Sunteți pe pagina 1din 50

www.bydauto.com.

cn

BYD AUTO

BYD S6 Maintenance &Repair manual

Foreword
This Repair Manual provides information about diagnosis and
repair procedures, adjustment and specifications for repair
technicians. Please use this Repair Manual together with structural
drawings book when necessary.
If you need information about product brand, part number or
special tool mentioned in this Repair Manual, please feel free to
contact BYD Auto Co., Ltd. All information, illustrations and product
description used in this Manual are applicable to situation when
this Manual is going to publish. BYD reserve rights to change
information in this Manual at any time without further Notes and any
restraint.
Without permission of BYD Auto Co., Ltd., do not copy, store any
part of this manual on retrieval system or spread it by means of
electronic, mechanical, copy or recording methods. The abovementioned is applicable to words, graphs and tables, etc.

BYD Auto Co., Ltd.


Date
All rights reserved

BYD AUTO

BYD 6S Maintenance &Repair manual

Caution
Warning: in order to reduce possibility that person and/or property is damaged, please
observe the following descriptions:
1.

This Manual is prepared by BYD Auto Co., Ltd. for qualified professional technicians. Anyone
without proper training, tools and equipment who tries to repair and maintain this car may
cause self or other persons to be injured.

2.

Correct repair and maintenance methods are important for the personal safety of repair
technicians, safe and reliable operation of the motor vehicle. Please use the same original
part as one part which you need to replace, or the part specified by BYD Auto Co., Ltd.. Do
not use replacement parts unauthorized by BYD Auto Co., Ltd..

3.

Repair procedures recommended or described in this Manual are effective methods for
repair and maintenance. A specially designed tool needs to be used in some procedures.
Therefore, you must ensure that personal safety or safe operation of vehicle will not be
threatened when you use replacement parts, repair procedures or tools which have not
authorized or accepted by BYD Auto Co., Ltd..

4.

This Manual contains information under "Warning", "Special Note" and "Notes" which
should be complied with to avoid injury in repair and maintenance. Improper maintenance
may damage vehicle or bring potential risk to the vehicle. These "warning", "special notes"
and "Notes"do not cover all cases. BYD Auto Co., Ltd. cannot give warning and compensate
for potential risk due to violation of these notes.

5.

This Manual includes repair procedures for vehicle equipped with safe airbag system
(hereinafter referred to as the "air bag"). Refer to "Warning", "Special Notes", "Notes" and
"Warnings" in "Protection Device ". Please refer to parts of air bag and line position drawing
in "Protection Equipment" before repairing parts of air bag or its line or adjacent to the airbag.
Violation of information under "Warning" will cause the air bag deployment, personal injury or
unnecessary repair of airbag.
Violation of information under "Warning" will cause the air bag deployment, personal injury or
unnecessary repair of airbag.

BYD AUTO

BYD 6S Maintenance &Repair manual

Report errors and recommendations


If you find any error in this Repair Manual or have any recommendation for this Repair Manual,
please contact BYD Auto Co., Ltd. by letter or fax. Details of contact are as following:
Technical Service Department BYD Auto Sales Co., Ltd.
Address: Room 1-446#, BYD Auto, Pingshan Industrial Park, Longgang District, Shenzhen
Zip code: 518118
Fax: 0755-8992-4437
Please fill the following information in the Quality Report in contact:

Your name

Name of Sales and Service Store

Telephone and fax numbers of Sales and Service Store

Description of your concerns

Other necessary information (such as sample or marked page number)

Any applicable electronic information (such as parts identification number)


BYD Auto Co., Ltd. will answer your questions in follow procedure:

Forward your questions to the relevant repair motorer

Consult the relevant repair motorer

Provide you with answers to your questions within 10 working days

Repair Manual Quality Report


To Manager of Technical Service Department
Name
Manual

of

Dealer Name
Subject

Description of problem

Revision comments

Publication Date
Reporter name

BYD AUTO

BYD 6S Maintenance &Repair manual

Table of Contents
Table of Contents............................................................................................................................1
Section 1 Technical Performance and Parameters of Finished Automobile.....................3
1.1. Main technical parameters of finished automobile:..............................................3
1.2. Engine performance parameter:.............................................................................4
1.3. Engine accessory and chassis assembly type and parameter:..........................4
1.4. Body structure type..................................................................................................5
1.5. Body accessory........................................................................................................5
1.6. A/C system structure and parameter......................................................................6
1.7. Electric System Structure and Parameters............................................................6
1.8. Lubricating oil and fuel, and capacity....................................................................8
Section 2 Vehicle identification.............................................................................................9
2.1. Vehicle identification number(VIN).........................................................................9
2.2 Warning note label position:.................................................................................10
Section 3 Maintenance rule..................................................................................................11
3.1. Warning and notes..................................................................................................11
3.2. Instructions:............................................................................................................11
Section 4 Overhaul Specification........................................................................................30
4.1. Troubleshooting method........................................................................................30
4.2. Electric control system..........................................................................................31
4.3. Corrective maintenance procedure......................................................................38
Section 5 Abbreviations and Color Symbols of Electric Wires........................................40
5.1. Abbreviations..........................................................................................................40
5.2. Color symbols of electric wires............................................................................43

1.

This manual description


(4) This Manual does not describe the
following basic operations which should
be complied with strictly in practice:

(1) This manual is prepared accoding to


international standard and technical
standard of BYD Auto. Co., Ltd.

1 Using a jack or a lifter


(2) Repair
operation
includes
procedures as following:

main

Wash removed parts when necessary

Diagnosis

Visual inspection

Dismantle/install,
replace,
disassembly/assemble, check and adjust

2.

Preparation

Prepare special tools and special repair


materials which might be used according to
repair conditions; always use special tools and
special repair materials when necessary.
Carry out repair operations in strict
accordance with correct steps. Please refer to
the instruction of related repair and operation

Final inspection

(3) This manual describes the first two


procedures in maintenance procedure.
There is no description about ""final
check"".

BYD AUTO

BYD 6S Maintenance &Repair manual

parts in this manual.


3.

Descriptive text focuses on how to


complete this job and provides other
information such as specifications and
warnings

4.

Repair specification

Repair steps

(1) Provide composition diagram in each


section as required.
(2) Specify non-reusable parts, lubricated
parts, pre-painted parts and torque
requirement in the composition diagram.

"Specification Description" is indicated in


bold type in necessary position of this
Manual.

(3) Focus on tightening torque, lubricated


parts and non-reusable parts in
description of repair steps.
(4) Removal steps are exactly reverse as
installation steps. Therefore, detail
additional installation steps.

5.

Warnings indicate that it may cause


serious personal hurt to a maintainer.
Special notes indicate that it may damage
the vehicle or parts.

(5) Only describe key points in text section.


Indicate specific steps and other details in
illustration.

Notes indicate that it is helpful to


complete maintenance in an effective
method.

(6) Steps in this Manual are provided in


various modules:

Illustration indicates what and where to


do

Title indicates what job to be done

Definition of terms

6.

National standard units


Units used in this Manual are national
standard units

Section 1 Technical Performance and Parameters of Finished


Automobile
1.1.Main technical parameters of finished automobile:
Content

Design parameter

Internal code
Product model
Basic type

Integral body constructure, 5-door, 2-compartment, 1-cover

Drive type

Front-mounted engine, front wheel drive


Length

Outline
dimension
(mm)

Width
Height
(without
load)
Axle distance (mm)

Wheel track
(mm)

Front
Rear

Front overhang(mm)
Rear overhang(mm)
Minimum ground clearance
(mm)
Model
Complete
Mass
vehicle
parameters
kerb
(kg)
mass
Full load
mass
Rated seating
capacity (pc.)
Approach
Trafficability
angle
characteristics
Departur
(full load)
e angle
Minimum
diameter of
turning circle
(m)
Luggage
compartment
capacity (L)
Maximum
gradeability (%)

1725 (1680 with luggage rack) (without load)

1.2.Engine performance parameter:


Item

Unit

Type and parameters

Model

BYD483QB

In-line fourIn-line four-cylinder/16cylinder/16-valve MPI


valve MPI fuel
fuel injection double
injection
overhead camshafts
Single overhead
DOHC
camshafts SOHC

Type
Electronic fuel
injection system
type

BYD488QA

4G69S4M

In-line four-cylinder,
forced water cooling
cycle, double
overhead camshafts
DOHC, four stroke

Multipoint sequence fuel injection

Cylinder bore

88

Stroke

96

Displacement

2.362 L

Compression ratio

9.81

Rated power

123 /6000

Maximum torque

234/40004500

Minimum specific
fuel consumption

250+10

Fuel feed type

Electronic fuel injection

Ignition type

Spark ignition type

1.3.Engine accessory and chassis assembly type and parameter:


Assembly

Structure parameter

Exhaust system

Two-stage muffler, with three-way catalyst device

Intake system

Intake pipe, air resonant cavity, air filter

Fuel supply system

Including fuel tank, fuel pump, fuel filter, fuel pipe, accelerator pedal,
accelerator cable and fuel tank.

Cooling system

Water cooling type, engine electronic fan

Transmission

Model
Clutch
type

BYD483QB
Dry single plate,
diaphragm spring
constant pressure
Manual

Type
Model
Gear ratio 1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse

4G69S4M

Automatic

BYD488QA
Dry single plate,
diaphragm spring
constant pressure
Manual
Final ratio

Final ratio
Drive shaft
Suspension

Type

Breaking type

Front suspension

Mcpherson independent suspension

Rear suspension

Mcpherson three connecting rod independent suspension

Tyre type

Tubeless radial tire

Wheel and
tyre
Steering

Tyre size
Steering gear type

Pinion-and-rack, hydraulic power steering

Steering gear

Four-spoke steering wheel, OD ?370mm

Status

No load

Front wheel
camber
Front wheel toe-in
Wheel
alignment

Angle of toe-in of
kingpin
Kingpin inclination
Rear wheel
camber
Rear wheel toe-in
Structure type

Hydraulic dual pipe, anti-lock brake system (ABS), 10-inch


vacuum booster, boosting ratio ratio 7.3 dual cavity brake master
cylinder, diameter 22.22mm, stroke 21+21

Front brake

Ventilation disc brake, clearance automatic adjustment

Rear brake

Solid disc brake, clearance automatic adjustment

Brake
system

1.4.Body structure type


Content

Design parameters

Body type

Loading type, metal frame structure, 5-door 2-compartment, 1 cover

Door assembly

Window frame type, open clockwise, with side bumper bar

Engine cover

Opening upwards, mechanism hinge, common stay bar

Luggage compartment

Mechanism hinge, gas spring support, (365L/1084L/2398)5 L

1.5.Body accessory
Content

Design parameters

Door lock

Snap plate type door lock

Front/rear bumpers

Plastic, color is the same as the body

Instrument panel

Injection moulding

Interior guard plate

Injection moulding framework

ABC pillars

Injection moulding, buckle connection

Roof

Moulding press, non-woven surface layer

Sun visor

High configuration, with make-up mirror


Front windshield: double curved surface, sandwich glass, 5mm thick
Rear side wall window: double curved surface, full tempered glass, right
printed antenna, 4mm thickness

Windscreen

Front angle window: double curved surface, full tempered glass, 3.5mm thick
Rear windscreen: hyperboloid, full-tempered glasses,3.5mm thick
Side window: double curved surface, area tempered glass, 3.5mm thick,
electric window regulator

Sunroof

Openable wide front sunroof

Rearview mirror

Outside rearview mirror: convex reflectors on the left and right, electrically
regulated, heatable, foldable (economy, comfortable and honourable
versions are manual, foldable and heatable; flagship version is electric,
foldable and heatable, with a camera).
Inside rearview mirror: manual anti-dazzle type, double position inside
mirror, direction indicator
Front row seat: electric 6-direction adjusting luxury leather driver seat, with
heating function and headrest; electric 4-direction adjusting luxury leather
auxiliary driver seat, with headrest.

Seat

Middle row seat: 6:4 backrest foldable, cushion adjustable back and forth,
luxury leather seat, with headrest;
Rear row seat: optional
Front row seat is provided with three-point seat belt (each for main and
auxiliary driver seats), middle row seat is provided with three-point seat belt

Seat belt

1.6.A/C system structure and parameter


Content

Air conditioning
system

Design parameters

Structure type

Steam compression type refrigeration, water heating

Operation

Automatic constant temperature air conditioner, multizone separate temperature adjustment, with humidity
adjustment function and air filter.

Refrigerating fluid

HFC-134a, filling amount: 60050g

Compressor

Vortex, displacement: 106ml/revolution model: WXH106-F2

Parameters

Vortex, displacement: 106ml/revolution model: WXH106-B11

Blower

Centrifugal, air flow is not less than 550 m3/h

1.7.Electric System Structure and Parameters


Content

Design parameters

Circuit
Generator
Power supply,
starter, charging
system

Starter
Electric fan
Battery
Front
combination
light
Side steering
lamp
Front fog light
Rear
combination
lamp

Single wire system, negative earth, DC voltage 12V


AC generating power 14V , 110A
4G69: gear reduction, 1.4 KW
483QB: electromagnetic control, 1.2KW
488QA: electromagnetic control, 1.4KW
Two-stage speed regulation double fans
Maintenance-free lead-acid battery 12V, capacity 70AH
High beam: 12V-60W, 2 sets
Low beam: 12V-55W, 2 sets
Steering lamp: 12V-21W, 2 sets
Position lamp: 12V-5W, 2 sets
12V-5W, 2 sets, installed on outer rearview mirror
12V-55W, 2 sets
Reverse lamp: 12V-21W, 2 sets
Steering lamp: 12V-21W, 2 sets
Brake lamp/tail lamp: LED
Rear fog lamp: 12V-21W, 2 sets

Rear license
Power: 12V-5W, 2 sets
lamp
Front/rear
Power: 12V-5W, 6 sets
interior lamps
Top lamp
Power: 12V-8W
Lighting, signal
system
Rear interior
Power: 12V-5W,2 sets
light
Rear luggage
compartment
Power: 12V-5W, 2 sets
lamp
Door courtesy
Power: 12V-1.08W
lamp
Foot
illumination
Power: 12V-0.54W, 2 sets
light
Door lamp
12V-5W, 4 sets
Combination
instrument
LED
lamp
High-mounted
12V-5W,2 sets
brake lamp
Instrument
Combination
Combination instrument: fuel meter, speedometer, engine
system
instrument
tachometer and coolant temperature gauge etc.
Indicator lamp Including: left/right steering indicator lamp, low fuel warning
on combination lamp, high beam indicator lamp, parking brake indicator lamp,
instrument
safety system indicator lamp, seat belt indicator lamp,
supplement restraint system indicator lamp, door and trunk
opening indicator lamp, ABS brake indicator lamp, constant
speed cruise control indicator lamp(2.4 AT Luxury type), rear
fog lamp indicator lamp, front fog indicator lamp, low engine oil
pressure indicator lamp, intelligent key system warning lamp,
small lamp indicator lamp, charging system warning lamp,
engine malfunction indicator lamp, SVS indicator lamp etc.

Audio

Speed display, reverse radar icon display, outside temperature


Multifunction
display and multimedia information display, coolant temperature
screen
indication or and fuel indication, etc.
Left/right steering indicator lamp, seat belt indicator lamp,
Indicator lamp intelligent key system alarm lamp, vehicle-mounted telephone
on
indicator lamp, car telephone playing MP3 indicator lamp,
multifunction reverse radar display, water temperature display, time display,
screen
speed display, multimedia information display, outside
temperature display etc.
Vehicle-mounted CD(1CD/6CD), 6 loudspeaker (low
specification 2 loudspeaker), audio input interface, multi-disc
CD (virtual CD), high configuration NAVI(DVD) navigation
system, MP3 player etc.

Electrical
auxiliary system
Communication

Including cigarette lighter, vehicle-mounted power supply, etc.


CAN bus

1.8.Lubricating oil and fuel, and capacity


1.

Lubricant
Content

Engine oil

Design parameters
4G69: about 3.3~4.3L; API class: SG, SH or SJ
483QB: replace engine oil filter and fill 3.3L, do not replace engine
oil filter and fill 3.0L, SG grade and above
488QA: Replace engine oil filter and fill 4.3L, do not replace
engine oil and fill 4.1L, net fill 5.0L, SG grade and above

F4A4B:7.7LMITSUBISHI ATF SP3


VT2-04O4.1LESSO EZL799A
Transmission double curved
F5M41: 2.1L, SAE: 80W-90 (in summer in the north); 75W-90 (in
surface gear oil
winter in the north); 80W-90 or 85W-140 (all the year round in the
south). API: GL-4 or GL-4 above.
Bearing and ball pin
lubricating grease
2.

2.

Li-based

Fuel
Content

Design parameters

Fuel type

92# unleaded petrol for vehicle or above

Fuel tank capacity (L)

70

Steering fluid, brake fluid, coolant, A/C refrigerating fluid


Name

Brand

Power steering fluid

DEXRON-III

Clutch fluid and brake fluid

DOT3

Coolant

High quality glycol coolant

A/C refrigerating fluid

HFC-134a(R134a)

Windscreen washing fluid

Capacity

About 4.5L

Section 2 Vehicle identification


2.1.Vehicle identification number(VIN)
VIN description:

Assembly plant

There are several identification numbers on


the
vehicle
on
different
positions.

Year

Identification number position:

Check digit

Engine characteristics

Restraint system type

Body type

Transmission type and drive


type

Vehicle brand

Manufacturer

Production sequence number

absorber support. Vehicle nameplate


contains vehicle identification number
(VIN), engine, vehicle type, engine
displacement, maximum design total
mass, date of production, etc.

1 Engine model/engine number stamped on


the
engine
set.
2 Transmission number is located on the
nameplate the top of the transmission.
Do not confuse transmission number and
engine number.
3 Vehicle identification numbers are on left
upper of instrument panel and floor beam
under auxiliary driver seat as shown in the
Fig. Vehicle identification number is used
for registering the owner.

VIN
4 Vehicle

nameplate

is

on

left

shock

Nameplate of
complete
vehicle

2.2 Warning note label position:


Specific position for warning note label about
air bag, radiator and battery as shown in the
Fig.:
Coolant indicator
Cooling fan indicator

SRS warning
sign

Child protection
device

driver and/or passengers.

Section 3 Maintenance rule


3.1.Warning and notes
1.

Description for warning, special notes


and notes

Diagnosis and maintenance procedure in BYD


Maintenance Manual includes general and
specific warnings, special remarks and notes.
BYD Auto Co., Ltd. tries to provide
maintenance information and helps the
maintainer diagnose and maintain the system
so that the vehicle can run normally; but, if the
maintainer does not follow recommended
method, some procedures may cause risks to
the maintainer. Warning: special marks and
notes are to prevent the above risks and not all
the risks are foreseen.
This information is located at an obvious
position of Maintenance Manual. This kind of
information is edited for the following
information:
1)

Cause serious personal hurt to the


maintainer

2)

Damage the vehicle

3)

Unnecessary vehicle maintenance

4)

Unnecessary part replacement

5)

2.

Vehicle
part
maintenance
or
replacement improper. Any warning or
special remarks in general information is
quoted from each maintenance category.
Warning definition

Warning: Take some required measures or do


not take measures that are forbidden. If you
ignore warning, it may lead to the following
result:
1)

Cause serious personal hurt to the


maintainer

2)

Cause serious personal injury to other


maintainers in working area.

3)

If the vehicle is repaired improperly, it


will cause serious personal hurt to the

3.

Special remarks definition

Special remarks: pay attention to necessary


measures or forbidden measures. If you
ignore special remarks, it will lead to the
following results:
1) Damage the vehicle
2) Unnecessary vehicle maintenance
3) Unnecessary part replacement
4) Operation or performance for maintained
system or part is abnormal
5) Damage system or part that operates
normally depending on repaired system
or part
6) Operation or performance for any system
or part is abnormal depending on
repaired system or normal operation
7) Damage fasteners, basic tool or special
tool
8) Coolant, lubricating oil or other fluid
leakage
4.

Note Definition

Note: Declaration emphasizes necessity of


some diagnosis or maintenance procedure.
Notes declaration purpose as follows:
1)

Clear program

2)

In order to complete one procedure,


provide supplementary information

3)

Clarify reason that operation shall follow


recommended procedure

4)

Provide information
procedure in a more
provide experience to
as to complete the
easily

3.2.Instructions:

that completes
effective manner;
the maintainer so
procedure more

1.

Basic maintenance prompt

Operation requirements
1) Clothing: keep clean.

Pay attention to the operators

Working clothes Shoes Hands

Avoid metal or hard objects from being


exposed in working clothes. For
example:

Belt buckle Key chain Fastener

Tools in the pocket (such as wrench)


watch

Do not lean against the body; do not step


on the bumper

Keep enough distance between vehicles.

Do not place a piece of paper on the


vehicle for writing; do not use
accessories supplied with the vehicle,
such as cigarette lighter.

2) Vehicle protection
Before operation, prepare:

Floor mat steering wheel sleeve seat


cover

Fender cover Radiator grille cover

Door edge protector


Seat hood

Fender hood

Do not place tools and parts on the top of


vehicle, engine hood or trunk lid.

4) Prepare maintenance
measuring instruments

tools

and

Before operation, prepare tool rack, special


fault diagnosis tester, gauge, related tools
and instruments, engine oil, cloth and parts
for replacement.
5) Dismantle/install, disassemble/assemble

Keep enough room to open doors and


avoid doors from knocking into:

Wall Tool kit Desk

Analyze and diagnose fault phenomenon


thoroughly, then make related operation.

Before dismantling parts, check the


assembly installation conditions and
check the appearance for deformation
and damage.

If the assembly is very complicated, such


as electrical connection, a lot of bolts or
dismantled pipe, they shall be marked for
easy assembling. If necessary, pipe and
corresponding interface are marked
temporarily.

If necessary, clean dismantled parts and


check it thoroughly and then install it.
6) Dismantled parts

Put dismantled parts in order to avoid


mixing or contaminate new parts.

When two persons or above work


together, safety for other workers shall be
ensured.

For nonreusable parts, such as washer,


O ring and self-locking nut, replace them
according to the Manual.

If the user requests, we can store


dismantled parts for the user.

When the engine runs,


ventilation in workshop.

(2) Jack up and support the vehicle

When maintaining high temperature, high


pressure, rotating, moving or vibrating
parts, the operator shall wear appropriate
safety equipment. Handle with care to
avoid yourself or others from being hurt.

When jacking up and supporting the vehicle,


be careful. Jack up and support the vehicle at
the right positions.

When lifting a vehicle, safety equipment


shall be used.

Precoating parts refer to bolts and nuts


coated by sealant during the course of
production.

When jacking up the vehicle, safety


support shall be placed on the specified
position.

After precoated parts are loose or


dismantled, it is recoated by specified

3) Safety operation

keep

good

(3) Precoat parts

sealant before retightening.

When reusing precoated parts, old sealant


shall be removed and dry the parts with
compressed air. Then coat sealant on the
bolts and nuts.

If necessary, apply sealant on the washer to


prevent leakage.
(5) Bolt, nut and screw

Observe all descriptions of specified


tightening torque carefully.

Torque wrench shall be used.

Special note: tighten them according to


upper limit value of torque tolerance. .
Some sealant becomes hardening slowly.
Therefore, you have to wait for a while for
hardening.

(6) Fuse
When replacing fuse, new fuse with
appropriate rated current shall be used.
Rated value shall not too high or low.
(7) Buckle

Seal lock glue

(4) Washer

Dismantling and installing methods for body


trimming part buckles as shown in the
following Fig.
Special note: if these buckles are damaged
during the course of dismantling, they shall
be replaced by new buckles.

(8) Hose dismantling and disassembling

When disconnecting hose, first pinch


hose end and entwist to pull it down. Do
not pinch the middle to pull it forcedly.
Otherwise, it may damage the hose.

Error

dismantling the battery negative ground


wire.

Correct

In order to reassemble the hose, make a


label for easy identification when
disconnecting.

After completing these work, check it


carefully and make sure the hose is
correctly connected.

When using measuring meter, do not


connect the hose to oversized connector.
Adjust the connector size gradually. Note:
once the hose is straightened, it may
cause leakage.

2.

Vehicle provided with SRS and seat belt


pretensioner

BYD S6 is provided with supplementary


restraint system (SRS) and seat belt
pretensioner.
If correct operation procedures are carried out
during the repair of the airbag system, it might
cause accidental deployment of airbag,
leading to serious accident.

Before specific maintenance, first turn


ignition switch to LOCK, and dismantle
the battery negative ground wire, then
wait for more than 3 minutes. Otherwise,
air bag may expand accidentally. In
addition the removed cathode terminal
shall be insulated by insulation tape as
shown in figure.

Negative
terminal

After disconnecting the battery connector wire,


memory contents in clock and audio system
will be deleted. Therefore before working,
record memory contents in each memory.
When system overhauling is over, reset clock
and audio system according to original
method.
After a minor collision, you should check
the airbag system to be checked even if the
air bag is not deployed.

In addition, if mis-operation occurs during the


course of maintaining system, air bag cannot
expand
normally.
Therefore,
before
maintenance (including dismantling and
installing parts, check or replacement), please
read the following notes carefully and observe
correct operation procedures:

Do not use airbag parts removed from


another car. If it is required to replace
components, new components shall be
used.

You should remove the airbag ECU


before repair if the vehicle might be
vibrated when repairing the airbag system
or its components.

(1) General notes

It is forbidden to disassemble and repair


DAB PAB SABand install air bag
electronic control unit for reusing and
other reasons.

If DAB, PAB and airbag ECU and other


components fall down to the ground, or
are vibrated or knocked, or if their
housing, bracket or connector have crack,

Because it is very difficult to determine


SRS faults, fault code is the most
important maintenance basis. When
overhauling the system, please record the
status before dismantling the battery
negative ground wire, because DTC in
other systems will be lost when

indent or other damage, replace the


relevant parts.

It is forbidden to put DAB, PAB, SAB, air


bag electronic control unit into heating air
or flame directly.
When painting has
overheating (above
electronic control unit,
and clock spring shall
kept well.

Do not use detection lamp, common


voltmeter and ohmmeter when detecting.
Voltmeter and ohmmeter shall be high
resistant (minimum 10k/V). Do not use
an ohmmeter on DAB, PAB, SAB or
pretensioner, as shown in the Fig.

effect due to
93), air bag
DAB, PAB, SAB
be removed and

Don't use the ohmmeter on the airbag or


pretensioner

You may only conduct operations


specified in this Manual on the airbag
system. Do not test any circuit of the
airbag system by electrical testing device.
Attach warning lables on the relevant
positions in the components of the airbag
system and inside the car. Conform to
instructions specified in components
during operation.

Before replacing any component, conduct the


self-diagnosis of the system and check
completely that the system functions normally.
Warning for special tool of air bag system
In order to prevent air bag from expanding
unexpectedly when the system has a fault,
tool equipment specified in this manual shall
be used and instructions in this manual shall
be observed. If specified tool equipment is not
used according to instructions, air bag may
expand unexpectedly, which leads to personal
hurt and unnecessary air bag system repair.
Normal service life of airbag is 10 years; if
above service life, you must replace the
airbags and labels.

(2) Clock spring


Steering wheel shall be correctly installed on
steering column to ensure clock spring cable
is in the middle position. Otherwise, the cable
is disconnected or other faults occur.
(3) Driver air bag (DAB), passenger air bag
(PAB) and side air bag (SAB)

During the course of maintaining air bag,


air bag module shall be installed as soon
as it is taken from the container. If it is
necessary to stop working, air bag
module shall be returned to the container.
It is forbidden to keep air bag module
unattended. When storing dismantled air
bag module, be careful to avoid collision
and vibration. Before power on:

Remove dust and dirt, and lubricating


grease from mounting surface.

Put air bag module on mounting surface


horizontally.

Put the arrow on air bag module towards


the front of vehicle.

Correct

Correct

Error

Error

Do not measure the resistance of air bag


module detonation device. As a result, air
bag will expand, which leads to serious
hurt.

Do not apply any lubricating grease on


steering wheel and clean the liner with
any detergent.

The airbag expansion device contains


sodium azide and potassium nitrate, which are
toxic and highly flammable; if they contact
acid, water or heavy metal, harmful irritant gas
will be generated (easily generate sodium
hydroxide in a damp place) or combustible
compound forms. The airbag device contains
pressurized argon gas, and therefore you
should not attempt to decompose the airbag
device and should protect the airbag
expansion device against piercing and
burning. Do not have the airbag expansion
device contact electricity and gas. Do not
store it in a place with temperature above 93
.
No matter what position of the car will receive
electric welding, you must disconnect the
airbag system to avoid accidental explosion
before job.

same way of common waste. During the


course of discarding, if the container is
damaged,
some
substances
in
unexpanded air inflation module will lead
to serious disease or personal hurt.
According to expanding procedure in the
chapter, unexpanded air inflation module
is discarded safely. If you do not observe
discarding regulation, you may disobey
related regulations and may lead to
personal hurt.

Tighten all fasteners and support


fasteners of air bag module to the
specified torque value.

In order to prevent air bag module from


expanding unexpectedly, do not dispose
unexpanded air inflation module in the

After air bag expands, if instrument panel


is damaged, replace it.

For the seat with side air bag, there is a


label SRS SIDE AIRBAG (side air bag)
on the backrest. Because the seats with
air bag and without air bag have different
structures (backrest cover and seat),
correct parts shall be installed.

Side SRS warning sign

When cleaning, do not immerse the seat in


the liquid and do not spray steam towards the
seat. Do not repair damaged or worn backrest
cover and then replace it. After side air bag
expands due to collision, replace with a new
side air bag. If the back cushion is broken,
replace it. If backrest structure is deformed,
replace it, too. Do not install parts (cover,
cushion, seat heater, indicator lamp)
purchased from automobile part market.
After repair of the airbag system, do not
hurry to connect the airbag module into the
circuit. Firstly you should check electrical
circuit and then connect the airbag module
when you confirm that everything is correct.
(4) Seat belt pretensioner

Do not measure seat belt pretensioner


resistance. This may activate pretensioner, which may lead to personal
hurt.

Do not disassemble seat belt


pretensioner.

Do not install the seat belt pretensioner to


other vehicles.

In order to avoid damaged and unrepaired air


bag due to collision from personal hurt, check
each seat belt system for safety. If you have
any doubt about system parts, you have to
replace seat belt system.

Ambient temperature for storing seat belt


pretensioner shall be below 80 (176F).
Do not store it in high humidity, keep
away from electrical noise.
When taking away unexpanded seat belt
pretensioner:

Do not lift up seat belt pretensioner by


wire or connector.

Take seat belt pretensioner through


piston pipe. Two hands and fingers shall
keep away from the cable.

Make sure open end of seat belt


pretensioner is back on to you and
others.

Do not cover opening of seat belt


pretensioner piston pipe.

Wherever electric welding is used, before


working, disconnect power supply near
the battery to avoid the pretensioner from
being activated unexpectedly.

Before discarding a vehicle or seat belt


pretensioner, seat belt pretensioner shall
be activated. Operation shall be done in
safety area away from electrical noise.

Because seat belt pretensioner will be


heated after activation, it shall be cooled
before discarding. But, do not cool it with
water.

Do not spray oil or water onto outside


seat belt of front seat. Do not wash

outside seat belt of front seat with any


detergent.
(5) Air bag electronic control unit (ECU)

It is forbidden to reuse ECU dismantled


from other vehicles.

Before maintenance, first turn ignition


switch to LOCK, and disconnect the
battery negative ground wire, then wait
for more than 90s. Otherwise, air bag
may expand unexpectedly.

Air bag electronic control unit connector,


clock spring connector, DAB connector,
PAB connector, SAB connector and
pretensioner connector are provided with
protection mechanism that prevents air
bag from expanding unexpectedly.

(6) Wire harness and joint


All wire harness and joints in the system are
standard yellow. If system wire harness or
joint is damaged due to accident or other
reasons, it shall be replaced.
3.

Electrical control

(1) Battery dismantling and assembling

Before any electrical part maintenance or


vehicle maintenance, first disconnect
battery negative cable in order to prevent
tool or equipment from contacting
exposed live terminal, which leads to
short circuit, personal hurt and/or vehicle
control system control module or other
electrical parts damaged.

When connecting or disconnecting the


battery cable, the battery charger or
bridging the cable, ignition key shall be

turned off, and all electrical loads shall be


turned off, otherwise specified in
Operation Procedure.

(2) Dismantling and assembling electronic


parts

Special remarks
sensitive parts

for

handling

ESD

Electrostatic discharge (ESD) will damage


many solid-state electric parts. Not all parts
that are affected by electrostatic discharge
have ESD marks. Handle all electrical
components with care. Please observe the
following safety notes to avoid electrostatic
discharge from damaging:

When connecting or disconnecting the


battery cable, the battery charger or
bridging the cable, ignition key shall be
turned off. Loosen cable terminal nut
completely, then dismantle negative cable
from the battery binding post, disconnect
positive cable; when reconnecting, first
connect positive cable and then connect
negative cable. It is forbidden to twist or
pry cable terminal.
When dismantling the battery cable, all
clock data, audio system data and other
data are cleared, too. Before dismantling
the battery cable, record required data.
The battery contains corrosive acid,
which may generate explosive gases.
Current intensity generated by the battery
may result in burn injury. Therefore, in
order to reduce injury risk near the
battery, the following rules shall be
observed:

Wear safety goggles.

Avoid bending above the battery as far as


possible.

Do not place the battery near open fire or


spark.

Do not let the battery acid liquid contact


eyes or skin. Once it contact eyes or skin,
the following items shall be done:

Wash contact sites with water as soon as


possible.

See a doctor as soon as possible.

Before
maintaining
any
electronic
component, especially after your body
slides with the seat, first touch metal
earth point to discharge static electricity in
your body.

Do not touch exposed terminal. Terminal


may be connected with the circuit that is
easily affected by electrostatic discharge.

When maintaining the connector, do not


contact exposed terminal with a tool.

Do not dismantle any part from protective


case, unless it is allowed.

Otherwise
specified
in
diagnosis
procedure, the following procedures shall
be avoided:

Bridge or ground the part or connector.

Connect test equipment probe to part or


connector. When using test probe, first
connect ground lead.

Before opening protective case of one


part, first ground it. Do not place solidstate part on metal working table or on
the top of television, radio or other
electrical equipment.

inflammable. As long as there is fire


source, a fire will break out. In order to
avoid fire or explosion risk, do not
discharge or store gasoline or diesel in an
open container. In addition, operation will
be made where no electric welding
machine, grinder, electric drill, electric
motor, stove or other fire sources exist.
Prepare one dry chemical (class B) fire
extinguisher nearby.

Disconnect electronic part joint and pull


down the joint. It is forbidden to move the
cable.

Do not fall down, knock and vibrate


electronic parts, such as a sensor or
relay. If similar phenomenon occurs, it is
necessary to replace with a new part.

When cleaning the engine, electronic


parts, air filter and discharge components
with water and steam, no water is allowed
to go into them.

Do not use impact method to install or


dismantle electronic parts.

4.

When checking continuity of electronic


part joint, the probe is connected carefully
to avoid the terminal from bending.

(2) Dismantle and install fuel system parts

Before maintaining fuel system, first fuel


system pressure so as to power off fuel
pump and flame out or disconnect fuel
pipe joint to avoid personal hurt. After fuel
system pressure is released, a small
amount of fuel overflows at the time of
repairing fuel pipe, fuel injection pump or
joint. In order to reduce personal hurt, use
cotton cloth to cover fuel system
components before disconnecting pipes
or joints so as to absorb leaking fuel. After
disconnecting, put the cotton cloth into
allowable container.

When repairing fuel system, you have to


wear safety goggles to avoid fuel from
splashing into eyes.

Fuel pressure in fuel system shall not


exceed specified value. Otherwise it will
damage fuel pressure regulator or fuel
pressure gauge.

In order to reduce fire and hurt risks, the


following items shall be observed during
the course of maintaining fuel and
evaporation discharge pipe:

During the course of installing, replace all


cracked, scratched or damaged fuel
pipes. Do not try to maintain fuel pipe.

When installing new fuel pipe, do not


knock fuel pipe clamps with a hammer
directly. Fuel pipe damage will lead to fuel
leakage.

When heating and maintaining near a


steam discharge pipe, use a wet towel to

Dismantle and install fuel system part

(1) Dismantling and installing site for fuel


system part
Gasoline or gasoline steam is very

Do not operate in the pit or near the pit to


avoid fuel steam from accumulating here.

cover the steam discharge pipe. At the


same time, do not expose the vehicle at
85C above for more than one hour or
expose it at 60C above for a long period.

If engine support is broken, it can lead to


dislocation of some parts in drive system.
Dislocation of drive system parts may damage
drive system parts in the end.

Before connecting fuel pipe joint, make


sure fuel pipe joint is clean so as to
reconnect it correctly and avoid fuel
leakage.

Special remarks: if an engine support is


broken, the stress applied on other engine
supports will increase. This may cause other
engine supports to be broken.

Do not breathe air in evaporation


discharge pipe or hose. Fuel steam in
evaporation discharge part may lead to
personal hurt.

(3) Special remarks for fault diagnosis tester


with fault

When checking fuel tank, it is necessary


to tighten strap fasteners gradually and
alternately until it reaches the specified
torque. If strap fasteners are not
tightened according to the specification,
fuel tank bottom will bend up. When fuel
tank has no fuel, fuel gauge still indicates
that there is fuel.

Do not use fuel containing methyl alcohol


to avoid damaging or corroding fuel
system.

Do not try to straighten any twisted nylon


fuel pipe. Replace any twisted nylon fuel
pipe to damage the vehicle.

In order to prevent static electricity, fuel


pump, fuel tank and vehicle shall be
grounded. Do not water in this area to
prevent slipping. Do not wash spillage
and gasoline with water to avoid
spreading and fire risk. Put oily cloth into
fireproof container.

A special fault diagnosis tester for BYD


automobile shall be used. At the same time,
any fault for fault diagnosis tester during the
course of using shall be indicated. Fault
diagnosis tester that has a fault will lead to
wrong diagnosis and unnecessary part
replacement.
(4) Cooling fan

In order to avoid personal hurt and


vehicle damage, if fan blade or fan cover
is bent, cracked or damaged, replace it
immediately.

Even if the engine does not run,


electronic fan in the engine compartment,
which may lead to personal hurt. Two
hands, clothes and tools shall keep away
from electronic fan in the engine
compartment.

It is forbidden to use electrical equipment,


like electric motor or work lamp, and
hammer to avoid spark or high
temperature.

(5) When maintaining the engine cooling


system, in order to avoid scalds, do not
dismantle radiator cover or liquid
accumulator or pipe joint before the
engine cools. If radiator cover or liquid
accumulator cover or pipe joint is opened
before the engine and radiator do not
become cool, cooling system will give out
hot high pressure liquid and steam.

5.

Dismantle and assemble engine parts

(6) Intake system parts

(1) Special remarks for lifting engine

When maintaining intake system, use


clean cloth, adhesive tape or other
appropriate materials to cover intake
system opening and engine opening to
avoid foreign matters from entering into
the system.

If it is necessary to dismantle air filter

When lifting or supporting the engine, do not


put a jack under oil pan, any metal plate or
crankshaft pulley. Lifting the engine in a wrong
way will damage parts.
(2) Special remarks for engine support

assembly for maintenance, throttle valve


opening shall be covered to avoid foreign
matters from entering into the engine.

Modification may not make the vehicle


pass required emission check /
maintenance test.

Compressed valve spring will apply high


tension on valve spring compression tool.
If valve spring compression tool
compresses or releases valve spring
improperly, valve spring will bounce off
violently
from
compression
tool.
Therefore, when you compress or release
valve spring on valve spring compression
tool, dismantling or installing valve stem,
you have to be careful. Improper
operation will lead to personal hurt.

Modification for the following systems will


affect vehicle emission control system
and malfunction indicator lamp may be lit:

(8) Clutch
(1) When maintaining clutch parts, do not
grind or polish clutch disc, do not clean
parts with a dry brush or compressed air
because dust will be generated. Wet cloth
shall be used (but not immersed in
water). Clutch disc contains asbestos
fiber. If dust is generated, these fibers will
be mixed in the air. Dust containing
asbestos fiber is harmful to health.
(2) It is forbidden to use mineral oil or
paroline in hydraulic system of the clutch.
This oil will damage rubber parts in oil
cylinder.
(9) Exhaust system

In order to avoid scalds, do not maintain


exhaust system when exhaust system is
very hot. Please maintain the exhaust
system after cooling.
Modification for engine or other parts will
affect vehicle emission control and
malfunction indicator lamp may be lit.

Exhaust

If alternative tyre does not conform to tyre


performance standard of original tyre, it
will affect vehicle emission control.
Modification for these systems or the tyre
that does not conform to original tyre
standard will make some repaired items
beyond manufacturer warrantee scope.
This may not make the vehicle pass
required emission check / maintenance
test.

(7) Check transmission oil


When dismantling transmission oil screw plug,
the vehicle shall be static and horizontal.
Otherwise,
more
oil
will
overflow.
Transmission oil may be very hot.
Transmission oil may inject from oil screw
plug. Be careful to avoid scalds! Because
actual oil level is unknown, you have to keep
away from oil screw plug when you dismantle
it. Prepare a container to collect oil.

Engine transmission
system Fuel system

(10) Knock sensor


Hot engine coolant may lead to serious
scalds. Although cooling system is empty,
some coolant still remains in the engine water
jacket. When dismantling knock sensor, these
coolant shall be discharged.
(11) Catalytic converter

In order to prevent catalytic converter


assembly joint from damaged, the
converter shall be supported. When
moving catalytic converter assembly, do
not collide with and knock the case.

If a large amount of unburned gas mixture


goes into catalytic converter, it may
overheat catalytic converter and bring fire
risk. In order to prevent this, the following
notes shall be observed:

Only use recommended oil.

Avoid idling for 20 minutes.

Avoid spark-over test:

If necessary, spark-over test can be made


and completed as soon as possible.

When testing, do not run the engine at


high speed.

Avoid measuring engine pressure for a


long time. If necessary, it shall be
completed as far as possible.
When fuel tank is nearly empty, do not
run the engine. Otherwise, engine may
misfire so that catalytic converter is
additionally loaded.

(12) Heating type oxygen sensor and oxygen


sensor

parts
(1) Only use brake liquid in a clean and
sealed container or BYD special DOT 3
brake fluid. Do not use brake fluid in an
open container because brake fluid may
become damp.
If any other type of brake fluid except
recommended model or contaminated fluid
may damage hydraulic brake system
component or lead to brake failure, even
personal hurt.
Brake has irritation to eyes and skin. Once it
contact eyes or skin, the following measures
shall be taken:

Take the oxygen sensor with care to


avoid damaging parts. Do not drop or
mis-operate the oxygen sensor.

Electrical connector and exhaust port are


not contaminated. Do not use any
detergent to clean the sensor.

Do not repair conductor, connector or


terminal. If leading wire, connector or
terminal is damaged, replace the oxygen
sensor.

When maintaining the oxygen sensor, the


following rules shall be observed:

Do not dismantle or remove oxygen


sensor ground wire (if existing). The
vehicle using ground sensor may use this
ground wire as only one ground point of
the sensor. Dismantling ground wire will
lead to poor engine performance.

Make sure vehicle wire harness


connector seal is good to avoid damaging
due to water.

In this case, welding shall not be used


because it may damage this part.

6.

Dismantle and assemble brake system

Eye contact wash it thoroughly with


water.

Skin contact wash it with soap and


water.

Swallow see a doctor.

(2) Do not use a container containing


petroleum base brake fluid because
petroleum base brake fluid will expand
and age rubber parts in hydraulic brake
system while water and brake fluid
mixture will lower boiling point. All brake
fluid container shall be covered to prevent
contamination.
(3) When maintaining wheel brake parts,
please avoid the following operations:

Do not grind brake lining.

Do not grind brake lining with sand paper.

Do not clean wheel brake component with


a dry brush or compressed air.

(4) When overhauling, a piece of steel wire


shall be used to support brake caliper to
avoid damaging brake pipe.
(5) Avoid brake fluid from splashing onto
paint surface, electrical joint, wire or
cable. Brake fluid will damage paint
surface and corrode electrical parts. If
brake fluid contacts paint surface, wash it
off with water immediately. If brake fluid

contacts electrical joint, wire or cable,


repair cloth, appropriate container and
fender cover shall be used to prevent
brake fluid from contacting these
surfaces. Seal it again and wash off brake
fluid to avoid overflowing.
(6) Some components in anti-lock brake
system (ABS) can be repaired separately.
Trying to dismantle or disconnect some
components of the system may lead to
personal hurt and/or abnormal operation
of the system. Only maintain parts that
can be dismantled and installed.
7.

Dismantle and assemble steering system


parts

(1) Before disconnecting steering column or


middle shaft from steering engine, the
wheels shall be right ahead and steering
column shall be at LOCK position.
Otherwise, clock spring in steering
column will deviate from the center, which
damage clock spring.
(2) Before disconnecting the following parts,
steering column shall at LOCK position:

Steering column Middle shaft Lower


steering shaft
After disconnecting the above-mentioned
parts, do not move front wheel tyre and
wheel. If you do not follow these
procedures, these parts are not aligned
properly.

(3) Steering wheel is turned to the limit


position for not more than 3 seconds.
Otherwise, it will damage steering pump.
(4) If power-assisted steering system is
repaired, air in steering system shall be
discharged to obtain correct steering
liquid level reading. Air in steering liquid
can lead to cavitation in steering pump
and steering pump will be damaged after
a period of running.
(5) Do not start the vehicle when any inlet or
outlet hose of power steering engine is
disconnected.
When
the
hose
disconnects, openings of all parts shall be
plugged or covered. Otherwise, it will

contaminate or lose power steering fluid


and damage the system.
(6) When filling steering fluid or replace
steering fluid completely, it is necessary
to use DEXRON power steering liquid
or equivalent.
If you do not use correct power steering fluid,
power steering hose and seals may be
damaged, steering fluid leaks and steering
fluid pump has a fault.
8.

A/C system

(1) Avoid inhaling A/C system refrigerating


fluid 134a (R134a) and lubricating oil
steam or oil fog. These fluids will irritate
eyes, nose and throat. Operation shall be
made in a place with good ventilation. In
order to remove R134a from A/C system,
you have to use maintenance equipment
with SAE J2210 certification (R134a
regenerative facilities). If the system has
leakage, working area shall be ventilated
before maintenance. Other health and
safety information is available from
refrigerating fluid and lubricating oil
manufacturer.
(2) After broken glass falls into defroster air
outlet, it may be blown into passenger
compartment, which leads to personal
hurt.
9.

Dismantle
accessory

and

assemble

body

and

(1) Dismantle or connect engine cover


support, the pressure is only applied on
its end. It is forbidden to apply pressure in
the middle of the bar. Otherwise, it will be
damaged or bent.
(2) When dismantling or installing engine
compartment cover stay bar, other
devices shall be used to support engine
compartment cover to avoid vehicle
damage or personal hurt.
(3) If a door or windscreen is cracked but
intact, protective tape is crosswise pasted
to the door or windscreen to avoid the
door or windscreen from being damaged
or personal hurt.

(4) When installing front windshield glass, do


not use gaskets. Stress generated from
the gaskets will damage front windshield
glass.
(5) In order to avoid personal hurt or vehicle
damage, the carpet whose thickness and
size are the same as that of original
carpet shall be used when repairing or
replacing the carpet. Make sure the
carpet is installed in original position.
(6) When you remove adhesive or foreign
matters with a shaver blade or other
sharp tools or cotton cloth, you shall be
careful to avoid damaging body surface.
10. For vehicles with mobile communication
system
(1) An antenna shall keep away from ECU
and sensor of electronic system on the
vehicle.
(2) Antenna feeder shall keep 20cm from
ECU and sensor of electronic system on
the vehicle.
(3) Keep antenna and feeder away from
other wire. To prevent communication
equipment signal and other equipment of
the vehicle from mutual interference.
(4) Check if antenna and antenna feeder are
debugged correctly.
(5) Do not install highpower
communication system.

mobile

11. Others
(1) When executing this procedure, you have
to wear allowed safety goggle and gloves
to reduce the risk of personal hurt.
(2) In order to avoid hurting your body when
you are exposed in welding light or plated
metal poisonous smoke during the course
of grinding/cutting any type of metal or
compound moulded parts, you have to
work in a place with good ventilation and
wear allowed gas mask, safety goggles,
ear plugs, welding gloves and protection
clothes.

(3) When you work around running engine,


you cannot contact moving parts and hot
surface to avoid being hurt.
(4) Curing time for maintenance material is
24 hours at least. Before solidifying, do
not touch repaired part. If adhesive agent
is not completely cured, it may lead to
personal hurt.
(5) Correct fasteners shall be used at correct
positions. Part number of alternative
fastener shall be correct, which is
applicable to the application occasion.
For parts that require thread sealant,
lubricating oil, preservatives or sealant
shall be specially pointed out in
Maintenance
Procedure.
Unless
otherwise specified, do not apply paint,
lubricating oil or preservatives on
fasteners or joint surface of fasteners.
These substances will affect fastener
torque and clamping force of the joint,
and may damage fasteners. When
installing
fasteners,
follow
correct
tightening sequence to avoid damaging
parts and system.
(6) When moving flexible separation joint
from normal installation position, do not
bend excessively or damage flexible
separation joint. The maximum bending
for flexible separation joint is 6. It means
moving 1 inch per one foot pipe section.
The maximum amount of movement for 3
feet pipe shall not exceed 3 inches.
(7) Do not bend the hose during the course
of installation. In order to facilitate
installation, bend or deform the hose.
Otherwise, it will damage parts.
(8) To avoid personal hurt and/or part
damage, appropriate tool shall be used to
dismantle spiral spring of shock absorber.
When the spring is separate from shock
absorber, if all spring force is not
released, spiral spring will be at extreme
pressure and may bounce off.
(9) When maintenance personnel checks
reported fault location, the vehicle shall
be driven by specified staff. Otherwise, it
leads to personal hurt.

(10) When performing specified test in work


shop, one or more of the following rules
shall be observed:

attention to:

Lifting equipment weight class shall meet


or exceed vehicle weight.

During the test, if it is necessary to jack


up the vehicle and rotate drive wheel,
please observe the following safety notes:

Lifting equipment shall meet operation


standard of lifting equipment
manufacturer.

- When rotating one drive wheel but the


other drive wheel does not move, the
speed shall not exceed 56km/h.

Lift the vehicle on a clean, solid and dry


level ground.

Lift the vehicle only on the specified lifting


point. Lifting equipment is forbidden to
contact any other part of the vehicle.

- Under the above-mentioned conditions,


tachometer indicated value is half of
actual speed. Therefore, this limit is
necessary. If wheel speed is too high, it
may lead to personal hurt.
If all drive wheels rotates at the same
speed, the speed shall not exceed 112
km/h. If wheel speed is too high, it may
lead to personal hurt.
Personnel concerned shall keep away
from rotating parts and counter weight
locations to avoid personal hurt.
-

When the engine works in workshop for a


long time, do not make overheat the
engine and transmission.

During the test, if it is necessary to jack


up the vehicle and dismantle wheels and
brake disc,

Please
notes:
-

observe the

(2) Before lifting the vehicle, pay attention to


vehicle conditions:

The vehicle shall be without load. Take


out or fix all objects in the vehicle to avoid
moving during the course of lifting.

When dismantling main parts from the


vehicle and support the vehicle with a
lifting device, center of gravity for the
vehicle may change. Keep the vehicle
balancing: place counter weight to
prevent the vehicle from swinging or
moving; support the position on the
opposite side of parts to be dismantled
with a jack.

(3) Notes for using jacks and safety support

following safety

Support the suspension at normal driving


height.
Do not use brake after dismantling brake
disc.

During the course of maintenance, stop


block shall be always used on a level
position.

Safety support with rubber accessory


shall be used.
Rubber accesory

Turn off ignition switch to stop rotating


parts of powertrain.

(11) In safety conditions, road test is made


according to traffic regulations. Do not
attempt any operation that may endanger
the vehicle. Violation for the abovementioned notes will lead to serious
personal hurt and vehicle damage.
12. Vehicle Lifting
(1) Before lifting or lifting the vehicle, pay

When using a jack and rigid bracket, they


shall support specified locations.

When jacking up front wheels, release


parking brake and place stop block in the
rear of rear wheel; when jacking up rear
wheels, place stop block in the front of
front wheels.

When there is no rigid bracket, do not use


a jack.

When lowering a vehicle with front wheels


jacked up, release parking brake ad place
stop block in front of rear wheels.

Vehicle's center of gravity (no load)

Rubber accesory

If the above-mentioned procedures are not


followed, it may damage lifting equipment or
vehicle.

Vehicle's center of gravity

Section 4 Overhaul
Specification
Position of Jack
Vehicle's center of gravity (no load)
Surport position; strentch the jack position

(4) Notes for four-column lifting jack

Follow all safety procedures in this


manual.

Adopt supporting
accessory.

arm

with

Notes: lifter center is close to the center


of gravity for the vehicle as far as
possible (L shall be short as far as
possible).

(1) Inquiry diagnosis method

The inquirer shall be serious, responsible,


amiable and careful.

The inquiry shall be overall, grasp


emphasis and acquire the details of fault
history and frequency.

Analysis, judgment and preliminary


location shall be made through the inquiry
of fault symptom with the car owner.

rubber

The vehicle on the lifter shall be level as


far as possible, and lifter groove and
supporting position of rigid bracket are
aligned.

4.1.Troubleshooting method

(2) Observation diagnosis method

Artificial observation shall be all-round


and systematic in combination with fault,
emphasize some respects and follow
certain sequence.

Before lifting and during the course of


working, support arm shall be locked.

When the vehicle leaves the ground,


shake the vehicle to check if it is stable
on the premise of safety.

To conduct external examination for car,


carefully observe the cars water circuit,
gas circuit, oil circuit and electric circuit.

Preventative measures shall prevent


supporting arm from damaging tyre,
wheels and body.

To examine related instruments and


meters of the car, and then determine the
cause of fault.

To carefully observe fault symptom, fault


code, sound and others, and judge
accordingly.

(3) Part replacement method

(7) Inverse logical reasoning method

To replace new part for probably faulty


part.

To deduce the fault symptom provided a


part is faulty.

To fix the probably faulty part in another


car for further confirmation.

Replacement for any part shall be


reasonable rather than random or blind.

To accumulate and summarize the fault


symptoms of part damage to quicken fault
location.

(4) Case application method

To directly find out cause of fault referring


to the result of typical case, as can
reduce unnecessary examination.

Only applicable to faults with the same


symptom in the same model of car or the
same kind of system.

For common faults, even if fault


symptoms are the same, causes of fault
are diversified, so this method doesnt
apply.

(5) Empirical method

To continuously accumulate experiences


based on the results of previous
troubleshooting
and
improve
troubleshooting ability.

To judge according to the difference and


sameness of fault symptoms and through
the flexible application of previous
experiences.

To summarize special and typical faults


and record the success and failure of
troubleshooting
for
experience
optimization.

(8) Flow chart analysis method

For complicated faults.

To operate according to given flow chart


for fault location.

Other method may be used to aid


analysis and judgment.

4.2.Electric control system


A lot of ECU control systems are applied to
BYD S6. Usually ECU control system is
viewed as a kind of very complicated system
needing high level professional technical
knowledge and skill for troubleshooting. In
fact, if you fully know the system and have
basic electrical knowledge, then you can
make accurate judgment and necessary repair
for troubleshooting. For further details of ECU
control system of BYD S6, please refer to
relevant chapters.
(1) Use of detection instrument
a.

Before using a detection instrument, an


operator must carefully read its
instructions or operation manual.

b.

After the detection instrument connects


the system, please turn on the ignition
switch and start the instrument. If the
instrument cant communicate with ECU
control system, then the car or instrument
is faulty.

If communication is normal when the


instrument is connected with other car,
please examine and diagnose data line or
the cars ECU circuit.

If communication is still abnormal when


the instrument is connected with other
car, the instrument may be faulty, and
please read the accompanying manual or

(6) Logical reasoning method

To analyze the fault and deduce fault


point according to detection data and
system principle.
To master the operating principles and
functions of motor, electronic fuel injection
system and parts.
Its very necessary to make logical
reasoning and analysis for some faults.

contact the supplier for help.

Knock slightly

(2) Troubleshooting
Basic procedure is to determine the procedure
for troubleshooting of related circuit in
advance.
(3) Fault simulation
Its the most difficult thing that no fault
symptoms are found during troubleshooting.
In this case, thorough analysis must be made
for described fault of the car. Then the same
or similar condition and fault environment of
the car shall be simulated. For technical
personnel, no matter how experienced and
proficient they are, their failure to analyze or
confirm fault symptom may cause delay in
repair, miss or misoperation.
At the time of simulation test for fault
symptom, please confirm fault symptom and
find out faulty position, part or component.
Please contract the doubtable scope
according to fault symptom, connect fault
diagnosis instrument for symptom simulation
test, and judge whether the examined system
is damaged, meanwhile, confirm fault
symptom, finally find out the cause of fault
referring to system fault code table.
1

Vibration method

Shake slightly

Swing slightly

The method is used in such a case that it


seems that vibration is the primary cause of
fault.
A.

Parts and sensor: lightly knock the


suspicious parts by hand and inspect
whether there is a fault. If the relay is
vibrated by applying a great force, it may
possibly be opened.

B.

Joint: lightly shake the joint up and down.

C.

Wire harness: lightly swing the wire


harness up and down. Inspection shall lay
stress on the connection part of joint and
fulcrum position of swing.

Heating method

The method is used in such a case that it is


doubtful that some parts have a fault arising
from temperature increase.

fault.
Fault

(4) Circuit inspection


Basic inspection

Resistance measurement condition of


electronic parts

Caution:

All resistances shall be measured under the


condition of 20 indoor temperature, unless
otherwise specified. After the vehicle starts,
the temperature will have a great increase, so
if the resistance is measured at this time,
Measured data will exceed the specified
value. So the resistance shall be measured
after the engine cools down.

A.

Heating temperature shall not exceed


60 or the specified value.

Connection and disconnection of joint

B.

Don't directly heat the ECU parts.

Water-spraying method

When disconnecting the joint, first


squeeze the two ends of the joint with
hands,

Heat the suspicious parts by use of electric


drier or something of the kind and inspect
whether there is a fault.

The method is used in such a case that the


fault may possibly arise from rainy weather or
highly humid condition.
When spraying water onto the vehicle, pay
attention to:
A.

Don't directly spray water onto the


engine, but water can be sprayed onto
the front end of radiator to indirectly
change the temperature and humidity.

B.

Strictly prohibit directly spraying water


onto electronic components.

C.

If the vehicle leaks when it rains or ever


leaked, ECU electronic components or
joints may be damaged. Special care
must be taken when the test is
conducted.

High voltage load method

The method is used in such a case that the


fault may possibly arises from electronic
component overloading.
Open the warm air blower, headlight, rear
windshield defroster and all the other electric
devices, and then inspect whether there is a

Error

Error

Correct

Loosen the lock catch and then press lock


claw, and disconnect the joint.

When disconnecting the joint, strictly


prohibit withdrawing and pulling the wire
harness. The joint shall be directly held to
disconnect it.

Before connecting the joint, inspect it

whether there is deformation, damage


and port loss.

When connecting the joint, if hearing a


snap sound, it shows connection
succeeds.

When the joint needs to be detected by


use of probe at its back (wire harness
side), waterproof joint can not be
detected from its back and it shall be
detected by connecting wire harness;
when inserting the probe in a mobile way,
don't damage the terminal.

Correct

Error

If there is dust on the terminal, contact


point shall be cleaned by use of air gun or
with wiping cloth. Don't wipe contact point
with sand paper, because this will
damage the protective layer.

Joint inspection

When connecting the joint, squeeze its


two ends to make them completely
inserted and locked.

If contact pressure is abnormal, replace


the socket. Here it shall be replaced with
the same kind of plug and socket.

When disconnecting the joint, find the


uncoupled terminal, falling terminal, loose
terminal or damaged wire by lightly
pulling wire harness from the joint back.

The damaged, deformed or corroded


terminal shall be replaced. If the terminal
is locked in the outer shell, outer shell
also needs to be replaced.

Disassembly
harness

Before disassembling the wire harness,


first inspect the connection and fastening
condition of wire harness in order to
reinstall it correctly.

In addition, visually inspect whether there is


corrosion, metal fragment, foreign impurity
and water, as well as bend, rust, overheat,
pollution or terminal deformation, etc.

and

assembly

of

wire

Error

Error

Ternimal alike a plug

Prepare a plug that matches with the joint port


and insert it into socket; inspect them whether
there is good tightness when inserted and
after fully engaged.

Error

Inspection of terminal contact pressure

Maintenance method of joint terminal

Strictly prohibit using distorting and


stretching methods to loosen the wire
harness.

Strictly prohibit wire harness contacting


high temperature, rotating, moving and
vibrating parts or the parts with sharp
corner. Avoid contact with panel edge,
screw head or other similar objects.

be shaken lightly in the inspection.


Test connection
Joint A terminal 1
joint C terminal 1
Joint A terminal 2
joint C terminal 2

When installing parts, strictly prohibit


mixing wire harness with them.

Strictly prohibit cutting off or tearing off


wire harness sheath. If the sheath needs
to be cut off or torn off for maintenance, it
shall be replaced with new one or
repaired with ethylene adhesive tape or
similar articles.

Specified
conditions
10k or more
1

If the result accords with the above example, it


shows it is open circuit between joint A
terminal 1 and joint C terminal 1.

Figure 1
Sensor

Open
circuit

Disconnect joint B and


resistance between joints.

Open circuit inspection

Open circuit inspection shall be


conducted to the wire harness shown in
figure; conductivity and voltage shall be
inspected according to the requirements,
to determine open circuit position.

the

Specified conditions
1
10k or more

Sensor

Resistance inspection

Sensor

Test connection
Joint A terminal 1
joint B1 terminal 1
Joint B2 terminal 1
joint C terminal 1

measure

As shown in figure, disconnect joints A


and C and measure the resistance
between them: the resistance shall be
less than 1. Caution: wire harness shall

If the result accords with the above example, it


shows it is open circuit between joint C
terminal 1 and joint B2 terminal 1.

Voltage inspection

When the circuit is electrified, (ECU joint


terminal is electrified)

Sensor

Sensor

Determine the circuit whether it is in opencircuit state through voltage inspection.


As shown in figure, when each joint is in
connected state, respectively measure the
voltage value between ECU 5V output
terminal joint A terminal 1, joint B terminal 1
and joint C terminal 1 and car body grounding.

Result example:
Test connection

Specified
conditions

Joint A terminal 1car


body grounding
Joint B terminal 1car
body grounding
Joint C terminal 1car
body grounding

5V

Test connection
Joint A terminal 1car
body grounding
Joint A terminal 2joint
C terminal 2

Specified
conditions
1
10k or more

If the result accords with the above example, it


shows it is open circuit between joint A
terminal 1 and joint C terminal 1.

5V
5V

If the result accords with the above example, it


shows it is open circuit between joint B
terminal 1 and joint C terminal 1.

Disconnect joints A and C and measure


the resistance between terminals 1 and 2
in the joint A and car body grounding: the
resistance shall be 10k? or above.
Caution: wire harness shall be shaken
lightly in the measurement.

Short circuit inspection

Disconnect Joint B and then respectively


measure the resistance value between
terminal 1 in the joint A and car body
grounding and between terminal 2 and
car body grounding.

Test connection

Short circuit

Joint A terminal 1car


body grounding
Joint B2 terminal 1 car
body grounding

Specified
conditions
10k or more
1

If the result accords with the above example, it


shows it is open circuit between joint B2
terminal 1 and joint C terminal 1.

If wire harness is grounded short circuit


(as shown in figure), inspect the
resistance of car body grounding to find
out the short-circuit part.
Inspection of
conductivity

car

body

grounding

Inspection and replacement of ECU

Caution:

After the joint is connected with ECU,


inspect the joint from its back on one side
of wire harness.

If no special detection conditions are

specified, make the engine stall and turn


ignition switch to ON, and then begin to
detect it.

Inspect the joint whether it is completely


connected; inspect the line whether there
is looseness, corrosion or breakage.

Inspection of ECU grounding line

Intermittent contact arises from abnormal


connection between electric component and
electric wire, although magnetic circuit breaker
or solenoidal coil may possibly be out of order
occasionally. When poor contact is detected,
inspect the probably faulty circuit carefully.

Eg.

Grounding

Both connector and plug parts have poor


fit, or binding post is not completely in the
connector (move back).

Binding post is dirty or corroded. Binding


post must be kept clean and must not be
stained with any other matter that may
possibly obstruct normal connection of
binding post. However, strictly prohibit
using sand paper or similar articles to
clean the binding post.

The connector body is damaged. Binding


post is exposed to humid and dirty
environment, or it is possibly because the
position between binding post and fit
connector or component is wrong.

Binding post is wrong or damaged.

ECU side

Grounding
W/H side

Grounding

If the circuit has a fault, it shall be repaired; if


the circuit is normal, it shows ECU may
possibly have a fault, it shall be replaced with
a new ECU, and then inspect whether the
fault occurs again.

Measure the resistance between ECU


grounding terminal and car body
grounding: the resistance shall be less
than 1.
Disconnect ECU joint and inspect
grounding terminals (ECU and wire
harness) whether there is bend, corrosion
or foreign impurity. Finally inspect the
contact pressure of socket.
Intermittent contact and poor contact

Utilize the binding post fitting to the


corresponding connector and carefully detect
the binding post of each connector in the
faulty circuit, and make sure contact pressure
is enough. If contact is loose, adjust the
binding post to increase contact pressure or
replace the binding post.

Binding post and electric wire are in poor


contact

Lightly shake the wire harness with hand and


inspect poor contact in the faulty circuit. If any
abnormal phenomenon is found, immediately
repair or replace it.

Insulating layer of electric wire is worn out


and the exposed part contacts other wires
or other parts, which causes intermittent
short circuit.

may possibly be higher. If any abnormal


phenomenon is found, immediately repair
or replace it.

Electric wire in the insulating layer is


broken. In such a case, it had better
conduct conductivity test. However, for
multi-strand wire, only one or two strands
may possibly be intact and its resistance

4.3.Corrective maintenance procedure

Section 5 Abbreviations and Color Symbols of Electric Wires


5.1.Abbreviations
List of automobile English abbreviations that may be used in the factory regulations
ABS

Anti-Lock Brake System (ABS)

A/C

Air conditioning and air conditioner

ACL

Air filter

A/F

Air-fuel ratio

ALR

Automatic locking tighetner

ALT

AC generator

AMP

Ampere

ANT

Antenna

API

American Petroleum Institute

APPROX
ASSY
A/T
ATDC

Approximate
Assembly
Automatic transmission
After top dead center

ATF

Automatic transmission oil

ATT

Accessory

ATTS

Active torque transmission system

AUTO

Automatic

AUX

Accessory

BARO

Atmospheric pressure

BAT

Accumulator

BDC

Bottom dead center

BTDC

Before top dead center

CARB

Carburetor

CAT/CATA

Catalytic converter

CHG

Charge

CKG

Crankshaft rotating speed fluctuation

CKP

Crankshaft position

CO

Carbon monoxide

COMP
CPB

Complete
Clutch pressure return

CPC

Clutch pressure control

CPU

Central processing unit (CPU)

CVT

Continuous change

DPSF
DTC
DPSF

Double pump system fluid


Diagnostic trouble code (DTC)
Double pump system fluid

EBD

Electronic brake force distribution (EBD)

ECM

Engine control unit

ECT

Engine coolant temperature

EGR

Exhaust gas recirculation (EGR)

ELD

Electrical load detector

EPR

Evaporator pressure regulator (EPR)

EPS

Electrical power steering

EVAP

Evaporative emission control system (EVAP)

EX
F

Exhaust
Front

FIA

Fuel injection air

FL

Front left

FP

Fuel pump

FR

Front right

FSR

Fail-safe relay

FWD

Front wheel drive

GAL

Gallon

GND

Ground

GPS

(Satellite) GPS

H/B

Glide back (car body)

HC

Hydrocarbon

HID

High intensity discharge

HO2S

Heated oxygen sensor

IAB

Intake air bypass

IAC

Idle air control

IACV

Idle air control valve

IAR

Intake air resonator

IAT

Intake air temperature

ICM

Ignition control module

ID

Identification

ID or I.D.

Inside diameter

IG or IGN

Ignition

IMA

Idle mixture concentration control


Integrated engine auxiliary system

IMMOBI.

Anti-start unit

IN

Intake air

INJ

Injection air

INT

Intermittence

KS

Knock sensor

Left side

L/C

Locking clutch

LCD

LCD

LED

LED

LEV

Low emission vehicle

LF

Front left

LH

Left-hand drive (LHD)

LHD
LR

LHD
Left rear

LSD

Limited slip differential

L-4

Inline four-cylinder engine

MAP

Manifold absolute pressure

MAX.

Maximum value

MBS

Main shaft brake system

MCK

Motor inspection

MCU

Moment control unit

MIL

Fault indicator light

MIN.

Minimum value

MPI

Multi-point fuel injection

M/S

Manual steering

M/T

Manual transmission

Neutral

NOX

Oxynitride

OBD

On-board diagnostic

O2S

Oxygen sensor

OD or O.D.
P

Outside diameter
Parking

PAIR

Pulse auxiliary air injection

PCM

Power control module

PCV

Positive crankcase ventilation


Proportional control valve

PDU

Power drive unit

PGM-FI

Programmed fuel injection

PGM-IG

Programmed ignition

PH

Pressure high

PL

Pressure low, indicator light

PMR

Pump motor relay

P/N

Part number

PRI

Primary

P/S

Power steering

PSF

Power steering fluid

PSP

Power steering pressure

PSW

Pressure switch

Qty

Qty.

Right side

REF

Reference

RH

Right-hand drive (RHD)

RHD
RL
RON
RR

RHD
Left rear
Theoretical octane number
Right Rear

SAE

Society of Automotive Engineers

SCS

Signal of maintenance inspection

SEC

Second
Secondary

SOHC
SOL
SPEC

Single overhead camshaft


Solenoid valve
Specification

S/R

Sunroof

SRS

Supplemental restraint system

STD

Standard

SW

Switch

Torque:

TB

Throttle body

T/B

Timing belt

TC

Torque converter

TCM

Transmission control module

TCS

Traction control system

TDC

Top dead center

TFT

Thin film transistor

T/N

Tool number

TP

Throttle position

TWC

Three-way catalytic converter

VC

Viscous coupling

VIN

Vehicle identification number

VSC

Volume (net)

VSS

Vehicle speed ??sensor

VTEC

Variable valve timing and valve lift ECU

VVIS

Variable volume intake system

Equipped

W/O

Unequipped

WOT

Wide-open throttle

2WD

Two-wheel drive

4AT

4-speed automatic transmission

5MT

5-speed automatic transmission

6MT

6-speed automatic transmission


Parking
Reverse
Neutral
Automatic four gears (1st gear to 4th gear)
Automatic three gears (1st gear to 3rd gear)
2nd gear
1st gear
Automatic gear
2nd gear
Low speed gear

O/D
st

Overdrive gear

1st gear

2nd

2nd gear

rd

3rd gear

4th

4th gear

5th

5th gear

5.2.Color symbols of electric wires


B

Black

Blue

Br

Brown

Green

Gr

Grey

Lg

Tender green

Orange

Pink

Red

Purple

White

Yellow