Haval h5 Service Manual

Content
General Description of Complete Vehicle
Air Intake System
Exhaust System
Intercooler
Clutch
Transmission
Steering System
Body Electrical Appliance
Air Conditioning System
Airbag
Body Internal and External Trim
Body & Stamping Parts

General Description of Complete Vehicle-
General Description of Complete Vehicle
Basic Parameters of Complete Vehicle........................... 2

Structure Types and Technical Parameters of Main
Systems and Assemblies................................................. 4
Basic Parameters of Complete Vehicle

(1)
Model CC6461KM09 CC6461KM07 CC6461KM29 CC6461KM27
Mode 4×2 4×4
Rated passenger (person) 5
Curb weight of the complete vehicle (kg) 1725 1705 1805 1785
Max. gross mass (kg) 2200 2180 2280 2260
A x l e n o - Front axle (kg) 895 875 955 935
l o a d load Rear axle (kg) 830 830 850 850
d i s t r i - F u l l Front axle (kg) 995 975 1055 1035
bution load Rear axle (kg) 1205 1205 1225 1225
Length (mm) 4649
Overall di-
Width (mm) 1810
mensions
Height (mm) 1745 1735
Axle base (mm) 2700
Front (mm) 1515
Wheel base
Rear (mm) 1520
Min. ground clearance (mm) ≥180 ≥175
Min. turning diameter (m) ≤13
Front suspension (mm) 899
Rear suspension (mm) 1050
Approach angle (°) ≥22
Departure angle (°) ≥27.5
Four 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
Accelerating time of direct drive 30km/
≤32 ≤43 ≤32 ≤43
h~100km/h (s)
Accelerating time of initial starting of
≤20
gear 1 shifting to 100km/h (s)
Top speed ( full load, km/h) 160
Max. climbing capacity (%) ≥35 ≥30 ≥35 ≥30
Economical efficiency
Sliding distance with initial speed 50km/h
≥500
(m)
Fuel consumption under 90km/h cons-
≤8.65 ≤8.12 ≤8.65 ≤8.12
tant speed driving (L/100km)
≤12.14 ≤10.92 ≤12.14 ≤10.92
Fuel consumption combined(L/100km) ≤9.77 ≤9.5 ≤10.31 ≤9.5
Brake performance
Service braking distance of initial braking
≤19(no-load), ≤20(full load)
speed of 50km/h (m)
Emergency braking distance of initial
≤38
braking speed of 50km/h (m)
Grade parking brake (%)(less than Under no-load, it can be kept fixed-
5min)(%) ness on the road of the 20% grade
Noise
Outside noise when driving in accelera-
≤74
tion speed dB (A)
Inside noise when driving in uniform
≤79
speed of 50km/h dB(A)
Parotid noise beside the driver dB(A) ≤90
(2)
Model CC6461KM45 CC6461KM65
Mode 4×2 4×4
Rated passenger (person) 5
Curb weight of the complete vehicle (kg) 1825 1925
Max. gross mass (kg) 2510 2510
A x l e no-load Front axle (kg) 990 1060
load Rear axle (kg) 835 865
distri- Front axle (kg) 1180 1180
Full load
bution Rear axle (kg) 1330 1330
Length (mm) 4649
Overall dimen- Width (mm) 1810
sions
Height (mm) 1745 1735
Axle base (mm) 2700
Front (mm) 1515
Wheel base
Rear (mm) 1520
Min. ground clearance (mm) ≥180 ≥175
Min. turning diameter (m) ≤13
Front suspension (mm) 899
Rear suspension (mm) 1050
Approach angle (°) ≥22
Departure angle (°) ≥27.5
Four 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
Accelerating time of direct drive 30km/
≤32
h~100km/h (s)
Accelerating time of initial starting of

≤20
gear 1 shifting to 100km/h (s)
Top speed ( full load, km/h) ≥140
Max. climbing capacity (%) ≥45
Economical efficiency
Sliding distance with initial speed 50km/
≥500
h (m)
≤6.83 ≤6.83
≤9.94 ≤9.94
Fuel consumption combined(L/100km) ≤8.53 ≤8.53
Brake performance
Service braking distance of initial bra-
≤19(no-load), ≤20(full load)
king speed of 50km/h (m)
Emergency braking distance of initial
≤38
braking speed of 50km/h (m)
Grade parking brake (%)(less than Under no-load, it can be kept fixed-
5min)(%) ness on the road of the 20% grade
Noise
Outside noise when driving in accelera-
≤75
tion speed dB (A)
Inside noise when driving in uniform
≤79
speed of 50km/h dB(A)
Parotid noise beside the driver dB(A) ≤90
Structure Types and Technical Parameters of Main Systems and

Assemblies
Engine(1)
Vehicle type code CC6461KM09/CC6461KM29 CC6461KM07/CC6461KM27
Item Specifications and parameters
Engine model 4G69S4N 4G63S4M
Four-cylinder, in-line, water cooling, single over-head camshaft,
Mode
four-stroke, multiple-point electro-injection gasoline engine
Cylinder diameter×stroke (mm) 87×100 85×88
Displacement (L) 2.378 1.997
Compression ratio 9.8:1 10:1
Rated power and corresponding
100/5250 90/5250
rotation speed (kW/r/min)
Max. torque and corresponding ro-
200/2500-3000 170/2500-3000
tation speed (N·m/rpm)
Stable idle speed (r/min) 750±50 750±50
Max. net power (kW) 90 85
Engine(2)
Vehicle type code CC6461KM45/CC6461KM65
Item Specifications and parameters
Engine model GW2.5TCI
Four-cylinder, in-line, water cooling, four-stroke, superchar-
Mode
ge intercooling, high-pressure common rail diesel engine
Cylinder diameter×stroke (mm) 93×92
Displacement (L) 2.499
Compression ratio 17.2:1
Rated power and corresponding
80/3600
rotation speed (kW/r/min)
Max. torque and corresponding ro-
300/1800～2400
tation speed (N·m/rpm)
Stable idle speed (r/min) 800±30
Max. net power (kW) 74
Air Intake System
CC6461KM09/CC6461KM29, CC6461KM07/CC6461KM27 Naturally intake air, air cleaner with reso-
nance chamber.
CC6461KM45/CC6461KM65 Dry-type Air Cleaner, exhaust gas turbo charge inter-cooling system.
Exhaust System
CC6461KM09/CC6461KM29 It is equipped with first-level silencer, with catalytic converter. For Euro
Ⅳ, it is equipped with OBD.
Ⅳ, it is equipped with OBD.
Ⅲ, it is equipped with OBD.
Fuel Supply System
Fuel tank is plastic, with the capacity of 70L.
CC6461KM09/CC6461KM29, CC6461KM07/CC6461KM27 fuel supply control is mechanical pedal
type, with built-in electronic fuel pump.
CC6461KM45/CC6461KM65 fuel supply control is electronic control type.
Cooling System
Closed and forced water cooling, electronic fan or mechanical fan
Clutch
Friction type, disc type single plate, dry-type diaphragm spring clutch, with hydraulic control.
Transmission(1)
Vehicle type code CC6461KM09 CC6461KM29
Model ZM001DB ZM001DF
All synchronizer with manual me-
Manual mechanical step speed trans-
chanical step speed transmission of
Mode mission of all synchronizer, 5 forward
transfer case, 5 forward gears, 1 re-
gears, 1 reverse gear, and direct control
verse gear, and direct control
Gear Ⅰ 3.992 Gear Ⅰ 3.992
Gear Ⅱ 2.150 Gear Ⅱ 2.150
Gear Ⅲ 1.334 Gear Ⅲ 1.334
Gear Ⅳ 1.000 Gear Ⅳ 1.000
Speed ratio
Gear Ⅴ 0.857 Gear Ⅴ 0.857
Gear R (reverse) 4.22 Gear R (reverse) 4.22
Gear H (high) 1.00
Gear L (low) 2.48
Transmission(2)
Model 038M1 038M
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 H (high) 1.00
Gear L (low) 2.48
Transmission(3)
Model ZM001DB ZM001DF
Gear Ⅰ 3.992 Gear Ⅰ 3.992
Gear Ⅱ 2.150 Gear Ⅱ 2.150
Gear Ⅲ 1.334 Gear Ⅲ 1.334
Gear Ⅳ 1.000 Gear Ⅳ 1.000
Speed ratio
Gear Ⅴ 0.857 Gear Ⅴ 0.857
Gear H (high) 1.00
Gear L (low) 2.48
Drive Shaft
The rear drive shaft assembly of CC6461KM09 and CC6461KM07 and CC6461KM45 wagon includes
three cross axle universal joints, two drive shafts, and maintenance-free sectional structure with ex-
pansion spline and intermediate support.
The front and rear drive shaft assembly of CC6461KM29 and CC6461KM27 and CC6461KM65
wagon includes two cross axle universal joints, a drive shaft and maintenance-free integral structure
with expansion spline.
Front Axle
The front axle of CC6461KM09 and CC6461KM07 and CC6461KM45 and CC6461KM47 wagon is a
double-transverse arm independent suspension breakaway front axle.
For CC6461KM29 and CC6461KM27 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=4.22.
For CC6461KM65 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
CC6461KM09/CC6461KM29, CC6461KM07/CC6461KM27 It is equipped with integral drive axle,
punching welding axle case, hyperbolic gear single-stage main reducing gear, common bevel gear di-
fferential, and semi-floating half axle. The main reducing ratio i0=4.22.
CC6461KM45/CC6461KM65 It is equipped with integral drive axle, punching welding axle case, hy-
perbolic 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
Tyre type Tyre specification Rim specification Tyre pressure Wheel offset
235/65 R17 5°deep-groove rim
230kPa +38mm
Tubeless P235/65 R17 17×7J (2WD)
Radial tyre 235/70 R16 5°deep-groove rim
230kPa +38mm
P235/70 R16 16×7J (4WD)
Suspension
The front suspension is equipped with torsion bar spring, double-transverse arm independent suspen-
sion.
The rear suspension is equipped with five-bar linkage, coil spring and dependent 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 ad-
justable steering wheel angle.
Brake System
It is equipped with hydraulic dual-circuit layout, 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.
Electrical System
System Structure and parameters
Combination meter Electronic
Instrument sys- Indicator light LED
tem Sensor and dimming
Conform to related system
switch
One wire system, ground earth with negative pole, vol-
Circuit
tage direct current of 12V
P o w e r s u p p l y,
Generator Built-in adjuster
starting and char-
Starter 12V, 1.2kW(gasoline); 12V, 2.8KW(diesel)
ging system
A/C system Cold-warm automatic A/C
Battery 80Ah
Signal system Horn Basin, bi-tone horn
Audible equipment DVD player, optional CD player
Cigar lighter 12V, 1
Rear window defrost Rear windshield is electric heating windscreen
Auxiliary electri- Central control door lock With remote control
cal system Glass lifter Electric
ABS electric control sys- BOSCH ABS8.0 version, with EBD function (Electroni-
tem cally Brake Distribution)
Body and Interior/exterior trim

No. Item Structure and parameters
1 Vehicle body
Cab-behind-engine, two-carriage, four doors, five seats, all-
1.1 Type of vehicle body
metal close 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-co-
llision lever, four side doors with positive opening; rear tail door
1.3 Door assembly
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
2.1 Interior trim
and 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
Metal skeleton, PVC case, with PUR foaming layer in the
2.4 Handrail in the vehicle
middle
Panoramic bent windshield. Front windshield: Hyperbolic and
2.5 Windshield interlayer glass. Rear windshield: Hyperbolic and toughened
glass, with electric heating defrosting
Exterior rear-view mirror: Electric and electric heating defros-
2.6 Rear-view mirror ting, with convex reflectors on both sides. Interior rear-view
mirror: Manual, non-glare, plane interior mirror
Seats for driver and auxiliary driver: Independent seat, with ad-
justable front and rear/upper and lower position, backrest angle
2.7 Seat
and seat headrest. Rear seat: Independent seat, the backrest
can be turned and folded.
Fixing in two points for rear middle seat, emergency locking
2.8 Safety belt
mechanical safety belt fixed by three points for other seats
2.9 Front and rear bumpers Integral design, PP injection molding
A/C System
Structure and parameters
No. Item
GW2.5TCI 4G69
1 Structure type Automatic warm-cold A/C, vapor compression refrigeration, hot water heating
Performance Refrigerating output of 4.5kW, heat exchange output of 4.5kW, air flow of
2
parameters 450m3/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 HFC-134a
SD7V16 variable displacement com- Mitsubishi 105A fixed-displacement
5 Compressor pressor, with max. displacement of compressor, with displacement of
161.3ml 105ml
6 Condenser Parallel stream structure, with flat-tube thickness of 20mm
Two-box structure, layered evapora- Two-box structure, layered evapora-
7 Evaporator tor, F-type expansion valve, centrifu- tor, H-type expansion valve, centrifu-
gal blower gal blower
Dry fluid reser-
8 Outer diameter of φ32mm
voir
Refrigeration
Refrigeration pipe: combined type of rubber cooling hose and aluminium
9 pipe and hea-
pipe. Heating water pipe: rubber molding pipe
ting water pipe
10 Sensor Outdoor temperature sensor, indoor temperature sensor, evaporator temperature sensor
11 Pressure switch Tri-state pressure switch
Grades and Specifications of Operating Agent for Operating Parts of

Wagon(gasoline engine)
No. Operating parts Quantity Specifications
Use lead free gasoline for the vehicles of high
1 Engine fuel (RON) 70L±3L
quality above 93# (GB 17930—2006)
4.0L±0.1L (filled with
Lubricating oil for Above SAE SJ grade, choose oil according to
2 oil of 4.3L if replace
engine season
oil filter)
Main filling quantity:
6.5L±0.5L Ethylene— -35℃ ethylene glycol based antifreeze
3 Coolant
Auxiliary filling quanti- coolant
ty: 0.7L±0.1L
0.15L (within the
4 Clutch fluid DOT4 synthetic brake fluid
mark)
Manual transmis- 2.4L±0.1L (2WD)
5 API GL-4 grade hyperbolic gear oil
sion 2.5L±0.1L (4WD)
Front drive axle 1.4L±0.1L
Electric control
shift fork of front 0.19L±0.01L
axle
7 Rear drive axle 2.7L±0.1L API GL-5 grade hyperbolic gear oil
Power steering 791mL±32mL (within
8 ATF DEXRON III hydraulic transmission oil
fluid the mark)
0.525L (within the
9 Brake fluid DOT4 synthetic brake fluid
mark)
10 Battery terminal 1.0g Industrial vaseline
Normal temperature: use cleaning water with har-
Windshield was- dness less than 205g/1000kg. Low temperature
11 2.5L±0.2L
hing solution (-18℃±3℃): use methanol aqueous solution with
concentration of 50%
12 A/C Refrigerant 650g±20g HFC134a
Other motion fric-
13 - Universal lithium-based grease for 3# vehicle
tion pair
Grades and Specifications of Operating Agent for Operating Parts of

Wagon(diesel engine)
No. Operating parts Quantity Specifications
0# light diesel oil (choose -10#, -20# or -35#
1 Engine fuel (RON) 70L±3L according to the temperature in the winter)
(GB252-2000)
Conform to API standard: above CI grade, with
Lubricating oil for viscosity of 15W-40 and 5W-40 or conform to
2 4.2L±0.1L
engine A-CEA standard: A3/B4 15W-50, 5W-40 (specifi-
cally choose according to the local temperature)
Main filling quantity:
8.5L±0.5L
3 Coolant -35℃ ethylene glycol based antifreeze coolant
Auxiliary filling quanti-
ty: 0.7L±0.1L
0.15L(within the
4 Clutch fluid DOT4 synthetic brake fluid
mark)
Manual transmis- 2WD: 2.5L±0.1L
sion 4WD: 2.5L±0.1L
Front drive axle 1.4L±0.1L
6 Electric control API GL-5 grade hyperbolic gear oil
shift fork of front 0.19L±0.01L
axle
General Description of Complete Vehicle-10
7 Rear drive axle 2.7L±0.1L API GL-5 grade hyperbolic gear oil
Power steering
8 775mL±32mL ATF DEXRON III hydraulic transmission oil
fluid
0.525L(within the
9 Brake fluid DOT4 synthetic brake fluid
mark)
10 Battery terminal 1.0g Industrial vaseline
Normal temperature: use cleaning water with har-
Windshield was- dness less than 205g/1000kg. Low temperature
11 2.5L±0.2L
hing solution (-18℃±3℃): use methanol aqueous solution with
concentration of 50%
12 A/C Refrigerant 570g±20g HFC134a
Other motion fric-
13 - Universal lithium-based grease for 2# vehicle
tion pair
Air Intake System-
Air Intake System
Operating Instructions to Air Filter ...................................... 2

Parts Renewal .................................................................... 2
Air Intake System-
Air Intake System

Operating Instructions to Air Filter
1. It is requested to check and renew air filter element on a regular basis in compliance with ma-
intenance regulations and clean air filter element timely according to regulations of the routine
maintenance table.
2. Clean air ensures normal engine operation.
3. Driving without air filter element is strictly prohibited because this may damage engine.
4. Air filter element is fitted in the air filter assembly on the left side of engine.
Parts Renewal
(4G69 and 4G63 engine)
Type B worm drive type Engine iron inlet pipe
hose hoop 1. Remove air filter outlet pipe
(a) Unscrew type B worm drive type hose hoop bolts
between air filter casing and air filter outlet pipe
interface;
(b) Unscrew type B worm drive type hose hoop bolts
Outlet pipe of air filter between engine iron inlet pipe and air filter outlet
pipe interface;
(c) Unplug air filter outlet pipe and remove it.
2. Remove air filter inlet pipe

Air filter inlet pipe
(a) Unscrew type B worm drive type hose hoop bolts
Hexagon head bolt, between lower air filter casing and air filter inlet
elastic washer and plain
washer assembly parts pipe interface;
(b) Unscrew hexagon head bolt, elastic washer and
plain washer assembly parts at the joint of air filter
inlet pipe and inlet pipe bracket, 1 off;
(c) Unplug air filter inlet pipe and remove it.
Inlet pipe bracket
Hexagon-headed bolt, 3. Remove air filter

elastic washer and plain (a) Unscrew hexagon head bolt, elastic washer and
washer assembly parts
and right front splashboard, 3 off;
(b) Remove air filter from engine compartment.
4. Remove air filter

(a) Unscrew seven fixing bolts between upper casing
Upper air filter casing
and lower casing of air filter;
(b) Detach upper casing and lower casing of air filter;
Air filter element assembly
(c) Remove air filter element assembly.
Lower casing of air filter

Air Intake System-
5. Renew air filter element assembly

(a) Use a piece of wet cloth to clean inner side of upper
casing and lower casing of air filter;
(b) Renew with new air filter element assembly.
6. Fit air filter assembly
Fitting steps are opposite to disassembly or removal
steps.
Attention:
1. Air filter element must be fitted to designed posi-
tion.
(a) Partition plate of lower casing shall be necessarily

plugged into groove.
Groove
Partition plate
(b) Filter element seal ring has to be assembled into

limiting part of lower casing.
Filter element seal ring
2. Firstly plug three limiting edges on upper casing

of air filter into spacing grooves on lower casing
of air filter, align these edges with these grooves
and then screw down 7 bolts on upper casing of air
filter to fit the upper casing of air filter. The tighte-
ning torque is 1.6±0.2N•m.
Hexagon-headed bolt, 3. Tightening torque of three hexagon head bolt, elas-

elastic washer and plain tic washer and plain washer assembly parts at the
joint between air filter and right front splashboard
is 14±2N•m.
Air Intake System-
Type B worm drive type hose hoop (2.5TCI engine)

Type B worm drive 1. Detach air filter outlet pipe, air flow sensor unit and
Air filter outlet pipe type hose hoop
engine inlet hose
Air flow sensor unit
(a) Remove wiring harness plug of air flow sensor
unit;
(b) Remove clips between engine inlet hose and
Crankcase venti- crankcase ventilating hose and unplug crankcase
lating hose
ventilating hose;
(c) Unscrew type B worm drive type hose hoop bolts
Engine inlet hose between upper casing of air filter and air filter out-
let pipe connector;
(d) Unscrew type B worm drive type hose hoop bolts
between engine inlet hose and turbocharger inlet;
(e) Unplug one end of air filter outlet pipe connected
with upper casing of air filter, remove one end of
engine inlet hose connected with turbocharger
and detach joint among air filter outlet pipe, air
flow sensor unit and engine inlet hose.
2. Remove air filter inlet pipe

Air filter inlet pipe (a) Unscrew type B worm drive type hose hoop bolts
Hexagon head bolt, between lower casing of air filter and air filter inlet
elastic washer and plain pipe;
washer assembly parts (b) Unscrew hexagon head bolt, elastic washer and
inlet pipe and inlet pipe bracket, 1 off;
(c) Unplug air filter inlet pipe and remove it.
Inlet pipe bracket
Hexagon head bolt, elastic 3. Remove air filter

washer and plain washer (a) Unscrew hexagon head bolt, elastic washer and
assembly parts
plain washer assembly parts at the joint between
air filter and right front splashboard, 3 off;
(b) Remove air filter from engine compartment.
4. Disassemble air filter

(a) Unscrew seven fixing bolts on upper casing and
Upper air filter casing
lower casing of air filter;
(b) Detach upper casing and lower casing of air filter;
Air filter element assembly
(c) Disassemble air filter element assembly.
Lower casing of air filter

Air Intake System-
5. Renew air filter element assembly

(a) Use a piece of wet cloth to clean inner side of upper
casing and lower casing of air filter;
(b) Renew with new air filter element assembly.
6. Fit air filter assembly
Fitting steps are opposite to disassembly or removal
steps.
Attention:
1. Air filter element must be fitted to designed posi-
tion.
(a) Partition plate of lower casing shall be necessarily

plugged into groove.
Groove
Partition plate
(b) Filter element seal ring has to be assembled into

limiting part of lower casing.
Filter element seal ring
2. Firstly plug three limiting edges on upper casing

of air filter into spacing grooves on lower casing
of air filter, align these edges with these grooves
and then screw down 7 bolts on upper casing of air
filter to fit the upper casing of air filter. The tighte-
ning torque is 1.6±0.2N•m.
Hexagon-headed bolt, 3. Tightening torque of three hexagon head bolt, elas-

elastic washer and plain tic washer and plain washer assembly parts at the
joint between air filter and right front splashboard
is 14±2N•m.
Exhaust System-
Exhaust System
Part Drawing of Exhaust System (2.5TCI Left-hand Drive) 2

Remove exhaust system assembly..................................... 3
Fit exhaust system assembly ............................................. 4
Exhaust System-
Exhaust System
Part Drawing of Exhaust System (2.5TCI Left-hand Drive)
Three-hole rubber block
Catalytic converter washer I
Hexagon flange nuts Catalytic converter washer II
Hexagon flange bolts
Hexagon flange nuts

Particle trap assembly
Oxygen catalytic converter assembly
Hexagon flange nuts

Exhaust pipe outlet gasket
Hexagon head bolt
Three-hole rubber block Silencer assembly
Hexagon flange nuts Silencer washer
Hexagon flange nuts
Rear section assembly of exhaust pipe

Exhaust System-
Warning: Disassembling and removal of all parts in

exhaust system shall be necessarily fulfilled 30min
after parking to prevent high-temperature parts
causing personal injury.
Remove exhaust system assembly
1. Remove rear section assembly of exhaust pipe
(a) Firstly use M15 sleeve wrench or ratchet wrench
and extension bar to remove silencer assembly
and then flanges and connecting nuts in rear sec-
tion of exhaust pipe and finally remove gaskets
between flanges.
(b) Remove three-hole rubber blocks in back part of
rear section of exhaust pipe.
(c) Remove three-hole rubber blocks in front part of
rear section of exhaust pipe.
Attention: silencer washers between rear silencer
flange and rear flange of exhaust pipe mainly serve
as a sealing element. After being fitted once, they
may encounter stressed deformation and poor sea-
ling. Therefore, these washers can not be reused.
2. Remove silencer assembly

(a) If necessary, firstly remove rear section of exhaust
pipe according to steps of disassembling rear sec-
tion of exhaust pipe. If not necessary, only uns-
crew connecting nuts between silencer and flange
in rear section of exhaust pipe.
(b) Use M15 sleeve, ratchet wrench or open-end
wrench (double offset ring wrench) to unscrew
connecting bolts and nuts between front flange of
silencer assembly and flange of particle trap ass-
embly. Special personnel shall be arranged to su-
pport the silencer during the operation to prevent
it falling down and injuring the operator.
(c) Remove three-hole rubber blocks and then remo-
ve silencer assembly.
Attention: Catalytic converter washer II between
silencer and particle trap assembly mainly serves
as a sealing element. After being fitted once, it may
encounter stressed deformation and poor sealing.
Therefore, these washers can not be reused.
3. Remove particle trap assembly

(a) If necessary, firstly remove rear section of exhaust
pipe and silencer according to steps of disassem-
bling rear section of exhaust pipe and silencer. If
not necessary, only unscrew connecting bolts and
connecting nuts between silencer assembly and
particle trap assembly.
(b) Unscrew connecting nuts between front flange of
particle trap and rear flange of oxygen catalytic
converter.
Exhaust System-
(c) Remove three-hole rubber blocks.

(d) Remove particle trap assembly.
Attention: Catalytic converter washer I between
particle trap assembly and oxygen catalytic con-
verter mainly serves as a sealing element. After be-
ing fitted once, it may encounter drastic stressed
deformation and poor sealing. Therefore, the was-
her can not be reused.
4. Remove oxygen catalytic converter assembly

(a) Use M13 and M15 double offset ring wrench to
unscrew connecting bolts and nuts between front
flange of particle trap assembly and oxygen ca-
talytic converter.
(b) Use M13 sleeve, large-sized extension bar and
ratchet wrench to loosen and remove bolts at ex-
haust elbow outlet of turbocharger and then remo-
ve oxygen catalytic converter assembly.
Attention: Two flat flanges are connected by joint
gasket assembly. Such assembly is comprised
of stainless steel pressing and can be used only
once.
Fit exhaust system assembly

1. Keep clearance of exhaust pipe assembly towards
parts on both sides more than 15mm.
2. A proper amount of silicon oil is applied to three-
hole rubber block mounting holes. After being fit-
ted, the rubber blocks shall be evenly stressed.
3. Nut tightening torque of front exhaust pipe section
and exhaust manifold is 70±5N•m.
Intercooler-
Intercooler
Part Drawing of Intercooler.................................................. 2

Overview of Intercooler....................................................... 2
Function of Intercooler . ..................................................... 2
Classification of Intercooler ............................................... 3
Removal of Intercooler ....................................................... 3
Intercooler fitting ................................................................. 3
Intercooler Maintenance ..................................................... 3
Intercooler-
Intercooler
Part Drawing of Intercooler

Type B worm drive type hose hoop Q1840845FD
Type A worm drive type hose hoop Q67683
Q67565
Intercooler assembly
Intercooler rubber tube sleeve
Hexagon flange bolts Hexagon flange bolts
Q1840616FD Q1840845FD
Rubber tube bracket
Radiator suspen- Big washer

sion rubber bloc Q40208FD
Q1841025FD

Q1841025FD Intercooler mounting rubber block
Intercooler bracket
Type B worm drive type hose hoop
Q67683
Intercooler bracket II
Intercooler connecting hose Q1841025FD
Type A worm drive type hose hoop

Q67565 Intercooler rubber
tube sleeve II
Intercooler rubber
tube sleeve II

Q1840816FD
Rubber tube bracket II
Overview of Intercooler
An intercooler can be seen only in a vehicle equipped with turbocharger because it is actually an auxi-
liary part of turbocharger and aims to improve the air exchange efficiency of engine.
One of the reasons enabling a turbocharger engine to be more powerful than a common engine lies in
higher air exchange efficiency than a common engine featuring natural inflow. After flowing into turbo-
charger, air temperature rises drastically and air density reduces correspondingly. Thus, an intercooler
cools air. High-temperature air is firstly cooled by intercooler and then flows into engine. Without an in-
tercooler, pressurized high-temperature air will directly flow into engine, degrading engine power and
boosting fuel consumption consequently.
Function of Intercooler
The intercooler in a turbocharger engine plays a significant role in reducing engine air intake tempera-
ture, improving engine air intake volume and fully burning fuels, thus boosting engine power.
1. An engine emits high-temperature exhaust gas. Due to heat transmission through turbochar-
ger, the air intake temperature rises. Moreover, air density is strengthened after being com-
pressed, making air temperature rise inevitably and having an impact on induction efficiency
of engine. Greater progress in induction efficiency calls for lower air intake temperature. Re-
Intercooler-
lated data indicates that reducing the temperature of turbocharged air by 10℃ will increase
engine power efficiency by 3% to 5% at the same air-fuel delivery ratio and a specific range of
temperature.
2. Turbocharged air never being cooled flowing into combustion chamber will not only have an
adverse impact on induction efficiency of engine but also easily cause excessively high com-
bustion temperature and engine knock, etc. Besides, this will increase NOx contents in ex-
haust gas and accordingly lead to air pollution.
In order to eliminate the adverse impact of temperature rise of turbocharged air, an intercooler shall
be fitted to reduce temperature of air intake.
Classification of Intercooler
In general, an intercooler is made from aluminum alloys. Common intercoolers can be divided into air-
cooled intercooler and water-cooled intercooler in terms of cooling medium. The vehicle is equipped
with air-cooled intercooler.
Removal of Intercooler
1. Remove intercooler connecting hose
(a) Unfasten type A worm drive type hose hoop between intercooler connecting hose and engine air
intake elbow and unplug one end of intercooler connecting hose that is connected with engine air
intake elbow;
(b) Remove front bumper;
(c) Unfasten type B worm drive type hose hoop between intercooler connecting hose and intercooler
connector and unplug one end of intercooler connecting hose that is connected with intercooler
connector;
(d) Unscrew hexagon flange bolts on intercooler connecting hose bracket;
(e) Remove intercooler connecting hose.
2. Removal of Intercooler Connecting Hose II
(a) Unfasten type A worm drive type hose hoop between intercooler connecting hose II and turbo-
charger and unplug one end of intercooler connecting hose II connected with turbocharger;
(b) Unfasten type B worm drive type hose hoop between intercooler connecting hose II and inter-
cooler connector and unplug one end of intercooler connecting hose II connected with intercooler
connector;
(c) Unscrew hexagon flange bolts on intercooler connecting hose bracket;
(d) Remove intercooler connecting hose II.
3. Removal of Intercooler Assembly
(a) Unscrew flange bolts between intercooler assembly and intercooler bracket;
(b) Unscrew flange bolts between intercooler assembly and intercooler bracket II;
(c) Remove intercooler assembly.
4. Removal of Intercooler Bracket
(a) Unscrew two hexagon flange bolts among intercooler bracket, crash-proof steel beam and vehi-
cle frame;
(b) Remove intercooler bracket.
5. Removal of Intercooler Bracket II
(a) Unscrew two hexagon flange bolts among intercooler bracket II, crash-proof steel beam and ve-
hicle frame;
(b) Remove intercooler bracket II.
6. Removal of Intercooler Rubber Tube Sleeve and Intercooler Rubber Tube Sleeve II
(a) Remove intercooler rubber tube sleeve and intercooler rubber tube sleeve II respectively from
headlamp plate. Fitting steps are opposite to removal steps.
Intercooler fitting
Refer to reverse sequences of disassembling for fitting.
Intercooler Maintenance
Air-cooled intercooler is integrated with water tank radiator in the front of engine. An intercooler reali-
Intercooler-
zes cooling relying on fan and vehicle ventilating surface. Unfavorable cooling by intercooler will result
in low engine power and high fuel consumption. Therefore, you are kindly requested to check and
maintain intercooler on a regular basis.
1. External cleaning (Cleaning without disassembling the vehicle)
Intercooler is arranged at the forefront of a vehicle. Intercooler radiating ribs are usually clogged by
leaves, oil sludge (hydraulic oil overflowed from steering oil tank) and other substances, disabling heat
radiation. Therefore, it shall be regularly cleaned. It is proposed to keep a washing gun of not high
pressure vertical towards the intercooler plane for low-speed washing from top to bottom or bottom to
top. But, inclined washing is strictly prohibited to protect the intercooler.
2. Internal cleaning and check (Disassembly-based cleaning)
Oil sludge, gel and other pollutants usually adhere to internal pipelines of intercooler, narrowing the
air circulation passageway and weakening capacity of heat exchange for cooling. Thus, maintenance
and cleaning are really needed. In general, internal parts of intercooler shall be cleaned and checked
every year or at the same time with engine overhaul and water tank welding and repair.
As for cleaning methods, add water solution (with temperature ranging from 70℃ to 80℃) containing
2% pure soda into intercooler and fully fill it, wait for 15min and observe whether the intercooler en-
counters water leakage. If water leakage exists, disassemble intercooler and weld it (just like repairing
water tank). Upon no water leakage, shake it several times, discharge water solution, refill it with clean
water solution containing 2% pure soda for washing till the water is clean, and add clean hot water (at
temperature of 80℃ to 90℃) till the discharged water is clean.
Cleaning with water containing soda is proposed once intercooler is externally polluted by oil stains. In
detail, submerge the parts with oil stain into soda solution and eliminate oil stain by means of brush till
intercooler is completely clean.
After cleaning, dry internal parts of intercooler or naturally dry or keep intercooler and engine connec-
ting pipe disconnected temporarily during fitting intercooler by using compressed air, start engine and
keep it running till no water flows from intercooler air outlet and then connect induction pipe of engine.
If intercooler core is seriously polluted, please check whether air filter and induction pipe suffer from
leakage and remove failures.
Clutch-
Clutch
Cluch control mechanism................................................ 2

Clutch-
Cluch control mechanism

Components(2.5TCI Left Hand Drive)
25-30
Clutch master cylinder pipe
Hex flange nut

23±3
Clutch master cylinder
Pipe clip
20
Clutch release cylinder (with transmission)
Snap ring Spring clip
Clutch hose
Hex bolt assembly (with transmission)

Bolt with hole for hose connection
35±2
Seal washer
N·m :specified torque

Transmission (5DYG) MT-
Transmission (5DYG)
Page
Overview.................................................................... MT-73
Transmission Assembly......................................... MT-73
Areas of Importance.............................................. MT-73
Problem Diagnosis................................................. MT-73
Technical Parameters................................................. MT-74
Proper Use and Care................................................. MT-74
Troubleshooting.......................................................... MT-75
Transmission Removal............................................... MT-75
Transmission Installation............................................ MT-78
Technical Specifications for Adjustment..................... MT-90
Installation Precautions.............................................. MT-90
Threaded Part Tightening Torque Table..................... MT-91
MT- Transmission (5DYG)
Overview
Transmission Assembly
The 5DYG vehicle transmission is a triaxial step mechanical transmission. The forward gear has adopted the in-
ertia synchronizer gear-shifting mechanism, which offers smooth and easy gear shifting, reduces noise dramati-
cally, and improves the gear service life.
3rd gear 1st gear

Manipulation lid Shift lever
3rd & 4th gear sleeve 2nd gear 5th gear
1st & 2nd
gear sleeve
Output shaft
5th gear
Odometer
Front cover Reverse sleeve
gear shaft
Case
Input shaft Reverse
Intermediate shaft Inermediate Rear body
gear idler
plate
Clutch housing Intermediate

5th gear
Areas of Importance
Pay attention to the items below when using surface sealing materials:
1. When applied after removal, first remove the sealant overflowing from the junction surface and the in-
side with a scraper.
2. The joint surface should be free of oil, dirt, and other contaminants.
3. The coating position is the center of the sealing face. In case of holes, apply the sealant to the center
of the inside.
4. The amount of sealant should be such that a uniform sealant film is formed on the joint surface and
a small amount overflows the periphery after installation. The rubber line should be continuous and
have a cross-sectional diameter of around φ1.2.
5. Tighten the bolt within 10 minitues after sealant application and installation.
Problem Diagnosis
Symptom Possible cause Troubleshooting Page
Difficult or unable to The input shaft spline is dirty or Repair as required
shift gears has adhesions Disassemble and check the 4
Transmission malfunction transmission
Disassemble and check the
Transmission disengaged Transmission malfunction 4
transmission
Technical Parameters
Center distance (mm) 72
Input torque (N·m) 200
Net weight (kg) 40.2
1st 2nd 3rd 4th 5th Rev
Variable speed ratio
3.992 2.15 1.334 1.00 0.862 4.22
Odometer speed ratio 18/6
Lubricant type Lubricant 75W/90 (GL-4)

Lubricant capacity (L) 2.4
Match engine 4G63/4G64/4G69
Control type Floor control
1st 3rd 5th
Gear mode
2nd 4th Rev
Proper Use and Care

1. Correct gear shifting
(a) Choose an appropriate opportunity to shift gears properly according to the vehicle speed and road condi-
tion. During gear shifting, separate the clutch sufficiently and shift the gear gently, not excessively, in order
to avoid synchronization failure.
(b) To avoid breaking the teeth, do not start at a high speed.
(c) To avoid premature abrasion of the gear shift fork, do not always rest your hand on the shift lever while
driving.
(d) When backing the vehicle, to avoid gear shifting noise and gear damage, stop the vehicle before shifting
gears.
2. Sufficient lubrication
(a) Use the specified lubricant, whose number is: SAE 75W/90 GL-4. Do not use an unqualified lubricant. Do
not mix lubricants of different numbers.
(b) The product adopts a splash lubrication method. Add lubricant (2.4 L) according to the requirements, i.e.,
park the vehicle on a flat road surface and add lubricant until the liquid level is flush with the oil filler.
(c) For new vehicles (in the break-in period), the transmission's lubricant should be replaced after 1,500 km.
3. Three-level maintenance
(a) During the first level of maintenance, the liquid level of the lubricant should be checked. If not sufficient,
add lubricant to the specified position. Check and clean the breather plug to make it clean and expedite the
maintenance. If the breather plug is clogged, transmission leakage will occur.
(b) Level-two maintenance: The transmission's lubricant should be replaced the first time that the vehicle un-
dergoes the second level of maintenance. The quality of the lubricant should be inspected during the future
second level of maintenance practises. The lubricant should be replaced if diluted, gummy, or dirty.
(c) During the third level of maintenance, it should be removed for inspection, cleaning, and oil changing.
Troubleshooting
Symptom Possible cause Troubleshooting
Damaged bearing Replace the bearing
Gear surface has been knocked or has pitting corrosion Repair or replace the gear
The axial position or clearance of the gear is improper, or
Check, repair, and adjust
Noise is too loud internal components knock each other
or abnormal Lubricant level too low or insufficient lubrication Fill oil to the marked level
Replace with the specified lu-
The lubricant used does not meet the quality requirements
bricant
Damage of the components in the clutch Check, repair, and adjust
Improper adjustment and insufficient separation of the
Adjust
Difficult gear clutch
engagement Improper adjustment of the control mechanism Adjust
Serious abrasion of the synchronizer ring Replace the gear ring
The oil seal is worn or damaged Replace the oil seal
Too much oil is added, oil level too high Check and adjust
Leakage Non-uniform application of sealant or damaged gasket Recoat or replace the gasket
Joint surface damaged and not repaired in time Repair
Breather plug blocked Clean and penetrate
The gear sleeve or joint tooth is seriously worn out Replace
The control mechanism is installed improperly or damaged Check, adjust, or replace
Gear disengage- The fork is seriously deformed or worn out Replace
ment The positioning spring or steel ball is seriously deformed or
Check and replace
damaged
Too much gear axial clearance Check and adjust
Wrong gear The interlocking pin is lost or seriously damaged Replace
Insufficient lubrication or unqualified lubricant Check and replace
Abnormal failure Lubricant is too dirty Replace
of the bearing Poor cleanliness of the parts in the case Clean
Unqualified bearing Replace
Transmission Removal
1. Remove the clutch housing, front cover subassembly, input shaft and intermediate shaft front bearing
stopper ring, manipulation rod assembly, manipulation lid subassembly, position mechanism subas-
sembly, rear body subassembly (before removing the rear body subassembly, the 5th gear positioning
steel ball, spring, and shift shaft set screw should be removed), and the case in sequence. This is the
reverse of transmission installation steps 19 – 29.
2. Remove the control part of the intermediate plate subassembly (take out the positioning plug, spring,
steel ball, fork set screw, elastic spring, fork shaft, and fork of each gear in sequence). Refer to the
figure for details.
The steps are as follows:
(a) Remove the fork shaft positioning plugs, springs, and

steel balls.
(b) Remove the shift fork lock pin subassemblies, elastic

cylindrical pins, 1st & 2nd gear shift fork set screws,
and grip rings. When removing the shift fork lock pin
subassemblies and elastic cylindrical pins, use a punch
smaller than Φ5 (for example, Φ4.5) to knock out the
pin from the other side as shown in the figure.
(c) Remove the 5th reverse gear shift fork shaft, 5th gear
shift fork shaft, and 5th gear shift fork in sequence.
(d) Take out the interlocking steel ball in the 5th reverse
gear shift guide block and the interlocking steel ball
in the intermediate plate. Remove the 5th reverse gear
shift guide block, reverse gear shift fork shaft, and re-
verse gear shift block arm subassembly. After removing
the reverse gear shift fork shaft, take out the interlock-
ing guide pin.
(e) Take out the interlocking pin, remove the 1st & 2nd
gear shift fork shaft, and then take out the interlocking
guide pin.
(f) Take out the short interlocking pin and remove the 3rd
& 4th gear shift fork shaft, 1st & 2nd gear shift fork,
and the 3rd & 4th gear shift fork.
3. Remove the operating components of the intermediate

plate subassembly.
(a) Remove the intermediate shaft rear shaft retainer, 5th
gear coupling gear, intermediate shaft 5th gear subas-
sembly, intermediate 5th gear needle bearing, 5th gear
thrust washer, and steel ball (Φ6.35) in sequence.
(b) Remove the odometer drive gear retainer, odometer

drive gear, output shaft rear bearing plate, and output
shaft rear bearing stopper ring in sequence.
(c) Remove the reverse gear arm bracket subassembly and

reverse gear idler shaft plate. Then remove the reverse
gear idler subassembly and reverse gear idler shaft.
(d) Remove the intermediate shaft subassembly and its rear

bearing.
(e) Remove the input shaft subassembly (be careful not

to lose the needles in the shaft) and the 3rd & 4th gear
synchronizer ring.
(f) Remove the output shaft subassembly.
4. Finally, disassemble the shafts in sequence as shown

in the figure. Refer to the aftermentioned transmission
installation (the disassembly sequence is the reverse
of the installation sequence).
Transmission Installation
1. Install the output shaft assembly.
(a) As shown in the figure, install the 3rd & 4th gear syn-
chronizer subassembly, then install the 3rd gear needle
bearing, 3rd gear subassembly, 3rd, 4th & 5th gear
synchronizer ring, and the 3rd & 4th gear synchronizer
subassembly in sequence. Finally install the 3rd & 4th
gear hub shaft retainer.
Caution: The side with a 45º step of the 3rd & 4th gear
synchronizer gear hub should be directed towards the
input shaft. The side with a big chamfer of the 3rd & 4th
gear synchronizer gear sleeve should be directed to-
wards the input shaft. The openings of the two 3rd & 4th
gear synchronizer spring expansion rings should alter-
nate.
(b) As shown in the figure, install the 1st & 2nd gear syn-
chronizer subassembly, install the 2nd gear needle bear-
ing, 2nd gear subassembly, 1st & 2nd gear synchronizer
ring, and the 1st & 2nd gear synchronizer subassembly
in sequence. Coat the steel ball (Φ6.35) with grease
and install it into the output shaft, and then install the
1st gear, 1st gear sleeve, bearing, and 5th gear. Finally,
install the 5th gear shaft retainer.
Caution: The installation direction of the 1st & 2nd gear
synchronizer subassembly in relation to the output
shaft should be such that the side with fork slot is di-
rected towards the intermediate plate and the openings
of the two 1st & 2nd gear synchronizer spring expan-
sion rings alternate.
2. Install the output shaft into the intermediate plate.

(a) Pull the output shaft and at the same time tap on the
intermediate plate to install the output shaft into the in-
termediate plate.
(b) Install the output shaft rear bearing stopper ring with
clasp pliers.
Remark: The stopper ring should be pressed closely against
the surface of the intermediate plate.
3. Install the input shaft into the output shaft.

(a) Install the input shaft bearing on the input shaft and use
clasp pliers to install the input shaft retainer.
(b) Coat 13 needle bearings with grease, install the needle

rollers into the input shaft, and then place the 3rd, 4th
& 5th gear synchronizer ring.
Align (c) Install the input shaft into the output shaft, aligning the
three grooves of the synchronizer ring with the syn-
chronizer slider.
4. Install the intermediate shaft into the intermediate plate.

(a) Install the stopper ring on the intermediate shaft rear
bearing.
(b) Install the intermediate shaft into the intermediate plate

and, at the same time, hold the intermediate shaft and
install the intermediate shaft rear bearing.
SST
5. Install the rear bearing plate.

Install and tighten the screw with a torque socket wrench.
Tightening torque: See the table
MT-10 Transmission (5DYG)
6. Install the reverse gear idler and shaft.

(a) Install the reverse gear idler and shaft.
(b) Install the reverse gear idler shaft plate and tighten the
bolt.
7. Install the reverse gear arm bracket.

Place two small hollow position pins on the intermediate
plate, install the reverse gear arm bracket, and tighten 2 bolts.
8. Install the lock ball and 5th gear thrust washer.
Lock ball
9. Install the intermediate shaft 5th gear with 5th gear en-
gagement sleeve assembly and needle bearing.
(a) Install the intermediate shaft 5th gear assembly as
shown in the figure.
Caution: The side with chamfer of the spline in the syn-
chronizer gear sleeve should be directed towards the
rear body. The openings of the two synchronizer spring
expansion rings should alternate.
Transmission (5DYG) MT-11
(b) Coat the needle bearing with gear oil.

(c) Install the intermediate shaft 5th gear with the 5th gear
engagement sleeve and needle bearing.
10. Install the synchronizer ring and 5th gear coupling gear.
(a) Put the synchronizer ring on the conical surface of the
5th gear coupling gear.
(b) Remove the intermediate plate from the table vice.

(c) As shown in the figure, place the transmission upright
and install the 5th gear coupling gear, aligning the syn-
chronizer ring groove with the synchronizer slider.
(d) Select a split ring which can minimize the axial clear-
ance.
(e) Use a copper rod and hammer to install the split ring.
11. Measure the axial clearance of the intermediate shaft

5th gear.
Measure the axial clearance of the intermediate shaft 5th
gear with a feeler gauge.
Standard clearance: 0.1-0.3
Maximum clearance: 0.3
12. Install the 3rd & 4th gear shift fork shaft and 1st & 2nd
gear and 3rd & 4th gear shift forks.
(a) Install the 1st & 2nd gear and 3rd & 4th gear shift
forks. Install the 3rd & 4th gear shift fork shaft into the
intermediate plate and shift fork.
(b) Use a punch and hammer to install the shift fork lock
pin subassembly.
13. Install the 1st & 2nd gear shift fork shaft and 1st & 2nd
gear shift fork.
(a) Coat the interlocking guide pin with MP grease and in-
stall it on the 1st & 2nd gear shift fork shaft.
(b) Use a magnetic rod to install the short interlocking pin

into the intermediate plate. Install the 1st & 2nd gear
shift fork shaft into the 1st & 2nd gear shift fork and
intermediate plate.
(c) Install the 1st & 2nd gear shift mounting bolt and tight-
en the bolt.
14. Install the reverse gear shift fork shaft, reverse gear
shift lever, reverse gear arm and shift block.
(a) Install the reverse gear shift block on the reverse gear
arm and attach it with a split ring. Install the reverse
gear shift lever on the reverse gear arm and fix it with an
E-ring. Install the open end of the reverse gear arm on
the reverse gear arm bracket.
(b) Coat the interlocking guide pin with MP grease and in-
stall it on the reverse gear shift fork shaft.
(c) Use a magnetic rod to install the short interlocking pin

into the intermediate plate. Install the reverse gear shift
fork shaft into the reverse gear shift lever and interme-
diate plate.
15. Install the 5th reverse gear shift guide block, 5th gear
shift fork, and the 4th & 5th gear shift fork shaft.
(a) Install the 5th reverse gear shift guide block on the re-
verse gear shift fork shaft. Install the 5th gear shift fork.
(b) Use a magnetic rod to install the lock ball into the 5th
reverse gear shift guide block. Install the 5th gear shift
fork shaft as shown in the figure.
(c) Use a magnetic rod to install the interlocking steel ball

into the intermediate plate. Install the 5th gear shift
fork shaft into the intermediate plate.
(d) Install the 1st & 2nd gear shift mounting bolt and tight-
en the bolt.
(e) Install the 5th reverse gear shift fork shaft into the 5th
reverse gear shift guide block and intermediate plate.
(f) Use a punch and hammer to knock the elastic cylindri-

cal pin in the 5th reverse gear shift guide block.
16. Install the shift fork shaft split rings and use a steel rod
and hammer to knock in the split rings (3).
17. Install the lock ball, spring, and plug.

(a) Install the lock balls and springs (4 lock balls and 4
springs).
Remark: Install the short spring on the bottom of the inter-
mediate plate.
5th speed
(b) Coat the thread of the plug with sealant. Install and
tighten the plug with a torque socket wrench.
18. Install the odometer drive gear.

19. Install the transmission case.

(a) As shown in the figure, coat the transmission case with
sealing material.
Sealing
material
(b) As shown in the figure, place the intermediate plate up-

right.
(c) As shown in the figure, install the transmission case on
the intermediate plate.
(d) Use clasp pliers to install the 2 stopper rings on the in-
put shaft bearing and intermediate shaft front bearing.
20. Install the front cover.

Coating
Coat the thread of the bolt with sealant.
Install and tighten the bolt.
21. Install the rear body, shift shaft, and shift block.
(a) Before closing the case, install the components in the
Sealing rear body, such as the limiting mechanism and oil drain
material
slot.
(b) As shown in the figure, coat the rear body with sealing
material.
(c) Install the shift shaft with shift lever into the rear body.
Do not put it in place. Engage the 3rd gear of the trans-
mission.
(d) Put in the shift block from the opening of the rear case
so that the shift shaft is put through the shift block. Do
not tighten the bolt for the moment.
(e) Insert the shift lever into the 3rd & 4th gear fork shaft
groove, align the 5th reverse gear shift fork shaft with the
rear case mounting hole, and then push in the rear case.
(f) Install and tighten the rear body bolt.
(g) Install and tighten the shift block bolt.

22. Install the 5th gear self-locking steel ball, spring, and
plug.
(a) Coat the thread of the plug with sealant.
(b) Install the lock ball, spring, and plug.
23. After installing the rear body or transmission case,

check the following items:
(a) Check whether the rotation of the input shaft and out-
put shaft is flexible.
(b) Check whether the gear shifting is clear and reliable
and whether there is a reverse gear lock function.
24. Install the position mechanism subassembly.

25. Install the reverse gear switch.

26. Install the transmission manipulation lid of the trans-

mission.
(a) Apply sealant before installing the transmission ma-
nipulation lid.
(b) Install and tighten the bolt.
27. Install the odometer driven gear.

(a) Install the speedometer driven gear.
Tightening torque: See the bolt tightening torque table
28. Install the external parts: Oil filling/drain plug, breather

plug, manipulation rod.
29. Inspection.
Technical Specifications for Adjustment

Check the synchronizer ring allowance δ of each gear ac-
cording to the table below.
Shift position 1st & 2nd gear 3rd, 4th & 5th gear
Standard clear-
1–2 1–2
ance (mm)
Limit clearance
0.8 0.8
(mm)
Check the clearance of each gear according to the table below.

Shift position 1st, 2nd & 3rd 5th gear
gear
Axial clearance 0.1 – 0.25 0.1 – 0.3
(mm)
Installation Precautions
1. All oil seals, shaft retainers, and elastic pins should not
be reused.
2. Keep all parts clean and free of dust, chips, rust corro-
sion, oil build-up, or any other contaminants.
3. All rubbing surfaces must be coated with lubricant.
4. The openings of all oil seals should be coated with
grease and each oil seal should be pressed in vertically.
5. During installation of the bearings, do not use any kind
of rolling element to transmit pressure.
6. During the installation of synchronizer components, the
two sides of the spring piston's openings should alter-
nate.
7. During the transportion and installation of the assem-
bly, engage a gear and never erect the assembly or
subject it to strong impacts in the neutral position.
Threaded Part Tightening Torque Table

Fastening piece designation Quantity Tightening torque (N·m)
1st & 2nd gear shift fork set screw 1 13-17
Odometer bracket bolt with washer 1 15-20
Reverse gear arm bracket bolt with washer 2 17-22
Output rear bearing plate lobular screw 4 17-22

Reverse gear idler shaft plate (and intermediate
1 15-20
plate) hexagon head bolt with washer
Front cover hexagon head bolt with washer 8 15-20
Manipulation lid hexagon head bolt with washer 6 15-20
Case, intermediate plate, and rear body bolts 7 30-45
Positioning spring plug 6 17-22
Reverse gear switch 1 30-50
Oil filling plug 1 30-50
Oil drain plug 1 30-50
Oil drain slot hexagon head bolt with washer 1 15-20
Oil box hexagon head bolt with washer 2 5-10
Gear shift block set bolt 1 15-20
Position mechanism assembly 2 30-50

Transmission (5DYM26) MT-�

Transmission (5DYM26)
Page
Overview....................................................................... MT-93
Transmission Assembly............................................ MT-93
Areas of Importance................................................. MT-93
Problem Diagnosis................................................... MT-93
Technical Parameters................................................... MT-94
Proper Use and Care................................................... MT-94
Troubleshooting............................................................. MT-95
Transmission Removal.................................................. MT-95
Transmission Installation............................................... MT-98
Technical Specifications for Adjustment...................... MT-109
Installation Precautions............................................... MT-109
Threaded Part Tightening Torque Table...................... MT-110
MT-�
Overview
Transmission Assembly
The 5DYM26 vehicle transmission is a tri-axial step mechanical transmission. The forward gear has adopted the
inertia synchronizer gear-shifting mechanism, which offers smooth and easy gear shifting, reduces noise dra-
matically, and improves the gear service life.
Manipulation lid Shift lever
3rd gear 1st gear

Clutch housing 3rd & 4th
2nd gear 5th gear
gear sleeve
1st & 2nd
gear sleeve
Output shaft
5th gear sleeve

Reverse Rear body
gear shaft
Front cover Case Intermediate
Reverse plate assy
Input shaft gear idler
Intermediate shaft Intermediate 5th gear
Areas of Importance
Pay attention to the items below when using surface sealing materials:
1. When applied after removal, first remove the sealant overflowing from the junction surface and the in-
side with a scraper.
2. The joint surface should be free of oil, dirt, and other contaminants.
3. The coating position is the center of the sealing face. In case of holes, apply the sealant to the center
of the inside.
4. The amount of sealant should be such that a uniform sealant film is formed on the joint surface and
a small amount overflows the periphery after installation. The rubber line should be continuous and
have a cross-sectional diameter of around Φ1.2.
5. Tighten the bolt within 10 minitues after sealant application and installation.
Problem Diagnosis
Symptom Possible cause Troubleshooting Page
Difficult or unable to shift The input shaft spline is Repair as required
gears dirty or has adhesions
Transmission malfunction Disassemble and check the transmission 4
Transmission demeshing Transmission malfunction Disassemble and check the transmission 4

Center distance (mm) 72
Input torque (N·m) 200
Net weight (kg) 42
1st 2nd 3rd 4th 5th Rev
Variable speed ratio
3.992 2.15 1.334 1.00 0.862 4.22
Lubricant number 75W/90 GL-4
Lubricant capacity (L) 2.5
Match engine 4G63/4G64/4G69
Control type Floor control
1st 3rd 5th
Gear mode
2nd 4th Rev
Proper Use and Care

1. Correct gear shifting
(a) Choose an appropriate opportunity to shift gears properly according to the vehicle speed and road condi-
tion. During gear shifting, separate the clutch sufficiently and shift the gear gently, not excessively, in order
to avoid synchronization failure.
(b) To avoid breaking the teeth, do not start with high speed.
(c) To avoid premature abrasion of the gear shift fork, do not always rest your hand on the shift lever while
driving.
(d) When backing the vehicle, to avoid gear shifting noise and gear damage, stop the vehicle before shifting
gears.
2. Sufficient lubrication
(a) Use the specified lubricant, whose number is: 75W/90 GL-4. Do not use an unqualified lubricant. Do not
mix lubricants of different numbers.
(b) The product adopts a splash lubrication method. Add lubricant (2.5 L) according to the requirements, i.e.,
park the vehicle on a flat road surface and add lubricant until the liquid level is flush with the oil filler.
(c) For new vehicles (in the run-in period), the transmission's lubricant should be replaced after 1,500 km.
3. Three-level maintenance
(a) During the first level of maintenance, the liquid level of the lubricant should be checked. If not sufficient,
add lubricant to the specified position. Check and clean the breather plug to make it clean and expedite. If
the breather plug is clogged, transmission leakage will occur.
(b) Level-two maintenance: The transmission's lubricant should be replaced the first time that the vehicle un-
dergoes the second level of maintenance. The quality of the lubricant should be inspected during the future
second level of maintenance practices. The lubricant should be replaced if diluted, gummy, or dirty.
(c) During the third level of maintenance, it should be removed for inspection, cleaning, and oil changing.
MT-�
Troubleshooting
Symptom Possible cause Troubleshooting
Damaged bearing Replace the bearing
The gear surface has been knocked or has corrosive pitting Repair or replace the gear
The axial position or clearance of the gear is improper, or
Check, repair, and adjust
Noise is too loud internal components knock each other
or abnormal Lubricant level too low or insufficient lubrication Fill oil to the marked level
Replace with the specified
The lubricant used does not meet the quality requirements
lubricant
Damage of the components in the clutch Check, repair, and adjust
Improper adjustment and insufficient separation of the
Adjust
Difficult gear clutch
engagement Improper adjustment of the control mechanism Adjust
Serious abrasion of the synchronizer ring Replace the gear ring
The oil seal is worn or damaged Replace the oil seal
Too much oil is added, oil level too high Check and adjust
Leakage Non-uniform application of sealant or damaged gasket Recoat or replace the gasket
Joint surface damaged and not repaired in time Repair
Breather plug blocked Clean and penetrate
The gear sleeve or joint tooth is seriouly worn out Replace
The control mechanism is installed improperly or dam-
Check, adjust, or replace
aged
Gear disen-
The shift fork is seriously deformed or worn out Replace
gagement
The positioning spring or steel ball is seriouly deformed
Check and replace
or damaged
Too much gear axial clearance Check and adjust
Wrong gear The interlocking pin is lost or seriously damaged Replace
Insufficient lubrication or unqualified lubricant Check and replace
Abnormal
Lubricant is too dirty Replace
failure of the
Poor cleanliness of the parts in the case Clean
bearing
Unqualified bearing Replace
Transmission Removal
1. Remove the clutch housing, front cover subassembly, input shaft, and intermediate shaft front bearing
stopper ring, manipulation rod assembly, manipulation lid subassembly, position mechanism subas-
sembly, rear body subassembly (before removing the rear body subassembly, the 5th gear positioning
steel ball, spring and shift shaft set screw should be removed), and the case in sequence. This is the
reverse of transmission installation steps 19 – 29.
2. Remove the control part of the intermediate plate subassembly (take out the positioning plug, spring,
steel ball, fork set screw, elastic spring, fork shaft, and fork of each gear in sequence). Refer to the fig-
ure for details.
The steps are as follows:

(a) Remove the fork shaft positioning plugs, springs, and

steel balls.
(b) Remove the shift fork lock pin subassemblies, elastic

cylindrical pins, 1st & 2nd gear shift fork set screws,
and grip rings. When removing the shift fork lock pin
subassemblies and elastic cylindrical pins, use a punch
smaller than Φ5 (for example, Φ4.5) to knock out the
pin from the other side as shown in the figure.
(c) Remove the 5th reverse gear shift fork shaft, 5th gear
shift fork shaft, and 5th gear shift fork in sequence.
(d) Take out the interlocking steel ball in the 5th reverse
gear shift guide block and the interlocking steel ball
in the intermediate plate. Remove the 5th reverse gear
shift guide block, reverse gear shift fork shaft, and re-
verse gear shift block arm subassembly. After removing
the reverse gear shift fork shaft, take out the interlock-
ing guide pin.
(e) Take out the interlocking pin, remove the 1st & 2nd
gear shift fork shaft, and then take out the interlocking
guide pin.
MT-�
(f) Take out the short interlocking pin and remove the 3rd
& 4th gear shift fork shaft, 1st & 2nd gear shift fork,
and 3rd & 4th gear shift fork.
3. Remove the operating components of the intermediate

plate subassembly.
(a) Remove the intermediate shaft rear shaft retainer, 5th
gear coupling gear, intermediate shaft 5th gear subas-
sembly, intermediate 5th gear needle bearing, 5th gear
thrust washer, and steel ball (Φ6.35) in sequence.
(b) Remove the output shaft rear bearing plate and output
shaft rear bearing stopper ring in sequence.
(c) Remove the reverse gear arm bracket subassembly and

reverse gear idler shaft plate. Then, remove the reverse
gear idler subassembly and reverse gear idler shaft.
(d) Remove the intermediate shaft subassembly and its rear

bearing.

(e) Remove the input shaft subassembly (be careful not

to lose the needles in the shaft) and the 3rd & 4th gear
synchronizer ring.
(f) Remove the output shaft subassembly.
4. Finally, disassemble the shafts in sequence as shown

in the figure. Refer to the aftermentioned transmission
installation (the disassembly sequence is the reverse
of the installation sequence).
Transmission Installation
1. Install the output shaft assembly.
(a) As shown in the figure, install the 3rd & 4th gear syn-
chronizer subassembly, then install the 3rd gear needle
bearing, 3rd gear subassembly, 3rd, 4th & 5th gear
synchronizer ring, and the 3rd & 4th gear synchronizer
subassembly in sequence, and finally install the 3rd &
4th gear hub shaft retainer.
Caution: The side with a 45º step of the 3rd & 4th gear
synchronizer gear hub should be directed towards the
input shaft. The side with a big chamfer of the 3rd &
4th gear synchronizer gear sleeve should be directed
towards the input shaft. The openings of the two 3rd &
4th gear synchronizer spring expansion rings should
alternate.
MT-�
(b) As shown in the figure, install the 1st & 2nd gear syn-
chronizer subassembly, install the 2nd gear needle bear-
ing, 2nd gear subassembly, 1st & 2nd gear synchronizer
ring, and the 1st & 2nd gear synchronizer subassembly
in sequence. C��
oat the steel ball (Φ6.35) with grease
and install it into the output shaft and then install the
1st gear, 1st gear sleeve, bearing and 5th gear. Finally,
install the 5th gear shaft retainer.
Caution: The installation direction of the 1st & 2nd gear
synchronizer subassembly in relation to the output
shaft should be such that the side with fork slot is di-
rected towards the intermediate plate and the openings
of the two 1st & 2nd gear synchronizer spring expan-
sion rings alternate.
2. Install the output shaft into the intermediate plate.

(a) Pull the output shaft and at the same time tap on the
intermediate plate to install the output shaft into the in-
termediate plate.
(b) Install the output shaft rear bearing stopper ring with
clasp pliers.
Remark: The stopper ring should be pressed closely against
the surface of the intermediate plate.
3. Install the input shaft into the output shaft.

(a) Install the input shaft bearing on the input shaft and use
clasp pliers to install the input shaft retainer.

(b) Coat the 13 needle bearings with grease, install the

needle rollers into the input shaft, and then set the 3rd,
4th & 5th gear synchronizer ring.
(c) Install the input shaft into the output shaft, aligning the
Align
three grooves of the synchronizer ring with the syn-
chronizer slider.
4. Install the intermediate shaft into the intermediate plate.

(a) Install the stopper ring on the intermediate shaft rear
bearing.
(b) Install the intermediate shaft into the intermediate plate

and, at the same time, hold the intermediate shaft and
install the intermediate shaft rear bearing.
SST
5. Install the rear bearing plate.

Install and tighten the screw with a torque socket wrench.
MT-��
10 Transmission (5DYM26)
6. Install the reverse gear idler and shaft.

(a) Install the reverse gear idler and shaft.
(b) Install the reverse gear idler shaft plate and tighten the
bolt.
7. Install the reverse gear arm bracket.

Place two small hollow position pins on the intermediate
plate, install the reverse gear arm bracket, and tighten 2 bolts.
8. Install the lock ball and 5th gear thrust washer.
Lock ball
9. Install the intermediate shaft 5th gear with the 5th gear
engagement sleeve assembly and needle bearing.
(a) Install the intermediate shaft 5th gear assembly as
shown in the figure.
Caution: The side with the chamfer of the spline in the
synchronizer gear sleeve should be directed towards
the rear body. The openings of the two synchronizer
spring expansion rings should alternate.
Transmission (5DYM26) MT-��
11
(b) Coat the needle bearing with gear oil.

(c) Install the intermediate shaft 5th gear with the 5th gear
engagement sleeve and needle bearing.
10. Install the synchronizer ring and 5th gear coupling gear.
(a) Put the synchronizer ring on the conical surface of the
5th gear coupling gear.
(b) Remove the intermediate plate from the table vice.

(c) As shown in the figure, place the transmission upright
and install the 5th gear coupling gear, aligning the syn-
chronizer ring groove with the synchronizer slider.
(d) Select a split ring which can minimize the axial clear-
ance.
(e) Use a copper rod and hammer to install the split ring.
MT-��
11. Measure the axial clearance of the intermediate shaft

5th gear.
Measure the axial clearance of the intermediate shaft 5th
gear with a feeler gauge.
Standard clearance: 0.1-0.3
Maximum clearance: 0.3
12. Install the 3rd & 4th gear shift fork shaft and the 1st &
2nd gear and 3rd & 4th gear shift forks.
(a) Install the 1st & 2nd gear and 3rd & 4th gear shift
forks. Install the 3rd & 4th gear shift fork shaft into the
intermediate plate and shift fork.
(b) Install and tighten the fork set screw with a torque
socket wrench.
13. Install the 1st & 2nd gear shift fork shaft and 1st & 2nd
gear shift fork.
(a) Coat the interlocking guide pin with grease and install
it on the 1st & 2nd gear shift fork shaft.
(b) Use a magnetic rod to install the short interlocking pin

into the intermediate plate. Install the 1st & 2nd gear
shift fork shaft into the 1st & 2nd gear shift fork and
intermediate plate.
13
(c) Install the 1st & 2nd gear shift fork mounting bolt and
tighten the bolt.
14. Install the reverse gear shift fork shaft, reverse gear
shift lever, reverse gear arm and shift block.
(a) Install the reverse gear shift block on the reverse gear
arm and attach it with a split ring. Install the reverse
gear shift lever on the reverse gear arm and attach it
with an E-ring. Install the open end of the reverse gear
arm on the reverse gear arm bracket.
(b) Coat the interlocking guide pin with grease and install
it on the reverse gear shift fork shaft.
(c) Use a magnetic rod to install the short interlocking pin

into the intermediate plate. Install the reverse gear shift
fork shaft into the reverse gear shift lever and interme-
diate plate.
15. Install the 5th reverse gear shift guide block, 5th gear
shift fork, 5th gear shift fork shaft, and 5th reverse gear
shift fork shaft.
(a) Install the 5th reverse gear shift guide block on the
reverse gear shift fork shaft. Install the 5th gear shift
fork.
MT-��
(b) Use a magnetic rod to install the lock ball into the 5th
reverse gear shift guide block. Install the 5th gear shift
fork shaft as shown in the figure.
(c) Use a magnetic rod to install the interlocking steel ball

into the intermediate plate. Install the 5th gear shift
fork shaft into the intermediate plate.
(d) Install the 1st & 2nd gear shift set screw and tighten the
screw.
(e) Install the 5th reverse gear shift fork shaft into the 5th
reverse gear shift guide block and intermediate plate.
(f) Use a punch and hammer to knock the elastic cylindri-

cal pin in the 5th reverse gear shift guide block.
15
16. Install the shift fork shaft split rings and use a steel rod
and hammer to knock in the split rings (3).
17. Install the lock ball, spring, and plug.

(a) Install the lock balls and springs (4 lock balls and 4
springs).
Remark: Install the short spring on the bottom of the inter-
mediate plate.
5th speed
(b) Coat the thread of the plug with sealant. Install and
tighten the plug with a torque socket wrench.
18. Install the transmission case.

(a) As shown in the figure, coat the transmission case with
sealing material.
Sealing
material
MT-��
(b) As shown in the figure, place the intermediate plate up-

right.
(c) As shown in the figure, install the transmission case on
the intermediate plate.
(d) Use clasp pliers to install the 2 stopper rings on the in-
put shaft bearing and intermediate shaft front bearing.
19. Install the front cover.

Coating:
Coat the thread of the bolt with sealant.
Install and tighten the bolt.
20. Install the rear body, shift shaft, and shift block.
(a) Before closing the case, install the components in the
Sealing rear body, such as the limiting mechanism and guide
material nozzle.
(b) As shown in the figure, coat the rear body with sealing
material.
(c) First, put the shift shaft into the rear body from the hole
on the back end of the rear body, then use a punch and
hammer to knock the elastic cylindrical pin into the
connecting hole between the shift lever and the shift
shaft through the hole of the rear body to connect the
shift shaft with the shift lever, finally put on the plug.
After that, engage the 3rd gear of the transmission.
(d) Put in the shift block from the opening of the rear case
so that the shift shaft is put through the shift block. Do
not tighten the bolt for the moment.
17
(e) Insert the shift lever into the 3rd & 4th gear fork shaft
groove, align the 5th reverse gear shift fork shaft with the
rear case mounting hole, and then push in the rear case.
(f) Install and tighten the rear body bolt.
(g) Install and tighten the shift block bolt.
(h) Put a bowl-shaped tabular plug in the hole on the back
end of the rear body.
21. Install the 5th gear self-locking steel ball, spring, and
plug.
(a) Coat the thread of the plug with sealant.
(b) Install the lock ball, spring, and plug.
22. After installing the rear body or transmission case, check

the following items:
(a) Check whether the rotation of the input shaft and out-
put shaft is flexible.
(b) Check whether the gear shifting is clear and reliable
and whether there is a reverse gear lock function.
23. Install the position mechanism subassembly.

24. Install the reverse gear switch.

25. Install the transmission manipulation lid of the trans-
mission.
(a) Apply sealant before installing the transmission ma-
nipulation lid.
MT-��
26. Install the external parts: Oil filling/drain plug, breather

plug, and shift lever subassembly.
27. Inspection.
Technical Specifications for Adjustment

Check the synchronizer ring allowance δ of each gear ac-
cording to the table below.
1st & 2nd 3rd, 4th &

Shift position
gear 5th gear
Standard clear-
1–2 1–2
ance (mm)
Limit clear-
0.8 0.8
ance (mm)
Check the gear clearance of each gear according to the table

below.
Shift position 1st, 2nd & 5th gear

3rd gear
Axial clear-
0.1 – 0.25 0.1 – 0.3
ance (mm)
Installation Precautions
1. All oil seals, shaft retainers, and elastic pins should not
be reused.
2. Keep all parts clean and free of dust, chips, rust corro-
sion, oil build-up, or any other contaminants.
3. All rubbing surfaces must be coated with lubricant.
4. The openings of all oil seals should be coated with
grease and each oil seal should be pressed in vertically.
5. During installation of the bearings, do not use any kind
of rolling element to transmit pressure.
6. During the installation of synchronizer components, the
two sides of the spring piston's openings should alter-
nate.
7. During the transportion and installation of the assem-
bly, engage a gear and never erect the assembly or
subject it to strong impacts in the neutral position.
19
Threaded Part Tightening Torque Table

Tightening
Fastening piece name Quantity
torque (N·m)
Gear shift fork set screw 3 13-17
Reverse gear arm bracket bolt with washer 2 17-22
Output rear bearing plate lobular screw 4 17-22
Reverse gear idler shaft plate (and intermediate plate) hexagon

1 15-20
head bolt with washer
Front cover hexagon head bolt with washer 8 15-20
Manipulation lid hexagon head bolt with washer 6 15-20
Positioning spring plug 6 17-22
Reverse gear switch 1 30-50
Oil filling plug 1 30-50
Oil drain plug 1 30-50
Gear shift block set bolt 1 15-20
Position mechanism assembly 2 30-50

Steering System-
Steering System
Components Diagram(4G69 Left-hand Drive)................. 2

Components Diagram(2.5TCI Left-hand Drive)............... 3
Disassembly and Installation of Steering Pipe
Column............................................................................... 4
Disassembly and Installation of Steering Gear.............. 5
Disassembly and Installation of Steering Lower
Transmission Shaft........................................................... 6
Disassembly and Installation of Steering Oil Pump...... 6
Disassembly and Installation of Steering Oil Pipe......... 8
Removal of Steering Oil Tank and Steering Oil Tank
Bracket............................................................................... 9
Steering System-
Steering Drive Device

Components Diagram(4G69 Left-hand Drive)
Fixing screw of cover plate
25±3
Steering pipe column assembly
Cover plate assembly

of steering wheel
25±3
25±3 Hexagon nut and

conic elastic washer
subassembly
Steering wheel body assembly
Lower transmission shaft assembly 120±10
Assembly of power steering gear with tie rod
25±3
Ball head assembly

100±10
160±10
Fuel intake hose 27.5±2.5

Ribbed belt 4PK1100
Power steering oil tank assembly
Power steering oil pump with bracket assembly
17.5±2.5
Inlet oil return pipe stack of power steering gear
Power steering oil tank bracket assembly Hexagon flange bolt

Q1840616FD
N·m ：specified torque
Steering System-
Components Diagram(2.5TCI Left-hand Drive)

25±3

25±3 of steering wheel
25±3 Hexagon nut and

conic elastic washer
subassembly
Lower transmission shaft assembly 120±10

25±3
Ball head assembly
100±10 160±10
Power steering oil pump assembly
Hexagon-head bolt
Q150B1055 Hollow bolt
30±5
Hexagon-head bolt, B worm drive hose

spring washer and plain clamping ring
washer assemblies
Q1461030
6PK ribbed belt
17.5±2.5
Hexagon flange bolt

Q1840616FD
Hexagon flange bolt
Q1840616FD
N·m ：specified torque Inlet oil return pipe stack of power steering gear
Steering System-
Disassembly and Installation of Steering Pipe Column

Hexagon nut and conic elastic washer subassembly
Hexagon flange nut
Q32008FD
Hexagon-head bolt, spring
washer and large washer
assemblies
Q1460825FD(Q40208)
of steering wheel
Hexagon flange bolt
Q1840835
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
transmission shaft assembly by a M10 socket wrench to disconnect them.
(d) 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 instrument panel reinforcement 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 co-
lumn.
(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 soc-
ket wrench.
Tightening Torque: 25±3N•m
(c) Install 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 instrument panel reinforcement by a M13 socket wren-
ch.
Steering System-
Disassembly and Installation of Steering Gear

Hexagon-head bolt
Q150B0832
Spring washer
Q40308
Steering lower transmission
shaft assembly
Split pin
Hexagon slotted nut
Ball head assembly
Plain
washer
Hexagon flange bolt-oversized series Inlet oil return pipe
Q1861225FD I-shaped hexagon nut stack of power steering
Q341B16
Hexagon-head bolt-fine pitch thread
Q151B16190
1. Disassembly
(a) Remove the hexagon-head bolt and spring washer for connecting the steering lower transmis-
sion shaft and steering gear by a M13 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 steering power-assistance oil.
(c) Remove the two hexagon flange bolts-oversized series for connecting the steering gear and ve-
hicle 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 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
then install the I-shaped hexagon nut by a M14 open end wrench and M21 open end wrench.
(f) About installing the ball head assembly, first install it by a M21 socket wrench, then install the
split pin by pliers.
(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 instru-
ment and align the steering wheel.
Steering System-
Disassembly and Installation of Steering Lower Transmission Shaft

Hexagon-head bolt
Hexagon flange bolt
Q150B0832
Q1840835
Spring washer
Q40308

Lower transmission shaft 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-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 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 trans-
mission 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-head bolt and spring washer for connecting the lower transmission shaft ass-
embly and assembly of power steering gear with tie rod by a M13 socket wrench.
Disassembly and Installation of Steering Oil Pump
Hexagon-head bolt and plain gasket
4G69 Left-hand Drive sub-assemblyQ1400820FD
Power steering oil pump bracket
Hexagon flange bolt

Q18408105
Steel-strip elastic clamping ring

Q673B205
Fuel intake hose

Inlet oil return pipe stack of power steering
Steering System-
1. Disassembly
(a) Remove the high pressure fuel pipe for connecting the inlet oil return pipe stack of power stee-
ring 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.
(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 wren-
ch.
(h) Take off the power steering oil pump bracket.
2. Installation
(a) Fasten the Hexagon-head bolt and plain gasket sub-assembly (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 stee-
ring oil pump by a M17 open end wrench.
(g) Fill steering power-assistance fluid as required and completely discharge air in the hydraulic system.
2.5TCI Left-hand Drive Hexagon-head bolt

Q150B1055
Hollow bolt
Hexagon-head bolt,
spring washer and
plain washer assem-
blies Q1461030
Ribbed belt 6PK1510

B worm drive hose clamping ring
Inlet oil return pipe

stack of power steering
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 6PK1510 belt.
(c) Loosen the B worm drive hose clamping ring for connecting the oil return hose of the inlet oil re-
turn 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 dis-
charge 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
steering by a M20 open end wrench or M20 socket wrench.
Steering System-
(f) Take off the power steering oil pump.

2. Installation
(a) Install the power steering oil pump to the correct position.
(b) Install the ribbed belt 6PK1510 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
steering by a M20 open end wrench or M20 socket wrench.
(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.
Disassembly and Installation of Steering Oil Pipe
4G69 Left-hand Drive
Power steering oil tank assembly Fuel intake hose
Power steering oil pump

with bracket assembly
Inlet oil return pipe

Hexagon flange bolt
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-
2.5TCI Left-hand Drive

Hollow bolt
30±5
B worm drive hose clamping ring
17.5±2.5
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 the oil fluid.
(c) Remove the hexagon flange bolt (Q1840616FD) 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 screwdri-
ver.
(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 three 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.
Removal of Steering Oil Tank and Steering Oil Tank Bracket
4G69 Left-hand Drive Power steering oil tank bracket assembly
Steel-strip elastic clamping ring Hexagon flange bolt

Q673B205 Q1840616FD
Fuel intake hose Steel-strip elastic clamping ring

Q673B155

Steering System-10
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.
Body Electrical Appliance (K5)-
Body Electrical Appliance (K5)
Schematic Diagram of Harness Mid-Connection

Numbering and Pin Function 1........................................ 2
No. 1 Fuse Box (gasoline)................................................. 9
No. 2 Fuse Box (gasoline)................................................. 11
Storage Battery/Starter/Generator................................... 13
Engine Electronic Control System.................................. 14
Anti-theft / Airbag.............................................................. 16
ABS EBD Electronic Control System.............................. 17
TCS Electronic Control System....................................... 18
Reversing Radar / Reversing Display.............................. 19
AWD Electronic Control System...................................... 20
Electric Horn / Combination instrument.......................... 21
Cigar Lighter/Power Rear-View Mirror/Rear
wiper/Washer..................................................................... 22
A/C...................................................................................... 24
Power Window................................................................... 25
Electric Heating Power Seat/Power Socket/Sunroof..... 27
New airbag control system............................................... 28
Central Lock System......................................................... 29
Body Control Module ....................................................... 30
Reversing Camera System............................................... 38
Lighting system ................................................................ 40
Schematic Diagram of Harness Relationship and
Plug Connection Numbering............................................ 43
BCM/Lamp/Front washer and wiper................................ 44
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
Connecting the power Connecting the engine

supply harness 1 room harness 1
C02
3 B/R
Connecting the power Connecting the engine

supply harness B room harness 2
C03
Connecting the engine harness 1 Connecting the engine room harness 1
C04
Connecting the engine harness 2 Connecting the engine room harness 2
C05
Connecting the instrument harness 2 Connecting the engine room harness 2


Pin Function 2 C06
318 B01 A42

0.5 0.85
G/B R/P 0.5
Br/G
A42 B01 318
0.5 0.85 0.5 B02 A39
Br/G R/P G/B 0.5
0.85 Br/B
A39 73 B02 B/R
0.5 0.5 0.85
Br/B L/R B/R 38 B03
B03 38 0.85 0.5
0.5 0.85 Y/G B/R
B/R Y/G
106 315 315 106
1.25 2.0 2.0 1.25
L/W Br Br L/W
Connecting the instrument panel Connecting the engine

and console harness 1 room harness 1
C09
315
0.85 2.0 1.25
315 L/W Br L/Y
2.0
Br D44B E44A
D44B E44A 0.85 0.85 1.25
0.85 0.85 R/L R/Y Y
R/L R/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 harness Connecting the 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 0.5
0.85 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 floor harness 2 Connecting the instrument harness 2
C13
517
C/O
0.5
Connecting MT harness assembly Connecting the instrument harness


Pin Function 3 C07
Connecting the instrument harness 4 Connecting the engine room harness 4
C08
Connecting the engine room harness 3
Connecting the instrument harness 3
C11
Connecting Connecting Connecting Connecting

the floor the floor the instrument the instrument
harness 1A harness 1B C12 harness 1A harness 1B
Connecting the instrument harness Connecting the instrument harness

DJ7031-6.3-11 DJ7031-6.3-11

Pin Function 4
C14
504
0.5 1.25 0.85
V/L L/R L/W
50X
0.5 0.85 0.5
W B R/L
Connecting the ceiling harness Connecting the cabin 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
Connecting the right front door harness 1 Connecting the cabin harness 1
C16
E E 0.85 0.85 0.85

0.85 0.85 0.85 W/G B/W B/G
B/G B/W W/G
261
C M B 0.85 2.0 0.85 0.85 2.0
2.0 0.85 0.85 2.0 0.85 L/Y B Y/R R/L R
R R/L Y/R B L/Y
Connecting the right front door harness 2 Connecting the floor harness 2
C17
0.85 0.5 1.25 0.5 0.85

1.25
G/Y Y/R Y Y Y/R G/Y
L 612 611 610 609 0.5 0.5 0.5 0.5 1.25

1.25 0.5 0.5 0.5 0.5 G/B G/R G/L G/Br
B
B G/Br G/L G/R G/B
Connecting the chassis harness Connecting the cabin harness
C18
T01 T02 T02 T01

0.5 0.85 0.5 0.5 0.85 0.5
T12 T11
Gr/B B/W Br/L Br B/W Gr/B
504
0.5 0.85 0.85 0.5 A 0.5 0.85 0.85 0.5
0.5 W V/L L/Y W/G
Gr/w W/G L/Y V/L G/R W Gr/w
Connecting the left front door harness 1 Connecting the floor harness 1

Pin Function 5
C19
260B U 260
R/L B 2.0 0.85 2.0
R/G B R/L R/G
Gr/B Gr/R R/Y G Y/W 0.85 0.85 0.85 0.85 0.85

Y/W G R/Y Gr/R Gr/B
Connecting the left

Connecting the cabin harness 2
front 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 Connecting the cabin harness

rear door harness
C21
T31
0.5
504 504
0.5
T31
0.5
Br/Y V/L V/L T31A
T32 A
0.5 0.85
0.85
T32
R/L
Br/Gr W R/L W T32A
Connecting the right
rear door harness Connecting the cabin 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
Br/G Br/B B/W W V/L R/L
Connecting the left Connecting the cabin harness

rear door harness

Pin Function 6
C23
A
L/Y Y/L Y/L L/Y
B73 B74 H B74 B73
W/G B/W O/G B B O/G B/W W/G
Connecting the tail-gate Connecting the cabin harness

transition harness
C24
C
C 0.85
0.85 R/B
R/B A
A 0.5 0.85
0.85 0.5 W O
W
O
Connecting the tail-gate Connecting the cabin harness

transition harness
C25
Connecting the tail gate Connecting the tail-gate

transition harness
C26
Connecting the tail-gate

Connecting the tail gate
transition harness
C27
Connecting the reversing

Connecting the cabin harness
radar transition harness
C28
Connecting the transition harness 1 Connecting the reversing radar harness 1
C29
Connecting the transition harness 2 Connecting the reversing radar harness 2

No. 1 Fuse Box (gasoline)

Label of fuse box
Right-
side Left-side Defrost Power Spare Spare
Brake Cigar
power power lighter seat
lamp
window window
Spare
Reserved
Spare
Spare
Rear door IG unloading

motor relay relay
Reserved Reserved
Spare Central
control
Defrost relay
door
lock
Spare
Sunroof Tail gate Rear Front

Audio motor
Combination Airbag A/C wiper wiper
instrument Central control door motor motor
lock relay Front wiper relay
Back pin diagram of fuse box

Body Electrical Appliance (K5)-10
Connecting No.1 fuse box E
Connecting fuse box A Connecting fuse box C Connecting fuse box B
Connecting No.1 fuse box D

No. 2 Fuse Box (gasoline)

Label of fuse box
Main relay of Blower High-speed relay for
Normal power supply of ECU

Fuel pump relay Power of
engine blower
1# fuse box
relay
15A
Main relay of engine
Fuel pump
Compressor
Power of
1# fuse box
Spare
Power management
Electric heating seat
Front fog lamp

Electric horn
Start Blower
power of 1# fuse box
Spare
Starting
Power mana-
relay high
Room lamp
gement relay
Spare
beam
relay
Spare
Reversing lamp
high beam
Compressor
relay Lower
beam Electric horn
Right lower beam
Left lower beam
relay relay Front fog

lamp relay
Sunroof
Great Wall Motor Company Limited
Back pin diagram of fuse box

Body
Control
Front
Connecting No.2 fuse box D Connecting No.2 fuse box B
Connecting No.2 fuse box A Connecting No.2 fuse box G

Storage Battery/Starter/Generator
From ECU fuse
Red White Red/ Red/

Ignition switch Blue/ Black/ Green/ Yellow
R e d / Green
/Red Blue Green Black White Red Yellow
Position of Key Key plugged in
the key pulled
out
Outgoing Status of
the switch
terminal
Red
No such wire for engine
Charging indicator lamp

R e d /
White
Red
Starting relay
Black/ Green/ White/

Red Yellow Red
Storage battery
R e d /
Yellow
Generator
R e d /
Blue
>
Starter
Black
Ignition switch
CD-H005
BCM39 From the

BCM42
pin
From
the
pin
Brown/White
Brown/White
supply TCU9
normal From
the
pin
Red Low-speed fan relay Red

the ECU
Diagnostic plug
power
From
fuse
Green/Black
Brown/White
Green/White
Cooling fan
normal
power
Black/Red Red
supply
Red/White
From ECU fuse
Blue/Red
Low acceleration sensor

Green/Yellow Red/Grey
White/Black
High-speed fan relay

pressure mid-pressure
From the
switch
Black/White
White/Red White/Red
Blue/White Blue/White
Pressure and temperature sensor for

the low
switch
From
Blue/Black
Brown/Red Brown/Red
Black/Red
Brown/Black Brown/Black
From ECU fuse
air intake manifold

Engine Electronic Control System
Green
White
Maintenance indicator lamp

Green/Yellow Blue Red/Yellow
speedometer
From the
Brown Malfunction indicator lamp Brown
Throttle valve position sensor

Blue/Red
supply tachometer
White/Black White/Black
power From the
ECU normal power supply fuse
Blue/White
Red/Green Red
Normal
Black/White
Red
Black/White
Compressor relay
Compressor
Electromagnetic clutch
Knock sensor
Normal
supply
Red Grey/Black
power
Blue
Green/Yellow Blue/Yellow
ECU fuse
Coolant temperature sensor

Black/White
From IG1
Blue/White Green/Yellow
Violet/Black
Charcoal canister cleaning control solenoid valve
Black
Crankshaft position sensor

Red/White
White
Spark plug
Fuel injector 4
Grey/Red
Fuel injector 3
Grey/White
PCP ignition coil
Black/Yellow
White/Red
Fuel injector 2
White/Black
Idle control valve
Grey/Brown
Brown/Black
Fuel injector 1
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
Fuel pump relay
Connecting ECU engine
A42
0.5
Br/G
A39
0.5
Br/B
Connecting the
water tempera-
Connecting the engine Connecting the diagnostic equipment ture plug
36 room harness 2
0.5
Y/R
Connecting the engine Connecting the

Connecting the ac- Connecting the radiator fan
room harness 1 temperature sen-
celeration sensor sor
Connecting the Connecting the fuel Connecting the fuel Connecting the fuel Connecting the fuel
ignition coil injection nozzle I injection nozzle II injection nozzle III injection nozzle IV
B A
1.25 0.5 0.5 1.25
Y Y/R B B
Connecting the
compressor
Connecting the idle Connecting the front
Connecting the fuel pump control valve oxygen sensor
Connecting the throttle Connecting the charcoal Connecting the Connecting the
valve position sensor canister control valve knock sensor crankshaft position
sensor
Connecting the intake temperature

and pressure sensor
Anti-theft / Airbag
From IG1 From ECU fuse
To the diagnosis To the BCM

connector
Brown/ Green/ Red Red
Brown/White
Yellow
Green/
Blue/White
White Yellow
From
Driver seat belt indicator lamp
Impact unlocking
Warning lamp of airbag
Anti-theft indicator lamp
Red
Blue/White
Green/ Airbag ECU
Red
Passenger seat belt indicator lamp

White/Red
Green
White/
Anti-theft ECU
Warning lamp
Seat belt switch
assembly
Seat belt switch

Seat belt warning lamp
Blue/Red
Blue/Yellow
Yellow/Black
Yellow/Red
Clock spring
Key detection
Assistant driver’ Passenger seat belt Driver seat belt

Driver airbag s side airbag
pretensioning pretensioning
Seat sensor
0.5
R/G
0.5 0.5 0.5

B/W V/W W/B
Connecting PAB Connecting the

Connecting PAB switch Connecting airbag
接安全气囊 generator (yellow) clock spring
T:DJ621-G2.3*0.6A 2EA
(yellow)
anti-theft module
0-0282366-1
0-0173850-1
ABS EBD Electronic Control System

To the
From the brake Normal power Normal power
diagnosis From ECU fuse
lamp switch From ECU fuse supply supply
connector
Red/Black
Green/Yellow
Red
Red
Green/Yellow
Brown/White
Acceleration sensor
(4WD)
Alarm lamp
Alarm lamp
Brown/Black
Green/Brown
Brown/Red
Brown/White
Red/Black
Red/Black
Red/Green
Brown/Red
Brown/Black
Oil pump motor
Green/Yellow
Green/Brown
Green/Brown
Green/Blue
Green/Red
Green/Black
Green/Blue
Yellow/Blue
Yellow/Brown
Green/Brown
Yellow/Black
Yellow/Black
Yellow/Red
Yellow/Red
Control solenoid valve
Integrated ABS control module assembly
Left front (2WD) Left front (4WD) Right front Left rear Right rear
Wheel speed sensor
0.5 0.5 0.5 0.5

G/L G/Br G/B G/R
ABS right rear sensor ABS left rear sensor Right front ABS-FR sensor
AMP A1-967644-1 AMP A1-967644-1 Left front ABS-FL sensor A1-967644-1
Band
Leading out from this side
ABS-ECU
1 928 D00 981
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/
Red/ Red/ R e d /
White
Green/ Black Black Green
White
Brown/ Brown/ Green/
Red Black Yellow
Oil pump motor
Green/ Green/ G r e e n / Green/

Blue Brown Brown Yellow
Yellow/ Yellow/ G r e e n / 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 Left rear Right rear
Wheel speed sensor
Band
TCS-ECU
Reversing Radar / Reversing Display
From IG1
To DVDc1-1 pin To DVDc1-4 pin From DVD

From DVD
Yellow/ Blue/
Green White
Fuse for reversing lamp
Negative pole of video
Positive pole of video

Green/
White
Reversing radar ECU
Ye l l o w / Yellow/ Yellow/ Green/

Green/
Black Blue Red Blue
Red
Green/
White
Reversing display
Reversing lamp
Left side Left middle Right middle Right side
Ultrasonic sensor
BrW
Connecting the re-

Connecting the
Connecting ECU versing camera
cabin harness
H:MG610159
Connecting the Connecting the Connecting the Connecting the

left side probe left middle probe right middle probe right side probe
Indicator lamp
Center control switch
White/ Closing indicator lamp

Green
Green/ Seat belt untying indicator lamp
White
Green/White
Cigar lighter illumination Red/Blue
Small lamp
Green/Yellow
management
From power
relay
White
From ECU fuse
AWD Electronic Control System
Green/Yellow
4WD motor unit

To BCM Blue/Green
Blue/Green
From the reversing
Power clutch
lamp fuse
Yellow/Green
Normal power supply
Red
Speed sensor
To the diagnosis
Brown/ White Green/
White
connector
To ECU pin 45
White/Black
Tachometer
Red/Green Speed sensor
To ECU pin 3
Brown
Brown/Green
Speedometer
Electric Horn / Combination instrument
Combination instrument
Water temperature gauge

Water temperature sensor
Brown/Grey
Combination instrument A
Fuel alarm lamp
Combination instrument B
Fuel gauge Fuel sensor
Yellow/Red
H:1318389-1
Engine oil pressure indicator lamp Engine oil pressure switch
Yellow/Black
H:1318774-1
From ECU fuse
Red/Green
Brake malfunction indicator lamp Brake fluid level switch
Blue/Black
Parking brake indicator lamp Parking brake switch
White/Blue
From BCM
Instrument illumination lamp

From BCM
Power clutch indicator lamp

Yellow
Yellow
Door indicator lamp
From BCM
Right electric horn

Left electric horn
Electric horn
Normal power supply
Orange/Blue
Red Red/White
Horn switch
Horn relay
Cigar Lighter/Power Rear-View Mirror/Rear wiper/Washer

From the
center
control From IG2
switch From No.1 fuse box From IG unloading relay
Red/Blue
Red/Yellow
Yellow
Orange/
Green
Black/Yellow
Red/White
Rear washer
Rear wiper switch

Middle
Power rear-view mirror switch
Left
Right
Rear wiper
Upper
Lower
Middle
Yellow/Blue
Green/Red
Orange
Left
Turn off
Right
Upper
Wiping intermittent relay

Lower
Rear washer motor

Cigar lighter
Middle
Left
Right
Upper
Lower
Yellow/Red
Yellow/White
Green
Black/Green
Red/Yellow
Vertical
Vertical
Rear wiper motor

Left rear-view mirror
Right rear-view mirror

Horizontal
Horizontal
Power rear-view mirror switch Rear washer motor
Left power rear-view mirror Right power rear-view mirror

DVD机
Negative pole of video
Positive pole of video

From BCM adjustment light
Green/ Yellow White

Brown Blue/
White
Normal power supply

Red
Red/
Blue
BCM adjustment light
Right front speaker

Left front speaker
Red/ Blue/
Blue Red
Speed detection
Reversing detection
Brown/Blue
Brown
Brown/ Brown/
Red White
Liquid crystal
display DVD player assembly
Dedicated communication
USB interface
cable
Key-control grounding
Blue
Key-control input A
Brown/ Brown/ Brown/ Brown/
Black Green Yellow Grey
Left rear speaker
Right rear speaker

Signal feed line
Overhead antenna
Connecting the
line-control transi- DVD player A DVD player B
tion harness Connecting DVD player
T01 T41 T51 T31

0.5 0.5 0.5 0.5
Br/L Br/R Br/G Br/Y
T02 T42 T32
T52
0.5 0.5 0.5
0.5
Br Br/W Br/Gr
Br/B
Connecting Connecting Connecting

USB interface the left front Connecting Connecting
the right front the left rear the antenna
speaker the right rear
speaker speaker speaker
Internal and external
Speed governing module
warm air actuator

Blower relay
circulation actuator
Blower
H:DJ7072-3-21
A/C Cold and
Normal
Blue Red
supply
From the A/C fuse power
Black/Yellow Red/Black
Green
Blower high-speed relay

Tri-state pressure switch
To ECU pin 9
White/Red Blue/Orange
Blue/White Blue/Red
To ECU pin 39
Green/Black Defrost request Green/Black

Evaporator temperature sensor
governing
module
Speed
Mode actuator
Green/Black
Brown
Pink/Yellow
Blue/Yellow
Outdoor temperature sensor
A/C ECU assembly
Blue/Black
A/C
Internal and external circulation actuator
White
Blue
Yellow/Black
Indoor temperature sensor
Brown
temperature
Evaporator
Red/White
Green
Blue
Cold and warm air actuator
sensor
Brown
White/Blue
Pink/Red
A/C ECU
Red/Black
Blue
White/Black
White/Black Adjustment light illumination
White/Black Engine rotation speed
A/C mode actuator

H:DJ7072-3-21
Brown Speed sensor
Brown/Grey Water temperature sensor
Defrost indication
Blue/Yellow
Blue
Power Window
To BCM To BCM
To BCM
Normal Normal
From IG1 power power
supply supply
Red/Blue
Red/Black
Yellow
White/Red
IG unloading relay
Red
Red/Green
Grey/Red
Left front door Left rear door Right front door Right rear door
window switch window switch window switch window switch
Grey/Black
Blue/White
Red/White
Blue/White
Red/White
Red/White
Blue/White
Red/Blue
Anti-pinch Anti-pinch Anti-pinch Anti-pinch

ECU I ECU II ECU III ECU IV
Left front door motor Left rear door motor Right front door motor Right rear door motor
0.85 0.85 0.85

0.85 0.85 0.5 0.85
W/G B/W
W/G B/W Gr/w W/G B/W
A A D B24
0.5 0.85 0.5 0.5
Gr/B B B Gr/W
B
Left front door integrated Right rear door integrated

Right front door integrated Left rear door integrated door lock assembly (loc-
door lock assembly (locking door lock assembly (locking door lock assembly (locking king mechanism assembly)
mechanism assembly) mechanism assembly) mechanism assembly) CD-H054
Left front regulator Right front regulator Left rear regulator Right rear regulator
(rocker type) (rocker type) (rocker type) (rocker type)
0.85
R/L
2.0 2.0 2.0 2.0

L/W B R R/W
Left front regulator switch
CD-H033 Right front regulator switch Right rear
Left rear regulator switch regulator switch
CD-H034 CD-H034
B
2.0 2.0 2.0 2.0
L/W B R R/W 0.85
C R/L
2.0 0.5 0.5 0.85 C
2.0 2.0 2.0 2.0
B Gr/R Gr/B R/L
L/W B R/G R/W
Right front regulator switch Right rear

Left front regulator switch Left rear regulator switch
CD-H032 regulator
CD-H033 CD-H034
switch
Electric Heating Power Seat/Power Socket/Sunroof

From the central
control door lock
fuse From the radio fuse
From IG1 Normal power supply
Blue/Red
Red
Red/Green
Yellow
Blue/White
Sunroof switch
Brown Middle
Turn on
Turn off
Front power socket
Grey/Blue
Black/Blue
Driver seat heating switch Assistant driver seat heating switch Fore-and-aft adjusting switch for
Reclining switch for driver power seat
driver power seat
Rear power socket Sunroof ECU

assembly
Sunroof assembly
Driver seat heating resistance Assistant driver seat heating resistance
Fore-and-aft adjustment electric motor Reclining adjustment electric motor
B J 166 50 50
2.0 2.0 2.0 B B
Br B G 2.0 2.0
Power seat Driver seat Assistant driver

Connecting the
CD-H004 heating seat heating
seat heating
DJ7022-6.3-21
switch
Clock spring
Horn button
Driver airbag assembly
C252 G17 143 E1

Pretensioning seat belt
and the console harness
Diver’s pretensioning force-limiting Red
spring transition harness

Blue/White
seat belt
Connecting the clock

Driver seat belt switch
Assistant driver airbag assembly

Red/Blue
Connecting the instrument panel

Passenger’s pretensioning force-limiting
seat belt
K-line Brown/White
IEE - seat sensor (front-row passenger) Passenger seat belt switch
Crashout (unlock, low pulse)
H:DJ7021-2.3-21
T:DJ621-G2.3*0.6A 2EA
Passenger seat belt switch
Connecting the airbag ECU
New airbag control system
Red/Blue A warning lamp
C1 driver seat belt indicator lamp
Seat belt alarm output
Seat sensor
Pretensioning seat belt
Molex: 988 171 021

Central Lock System

Function Descriptions
1. Locking
BCM (Body Control Module) shall enable the function of locking under following conditions.
(a) Locking by means of remote control key
BCM successfully receives a command of locking from remote control keys and all doors are closed.
(b) Locking based on speed sensing
A vehicle reaches a calibrating speed (15km/h as initial speed) and all its doors are closed but not loc-
ked.
(c) Automatic protection
The key is not plugged into ignition switch and all doors fail to actuate in 30s based on remote control
unlocking, thus enabling locking.
(d) Locking by means of central control switch
BCM locks all doors as the main control locking switch enables locking.
(e) Locking by means of manual control key
Turn key of driver’s door to “LOCK”.
2. Unlocking
BCM shall enable the function of unlocking under following conditions.
(a) Unlocking by means of remote control key
BCM successfully receives a command of unlocking from the remote control key.
(b) Unlocking based on collision
As ignition switch is turned to ON or START, BCM will unlock five times in 3s after receiving a collision
signal;
As ignition switch is turned to ON or START, BCM will unlock five times in 3s since it detects irregular
safety airbag signals.
Special notes: Unlocking fails upon invalid collision signal from safety airbag. At this time,
please turn ignition switch continuously from OFF to ON and then OFF and then enable loc-
king.
(c) Unlocking by means of central control switch
As the central control switch is enabled, BCM will unlock all doors.
(d) Unlocking by means of manual control key
Turn key of driver’s door to “UNLOCK”.
(e) Unlocking based on key removal
Central lock is under the state of locking and the key is removed, enabling unlocking accordingly.
3. Unintended closedown protection
Unlocking will actuate once since any open door is closed while all locks are under the status of loc-
king.
Body Control Module

Function Descriptions
BCM (Body Control Module) realizes intelligent control and function over body electrical system. De-
tails are given below:
1. Realize the operation of outer lamps and room lamps by handling various light switches, such
as:
High beam lamp, low beam lamp, clearance lamp, license plate lamp, front and rear fog lamp, brake
lamp, hazard warning lamp, turn signal lamp, door lamp, ceiling lamp, foot well lamp, related indica-
tions through instrument clusters. Rely on rain and light sensor and related logical relations to realize
automatic lighting, “Follow Me Home”, vehicle search and other lighting functions;
2. Enable logical control over high-speed, low-speed and intermittent operation of front wiper
by operating wiper switch of offline vehicles and combine rain and light sensor to realize the
function of automatic wiper;
3. Rely on three keys of remote control to enable locking/unlocking, window closing and vehicle
searching;
4. Realize central lock system control, back door unlocking, unlocking based on vehicle colli-
sion, automatic locking upon running speed more than 15km/h and unintended closedown
protection;
5. Enable holding to lock remote control-based windows and provide the function of hand pro-
tection through horn warning;
6. Enable front axle control function of powered 4WD and 4WD indicator;
7. The system is configured with functions of power source management, high-and low-voltage
protection, delayed power disconnection and system dormancy, etc.
System structure
Electrode and cathode of power source High beam relay

Remote control RF antenna Low beam relay
Ignition lock switch Front fog lamp relay
Five-door micro-switch Rear fog lamp and instrument indicator
Central lock switch LH and right position lamp
BCM (Body Control Module)
Central key switch License plate lamp and instrument indicator

Instrument car speed signal Background light
Collision unlocking signal of safety airbag Brake lamp
Combined switch (light) Turning signal lamp and instrument indicator
Front fog lamp switch Warning indicator lamp on instrument
Rear fog lamp switch Room lamp
Combined switch (wiper) 2WD/4WD indicator lamp
Warning lamp switch Power saving relay
Brake lamp switch Rear defrosting relay
Background light regulating switch Front wiper relay
Window lifting switch Central lock motor relay
Power window hand protection module Hatch lock motor relay
Rear defrosting switch Horn relay
Transmission control unit (TCU) 4WD front axle motor
Rain and light sensor CAN communication diagnosis interface
BCM Interface Definition View and Pin Definition
No. Pin No. Pin Definition I/O characteristic

BCM_PWR
1 J1-B1 Power
车身控制器电源
Rear_Brake_Light
2 J1-B2 O-H(P)
后刹车灯
Daytime_Running_Light
3 J1-B3 O-H(P)
白昼运行灯
BCM_GND
4 J1-B4 Ground
地
Rear_Fog_Light
5 J1-B5 O-H(P)
后雾灯
Turn_Light_Right
6 J1-B6 O-H(P)
右转向灯
Turn_Light_Left
7 J1-B7 O-H(P)
左转向灯
HZ_PWR
8 J1-B8 Power
转向灯电源
2WD_4WD_Indicator
9 J1-A1 O-L
两驱四驱指示灯
Hazard_Indicator
10 J1-A2 O-H
开关上的危险报警灯
Backlight_Illumination
12 J1-A4 O-H(P)
背景灯
Position_Light_Left
13 J1-A5 O-H(P)
左位置灯
Position_Light_Right
14 J1-A6 O-H(P)
右位置灯
Rear_Defroster_Relay
15 J1-A7 O-L
后除霜继电器
Front_Wiper_Power_Relay
16 J1-A8 O-L
前雨刮电源继电器
Door Status indicator
17 J1-A9 O-L
仪表上的门状态指示灯
Horn_Control_Relay
18 J1-A10 O-L
喇叭继电器
Low_Beam_Relay
19 J1-A11 O-L
近光灯继电器
Trunk_Unlock_Relay
21 J1-A13 O-L
后掀门解锁继电器
High_Beam_Relay
22 J1-A14 O-L
远光灯继电器
Front_Wiper_Speed_Relay
23 J1-A15 O-L
前雨刮速度选择继电器
Door_Lock_Relay
24 J1-A16 O-L
中控闭锁继电器
Door_Unlock_Relay
25 J1-A17 O-L
中控解锁继电器
Battery_Saver_Relay
26 J1-A18 O-L
节电继电器
License_Plate_Light_Relay
27 J1-A19 O-H
牌照灯继电器
Front_Fog_Light_Relay
28 J1-A20 O-L
前雾灯继电器
45 J1-A37 LIN1 Comm
47 J1-A39 HS_CAN (H) Comm
Backlight_adjust_Sw
49 J1-A41 I-A
背景灯调节开关
51 J1-A43 LIN2 Comm
53 J1-A45 HS_CAN (L) Comm
Hazard_Light_Sw
56 J1-A48 I-D-L
危险报警灯开关
2WD_4WD_Transfer_B
57 J2-B1 In-Relay
两驱四驱电机B端
RLY_PWR
58 J2-B2 Power
内部继电器电源
60 J2-B4 BCM_GND Ground
2WD_4WD_Transfer_A
61 J2-B5 In-Relay
两驱四驱电机A端
62 J2-B6 BCM_GND Ground
Front_Wash_Motor
63 J2-B7 O-H
前喷水电机
Interior_Light
64 J2-B8 O-L
内灯
Turn_Left_Light_Sw
65 J2-A1 I-D-L
左转向灯开关
FL_Door_Ajar
66 J2-A2 I-D-L
左前门微动开关
FR_Door_Ajar
67 J2-A3 I-D-L
右前门微动开关
RL_Door_Ajar
68 J2-A4 I-D-L
左后门微动开关
Light_Sw_Position
69 J2-A5 I-D-L
位置灯开关
Light_Sw_Auto
70 J2-A6 I-D-L
灯开关自动档
Trunk_Ajar
71 J2-A7 I-D-L
后掀门微动开关
RR_Door_Ajar
72 J2-A8 I-D-L
右后门微动开关
Turn_Right_Light_Sw
73 J2-A9 I-D-L
右转向灯开关
Light_Sw_HighBeam
75 J2-A11 I-D-L
远光灯开关
Front_Wiper_Sw_Auto
76 J2-A12 I-D-L
前雨刷开关自动挡
Front_Wiper_Sw_Low
77 J2-A13 I-D-L
前雨刷开关低速挡
Master_Lock_Sw
78 J2-A14 I-D-L
中控闭锁开关
Front_Washer_Sw
80 J2-A16 I-D-L
前清洗器开关
2WD_4WD_Pos_FB
81 J2-A17 I-D-L
两驱四驱位置反馈
Rear_Defroster_Sw
82 J2-A18 I-D-L
后除霜开关
2WD_4WD_Select_Sw
83 J2-A19 I-D-L
两驱四驱选择开关
Trunk_Release_Sw
84 J2-A20 I-D-L
后掀门释放开关
Front_Wiper_Sw_High
87 J2-A23 I-D-L
前雨刷高速开关
Rear_Fog_Light_Sw
88 J2-A24 I-D-L
后雾灯开关
Brake_Pedal_Sw
89 J2-A25 I-D-H
刹车踏板开关
90 J2-A26 ACC I-D-H
91 J2-A27 ON I-D-H
Key_Inserted_Sw
93 J2-A29 I-D-L
钥匙插入检测开关
Post_Crash_Input
95 J2-A31 I-D-L
碰撞解锁信号
Light_Sw_LowBeam
96 J2-A32 I-D-L
近光灯开关
Master_Unlock_Sw
97 J2-A33 I-D-L
中控解锁开关
Front_Fog_Light_Sw
98 J2-A34 I-D-L
前雾灯开关
99 J2-A35 START I-D-H
Brake_Pedal_Fuse_FB
101 J2-A37 I-D-H
刹车踏板保险丝反馈
Front_Wiper_Park_Sw
103 J2-A39 I-D-L
前雨刷停止位开关
RF_Antenna
107 J2-A43 Comm
天线
Key_Cylinder_Sw
108 J2-A44 I-D-L
驾驶员侧门钥匙开关
Vehicle_Speed_Input
110 J2-A46 I-D-L
车速信号
Input/
Output English Chinese
(shortening)
O-H-(-P) Output, High-Side Driver (Power = High current) 高驱输出，P代表大功率，即大电流
O-L-(-P) Output, Low-Side Driver (Power = High current) 低驱输出，P代表大功率，即大电流
I-A Input, Analog 模拟输入
I-D-L Input, Digital, Active Low 数字输入低，带内部上拉
I-D-H Input, Digital, Active High 数字输入高，不带内部上拉
-WU Wake-up input 唤醒输入
- N/A 空，不使用
In-Relay Internal Relay 内部继电器
Comm Communication Port 通讯接口
Failure Information Index

Pin No. Failure description Pin No. Failure description
J1-A1 2WD/4WD indicator lamp encounters a short J1-B6 A 21W bulb of LH turning signal lamp is not
circuit to earth or open circuit available
RH turning signal lamp encounters an open
circuit
2WD/4WD indicator lamp encounters a short RH turning signal lamp encounters over-
circuit to power source load and a short circuit to earth
J1-A2 Hazard warning lamp encounters a short cir- J1-B7 A 21W bulb of LH turning signal lamp is not
cuit to power source or open circuit available
LH turning signal lamp encounters an open
Hazard warning lamp encounters a short cir- lamp
cuit to earth LH turning signal lamp encounters overload
or a short circuit to earth
J2-B7 Front water spraying motor output encounters J1-B8 Hazard power source encounters too low
an open circuit voltage
Front water spraying motor output encounters Hazard power source encounters too high
a short circuit to power source voltage
Front water spraying motor output encounters J2-B2 RLY power source encounters an open cir-
a short circuit to earth cuit or null internal relay
J1-A5 LH position lamp encounters a short circuit to J2-B7 Switch background light encounters a short
power source or open circuit circuit to power source or an open circuit
LH position lamp encounters a short circuit to Switch background light encounters a short
power source circuit to power source
LH position lamp encounters a short circuit to Switch background light encounters a short
earth or an open circuit circuit to earth or overload
J1-A6 RH position lamp encounters a short circuit to J2-B8 Room lamp output encounters a short cir-
power source or an open circuit cuit to power source or an open circuit
RH position lamp encounters a short circuit to Room lamp output encounters a short cir-
power source cuit to power source or overload
RH position lamp encounters a short circuit to N/A Not matched hand protection module
earth or an open lamp
J1-A7 Rear fog lamp encounters a short circuit to J1-A19 License plate lamp output encounters a
earth or an open circuit short circuit to power source or an open cir-
cuit
Rear fog lamp encounters a short circuit to License plate lamp output encounters a
power source short circuit
J1-A8 Front wiper power relay encounters a short N/A LH rear hand protection module encounters
circuit to earth or an open circuit a null Hall sensor
Front wiper power relay encounters a short N/A LH rear hand protection module encounters
circuit to power source a null relay
J1-A9 Door state indicator lamp encounters a short N/A RH rear hand protection module encoun-
circuit to power source or an open circuit ters a null Hall sensor
Door state indicator lamp encounters a short
circuit to earth
J1-A10 Horn relay encounters a short circuit to earth N/A RH rear hand protection module encoun-
or an open circuit ters a null relay
Horn relay encounters a short circuit to power N/A LH front hand protection module encoun-
source ters a null Hall sensor
J1-A11 Low beam lamp relay encounters a short cir- N/A LH front hand protection module encoun-
cuit to earth or an open circuit ters a null relay
Low beam lamp relay encounters a short cir- N/A RH front hand protection module encoun-
cuit to power source ters a null Hall sensor
J1-A13 Back door unlocking relay encounters a short N/A RH front hand protection module encoun-
circuit to earth or an open circuit ters a null relay
Back door unlocking relay encounters a short N/A Master switch encounters a null LH back
circuit to power source control switch
J1-A14 High beam lamp relay encounters a short cir- N/A Master switch encounters a null RH back
cuit to earth or an open circuit control switch
High beam lamp relay encounters a short cir- N/A Master switch encounters a null LH front
cuit to power source control switch
J1-A15 Front wiper speed selection relay encounters N/A Master switch encounters a null RH front
a short circuit to earth or an open circuit control switch
Front wiper speed selection relay encounters Rain sensor module encounters null hard-
a short circuit to power source ware
J1-A16 Central door locking relay encounters a short N/A Rain sensor module encounters null sensor
circuit to earth or an open circuit
Central door locking relay encounters a short N/A Rain sensor module encounters null tempe-
circuit to power source rature sensor
J1-A17 Central door unlocking relay encounters a N/A Rain sensor module encounters failed ini-
short circuit to earth or an open circuit tialization
Central door unlocking relay encounters a
short circuit to power source
J1-A18 Power saving relay encounters a short circuit N/A Rain sensor module encounters null power
to earth or an open circuit voltage
Power saving relay encounters a short circuit N/A LIN signal of LH rear hand protection mo-
to power source dule makes no response
J1-A20 Front fog lamp relay encounters a short cir- N/A LIN signal of RH rear hand protection mo-
cuit to earth or an open circuit dule makes no response
Front fog lamp relay encounters a short cir- N/A LIN signal of LH front hand protection mo-
cuit to power source dule makes no response
J1-A37 LIN communication channel 1 encounters a N/A LIN signal of RH front hand protection mo-
short circuit to earth dule makes no response
J1-A43 LIN communication channel 2 encounters a N/A LIN signal of rain sensor module makes no
short circuit to earth response
J2-A17 2WD/4WD motor fail to reach appointed posi- N/A LIN signal of master switch makes no res-
tion ponse
J2-A31 Collision signal input encounters invalid N/A Rain sensor module receives fault LIN sig-
waveforms nals
J2-A37 Brake pedal fuse encounters an open circuit N/A LH rear hand protection module receives
fault LIN signal
J2-A39 Front wiper motor encounters locking N/A RH rear hand protection module receives
fault LIN signal
J1-B1 BCM power source encounters too low volta- N/A LH front hand protection module receives
ge fault LIN signal
BCM power source encounters too high vol- N/A RH front hand protection module receives
tage fault LIN signal
J1-B2 Rear brake lamp encounters a short circuit to N/A Master switch receives fault LIN signal
power source or an open circuit
Rear brake lamp encounters a short circuit to
power source
Rear brake lamp encounters a short circuit to
earth or overload
J1-B5 Rear fog lamp encounters a short circuit to
power source or an open circuit
Rear fog lamp encounters a short circuit to
power source
Rear fog lamp encounters a short circuit to
earth or overload
Maintenance Instructions
1. System diagnosis
Connect X431 with diagnosis interface of the whole vehicle, turn ignition switch from LOCK to ON,
log in diagnostic trouble code (DTC) reading page to acquire DTC and understand whether BCM is in
normal operation to make sure the scope of failure maintenance.
2. DTC clearing
Enable X431 to enter DTC clearing page, fulfill related operations to clear DTC, turn ignition switch
from ON to LOCK and keep authentic DTC still existent.
3. Actuation test
Enable X431 to enter offline actuation menu, force output to work and the distinguish output problem
and output failure.
4. Data stream reading
Enable X431 to enter the data stream reading menu, fulfill related operations to view I/O state and
help analyze related problems.
Attentions:
1. Be familiar with system structure.
2. Don’t connect with unspecific fake loads at will.
3. Don’t try bridge connection with wire at will.
4. Use X431, universal meter and oscillograph for diagnosis, surveying and maintenance.
5. Turn ignition switch from LOCK to ON once after maintenance to check whether all function
outputs are normal.
6. Special notes
(a) Use X431 to allocate vehicle information code after renewing BCM;
(b) BCM is configured with multiple functions. After renewing BCM, please use X431 to disable unex-
pected functions according to configurations of the whole vehicle. See detailed flows below.
Enter into function confi- Enable or disable co- Enable X431 to exit the
guration menu (read data rresponding functions function configuration
stream) through X431 menu.
7. As for renewing BCM, use X431 for the learning of remote control key according to follow
steps:
Connect X431 with the vehicle
Plug the first key (A) and turn it to ON
Enable X431 to enter the key learning menu
Enable holding for more than 1s towards locking key and unlocking key of the second key (B)
X431 indicates successful learning of key (B)
Remove key (A)
Enable holding for more than 1s towards locking key and unlocking key of key (A)
X431 indicates successful learning of both keys
X431 exits the key learning menu
Operate locking key of two keys respectively (at an interval of 2s)
Doors are unlocked and the warning lamp flashes (OK)
8. While renewing with a new key, please use X431 for remote control key learning.
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 system
camera lens
Reversing
lamp switch
Reversing
Definition of camera lens interface
NO. Name of Pin Position

1 Video negative pole
2 Video positive pole
3 Power supply negative pole
4 Power supply positive pole (drawn from reversing lamp)
Harness Connection and Interface Definition

Video negative pole
Reversing camera lens
Video positive pole
Power supply negative pole

DVD player
Power supply positive pole
Connecting to DVD Connecting to reversing 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
Lighting system
Combined headlamp assembly
Renewing
1. Detach wire connector of battery cathode (-)
2. Remove front bumper;
3. Unscrew four combined headlamp fixing bolts,

detach wire connector of combined headlamp and
remove combined headlamp assembly;
4. Remove bulb of low beam lamp

(a) Turn counterclockwise to open sealing cover (as
ON shown in Fig. 1);
ON (b) Remove bulb plug;
ON (c) Detach bulb pressing spring and then remove
OFF bulb.
OFF 5. Remove bulb of high beam lamp
OFF
1 3 (a) Turn counterclockwise to open sealing cover (as
2
shown in Fig. 2);
(b) Remove bulb plug;
(c) Detach bulb pressing spring and then remove
bulb.
6. Remove bulb of front position lamp
Turn counterclockwise to open bulb holder of position
lamp and remove bulb from the bulb holder (as shown
in Fig. 3).
7. Fit combined headlamp assembly
Bulb of low Fitting combined headlamp assembly complies with re-
beam lamp
verse steps of removing the assembly.
Bulb of front
position lamp Bulb of high beam lamp
Light-adjustment motor of low beam lamp Regulating

B Headlamp is adjusted by focusing on a zone. Light spot
of headlamp can be regulated by means of headlamp
C adjusting screw.
High Instructions to regulating:
A beam 1. Letter A marks LH/RH adjusting screw of low beam
lamp
lamp. Use a cross head driver to turn the adjusting
screw clockwise to make the light move rightwards
D and turn it counterclockwise to make the light
Low beam lamp
move leftwards;
2. Letter B indicates up-down adjusting screw of low beam lamp. Use a cross head driver to turn
the adjusting screw clockwise to make the light move downwards and turn it counterclockwise
to make the light move upwards;
3. Letter C represents up-down adjusting screw of high beam lamp. Use a cross head driver to
turn the adjusting screw clockwise to make the light move downwards and turn it countercloc-
kwise to make the light move upwards;
4. Letter D marks LH/RH adjusting screw of high beam lamp. Use a cross head driver to turn the
adjusting screw clockwise to make the light move rightwards and turn it counterclockwise to
make the light move leftwards.
Combined front fog lamp and turn signal

lamp assembly
Renewing
1. Detach wire connector of battery cathode (-);
2. Unscrew four fixing tapping bolts, detach wire con-
nector of combined front fog lamp and turn signal
lamp and remove the assembly.
3. Remove front turn signal lamp bulb

(a) Turn counterclockwise to open bulb holder (as
shown in Fig. 4);
(b) Unscrew bulb from bulb holder;
ON 4. Remove bulb of front fog lamp
ON (a) Turn counterclockwise to open sealing cover (as
shown in Fig. 5);
OFF (b) Remove bulb plug;
4 5 OFF (c) Detach bulb pressing spring and remove bulb.
5. Fit combined front fog lamp and turn signal lamp
assembly
Fitting combined front fog lamp and turn signal lamp
assembly complies with steps of removing the assem-
bly.
Combined tail lamp assembly
Renewing
2. Unscrew four fixing bolts, detach wire connector

of combined tail lamp and remove upper and lower
combined tail lamp assembly respectively;
Bulb of rear turn signal lamp 3. Remove bulb of rear turn signal lamp and backing-
up lamp
(a) Turn counterclockwise to turn bulb holder;
(b) Remove bulb from bulb holder.
Bulb of backing-up lamp
4. LED is equipped as the light source of tail lamp

assembly and can not be removed. In case of light
source failure, replace the whole lamp.
5. Fit combined tail lamp assembly
Fitting combined tail lamp assembly complies with re-
verse steps of removing the assembly.
Rear fog lamp assembly

Renewing
2. Unscrew three fixing tapping screws, detach wire
connector of rear fog lamp and remove rear fog
lamp assembly;
3. Use LED as the light source of rear fog lamp. It can
not be removed. Upon light source failure, the who-
le lamp shall be replaced.
4. Fit rear fog lamp assembly
Fitting rear fog lamp assembly complies with the rever-
se steps of removing the assembly.
Schematic Diagram of Harness Relationship and Plug Connection Numbering
Floor harness Right front door harness Right rear door harness
Engine compartment harness Instrument harness
Water pipe
Regulator (rocker type)
Anti-nip
function Speaker
Speaker High tone speaker Door lamp
C16
mechanism assembly)
door assembly(locking
Regulator switch
C05
Integrated right front

interface with the instrument
Connecting the CD player
C12
Connecting the antenna

Integrated right rear lock
assembly(locking mechanism
assembly)
GPS signal line

C06 C15 C20
Internal and external
circulation actuator C10 Connecting the right front lamp switch
High tone
Speed- speaker
Connecting the
Regulator (rocker
regulating
module
type) Door lamp
C21 right rear lamp
switch
Regulator
switch
Regulator (rocker
type)
Anti-nip riser (rocker
type)
Power rear-view mirror
temperature sensor
Connecting the acceleration sensor

Evaporator
Water pipe
Connecting the PAB switch
Cigar lighter
Cigar lighter
illumination
2WD/4WD

conversion
socket Body grounding Outdoor high -mounted
Oil pressure sensor Generator
Blower
stop lamp
Connecting the positive pole of storage battery
motor
A/C ECU
Seat electric heating
Electric 4WD controller

Front wiper
C30 Connecting the seat

Connecting the negative pole of
Charging
harness
storage battery
ABS-FR sensor heating switch Right tail lamp

power supply upper
Footwell lamp
Transmission harness
Right tail lamp Rear tailgate harness
Antenna interface
Generator
Glove box lamp

lower
Connecting the airbag

Engine grounding
Connecting Grounding
Frame harness
the starter
windscreen
pole of rear
Grounding
Integrated tail-gate lock assembly (locking defroster

Negative
搭铁
Rear washer motor
Grounding
Leveling ABS left rear sensor

USB interface
Glove box switch

devices
for right USB interface
Starter control
combination lamp
Right side turn
headlamp ABS right rear sensor

signal lamp
Front washer motor
C02
License lamp
C01
Right
Combination instrument B
Handbrake
reversing camera
BCM antenna Oil pump
Connecting
mechanism assembly)
Alarm switch
Right front fog
Connecting the Grounding Rear fog lamp

lamp
Grounding point
Electric
fan special
ground Connecting
crankshaft position
Sensor CT19 C13
Rear wiper motor

distribution box Seat belt switch
C17
L
Right-side
Condenser fan
Rear tailgate transition

A/C pressure switch (Tri-
electric horn
Connecting distribution box
Left tail lamp
Combination instrument A
No. 2 junction box
motor
upper
Leveling
Engine harness harness
Connecting distribution box
state switch)
License lamp
devices for Rear fog lamp
Connecting Connecting Connecting
Left combination lamp
left headlamp No. 1 nozzle No. 2 nozzle No. 3 nozzle Connecting No.4
DVD player B
DVD player A
CT12(blue) nozzle CT15
distribution box
CT13 CT14(blue) Power seat Left tail lamp
windscreen defroster
Connecting
Positive pole of rear

Connecting
distribution
lower
box
Connecting
Connecting the left rear
A/C clutch
Control switch assembly

door lamp switch
Left side turn
signal lamp
CT8 Knock sensor

C23 C25
Connecting the line-

control transition
electric horn
Reversing switch
Left-side
harmess
Horn
Driver’s seat
C03 heating
High-mounted
Left front fog
C24 C26
stop lamp
lamp
Electric horn Combined
Electric rear-view mirror switch

Brake fluid
switch Connecting the left front
A/C mode actuator
level alarm Connecting the

acceleration sensor
Water temperature sensor CT9 door lamp switch Backup power
C04
Connecting the idle
Ignition switch
speed control valve
Speedometer sensor
Rear ceiling lamp
Video outer connector
Connecting the Connecting the charcoal
wrapped with foam piece
C18
canister control valve
electric control clutch Throttle valve Integrated right front door
Connecting the ignition coil CT5
Connecting the No.1 Footwell lamp Anti-pinch regulator Speaker
position sensor Door lamp assembly(locking mechanism assembly)
Connecting the Regulator switch
fuse box A
Connecting the rear

fuse box D
oxygen sensor CT7

接1号保险盒D
接保险盒A
ABS-FL sensor Grounding
Water temperature plug
Clutch switch C22 Anti-pinch
A/C cold and warm
Malfunction diagnosis interface Connecting the intake air Regulator (rocker type)
air actuator
temperature pressure sensor

C19
Connecting the No.1
Connecting the front

接1号保险盒E
oxygen sensor CT7 Door lamp

box E
Connecting ECM Left front door locking Regulator switch

mechanism assembly Regulator (rocker type)
Light sensor
Grounding point
Stop lamp switch Regulator Speaker
fuse
Left front door Left rear door
Gearshift actuator
接保险盒B the
Connecting High tone speaker
Anti-thief module Connecting the

fuse box B High tone speaker Power rear-view
mirror harness harness
接保险盒C
fuse box C
Connecting the buzzer
Medium ceiling Reversing radar transition wire

lamp
C07 Front ceiling
Sunroof ECU
C27
lamp
Electromagnetic clutch
and speed sensor
Connecting the rain
C14
sensor (black)
Connecting ECU
C08
C28
C29
Diode components
Diode components
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 wire
C09
Ceiling harness Connecting the probe Connecting the probe
Connecting the probe

From the BCM
Right rear door lamp
Left rear door lamp
Right headlamp
White
Right front door lamp

levelling
Left front door lamp

From the BCM
Rear ceiling lamp
Middle ceiling lamp
Front reading lamp
Right headlamp
Assistant driver's side sun visor & make-up lamp

White
From the power management relay

Driver's side sun visor & make-up lamp Front fog lamp indicator lamp
Right front fog lamp
From the front fog lamp relay Green/Yellow Left front fog lamp
position lamp
Right front
Right headlamp
Blue/Black
Left headlamp
From the lower beam relay
Blue/White
From the high beam relay
Blue/Red
Blue/Red
High beam indicator lamp
Left headlamp
levelling
To the A/C ECU

Green/Black From the defroster switch
Defroster indicator lamp
Blue/Yellow
Defroster relay
Right rear-view mirror defroster
Normal power supply
Left rear-view mirror defroster
To the ceiling lamp Rear windscreen defroster
Blue/Yellow
Left headlamp
BCM/Lamp/Front washer and wiper
Green/Black
Clutch motor
Yellow/White
Background lamp adjustment switch
Blue/Red
Control switch inner
Blue/White
Front wiper switch
Warning switch position lamp
H:0436001
Light
green
Left front
Warning
switch
lamp
Light switch
From the window switch

Automatic light
Headlamp
Width lamp
Orange
Yellow/Blue
Turn off
From the window switch
Connecting the BCM-B

Dimmer switch
Red/White From the horn switch

Yellow To the combination instrument
Lower beam
Flashing
High beam
Blue/
Green From TCU Left turn indicator lamp
Red/Blue Left rear turn lamp
From the power window switch
Left front turn lamp
Yellow
Right turn indicator lamp

Steering switch
Blue/Yellow
Right rear turn lamp

Right front turn lamp
Right
Left
From the control switch

IG power supply
From the control switch
Yellow
Tail gate unlock relay

Combination switch
Rain sensor
Red/Green
Right rear door locking mechanism
Normal power supply Left rear door locking mechanism
Red Red Red
Normal power supply
Connecting the BCM-A

Normal power supply Right front door locking mechanism
Front washer switch
Front washer motor Left front door key switch
To the electrical equipment Grey/Red
Black/White
Central control
Red
door lock relay
Grey/Black
Power management relay
Normal
supply
Front fog lamp relay

power
Red
Green/Yellow
Red/Yellow
Normal power supply
Red/Green Daytime running lamp
Power clutch indicator lamp
Lower beam relay Daytime running lamp
Rear fog lamp indicator lamp
Green/Yellow Right rear fog lamp
Red
Left rear fog lamp

High beam relay
Normal
Right brake lamp

supply
power
Left brake lamp

From the BCM instrument bright adjustment
Right position lamp
To diagnosis interface
Left headlamp
Right headlamp
levelling motor
To diagnosis interface Left position lamp
levelling motor
Control switch assembly
Rear license plate indicator lamp
To the BCM rear fog lamp request
Red/ Red/White Rear license plate lamp
Blue Red/Black
Rear license plate lamp Front fog lamp JDQ
Brake lamp switch From the BCM rear fog lamp signal Yellow/White
Crash unlock signal Tail gate handle switch
Red/Blue To the BCM front fog lamp request
Speed signal
Tail gate switch
Adjustment light output
Green Green Right rear door switch Blue/white From the BCM adjustment light
Left rear door switch
Right front door handle switch From the lower beam relay
Left front door handle ajar switch
High mounted brake lamp
To ABS
Ceiling lamp switch signal
Air conditioning System-
Air conditioning System
Part Drawing of Air-conditioning System (A/C).............. 2

A/C control system structure .......................................... 3
Instructions to A/C system keys (See Fig. A) ................ 3
A/C controller plug and socket and definitions
(Fig. A) ............................................................................... 3
System trouble diagnosis procedures (Fig. A) . ............ 4
Port definition (Fig. B) . .................................................... 6
Self-checking process (Fig. B) ........................................ 7
Diagnostic trouble code (DTC) display (Fig. B) ............. 7
Diagnostic trouble code (Fig. B) ..................................... 7
Part Drawing of Air-conditioning System (A/C)
Diesel engine 2.5TCI
Heater assembly
Evaporator assembly
Blower assembly
Refrigeration compressor assembly
A/C low-pressure
hose assembly Condenser assembly
A/C high-pressure
hose assembly
A/C high-pressure rigid tube assembly
Gasoline engine 4G69

A/C high-pressure rigid tube assembly
Condenser assembly
A/C low-pressure rigid tube assembly
Expansion valve assembly

Blower assembly
Refrigeration compressor
bracket assembly
A/C high-pressure
hose assembly
Evaporator assembly
Refrigeration compressor assembly
Heater assembly
A/C low-pressure hose assembly
A/C control system structure

The A/C control system is mainly comprised of A/C control unit, sensor and actuator element. Whe-
rein, indoor temperature sensor and A/C control unit are integrated onto A/C control panel.
Fig. A Outside air damper actuator
9 13
10 11 12
Speeder module
Mode air damper

actuator 1
2
4
5
6 7 3
8
Evaporator temperature sensor
Temperature air damper actuator
SN Name SN Name
1 Controller panel 8 OFF key
2 Air speed adjusting knob 9 Face blowing key
3 Temperature adjusting knob 10 Foot blowing key
4 AC key 11 AUTO key
5 Circulation key 12 Foot blowing and defrost key
6 Defrost key 13 Face and foot blowing key
7 Rear defrost key
Instructions to A/C system keys (See Fig. A)

Air speed key and temperature control key of K109 are realized in the form of adjusting knob. Howe-
ver, K1 is configured with feather-touch function keys. Accordingly, they are differently handled.
1. Air speed adjusting knob
Under electrical control, the highest air speed is still kept after A/C is restarted next time upon power
failure or enabled OFF key as A/C is at its highest air speed. However, the air speed is switched when
the air volume increases to the max. volume. Under AUTO mode, the air speed is still under automatic
control.
2. Temperature adjusting knob
Under modes of COOL (17℃) or HOT (32℃), exit automatic control before these modes prevail. Un-
der the mode of COOL or HOT, AUTO key is unavailable. AUTO is accessible only after exiting the
state of max. cooling capacity or max. warming capacity.
A/C controller plug and socket and definitions (Fig. A)
Model of plug and socket: AMP C-966658-1 (Green)
Definitions of plug and socket (Fig. A)

SN Port Signal Voltage Current Remarks
1 A1 IG2 12V <500mA
2 A2 GND 0V <500mA
3 A3 HS 0V/12V <150mA High-speed relay drive (available upon low value)
4 A4 T+ 0V/12V 120mA Temperature actuator positive drive
5 A5 M+ 0V/12V 120mA Mode actuator positive drive
6 A6 I+ 0V/12V 120mA Circulation actuator positive drive
7 A7 +5V +5V 10mA +5V
8 A8 SGND 0V 12mA Simulating earth signal
9 A9 M F/B 0V-5V 5mA Mode actuator feedback signal
10 A10
11 A11 Incar 0V-5V 2mA Indoor temperature sensor signal
12 A12 TB 0V-12V 4mA Fan speed regulating drive signal
13 A13 Vehicle Speed 0V/12V 2mA Vehicle speed signal
14 A14 Engine Speed 0V/12V 2mA Engine speed signal
15 A15 BCM F/B 0V/12V 2mA Rear defrost feedback signal
16 A16
17 A17 IG2 12V <500mA
18 A18 GND 0V <500mA
Rear defrost signal (available as low PWL is kept for
19 A19 Rear Defrost 0V/12V <150mA
100ms)
20 A20 T- 0V/12V 120mA Temperature actuator negative drive
21 A21 M- 0V/12V 120mA Mode actuator negative drive
22 A22 I- 0V/12V 120mA Circulation actuator negative drive
Compressor request signal (available upon high va-
23 A23 A/C Req. 0V/12V <700mA
lue)
Electrical heating relay driver (available upon low
24 A24 Electrical Heating 0V/12V <150mA
value)
25 A25 T F/B 0V-5V 5mA Temperature actuator feedback signal
26 A26 Amb 0V-5V 2mA Ambient sensor signal
27 A27 Evap 0V-5V 2mA Evaporation sensor signal
28 A28 TC 0V-12V 1mA Fan voltage feedback
29 A29 EHD 0V/12V 1mA Electrical heating detection
30 A30 Water Temp. 0V-12V 2mA Water temperature sensor signal
31 A31 Fuel Heating 0V/12V 2mA Fuel heating signal
32 A32 Lamp 0V/12V 60mA Background light signal (PWM input)
System trouble diagnosis procedures (Fig. A)

1. Press AC key and circulation key synchronously and enter into failure detection state after 2s.
2. Observe whether mode VENT, mode BL, mode FOOT, mode MIX, AUTO, defrost, back window
heating and other indicator lamps flash to judge failures. Under normal operating conditions,
these indicator lamps will not flash. Otherwise, the system encounters failures.
3. Press “OFF” to exit the failure detection mode and return to the state before failure detection.
4. Procedures of failure detection are listed in the table below.
Failure detec- Corresponding failu-

Normal display Failure display Failure removal
tion point re indicator lamp
Face blowing in-
Mode actuator Nothing displayed Flash
dicator lamp
Face and foot blo-
Temperature actuator Nothing displayed Flash
wing indicator lamp
Indoor tempera- Foot blowing in-
Nothing displayed Flash Tinc=25℃
ture sensor dicator lamp
Ambient tempe- Foot blowing and de-
Nothing displayed Flash Tamb=20℃
rature sensor frost indicator lamp
Evaporation tem- Automatic control in-
Nothing displayed Flash Tevap=2℃
perature sensor dicator lamp
Water tempera- Front defrost in-
Nothing displayed Flash Twat=90℃
ture sensor dicator lamp
Electrical hea-
Rear defrost indicator lamp Nothing displayed Flash
ting sensor
Fig. B
Outside air damper actuator
6
3
4
5 Speeder module
Mode air damper actuator

7
8
9
Temperature air damper actuator
10 Evaporator temperature sensor
SN Name SN Name
1 AUTO key 6 OFF key
2 Air volume increase key 7 Air circulation key
3 Air volume decrease key 8 Front defrost key
4 Mode key 9 Rear defrost key
5 A/C key 10 Temperature adjusting knob
Port definition (Fig. B)

Sheath model: AMP 966658-1 (Green)
Engaging sheath model: AMP 1534222-1 and AMP 1420000-1
Model of engaging plug and socket: AMP 928999-1
32 17
16 1
Port Definition Remarks

A1 Ignition power source +12V 9-16V
A2 Power ground
A3 High-speed relay control signal Rated current＜150mA
Temperature actuator positive drive sig-
A4 Rated current 120mA and max. locking current 500mA
nal
A5 Mode actuator positive drive signal Rated current 120mA and max. locking current 500mA
A6 Circulation actuator positive drive signal Rated current 120mA and max. locking current 500mA
A7 +5V 4.75-5.25V
A8 Simulating earth signal
A9 Mode actuator feedback signal 0-5V
A10 Null
A11 Indoor temperature sensor signal 2mA
A12 Blower speed regulating drive signal 4mA
A13 Vehicle speed signal 0/12V
A14 Engine speed signal 0/12V
A15 Rear defrost feedback signal 0/12V
A16 Null
A17 Ignition power source +12V 9-16V
A18 Power ground
A19 Rear defrost signal Low-level pulse signal (available after it is kept for 40mS)
A20 Temperature actuator negative drive Rated current 120mA and max. locking current 500mA
A21 Mode actuator negative drive Rated current 120mA and max. locking current 500mA
A22 Circulation actuator negative drive Rated current 120mA and max. locking current 500mA
A23 Compressor request signal Rated current＜700mA
A24 Electrical heating relay drive signal Rated current＜150mA
A25 Temperature actuator feedback signal 0-5V
A26 Ambient sensor signal 2mA
A27 Evaporation sensor signal 2mA
A28 Blower voltage feedback 0-12V
A29 Electrical heating detection 0/12V
A30 Water temperature sensor signal 0-5V
A31 Fuel heating signal 0/12V
A32 Background light power source PWM input
Self-checking process (Fig. B)

IGN OFF ON
Press AUTO key and press OFF key for four successive times in 2s
LCD flashes five times
Operate OFF key

Self-diagnosis items are checked (All items are checked one by one)
Operate AUTO key Operate AUTO key
Operate AC key to enter into the next diagnosis item Self-diagnosis items are checked (Current items actuate successively)
Operate OFF key
Return the mode previous to self-diagnosis mode
Diagnostic trouble code (DTC) display (Fig. B)

As for data display, two numbers to indicate set temperature are defined. Upon a trouble, related code
is displayed. If no trouble, 00 is displayed. The data will be displayed every 0.5s. The display duration
is 0.5s. Time interval of a trouble is 1s. Every DTC is displayed twice. For example, as trouble 1 and 2
occurs, the display is shown in the Figure below.
11 11 12 12 11
0.5S 0.5S 0.5S 1S 0.5S 0.5S 0.5S 1S 0.5S
One1周期
cycle
Diagnostic trouble code (Fig. B)

SN DTC Description Basis of judging the trouble
1 00 Normal
Indoor sensor encounters short circuit or open cir-
2 11 Detected voltage is 0V or 5V
cuit
Outdoor sensor encounters short circuit or open cir-
cuit
Evaporation sensor encounters short circuit or open
circuit
Mode motor feedback terminal encounters short
6 15 Mode motor feedback voltage is 0V or 5V
circuit or open circuit
7 16 Mode motor encounters unfavorable drive Mode damper motor is restricted
Cooling and warming motor feedback terminal en- Feedback voltage of cooling and war-
8 17
counters short circuit or open circuit ming motor is 0V or 5V
Cooling and warming motor encounters unfavora-
9 18 Cooling and warming motor is restricted
ble drive
Airbag-
Airbag
Electrical Schematic Diagram of Airbag ........................ 2

Schematic Diagram of the center control Switch........... 2
Schematic Diagram of PAB Switch.................................. 3
Precautions for Maintenance .......................................... 3
Testing instrument............................................................ 5
Troubleshooting................................................................ 5
Troubleshooting................................................................ 8
Diagnosis to Vehicle Impact............................................. 23
Warning Sign..................................................................... 25
Method for Removing Each Parts.................................... 26
Essentials of discarding airbag modules....................... 31
Airbag-
Electrical Schematic Diagram of Airbag
Driver seat belt indicator lamp
Airbag warning lamp

Brown/White
Green/Yellow
Blue/White
Crash unlock
Red
Blue/White
Airbag ECU
Passenger seat belt switch

White/Red
White/Green
Seat belt warning output
PAB indicator lamp

Passenger seat belt indicator lamp
PAB switch
Blue/Red
Blue/Yellow
Yellow/Red
Yellow/Black
PAB indicator lamp

Combination instrument pin 37
Clock spring
Assistant driver Passenger seat Driver seat belt Seat sensor

Driver airbag
airbag belt pretensioning pretensioning
Schematic Diagram of the center control Switch
indicator lamp for indicator lamp for

Symbol illumination lamp LPG switch ESP(or TCS) switch Airbag turning off Airbag untying
Electrified “ON” position
1
20
2H switch 4L switch 4H switch
2
Electrified “ACC and ON” position
IC
475Ω 475Ω
1KΩ 1KΩ
MCU
IC
4 5 10 11 12 13 16 17
lamp 7 8
BCM External BCM

外接BCM
(Send PWM adjustment light signal to switch)
Airbag-
Schematic Diagram of PAB Switch

Power supply
PAB switch indicator lamp 2 1
6 5 4 3
PAB switch warning lamp status
PAB status Resistance Warning lamp PAB switch
Deployed Not lighted PAB switch external mark status

Not deployed Lighted PAB switch external mark status
Do not stand for the external icon indication

(opposite to the external icon)
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 pur-
suant 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
(h) Body controller
(i) Center control switch
(j) Combination instrument
4. For the electrical basic diagram of airbag, schematic diagram of the center control switch,
schematic diagram of PAB switch (see Pages 2, 3); for SRS-ECU pin definition, see the diagram
below; for the position and shape of airbag malfunction indicator lamp, see Page 4.
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
pretensioner
B seat
Positive pole of passenger seat

9 NC 21
belt pretensioner
Negative pole of passenger seat
10 PABswitch 22
belt pretensioner
Passenger seat belt latch switch
11 23 Negative pole
Passenger seat sensor
12 Positive pole 24 Malfunction indicator lamp
Airbag-
5. Disconnect the battery negative pole and hold on for 60s before maintenance. The disconnec-
ted 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 cer-
tain 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 pro-
perly 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 norma-
lly after maintaining the SRS airbag system.
Malfunction alarm lamp

of airbag system
Driver seat charge Impact sensor and Passenger seat charge element and airbag
element and airbag diagnosis module
Insulating tape
Battery
Wire
Airbag-
Testing instrument
Instrument Name Utility
Inspect the SRS airbag system for

X-431 Diagnostic detection instru-
system malfunction and clear the
ment
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 per-
manently 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 main-
tained.
• 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 diagnostic equipment 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
Airbag-
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

GWM Bosch
DTC Description/故障代码描述
DTC DTC
Electronic Control Unit(ECU)internal fault/ECU内部故障 B1000 $9000
Configuration fault/配置错误 B1001 $9001
Front Airbag Driver Loop Open/司机安全气囊开路 B0026 $8026
Front Airbag Driver Loop Resistance Low/司机安全气囊阻值过低 B0022 $8022
Front Airbag Driver Loop Short to GND or Cross Coupling/司机安全气囊对地短路
B0024 $8024
或搭线
Front Airbag Driver Loop Short to Battery/司机安全气囊对电池短路 B0025 $8025
Front Airbag Passenger Loop Open/乘员安全气囊开路 B0017 $8017
Front Airbag Passenger Loop Resistance Low/乘员安全气囊阻值过低 B0016 $8016
Front Airbag Passenger Loop Short to GND or Cross Coupling/乘员安全气囊对地
B0018 $8018
短路或搭线
Front Airbag Passenger Loop Short to Battery/乘员对电源短路 B0019 $8019
Belt Pretensioner Front Driver Loop Open/司机安全带预紧器开路 B0065 $8065
Belt Pretensioner Front Driver Loop Resistance Low/司机安全带预紧器阻值过低 B0064 $8064
Belt Pretensioner Front Driver Loop Short to GND or Cross Coupling/司机安全
B0066 $8066
带预紧器对地短路或搭线
Belt Pretensioner Front Driver Loop Short to Battery/司机安全带预紧器对电源
B0067 $8067
短路
Belt Pretensioner Front Passenger Loop Open/乘员安全带预紧器开路 B0058 $8058
Belt Pretensioner Front Passenger Loop Resistance Low/乘员安全带预紧器阻值过
B0057 $8057
低
Belt Pretensioner Front Passenger Loop Short to GND or Cross Coupling/乘员安
B0059 $8059
全带预紧器对地短路或搭线
Belt Pretensioner Front Passenger Loop Short to Battery/乘员安全带预紧器对电
B0060 $8060
源短路
* Side Airbag Front Driver Loop Open/司机侧面安全气囊开路 B0041 $8041
* Side Airbag Front Driver Loop Resistance Low/司机侧面安全气囊阻值过低 B0040 $8040
* Side Airbag Front Driver Loop Short to GND or Cross Coupling/司机侧面安全
B0045 $8045
气囊对地短路或搭线
* Side Airbag Front Driver Loop Short to Battery/司机侧面安全气囊对电源短路 B0046 $8046
Airbag-
GWM Bosch
DTC DTC
* Side Airbag Front Passenger Loop Open/乘员侧面安全气囊开路 B0029 $8029
* Side Airbag Front Passenger Loop Resistance Low/乘员侧面安全气囊阻值过低 B0028 $8028
* Side Airbag Front Passenger Loop Short to GND or Cross Coupling/乘员侧面安
B0030 $8030
全气囊对地短路或搭线
* Side Airbag Front Passenger Loop Short to Battery/乘员侧面安全气囊对电源短
B0032 $8032
路
* Curtain Airbag Driver Loop Open/司机安全气帘开路 B0062 $8062
* Curtain Airbag Driver Loop Resistance Low/司机安全气帘阻值过低 B0061 $8061
* Curtain Airbag Driver Loop Short to GND or Cross Coupling/司机安全气帘对地
B0068 $8068
短路或搭线
* Curtain Airbag Driver Loop Short to Battery/司机安全气帘对电源短路 B0063 $8063
* Curtain Airbag Passenger Loop Open/乘员安全气帘开路 B0070 $8070
* Curtain Airbag Passenger Loop Resistance Low/乘员安全气帘阻值过低 B0069 $8069
* Curtain Airbag Passenger Loop Short to GND or Cross Coupling/乘员安全气帘
B0071 $8071
对地短路或搭线
* Curtain Airbag Passenger Loop Short to Battery/乘员安全气帘对电源短路 B0076 $8076
* Knee Airbag Loop open/膝部安全气囊开路 B102E $902E
* Knee Airbag Loop Short to Battery/膝部安全气囊对电源短路 B102D $902D
* Knee Airbag Loop Short to GND/膝部安全气囊对地短路 B102C $902C
* Knee Airbag Front Passenger Loop Resistance Low/膝部安全气囊阻值过低 B102F $902F
* Driver Side Impact Sensor (PAS) Performance fault or Cross Coupling/司机侧
B0077 $8077
外围加速度传感器性能故障或者搭线
* Incorrect Driver Side Impact Sensor (PAS) Installed/司机侧外围传感器安装不
B0079 $8079
正确
* Driver Side Impact Sensor (PAS) Defect or Plausibility Fault/司机侧外围传
B0080 $8080
感器损坏或者可靠性故障
* Passenger Side Impact Sensor (PAS) Performance fault or cross coupling/乘
B0078 $8078
员侧外围加速度传感器性能故障或者搭线
* Incorrect Passenger Side Impact Sensor (PAS) Installed/乘员侧外围传感器安
B0081 $8081
装不正确
* Passenger Side Impact Sensor (PAS) Defect or Plausibility Fault/乘员侧外围
B0082 $8082
传感器损坏或者可靠性故障
Battery Voltage High/电源电压过高 B1328 $9328
Battery Voltage Low/电源电压过低 B1327 $9327
BLFD short to Battery/司机安全带锁扣对电源短路 B0097 $8097
* BLFP short to Battery/乘员安全带锁扣对电源短路 B0096 $8096
PADS Voltage Out of Range/PAB开关故障 B0090 $8090
PADS: Wrong State/PAB开关电阻设置错误 B0091 $8091
System Warning Lamp Circuit Short to GND or Open/系统故障灯对地短路或开路 B0671 $8671
System Warning Lamp Circuit Short to Battery/系统故障灯对电源短路 B0673 $8673
Passenger Airbag Disabled Indicator Short to GND or Open/PAB指示灯对地短路或
B0681 $8681
开路
Passenger Airbag Disabled Indicator Short to Battery/PAB指示灯对电源短路 B0683 $8683
Fasten Passenger Seatbelt Indicator Circuit Fault/乘员安全带指示灯故障 B059A $859A
Fasten Driver Seatbelt Indicator Circuit Fault/司机安全带指示灯故障 B0595 $8595
Chime out Circuit Short to Battery/安全带提醒电路对电源短路 B0883 $8883
Chime out Circuit Short to GND or Open/安全带提醒电路对地短路或开路 B0882 $8882
Front Airbag Deployment Commanded/前气囊已引爆 B0051 $8051
* Side(and Curtain)Airbag Deployment Commanded/侧面安全气囊或者安全气帘已引
B0034 $8034
爆
Airbag-
GWM Bosch
DTC DTC
ABM reaches the maximum usage, and it can not be reusable/安全气囊控制器达到
B0052 $8052
最大使用限度并无法继续使用
Crash Output of Controller Short to battery/碰撞输出线路对电源短路 B0049 $8049
Crash Output of Controller Short to GND or Open/碰撞输出线路对地短路或者开路 B0048 $8048
Note/注意:
DTC with * means only for 9 loops ABM.
带* 的DTC只适用于9回路安全气囊控制器
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
current malfunction 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
Alarm circuit malfunction of airbag system or exter-
2 The airbag system alarm lamp is always on.
nal 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 reasons Combination instrument malfunction
Malfunction of the harness between instrument group and ECU or fuse is broken
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, ter-
minal 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 indi- Place the ignition switch at LOCK
cator lamps. Yes position, and then turn to next
• Place the ignition switch at ON position. step.
1 • Are the other alarm lamps and indicator lamps Inspect the instrument group
on? power supply system and groun-
No
ding system (fuse), then turn to
the step 5.
Inspect the bulb
Warning:
Improper handling of airbag system elements may Yes Turn to the next step.
deploy the airbag or pretensioning seat belt acciden-
tally, which may lead serious accident. Please read
the airbag system maintenance warnings before ope-
2 ration.
• Place the ignition switch at LOCK position.
• Cut off battery negative pole wire and hold on for No Replace the alarm lamp bulb.
at least 60s.
• Remove the combination instrument.
• Measure the two relevant pins of airbag alarm
lamp to see if they are conducted.
Airbag-
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
• Inspect the relevant parts of alarm lamp circuit to NO turn to the step 5.
see 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
Combination instrument inner alarm malfunction
BCM malfunction
Center control switch 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 impossi-
ble.
Step Detection Operation

Inspect battery Yes Turn to the next step.
Inspect battery voltage Battery power supply insuffi-
1 Is the voltage above 9V? ciency. Inspect the charge/dis-
NO
charge system, and then turn
to the step 5.
Inspect the conductivity of the harness between
ECU and combination instrument.
Yes Turn to the next step.
Place the ignition switch at LOCK position.
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.
Inspect the circuit and turn to
Place the ignition switch at ON position. NO
the step 5 after it is repaired.
Inspect the voltage between relevant connector ter-
minals 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 con-
3 Repair or replace the harness
nector and diagnosis connector to see if they are NO
and then turn to the step 5.
conducted (the two ends of diagnosis K-line).
Airbag-10
Step Detection Operation

Cut off the battery negative pole wire and hold on
for at least 1 min.
Cut off the ECU connector.
3 Replace the harness and then
Cut off the instrument group connector. No
Is the circuit between the ECU connector terminal turn to the step 5.
24 and instrument connector conducted?
Yes Replace ECU
Remove the ECU to see if the terminal is complete,
4 Reconnect ECU connector and
or if the short-circuit rod is broken. No
then turn to the next step.
Make sure the malfunction doesn’t recur after repai- Solve the malfunction and then
ring. Yes explain the maintenance pro-
Place the ignition switch at LOCK position. cedures to the customer.
Cut off battery negative pole wire and hold on for at
least 1 min.
Connect all the ECU connectors.
Connect the airbag component connectors at dri-
ver’s side
Connect the airbag assembly connector at passen-
ger’s side
5 Connect the driver and passenger pretensioning
Inspect again, and start from
seat belt connectors.
No the first step if the malfunction
(Vehicle with pretensioning seat belt)
recurs.
Connect the clock spring connector
Connect the BCM connector;
Connect the combination instrument connector
Connect the PAB control switch and the center con-
trol 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 malfunc-
Inspection tion code before inspection by DTC. The incorrect operation for this malfunction ins-
conditions pection may lead personnel injury or system damage, so preparation should be made
before inspection.
Internal circuit malfunction of SRS airbag system ECU
Possible rea-
Internal malfunction of SRS airbag system unit
son
Operation
Replace the SRS airbag system unit. Refer to the “Disassembling and assembling of airbag system
unit” under the “SRS airbag system unit” section.
Airbag-11
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 by DTC. The incorrect operation for this malfunction inspection
Inspection
may lead personnel injury or system damage, so preparation should be made before ins-
condition
pection.
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
reason system ECU.
Step Inspection Operation
Inspect the battery Yes Turn to the next step.
1 Measure the battery voltage Low battery power supply; inspect
No
Is the voltage above 9V? the charge and discharge system
Inspect the harness between battery and
fuse box.
Remove the fuse box without loosening the
connector
2
No Inspect the harness
Measure the voltage between two relevant
terminals of fuse box to see if it is above
9V?
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 injury. Please read the airbag
system maintenance warnings carefully be-
fore operation. Refer to the “Airbag system
maintenance warnings” section.
Remove the steering column shell and
loosen the clock spring connector at least
3 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). No Replace the harness
Loosen the airbag module connector at
passenger’s side.
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 connec-
tor pin 12 and 23 (ground) of SRS airbag
system unit to see if it is above 9V.
Airbag-12
Place the ignition switch at LOCK position. [Current malfunction code]

Loosen the battery negative pole terminal Replace the SRS airbag system unit.
and hold on for at least 1min. Refer to the “Disassembling and ass-
Remove left inner trim board Yes embling of airbag system unit” under
Cut off the connector of SRS airbag system the “SRS airbag system unit” section.
4 unit [Historical malfunction code ]
Install the battery negative pole wire and The malfunction diagnosis is over.
place the ignition switch at ON position,
then measure the voltage between relevant
No Replace the harness
pin and (ground) of connector to see if it is
above 9V.
Driver’s Side Airbag Malfunction

Malfunction Driver’s side airbag malfunction (high resistance, low resistance, short-circuit or groun-
code ding etc.)
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 ma-
intenance warnings carefully before operation. Refer to the “Airbag system maintenance
Inspection
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 sys-
tem 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 ele- Refer to the “Disassembling
ments may deploy the airbag module acci- and assembling of clock spring”
dentally, which may lead personnel injury. under the “Airbag system” sec-
Please read the airbag system maintenan- tion.
ce warnings before operation.
1
Refer to the “Airbag system maintenance Abnormal
warnings” section.
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 neces-
sary.
Airbag-13
Confirm whether the malfunction occurs on Replace the driver's side airbag
the airbag module at drive’s side or other module.
parts. Refer to the “Disassembling
Yes
Replace the DAB with a good one. and assembling of drive’s side
2
Install the battery negative pole wire airbag module” under the “Air-
Place the ignition switch at ON position. bag system” section.
Is malfunction code displayed or can it be
No Turn to the next step.
cleared?
Inspect the clock spring harness connector Normal Turn to the next step.
Loosen the battery negative pole terminal
3 and hold on for at least 1min
Abnormal Replace the harness
Remove the steering column shell
Loosen the clock spring connector
Is the clock spring connector normal?
Confirm whether the malfunction occurs Yes Turn to the next step.
on the clock spring at drive’s side or other Replace the clock spring.
parts. Refer to the “Disassembling
Set the special tools, fuel and temperature and assembling of clock spring”
4 inspection instrument at the position of 2 under the “Airbag system” sec-
No
ohm. tion.
Install the battery negative pole wire
Is malfunction code displayed?
Inspect the harness between the clock Replace the SRS airbag system
spring and SRS airbag system ECU unit. Refer to the “Disassem-
Place the ignition switch at LOCK position. Normal bling and assembling of airbag
Loosen battery negative pole wire and hold system unit” under the “SRS
on for at least 1min
airbag system unit” section.
Remove the PAB trim cover and glove box Replace the harness
cover)
Loosen the airbag module connector at
passenger’s side
5
Loosen all the connectors of SRS airbag
system.
Inspect the harness between connector Abnormal
terminals 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 Replace the harness or con-
Loosen the clock spring connector Abnormal
nector
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 assem- Refer to the “Disassembling
bling of clock spring” under the “Airbag and assembling of clock spring”
7
system” section.. Inspect the clock spring Abnormal under the “Airbag system” sec-
Refer to the “Inspection of clock spring” tion..
under the “Airbag system” section..
Is the clock spring normal?
Airbag-14
Inspect the harness between the clock Normal Turn to the next step.
spring and SRS airbag system ECU. Replace the clock spring.
Place the ignition switch at LOCK position Refer to the “Disassembling
Loosen battery negative pole wire and hold and assembling of clock spring”
on for at least 1min under the “Airbag system” sec-
Remove the PAB trim cover and glove box tion..
cover)
Loosen the passenger’s side airbag modu-
le connector
8
Loosen all the connectors of SRS airbag Abnormal
system.
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
code circuit or grounding etc.)
B0017
B0016
B0018
B0019
Warning
Improper handling of airbag system elements may deploy or tension the airbag module
and 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 warnings” section.
Inspection
If there is passenger’s side airbag
condition
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 passen- Yes Turn to the next step.
1
ger’s side airbag module? No Turn to the step 5.
Airbag-15
B0017
B0016
B0018
B0019
Inspect the passenger’s side airbag module [Current malfunction code]
Warning Turn to the next step.
Improper handling of airbag system elements Normal Historical malfunction
may deploy the airbag module and pretensioning code
seat belt accidentally, which may lead serious Turn to the next step.
personnel injury. Please read the airbag system Replace the harness
maintenance warnings carefully before opera-
tion.
Refer to the "Airbag system maintenance war-
2
nings” section.
Place the ignition switch at LOCK position
Abnor-
Loosen the battery negative pole terminal and
mal
hold on for at least 1min
Remove the PAB trim cover and glove box (pas-
senger’s side airbag is under the trim cover)
Loosen the airbag module connector at passen-
ger’s side
Is the passenger’s side airbag module normal?
Confirm whether the malfunction occurs on the Yes Turn to the next step.
airbag module at passenger’s side or other parts. Replace the passenger's
Connect a good module with the terminal A and side airbag module.
B of the airbag module at passenger’s side Refer to the “Disassem-
3
Connect the battery negative pole wire No bling and assembling of
Place the ignition switch at ON position passenger’s side airbag
Is the malfunction code displayed? module” under the “Airbag
system” section.
Inspect the harness between airbag module at [Current malfunction code]
the passenger’s side and SRS airbag system Replace the SRS airbag
ECU system unit. Refer to the
Place the ignition switch at LOCK position “Disassembling and ass-
Loosen the battery negative pole terminal and embling of airbag system
hold on for at least 1min. Normal unit” under the “SRS air-
Remove the steering column shell bag system unit” section.
Loosen the clock spring connector [Historical malfunction
Loosen the airbag module connectors at driver code ]
4
and passenger’ side The malfunction diagnosis
Loosen all the connectors of SRS airbag system. is over.
Inspect the harness between connector termi- Replace the relevant har-
nals of SRS airbag system unit and clock spring ness
to see if there is the following malfunction:
Abnor-
• Ground
mal
• Broken circuit
Airbag-16
B0017
B0016
B0018
B0019
Place the ignition switch at LOCK position Yes Turn to the step 2.
Loosen the battery negative pole terminal and The malfunction is that
hold on for at least 1min there is no passenger’s
Install a good passenger’s side airbag module at side airbag module
5
proper position No
Place the ignition switch at ON position
Is the malfunction code displayed?
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
The resistances of pins 19, 20, 21 and 22 of the SRS airbag system unit connector don’t
conditions
lie in the specified 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 system ECU
Malfunction of the connector between the SRS airbag system unit and the grounding po-
Possible int
reason Broken circuit or short circuit between the pretensioning force-limiting seat belt and the
SRS airbag system ECU
Broken circuit or short circuit between the SRS airbag system unit and the grounding po-
int
Malfunction of the SRS airbag system unit
Step Inspection Operate
Is the vehicle equipped with any preten- Yes Turn to the next step
1
sioning force-limiting seat belt? No To Step 5
Airbag-17
Check the warnings for the connector [Current malfunction code]

of the pretensioning force-limiting seat Turn to the next step
Normal
belt. [Historical malfunction code]
Improper handling of airbag system Turn to the next step
elements may deploy or tension the air-
bag module and pretensioning seat belt
accidentally, which may lead serious
system maintenance warnings carefully
before operation.
2 Refer to the “Airbag system maintenan-
ce warnings” section.
Place the ignition switch at “LOCK” po- Abnormal Replace the harness
sition.
Loosen the battery negative pole termi-
nal and hold on for at least 1min.
Remove the protective board of pillar B.
Loosen the connector of the pretensio-
ning force-limiting seat belt
Is the connector of the pretensioning
force-limiting seat belt normal?
Confirm whether the malfunction: oc- Normal Turn to the next step
curs on the pretensioning force-limiting Replace the pretensioning force-
3 seat belt or other parts? limiting seat belt.
Abnormal
Is the pretensioning force-limiting seat
belt normal?
Check the harnesses between the pre- [Current malfunction code]
tensioning force-limiting seat belt and Replace the airbag system unit
the SRS airbag system ECU Refer to the “Disassembling and
Turn the ignition switch to “LOCK” assembling of airbag system unit”
Normal
Loosen the negative pole wire of the under the “SRS airbag system
battery and wait for more than 1 minute unit” section.
Remove the protective plate of the B [Historical malfunction code]
column The malfunction diagnosis is over.
Loosen the connector of the pretensio- Replace
ning force-limiting seat belt the relevant harness
Loosen all the connectors of the SRS
4 airbag 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 Abnormal
belt
Determine whether there is any situa-
tion in the circuit as follows:
• Grounding
• Short to the power supply
• Broken circuit
Are these harnesses foresaid normal?
Airbag-18
Place the ignition switch at LOCK posi- Yes Turn to the step 2.
tion The malfunction is that there is no
Loosen the battery negative pole termi- pretensioning force-limiting seat
nal and hold on for at least 1min belt
5 Install a good pretensioning force-limi-
No
ting seat belt at proper position
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
Malfunction of the connector between combination instrument and SRS airbag system
Possible ECU
reason Malfunction of the connector between SRS airbag system unit and grounding point
Broken circuit or short circuit between the combination instrument and the SRS airbag
system ECU
Steps Inspection Operation item
Is the vehicle equipped with any combi- Yes Turn to the next step
1
nation instrument? No Turn to Step 5
Check the warning of the connector of [Current malfunction code]
the combination instrument. Turn to the next step
Normal
Improper handling of airbag system ele- [Historical malfunction code]
ments may deploy or tension the airbag Turn to the next step
module and pretensioning seat belt acci-
dentally, which may lead serious person-
nel injury. Please read the airbag system
maintenance warnings carefully before
operation.
2 Refer to the “Airbag system maintenan-
Place the ignition switch at “LOCK” posi- Abnormal Replace the harness
tion.
nal and wait for at least 1 min.
Loosen the combination instrument con-
nector.
Is the combination instrument connector
normal?
Airbag-19
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
Confirm whether the malfunction: occurs Normal Turn to the next step
on the combination instrument or other
3 Replace the combination instru-
parts? Abnormal
ment.
Is the combination instrument normal?
Check the harness between the combi- [Current malfunction code]
nation instrument and the SRS airbag Replace the airbag system unit.
system ECU Refer to the “Disassembling and
Place the ignition switch at “LOCK” posi- assembling of airbag system unit”
Normal
tion. under the “SRS airbag system
Loosen the battery negative pole termi- unit” section.
nal and wait for at least 1 min. [Historical malfunction code]
Loosen the combination instrument con- The malfunction diagnosis is over.
nector
4 airbag system unit
Check the connector terminals between
the SRS airbag system ECU and the cir-
cuit between the combination instrument
connector terminals Abnormal Replace the relevant harness
Determine whether there are any situa-
tions in the circuit as follows:
• Grounding
• Broken circuit
Place the ignition switch at LOCK posi-
tion
Yes Turn to the step 2.
nal and hold on for at least 1min
5 Install a good combination instrument at
proper position
The malfunction is that there is no
Connect the battery negative pole wire No
combination instrument
Malfunction of BCM
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
Airbag-20

Malfunction of the connector between the BCM and the SRS airbag system ECU
Possible
reason
int
Broken circuit or short circuit between the BCM and the SRS airbag system ECU
Yes Turn to the next step
1 Is the vehicle equipped with any BCM?
No To Step 5
BCM Turn to the next step
Improper handling of airbag system ele- Normal
[Historical malfunction code]
ments may deploy or tension the airbag Turn to the next step
module and pretensioning seat belt acci-
dentally, which may lead serious person-
nel injury. Please read the airbag system
maintenance warnings carefully before
2 operation.
Refer to the “Airbag system maintenan-
ce warnings” section. Abnormal Replace the harness
Place the ignition switch at “LOCK” posi-
tion.
nal and wait for at lease 1 min.
Loosen the BCM connector
Is the BCM connector normal?
Confirm whether the malfunction occurs Normal Turn to the next step
3 on the BCM connector or other parts
Is the BCM normal? Abnormal Replace the BCM
Check the harness between the BCM [Current malfunction codes]

and the SRS airbag system ECU Replace the airbag system unit.
Place the ignition switch at “LOCK” posi- Refer to the “Disassembling and
tion. assembling of airbag system unit”
Loosen the battery negative pole termi- Normal
under the “SRS airbag system
unit” section.
Loosen the BCM connector
Loosen all the connectors of the SRS [Historical malfunction code]
airbag system unit The malfunction diagnosis is over.
4 Check the connector terminals between
circuit between the BCM connector ter-
minals
Abnormal Replace the relevant harness
tions in the circuit as follows:
• Grounding
• Broken circuit
tion
5 The malfunction is that there is no
Install a good BCM at proper position No
Connect the battery negative pole wire BCM
Airbag-21
Malfunction of PAB Switch

Malfunction Malfunction of PAB switch
codes Switch resistance setting error
B0090
B0091
Warning
Inspection and pretensioning seat belt accidentally, which may lead serious personnel injury. Please
conditions read the airbag system maintenance warnings carefully before operation.
Check the switch resistance varies between 100 Ω and 400 Ω (“OFF” and “ON”)
Malfunction of the connector between the PAB switch and the SRS airbag system ECU
Possible
reason
int
Broken circuit or short circuit between the PAB switch and the SRS airbag system ECU
Is there any PAB switch readily-equip- Yes Turn to the next step
1
ped? No To Step 5
the PAB switch Turn to the next step
Improper handling of airbag system Normal
elements may deploy or tension the air- [Historical malfunction code]
bag module and pretensioning seat belt Turn to the next step
accidentally, which may lead serious
system maintenance warnings carefully
2 before operation.
Refer to the “Airbag system maintenan-
Place the ignition switch at “LOCK” po- Abnormal Replace the harness
sition.
Loosen the PAB switch connector
Is the PAB switch connector normal?
Confirm whether the malfunction occurs Normal Turn to the next step
3 on the PAB switch or other parts
Is the PAB switch normal? Abnormal Replace the PAB switch
Check the harness between the PAB [Current malfunction code]
switch and the SRS airbag system ECU Replace the airbag system unit.
Place the ignition switch at “LOCK” po-
sition. Refer to the “Disassembling and
Loosen the battery negative pole termi- assembling of airbag system unit”
Normal
nal and wait for at least 1 min. under the “SRS airbag system
Loosen the PAB switch connector unit” section.
airbag system unit [Historical malfunction code]
4 Check the connector terminals between The malfunction diagnosis is over.
circuit between the PAB switch connec-
tor terminals
tions in the circuit as follows: Abnormal Replace the relevant harness
• Grounding
• Broken circuit
Airbag-22
tion
5 Install a good PAB switch at proper po- The malfunction is that there is no
sition No
PAB switch
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 Malfunction of the passenger seat belt indication lamp
B0683 Malfunction of the driver seat belt indication lamp
B059A
B0595
Warning
Inspection and pretensioning seat belt accidentally, which may lead serious personnel injury. Please
conditions read the airbag system maintenance 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.
Airbag-23
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) BCM(body control module)
(f) Combination instrument
(g) Center control switch
(h) SRS-ECU
(i) Driver/passenger side airbag module/pretensioning 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 mo-
ves 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 connec-
tors or any deformation to the terminals.
3. Check the installation status of the SRS-ECU brac-
ket.
(a) Check whether there is any pit, crack, deforma-
tion, etc. on the cover.
(b) Check whether there is any damage to the con-
nector, any deformation to the terminal or the har-
ness is seized.
(c) Check whether there is any pit, crack, deforma-
tion, 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
Airbag-24
Driver’s side
Driver’s side airbag module
Generator
Bracket
Connecting the Clock spring

driver module 1. Check to see whether there is any damage to the
connector and the protective pipe or any deforma-
Connecting tion to the terminal.
the horn
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.
Airbag-25
Inspection to harness connectors (instrument

panel harnesses)
Check to see whether the harnesses are installed fir-
mly, there is any damage to the connectors, or any de-
formation 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 Driver’s side airbag module
Clock spring
Warning Sign
SRS-ECU
SRS-ECU
Airbag-26
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 periphe-
ral 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 adhesi-
ve tape
SRS-ECU 2. Sequence of removing
(a) The cover plate at the central passage side (or re-
move 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
Airbag-27
(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 troubleshoo-
ting.
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 re-
moved (-) 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 har-
ness 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.
Airbag-28
3. Sequence for removing the driver’s side airbag mo-

dule
(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 self-tapping screw of the instrument panel right upper cover.
(d) Remove the instrument panel right upper cover with the PAB switch
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. Driver’s side airbag module (DAB) and its 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.
• Install the PAB to the right upper cover of instrument panel, and then install them to the vehicle to-
gether.
• 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
Airbag-29
Use a hexagon socket sleeve Removing of steering wheel

(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 (Becau-
se the steering wheel is connected with the clock
spring at the lower side, forced removal may dama-
ge the clock spring).
Note
Diagnose the circuit of airbag module with electro-
nic 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 X-431 diagnosis tester to the diagno-
sis interface (16-pin)
Note:
Set the ignition switch to “LOCK” when connecting
or disconnecting the X-431 diagnosis tester.
• Set the ignition switch to “ON”.

• 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 ad-
hesive tape for the sake of insulation.
Note:
Disconnect the (-) negative pole of battery and ope-
rate after 60s.
Get the clock spring aligned and then install it onto
the steering wheel.
Airbag-30
(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 cir-
cuit 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 su-
bassembly after getting the center of the clock
spring aligned.
Note:
Don’t clamp the clock spring harnesses when ins-
talling the steering wheel and airbag module su-
bassembly.
• After installing, turn the steering wheel leftwards
and rightwards as properly as possible to see whe-
ther there is any abnormality.
(d) Inspection after installing
• Turn the steering wheel leftwards and rightwards
gently to see whether there is any abnormality or
Malfunction
warning lamp of
noise. (Driver’s side airbag module, clock spring)
airbag module • Set the ignition switch to “ON”.
system • The SRS warning lamp goes off after it is on for 4s.
• Conduct troubleshooting if it goes off and then per-
sists 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 sequen-
ce 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.
Airbag-31
(b) Inspection to clock spring

Inspect the following items. Replace the used clock
spring with the new and corresponding ones in case of
Casing
壳体 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
防护管 pipe • Check to see whether the circuit is normal between
2
the upper connector terminal of the clock spring
and the lower counterpart.
• Insert a fine probe from the backside of the 3# con-
nector 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 jam-
ming 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 bat-
tery 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 (ye-
llow).
Casing
壳体
Note:
Take off the connector of clock spring from the ins-
trument panel harness and the clock spring will be
3 involved with short circuit itself, thus preventing
the fatal accident due to static electricity in the de-
Protective
防护管 pipe ployment of the driver’s side airbag module.
2
Airbag-32
(c) Connect the switchover harness of SRS airbag to

Short circuit position
two 6m above long harnesses for deployment. En-
Harness for deployment lace the connecting position with insulating tape
for insulating.
6m above long
Connect other ends of the harnesses for deployment
SRS switchover 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 outsi-
Clock spring connector de the vehicle.
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 deployment At first, confirm whether there is any person in and
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.
Airbag-33
(a) Disconnect the (-) negative pole and the (-) positi-
ve pole of battery and remove them from the bat-
tery
Note:
Operate 60s later after removing the battery.
(b) Deploy the airbag module in the following sequen-
ce
• 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 arti-
cles laid on it if any mistaken deployment occurs.
• Prepare two 6m above long harnesses for deploy-

Harness for deployment ment and connect the other ends of them with each
Short circuit position other (to form a short circuit) to avoid any deploy-
ment 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.
Harness for deployment • Disconnect the harness of driver’s side airbag

module and then connect it with the foresaid two
harnesses for deployment. Enlace the connecting
position with the insulating tape for the sake of in-
sulating.
Short circuit
position
Insulating tape
Airbag-34
• Apply the unused bolts into the bolt holes at the in-
ner 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 mo-
dule upwards with the metal wire connected to the
bolt.
• Put three used tyres without hub onto the tyre fixing
the driver’s side airbag module.
Used tyre without hub
• 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 re-
moved from the vehicle and get the airbag module
deployed.
Note:
Deploy the airbag module after ensuring there is
nobody nearby.
The gas generator is in a status of high temperatu-
re 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 Internal and External Trim-
Body Internal and External Trim
Body Internal and External Trim.......................................... 1

Instrument panel . ............................................................... 2
Front Bumper...................................................................... 7
Rear Bumper....................................................................... 9
Front Windshield................................................................. 11
Luggage Rack..................................................................... 13
Front Door .......................................................................... 14
Back Door............................................................................ 16
Driver’s Seat........................................................................ 18
Rear seat............................................................................. 21
Instrument panel
Instrument panel removal
1. Remove central upper cover of instrument panel
(a) Detach four clips.
(b) Remove central upper cover of instrument panel.
2. Remove LH cover assembly of instrument panel

1 (a) Detach three clips.
(b) Remove LH cover assembly of instrument panel.
1. LH cover assembly of instrument panel

2. 09650006 Clip
3. Instrument panel body
3. Remove RH cover of instrument panel

(a) Detach three clips.
1
(b) Remove RH cover assembly of instrument panel.
3
4
1. Instrument panel body assembly
2. RH cover of instrument panel
3. 09650006 Clip
4. PAB control switch assembly
4. Remove LH/RH trim of instrument panel and instru-

1 2
ment cluster
(a) Detach three clips.
3
(b) Remove LH trim A of instrument panel.
3 (c) Detach two clips.
4 (d) Remove RH trim B of instrument panel.
5 (e) Detach five clips.
6 (f) Remove RH trim of instrument panel.
3
7 (g) Unscrew three tapping screws.
1. LH trim A of instrument panel
(h) Remove the instrument cluster.
3. 09650010 Clip
4. LH trim B of instrument panel
5. Combination instrument assembly
6. Q2714813FD
Cross recessed pan head tapping screw
7. RH trim of instrument panel
5. Remove instrument cover assembly

1
(a) Detach six clips and two catches.
(b) Remove instrument panel cover.
3
2. Instrument cover assembly
3. 09650010 Clip
1
6. Remove LH upper cover assembly of instrument
panel
2 (a) Unscrew one tapping screw.
(b) Detach 15 clips.
(c) Remove LH upper cover assembly of instrument
panel.
1. LH upper cover assembly of instrument panel

2. Q2714813FD
7. Remove RH upper cover assembly of instrument

1
panel
2
(a) Unscrew three tapping screws.
(b) Detach 15 clips.
(c) Remove RH upper cover assembly of instrument
panel
1. RH upper cover assembly of instrument panel

2. Q2714813FD
8. Remove LH lower shield of instrument panel

1
(a) Unscrew two tapping screws.
(b) Remove pull wire latch of engine hood lock.
2 (c) Detach six clips.
(d) Remove LH lower shield of instrument panel.
3
5 4
2. Q2714813FD
3. 09650010 Clip
4. LH lower shield of instrument panel
5. Pull wire latch of engine hood loc
9. Remove glove box assembly

1
(a) Unscrew two screws.
(b) Push RH wall and then LH wall to release the
chock block.
(c) Pull out glove box body backward to make conve-
nience for disassembling it.
2
3

2. Glove box assembly
3. Q1840516FD
Hexagon flange bolt
10. Remove LH/RH trim of auxiliary instrument panel

1 (a) Detach two clips.
(b) Remove LH trim of auxiliary instrument panel.
2
(c) Detach two slips.
(d) Remove RH trim of auxiliary instrument panel.
3
2
1. RH trim of auxiliary instrument panel
2. 09650010 Clip
3. LH trim of auxiliary instrument panel
11. Remove shift lever decorative cover assembly

1 (a) Detach six clips.
2
(b) Remove shift lever decorative cover assembly.
1. Q2204816FD
and plain washer assembly
2. Shift lever decorative cover assembly
12. Remove rear section assembly of transmission de-

1 corative cover
3 (a) Unscrew four screws.
2
(b) Remove rear section assembly of transmission
decorative cover.
4 (c) Unscrew two nuts.
(d) Remove rear section mounting frame assembly of
5
transmission decorative cover.
1. Q2300616FD
Cross recessed pan head screw and plain
washer assembly
2. Q2204816FD
Cross recessed pan head tapping screw and
plain washer assembly
3. Rear section assembly of transmission deco-
rative cover
4. Q32106FD
Hexagon flange self-discharging nut
5. Rear section mounting frame assembly of
transmission decorative cover
13. Remove front section assembly of transmission

1 decorative cover
2
6
(a) Unscrew four screws.
3
(b) Detach four clips.
4
(c) Remove front section assembly of transmission
decorative cover.
5
1. Front section assembly of transmission

decorative coverwasher assembly
2. Q2204816FD
and plain washer assembly
3. Q2140612FD
Cross recessed pan head screw
4. Q40206FD Big washer
5. Q2140612FD
6. Q2714813FD
14. Remove console

1 (a) Detach five clips.
(b) Remove central vent panel assembly of instru-
2 ment panel.
3 (c) Detach four clips.
4 (d) Remove air-conditioner control panel assembly.
5
(e) Unscrew two screws of DVD player upper bracket
6 and four bolts of DVD player assembly mounting.
8 (f) Detach four clips.
7 4 (g) Remove DVD assembly.
1. Instrument panel body assembly with cen-

tral frame
2. Electrical rearview mirror switch assembly
3. Control switch assembly
4. 09650010 Clip
5. DVD player assembly
6. Q1840516FD Hexagon flange bolts
7. Air-conditioner control panel assembly
8. Central vent panel assembly of instrument
panel
15. Remove central frame of instrument panel

1
(a) Detach six clips.
(b) Remove central cover of instrument panel
2
2
4

2. 09650010 Clip
3. Central frame of instrument panel
4. Q2714813FD
16. Remove instrument panel

1 (a) Unscrew three self-discharging nuts.
2 (b) Unscrew seven bolts.
(c) Remove instrument panel body.
1. Q32106FD
Hexagon flange self-discharge nut
3. Q1840616FD
Hexagon flange bolt
4. Q1840616FD
Hexagon flange bolt
Front Bumper
Part Drawing
Upper shielding screen of front bumper

LH plastic clip of front bumper
Upper shielding screen trim
RH plastic clip of front bumper of front bumper
Q1400616FD
LH front fog lamp

decorative cover
Lower shielding screen of front bumper
Front bumper
body
Tow hook cover
RH front fog lamp decorative cover

Front license plate mounting plate
Removal of Front Bumper

1. Unscrew fixing bolts of front bumper.
Unscrew bolts connecting upper bumper end with headlamp mounting plate and then detach bumper
expansion clips connecting lower bumper end with splasher trim.
2. Tapping screw on both sides
Use screw driver to remove cross recessed hexagon head tapping screw with indentation and big
washer assembly connected with fender on both sides of the bumper.
3. Unscrew bumper mounting bolts
Unscrew hexagon head bolts connecting bumper with bracket.
4. Remove front bumper body from LH/RH bumper mounting bracket
5. Detach LH/RH fog lamp wire harness
6. Remove bumper accessories
Remove front bumper plastic bracket from vehicle body.
Rear Bumper
Part Drawing
RL mounting bracket assembly of rear bumper
LL mounting bracket assembly of rear bumper RH supporting plate of rear bumper
Base plate assembly of rear bumper

LH supporting plate of rear bumper
Spring clip
Upper fixing clamp

brackets of rear bumpe Rear bumper body
RH mounting bracket assembly of
Bumper expansion clip

rear bumper base plate bumper
LH mounting bracket assembly of rear bumper base plate
Small cove
Bumper expansion clip

RL splashboard of rear bumper
LL splashboard of rear bumper

Body Internal and External Trim-10
Removal of Rear Bumper

1. Detach bumper expansion clips
Use a screw driver to remove bumper expansion clips from upper bumper end.
2. Tapping screw on both sides
Use a screw driver to remove cross recessed hexagon head tapping screw and big washer assembly
on two bumper sides connected with side walls.
3. Unscrew nut connecting lower bumper end with splasher trim.
4. Unscrew bumper fixing bolts
Unscrew rear bumper fixing bolts connecting upper LH/RH side of rear bumper with vehicle body
5. Remove bumper
Remove rear bumper from LH/RH bracket of rear bumper.
6. Detach LH/RH fog lamp wiring harness
7. Remove plastic bracket
Remove cross recessed hexagon head tapping screw and big washer assembly on rear bumper
mounting bracket and remove rear bumper plastic mounting bracket.
Front Windshield
Part Drawing
Upper weatherstrip of front windshield LH weatherstrip of front windshield
Front windshield assembly
RH weatherstrip of
front windshield
Front windshield support
Front windshield rubber buffer
Front vent window cover body
Mounting hole cover of front

vent window cover
Guard staple of front
vent window cover
Clamp bracket of front
vent window cover
Right wiper blade Expansion clip of front vent window cover
Right front wiper arm Lower weatherstrip of

Left front wiper arm front vent window cover
Left front wiper arm
Front wiper decorative bonnet
Mounting expansion clip of front bumper
Large expansion joint of roof

LH decorative part of engine compartment rainproof rubber strip
RH decorative part of engine compartment rainproof rubber strip

Removal of Front Vent Window Cover

1. Remove front wiper blade (refer to the part of electric appliance).
2. Remove six mounting hole covers of front vent window cover.
3. Remove six tapping screws and expansion clips of front vent window cover.
4. Remove five front vent window cover guard staples and clamp brackets.
5. Remove front vent window cover.
Removal of Front Windshield
1. Unscrew tapping screws and remove inner rearview mirror.
2. Remove front windshield weatherstrip from vehicle body.
3. Cut glass cements around the windshield by means of steel wire.
4. Eliminate glass cements on inner edges of windshield by means of blade.
5. Remove glass cements completely from windshield frame by means of polishing machine.
Front Windshield Fitting
1. Apply primers onto front windshield frame and front windshield edge.
2. Use a glass cement gun to apply glass cements onto front windshield and keep the glass ce-
ment thickness at (10±2) mm.
3. Fit front windshield.
4. Use adhesive tapes on front windshield and metal panel around front windshield to fix front
windshield
5. Remove adhesive after 24h of glass cement coagulation.
6. Fit windshield weatherstrip onto front windshield.
Luggage Rack
Part Drawing
Luggage rack mounting hole cover III

Rear section body of RH luggage rack
Middle section body of right luggage rack Rear frame of RH luggage rack
Luggage rack mounting hole cover II Square head bolt

Front section body of RH luggage rack
Middle frame of RH
Front section body luggage rack
of RH luggage rack
RH luggage rack assembly
Luggage rack mount-

ing hole cover I
LH luggage rack assembly
M8 nonstandard bolt
Cushion
Rear section body of
LH luggage rack
Rear frame of LH luggage rack
M6 nonstandard bolt
Middle section body of LH luggage rack
Front section body Middle frame of LH luggage rack
of LH luggage rack
Slider
Front frame of LH luggage bracket
Removal of Luggage Rack

1. Remove luggage rack mounting hole cover;
2. Unscrew M6 nonstandard fixing bolts of front section of luggage rack;
3. Unscrew M8 nonstandard fixing bolts of middle and rear section of luggage rack;
4. Firstly remove front section and rear section of luggage rack and then middle section.
Refer to reverse steps of disassembling for assembling.
Front Door
Part Drawing
LF side door glass assembly
Exterior weatherstrip
of LF side door
Inner cover cloth

of LF side door Glass run channel of
LF side door
Weatherstrip of
LF side door
Interior door cover clip
Window lifter
Window switch and panel Exterior rearview mirror set square

assembly of LF side door
Exterior rearview mirror

set square cover
Q2540408F31
Interior buckle bolt cover

of LH side door
Interior door cover clip
Q1840616FD
Interior buckle cover plug of front door
Door lamp Trim plate assembly of LF side door

Front Door Removal

1. Remove front door trim plate.
(a) Remove exterior rearview mirror set square of front door.
(b) Lift interior buckle bolt cover and then remove interior buckle bolts (Q2540408F31) and interior
buckle of door.
(c) Firstly remove front interior buckle cover plug and use M6 sleeve to unscrew M6×16 hexagon
flange bolts.
(d) Detach electric switch and wiring harness.
(e) Plug clip opener between door clips and loosen clips between door trim plates.
Attention: Before using clip opener, wrap clip opener head with adhesive tapes.
(f) Remove door trim plates and detach wiring terminals of lamp door, high tone loudspeaker and
low tone loudspeaker.
(g) Remove door cover cloth.
2. Remove front door exterior weatherstrip
Regulate glass to the required level, unscrew front fixing bolts, forcibly lift weatherstrip with two hands
and remove it.
3. Remove front door glass assembly
(a) Regulate glass to make glass bracket mounting bolt aligned with door trim plate mounting hole
and unscrew two glass bracket fixing bolts.
(b) Elevate the glass and make it inclined and then remove it.
4. Remove front door glass run channel
5. Remove front door glass guide assembly.
6. Renew front door glass assembly
(a) Regulate front door window to make glass bracket fixing bolt aligned with door trim plate moun-
ting hole.
(b) Unscrew glass bracket fixing bolts and renew the glass.
Assembly of Front Door
1. Apply lubricating grease
Before fitting parts, apply MP lubricating grease to these parts.
(a) Apply MP lubricating grease to sliding surfaces and window lifter’s gears.
Attention: Please don’t apply MP lubricating grease to glass regulator spring.
(b) Apply MP lubricating grease to door lock sliding surface.
2. Fit exterior door buckle and door lock equipped with lock core.
3. Fit interior door lock trigger button.
4. Fit glass regulator.
5. Fit guide and bolt onto front door glass guide assembly.
6. Fit front door glass run channel.
7. Fit front door glass assembly.
Fit glass into door cavity and use two bolts to fix the glass onto glass regulator.
8. Fit front door exterior weatherstrip
Regulate glass downwards to the required level, fit weatherstrip onto outer door trim plate bayonet
and screw down bolts.
9. Fit door cover cloth.
10. Fit door trim plates.
Back Door
Part Drawing
Side vent run channel of LR side door

Side vent run channel of LR side door
Glass run channel of
Exterior weatherstrip of LR side door LR side door
Dustproof rubber strip LR side door glass

of LR side door
Interior cover cloth of LR side door
Glass regulator
Weatherstrip of LR side door
Window switch and panel assembly of l LR side door
Door trim plate clip
Q2540408F31
Interior buckle bolt cover of left

back side door lock
Interior buckle of left back side door link
Q1840616FD
Left back side door trim plate assembly

Interior buckle cover plug of back door
Door lamp
Back Door Removal

1. Disassemble back door trim plate
(a) Lift interior buckle bolt cover and remove interior buckle bolt (Q2540408F31) and interior buckle.
(b) Remove interior buckle cover plug of back door and use M6 sleeve to unscrew M6×20 hexagon
flange bolts.
(c) Detach electric switch and wiring harness.
(d) Plug clip opener between door clips and loosen clips between door trim plates.
Attention: Before using clip opener, necessarily wrap its head with adhesive tapes.
(e) Remove door trim plates and detach wiring terminals of door lamp and low tone loudspeaker.
(f) Remove door cover cloth.
2. Remove exterior weatherstrip of back door
Regulate glass downwards the required level, unscrew fixing bolts, forcibly pull the weatherstrip out
with two hands and remove it.
3. Remove back door glass assembly
(a) Lower back door regulator to a position enabling free motion of rocker, make the glass downward
and release the rocker from guide at lower end of glass.
(b) Pull upward the glass and then disassemble glass through inclining backward.
4. Remove back door glass run channel
5. Remove back door glass guide assembly
6. Remove glass regulator
7. Remove interior lock trigger button
8. Renew back door glass assembly
(a) Regulate back door glass to glass bracket fixing bolt aligned with door trim plate mounting hole.
(b) Unscrew glass bracket fixing bolts and renew glass.
Back Door Assembly
1. Apply lubricating grease
Before fitting parts, apply MP lubricating grease to these parts.
(a) Apply MP lubricating grease to sliding surfaces and window lifter’s gears.
Attention: Please don’t apply MP lubricating grease to glass regulator spring.
(b) Apply MP lubricating grease to door lock sliding surface.
2. Fit exterior door buckle and door lock equipped with lock core.
3. Fit interior door lock trigger button and connect it with control rod.
4. Fit glass lifter.
5. Fit guide and bolt onto back door glass guide assembly.
6. Fit back door glass run channel.
7. Fit back door glass assembly.
Lower regulator rocker to a position enabling its free motion, fit glass into door cavity and make glass
regulator rocker successfully enter into guide at lower glass end.
8. Fit back door exterior weatherstrip
Regulate glass downwards to the required level, fit weatherstrip onto outer door trim plate bayonet
and screw down bolts.
9. Fit door cover cloth.
10. Fit door trim plates.
Driver’s Seat
Part Drawing
Inner side plate of driver’s seat Headrest assembly

Headrest fixing tube
Safety belt lock fixing bolt

Waist supporter regulating handle
Safety belt lock
Inner cover of inner side

plate of driver’s seat
Back plate
Angle regulator
Backrest frame fixing bolt
Backrest protective covering of driver’s seat

Cushion protective covering (with Rear floor cover of driver’s seat
soft cushion) of driver’s seat
Q1401025FD(M10X1.25)
Side plate mounting bolt
Cushion assembly
of driver’s seat Q1401025FD(M10X1.25)
Inner cover of inner side

plate of driver’s seat
Side plate mounting bolt
Front protective covering of driver’s seat
Front floor cover of driver’s seat Adjusting knob

Outer side plate of driver’s seat
Renew
Notice:
Fitting steps are opposite to removal steps. However, only those fitting steps containing additional in-
formation are involved.
Co-driver’s seat can be removed and assembled as per the same steps of assembling and disassem-
bling driver’s seat.
Attention:
Please wear safety gloves because cut surfaces of backrest frame and seat regulator may hurt
your hands.
Start working after ignition switch is turned to “LOCK” and 90s since cathode (-) terminal ca-
ble is detached with storage battery. (SRS is provided with standby power source. If the work
is started in 90s after the cable disconnection, SRS may inflate.)
1. Remove driver’s seat assembly
(a) Unscrew four bolts and remove mounting bolts and hood of main driver’s seat.
(b) Detach connector.
(c) Remove seat.
2. Remove head restraint assembly of driver’s seat
3. Remove inner side plate of driver’s seat
(a) Use a screw driver to unscrew three bolts.
(b) Detach catches and remove inner side plate of seat cushion.
4. Remove safety belt lock of driver’s seat
(a) Detach safety belt lock wiring harness from seat regulator.
(b) Unscrew bolts and remove safety belt lock.
5. Remove backrest angle regulating handle of driver’s seat
(a) Use a screw driver to remove backrest angle regulating handle.
Notice:
Before using screw driver, please wrap its head with adhesive tapes.
6. Remove outer side plate of driver’s seat cushion
(a) Unscrew three bolts.
(b) Detach five catches and remove outer side plate of driver’s seat cushion.
7. Remove front guard plate of driver’s seat cushion
(a) Unscrew two bolts.
(b) Detach and remove guard plate of driver’s seat cushion.
8. Remove back plate of driver’s seat
(a) Unscrew two bolts.
(b) Detach four catches and remove back plate of driver’s seat cushion.
9. Press unlocking device by hand to detach head restraint of main driver’s seat upwards.
10. Remove backrest assembly of driver’s seat
(a) Remove snap ring.
(b) Lift backrest protective covering and remove snap ring.
(c) Detach clips.
(d) Unscrew four bolts and remove backrest.
11. Remove head restraint fixing tube of driver’s seat
(a) Lift backrest protective covering to the highest level, detach four catches and remove two head
restraint fixing tubes.
12. Remove backrest protective covering of driver’s seat
(a) Remove backrest soft cushion
(b) Remove snap ring and backrest protective covering.
13. Remove cushion protective covering of driver’s seat
(a) Remove snap ring.
(b) Detach front and rear catches of seat regulator.
(c) Detach hook and remove seat cushion protective covering (with soft cushion).
(d) Remove snap ring and seat cushion protective covering.

14. Remove inner lid of driver’s seat backrest angle regulator
(a) Remove four inner catch lids. (Removing RH parts share the same method with removing LH
parts)
15. Fit cushion protective covering of driver’s seat
(a) Use new snap rings to fit cushion protective covering onto soft seat cushion.
(b) Fit seat cushion protective covering (with soft cushion) onto seat regulator.
Attention:
Don’t damage and pollute seat cushion protective coverings.
Notice:
Please avoid corrugations during snap ring fitting.
16. Fit driver’s seat backrest assembly
(a) Use four bolts to fit seat backrest.
Torque: 43N•m
(b) Fit new snap rings onto the back of backrest.
(c) Fit two head restraint brackets and then fit head restraints.
17. Fit safety belt lock of driver’s seat
Torque: 42N•m
18. Fit driver’s seat assembly
(a) Put driver’s seat into compartment.
(b) Connect the connector.
(c) Screw down four bolts.
Torque: 38N•m.
(d) Fit side plates of driver’s seat.
Rear seat
Part Drawing
Headrest assembly of back seat

Headrest fixing tube of back seat
Middle safety belt guard plate of back seat

Back plate of back seat
Middle safety belt of back seat Backrest frame as-
Right backrest lock cover of back seat sembly of back seat
Backrest unlocking but-
Q2140520F31 Backrest unlocking ton of back seat
button of back seat Left backrest lock
cover of back seat
Q2714895F31 Q2140520F31
Q2140520F31 BoltM8×1.25
Q2714895F31
Right backrest lock
assembly of back seat
60% backrest of back seat Q2140520F31
Bolt M8×1.25
Left backrest lock as-
sembly of back seat
60% cushion of back seat
40% backrest of back seat

Back seat central arm
Floor assembly of back seat
40% cushion of back seat
Floor cover
Q1401025FD(M10X1.25)
Floor cover
Renew
Notice:
Fitting steps are opposite to removal steps. However, only fitting steps containing additional informa-
tion are involved.
Attention:
Please wear safety gloves because cut surfaces of seat cushion frame and seat regulator may
hurt your hands.
1. Remove 40% rear seat cushion assembly equipped with cushion protective covering
(a) Remove two floor covers and unscrew fixing bolts
(b) Pull seat cushion and then remove it.
2. Remove 60% rear seat cushion assembly equipped with soft cushion protective covering
(a) Remove two floor covers and unscrew fixing bolts
(b) Pull seat cushion and then remove it.
3. Remove rear seat backrest assembly
(a) Unscrew four fixing bolts and two nuts
(b) Press unlocking device of backrest lock and then remove backrest.
4. Remove LH back backrest lock cover
(a) Unscrew two bolts and then remove LH back backrest lock cover.
5. Remove RH back backrest lock cover
(a) Unscrew two bolts and then remove RH back backrest lock cover.
6. Remove rear seat head restraint assembly
(a) Remove head restraint.
7. Remove backrest unlocking button of rear seat
8. Only RH side:
Remove middle safety belt guard plate of rear seat
(a) Use a screw driver to remove middle safety belt guard plate.
9. Remove head restraint fixing tube
(a) Detach catches and remove head restraint fixing tubes.
10. Remove back plate of rear seat
(a) Use a screw driver to remove 17 clips and then remove the back plate.
11. Remove LH rear seat backrest protective covering equipped with soft cushion
(a) Remove seat backrest protective covering (with soft cushion) from the rear seat backrest frame.
12. Remove RH rear seat protective covering equipped with soft cushion
(a) Remove seat backrest protective covering (with soft cushion) from the rear seat backrest frame.
13. Remove 40% backrest lock assembly of rear seat
(a) Unscrew three bolts and remove seat backrest lock assembly.
14. Remove 60% backrest lock assembly of rear seat
(a) Unscrew three bolts and remove seat backrest lock assembly.
15. Remove middle safety belt assembly of rear seat
(a) Unscrew bolts and remove safety belt.
16. Remove rear seat central arm assembly
(a) Unscrew two bolts and then remove the assembly.
17. Fit central safety belt assembly of rear seat
(a) Use bolts to fit seat safety belt.
Torque: 42N•m
18. Fit 40% backrest protective covering of rear seat with soft cushion
(a) Fit seat backrest protective covering (with soft cushion) onto seat frame.
Attention:
Don’t damage and pollute backrest protective covering (equipped with soft cushion).
19. Fit 60% backrest protective covering of rear seat equipped with soft cushion
Notice:
Execute the same steps with fitting on the LH side.
20. Fit backrest of rear seat
(a) Use for bolts and two nuts to fit backrest assembly.
Torque: 38N•m
Body & Stamping Parts-
Body & Stamping Parts
Engine hood....................................................................... 2
Engine hood
1. Check the engine hood subassembly
(a) Check to ensure the clearances lie in the criterion
range.
A
Criterion:
B
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.
• Screw the four hinge mounting bolts at the side of
the engine hood and a fender mounting bolt .
• Adjust the clearance by moving the engine hood to

get it laid in the criterion range.
Criterion range (A): 5.0mm
A
• Fasten the hinge mounting bolts at the side of the

engine hood and the fender mounting bolt.
Torque: 11.5N•m
(b) Adjust the front height of the engine hood with the
adjusting block so as to get the engine hood alig-
ned with the fender.
Note: move the adjusting block by rotating it up and
down.
(c) Adjust the engine hood lock.
• Remove the clamp and the grid.
• Adjust the position of the engine hood so as to

smoothly get the latch in.
• Screw down the engine hood lock bolts after adjus-
ting.
Torque: 7.0N•m
Loosening cable of 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 lat-
ch 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
2. Install the loosening cable of engine hood latch
Note: the contact among the different metals will acce-
lerate the erosion. Be sure to use the right fasteners to
avoid early erosion.
(a) Install the cable onto the loosening mechanism
(b) Install the loosening mechanism assembly of en-
gine hood latch with bolts.
(c) Install the cable onto the loosening handle of engi-
ne hood latch.
(d) Install the loosening handle of engine hood latch
onto the instrument panel.
(e) Close the engine hood.

Haval h5 Service Manual

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Content

General Description of Complete Vehicle

Air Intake System

Body Electrical Appliance

Air Conditioning System

Body Internal and External Trim

Body & Stamping Parts

General Description of Complete Vehicle

Basic Parameters of Complete Vehicle........................... 2

Basic Parameters of Complete Vehicle

Accelerating time of initial starting of

Structure Types and Technical Parameters of Main Systems and

For CC6461KM65 wagon, it is equipped with double-transverse arm independent suspension

Body and Interior/exterior trim

Grades and Specifications of Operating Agent for Operating Parts of

Grades and Specifications of Operating Agent for Operating Parts of

Air Intake System

Operating Instructions to Air Filter ...................................... 2

Air Intake System

2. Remove air filter inlet pipe

Inlet pipe bracket

Hexagon-headed bolt, 3. Remove air filter

4. Remove air filter

Lower casing of air filter

5. Renew air filter element assembly

(a) Partition plate of lower casing shall be necessarily

(b) Filter element seal ring has to be assembled into

Filter element seal ring

2. Firstly plug three limiting edges on upper casing

Hexagon-headed bolt, 3. Tightening torque of three hexagon head bolt, elas-

Type B worm drive type hose hoop (2.5TCI engine)

2. Remove air filter inlet pipe

Hexagon head bolt, elastic 3. Remove air filter

4. Disassemble air filter

Lower casing of air filter

5. Renew air filter element assembly

(a) Partition plate of lower casing shall be necessarily

(b) Filter element seal ring has to be assembled into

Filter element seal ring

2. Firstly plug three limiting edges on upper casing

Hexagon-headed bolt, 3. Tightening torque of three hexagon head bolt, elas-

Part Drawing of Exhaust System (2.5TCI Left-hand Drive) 2

Hexagon flange nuts

Hexagon flange nuts

Three-hole rubber block Silencer assembly

Hexagon flange nuts Silencer washer

Hexagon flange bolts

Three-hole rubber block

Hexagon flange nuts

Rear section assembly of exhaust pipe

Three-hole rubber block

Warning: Disassembling and removal of all parts in

2. Remove silencer assembly

3. Remove particle trap assembly

(c) Remove three-hole rubber blocks.

4. Remove oxygen catalytic converter assembly

Fit exhaust system assembly

Part Drawing of Intercooler.................................................. 2

Hexagon flange bolts

Rubber tube bracket

Radiator suspen- Big washer

Hexagon flange bolts

Type A worm drive type hose hoop

Hexagon flange bolts