgate Stamping Parts ........................................................ 11
Front Body Stamping Parts
Left stiffening beam

assembly of front bumper
Radiator frame assembly Hexagonal flange face automatic

chip-removal nut 14XQ32106FD
Middle stiffening beam

assembly of front bumper
Left lower mounting

bracket of front bumper
Middle lower mounting

bracket of front bumper
Right stiffening beam Right lower mounting bracket of

assembly of front bumper front bumper
Hexagon head bolt, elastic washer and plain
washer subassembly 3XQ1460820FD
Replacement
Note: the steps of assembling are inverse to that of disassembling. The Step 2~4 and Step 6~7 are in
no particular order.
1. Remove the front bumper assembly
2. Remove the left lower mounting bracket of front bumper
(a) Screw two nuts out with a wrench,
(b) Take off the left lower mounting bracket of front bumper.
3. Remove the right lower mounting bracket of front bumper
(b) Take off the right lower mounting bracket of front bumper.
4. Remove the middle lower mounting bracket of front bumper
(b) Screw one bolt out with a wrench,
(c) Take off the middle lower mounting bracket of front bumper.
5. Remove the middle stiffening beam assembly of front bumper
(b) Take off the middle stiffening beam assembly of front bumper.
6. Remove the left stiffening beam assembly of front bumper
(a) Screw three nuts out with a wrench,
(c) Take off the left stiffening beam assembly of front bumper
7. Remove the right stiffening beam assembly of front bumper
(a) Screw three nuts out with a wrench,
(c) Take off the right stiffening beam assembly of front bumper.
Stamping Parts for Rear Carriage
Side wall outside plate

lower rubber plug
Right supporting plate of
rear bumper
Right lower mounting bracket

Right upper fixing bracket

Left supporting assembly of rear bumper
plate of rear pallet
bumper
Left lower mounting bracket
Hexagonal flange face automatic
Install the rubber plug in Rear bumper chip-removal nut 8XQ32108FD
this hole at the right side pallet assembly
Hexagonal flange face Left upper fixing bracket
automatic chip-removal nut assembly of rear bumper pallet
8XQ32106FD
Replacement
1. Remove the rear bumper assembly
2. Remove the left lower mounting bracket of rear bumper
(b) Take off the left lower mounting bracket of rear bumper.
3. Remove the right lower mounting bracket of rear bumper
(b) Take off the right lower mounting bracket of rear bumper.
4. Remove the left supporting plate of rear bumper
(b) Take off the left supporting plate of rear bumper.
5. Remove the right supporting plate of rear bumper
(b) Take off the right supporting plate of rear bumper.
6. Remove the rear bumper pallet assembly
(a) Screw four nuts out with a wrench,
(b) Take off the rear bumper pallet assembly.
7. Remove the left upper fixing bracket assembly of rear bumper pallet
(b) Take off the left upper fixing bracket assembly of rear bumper pallet.
8. Remove the right upper fixing bracket assembly of rear bumper pallet
(b) Take off the right upper fixing bracket assembly of rear bumper pallet.
Instrument Panel Stiffener

Left-hand drive Hexagon head bolt, spring washer and
large washer assembly
2×Q1460620FD(Q40206)
Hexagonal flange face automatic

Hexagon head bolt, spring washer chip-removal nutQ32106FD
and plain washer assembly Instrument panel stiffening
6×Q1460620FD beam assembly
Left mounting bracket

assembly of instrument
panel stiffening beam
Right mounting
bracket assembly
Left lower cover of instrument
bracket assembly panel stiffening
of instrument panel beam
Hexagon head bolt,

washer assembly Hexagon nut and
2×Q1460616FD(Q40206) Right bracket assembly conic elastic washer
of instrument panel subassembly
Hexagon head bolt, Hexagon head bolt, cross beam
spring washer and 4×Q32208LFD
plain washer assembly washer assembly Hexagonal flange nut
4×Q1460620FD 4×Q1460620FD(Q40206) 4×Q32006FD
Left bracket assembly of
instrument panel cross beam
Right-hand drive
Hexagonal flange
face automatic chip- Hexagon head bolt, spring washer
removal nutQ32106FD and large washer assembly2
×Q1460620FD(Q40206)
Instrument panel stiffening
beam assembly Hexagon head bolt,
Left mounting bracket spring washer and plain
assembly of instrument washer assembly
panel stiffening beam 6×Q1460620FD
Right mounting
bracket assembly
of instrument panel
stiffening beam
Hexagonal flange nut

4×Q32006FD
Left bracket assembly

of instrument panel Left lower cover
cross beam bracket assembly of
instrument panel
Hexagon head bolt, spring washer
Hexagon head bolt, and large washer assembly
spring washer and large 2×Q1460616FD(Q40206)
Hexagon nut and washer assembly
conic elastic washer 4×Q1460620FD(Q40206) Hexagon nut and conic hexagon
subassembly Right bracket assembly of head bolt, spring washer and
4×Q32208LFD instrument panel cross beam plain washer subassembly
4×Q1460620FD
Replacement
1. Remove the instrument panel assembly
2. Remove the left lower cover bracket assembly of instrument panel
(a) Screw six bolts out with a wrench,
(b) Take off the left lower cover bracket assembly of instrument panel.
3. Remove the left bracket assembly of instrument panel cross beam
(a) Screw two bolts out with a wrench,
(b) Screw two nuts out with a wrench,
(c) Take off the left bracket assembly of instrument panel cross beam.
4. Remove the right bracket assembly of instrument panel cross beam
(b) Screw one nut out with a wrench,
(c) Take off the right bracket assembly of instrument panel cross beam.
5. Remove the instrument panel stiffening beam assembly
(a) Screw one nut in the middle out with a wrench,
(b) Screw four nuts at the both sides out with a wrench,
(c) Screw two nuts out with a wrench,
(d) Take off the instrument panel stiffening beam assembly
6. Remove the left mounting bracket assembly of instrument panel stiffening beam
(a) Screw three bolts in the middle out with a wrench,
(b) Take off the left mounting bracket assembly of instrument panel stiffening beam.
7. Remove the right mounting bracket assembly of instrument panel stiffening beam
(a) Screw three bolts in the middle out with a wrench,
(b) Take off the right mounting bracket assembly of instrument panel stiffening beam.
Fuel Tank Door
Cross slot pan head screw

2XQ2140610FD Side wall assembly
Fuel tank door damping

rubber plug
Fuel tank door cover plate assembly
Procedures of disassembling
1. Open the fuel tank door
2. Remove the two bolts at the joint of fuel tank door and the outside plate of side wall.
3. Take off the two rubber plugs connected with the side wall.
Procedures of installation
1. Install the two rubber plugs into the mounting hole on the outside plate of side wall.
2. Set the fuel tank door open,
3. Insert the seat plate of fuel tank door inside the outside plate of side wall.
4. Get the position of the two mounting holes in the seat plate of fuel tank door and the outside
plate of side wall aligned.
5. Screw in the two bolts at the joint of fuel tank door and the outside plate of side wall.
6. Close the fuel tank door.
Engine hood
1. Check the engine hood subassembly
A
B (a) Check to ensure the clearances lie in the criterion
range.
Criterion:
Position Measured value
A 5.0mm
B 0mm
2. Adjust the engine hood lock subassembly

(a) Adjust the engine hood from the horizontal and
vertical directions.
(1) Screw the four hinge mounting bolts at the side
of the engine hood.
(2) Adjust the clearance by moving the engine

hood to get it laid in the criterion range.
Criterion range (A): 5.0mm
(3) Fasten the hinge mounting bolts at the side of
the engine hood.
Torque: 11.5N•m
(b) Adjust the front height of the engine hood with

the adjusting block so as to get the engine hood
aligned with the fender.
Note: move the adjusting block by rotating it up and
down.
(c) Adjust the engine hood lock.
(1) Remove the clamp and the grid.
(2)Adjust the position of the engine hood so as to

Left-hand drive
smoothly get the latch in.
(3)Screw down the engine hood lock bolts after
adjusting.
Torque: 7.0N•m
Right-hand drive
Left-hand drive Loosening cable of left-hand drive

engine hood latch
1. Remove the loosening cable of engine hood latch
(a) Open the engine hood
(b) Remove the loosening handle of engine hood
latch from the instrument panel.
(c) Remove the cable from the loosening handle of
engine hood latch.
(d) Remove the bolts and the loosening mechanism
assembly of engine hood latch.
(e) Remove the cable from the loosening mechanism
Right-hand drive assembly of engine hood latch.
2. Install the loosening cable of engine hood latch
Note: the contact among the different metals will
accelerate the erosion. Be sure to use the right
fasteners to avoid early erosion.
(a) Install the cable onto the loosening mechanism
assembly of engine hood latch.
(b) Install the loosening mechanism assembly of
engine hood latch with bolts.
(c) Install the cable onto the loosening handle of
engine hood latch.
(d) Install the loosening handle of engine hood latch
onto the instrument panel.
(e) Close the engine hood.
Front Door Stamping Parts
Left front side door assembly
Hexagonal flange bolt

4XQ1410820LFD
Upper hinge assembly of left front side door
Hexagonal bolt and conic

elastic washer subassembly
4XQ1860820FD
Hexagonal flange nut
2XQ32006FD
Lower hinge assembly

of left front side door
Front side door check assembly
Hexagonal flange
bolt1XQ1840616FD
Replacement
Note: the steps of assembling are inverse to that of disassembling; the left front side door is
symmetrical to the right one. The Step 2~5 is in no particular order.
1. Remove the left front side door assembly
(a) Screw five bolts out with a wrench,
(b) Take off the left front side door assembly.
2. Remove the left front side door check assembly
(c) Take off the left front side door check assembly.
3. Remove the connecting plate of left check
(a) Remove the left front door check assembly,
(b) Take off the connecting plate of left check.
4. Remove the upper hinge assembly of left front side door
(b) Take off the upper hinge assembly of left front side door
5. Remove the lower hinge assembly of left front side door
(b) Take off the lower hinge assembly of left front side door.
Rear Door Stamping Parts

Cross recessed raised
countersunk head screw
Q2540410FD Left rear side door assembly
Installation part of left

rear side door glass
guide rail assembly

4XQ1410820LFD
Hexagonal bolt and conic
elastic washer subassembly
4XQ1860820FD
Upper hinge assembly
of left rear side door
Hexagonal flange nut 2XQ32006FD
Rear side door check assembly
Lower hinge assembly of

left rear side door
Cutting groove bolt

1XQ1840616FD
Replacement
Note: the steps of assembling are inverse to that of disassembling; the left rear side door is
symmetrical to the right one. The Step 2~5 is in no particular order.
1. Remove the left rear side door assembly
(a) Screw five bolts out with a wrench,
(b) Take off the left rear side door assembly.
2. Remove the installation parts of left rear side door glass guide rail assembly
(a) Screw one screw out with a cross screw driver,
(c) Take off the installation parts of left rear side door glass guide rail assembly.
3. Remove the left rear side door check assembly
(c) Take off the rear side door check assembly
4. Remove the upper hinge assembly of left rear side door
(b) Take off the upper hinge assembly of left rear side door
5. Remove the lower hinge assembly of left rear side door
(b) Take off the lower hinge assembly of left rear side door.
Rear Liftgate Stamping Parts

4XQ1860820FD
Liftgate assembly
Hexagon nut and

oversize conic elastic
washer subassembly Liftgate hinge assembly
4XQ32208LFD

4XQ1840616F31
Right boosting stay bar

assembly of liftgate
Butyl sealing rubber pad Left boosting stay bar

assembly of liftgate
Butyl sealing rubber pad
Replacement
Note: the steps of assembling are inverse to that of disassembling.
1. Remove the boosting stay bar assembly of liftgate
(a) Screw four bolts out with a wrench,
(b) Screw one ball head bolt of boosting stay bar out with a wrench.
(c) Take off the boosting stay bar assembly of liftgate.
2. Remove the liftgate assembly
(a) Screw four nuts out with a wrench,
(b) Take off the liftgate door assembly
3. Remove the liftgate hinge assembly
(a) Screw four bolts out with a wrench,
(b) Take off the liftgate hinge assembly.
Bolt Tightening Torque (Chassis)-1
Bolt Tightening Torque (Chassis)

Torque Torque
No. Working Part & Specification No. Working Part & Specification
N·m N·m
Upper arm shaft fixing bolt Steering gear - frame fixed bolt
1 175±20 41 90±10
M14×1.5-10.9 M12×1.25-8
Lower arm front shaft connec- Locking bolt of steering system
2 ting bolt 240±20 42 universal joint 25±3
M16×1.5-10.9 M8×1.25-8.8
Lower arm rear shaft connec-
Steering link ball head fixed nut
3 ting bolt 290±30 43 120±10
M14×1.5-8
M18×1.5-10.9
Lower arm limiting stopper Steering link adjusting locking
4 fixed bolt 63±5 44 nut 63±5
M10×1.25-8.8 M14×1.5-8
Upper arm ball stud seat con- Front connecting bolt of short
5 necting bolt 78±10 45 vertical rod 180±15
M10×1.25-10.9 M14×1.5-10.9
Lower arm ball stud seat con- Rear connecting bolt of short
6 necting bolt 140±10 46 vertical rod 180±15
M12×1.25-10.9 M14×1.5-10.9
Front torsion bar anchor con-
Tie rod – frame connecting bolt
7 necting bolt 140±10 47 180±15
M14×1.5-10.9
M12×1.25-10.9
Upper arm ball stud throttled
Tie rod – rear axle fixed nut
8 fixed nut 145±15 48 180±15
M14×1.5-8
M16×1.5-10
Lower arm ball stud throttled Connecting bolt of long vertical
9 fixed nut 230±20 49 rod 180±15
M18×1.5-10 M14×1.5-10.9
Upper fixed nut of front shock Rear stabilizer anti-roll bar - rear
10 absorber 1/3 50 axle fixed bolt 23±3
M10×1.25-8 M8×1.25-8.8
Lower connecting bolt of front Rear stabilizer anti-roll bar - con-
11 shock absorber 90±10 51 necting rod - frame nut 63±5
M12×1.25-9.8 M10×1.25-8
Upper fixed nut of rear shock
Spare wheel bracket fixed bolt
12 absorber 1/3 52 63±5
M10×1.25-8.8
M10×1.25-8
Lower fixed nut of rear shock
Spare tire lifter fixed bolt
13 absorber 170±15 53 23±3
M8×1.25-8.8 K1
M14×1.5-8
Front stabilizer anti-roll bar -
Steering gear – frame fixed nut
14 frame fixed bolt 23±3 54 160±10
M16×1.5-8
M8×1.25-8.8
Front stabilizer (anti-roll)bar -
Steering gear – frame fixed bolt
15 connecting rod - lower arm nut 63±5 55 160±10
M16×1.5-8.8
M10×1.25-8
Steering wheel - steering column
Wheel nut
16 135±15 56 fixed nut 30±5
M12×1.25
M12×1.25-8
Steering oil pipe - oil pump tig- Steering oil pipe - oil pump tig-
17 27.5±2.5 57 30±5
htening torque (gasoline) htening torque (diesel)
Steering angle driven pairs – fra-
Steering oil pipe - steering gear
18 17.5±2.5 58 me bolt 70±10
tightening torque (gasoline)
M10×1.25-9.8
Torque Torque
N·m N·m
Steering angle driven pairs – fra-
19 Engine oil pan drain plug 40±5 59 me bolt 50±5
M10×1.5-9.8
Brake pipe and three-way con- Transmission mounting and fra-
20 60
nection (left) me connecting bolt (left)
45±5
Brake pipe and three-way con- Transmission mounting and fra-
21 61
nection (right) me connecting bolt (right)
(4WD) Drive shaft and left upper
62
Rear brake oil pipe and frame nut of front axle connection
22
two-way connection (right) (4WD) Drive shaft and left lower
63
nut of front axle connection
Rear brake oil pipe and hose (4WD) Drive shaft and right up-
23 20±2 64
connection (left) per nut of front axle connection
(4WD) Drive shaft and right lo-
65
Rear brake oil pipe and hose wer nut of front axle connection
24 78±5
connection (right) Drive shaft and left upper nut of
66
rear axle connection
Left rear brake oil pipe and Drive shaft and left lower nut of
25 67
brake hose (left) rear axle connection
Right rear brake oil pipe and Drive shaft and right upper nut of
26 68
brake hose (right) rear axle connection
Front driving axle and frame Drive shaft and right lower nut of
27 69
fixed connecting bolt (left front) rear axle connection
Front driving axle and frame
Fixed bolt of engine with clutch
28 fixed connecting bolt (right 70
assembly (M10×35)
front)
180±15
Front driving axle and frame
Fixed bolt of engine with clutch 55±5
29 fixed connecting bolt (right 71
assembly (M10×40)
rear)
Front driving axle and frame Fixed bolt of engine with clutch
30 72
fixed connecting bolt (left rear) assembly (M10×70)
Starter and transmission connec-
31 Fuel filler bolt of front axle 73 ting bolt 30±3
(M10×60) - (upper) (lower)
120±10
Front brake hose, steering knuc-
Fuel filler and oil drain hole bolt
32 74 kle and wheel hub brake connec- 35±3
of rear axle
tion (left)/(right)
(2WD) Left supporting seat of Brake pipe and brake main cylin-
33 75 16±2
drive shaft der connection
65±5
(2WD) Right supporting seat of Brake pipe and ABS hydraulic
34 76 16±2
drive shaft unit connection
Transmission and engine con-
35 Fuel filler bolt of transmission 32.5±2.5 77 necting bolt 45±5
M10×1.25 - 8.8
Diesel engine and transmission
36 Oil drain hole bolt of front axle 30-35 78 40±5
(M12)
Gasoline engine moun-
ting Q1421020, Q1421025, Diesel engine and transmission
37 65±5 79 45±5
Q1841025FD (M10)
(M10×1.25-8.8)
Diesel engine mounting
38 65±5 80 Clutch pump 40±5
(Q1841025FD)
“Exhaust tube outlet nut” for Transmission, transfer case, dra-
39 85±5 81 30-35
gasoline engine (1008012-K00) in plug
Torque Torque
N·m N·m
“Hexagonal-head bolt, hexa-
gonal flange face nut” for die- Body mounting connecting bolt
40 70±5 82 75±5
sel engine (Q150B1040FD, M10×1.25-9.8
Q32010FD)

GREAT WALL HOVER - Service - Manual PDF

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Preface

tomers for its elegant appearance, excellent performance&price ratio,concept of double

and the related technical parameters.

tor Co., Ltd.

How to use this manual ................................................... 2

How to use this manual

★upper arm shaft

upper arm bush

washer upper arm

upper ball pin

N·m :specified torque

The maintenance procedure is explained in the form

3. Check the drive of ball pin

(b) As shown in the Figure, shake the ball pin back

This format can help the experienced technical per-

vehicle VIN NO.

Motor serial number

Comprehensive maintenance ins-

(e) Mount the cable terminal onto the binding post

12. Paying attention to the following matters to avoid

General Description of Complete

CC6460K and CC6460KY Wagon (4G64)

No. Item Parameters No. Item Parameters

1. Four-wheel Alignment Adjustment

2 Lighting and signal system

Non-metal Material Consumption Breakdown

Windshield washer Q35 Front and rear windows L 3

CC6460KM55 and CC6460KM75 Wagon (2.5TCI Right-hand Drive)

Structure Type and Technical Parameters of Main System and Assembly

11 Pressure switch Tri-state pressure switch

Front drive axle 1.4L±0.1L

CC6460KM07 and CC6460KM27 Wagon (4G63 Left-hand Drive)

Sliding distance with initial speed 50km/h (m) ≥500

Structure Types and Technical Parameters of Main Systems and

11 Pressure switch Tri-state pressure switch

5 Manual transmission 1.4L±0.1L API GL-4 grade hyperbolic gear oil

Front drive axle 1.4L±0.1L

CC6460KM19 and CC6460KM39 Wagon (4G69)

Structure Types and Technical Parameters of Main Systems and

Gear I 3.992 Gear I 3.992

11 Pressure switch Tri-state pressure switch

2.4L±0.1L （4WD） API GL-4 grade hyperbolic gear oil，

9 Brake fluid 0.45L±0.035L DOT4 synthetic brake fluid

Fuel-supply System I (of Petrol, with Canister

Petrol (with Canister Installed Front)

Accelerator pedal assembly

Air outlet rubber

Hose fixing clip

Steel strip type

N·m : specified torque

Attention: If it is necessary to disassemble the

3. Remove the bolts for tank installation (six in total);

4. Remove the fuel tank and let the joints of return

5. Separate the fuel tank, the tank pallet and its

Removal and Installation of Fuel Pump

Removal of Fuel Filling Pipe

Removal of Fuel Pipe

2. Removal of the front section of fuel rigid pipe

3. Removal of the rear section of fuel rigid pipe