Electrical Appliance & Structure Volume of Vehicle Body: Maintenance Manual of Tojoy Sedan

Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Electrical Appliance & Structure Volume of Vehicle Body
Chapter I Electrical Appliance of Vehicle Body.................................................................................1
Section I Safety Airbag System ......................................................................................................1
I. Precautions .....................................................................................................................1
II. Preparation......................................................................................................................2
III. Principles of Safety Airbag System..................................................................................3
IV. Safety Airbag Module at Driver’s Seat Side.....................................................................5
V. Safety Airbag Module at the Second Driver’s Seat Side..................................................7
VI. Safety Belt .......................................................................................................................9
VII. Pretensioner of Front Seat Safety Belt ..........................................................................15
VIII. Clock Spring of Safety Airbag ........................................................................................16
IX. Control Module of Safety Airbag (SDM) ........................................................................18
X. Trouble Diagnosis..........................................................................................................20
XI. Overhaul of Safety Airbag System.................................................................................22
XII. Disposal Methods of Safety Airbag System Components..............................................24
Section II Air Conditioning System................................................................................................28
I. Precautions ...................................................................................................................28
II. Preparation....................................................................................................................30
III. Check of System ...........................................................................................................32
IV. Control of System..........................................................................................................35
V. Illustration on Function, Location and Check of System Elements ................................41
VI. Dismantlement and Installation of System (Evaporator\Warm air blower\3

Motors\Resistor\Panel) ..................................................................................................54
VII. Filter of Air Conditioner ..................................................................................................64
VIII. Maintenance Data .........................................................................................................66
Section III Information and Time Electronic Control System (ETACS)..........................................67
I. Precautions ...................................................................................................................67
II. Schematic Diagram of Elements ...................................................................................67
III. Illustration on Functions.................................................................................................68
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IV. Definition of ETACS Control Module Terminals .............................................................83
V. Operation Illustration of ETACS Key Code ....................................................................83
VI. Replacement of ETACS Module and Alarm...................................................................84
VII. Technical Parameters ...................................................................................................87
Section IV Combined Switch ........................................................................................................88
I. Illustration ......................................................................................................................88
II. Test of Elements ...........................................................................................................91
III. Replacement of Combined Switch ................................................................................91
Section V Lighting System............................................................................................................94
I. Precaustions:.................................................................................................................94
II. Headlamp ......................................................................................................................94
III. Front Fog Lamp...........................................................................................................104
IV. Tail Lamp.....................................................................................................................107
V. Highmounted Stop Lamp.............................................................................................115
VI. License Plate Lamp .....................................................................................................116
VII. Illuminating Lamp of Boot ............................................................................................118
VIII. Side Turn Signal Lamp ................................................................................................119
IX. Illuminating Lamp of Glove Box...................................................................................121
X. Reading Lamp .............................................................................................................123
XI. Maintenance Data and Specification ...........................................................................125
Section VI Combined Device ..................................................................................................... 127
I. Illustration on Functions...............................................................................................127
II. Illustration on Connector Terminal of Combined Device ..............................................130
III. Replacement of Combined Device ..............................................................................130
IV. Speed Meter and Odometer ........................................................................................132
V. Tachometer .................................................................................................................134
VI. Water Thermometer ....................................................................................................136
VII. Fuel Oil Meter..............................................................................................................138
VIII. Alarm Lamp of Engine Oil Pressure ............................................................................140
IX. Alarm Lamp of Braking System ...................................................................................141

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X. Alarm Lamp of Door Open...........................................................................................141
Section VII Windscreen Wiper and Its Cleanser .........................................................................142
I. System Composition ...................................................................................................142
II. Precautions .................................................................................................................142
III. Front Windscreen Wiper..............................................................................................142
IV. Rear Windscreen Wiper ..............................................................................................152
V. Cleanser of Windscreen Wiper....................................................................................155
VI. Overhaul for Trouble ...................................................................................................159
Section VIII Horn and Cigar Lighter ............................................................................................164
I. Location of Elements ...................................................................................................164
II. Basic Diagram .............................................................................................................164
III. Check of Horn .............................................................................................................165
IV. Overhaul for Trouble....................................................................................................165
V. Replacement of Horn ..................................................................................................167
VI. Replacement of Horn Button .......................................................................................168
VII. Cigar Lighter................................................................................................................170
Section IX Audio System ............................................................................................................171
I. Location Plan of Elements...........................................................................................171
II. Basic Diagram of Audio System ..................................................................................171
III. Illustration of Audio Changer .......................................................................................172
IV. Replacement of Audio Changer and Antenna..............................................................172
V. Replacement of Rear Loudspeaker of Three-carriage Car..........................................174
VI. Replacement of Rear Loudspeaker of Two-carriage Car.............................................175
VII. Replacement of Front Door Loudspeaker....................................................................176
Section X Parking Auxiliary System ............................................................................................178
II. Basic Diagram .............................................................................................................179
III. Testing of Elements .....................................................................................................179
IV. Replacement of Control Module of Parking Auxiliary System......................................181
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V. Replacement of Buzzer of Parking Auxiliary System...................................................182
VI. Replacement of Sensor of Parking Auxiliary System...................................................183
VII. Common Troubles and Maintenance Methods ............................................................184
VIII. Trouble Diagnosis Procedure ......................................................................................185
IX. Trouble Maintenance Methods ....................................................................................186
Section XI Rear View Mirror........................................................................................................188
II. Basic Diagram .............................................................................................................189
III. Testing for Elements ....................................................................................................189
IV. Replacement of Internal Rear View Mirror...................................................................191
V. Replacement of External Rear View Mirror .................................................................194
VI. Replacement of Electric Rear View Mirror Switch .......................................................196
Section XII Central Control Door Lock ........................................................................................198
I. Basic Diagram .............................................................................................................198
II. Replacement of Outside Handle of Door .....................................................................198
III. Replacement of Door Lock Assembly .........................................................................199
IV. Replacement of Actuator of Trunk Door Lock..............................................................202
V. Replacement of Controller of Trunk Door Lock ...........................................................204
VI. Analysis for Troubles ...................................................................................................205
Section XIII Electric Window .......................................................................................................206
I. Illustration on Elements ...............................................................................................206
II. Illustration on Functions...............................................................................................206
III. Basic Diagram .............................................................................................................208
IV. Replacement of Element .............................................................................................209
V. Trouble Diagnosis .......................................................................................................215
Chapter II Structure of Vehicle Body..............................................................................................216
Section I Engine Hood and Door ................................................................................................216
I. Engine Hood Assembly ...............................................................................................216
II Fender .........................................................................................................................222
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III Replacement of Front Door Assembly .........................................................................226
IV Replacement of Rear Door Assembly .........................................................................251
V. Boot Cover ..................................................................................................................264
VI. Oil Filler of Fuel Tank...................................................................................................275
VII. Replacement of Locking System .................................................................................278
Section II Interior & Exterior Trimmings ......................................................................................285
I. Precautions .................................................................................................................285
II. Replacement of Front Bumper ....................................................................................285
III. Replacement of Front Bumper Frame .........................................................................288
IV. Wheel Cover................................................................................................................289
V. Replacement of Ceiling Stripe .....................................................................................291
VI. Replacement of Rear Bumper .....................................................................................292
VII. Replacement of Rear Bumper Frame..........................................................................293
VIII. Replacement of Sun Visor...........................................................................................295
IX. Replacement of A-pillar Trim Board.............................................................................296
X. Replacement of Front Door Pedal ...............................................................................296
XI. Replacement of A-pillar Lower Trim board...................................................................297
XII Replacement of Rear Door Pedal................................................................................298
XIII. Replacement of B-pillar Trim board .............................................................................299
XIV. Replacement of C-pillar Trim board.............................................................................303
XV. Replacement of Auxiliary Handle.................................................................................305
XVI. Replacement of Ceiling ...............................................................................................306
XVII. Replacement of Carpet................................................................................................307
XVIII. Replacement of Front Trimming Plate of Coatrack......................................................308
XIX. Replacement of Protecting Plate of Rear Boot Cover .................................................309
XX. Replacement of Front Seat..........................................................................................310
XXI. Replacement of Rear Seat ..........................................................................................311
XXII. Replacement of Name Plate........................................................................................314
XXIII. Replacement of Front Windshield ...............................................................................316
Section III Console......................................................................................................................324

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I. Precautions .................................................................................................................324
II. Replacement of Driver Airbag Module .........................................................................324
III. Replacement of Steering Wheel ..................................................................................324
IV. Replacement of Trimming Cover of Steering Column..................................................328
V. Replacement of Clock Spring of Safety Airbag ............................................................329
VI. Replacement of Lower Protective Cover of Console at Driver’s Side..........................329
VII. Replacement of Ignition Switch ...................................................................................330
VIII. Replacement of Glove Box..........................................................................................331
IX. Replacement of Auxiliary Fascia Console ...................................................................332
X. Replacement of Steering Column................................................................................336
XI. Replacement of Combined Device ..............................................................................337
XII. Replacement of Control Panel of Air Conditioner ........................................................338
XIII. Replacement of Console .............................................................................................340
XIV. Replacement of Console Support................................................................................344
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Chapter I Electrical Appliance of Vehicle Body
Section I Safety Airbag System

I. Precautions
Warning:
■ During maintenance, if the proper processes aren’t followed, the airbag system may be ignited
accidentally, which will result in serious accidents.
■ The mistakes during maintenance will make the airbag incapable of ignition when it is required to,
which will result in serious accidents.
■ Before the maintenance (including dismantlement, installation, check or replacement of spare parts),
do carefully read the following notes, and operate according to the proper process defined in the
maintenance manual.
1. Don’t disassemble the safety airbag components such as safety airbag assembly at driver’s seat
side and safety airbag assembly at the second driver’s seat side.
2. Don’t repair the following parts but use the replacements to replace them.
1) Safety airbag at driver’s seat side.
2) Safety airbag at the second driver’s seat side.
3) Safety belt tensioner.
4) Control module of safety airbag.
5) Clock spring.
3. Don’t make the airbag exposed to the high temperature or flame.
4. Immediately use a dry cloth to wipe if the liquid exists on the airbag such as butter, detergent,
engine oil or water.
5. Don’t make the airbag fall and the fallen airbag is not allowed to use.
6. The original replacements shall only be obtained from the authorized dealer.
7. After disassembling the airbag, store it in a stable place with its face upwards. Don’t put any articles
on its top.
8. Check whether the replacement part number is correct. Don’t use the parts of other vehicles as the
replacement of this vehicle.
9. Even if the airbag is not ignited in light impacts, the pad surface and airbag sensor shall be checked.
If the situations such as sunken, crack or deformation are found, a new airbag assembly shall be
used.
10. When the vehicle or airbag is discarded, the airbag shall be dealt with first.
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11. After the airbag is ignited, the inflation device will become very hot, so, it shall be handled after
natural cooling. Don’t use water to cool it.
12. It is not allowed to measure the circuit resistance of airbag module, for it will result in the ignition of
airbag.
II. Preparation
General tools and special tools are required to use during maintenance.
Table for Special Tools

Tool Diagram Application
Ignition tool To ignite airbag.
Inspector of module wire

Diagnosis inspector
harness
Simulator connector used

Simulator for checking the resistance
of wire harness
2
III. Principles of Safety Airbag System
1. Opening Condition of Airbag
Diagram for the Impact Angle Which may Result in the Openness of Airbag
The airbag will open if the frontal impact happens within the 30°away from the center line of vehicle and
impact force is big enough.
2. Schematic Diagram for Element Location
Schematic Diagram for Element Location of Airbag
1-airbag at driver’s seat side 2-airbag at the second driver’s seat side
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3. Working Principle of Restraint System
The impact will result in the rapid change of vehicle speed. Due to the inertia, the passenger keeps on
moving forward, and then the impact between passenger and inner structures happens. And the function
of occupant restraint system is to avoid or alleviate the hurt caused by the impact between passenger
and inner structures through restraint system (including seat, safety belt, airbag and so on).
1) Working schematic diagram of restraint system
Airbag system
Control
Impact sensor Ignite Airbag
/Diagnosis
system
Restrain
Pretensioner Restrain
Safety belt
Driver/the
second driver
Load restriction
Pretensioner system of safety

belt
Working Schematic Diagram of Restraint System
2) Working principle of airbag
Before the impact between passenger and inner structures, an airbag inflated with air is quickly inserted
between them. Through the breathability of airbag itself and exhaust throttle function of discharging hole,
the kinetic energy of passenger is absorbed to alleviate the fierce impact and the passenger is separated
from the inner structures, so that the passenger is protected.
Fig.1. 1.001
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3) Working Principle of Safety Belt
First of all, frap in time, that is, at the first moment of accident, with the help of impact acceleration,
incline angle of vehicle and acceleration created by mesh belt, the safety belt “presses” the passenger
on the seat; then, relax properly, that is, when the impact force peak is over or passenger has been
already protected by airbag, the safety belt relaxes properly.
Initial state At the moment of impact, the Mesh belt withdraws.

pretensioner bursts.
Working Schematic Diagram of Safety Belt
IV. Safety Airbag Module at Driver’s Seat Side
1. Element
Fig.1. 1.002
The safety airbag module at driver’s seat side
locates on the steering wheel.
2. Specification:
■ Airbag Volume: 50 L
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Attention:
Fig.1. 1.003
■ When the safety airbag module at driver’s seat
side is dismantled or the new safety airbag module
at driver’s seat side is mounted, the face of pad
shall be upward.
■ The electric resistance of airbag module shan’t be

measured, or else, the accidental ignition of airbag
will happen.
Wrong Placement
■ The safety airbag module at driver’s seat side shall
be stored in the place with an ambient temperature
lower than 80°C which is away from electrical
noise.
■ When the welding work is conducted, the negative

Fig.1. 1.004
pole of storage battery shall be disconnected as
well as connector of airbag.
■ When the vehicle or airbag is discarded, the

special tools shall be used to ignite the airbag.
Correct Placement
3. Dismantlement steps:
Fig.1. 1.005
1) Disconnect the negative pole of storage battery
for over 3 minutes.
Warning:
■ When the engine is running, don’t disconnect the

negative pole of storage battery, or else, the
electrical system of vehicle will be damaged.
■ Before the negative pole of storage battery is

disconnected, make sure that there is no required
information in the engine control module. No
matter whether the control module is dismounted
or not, disconnecting the negative pole of storage
battery will delete all of the trouble codes and
control parameters in the control module memory
(KAM).
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2) Use a cross-screwdriver to loose the clamping

Fig.1. 1.006
screws at two sides.
3) Take the connector apart, and take the airbag

Fig.1. 1.007
module out.
4) Properly place the airbag module according to

the requirements.
4. Installation steps:
Assemble in the reverse order with dismantlement.
V. Safety Airbag Module at the Second Driver’s

Seat Side Fig.1. 1.008
1. Schematic diagram of sub-assembly
The safety airbag module at the second driver’s

seat side locates on the console before the second
driver’s seat.
Attention:
■ Please don’t put or post any articles on the

surface of airbag module.
2. Specification:
■ Airbag Volume: 90 L
Attention:
7
3. Dismantlement Fig. 1. 1.009

for over 3 minutes.
2) Dismount the glove box. Refer to the

Fig.1. 1.0010
replacement of glove box.
3) Dismount the glove box lamp. Refer to the Fig.1. 1.0011

replacement of glove box lamp.
8
4) Dismount the front seat airbag from the Fig.1. 1.0012

dismantlement hole.
5) Take the connector apart, take out the front

Fig.1. 1.0013
seat airbag module and place it properly in
accordance with the requirements.
4. Installation
Assemble in the reverse order with dismantlement

steps.
VI. Safety Belt

Fig.1. 1.0014
1. Schematic diagram of front-seat safety belt
sub-assembly
2. Dismantlement of front-seat safety belt
Attention:
■ Before dismantlement or installation, make

sure that ignition switch is shut off and negative
pole of storage battery is disconnected, and
then wait for at least 3 minutes.
9
1) Adjust the front seat in proper position.

Fig.1. 1.0015
2) Dismount the front door pedal. Refer to the Fig.1. 1.0016

replacement of front door pedal.
3) Dismount the trimming plate of rear door pedal.

Fig.1. 1.0017
Refer to the replacement of rear door pedal.
4) Dismount the fastening bolt at the end of safety

Fig.1. 1.0018
belt.
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5) Dismount the B-pillar lower trimming plate.

Fig.1. 1.0019
6) Take off the trimming cover of fastening bolt at the

Fig.1. 1.0020
upside of safety belt.
7) Dismount the fastening bolt at the upside of safety

belt.
8) Dismount the fastening bolt of safety belt body. Fig.1. 1.0021
9) Disconnect the connector of pretensioner, and take

Fig.1. 1.0022
the safety belt assembly out. Attention:
■ To disconnect the connector of pretensioner, insert

the screw driver wrapped with tape into the incision
to raise the lock.
10) Check the safety belt assembly carefully.
Attention:
■ Don’t use the electric test devices to check the

pretensioner of safety belt.
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■ Don’t use the disassembled snap ring or safety belt assembly.
■ Replace it immediately if the fastening bolt is deformed or worn.
■ Don’t lubricate the tongue depressor and snap ring.
■ If the spare parts and components of safety belt assembly have any problems, they shan’t be
repaired. Directly replace the assembly.
■ If the safety belt has defects such as rupture, abrasion or damage, replace the safety belt assembly.
■ When the safety belt assembly is replaced, authentic JAC safety belt assembly shall be used.
3. Installation of Front Seat Safety Belt
Attention:
■ Before the installation of front seat safety belt, the B-pillar upper trim board is required to install
eudipleurally. And the mortise lock of safety belt buckle shall be mounted on the seat.
■ Make sure that the connection of safety belt pretensioner connector is reliable.
■ Put the safety belt body into the space corresponding to B pillar and make it aim at the mounting hole.
Use the bolt of 7/16 British System to make it fastened to B pillar with the tightening torque of 40〜55
N•m.
■ Make the bolt of 7/16 British System go through the upper protecting plate of B pillar to fasten the
guide components of safety belt to the sheet metal of B pillar with the tightening torque of 40～55
N•m.
■ After the installation of B-pillar lower trim board, use the bolt of 7/16 British System to fasten the end
of safety belt to the vehicle body sheet metal with the tightening torque of 40～55 N•m.
4. Dismantlement of Rear Seat Safety Belt Fig.1. 1.0023

1) Dismount the rear seat cushion.
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2) Dismount the backrest of rear seat.

Fig.1. 1.0024
3) Dismount the clamping screw at the end of

Fig,1. 1.0025
safety belt.
4) Dismount the trimming plate of rear coatrack.

Fig.1. 1.0026
5) Dismount the C-pillar upper trim board.

Fig.1. 1.0027
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6) Dismount the C-pillar lower trim board.

Fig.1. 1.0028
7) Dismount the fastening bolt at upper side of

Fig.1. 1.0029
safety belt.
8) Dismount the body fastening bolt of safety

belt.
9) Take the safety belt assembly out.
■ Check the safety belt assembly and replace it if

it is damaged.
5. Installation of Rear Seat Safety Belt
Attention:
■ Align the locating pin hole with bolt hole and use the bolt of 7/16 British System to fasten the safety
belt body with the tightening torque of 40〜55 N•m.
■ Use the bolt of 7/16 British System to fasten the guide components to the sheet metal of C pillar, then
go though the upper trim board of C pillar. The tightening torque is 40〜55 N•m.
■ Use the bolt of 7/16 British System to fasten the mounting point below C pillar and the mounting point
is at the end of safety belt. The tightening torque is 40〜55 N•m.
■ Use the bolt of 7/16 British System to eudipleurally fasten the 3 safety belt latch assemblies and 1
middle 2-point safety belt to the floor. The tightening torque is 40〜55 N•m.
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VII. Pretensioner of Front Seat Safety Belt
1. Specification
■ The ambient temperature for air generator: -35℃〜+105℃
Attention:
■ Using the safety belt and supplemental restraint system such as airbag and pretensioner of safety
belt at the same time is helpful for driver and passenger at the front seat to reduce the danger of
injury when impacts happen.
■ In order to avoid increasing danger of personal casualty caused by the failure of airbag when impacts
happen, all of the maintenance operations shall be conducted by authorized JAC service centers.
■ The improper maintenance, including wrong dismantlement and installation of safety belt
pretensioner may result in the wrong behavior of system so that accidental personal injuries happen.
■ It is not allowed to use electrical test devices to test any circuit of airbag system except the
operations specified in this manual.
2. Dismantlement and Installation of Pretensioner of Front Seat Safety Belt
Refer to “Safety Belt”.
Attention:
■ Before the dismantlement or installation, make sure that the ignition switch is shut and negative pole
of storage battery is disconnected, and then, wait for over 3 minutes.
■ Don’t use electrical test device to check the pretensioner of safety belt.
15
VIII. Clock Spring of Safety Airbag Fig.1. 1.0030

1. Schematic diagram of sub-assembly
2. Dismantlement of clock spring of safety airbag

Fig.1. 1.0031
for over 3 minutes.
2) Dismount the safety airbag module at driver’s

Fig.1. 1.0032
seat side.
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3) Dismount the clamping nut of steering wheel

Fig.1. 1.0033
and take the steering wheel out.
Attention:
■ The clamping nut can be taken out only when

the steering wheel is loose, or else, the steering
wheel will result in personal injury.
4) Disconnect the connector of horn and clock

Fig.1. 1.0034
spring.
5) Dismount 4 clamping screws.

Fig.1. 1.0035
6) Take the clock spring of safety airbag out.

Fig.1. 1.0036
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3. Installation of clock spring of safety airbag

Install it in the reverse order with dismantlement.
Attention:
■ Take the clock spring of safety airbag out from the package and check whether it is intact and
whether the anchor pin is on the spare part.
■ Open the gland bush of connector, insert the airbag wire harness connector into the jack and then
fasten the gland bush.
■ Before the installation of clock spring of safety airbag, first make sure that the front wheel direction is
in the middle (towards).
■ Before the installation of clock spring of safety airbag, make sure that the clock spring is in the middle
(clockwise rotating to the end and then rotating reversely for 2.5 turns).
IX. Control Module of Safety Airbag (SDM)
1. Specification and function of control module of safety airbag (SDM).
1) To sense the vehicle impact.
2) To ignite the airbags both at driver’s seat side and the second driver’s seat side.
3) To ignite the safety belts with pretensioners both at driver’s seat side and the second driver’s seat
side.
4) To monitor the working state of airbag system.
5) To report the airbag system state to driver through warning indicator light: ready or in trouble.
6) To conduct the diagnosis maintenance for airbag system through the serial diagnosis communication
port.
7) To record the working state of each component of airbag system and relevant impact information
data.
2. Pins of control module of safety airbag (SDM)
Diagram for Pins of Control module of safety airbag
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3. Dismantlement steps
Fig.1. 1.0037
1) Shut the ignition switch, disconnect the
negative pole of storage battery and wait for at
least 3 minutes until the discharge of reservoir
capacitance inside the SDM is finished.
2) Dismount the extension trimming plates at two

Fig.1. 1.0038
sides under the central control console.
3) Loose and pull out the connector of SDM wire harness, dismount 4 bolts which are used for fixing
SDM and take out SDM. Attention:
■ Don’t make the SDM fall or impact.
4. Installation
Install it in the reverse order with dismantlement.
Attention:
■ When installing it, pay attention to the direction of SDM, and make sure that the arrowhead marked
on SDM is in accordance with the travel direction of vehicle.
19
The direction pointed by the

arrowhead on the label of SDM is the
travel direction of vehicle.
Schematic Diagram for Mounting Direction of SDM
X. Trouble Diagnosis
1. Airbag system diagnosis
After the ignition switch is shifted to “ON” position, the airbag indicator light on the console will twinkle for
a few seconds and go out, which means the airbag is in the normal working state, if it doesn’t light or
keeps lighting, then the airbag system has troubles. In order to further confirm the reason for trouble, a
special trouble diagnosis apparatus shall be used to diagnose.
1) Use a diagnosis apparatus to read the trouble code.
2) Maintain according to the prompt provided by trouble code.
3) Use the diagnosis apparatus to eliminate trouble codes. Attention:
■ Please do the troubleshooting according to the content of “Overhaul of Airbag System”.
■ After the trouble is eliminated, the diagnosis apparatus shall be used to delete the trouble code
stored in the system.
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2. Table for Trouble Code
Table for Trouble Code of Airbag System
Trouble Code Meaning

B1021 The impedance of airbag before driver is overlarge.
B1022 The impedance of airbag before driver is too small.
The airbag before driver is short-circuited to the
B1024
ground.
The airbag before driver is short-circuited to the
B1025
power source.
The impedance of driver’s safety belt pretensioner is
B1015
overlarge.
The impedance of driver’s safety belt pretensioner is
B1016
too small.
The driver’s safety belt pretensioner is
B1018
short-circuited to the ground.
The driver’s safety belt pretensioner is
B1019
short-circuited to the power source.
The impedance of airbag before second driver’s
B1041
seat is overlarge.
The impedance of airbag before second driver’s
B1042
seat is too small.
The airbag before second driver’s seat is
B1043
The airbag before second driver’s seat is
B1044
The impedance of passenger’s safety belt
B1045
pretensioner is overlarge.
The impedance of passenger’s safety belt
B1046
pretensioner is too small.
The passenger’s safety belt pretensioner is
B1047
The passenger’s safety belt pretensioner is
B1048
B1031 The voltage of storage battery is overhigh.
B1032 The voltage of storage battery is too low.
B1061 The alarm light has troubles.
B1051 Frontal impact record
B1058 Safety belt pretensioner impact
B1056 Driver’s side impact record
B1054 The maximum reuse times are in excess.
Interior trouble (replacing control module of safety
B1071
airbag(SDM))
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XI. Overhaul of Safety Airbag System
1. Precautions after impact
Attention:
■ The safety belt assembly of all the seats shall be checked after any impact, including retractor and
other metallic spare parts and components.
■ It is suggested by our company that all the safety belt assemblies used during impact shall be
replaced. Or else, serious personal injuries may happen in an accident. For example, the frontal
impact which results in the ignition of airbag happens, even if the safety belt is not used, the
pretensioner of safety belt shall be replaced.
Please replace the safety belt assembly (including the fastening bolt) if the following conditions happen:
■ The safety belt is used when the impact happens (except that the impact is very light and safety belt,
retractor and snap ring are not damaged and their functions are normal).
■ The safety belt is damaged entirely during an accident. (That is, the safety belt is broken; retractor
bends or slide groove appears).
■ The fastening point of safety belt is entirely damaged during an accident. Before the installation of
new safety belt assembly, whether the fastening area of safety belt is damaged or deformed shall be
checked and repair it when necessary.
■ The fastening bolt is deformed or worn.
2. If the airbag is not ignited when the vehicle impacts in low speed, and a side impact, a side-rollover
or pileup happens, the following items shall be checked:
■ Check whether the SDM shell and installation support have dints, cracks or deformations.
■ Check whether the connector is damaged or whether the terminal is deformed.
■ Check whether the installation bolt and grounding wire are in good condition.
3. Maintenance and Check of Airbag System
1) Airbag module
① Check whether the pad cover has dints, cracks or deformations.
② Check whether the connector is damaged, whether the terminal is deformed and whether the wiring
is stuck.
③ Check whether the air generator shell of airbag has dints, cracks or deformations.
④ Install the airbag sub-assembly to the steering wheel and check the matching and alignment
condition.
2) Clock spring
① Check whether the clock spring connector and protecting sleeve are damaged and whether the
terminal is deformed.
22
② Check whether the shell is damaged with naked eye.

3) Steering wheel and steering column
① Check whether the electrical wiring (inside the steering wheel) and connector are damaged and
whether the terminal is deformed.
② Install the airbag sub-assembly to the steering wheel and check the matching and alignment
condition.
③ Check whether the steering wheel has noises, whether the operation is flexible and whether the
looseness is overlarge.
Attention:
■ First calibrate the clock spring which is at the bottom of steering wheel, and then mount the steering
wheel on the steering column.
■ Calibration method of clock spring:
First shift the protecting sleeve of clock spring to the dead center, and turn about 2.5 circles back to
make the protecting sleeve aim at the mounting groove on lower cover of steering column.
4) Other spare parts
■ Check whether the wiring is stuck, whether the connector is damaged or has a poor connection and
whether the terminal is deformed.
■ All the airbag parts shall be replaced after troubles appear. Don’t use them even if they have been
repaired.
■ If the spare parts of airbag system are required to dismantle or replace for maintenance and
troubleshooting, the operating sequence shall be obeyed.
5) Warning/attention brand marks
There are a lot of warning/attention brand marks about SRS on vehicle.
■ On the frame of steering wheel.
■ On the airbag sub-assembly at driver’s side.
■ On the clock spring.
■ On the airbag sub-assembly at the second driver’s seat side.
■ On the control module of safety airbag (SDM).
■ On the sunroof at the upward side of front windshield.
■ The illustrations on brand marks shall be obeyed when the overhaul of SRS is being done. And if the
brand marks are dirty or damaged, they shall be replaced.
6) Control module of safety airbag (SDM)
Attention:
■ The faulty SDM shall be replaced rather than repaired.
23
XII. Disposal Methods of Safety Airbag System Components
Before the airbag or vehicle with airbag is discarded, the following disposal methods shall be
used to ignite them.
1. Disposal methods for unignited airbag module
1) If the vehicle is discarded, the airbag shall be ignited inside the vehicle. And if the vehicle will still be
used and only the airbag is discarded, the airbag shall be ignited outside the vehicle.
2) There will be a lot of smoke caused by the ignition of airbag, so, you shall be careful of not breathing
in. Otherwise, it will irritate the throat and may result in asphyxia. Therefore, the resident area shall
be avoided as much as possible.
3) Due to the loud noise caused by the ignition of airbag, the resident area shall be avoided as much
as possible. If someone is around, a warning for the imminent noise shall be given to him.
4) Only one airbag module shall be ignited for every time.
5) When the airbag module and safety belt pretensioner are ignited, the person shall be at least 10 m
away from the ignited component.
6) Due to the high temperature, the airbag module shall be placed at least 30 minutes after ignition.
7) The person in charge of this mission or persons in site shall wear proper protective articles for ears.
2. Disposal methods of ignition inside vehicle (when the vehicle is discarded)
1) Move the vehicle to the isolated place.
2) Disconnect the positive and negative cables from the terminals of storage battery, and then
dismount the storage battery from vehicle.
Attention:
■ After the negative pole of storage battery is disconnected, at least 3 minutes shall be waited for until
the next step.
3) Airbag module ignition (at driver’s side):
① Dismount the lower cover of steering column.
② Disconnect the connection between pin connector of clock spring of safety airbag and harness
connector of body airbag.
Attention:
■ After the connector of clock spring of safety airbag is disconnected from the harness of airbag of
vehicle body, the pole of connector of clock spring will automatically create a short circuit to prevent
the accidental ignition of airbag due to static and so on.
24
4) Connect 2 wires with a length of over 10 m to the 2 lead wires of airbag adapter wiring, and use the
insulating tape to pack the joint. Besides, the other end of these two wires shall be connected each
other (short circuit) to prevent the sudden and accidental ignition of airbag.
5) Connect the pin connector of airbag to the airbag adapter wiring, and extend the wire used for
ignition outside the vehicle.
6) In order to restrain the ignition noise as much as possible, all the doors and windows shall be shut
and a vehicle cover shall also be used.
Attention:
■ If the window glass has any trace of damage, it will fall to pieces during ignition. Therefore, a vehicle
cover is required to be used.
7) Disconnect the 2 connected wires in the place which is far away from the vehicle as much as
possible, and then connect them to 2 terminals of storage battery (this battery has already been
dismounted from the vehicle) to ignite the airbag.
Attention:
■ Before using this method to ignite the airbag, first check and make sure that nobody is around or
inside the vehicle.
■ Please wear the protective eyeglasses.
■ The aerator is very hot immediately after ignition, therefore, it shall be moved at least 30 minutes
later. Although the gas created by the ignition of airbag is innoxious, it can’t be breathed in. And
please refer to disposal methods of ignited airbag components for the move rules of airbag after
ignition.
■ If the airbag sub-assembly can’t be ignited according to the above methods, don’t walk towards it.
Please contact local dealers.
8) After ignition or operation, please dispose this airbag sub-assembly in accordance with the disposal
methods for ignited airbag sub-assembly.
3. Disposal methods of ignition outside vehicle
1) This ignition shall be conducted in an open even ground where is away from barriers and persons
over 10 m.
2) The ignition can’t be conducted outside in windy days. Even if in breezy days, the airbag module
shall be ignited on the lee of storage battery.
① Disconnect the positive and negative cables from the terminals of storage battery, and then
dismount the storage battery from the vehicle.
25
Attention:
■ After disconnecting the cables of storage battery, at least 3 minutes shall be waited for until the next
step.
② Dismount the airbag module from the vehicle.
Attention:
■ The airbag sub-assembly shall be put on an even ground with its lining cover upward. And no
articles shall be put on its top.
3) When the airbag module at driver’s side is ignited:
Connect 2 wires with a length of over 10 m to the 2 lead wires of airbag adapter wiring, and use the
insulating tape to pack the joint. Besides, the other end of these two wires shall be connected each other
(short circuit) to prevent from the sudden and accidental ignition of airbag.
4) The airbag module is set as follows-
① Hold the airbag adapter wire connected with the above wire, make it cross the underside of old tire
assembly prepared and connected it to the airbag module.
② Make the thick wire go through the mounting hole of airbag sub-assembly, and then fasten the
airbag sub-assembly to the old tire of wheel with the pad upward.
Attention:
■ Leave a little space for the adapter wiring under wheels. If not, the counterforce caused by ignition
of airbag may destroy the adapter wiring.
③ Lay three old tires without hubs on the top of tire which fixes the airbag sub-assembly.
④ Disconnect the 2 connected wires in the shielded place which is far away from the airbag module as
much as possible, and then connect them to 2 terminals of storage battery (this battery has already
been dismounted from the vehicle) to ignite the airbag.
Attention:
■ Before ignition, make sure that nobody is around.
■ The ignited gas generator is very hot, therefore, it shall be moved at least 30 minutes later. Although
the gas created by the ignition of airbag is innoxious, it can’t be breathed in. And please refer to
disposal methods of ignited airbag components for the move rules of airbag after ignition.
■ If the airbag sub-assembly can’t be ignited according to the above methods, don’t walk towards it.
Please contact local dealers.
26
■ After ignition or operation, please dispose this airbag sub-assembly in accordance with the disposal
methods for ignited airbag sub-assembly.
4. Disposal methods for ignited airbag
After the ignition of airbag, it shall be disposed as other spare parts, and the followings shall be
especially paid attention to:
1) The gas generator is very hot after ignition, therefore, it shall be moved at least 30 minutes later.
2) Don’t splash water or oil on the airbag after ignition.
3) The substance which will irritate eyes and skin may adhere to the ignited airbag sub-assembly,
therefore, gloves and eyeglasses shall be worn when the ignited airbag sub-assembly is being
moved.
Attention:
■ If any substance still enters eyes or adheres to skin after these attentions are obeyed, abundant and
clean water shall be used immediately to wash. And if the skin or other physical parts rankle,
medical cares shall be obtained.
4) Tightly seal the powerful PVC bag which contains the discarded airbag sub-assembly.
5) The hands must be washed after these works.
27
Section II Air Conditioning System

I. Precautions
Caution:
■ The following precautions must be complied with when checking and repairing air conditioning
system. Otherwise, it may lead to damage of vehicle and physical injury.
Attention:
■ As the refrigerant is of low freezing point and high volatility, do wear gloves and glasses to avoid
chilblain, blindness, etc. when the skin contacts with refrigerant.
■ If the eye or skin contacts with refrigerant, wash it with water immediately and see an oculist or
dermatologist. Don’t rub the eye with hands or handkerchief.
■ The site shall be ventilated when conducting operations related to refrigerant. Great emission of
refrigerant in a closed place will lead to oxygen deficit.
■ The allowable emission of refrigerant is 1,000 ppm (4,184 mg/m2).
Excessive emission of refrigerant will lead to abnormality or allergy of heart and cardiovascular
system, immune system and respiratory system, or skin disease.
■ When conducting operations related to refrigerant, there shouldn’t be any foreign substances such
as moisture, dust in the surrounding environment. These foreign substances which flow into the air
conditioning system are harmful to the system.
■ When conducting operations related to refrigerant, it is necessary to prepare a gas leakage detector.
When the R-134a refrigerant contacts with high-temperature objects, it will produce harmful gas.
Thus, it is necessary to prevent gas leakage.
■ The refrigerant adopted for this model must be R-134a refrigerant. Otherwise, there will be harmful
effect for the components of system.
■ R-134a refrigerant is incompatible with R-12 refrigerant. Thus, even the amount is extremely small,
they can not be mixed together.
■ When conducting operations related to refrigerant, there shouldn’t be any pyrophorus or

inflammable materials around the vehicle. Besides, the refrigerant tank exposed to the heat source
will lead to explosion. Thus, please pay careful attention to it.
■ As the R134a container is under high pressure, it is definitely forbidden to put it under high
temperature. Meanwhile, check if the temperature of storage environment is lower than 52℃.
■ Generally, there is a dust guard to prevent the sewage, dust, moisture from flowing into the
components of air conditioner. The dust guard shall be removed before operation and sealed up
after operation.
28
■ The synthetic (PAG) refrigerant oil which is applicable to R-134a is easier to absorb moisture than
R-12, and its absorption rate is 10 times higher than that of mineral (MINERAL) refrigerant oil. If the
moisture is too much, the compressor, lubricating function and endurance will be affected.
■ Since moisture is extremely harmful to the air conditioner, it is better to avoid operation in rainy
days.
■ When mounting the air conditioning system again after dismantlement, do coat the “O” ring with
refrigerant oil. Especially for the screw-type connecting parts, assemble them with 2 spanners after
manual installation.
■ When assembling flange-type connecting parts, connect the nut and bolt while gently pushing the
pipeline.
■ When mounting air conditioner, if the torque

Fig. 1.2.001 Bolt Locating pin
used is over than the specified one or if the
“O” ring is clamped, there will be leakage of
refrigerant. Thus operations shall be
Male connecting Female connecting
Nut
conducted with the specified torque. piece piece
Push
■ The hose shall not be twisted.
■ It is forbidden to separate the air conditioning system before completely recycling the refrigerant.
Otherwise, refrigerant and refrigerant oil will be discharged under the system pressure and bring
pollution to the surrounding environment.
■ When replacing components of air conditioner, fill refrigerant oil (model: PAG56) when filling
refrigerant.
29
II. Preparation
General tools and special tools will be used during maintenance.
Table of Special Tools for Overhaul of Air Conditioning System
Name of Tool Figure of Tool Name of Tool Figure of Tool
High Intensity
Digital Multimeter Invisible Light
Lamp
R-134A Manifold
Cable Removing
Measuring
Caliper
Instrument
Halogen Leakage Tracing Paint

Detector Injector
R134A Tracing
Microthermometer
Paint
Forward Flow Shaft Seal

Control Valve Protective Device
50-pound
Pressure Test
Rechargeable
Adaptor
Recycling Tank
30
Name of Tool Figure of Tool Name of Tool Figure of Tool
Withdrawal Tool for Air

“O” Ring
Conditioning System
Withdrawal Tool
Lip Seal
Valve Core Withdrawal “O” Ring

and Installation Tool Installation Tool
Spring Clamp
Spring Clamp Caliper
Caliper
Refrigerant
Passive Test
Recycling/Regenerating
Lamp
and Refilling System
31
III. Check of System
1. Check of Air Conditioner and Filling of Fig. 1.2.002 Low

High
Refrigerant
Mount refrigerant filling device

Off
1) Close the manual valves at both sides of the
On
refrigerant filling device.
2) Mount the filling pipe of refrigerant filling

device to the connecting position. Connect the
low-pressure pipe with the low-pressure
nozzle; connect the high-pressure pipe with
the high-pressure nozzle and then screw up
the nut by hand.
2. Operation for Discharging Refrigerant
1) Connect the refrigerant filling device to the system.
2) Put a clean cloth on the open position of central hose.
3) Gradually open the high-pressure manual valve and discharge the refrigerant.
Attention:
■ If discharging too fast, the refrigerant oil of compressor will be discharged from the system.
4) Check if there is refrigerant oil on the cloth. If there is, slightly close the manual valve.
5) When the reading on the scale of filling device is lowered to 3.5 kg/cm2, slowly open the
low-pressure manual valve.
6) To reduce the system pressure, slowly open the high-pressure and low-pressure manual valves until
the reading on the filling scale is 0 kg/cm2.
3. Operation for Vacuumizing the Air Conditioning System
Attention:
■ The system must be vacuumized after discharging the refrigerant so as to remove the air and
moisture flowing into the system. Conduct vacuumization for 15 minutes after mounting each
component.
1) Make sure if the engine is “off”.
2) Connect the filling device to the connecting position of compressor and close the two sides.
3) Make sure if the refrigerant is discharged from the system.
4) Connect the central pipeline to the suction position of vacuum pump.
5) After operating vacuum pump, open the high-pressure and low-pressure valves of filling device.
32
6) 10 minutes later, the reading on the scale of low pressure detector shall be more than 0.96 kg/cm2,
(vacuum). Otherwise, there is leakage of system. Repair it according to the following steps:
■ Fill the system by using refrigerant container.
■ Find out the leakage position with leakage detector and repair it.
■ Discharge the refrigerant and vacuumize the system.
■ If there isn’t any leakage, keep on vacuumization.
7) Operate the vacuum pump again.
Low High
Fig. 1.2.003
Close
Close
Air
Vacuum pump
8) The reading on the scales of filling device at both sides shall be kept as 0.96 kg/cm2 (vacuum).
9) Keep on vacuumization until the reading on the scale is 0.96 kg/cm2.
10) After 15 minutes of vacuumization, close the pressure valve of filling device, stop vacuum pump and
separate the pipeline from vacuum pump so as to fill refrigerant.
4. Utilization of Refrigerant Control Valve
1) Before connecting the valve and refrigerant container, completely rotate the handle anticlockwise.
2) Locate the disk to the highest position anticlockwise.
3) After connecting the central pipeline to the valve device, rotate the disk by hand clockwise.
4) Rotate the handle clockwise and drill on the upper part of sealing.
5) Unscrew the nut at the connecting pipeline of central connector of filling device.
6) Screw up the nut after exhausting for several seconds.
33
5. Filling of Refrigerant (Gas State)

Fig. 1.2.004 Low High
Attention:
■ This operation is for filling the gas refrigerant

to system by the device at low pressure side. On Off
In this case, the refrigerant container shall be
put vertically to let the gas refrigerant flow into
Refrigerant
the system.
1) Mount the refrigerant container to the

adjusting valve.
2) Open the low-pressure valve and adjust it to make the reading on low pressure scale lower than 4.2
kg/cm2.
3) Start the engine and air conditioner.
Attention:
■ Put the container vertically to prevent filling the liquid refrigerant into the compressor through air
suction port.
4) Close the low-pressure valve after filling specified amount of refrigerant.
■ Specified filling amount of refrigerant: 480 g.
5) If the refrigerant filling speed is too slow, put

Fig. 1.2.005
the container to a water container at around
40 ℃.
Attention:
Put it into water and heat it to
■ In any case, don’t heat the water to higher around 40℃.
Refrigerant
than 52℃.
■ The high-temperature light shall not shine on

the container.
6. Filling of Refrigerant (Liquid State)
Attention:
■ This operation is for filling by the device at high pressure side. In this case, the refrigerant container
shall be inverted to let the refrigerant flow into the system.
1) After vacuumizing the system, completely close the high-pressure and low-pressure valves.
2) Mount the adjusting valve of refrigerant container.

34
3) Completely open the high-pressure valve and

Fig. 1.2.003
then invert the container.
4) If the system is over filled, the discharging

pressure will be increased. Thus, fill by correct
Refrigerant
amount while weighting the refrigerant, and
then close the high-pressure valve.
■ Specified filling amount of refrigerant: 480g.
5) Close the valve of filling device after filling

specified amount of refrigerant.
6) Check for gas leakage by leakage detector.

Attention:
■ Don’t start the engine when filling by the

device at high pressure side.
■ Don’t open the low-pressure valve when filling

with liquid refrigerant.
■ Conduct a performance test before separating

the filling detector.
IV. Control of System
1. Summary of System
Manual control air conditioning system is adopted for this model. The condenser is overcooling
condenser, so the refrigeration performance is improved. To improve defrosting performance, it will
automatically shift to external circulation mode when the mixed mode and defrosting mode are selected.
On the basis of different vehicle speeds, cooling water temperatures and refrigerant pressures, the fan of
condenser is controlled by low and high stages. The increase of air volume of blower and the air mixing
capacity will lead to improvement of heating and refrigeration performances.
Figure of Air Conditioning Control Panel
35
2. Basic Diagram for Refrigeration
High-temperature Low-temperature
High-pressure Low-pressure
Gas Liquid
High-temperature Low-temperature
High-pressure Low-pressure
Liquid Gas
Condenser:
Condenser is
Evaporator:
mounted at the front When the vaporous refrigerant
part of vehicle. It is is changed into gas, the heat
used for transferring will be absorbed from the air
the gas refrigerant passing through the evaporator
into liquid refrigerant by the blower.
with high
temperature and
high pressure.
Blower:
It is for sending the air to
evaporator and sending the
Drying Bottle: Compressor: cooled air into the vehicle.
The gas refrigerant with low
It will absorb the
temperature and low pressure
moisture of refrigerant
will be transferred into
and keep the refrigerant.
high-temperature
high-pressure gas by belt Expansion Valve:
pulley of engine and then sent
It will expand the
to the compressor. It is
refrigerant quickly and
controlled by clutch.
transfer it into
low-temperature
low-pressure liquid.
Basic Diagram for Refrigeration of Air Conditioning System
36
3. Schematic Diagram for Sub-assembly
Schematic Diagram for Air Conditioning System Sub-assembly
1-Heat installation assembly 2-Blower/evaporator/internal/external circulation 3-Condenser/drying bottle

4-Cooling fan 5-Compressor 6-Compressor support 7-Control panel 8-Internal/external circulation switch
9-Rear demister switch 10-Pipeline/expansion valve 11-Pipeline 12-Heater inlet pipe 13-Heater outlet
pipe
37
4. Illustration on Control Mode and Function of Air Conditioning Control Panel

The air conditioning is manually controlled. The panel integrates the rear defrost switch. The
temperature control adopts wire control mode, the internal and external air circulation mode and blowing
mode are controlled by servo motor, the panel illumination adopts backlight/LED and the button symbol
adopts paint spraying and laser carving. The functions of the buttons and knobs on the panel are shown
in the following figure.
Schematic Diagram for Air Conditioning Control Panel

1-Temperature adjustment knob 2-A/C switch 3-Blowing mode knob 4-Internal/external circulation button
5-Blower air volume knob 6-Rear defrost button
Table of Function Illustration of Air Conditioning Panel Buttons
Name of Button Function Illustration
The wire controlled knob is of pinion/rack structure. It is used for changing the
Temperature
mixing ratio of hot and cold air by adjusting the position of air door with
Adjustment Knob
wiredrawing, so as to conduct temperature adjustment.
It is for starting the compressor when the blower motor is under operation. The
A/C Switch
control element is the thermostat which is mounted at the evaporator.
The actuating element is the blower mode motor which is set on the warm air
Blowing Mode Knob blower. It is for adjusting five modes, i.e. face-blow, face-blow/feet-blow,
feet-blow, defrost/feet-blow and defrost.
The actuating element is air inlet servo motor which is set at the air door of
Internal/External blower. The armature of motor is connected to the air inlet door with connecting
Circulation Button rod. The change over switch will drive the connecting rod to rotate clockwise
and anticlockwise so as to change the angle of air door.
Blower Air Volume Knob It is for controlling four air speed gears.
Rear Defrost Button It is for defrosting by controlling the heat installation on the rear windscreen.
38
5. Operational Function of Knob and Button

Operational Function Table of Knob and Button
Operational
Function Operation of System Removal of Function
Switch
- There are “off” position, and gear 1~4 for
air volume of blower.
Adjusting air - When the air gear switch is turned to - The air volume won’t be affected
Air Gear Switch
volume “OFF” position, the blower is off; the AC is when operating other switches.
shut down and the indicator light of AC is
off when it is at “OFF” position.
- There are 36 gears in total distributed
evenly between the full cooling and the
Adjusting the full heating mode. If rotating clockwise,
Temperature position of the air will be warmer; if rotating - The air volume won’t be affected
Knob temperature air anticlockwise, the air will be cooler; along when operating other switches.
door the clockwise direction, the starting
position is the coldest and the final
position is the hottest.
- There are five modes. If rotating the mode
Adjusting the air - The air volume won’t be affected
Mode Switch knob, the mode air door will be switched
outlet mode when operating other switches.
to the corresponding position.
Air Gear Switch
- When pressing down [AC] button - When it is at OFF position, the
repeatedly, the compressor will be started AC is forced to be shut down;
Controlling the
A/C Button and shut down repeatedly. In this case, Mode Switch
compressor
the A/C indicator light will be on and off - The AC is forced to be started
correspondently. when it is under defrost mode
and feet-blow/defrost mode.
The inside/outside air mode won’t be
affected by the operation of air gear
- When operating this button under fresh air switch and AC button, temperature
mode, it will be changed into return air knob;
mode and the indicator light will be on; Mode Switch
Inside/Outside Controlling
- When operating this button under return - When it is under defrost mode
Air Selection inside/outside air
air mode, it will be changed into fresh air and feet-blow/defrost mode, it
Button mode
mode and the indicator light will be off; will be fresh air automatically. In
- When the air gear is at OFF position, it this case, if operating the
can still be operated. inside/outside air button, the
automatic fresh air will be
changed into return air mode.
6. Control of Compressor
Switch on the A/C and make there is A/C signal output only when the blower motor is working; A/C signal
is connected in series with the temperature switch and the signal is input to the engine ECM through
pressure switch; the engine ECM controls the switching on/off of compressor.
Attention:
■ When operating for more than 4 seconds at temperature lower than 1℃, shut down the compressor.
7. Constraint Control of Motor
The output time for the motor (actuator) of air conditioning system is 40 s. When it can’t arrive at the
control position, it is deemed that the motor is constrained; when the motor is constrained, conduct
motor protection and constraint and then confirm its function (output for 3 times).
39
8. Basic Diagram for Control Circuit and Illustration of Pin
Blower relay
Signal of
turning on of
A/C Blower
End of small
lamp relay Blower
switch switch
Speed regulating
End of resistance
dimming A/C
switch relay
Blowing mode
motor
Compressor Air
conditioning
control panel
Radiator fan
relay
Air intake
Radiator
mode motor
fan
3-phase pressure switch

Condenser fan relay
Thermostat
Condenser fan
Protecting Sleeve Model of A108 Control Panel:

KET 050 23M MG 642179
Basic Diagram for Control Circuit of Air Conditioning System and Illustration of Pin
40
V. Illustration on Function, Location and Check of System Elements
1. Function of Evaporator and Blower
The blower consists of motor and fan. It is for shifting inside/outside air mode by the air door motor at the
air suction port, and for suction of the inside or outside air.
The function of the air door motor at the air suction port is realized by the inside/outside air button on the
controller. When it is under internal circulation mode, air will be taken in from the two lateral air inlets;
when it is under external circulation mode, air will be taken in from the filter mounted on the front
protecting cover at the front of vehicle.
In this case, the air is taken in by the blower. After heat exchange by evaporator, the cooled air will be
sent into the vehicle.
When the refrigerant in the evaporator passing through the expansion valve, the low-temperature
low-pressure liquid will absorb the heat from the air coming from outside and be changed into gas
refrigerant to lower the temperature.
2. Names of Main Parts of Evaporator and Blower
Component Diagram for Evaporator and Blower
1-Air bellow-evaporator 2-Air bellow-upper part 3-Air bellow-lower part 4-Air intake motor 5-Cooling pipe
6-Blower 7-Speed regulating resistance 8-Thermistor (evaporator temperature sensor) 9-Air filter 10-Air filter
cover 11-Wire harness 12-Heat insulating trimming
41
3. Evaporator Temperature Sensor

Fig. 1.2.007
1) Function
It is for sensing the temperature of the core body of
evaporator to prevent the evaporator from being
frozen.
2) Installation Location
It is assembled at the core body of evaporator.
Since there is thermistor with negative temperature
coefficient in the sensor, the resistance will
increase when the temperature is decreased and
reduce when the temperature is raised.
3) Parameter Table
(temperature-resistance-output voltage)
Parameter Table of Evaporator Temperature Sensor
Temperature Temperature
Resistance (kΩ) Voltage (V) Resistance (kΩ) Voltage (V)
(℃) (℃)
30 1.977 6. 54 6. 54 6. 54 2. 37
25 2. 45 6. 87 6. 87 6. 87 2. 44
20 3. 063 6. 54 6. 54 6. 54 2. 50
15 3. 85 6. 87 6. 87 6. 87 2. 56
10 4. 876 6. 54 6. 54 6. 54 2. 63
5 6. 221 6. 87 6. 87 6. 87 2. 69
4 6. 54 6. 54 6. 54 6. 54 2.71
3 6. 87 6. 87 6. 87 6. 87 2. 82
4. Speed Regulating Resistance
1) Function
When connected in series with the blower, the speed regulating resistance may be used to regulate the
rotating speed of blower.
2) Installation Location Fig. 1.2.008
42
3) Appearance
Fig. 1.2.009
4) Parameters
Diagram for Parameters of Speed Regulating Resistance
■ At 25℃, the specification of resistance is: HI-MH: 0.65Ω, HI-ML: 1.3Ω, HI-LO: 2.3Ω.
5. Inside/Outside Air Door Motor
1) Function
It is mounted at the inside/outside air inlet duct of evaporator and blower and its function is realized by
controlling the inside/outside air selection button.
2) Location
Fig. 1.2.010
43
3) Appearance Fig. 1.2.011
4) Circuit and Detection Method
Operation Method
Input Voltage Output Direction
(Reference for
Terminal ① Terminal ②
Installation)
+ - Outside Air
- + Inside Air
Diagram for Inside/Outside Air Door Motor Circuit and Detection Method
6. Blower Motor
1) Function
With the vehicle power, it may rotate the fan to generate air volume required by the system.
2) Specification
Fig. 1.2.012
Rotation direction: Clockwise (At the Location of the
Fan)
Fan: Φ147 × 76.2 H
Motor: Φ68, 234 W
3) Detection “+” pole “-” pole
Apply any voltage on “+” terminal and conduct

inspection after grounding the “-” terminal. Generally,
the higher the voltage is applied, the higher the
rotating speed of blower is.
44
7. Expansion Valve
1) Function
The expansion valve is assembled at the inlet of evaporator. With releasing function, it may transfer the
liquid refrigerant with high temperature and high pressure which flows from the condenser into saturated
refrigerant steam with low temperature and low pressure, so as to help the evaporator to evaporate the
refrigerant.
2) Location Fig. 1.2.013

It is at the inlet of evaporator.
3) Specification:
Type: H type
Capacity: 1.5 RT
Attention:
■ When the cover of expansion valve falls, the heat of engine will be transferred to the thermo-bulb,
thus the pressure of expansion valve will be increased and the refrigerant in evaporator will be
excessive. If the evaporator is not working normally, the liquid refrigerant will flow to the compressor
and result in damage.
8. Heat Installation Assembly

Fig. 1.2.014
Based on different degree of opening and closure
of temperature control air door, part of the air
passing through the evaporator will be sent to the
heat installation core body and the rest of them will
be sent to the upper part of heat installation
housing. To control the regulation of indoor
temperature and the mixture of air, mix the air
passing through the heat installation core body and
the air which flows into the upper part of heat
installation housing at the rear part of the heat
installation housing. The mixed air will be sent to
the specified air outlet by function of mode air door
motor to regulate the indoor temperature and
defrosting/demisting. That is to say, the heat
installation assembly regulates the mixture of air
and controls the temperature and air outlet
direction.
45
9. Mode Air Door Motor

Fig. 1.2.015
1) Function
It is assembled at the left part of heat installation

housing and controlled by the signal of mode
switch on the air conditioning panel (FTAC). It
starts the small motor in the air door motor to
regulate the position of air mode door. The variable
voltage difference, when starting the motor, will be
fed back to the FATC which will judge the feedback
signal. When the air door arrives at the specified
position, the motor will stop.
3) Circuit and Detection Method Fig. 1.2.016
Circuit Diagram for Mode Air Door Motor
■ Detection:
When ① is connected to + pole and ② is connected to – pole, the motor operates towards the VENT
(face-blow) direction.
When ① is connected to – pole and ② is connected to + pole, the motor operates towards the DEF
(demist) direction.
46
10. Temperature Control Air Door Motor
1) Function
It is mounted at the lower part of heat installation housing and controlled by the operational signal of
temperature switch on the air conditioning panel (FTAC). It starts the small motor to regulate the position
of temperature control air door. The variable voltage difference, when starting the motor, will be fed back
to the FATC which will judge the feedback signal. When the air door arrives at the specified position, the
motor will stop.
Fig. 1.2.017
3) Circuit and Detection Method
Circuit Diagram for Temperature Control Air Door
■ Detection:
When ① is connected to + pole and ② is connected to – pole, the motor operates towards the COOL
(refrigeration) direction.
47
When ① is connected to – pole and ② is connected to + pole, the motor operates towards the HOT
(heating) direction.
11. Condenser and Drying Bottle
1) Function
It may cool the gas refrigerant with high temperature and high pressure coming from the compressor at
ambient temperature. The cooling of condenser depends on the running air and the forcible air volume of
fan. The condenser for this model is of overcooling type and works with drying bottle. By overcooling, it
improves the refrigeration performance and reduces the amount of refrigerant required by the system.
Besides, the incorporation with drying bottle reduces the amount of components. In the past, when there
is pollution of system, it is required to replace the drying bottle. But for this model, after separating the
cover at the lower part of drying bottle, it is only required to replace the dryer.
2) Installation Location Fig. 1.2.018
3) Schematic Diagram for Dismantlement and Installation
Schematic Diagram for Dismantlement and Installation

1-Bolt 2-Buffer 3-Buffer block 4-Dryer 5-Filter 6-Snap ring
48
12. Cooling System
1) Concept of Cooling Fan Control
After comparing the input vehicle speed, the load of air conditioner and the cooling water temperature,
the engine ECM is divided into two stages (high/low) to control the rotating speed of cooling fan.
■ When there is trouble with speed sensor and cooling water temperature sensor, the engine ECM
drives the cooling fan to run at high rotating speed.
■ When the air conditioner compressor is shut down due to overheating, the starting temperature is
115℃.
2) Cooling Fan Control
Table of Cooling Fan Control
Water Temperature (℃)

91. 5 94. 5 99 102 104 107
A/C Speed Low speed On
OFF km/h of fan Off
High speed On
V<45 of fan Off
Low speed On
45≤ of fan Off
V<80 High speed On
of fan Off
Low speed On
of fan Off
V>80
High speed On
of fan Off
A/C Medium-voltage
switch is
Fan running at low speed
disconnected (low
signal)
ON Medium-voltage
switch is connected Fan running at high speed
(high signal)
49
3) Circuit of Cooling Fan Control
Ignition switch Storage battery
Compressor relay
Fan relay
Pressure switch
Cooling fan
Fan relay
Fan relay
Fan
Circuit Diagram for Cooling Fan Control
50
4) Location of Cooling Fan
Fig. 1.2.019
5) Specifications
■ Fan
Type: PUSH TYPE Dimension: Φ 304
■ Motor
Type: FLATE Dimension: Φ 99 × 41.5 Power: 120 W
13. 3-phrase Pressure Switch
1) Function
In the 3-phrase pressure switch, a medium pressure is added between the two end pressures of air
conditioner. When the system pressure increases, the pressure switch will be started and send signal to
engine ECM.
At that time, the engine ECM drives the cooling fan to run at high rotating speed to avoid lower
performances as a result of increased pressure. Besides, in this way, the air conditioning system may be
protected when the pressure is abnormal (high/low pressure).
Fig. 1.2.020
51
3) Circuit Diagram
Circuit Diagram for 3-phrase Pressure Switch
4) Specifications
Specification Table of 3-phrase Pressure Switch
Classification ON OFF Remarks

2 2
High 26.0 (kg/cm ) 32.0 (kg/ cm )
Low 2. 3 2.0
Medium 18.0 14.0
14. Internal/External Circulation Switch Fig. 1.2.021

1) Appearance
52
2) Circuit and Terminal Diagram
Circuit and Terminal Diagram for Circulation Switch
15. Rear Demister Switch Fig. 1.2.022

1) Appearance
2) Circuit and Terminal Diagram
Circuit and Terminal Diagram for Rear Demister Switch
53
VI. Dismantlement and Installation of System (Evaporator\Warm air blower\3

Motors\Resistor\Panel)
1. Dismantlement and Installation of Evaporator Blower Assembly
1) Dismantlement
① Use special refrigerant recycling equipment to recycle the refrigerant in the system.
② Cut off the negative terminal of storage battery.
Fig. 1.2.023
③ Dismantle the console assembly. Please refer to “Dismantlement and Installation of Console” for the
dismantlement steps.
④ Open the engine cabin and dismantle the fixed bolt of expansion valve.
⑤ Dismantle the fixed bolt of the evaporator blower assembly.
⑥ Cut off the connector of the circuit and take off the evaporator blower assembly.
2) Installation
Fig. 1.2.024
2. Dismantlement and Installation of Warm Air Blower
1) Dismantlement
① Cut off the negative terminal of storage battery.
54
Fig. 1.2.025
② Dismantle the console assembly. Please refer to “Dismantlement and Installation of Instrument
Desk” for the dismantlement steps.
③ Open the engine cabin and cut off the joint of warm air blower water pipe.
Fig. 1.2.026
④ Dismantle the fixed bolt of warm air blower.
■ Tightening torque: 23 ± 4 N.m
Fig. 1.2.027
⑤ Cut off the connector and take off the warm air blower assembly.
2) Installation

55
3. Dismantlement and Installation of Temperature-controlled Motor
1) Dismantlement
Fig. 1.2.028
② Dismantle the console. Please refer to “Dismantlement and Installation of Console”.
③ Cut off the connectors and dismantle the fixed bolt of temperature-controlled motor.
Fig. 1.2.029
④ Take off the temperature-controlled motor.
Fig. 1.2.030
2) Installation
56
4. Dismantlement and Installation of Mode Air Door Motor
1) Dismantlement
Fig. 1.2.031
③ Cut off the connectors and dismantle the fixed bolt of mode air door motor.
Fig. 1.2.032
④ Take off the mode air door motor.
Fig. 1.2.033
2) Installation
57
5. Dismantlement and Installation of Inside/Outside Air Door Motor
1) Dismantlement
Fig. 1.2.034
③ Cut off the connectors and dismantle the fixed bolt of inside/outside air door motor.
Fig. 1.2.035
④ Take off the inside/outside air door motor.
Fig. 1.2.036
2) Installation
58
6. Dismantlement and Installation of Power Amplifier
1) Dismantlement
Fig. 1.2.037
③ Cut off the connectors of power amplifier wire harness and dismantle the two fixed bolts.
Fig. 1.2.038
④ Pull the power amplifier upwards and take it off.
Fig. 1.2.039
2) Installation
59
7. Dismantlement and Installation of Air Conditioning Panel
Fig. 1.2.040
1) Pry out the trimming frame of air conditioning panel with slotted screw driver.
Fig. 1.2.041
2) Dismantle the fixed bolt of air conditioning panel and take the panel off.
Fig. 1.2.042
3) Installation
60
8. Dismantlement and Installation of Condenser Fig. 1.2.043

1) Dismantlement
① Use special refrigerant recycling equipment to

recycle the refrigerant in the system. Please
refer to “Recycle of Refrigerant”.
② Cut off the negative terminal of storage

battery.
③ Dismantle the front bumper. Fig. 1.2.044

Please refer to “Replacement of Front Bumper”.
④ Dismantle the front bumper frame. Please Fig. 1.2.045

refer to “Replacement of Front Bumper
Frame”.
⑤ Discharge the coolant and dismantle the Fig. 1.2.046

radiator assembly.
61
⑥ Cut off the connection of each pipeline. Fig. 1.2.047

⑦ Dismantle the fixed bolt of condenser.
⑧ Take off the condenser assembly towards the engine.
2) Installation
Attention:
■ Air conditioning pipe of drying bottle
Tightening torque: 9 ± 2 N.m
■ Fixed bolt of condenser
Tightening torque: 23 ± 4 N.m
9. Compressor Assembly
Fig. 1.2.048
1) Disassembly of Compressor
① Dismantle suction cup
Use special tools to dismount the suction cup as

shown in the figure.
62
② Dismantle the clamp spring. Fig. 1.2.049

■ Dismantle the armature and coil.
■ Use special tools to dismount the bearing cap

and retainer.
2) Check of Safety Valve Fig. 1.2.050

① When the high pressure of the air conditioning
system which is under operation is over than
Spring
3,550 kPa, discharge part of the refrigerant
into the air with high-pressure relief valve for
Valve
protection.
Compressor
② Once the system pressure is lower than 2,400
kPa, close the high-pressure relief valve to
make the machine keep on working.
③ If there is leakage at A position, replace the high-pressure relief valve. If there is no leakage, the
valve still can be used.
④ If there is leakage at B position, please tighten the valve. If there is still leakage after tightening,
replace the seal gasket.
3) Installation
Fig. 1.2.051 Clearance Gauge
Attention:
■ Check if the clutch clearance is within the

range of standard value.
■ Standard value: 0.3~0.75 mm
■ If the clearance is not within the range of

standard value, adjust the number of gasket to
adjust the clearance.
63
VII. Filter of Air Conditioner
1. Function
The air conditioner adopts particulate filter to remove the foreign substances and odor in the vehicle, so
as to keep a comfortable indoor environment. For convenience of replacement, a 2-plate filter is
adopted.
Fig. 1.2.052
2. Replacement Cycle
If the filter is not replaced for a long time, the filter will be blocked by foreign substances, the noise of
blower will be increased and the air outlet volume will be reduced, etc.
The replacement cycle is 5,000~12,000 km. It is necessary to check and replace the filter frequently in
region with serious air pollution or poor road condition.
3. Replacement Steps Fig. 1.2.053

1) Hold the two sides of glove box and dismantle
it downwards.
64
2) Push the glove box towards the two sides and push the air conditioner filter upwards to separate it.
Fig. 1.2.054
3) Hold the upper air conditioner filter and pull it Fig. 1.2.055
out.
4) Hold the lower air conditioner filter, move it

upwards and pull it out. Fig. 1.2.056
5) Assemble in the reverse order with dismantlement.
Attention:
■ When replacing filter, the arrow shown at the front end shall points to the core body. Don’t assemble
constrainedly.
65
VIII. Maintenance Data

1. Trouble Protection Mode
Table of Trouble Protection Mode
Item Trouble Function
Indoor temperature Short circuit and
25℃ control
sensor open circuit
Outdoor (environment) Short circuit and
20℃ control
temperature sensor open circuit
Short circuit and
Air duct sensor -2℃ control
open circuit
Short circuit and Set to face-blow (VENT) when it is no more than 25℃.
Mode motor
open circuit Set to defrost (DEF) when it is more than 25℃.
Temperature-controlled Short circuit and Set to the coldest position when it is no more than 25℃.
motor open circuit Set to the hottest position when it is more than 25℃.
2. Specification of Tightening Torque
Table of Tightening Torque
Item Tightening Torque (N.m)

Mounting bolt of compressor 20~30
Mounting bolt of expansion valve 8~12
Mounting nut of expansion valve 10~15
Connecting nut of compressor and refrigerant pipe 5~7
Connecting nut of air suction pipe and hydraulic pipe 5~7
3. Filling Specification of Refrigerant Oil
Table of Refrigerant Oil Filling Specification
Filling of refrigerant 480 cc

Replacement of condenser 30 cc
Replacement of drying bottle 30 cc
Replacement of evaporator 50 cc
Replacement of pipeline 30 cc
66
Section III Information and Time Electronic Control System (ETACS)
I. Precautions
Strictly comply with the precautions for operation of SRS, or else, damage to vehicle and people
may be caused.
Dismount the negative pole of storage battery and wait for at least 1 min before dismounting the
connector of electrical appliance, or else, vehicle damage will be caused.
■ Use cloth to protect the dismounted spare parts from being damaged and scratched during
dismantling and installing the elements.
■ Wrap the right-angled screwdriver blade with cloth, when dismantling the metal clip from trimmings.
■ Pay no attention to damaging the vehicle body elements.
■ Make sure the clips are firmly mounted into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
II. Schematic Diagram of Elements
Alarm
ETACS module
Location Plan of ETACS Elements
67
III. Illustration on Functions
1. Front/rear Washing Apparatus Associated Wiper Control
Ignition switch
More than 0.6s
Front/rear washing
switch
Front/rear wiper
T1: 0. 6 ± 0.1s T2: 2. 5—3. 8s T3: 0. 2—0. 6s (MAX) T4: One wiping period
When the ignition switch is turned to the “ON” position, after the washing switch is turned on for more
than 0.6s, the wiper will operate after T1 (0.6 ± 0.1s) of the wiper switch turns on until it is turned off, and
the wiper will wipe for another three periods T2 (that is 3 times); after the time of the washing switch
turned on is within 0.2 ~ 0.6s, the wiper will wipe once again.
2. Intermittent Control of Speed Sensitive Type
Ignition switch
Front pause switch
Front wiper
T1: 0.3s T2: 0. 7 ± 0. 1s
T3: when the speed = 0Km/h, it can be adjusted in the range of 2.6 ± 0.7s (VR = OKΩ) ~ 18. 0 ± 1 s (VR
= 50KΩ).
68
When the speed is more than 100Km/h, it can be adjusted in the range of 1.0 ± 0.2s (VR = OKΩ) ~ 10. 0
± 1 s (VR = 50KΩ). The ignition switch is at “ON” position, the pause switch has been turned on for T1
(0.3s) and then begins to act, and the wiper acts. The finished time of each wiping action is T2 (0.7 ±
0.1s), when the speed=0Km/h, the interval of each wiping action can be adjusted within the range of 2.6
± 0.7s (VR = 0KΩ) ~ 18.0 ± 1s (VR = 50KΩ. When the speed is more than 100Km/h, it can be adjusted in
the range of 1.0 ± 0.2s (VR = 0KΩ) ~ 10.0 ± 1s (VR = 50KΩ).
3. Defrost Time Control of Rear Windscreen
"L" end of
generator
Defrost switch
Defrost relay
T1: 20 ± 2ms
When the generator is in operation, turn on the defrost switch, the defrost relay begins to work and it will
last for T1 (20 ± 2ms). If the interval of pressing the defrost switch is less than T1, the defrost function will
be disabled when defrost switch is pressed for the second time.
4. Illumination Control of the Ignition Key Hole
When the ignition switch is the OFF position, any one of the left and right front doors can be open, the
ignition lock lighting is on, and it will be off after T1 (10 ± 1s) of the door closed; if the front door is open,
the lighting will be off after the ignition switch is turned to the “ON” position.
69
Ignition switch
IGN. S/W
Front door switch

DR S/W
Illumination of
ignition lock
hole
T1: 10 ± 1s
5. Illumination Control of the Driver’s Front Dome Lamp
Set the front dome lamp in the DOOR position, the front door is open and the front dome lamp is on,
when the door is closed and after the ignition switch is at the ACC position, the front dome lamp will go
out gradually after T1 (5.5 ± 0.5s); and after the ignition switch is at the “ON” position, the front dome
lamp will go out directly.
Front door switch
Igniton switch
Illumination of front
dome lamp
T1: 5. 5±0.5s
6. Starting and Braking Alarm Control
When the ignition switch is at “ON” position and the parking handle is not released, after the speed is
more than17Km/h, the door bell will ring at the interval of T1 (0. 3 ± 0. 1s), and if the parking handle is
released at this moment, the door bell will stop ringing; and when the speed is less than17Km/h, the door
will not ring.
70
Ignition switch
Parking brake
switch
More than 17km/h
Speed sensor
Less than 17km/h
Harmonic bell
T1: 0. 3 ± 0. 1s
7. Acousto-optic Control of Safety Belt
Ignition switch
Take off
Safety belt switch
Enable
Safety belt alarm

light
Harmonic bell
T1: 0. 3 ± 0. 1s T2: 0. 45 ± 0.1s T3: 6 ± 1s
When the ignition switch is at the “ON” position and the driver does not wear the safety belt, the safety
belt alarm lamp flashes with the duty cycle of 50% at the interval of T1 (0.3 ± 0.1Is), and the door bell will
ring at the interval of T2 (0.45 ± 0.1s) and with the period of T3 (6 ± 1s); when the driver wears the safety
belt, the alarm lamp will flash for one period and give out a warning tone; the alarm lamp will flash and
71
give out a warning tone if the safety belt is unfastened, indicator lamp for not wearing safety belt will be
still on after flashing for one period, vise versa, the safety belt indicator lamp will go out after flashing for
one period.
8. Time Control of the Electric Window
When the ignition switch is at the “ON” position and the front door is closed, the electric window can
operate. When the ignition switch is at the LOCK or ACC position, the electric window can operate within
T1 (30 ± 3s); if the front door opens in T1 (30 ± 3s), the electric window can’t operate.
Ignition switch
Front door switch

DR S/W
Electric window
motor
T1: 30±3s
9. Automatic Control of the Tail Lamp Extinction
When the lamp switch (left switch of the combined switch) is turned to “ON” from OFF in any case, the
tail lamp will turn on.
The tail lamp will go out automatically at the following conditions:
1) The lamp switch (left switch of the combined switch) is turned from “ON” to OFF.
2) After the key is drawn out, the door at driver’s side will be open, and meanwhile the tail lamp will go
out; if inserting the key at this moment, the tail lamp will turn on.
Note: Here the tail lamp refers to the small lamp system.
72
Insert
Ignition Key
Draw out
Small lamp switch
Door switch at the

driver’s seat side
Tail lamp relay
10. Rear Fog Lamp Control
When the ignition switch is at the OFF position, the lamp switch is turned on (at the left side of combined
switch), and the front fog lamp switch is turned on, the rear fog lamp will not be lighted when the rear fog
lamp switch is turned on; when the ignition switch is at the “ON” position, the lamp switch is turned to the
gear of small lamp (at the left side of combined switch), and the front fog lamp switch is turned on, the
rear fog lamp will be lighted when the rear fog lamp switch is turned on, while the front fog lamp is turned
off at this moment, the rear fog lamp will be turned off at the same time; when the ignition switch is
turned to other lamp positions, the work of the rear fog lamp is not controlled by the front fog lamp, that is,
when the front fog lamp switch is turned off, the rear fog lamp switch can control the rear fog lamp
automatically.
Tail lamp relay
Ignition switch
Front fog lamp

switch
Rear fog lamp

switch
Rear fog lamp
73
11. Electric Door Lock Control
There is a central control door lock which can control the four doors at the driver’s side and passenger’s
side. When the door is shut at the driver’s side, the fastener outputs the lockout signal, and the door is
locked; when the door is opened at the driver’s side, the fastener outputs the unlock signal, and the door
is opened. The control process of door lock at passenger’s side is also the same with that of at driver’s
side.
Pull up
Door switch at the

driver’s side
Press
Pull up
Door switch at the
passenger’s side
Press
Door lockout
output
Door unlock output
12. Vehicle Key Management Control
When the key is not removed and the door at driver’s side is open, the fastener output a signal, and the
door can not be locked; if the fastener switch is pressed continuously, the fastener outputs an unlock
signal, after that it outputs the unlock signal for 3 times; if the door at driver’s side is closed in T3 (0s
<T3<0.5s) of the fastener switch being pressed, the fastener switch is released, meanwhile, the fastener
will output an unlock signal, and the door is not locked.
74
Insert in
Ignition key
Draw out
Turn on
Door switch at the
driver’s side Turn off
Lockout
Door lock switch
Unlock
Unlock the front
door
Output
T1: 0. 5 ± 0. 1s T2: 1 ± 0.1s T3: 0 s<T3<0. 5s
13. Central Control Automatic Opening
When the collision occurs, the airbag will be unfolded, meanwhile the airbag control module will output
an OV signal to ETACS, and then the ETACS will output an unlock signal to the fastener, subsequently
the fastener will output an unlock action of T3 (5s) after T2 (40s). After that the door will be unlocked.
Unfolded
The airbag
unfolded condition
Folded
Airbag module
Collision signal
Unlock
The electric door is
open
Lockout
Output signal
T1: 200ms T2: 40ms T3: 5s
75
14. Automatic Lockout
When the ignition switch is at “ON” position and the door is not locked, if the vehicle travels with a speed
of more than 40Km/h for T1 (1 ± 0.3s), the door will be locked automatically; if the fastener unlocks
during traveling, the door will be locked automatically again after T1 (1 ± 0.3s).
Ignition switch
More than 40km/h
Speed sensor
Less than 40km/h
Unlock
Lockout switch of
the entire door Lockout
Lockout relay
T1: 1 ± 0. 3s
15. Automatic Unlock by Key Removal
When drawing out the key under locked state of the vehicle door, the lockout relay will send an unlock
signal of T1 (0.5 ± 0.1s), after that the door will be unlocked.
Insert
Ignition switch
Remove
Unlock
Lockout switch of
the entire door Lockout
Lockout relay
T1: 0. 5 ± 0. 1s
76
16. Guard Function
When the doors and the engine cover are closed, the door shall be locked with remote controller, the
hazard alarm lamp will flash for T2 (1.0 ± 0.2s), and the vehicle is in guard status; when there is door not
closed, it shall be locked with remote controller, after that the hazard alarm lamp will not flash, and the
vehicle is not in the guard status at the moment; when the doors are all locked, the hazard alarm lamp
will flash for T2 (1.0 ± 0.2s), and the vehicle is in guard status.
Open
Front cover of
each door Closed
Remote control
Lockout relay
Guard
Guard status
Guard release
Hazard alarm
lamp
T1: 0. 5 ± 0. Is T2: 1. 0 ± 0. 2s
17. Guard Release Function
When releasing guard with remote controller, the door is unlocked, and the hazard alarm lamp will flash
for T1 (0.5 ± 0.1s), and it will flash for another T1 after T2 (0.5 ± 0.1s). Moreover, when adopting the
remote controller to open the door, if the door is not open after 30s, the vehicle will be in guard status
automatically.
This function is set up to prevent the door from being opened accidentally.
77
Remote control
opening the door
Unlock relay
Guard
Guard status
Guard release
Hazard warning
light
Illumination of the
driver’s dome lamp
Door switch DR
S/W
Lockout relay
T1: 0. 5 ± 0. 1s T2: 0. 5 ± 0. 1s T3: 1 ± 0. 1s T4: 30 ± 1s
18. Alarm Function
When the vehicle is in guard status, after opening the door or the engine cover, the siren will alarm for Tl
(27 ± 2s) at one inteval of T2 (10 ± 1s). After repeating for 3 times, the vehicle is under guard status, the
hazard alarm lamp will flash for T3 (0.5 ± 0.1s) with the duty cyle of 50%, with same flash time as that of
the siren.
Guard
Guard status
Guard release
Open
Front cover of
each door Closed
Rear boot door
Siren
Hazard alarm
lamp
78
T1: 27 ± 2s T2: 10 ± 1s T3: 0. 5 ± 0. 1s

19. New Abnormalities Occured in the Guard Status
When the vehcile is in guard status, each door and engine cover are open, the siren sounds alarm, and
the hazard alarm lamp flashes; if the door acts during 3 alarms, the vehicle is in guard status after 3
alarms.
Open
Front cover of
each door Closed
Rear boot door
Starter relay
Siren
Hazard alarm light
20. Releasing Guard with Remote Controller in Guard Status

When the vehicle is in guard status, the guard can be released with remote controller, the unlock relay
outputs an unlock signal, and the door is in unlocked status; when the vechicle is in guard release status,
the siren will cease sounding, and the hazard alarm lamp will stop flashing after flashing for twice. At this
moment, the vehicle is guard released.
Remote control
opening door
Unlock relay
Guard
Guard status
Guard release
Starter relay
Siren
Hazard alarm
lamp
79
T1: 0. 5 ± 0. 1s T2: 0. 5 ± 0. 1s
21. Lockout with Remote Controller When the Vehicle is in Guard Status and the Door is Locked
When the vehicle is in guard status and the door is locked, the remote controller shall be adopted for
lockout, the relay shall be started to deenergize, and the hazard alarm lamp will go out after flashing for
T1 (1 ± 0.2s). At this moment, the vehicle is in guard status.
Open
Front cover of each
door
Rear boot door is
closed
Remote control
locking door
Lockout relay
Starter relay
Hazard alarm
lamp
T1: 1 ± 0.2s
22. Lockout with Remote Controller When the Vehicle is in Guard Status and the Door is Unlocked
When the vehicle is in guard status and the door is unlocked, the remote controller shall be adopted for
lockout, and the lockout relay outputs a lockout signal, and the relay shall be started to deenergize; if all
the doors are locked, and the hazard alarm lamp will flash once for T1 (1 ± 0.2s). At this moment, the
vehicle is in guard status.
Front cover of Open

each door
Rear boot door Closed
Remote control
locking door
Lockout relay
Starter relay
Hazard alarm
lamp
80
T1: 1 ± 0.2s
23. The Lost of Remote Key Releasing Guard in Guard Status
When the vehicle is in guard status, after the igniton switch is turned to the “ON” position, the vehicle will
be guard released after 30s.
Insert
Ignition key
Remove
Ignition
switch
Siren
Guard
Guard status
Guard release
24. Abnoramal Opening of the Door after Guard Status
After the guard status, the door re-opens abnormally, the siren still sounds alarm, and the initial guard
status is repeated.
Front cover of Open

each door
Rear boot door Closed
Starter relay
Siren
Hazard
alarm lamp
25. Dismantling and Mounting the Storage Battery in Guard Status and During Alarm
Mount the storage battery after dismounting the storage battery in guard status and during alarm, at this
moment the vehicle is still in guard status, and the siren sounds.
81
Guard
Guard status
Guard release
Front cover of each Open

door
Closed
Rear boot door
Dismount
Battery Mount
Starter relay
Siren
26. Dismantling and Mounting the Storage Battery in Guard Status
Dismantle the storage battery in guard status, and then mount it, at this moment the vehicle is guard
released.
Dismount
Battery
Mount
Guard
Guard
status Guard
release
82
IV. Definition of ETACS Control Module Terminals
Table of ETACS Control Module Terminals Definiton
Definiton of Connector A Definiton of Connector A

1 Room lamp 13 Small lamp realay
2 Anti-theft relay 14 Burglar alarm
3 Front wiper relay 15 Electric window relay
4 Rear defrost relay 16 Rear wiper relay
5 Safety belt alarm lamp 17 Door switch at the second driver’s side
6 Rear fog lamp relay 18 Hazard alarm relay
7 Rear wiper pause switch 19 Grounding
8 Door lockout relay 20 Key hole illumination
9 Buzzer power supply 21 Rear water-jet switch
10 B+ 22 Rear wiper low-speed switch
11 Door lockout realay 23 NC
12 Switch of the boot 24 Speed signal
Definiton of Connector B Definiton of Connector B

1 Door switch at the driver’s side 13 Small lamp realay
2 Rear fog lamp switch 14 Door lock switch at the driver’s side
3 Rear door lock switch 15 Unlock switch of the boot
4 Front water injector switch 16 Safety belt switch
Door lock switch at the second
5 17 Storage code
driver’s side
6 Hand brake switch 18 IG1
7 Rear defrost switch 19 Intermittent front wiper switch
8 Front fog lamp switch 20 Engien cover switch
9 ON 21 Airbag signal
10 Door switch 22 Front wiper intermittent adjustment
11 Door alarm switch 23 Generator L
12 Headlamp switch 24 External antenna
V. Operation Illustration of ETACS Key Code
1. Turn on the decoder switch.
2. Press any key on the remote controller, and re-press it after 3s.
3. Check by remote control.
4. If there are several remote controllers to be memorized, the step1, 2, and 3 can be repeated, one
key can be memorized each time, and 6 keys in all can be memorized.
83
VI. Replacement of ETACS Module and Alarm
1. Dismantle the negative pole of the storage battery.
2. Dismantle the console bottom cover at the diver’s side.
Fig.1.3.001
3. Dismount the engine cover handle.
Fig.1.3.002
4. Dismount the connectors of each connecting switch (front fog lamp switch, rear fog lamp switch,
combined device brightness adjustment switch, lighting distance adjustment switch of the front
headlamp).
Fig.1.3.003
84
5. Cut off the relevant connectors of the steering column.
Fig.1.3.004
6. Dismount the ETACS module fixed screw.
Fig.1.3.aa0
7. Cut off the ETACS module connector to dismount the ETACS module.
85
Fig.1.3.006
8. Dismantle the alarm assembly.
Fig.1.3.007
9. Install in the reverse order with dismantlement.
86
VII. Technical Parameters
Table of Technical Parameters
Item Specification
Operating volatage DC12V
Range of operating voltage DC9V ~ DC16V
Quiescent current MAX 10mA (at 12.8V)
Insultation resistance 100MΩ (DC500V megameter）
Operating temperature -40°C ~ 5°C
Storage temperature -55°C ~ 150°C
Front/rear wiper relay DC 12V, 200mA (relay load）
Defrost relay of rear windscreen DC 12V, 200mA (relay load）
Illumination of ignition key hole DC 12V, 1.4W (bulb load）
Illumination of dome lamp for driver DC 12V, 10WX2 (bulb load）
Acousto-optic device of safety belt DC 12V, 1.4W (bulb load）
Electric window relay DC 12V, 200mA (relay load）
Tail lamp realy DC 12V, 200mA (relay load）
Rear fog lamp relay DC 12V, 200mA (relay load）
Electric door relay DC 12V, 200mA (relay load）
Alarm DC 12V, 260mA (relay load）
Warning tone DC 12V, 350mA (relay load）
87
Section IV Combined Switch

I. Illustration
Diagram for Combined Switch Assembly

1-Lamp switch 2-Self-return switch 3-Switch of windscreen wiper
This combined switch assembly contains three functional components:
1. Lamp Control
Diagram 1 for Lamp Switch
1-Right turn lamp switch 2-0FF 3-Left turn lamp switch
88
Diagram 2 for Lamp Switch
4-Dipped headlamp 5-Small lamp 6-OFF 7-Overtaking lamp 8-High beam lamp
Control the signals of left/right turn lamp, headlamp, side turn lamp, and of overtaking lamp. In the mode
of headlamp, it can also realize two function options: shifting from high beam to low beam, or shifting
from low beam to high beam.
1) Turn Lamp
The turning signal level has two upwards (right turn) positions and two downwards (left turn) positions,
which are used for sending turning signal.
Put the level to the end upwardly or downwardly to send turning signal. When the turning movement is
fulfilled, the level will automatically return. One of the arrows on the combined device will flicker and
show the turning direction.
In order to send turning signal, you need only lift or press down the level until the arrow begins to filcher,
and hold the level there until the vehicle lane-changing is fulfilled. When you release the level, it will
automatically return. When you sending the turning signal, if the turning arrow flickers too fast, the signal
lamp maybe broken, and the other drivers can’t successfully notice the turning signal you send.
If some bulb is burned out, it shall be replaced, in case of traffic accidents. If the driver sends out turning
signal, but the arrow doesn’t flicker at all, you shall check whether the bulb is burned out, and then check
the fuse.
2) Headlamp/Dipped Headlamp Shifter
If you want to shift the headlamp from low beam to high beam, push the turning signal/ multi-functional
level in the direction deviating from you. When the high beam is powered on, if you turn on the ignition
switch, the combined device will display the high beam lamp signal.
If you want to shift the headlamp from high beam to low beam, you need pull the turning
signal/multi-functional level towards you.
89
3) Overtaking Flash
This function can help the driver send overtaking signal to the vehicle in front of him by the usage of high
beam headlamp. For using this function, pull the turning signal/multi-functional level towards the driver
until the high beam of the headlamp is turned on, and then release the level to turn off the headlamp.
2. Control Switch of Windscreen Wiper

Fig. 1.4.001
1) Operating Modes of Wiper Controlling (Washing, Interval, Low Speed, High Speed)
At the interim gear, the wiper has three different modes, viz. high, medium, and low modes for selection.
The front windscreen wiper is operated only when the ignition switch is powered on. Use the level at the
right side of the steering column to operate the front windscreen wiper.
HI (high): turning the level to this position can realize the high speed wiping function.
LO (low): turning the level to this position can realize the stable low speed wiping function.
INT (interim): turning the level to this position can choose wiping delayed for a cycle.
Turn the middle section of the wiper level towards the LO direction, and the delay is prolonged; while,
turn it towards the HI direction, and the delay is shortened. Only when the level is in the INT position can
the wiping speed be adjusted.
2) Washing Solution of Front Windshield
In order to wiping the front windscreen, pull the washing solution level of front windscreen wiper towards
you, with the ignition switch powered on, and the washing solution of the windscreen wiper will be
injected from the spray nozzle.
Attention:
■ In cold weather, the wiper is not allowed to be used until the front windscreen is preheated.
Otherwise, the washing solution will get frozen on the front windscreen and interfere with your view.
■ When you release the level, the washing apparatus will stop working, however, the wiper will
continue to work for other three cycles and then either stop or recover to the wiping speed you
select before.
90
II. Test of Elements
Inspect the on-state between each terminals of the lead wire connector according to the following charts.
If the on-state doesn’t confirm with the following charts, replace the switch.
Dipped headlight
Small light
High beam light
Big light
Overtaking
Terminal
Function
Interm
Low speed
High speed
Front washer
Intermission
time adjusting
Rear washer
Rear wiper on
Rear wiper off
Inspection Diagram for Combined Switch
III. Replacement of Combined Switch
Precaution:
Strictly comply with the precautions for operation of SAS, or else, damage to vehicle and people
may be caused.
91
Dismount the negative pole of storage battery and wait for at least 1min before dismounting the
1. Dismantlement Steps:
1) Dismount the negative pole of the storage battery.
2) Dismount the steering wheel. Refer to the “Replacement Steps of Steering Wheel”.
3) Dismount the upper and lower covers of steering column cap. Refer to the “Replacement Steps of
Upper and Lower Cover of Steering Column Cap”.
4) Dismount the clock spring of safety airbag. Refer to the “Replacement Steps of Clock Spring of
Airbag”.
5) Disconnect the connector of combined switch.
Fig. 1.4.002
6) Dismount the three clamping screws of the combined switch.
92
Fig. 1.4.003
7) Take off the combined switch assembly.
8) Mount back the clamping screws of the

Fig. 1.4.004
combined switch.
2. Installation Steps:
Install in the reverse order with dismantlement.
■ Tightening torque for the clamping screw: 2 N·m
93
Section V Lighting System

I. Precaustions:
may be caused.
Dismount the negative pole of storage battery and wait for at least 1min before dismounting the
II. Headlamp
1. Location Plan of Element
Location Plan of Headlamp Element
94
2. Basic Diagram of Headlamp
Power Power
supply supply
Relay of lower
Relay of beam lamp
upper
beam
lamp
Left lower beam
Right lower beam

Left upper beam
Right upper
beam lamp
Lower beam
lamp
lamp
lamp
Upper beam Headlamp
Overtaking Small lamp
Grounding Grounding Grounding
Basic Diagram of Headlamp

3. Detection of Headlamp Element
1) Switch of headlamp
Check the continuity with multimeter according to the figure below. If the actual condition doesn’t
conform to the figure, please replace the headlmap switch.
Lower beam
Headlamp Upper beam
Small lamp
Overtaking
Inspection Diagram for Headlamp Switch

95
2) Relay of headlamp
Less than 2Ω
Multimeter
Storage battery
Inspection Diagram for Headlamp Relay

As it is shown in above figure, when the negative pole of the battery connects with the terminal 85 of
relay and the positive pole connects with terminal 86 of relay, check if the terminals 30 and 87 are
conducting with multimeter. The measured resistance value should be less than 2Ω, or else, replace the
headlamp relay.
96
4. Replacement of Headlamp
1) Dismantlement steps:
① Cut off the negative pole of storage battery.
Fig. 1.5.001
② Dismount the front bumper. Please refer to

“Replacement of Front Bumper”.
③ Dismount the fixed bolt under headlamp.
Fig. 1.5.002
④ Dismount the fixed bolt above headlamp.
Fig. 1.5.003
97
⑤ Move the headlamp carefully and dismount

the electrical connector.
Fig. 1.5.004
⑥ Dismount the headlamp assembly.
Fig. 1.5.005
2) Installation steps:
① Connect the electrical connectors of headlamp
assembly.
② Mount the headlamp assembly and fixed bolt.
Tightening torque: 5N•m
Fig. 1.5.006
98
③ Mount the front bumper. Please refer to

“Replacement of Front Bumper”.
Fig. 1.5.007
④ Mount the negative pole of storage battery.
Fig. 1.5.008
⑤ Check if the light meets the requirement.

If not, adjust it. Please refer to “Adjustment of Headlamp Light”.
5. Replacement of Lower/upper Beam Lamp Bulb
Attention:
Don’t dismount the headlamp from reflector for a long time, or else, the performance of lamp may be
affected due to ingress of dust, moisture, smoke, etc. Once the bulb in reflector of headlamp is
dismounted, mount a new bulb as soon as possible.
The headlamp is of semi-closed beam type, and the replaceable halogen bulb is applied. The
replacement of bulb can be carried out in engine compartment after the dismantlement.
When dealing with the bulb, hold the plastic seat of bulb rather than touch the glass shell.
Don’t shake or screw the bulb during its dismantlement.
99
Dismantlement steps:
Fig. 1.5.009
② Turn the seal cover of upper/lower beam lamp

anti-clockwise to dismount it.
Fig. 1.5.010
③ Disconnect the connector from the rear of bulb and loose the snap-in.
④ Dismount the headlamp bulb carefully.
⑤ Don’t shake or screw the bulb during dismantlement.
2) Install in the reverse order with dismantlement.
Attention:
6. Replacement of Turn Lamp Bulb of Headlamp
Attention:
100
Don’t shake or screw the bulb during dismantlement.
Fig. 1.5.011
② Screw off the seat of turn lamp seat

anti-clockwise.
Fig. 1.5.012
③ Slightly press down the bulb and screw off the

bulb of turn lamp.
Fig. 1.5.013
101
④ Replace the bulb of turn lamp.
Fig. 1.5.014

7. Replacement of Small Lamp Bulb of Headlamp
Attention:
Don’t shake or screw the bulb during dismantlement.
Fig. 1.5.015
102
② Screw off the seat of small lamp anti-clockwise.

Fig. 1.5.016
③ Dismount the bulb of small lamp.

Fig. 1.5.017
④ Replace the bulb of small lamp.
Fig. 1.5.018

8. Adjustment of Headlamp Light
1) Make sure that the pressures of all tyres are normal.
2) Place the vehicle and tester on the same level surface.
3) Make sure the vehicle is under no load when the driver (or article with equal weight on driver’s seat)
is not taken into account (the coolant and engine oil is filled to normal level and the fuel tank is full).
103
4) Turn on the lower beam lamp of headlamp.

5) Carry out aim adjustment with adjusting screw.
Screw down the adjusting screw at first, and then loose it for adjustment. If the front of vehicle body is
repaired or the headlamp assembly is replaced, check the aiming and adjust it to be in proper condition
with light detector.
6) Carry out aiming in accordance with alignment meter until it is properly adjusted.
III. Front Fog Lamp
Location Plan of Element of Front Fog Lamp

2. Replacement of Front Fog Lamp
Fig. 1.5.019
104
② Dismount the front bumper. Please refer to “Replacement of Front Bumper”.
Fig. 1.5.020
③ Dismount the clamping screw on fog lamp from front

bumper.
Fig. 1.5.021
④ Disconnect the electrical connector and dismount the fog

lamp assembly.
① Mount the fog lamp assembly.
Tightening torque of fixing screw: 2N•m Fig. 1.5.022
② Connect the electrical connector.

③ Mount the front bumper. Please refer to “Replacement of Front Bumper”.
④ Mount the negative pole of storage battery and detect the light. If the requirements are not met,
adjustment should be carried out. Please refer to “Adjustment of Beam of Front Fog Lamp”.
105
3. Replacement of Front Fog Lamp Bulb.

1) Dismantlement steps: Fig. 1.5.023
① Prize up the fixed snap-in on connector of fog

lamp assembly.
② Screw the rubber cover of bulb seat

anti-clockwise .
③ Dismount the connector of fog lamp and take
off the rubber cover of bulb seat
④ Dismount the fixed snap-in for bulb seat.
Fig. 1.5.024
⑤ Dismount the fog lamp bulb from bulb seat.

⑥ Replace the fog lamp bulb.
Detect the light after installation. If the requirements are not met, carry out adjustment. Please refer
to “Replacement of Beam of Front Fog Lamp”.
4. Replacement of Beam of Front Fog Lamp
Attention:
Correct road lighting can be provided only after the adjustment of beam of front fog lamp.
As the mounting support for front fog lamp may be disturbed by installation of new fog lamp
assembly or repair of forehead of vehicle, the adjustment of beam of front fog lamp must be
checked.
The beam of front fog lamp assembly of this model can not be adjusted horizontally.
1) To assure the precise adjustment of vertical beam of front fog lamp, make preparation for the
vehicle according to following steps at first.
① If other maintenance has been carried out for the vehicle, make sure all the components of vehicle
are available firstly.
106
② Make sure the fuel achieves the full level or slightly below.
③ Stop the vehicle on level ground and keep a 1.52m distance with target screen.
④ Stop other operations carried out on the vehicle.
⑤ Rock the vehicle to make the suspension be available.
⑥ Cover the headlamp during the adjustment of beam of fog lamp.
2) Turn on the front fog lamp.
3) Insert the cross screwdriver through the space under front bumper to get close to the vertical
adjusting screw.
4) Adjust the fog lamp upward/downward to make the top edge of highlight area be 102mm lower than
the horizontal centerline (2). The area shown in target screen is the ground boundary (5) which is
0mm below the horizontal centerline (3).
5) Turn off the front fog lamp.
Fig. 1.5.025
IV. Tail Lamp

Location Plan of Element of Tail Lamp
107
2. Replacement of Tail Lamp

Fig. 1.5.026
② Open the boot cover.
Fig. 1.5.027
③ Dismount the trim strip of boot cover. Please refer to “Replacement of Trim Strip of Boot Cover”.
④ Take off the cover plate of spare tyre. Please refer to “Replacement of Cover Plate of Spare Tyre”.
Fig. 1.5.028
108
⑤ Dismount the sill panel of boot.

Please refer to “Replacement of Sill Panel of Boot”.
Fig. 1.5.029
⑥ Dismount the side guard plate of boot. Please

refer to “Replacement of Side Guard Plate of
Boot”.
Fig. 1.5.030
⑦ Dismount the fixed bolt for tail lamp.
Fig. 1.5.031
109
⑧ Pull out the connector of tail lamp and take off the tail lamp.
Fig. 1.5.032

Attention:
Check if the tail lamp is in good condition before installation.
Don’t damage the tail lamp during installation.
Check if the tail lamp is properly mounted after installation and if the matching clearance with body
is proper. If not, re-mount the tail lamp.
Don’t dismount the bulb for a long time, or else, the performance of lamp may be affected due to
ingress of dust, moisture, smoke, etc. Once the bulb is dismounted, mount a new bulb as soon as
possible.
3. Location Plan of Each Element of Tail Lamp
1-Tail lamp assembly Fig. 1.5.033

2-Rear fog lamp
5
3-Small lamp
4-Turn lamp 4
5-Stop lamp 6
3
6-Reversing lamp
110
4. Replacement of Stop Lamp Bulb

① Dismount the inner guard plate of tail lamp.
② Screw off the stop lamp seat anti-clockwise.
③ Slightly press the bulb down and screw off the stop lamp bulb anti-clockwise.
④ Replace the stop lamp bulb.
Attention:
Check if the bulb is in good condition before installation.
Mount the bulb properly on the lamp seat.
Carry out alignment for mounting hole during installation of lamp seat and mount it properly.
Conduct inspection after installation.
possible.
5. Replacement of Turn Lamp Bulb
Fig. 1.5.034
② Screw off the turn lamp seat anti-clockwise.

③ Slightly press down the bulb and screw off the turn lamp bulb anti-clockwise.
111
④ Replace the turn lamp bulb.

Attention:
possible.
6. Replacement of Reversing Lamp Bulb

Fig. 1.5.035
② Screw off the reversing lamp seat
anti-clockwise.
③ Dismount the reversing lamp bulb.
④ Replace the reversing lamp bulb.
2) Install in the reverse order with
dismantlement.
Attention:
Check if the bulb is in good condition before
installation.
Carry out alignment for mounting hole during
installation of lamp seat and mount it properly.

possible.
112
7. Replacement of Rear Fog Lamp Bulb

② Screw off the rear fog lamp seat anti-clockwise.
③ Slightly press down the bulb and screw off the rear fog lamp bulb anti-clockwise.
④ Replace the rear fog lamp bulb.
Attention:
possible.
8. Replacement of Small Lamp Bulb
Fig. 1.5.036
② Screw off the small lamp seat anti-clockwise.
113
③ Dismount the small lamp bulb.
Fig. 1.5.037
④ Replace the small lamp bulb.

Attention:
possible.
114
V. Highmounted Stop Lamp

Location Plan of Element of Highmounted Stop Lamp
2. Replacement of highmounted stop lamp

Fig. 1.5.038
② Dismount the rear seats. Please refer to

“Replacement of Rear Seat”.
③ Dismount the fixed tapping screw on coatrack.
Fig. 1.5.039
④ Remove the coatrack and disconnect the

electrical connector of highmounted stop lamp
on coatrack.
115
⑤ Take out the coatrack and replace the

high-mounted stop lamp.
Fig. 1.5.040
2) Assemble in the reverse order with

dismantlement.
VI. License Plate Lamp

Location Plan of Element of License Plate Lamp

2. Replacement of License Plate Lamp
① Dismount the tail guard plate. Please refer to “Replacement of Tail Guard Plate”.
② Prize up the license plate lamp with Fig. 1.5.041

right-angled screwdriver.
116
③ Disconnect the electrical connector. Fig. 1.5.042
④ Take off the license plate lamp and replace it.

Fig. 1.5.043

3. Replacement of License Plate Bulb
1) Dismount the license plate lamp. Please refer to “Replacement of License Plate Lamp”.
2) Screw off the license plate lamp seat anti-clockwise.
3) Replace the license plate lamp bulb.
Attention:
117
VII. Illuminating Lamp of Boot

Location Plan of Element of Boot Illuminating Lamp

2. Replacement of Illuminating Lamp of Boot
① Open the boot cover.
② Prize up the illuminating lamp of boot with screwdriver.
Fig. 1.5.044
③ Disconnect the electrical connector.

④ Replace the illuminating lamp of boot.
118
3. Replacement of Illuminating Lamp Bulb of Boot

1) Dismount the illuminating lamp of boot. Please refer to “Replacement of illuminating lamp of boot”.
2) Take off the bulb from boot illuminating lamp seat.
3) Replace the bulb of illuminating lamp of boot.
Fig. 1.5.045
VIII. Side Turn Signal Lamp

Location Plan of Element of Side Turn Signal Lamp
119
2. Replacement of Side Turn Signal Lamp

① Disconnect the side turn signal lamp from the fender with right-angled screwdriver.
Fig. 1.5.046
② Dismount the electrical connector.
Fig. 1.5.047
① Connect the electrical connector.
② Mount the side turn signal lamp on the fender.
4. Replacement of Side Turn Signal Lamp Bulb
① Dismount the side turn signal lamp. Please refer to “Replacement of Side Turn Signal Lamp”.
② Anti-clockwise screw the turn lamp seat out from the mounting hole.
③ Dismount the bulb from the side turn signal lamp seat.
④ Replace the bulb of side turn signal lamp.
Attention:
120
possible.
IX. Illuminating Lamp of Glove Box

Fig. 1.5.048
2. Replacement of illuminating lamp of glove box

Fig. 1.5.049
① Open the glove box.
② Prize up the illuminating lamp of glove box

with right-angled screwdriver. Fig. 1.5.050
121
③ Disconnect the electrical connector.
Fig. 1.5.051
④ Replace the illuminating lamp of glove box.

3. Replacement of Bulb of Illuminating Lamp of Glove Box
1) Dismount the illuminating lamp of glove box. Please refer to “Replacement of illuminating box of
glove box”.
2) Take off the bulb from the seat of illuminating lamp of glove box.
3) Replace the bulb of illuminating lamp of glove box.
Fig. 1.5.052
122
X. Reading Lamp
Location Plan of Element of Reading Lamp
2. Replacement of Reading Lamp

Fig. 1.5.053
① Prize up the lampshades of reading lamp
orderly.
② Dismount the clamping screws for reading
lamp orderly.
③ Dismount the reading lamp from the roof inner

liner carefully and disconnect the connector. Fig. 1.5.054
④ Replace the reading lamp.

dismantlement.
123
3. Replacement of Reading Lamp Bulb

① Dismount the reading lamp. Please refer to “Replacement of Reading Lamp”.
② Dismount the reading lamp bulbs in turns from the mounting base.
③ Replace the reading lamp bulb.
Fig. 1.5.055

Attention:
Select the bulb to be replaced according to the condition in practical operation.
Mount the bulb properly on the mounting base.
Check if the requirements are met after installation.
124
XI. Maintenance Data and Specification

1. Light Parameter and Bulb Specification
Table of light parameter and general bulb specification
Bulb Type Power

Halogen headlamp (upper/lower beam lamp) Bayonet type 55/60W
Parking lamp Sucking fit 5W
Front turn lamp Bayonet type 21W
Side turn lamp Sucking fit 5W
Rear turn lamp Bayonet type 21W
Stop lamp/tail lamp Bayonet type 21/5W
Reversing lamp Bayonet type 21W
License plate lamp Bayonet type 5W
2. Power of Bulb and Light Color

Table of lighting fitting parameter
Name Bulb Type Power of Bulb Light Color

Front position Bulb (W) 2X5W White
lamp
Headlamp Upper/lower Tungsten-halogen lamp 2X60(55)W White
beam lamp (H4)
Turn lamp Bulb (P25-1) 2X21W Amber
Side turn lamp Bulb (WY) 2X5W Amber
Front fog lamp Bulb (H3) 2X55W White
Stop lamp Bulb (P) 2X21W Red
Rear turn lamp Bulb (PY) 2X21W Amber
Rear
Reversing lamp Bulb (W) 2X21W White
combination
Rear position Bulb (R) 2X5W Red
lamp
lamp
Rear fog lamp Bulb (P) 2X21W Red
License plate lamp Bulb (W) 5WX2 White
Highmounted stop lamp Bulb (P) 21W Red
Reading lamp Bulb (KD) 40W White
Left/right front door lamp Bulb (P) 5WX2 Red
Illuminating lamp of boot Bulb (KHA) 5W White
Illuminating lamp of LED / -
instrument
Illuminating lamp of glove Bulb (KHA) 5W White
box
Illuminating lamp of cigarette Bulb (KD) 1.2W White
lighter
Illuminating lamp of ignition Bulb (KD) 1.4W -
switch
125
4. Lighting Switch
Table of lighting switch parameters
Name of Switch Load Rated Load

Switch of small lamp Relay of small lamp 180mA (inductive load)
Switch of lower beam lamp Headlamp relay 180mA (inductive load)
Switch of upper beam lamp Upper beam lamp 180mA of bulb load (driven by relay)
Overtaking switch Upper beam lamp 180mA of bulb load (driven by relay)
Switch for left turn Left turn lamp Relay
Switch for right turn Right turn lamp Relay
Switch of front fog lamp Relay of front fog lamp 180mA (inductive load)
Switch of rear fog lamp Relay of rear fog lamp 180mA (inductive load)
Switch of alarm lamp Left/right Turn lamp Relay
Stop lamp, highmounted
Switch of brake pedal Bulb load
stop lamp
Contact switch of door Left/right front door lamp Bulb load
Switch of boot Illuminating lamp of boot Bulb load
Dimming switch - -
Illuminating lamp of glove
Contact switch of glove box Bulb load
box
2. Torque Specification
Table of Torque Specification
Name N•m Lb-lf Lb-in

Fixed bolt for headlamp 10 ― 53
assembly
126
Section VI Combined Device

I. Illustration on Functions
Fig.1.6.001
1. Speed meter: the pointer moves according to the signals which are from speed sensor, showing the
travel speed of vehicle.
2. Tachometer: the pointer moves according to the rotate speed signals inputted by ECM of engine,
showing the rotate speed of engine.
3. Water thermometer: the pointer moves according to the signals which are from the coolant
temperature sensor, showing the temperature of engine coolant.
4. Fuel oil meter: the pointer moves according to the signals which are from the fuel oil sensor,
showing the amount of remained oil in the fuel tank.
5. Odometer: it calculates the total (accumulated) travel distance of vehicle through pulse signals
which are from speed sensor and it can switch short trips (subtotal).
127
6. Table for Symbols of Warning Functions
Table for Symbols of Warning Functions
Input Mode of
No. Name of Indicator Lamp Symbol Color Remarks
Signal
Charge-discharge indicator
1 Red Low level LED
lamp
Alarm lamp of engine oil
2 Red Low level LED
pressure
3 Fuel oil alarm lamp Yellow Low level LED
4 Engine trouble lamp Yellow Trouble LED
5 Distant light Indicator lamp Blue Low level LED
6 Indicator lamp of rear fog lamp Yellow Low level LED
7 Left turn indicator lamp Green Low level LED
8 Right turn indicator lamp Green Low level LED
Braking system trouble

9 Red Trouble LED
indicator lamp
10 Indicator lamp of safety belt Red Low level LED
11 Indicator lamp of safety airbag Red Trouble LED
12 ABS trouble alarm lamp Yellow Trouble LED
13 Indicator lamp of door open Red Low level LED
14 Boot cover indicator lamp Red Low level LED
Water temperature alarm

15 Red Trouble LED
indicator lamp of engine
16 EOBD indicator lamp EOBD Yellow Trouble LED
Burglarproof indicator lamp of

18 Red Red Reserved
engine
128
7. Relevant Parameters of Combined Device
Parameters of Combined Device
Structural form Imitation type

Symbol of indicated unit Km/h
Indication range 0～200
Speed meter
Maximum vehicle speed >160
Driven by stepper
Drive mode
motor
Symbol of indicated unit X100rpm
Indication range 0〜8000rpm
Tachometer
Red zone 6000〜8000rpm
Driven by stepper
Drive mode
motor
Symbol of oil level EF
Four-meter scale Red zone for empty oil level 1/8
Fuel oil meter Indication range E~F
Range for warning 1/8
Driven by stepper
Drive mode
motor
Structural form Analogue
Temperature symbol °C
C(50°C)〜
Indication range
H(120°C)
Temperature for alarm 115°C〜120°C
Water thermometer Red zone for indication of hot
115°C
temperature
Range of normal working
Below 100°C
temperature
Driven by stepper
Drive mode
motor
LCD (segment Subtotal of mileage (Trip) 0〜9999. 9
code) Accumulated mileage (0D0) 0〜999999
Display mode Negative Image
LCD Adjusting method Dutyfactor
Dimension of display screen Double-line display
Illumination color of
Orange
back-lighting of dial
Illumination color of
Illumination Color -
scale/character
LCD illumination color Yellow
Illumination color of pointer Red
129
II. Illustration on Connector Terminal of Combined Device
The illustration on connector terminal of combined device is as follows:
3
1
Illustration Diagram for Connector Terminal of Combined Device
1-Connector A (Black） 2-Connector B (Blue） 3-Connector C (White)
III. Replacement of Combined Device
① Dismount the negative pole of storage battery.
② Dismount the clamping screw for exterior cover of combined console.
Fig.1.6.002
130
③ Dismount the clamping screw for combined

device.
Fig.1.6.003
④ Cut off the connector of combined device and

dismount the combined device assembly.
Fig.1.6.004
① Put in the combined device assembly, and

connect the connector of combined device.
Fig.1.6.005
② Mounting the clamping screw for combined device.
Torque of clamping screw: 1.7~2.3 N•m
131
③ Put in the exterior cover of combined device.
Fig. 1.6.006
4) Mounting the clamping screw of exterior cover Fig.1.6.007

of combined device.
Tightening torque: 1.5~2.5 N•m.
IV. Speed Meter and Odometer
1. Principle
1 2
Basic Diagram for Speed Meter and Odometer
1-Speed meter 2-Odometer
The crossed coil speed meter and odometer are used in this vehicle to indicate the vehicle’s traveling
speed and accumulated traveling mileage, and a digital odometer is also set. A magnetic-type structure
is adopted for measuring vehicle speed while a multifunctional LCD is used to control the recording of
mileage.
132
When the speed meter doesn’t work, the pointer will be at the zero position. When the vehicle travels,
the lines of magnetic force of permanent magnet driven by a driving gear in the transmission to cut the
HALL vehicle speed sensor will make the HALL vehicle speed sensor produce pulse-width signals and
provide them for the cross coil speed odometer so as to drive the pointer of speed meter to move.
Meanwhile, it provides the control mileage for the multifunctional LCD which records the mileage.
2. Testing
1) Testing:
① Adjust the tire pressure to the specified value.
② Put the vehicle on the speed test-bed.
③ Make sure that the behavior of parking brake is correct.
④ In order to prevent the vehicle from moving around, the left and right of vehicle shall be fixed.
⑤ In order to prevent the vehicle from rushing out, a chain or steel wire shall be used to fasten the rear
and make sure the ends of chain or steel wire are fixed tightly.
⑥ Check whether the indication of speed meter is within the range of standard value.
Comparison Table for Indicated Standard Range and Frequency of Speed Meter
Speed Meter Instrument (Pin27)

Speed Frequency
60Km/h 40.1Hz
100Km/h 66.1Hz
160Km/h 107.3Hz
Attention:
During test, don’t operate the clutch suddenly or increase and reduce the speed rapidly.
Check whether the circuit and plug resistance of combined device and speed sensor are conducted.
And the electrical resistance value shall be less than 0.5Ω.
Detect the waveform between input terminal of combined device and grounding of vehicle body, and
it shall be the rectangular wave with 12V.
Verify the change of frequency:
Verify the change of frequency along with vehicle speed, that is, the frequency shall increase with the
times of 7.08 Hz when the vehicle speed is increased from 10 to 20 to 30 km/h.
133
V. Tachometer
1. Principle
The tachometer of engine is used for indicating the running speed of engine. When the engine is running,
its rotating speed sensor will send rotating speed signals to ECM of engine. The ECM will send an
impulse square wave to the combined device according to the rotating speed of engine, then, the
combined device controls the pointer of tachometer of engine according to this signal in order to indicate
the actual rotating speed of engine.
Location Plan for Tachometer of Engine
2. Check for Tachometer
1) Connect the tachometer of engine.
Remarks：
It had better to use a fluxmeter type tachometer of engine to conduct the check. (Because the
fluxmeter only needs clipping on the high-voltage wire.)
2) Compare the reading of tachometer of engine with reading of tachometer in the vehicle under each
rotating speed of engine, and make sure that the difference between them is within the range of
standard value.
134
Comparison Table for Indicated Standard Range and Reference Frequency of Tachometer
Standard Rotating Speed (r/min) Reference Frequency (Hz)
750 25Hz
1050 35Hz
1500 50Hz
3000 100Hz
4500 150Hz
6000 200Hz
7500 250Hz
3. Trouble Check Process
Possible Cause
The tachometer doesn’t work. 1 The tachometer has troubles.

2 The wiring or connector has troubles.
Disconnect the connector B and C, and 1 is Check the

Abnormal
Repair it.
measure at the wiring’s side: abnormal. connector.
1. Measure whether there is a
pulsed voltage between #1
terminal of C and grounding part of
vehicle body when the engine is
running. Normal
Normal: there is a pulsed voltage.
2. Measure the continuity condition
between #2 terminal of B and
grounding part of vehicle body. Check the rotational speed
Normal: in conducted. sensor of engine, and repair it
if necessary.
Normal
2 is
abnormal. Check the wiring, and repair
Replacing the tachometer. it if necessary.
135
VI. Water Thermometer
An analog water thermometer (coolant thermometer) driven by stepper motor is used. And it is shown in
the following diagram.
Location Plan of Water Thermometer
The adopted coolant temperature sensor is a thermistor sensor, and its location is shown as the
following diagram:
The coolant temperature sensor is assembled

in the small circulating path of coolant behind Fig.1.6.008
engine.
1. Illustration on Water Thermometer
Below C——Low temperature zone
During start and warm-up, the engine will work in this zone for a short time. And in this temperature zone,
the engine shall be prevented from running with a high rotate speed, at the same time its working load
shan’t be overlarge.
136
Between C and H——Normal temperature zone The pointer shall be within this range when the
vehicle is traveling normally.
When the outside temperature is very high and load of engine is very heavy, the pointer may deviate
from this range. As long as the coolant alarm lamp doesn’t flash, the vehicle still can travel normally.
However, if it flashes to warn, the engine shall be shut and the cooling system shall be checked.
Above H——Overheated zone
If the pointer enters this red zone, it means that the engine is overheated. Please safely stop the vehicle
immediately, shut down the ignition switch and find out the cause after the engine is cooled off.
Illustration:
If the auxiliary headlamp is mounted in front of cold air inlet which is under the front bumper, it will affect
the circulation of cooling air and be harmful for cooling of engine. If the outside temperature is very high
and engine is working with a heavy load, the engine is easy to be overheated. The front spoiler is also
helpful for guiding cooling air. If it is damaged or even ruptures due to impact, the overheating of engine
may happen.
2. Check for Coolant Temperature Sensor of

Engine Fig.1.6.009
1) Dismount the coolant temperature sensor of

engine.
2) Immerge the sensor in hot water to measure

the electrical resistance.
3) See the following table for standard value.
4) Reassemble it after check.
Table for Electrical Resistance Parameters of Temperature Sensor
Temperature (℃) Resistance Value (Ω)/(PinA8)

60 153
85 66
110 29
125 20
3. Check for Water Thermometer
If the electrical resistance value of coolant temperature sensor of engine is normal, the circuit of sensor
and water thermometer shall be checked. If not, the maintenance or replacement shall be conducted.
Please refer to “Maintenance Volume of Circuit”.
137
VII. Fuel Oil Meter
The working condition of fuel oil meter is basically the same with the water thermometer, that is, an
analog instrument driven by stepper motor is used.
Location Plan for Fuel Oil Meter
When the floater changes with the oil level in fuel oil tank, the sliding contact linked with floater rod
responds to change the electrical resistance value of thick-film resistor. Therefore, when the fuel oil tank
is filled with fuel oil, the electrical resistance value of thick-film resistor is the smallest, and the pointer of
fuel oil meter points to the maximum scale value F. On the contrary, when the fuel oil in fuel oil tank is
used out, its electrical resistance value is the largest, and the pointer points to the minimum scale value
E.
1. Testing Method
1) Check the operation of fuel oil meter
When the pointer reaches the empty position (E), there is fuel oil of about 10 L in the fuel tank. And it
leaves the full position (F) only when the vehicle has traveled for a distance after the fuel tank is filled.
With oil remained, the quantity of fuel oil that can be added will lower than the marked capacity when the
oil is added renewedly.
138
2. Simple Check Process of Fuel Oil Meter
Dismount the connector of fuel oil meter

sensor sub-assembly.
Use special tools to connect the testing

Replace the fuel oil meter sensor
lamp (12V -3.4V) to the connector at the
sub-assembly.
side of wiring.
Normal
When ignition switch is at ON position, the Normal

testing lamp turns on. The pointer of fuel oil meter swings.
Abnormal
Repair the electrical wiring.

Replace the fuel oil meter.
Abnormal
Repair the electrical wiring.
3. Check for Fuel Oil Meter Sensor Sub-assembly

In order to check, please dismount the fuel oil meter sensor sub-assembly from fuel oil tank.
4. Electrical Resistance of Fuel Oil Meter Sensor Sub-assembly
1) Check whether the electrical resistance values among terminals of fuel oil meter sensor are within
the range of standard value when the floater of fuel oil meter sensor sub-assembly is at F position
(highest) and E(lowest) position.
Comparison Table for Electrical Resistance and Instrument Indication of Fuel Oil Meter Sensor
Scale Line Reference Resistance Value ( )

Empty 244±6
1/8(RED) 154±5
1/4 124±5
3/8 104±5
1/2 85±4
5/8 71±4
3/4 58±3
7/8 49±3
FULL 40±2
139
2) Check whether the electrical resistance value Fig.1.6.010

changes stably when the floater moves slowly
Stopper
between F (highest) and E (lowest) position.
Position F
5. Height of Floater of Fuel Oil Meter Sensor
(Highest)
Sub-assembly
Position E
(Lowest)
Move the floater and measure the height A of F
Stopper
(highest) and height B of E (lowest) when the
floater rod contacts the stopper.
Indicated reference value:
A: 275 mm
B: 158.8 mm
VIII. Alarm Lamp of Engine Oil Pressure
1. Illustration on Indicator Lamp
When ignition switch is on, this indicator lamp shall light immediately and go out after the engine is
started. If this lamp doesn’t go out after engine starting or it lights when the rotating speed of engine
exceeds 2000 r/min during traveling, stop the vehicle immediately, switch off the engine and check the
oil level of engine oil. If the oil level is too low, add oil immediately.
2． Testing of Indicator Lamp
Disconnect the connector from alarm lamp switch, and connect the connecting terminal in the end of
wiring to earth. Shift the ignition switch to “ON”, and alarm lamp shall light. If not, the bulb shall be tested.
3. Engine Oil Pressure Switch
Engine oil pressure switch
Combined
device
Basic Diagram for Circuit of Engine Oil Pressure Switch

① Disconnect the connector from switch.
② When engine stops, the terminal and earth shall be conducted.
③ When engine runs, the terminal and earth shan’t be conducted.
Notes: The engine oil pressure shall be higher than 24. 5 kPa (0.25 kilopond/cm2, 3. 55 Lbf/Square
inch). If the actual conditions don’t comply with the specified conditions, the switch shall be replaced.
140
IX. Alarm Lamp of Braking System
1. Illustration on Alarm Lamp of Braking System
This lamp works when ignition switch is turned on.
And it keeps on when the parking brake is placed.

Diagram for Alarm Lamp of Braking System
If the lamp is still on after the parking brake is released, then the oil level of brake fluid is too low.
Therefore, the brake fluid shall be added until its level is between MIN and MAX marks.
2. Testing of Alarm Lamp of Braking System
Disconnect the connector from the switch of alarm lamp of brake fluid, loose the parking brake, and start
the engine. At this moment, the alarm lamp shall turn on, if not, test the bulb and wiring.
3. Check for the Switch of Alarm Lamp of Brake Fluid Level
Dismount the stock solution tank cover and strainer screen, disconnect the connector, and shift the
switch to “OFF” position (the floater floats). At this moment, the terminals shall not be conducted. Use a
siphon to suck out the liquid in stock solution tank and shift the switch to “ON” position (the floater falls).
And now, the terminals shall be conducted. At last, pour the liquid back in stock solution tank. If the
actual conditions don’t comply with the above conditions, the switch shall be replaced.
X. Alarm Lamp of Door Open
1. The alarm lamp shall light when any door or trunk is opened.
2. If the alarm lamp doesn’t light, disconnect the connector of courtesy lamp switch and connect the
terminal 1 at the end of wiring to earth. In this condition, it shall turn on, if not, check the bulb or
wiring.
141
Section VII Windscreen Wiper and Its Cleanser

I. System Composition
As the traveling safety will be affected when the dust and dirt on the windscreen is not cleared in time,
the wiper washing system is applied on the vehicle. This model of vehicle equipped the wiper with 2
speeds and intermittent working mode and consists of drive motor, worn gear mechanism, rocker arm,
wiper blade, etc.; the washing system consists of washer reservoir, motor, pipeline, spray nozzle and so
on.
II. Precautions
Before dismounting the electrical connecting wire of system, dismount the negative pole of storage
battery and wait for at least 1min, otherwise, it may cause physical injury.
III. Front Windscreen Wiper
The motor of front windscreen wiper, which is controlled by combined switch and timing relay of
windscreen wiper, can run at 2 speeds and connect with a limit switch for stop position.
When the ignition switch is set at “ON” position, the following 4 functions are available:
1) Shutdown.
2) Intermittent operation of windscreen wiper.
3) Low-speed operation of windscreen wiper.
4) High-speed operation of windscreen wiper.
142
Location Plan of Element of Front Windscreen Wiper
ETACS module
Windscreen wiper
switch
Terminal
Function
Intermittent
relay of front
windscreen
wiper
Intermittent
Low speed
High speed
Adjustment of
interval
Motor of front windscreen wiper
Schematic Diagram of Windscreen Wiper
3. Pressure Check at Wiper Arm End
1) Make the wiper arm and wiper blade run to the middle position.
2) Dismount the wiper blade from the wiper arm.
143
3) Connect the spring to one end of the wiper arm and measure the required torque for lifting the
wiper arm to normal working height when it is vertical to the windscreen (the specified value is
6~8N•m).
4) Replace the wiper arm when the measured value does not conform to the specified value.
5) Mount the wiper blade on the wiper arm.
4. Adjustment and Check of Wiper Blade Rubber Strip
1) Dismount the wiper blade from the wiper arm,
2) Check the length of rubber strip of wiper blade.
3) Replace the rubber strip of wiper blade when the rubber parts contacting with the windscreen is not
within wiper blade centerline ±15°.
4) Mount the wiper blade on the wiper arm.
5. Check of Front Windscreen Wiper Switch
During the application of the following 4 functions of front windscreen wiper switch: OFF, intermittent
operation, low-speed operation and high-speed operation, check if its conductivity complies with the
figure below. If not, replace the switch.
Terminal
Function
Intermittent
Low speed
High speed
Adjustment of
interval
Inspection Diagram of Front Windscreen Wiper Switch

6. Check of Front Windscreen Wiper Motor
1) Dismount the connector of windscreen wiper motor.
Circuit Diagram of Windscreen Wiper Motor
144
2) Connect the positive pole of storage battery with pin 4 of front windscreen wiper motor and connect
the negative pole with pin 2, so that the motor of front windscreen wiper will operate at high speed. If
not, please replace the motor of front windscreen wiper.
the negative pole with pin 1, so that the motor of front windscreen wiper will operate at low speed. If
not, please replace the motor of front windscreen wiper.
the negative pole with pin 1, so that the motor of front windscreen wiper will operate at low speed.
Then cut off the connection between pin 1 of motor terminal and negative pole of storage battery
during the operation of windscreen wiper motor. Check the conductivity between pin 4 and 5 with
multimeter. If the specification is not complied with, please replace the motor of front windscreen
wiper.
7. Replacement of Windscreen Wiper Arm
① Push it to the bottom of clamp of windscreen wiper blade and dismount the windscreen wiper blade
from the inner side of wiper arm.
② Take out the wiper arm from the opening of wiper blade.
① Place the wiper blade claw groove inside the wiper arm claw.
② Pull the wiper blade claw groove into the wiper arm claw until the claw groove is fixed into the hook.
③ Actuate the windscreen wiper and check if it is working normally.
8. Replacement of Rubber Strip of Windscreen Wiper Blade
Attention:
If the rubber strip from windscreen wiper blade is dismounted, replace it with a new one.
① Dismount the wiper blade from wiper arm. Fig. 1.7.001

Please refer to “Replacement of Windscreen Wiper
Blade and Arm”.
② Dismount the lower claw of wiper blade from
the scotch in rubber strip of wiper blade.
③ Take out the rubber strip of wiper blade
through the claw of wiper blade.
145
Attention:
Keep the wiper blade claw in the slide track of rubber claw of wiper rubber strip, and do not let the
wiper blade claw contact with the metal groove of wiper rubber strip.
① Insert the opening end of rubber strip of wiper blade into the lower claw of wiper blade.
② Introduce the rubber strip of wiper blade into the sub-assembly of wiper blade claw.
③ Insert the lower claw of wiper blade rubber strip into the wiper blade notch.
④ Mount the wiper blade on wiper arm. Please refer to “Replacement of Windscreen Wiper Arm and
Blade”.
9. Replacement of Front Windscreen Wiper Arm

① Set the ignition switch at OFF position.
② Set the wiper switch at OFF position.
③ Take off the nut cap.
④ Dismount the nut from wiper arm.
⑤ Dismount the wiper arm form the drive shaft of

Fig. 1.7.003
wiper transmission by rocking.
① Set the ignition switch at “ON” position.
② Set the wiper switch at low-speed position and shut down the low-speed gear after the wiper motor
is actuated.
③ Turn off the ignition switch when the transmission system of windscreen wiper is stopped.
④ Mount the wiper arm on drive shaft of wiper transmission.
146
⑤ Mount the nut on the drive shaft of wiper transmission and the wiper arm and tighten it.
Tightening torque: 10~12N'm
⑥ Mount the nut cap.
⑦ Operate the windscreen wiper to check if its operation is normal.
10. Replacement of Transmission Parts of Front Windscreen Wiper

① Disconnect the negative pole of storage
battery.
② Dismount the wiper arm from the drive shaft of

wiper driving rod. Please refer to “Replacement of
Windscreen Wiper Blade”.
③ Prize up the waterproof strip of engine
department.
Fig. 1.7.005
④ Dismount the 2 screws on the right ventilation Fig. 1.7.006

window.
147
⑤ Dismount the right ventilation window. Fig. 1.7.007
⑥ Dismount the 2 screws on the left ventilation Fig. 1.7.008

window.
⑦ Dismount the left ventilation window. Fig, 1.7.009
⑧ Dismount the rocker arm of wiper motor from Fig. 1.7.010

the wiper driving rod.
148
⑨ Disconnect the connector of front windscreen Fig. 1.7.011

wiper.
⑩ Dismount the fixing screw for front windscreen Fig. 1.7.012

motor assembly.
⑪. Take off the front windscreen wiper motor

assembly.
⑫. Dismount the fixing screw for wiper
transmission system.
Fig. 1.7.013
⑬. Dismount the driving rod assembly of

windscreen wiper.
149
① Mount the driving rod assembly of windscreen
wiper.
② Mount the fixing screw for wiper transmission
system.
■ Tightening torque: 9~12N•m.
Fig. 1.7.014
③ Mount the front windscreen wiper motor Fig. 1.7.015

assembly.
④ Dismount the screw for the front windscreen
wiper motor assembly.
■ Tightening torque: 3.5~4.5N•m.
⑤ Mount the connector on the wiper motor. Fig. 1.7.016

⑥ Connect the driving rod of windscreen wiper
with the rocker arm of windscreen wiper motor.
⑦ Mount the left ventilation window.
150
⑧ Mount the 2 screws for left ventilation window.

■ Tightening torque: 1.4N•m.
Fig. 1.7.017
⑨ Mount the right ventilation window.
Fig. 1.7.018
⑩ Mount the 2 screws for right ventilation

window.
■ Tightening torque: 1.4N•m
Fig. 1.7.019
151
⑪. Mount the waterproof strip of engine

compartment. Fig. 1.7.020
⑫. Mount the wiper arm on the drive shaft of

wiper driving rod. Please refer to Fig. 1.7.021
“Replacement of Windscreen Wiper Arm”.
⑬. Mount the negative pole of storage battery.
⑭. Operate the wiper to check if its operation is

normal.
IV. Rear Windscreen Wiper
Fig. 1.7.022
152
2. Circuit Diagram
Rear windscreen wiper switch
Intermittent relay of rear

Terminal
windscreen wiper
Function
Rear windscreen
wiper ON
Rear windscreen
wiper OFF
Circuit Diagram of Rear Windscreen Wiper

3. Detection of Element
1) Check of rear windscreen wiper switch
Turn on the rear windscreen wiper switch and check if the conductivity between terminal 2 and 3
conforms to the figure below. If not, replace the switch.
Terminal
Function
Rear windscreen wiper

ON
Rear windscreen wiper

OFF
Terminal Diagram of Rear Windscreen Wiper Switch
2) Check of rear windscreen wiper motor
① Disconnect the connector of rear windscreen wiper motor.
② Connect the positive pole of storage battery with terminal 1 of rear windscreen wiper motor, and
then connect the negative pole with terminal 2, so that the rear windscreen wiper motor will be
actuated. If not, replace the rear windscreen wiper motor.
153
Circuit Diagram of Rear Windscreen Wiper Motor
③ Connect the positive pole of storage battery with terminal 1 of rear windscreen wiper motor and
connect the negative pole with terminal 2. Then cut off the connection between terminal 2 of motor
and negative pole of storage battery during the operation of rear windscreen wiper motor. Check the
conductivity between pin 3 and rear windscreen wiper motor with multimeter. If the specification is
not complied with, please replace the motor of rear windscreen wiper.
4. Replacement of Rear Windscreen Wiper Arm
① Set the ignition switch at “ON” position.
② Set the wiper switch at OFF position.
③ Turn off the ignition switch when the rear windscreen wiper arm is stopped.
④ Dismount the nut cap.
Fig. 1.7.023
⑤ Dismount the nut and gasket from the motor shaft.

⑥ Dismount the rear windscreen wiper arm.
⑦ Dismount the wiper blade from the windscreen wiper. Please refer to “Replacement of Windscreen
Wiper Arm and Blade”.
154
① Mount the wiper blade on wiper arm. Please refer to “Replacement of Windscreen Wiper Arm and
Blade”.
② Mount the rear windscreen wiper arm on the motor shaft:
Set the ignition switch at “ON” position.
Set the rear windscreen wiper switch at OFF position.
Turn off the ignition switch when the transmission system of windscreen wiper is set at stop position
and doesn’t move.
Mount the rear windscreen wiper arm on the motor shaft.
③ Mount and tighten the washer and nut on motor shaft.
Tightening torque: 10.0~11.0N•m
④ Press down the cap.
⑤ Operate the rear windscreen wiper to check if its operation is normal.
V. Cleanser of Windscreen Wiper

Fig. 1.7.024
155
2. Schematic Diagram
EATCS module
Terminal
Function
Windscreen wiper switch

Intermittent
Low speed
High
speed
Front
Intermittent relay of front

Intermittent windscreen wiper washing
relay of
rear Adjustment
windscreen of interval
wiper
Rear washing
Rear windscreen
wiper ON
Rear
water Rear windscreen
spray wiper OFF
motor
Rear windscreen wiper Front windscreen wiper

motor motor
Front water spray
motor
Schematic Diagram of Cleanser of Windscreen Wiper

3. Detection of Element
Terminal
Function
Intermittent
Low speed
High
speed
Front washing
Adjustment of
interval
Rear
washing
Rear
windscreen
wiper ON
Rear
windscreen
wiper OFF
Terminal Diagram of Cleanser Switch of Windscreen Wiper

156
1) Check of Cleanser of Windscreen Wiper

① Open the cleanser of rear windscreen wiper to check if the conductivity between terminal 1, 2 and 3
conforms to the figure below. If not, replace the switch.
② Open the cleanser of rear windscreen wiper to check if the conductivity of terminal 5 and 8 conforms
to the figure below. If not, replace the switch.
2) Check of cleanser motor of windscreen wiper
① Dismount the connector of cleanser motor of windscreen wiper.
② Connect the positive pole of storage battery with terminal 1 of cleanser motor of windscreen wiper,
and then connect the negative pole with terminal 2, so that the cleanser motor of windscreen wiper
will be actuated. If not, replace the cleanser motor of windscreen wiper.
Circuit Diagram of Cleanser Motor of Windscreen Wiper

4. Replacement of Solvent Tank, Pump Nozzle and Hose of Cleanser
② Dismount the front bumper. Please refer to “Replacement of Front Bumper”.
③ Dismount the headlamp. Please refer to “Replacement of Headlamp”.
④ Dismount the front wheel cover. Please refer to “Left Front Wheel Cover”.
⑤ Disconnect the hose on cleanser pump.
⑥ Disconnect the electrical connector on cleanser pump.
⑦ Dismount the nut on flange of solvent tank of cleanser.
157
⑧ Dismount the solvent tank of cleanser from the

right side of vehicle. Fig. 1.7.025
⑨ Dismount the pump on solvent tank of

cleanser.
⑩ Dismount the pump seal from solvent tank.
⑪ Dismount the clamp from claw groove of Fig. 1.7.026

engine hood.
⑫ Dismount the connecting hose of nozzle from
the engine hood.
⑬ Dismount the nozzle assembly from the
engine hood.
① Mount the nozzle assembly on engine hood.
② Mount the hose assembly on engine hood.
③ Connect the nozzle and hose, and then mount the nozzle on engine hood.
④ Mount the sealing element on solvent tank of cleanser.
⑤ Mount the water injection pump on solvent pump of cleanser.
⑥ Mount the solvent pump of cleanser at the right side in front of vehicle.
⑦ Mount the nut to fix the solvent tank.
■ Tightening torque: 1.5~2.0N•m
⑧ Connect the hose and pump.
⑨ Mount the hose clamp on the claw groove of engine hood.
⑩ Connect the electrical connector with water injection pump.
⑪ Mount the negative pole of storage battery.
158
5. Replacement of Rear Nozzle and Rear Hose
① Disconnect the rear hose on cleanser pump.
② Dismount the seal ring from the left side of vehicle.
③ Dismount the rear nozzle from rear lift gate and disconnect the rear hose on rear nozzle.
④ Dismount the claw grooves from rear lift gate and left side of vehicle.
⑤ Dismount the rear hose from the left side of vehicle body.
① Mount the ear hose on left side of vehicle body.
② Mount the seal ring on left side of vehicle body.
③ Connect the rear hose and cleanser pump.
④ Get the hose through claw groove and mount the rear hose in rear lift gate.
⑤ Mount the claw groove on rear lift gate and left side of vehicle body.
⑥ Connect the hose and rear nozzle, and then mount the rear nozzle on rear lift gate.
VI. Overhaul for Trouble
Check List for Common Troubles
Common Trouble Trouble Cause and Troubleshooting Method

1. Jamming of movable parts 1. Eliminate the jamming trouble
2. Disconnection of power supply and falling 2. Connect the power supply
Operation stop
of wire end of connector 3. Replace the motor with a new
3. Burnout of motor one
1. Abnormal sound arising from inside of 1. Replace the motor
motor 2. Eliminate the trouble of hit and
Abnormal sound and 2. Hit and rub of interlock mechanism during rub
operation movement 3. Clean the windscreen
3. Abnormal sound arising from the place
between blade and windscreen
Judder of blade during Fill detergent into washing solution kettle to decrease the friction during water
scraping injection and scraping
Out-of-level of blade Dismount the wiper arm for reinstallation to keep the blade leveled
1. Uncleanness of windscreen 1. Wash the windscreen to be
2. Severe abrasion of blade clean
Failure of wiping 2. Replace the blade (it is
recommended to replace it every
3 months)
159
1) Check of Cleanser System of Windscreen Wiper
Check List of Cleanser System of Windscreen Wiper
Step Measure Normal Result Abnormal Result

The windscreen wiper operates at
low speed. The cleanser keeps
Set the ignition switch at spraying to windscreen when its
RUN position. Keep the switch is set at “ON” position. After The cleanser fails to
1
cleanser switch at “ON” the switch is turned off, the cleanser work.
position. stops working and the wiper returns
to stop position after wiping for 2~4
times.
The delay mode of wiper
Set the windscreen wiper The wiper operates for a cycle, fails to work.
2 switch at delay (pulse mode) pauses for 1-22s, and then operates The defogging, delay
position. for next cycle. and low-speed modes of
wiper fail to work.
The cleanser keeps spraying to The cleanser fails to
windscreen when its switch is set at work.
Set the windscreen wiper “ON” position. The windscreen wiper The delay mode of wiper
switch at delay position and operates at low speed during water fails to work.
3
keep the wiper switch at injection and continues to operate for The defogging, delay
“ON” position for 1-2s. 2-4 times after the cleanser switch is and low-speed modes of
turned off. Then the wiper will go wiper fail to work.
back to pulse operation mode.
Set the windscreen wiper The defogging, delay
The wiper continues to operate at low
4 switch at low-speed and low-speed modes of
speed.
position. wiper fail to work.
The high-speed mode of
Set the windscreen wiper at The wiper continues to operate at wiper fails to work while
5
high-speed (HI) position. high speed. the low-speed mode is
available.
The windscreen wiper
Set the windscreen wiper at The wiper gets back to stop position can not stop working
6
OFF position. at low speed. The wiper keeps
working.
The delay mode of wiper
fails to work due to
Set the rear windscreen
malfunction. The
7 wiper switch at “ON” The wiper pauses for about 8s.
defogging, delay and
position.
low-speed modes of
wiper fail to work.
160
2) Diagnosis Procedure for Windscreen Wiper/Cleanser System
Trouble mode: the wiper and cleanser fail to work no matter of the position the wiper switch is set at
Step Measure Yes No

1 Check if the wiper fuse is broken. To step 3 To step 2
Dismount the wiper switch and check if it is in good condition.
Measure the wire harness with digital multimeter.
2 To step 5 To step 4
Check if the pressure within the area between connector and
wiper switch is normal.
3 Replace the broken fuse. To step 2
Check the console wire harness between fuse and wiper switch
4 and repair it when necessary. To step 5
Make sure the wiper switch and connector of wire harness contact
properly. Disconnect the wire harness and wiper motor, check the
5 To step 6
console wire harness between wiper switch & fuse and wiper
motor according to circuit diagram and repair it when necessary.
Check the wiper motor and repair it when necessary. Make sure
6 the wiper motor is in good condition and the connector of wiper To step 7 -
motor contacts properly.
Check the earth wire of wiper motor at wire harness of console
7 To step 8
and repair it when necessary.
8 Check if the system is in good condition.
3) Trouble mode: only the high-speed gear fails to work
Step Measure Yes No

Disconnect the wire harness connector from the wiper motor.
1 Measure the pressure of pin at wire harness side is normal with To step 2 To step 3
digital multimeter.
Check the internal structure of wiper motor and replace or repair it
2
when necessary.
Dismount the wiper switch and check if it is in good condition. Check
the console wire harness between wiper switch and wiper motor and
3
repair it when necessary.
4) Trouble mode: only the mid-speed gear fails to work
Step Measure Yes No

Disconnect the wire harness connector from the wiper motor. Check
1 if the pressure of pin measured at wire harness side with digital To step 2 To step 3
multimeter is normal.
Check the internal structure of wiper motor and replace or repair it
2
when necessary.
Dismount the wiper switch and check if it is in good condition.
3 Replace or repair it when necessary. To step 4
Check the console wire harness between wiper switch and wiper
4 motor and repair it when necessary.
161
5) Trouble mode: only the interval gear fails to work
Step Measure Yes No

Dismount the wiper relay, set the ignition device at “ON” position
and turn the wiper switch to the inner gear position. Check if the
pressure of pin measured on the relay with digital multimeter is
normal.
Dismount the wiper switch and check if it is in good condition; if
2 To step 3
not, replace or repair it when necessary.
3 To step 7
relay and repair it when necessary.
4 Check the earth wire at relay is properly earthed. To step 6 To step 5
5 Repair the earth wire and make sure it is earthed properly.
6 Replace the wire relay. Check if the system is in good condition.
Check the console harness between wiper switch and relay to
make sure it is in good condition.
Dismount the new wiper relay and check if the pressure measured
8 To step 10
at relay with digital multimeter is normal.
Please check if the console wire harness is in good condition and
9 To step 10
repair it when necessary.
Check if console wire harness between relay and wiper motor is in
10 good condition and repair the console when necessary; check if
the system is in good condition.
6) Trouble mode: the wiper blade does not stop at its original position
Step Measure Yes No

Dismount the wiper switch and check its internal structure. Replace
1 or repair the switch when necessary and make sure it is in good To step 2
condition.
Disconnect the connector of wiper motor; check if the pressure of
pin measured at wire harness side with digital multimeter is normal.
Check if the console wire harness between the fuse and wiper
3 To step 4
motor is in good condition according to the circuit diagram.
Dismount the wiper motor to check the structure; repair or replace it
4
when necessary. The system is in good condition.
162
7) Trouble mode: the wiper keeps working
Step Measure Yes No
1 Check if the fuse is in good condition. To step 2 To step 3

2 Replace the broken fuse. To step 3
Dismount the wiper switch and check if the pressure measured at
3 the switch with digital multimeter is normal. To step 5 To step 4
Check the console wire harness between the fuse and wiper switch
and repair it when necessary.
Check the internal structure of wiper switch and replace or repair
5 the switch when necessary. Make sure the switch is in good To step 10
condition. Check if the system is in good condition.
Disconnect the connector from wiper motor, set the ignition switch
at “ON” position, turn the wiper switch to high-speed position and
check if the pressure measured at the connector pin (wire harness
side) with digital multimeter is normal.
Check if the console wire harness between wiper switch and wiper
relay is in good condition.
8 Check if the earth wire is earthed properly with digital multimeter.
Dismount the wiper motor and repair or replace it. The system is in
9 To step 10
good condition.
motor according to circuit diagram; repair it when necessary and
10
make sure it is in good condition. Check if the system is in good
condition.
8) Trouble mode: the cleanser fails to work
Step Measure Yes No

Dismount the wiper/cleanser switch; set the ignition switch at “ON”
1 position; check if the pressure of pin measured at the original position To step 3 To step 2
of switch with digital multimeter is normal.
Check the console wire harness between fuse and wiper/cleanser
2 switch and repair it when necessary. Make sure it is in good condition. To step 3
Check the internal structure of wiper switch. Repair or replace it when

3 necessary and make sure it is in good condition. Check if the system is To step 4
in good condition.
Mount the wiper/cleanser switch; disconnect the connector of cleanser
motor and set the wiper/cleanser switch at “Washing” position. Check if
the pressure of pin measured at the connector of cleanser motor (wire
harness side) with digital multimeter is normal.
Check and repair the wire harness between wiper/cleanser and
5 To step 6
cleanser motor according to circuit diagram.
Please check if the console wire harness between wiper motor and
6 wiper/cleanser switch is in good condition according to the circuit To step 7
diagram.
7 Replace the cleanser motor. Check if the system is in good condition.
163
Section VIII Horn and Cigar Lighter

I. Location of Elements
1. Horn button Fig.1.8.001
2. Horn Fig.1.8.002
II. Basic Diagram
Connect the storage battery
Bass horn
Horn
button
Basic Diagram of the Horn System
164
III. Check of Horn
1. Dismantle the front bumper. Refer to “Replacement of Front Bumper”.
2. Disconnect the connector of the horn.

Fig.1.8.003
1 2
3. Connect terminal 1 of the horn with the positive pole of the storage battery and connect terminal 2
with the negative pole of the storage battery, and then the horn will sound.
4. If the horn doesn’t sound, replace it.
IV. Overhaul for Trouble
Steps Measure Normal Result Abnormal Result

When the horn button is pressed
Press and release the down, the horn will sound; when the The horn is out of work.
1
horn button horn button is released, the horn will Horn-with abnormal noise
stop sounding.
1. The horn is out of work.
Steps Measure Yes No

Check whether the horn fuse is broken.
1 To step 3 To step
Is the horn fuse burned out?
1. Pull out the connector of the horn assembly.
2. Connect terminal 1 of the connector of the horn
2 assembly with terminal 2 with the test lamp. To step 4 To step 5
3. While pressing down the horn button, watch the test
lamp. Is the lamp lightened?
To “Check of the
3 Replace the horn fuse _
Horn System”
To “Check of the
4 Replace the horn assembly _
Horn System”
1. Connect the horn again.
2. Disconnect the horn relay.
165
3. Connect pin 4 and pin 8 of the relay with the test lamp.
Does the horn sound?
1. Install the horn relay again.
2. Disconnect the electrical system of the airbag.
3. Dismantle the lead of the horn switch from the steering
wheel.
4. Connect joint 1 and joint 2 of the horn button with the
test lamp. Does the horn sound?
To “Check of the
7 Replace the button horn -
Horn System”
1. Place the test lamp at the same position (between joint 1
and joint 2 of the horn button).
8 2. Connect pin 4 with the pin 8 of the horn relay terminal To step 9 To step 10
temporarily with a 5 A fuse.
Is the test lamp lightened?
To “Check of the
9 Replace the horn relay -
Horn System”
Check whether the grounding is good and connect the test
lamp:
10 1. Terminal 8 of the horn relay and the ground. To step 11 To step 12
2. Terminal 1 of the horn button and the ground.
Is the test lamp lightened?
To “Check of the
11 Repair lead of bad grounding _
Horn System”
To “Check of the
12 Repair circuits of poor contact _
Horn System
2. Abnormal noise of the horn

1) Press the horn button to identify items concerned by the vehicle owners. Please refer to “Check of
the Horn System”.
2) If the horn has obviously abnormal noise, conduct the following routine check:
① Check whether the terminal is poorly contacted, if any, repair it.
② Check the grounding connection for obviously poor contact, if any, repair it.
③ Make sure that the fixed bolt of the horn assembly is properly fixed.
④ Make sure that there is no contact between the horn assembly and any other objects. If the contact
occurs, re-determine the correct positions of other objects or bend the support of the horn assembly
as required.
3) Press the horn button and check whether the situation still exists. If it still exists, please figure out
the type of the tone produced by the horn:
■ Low tone.
■ High-pitched and weak tone.
166
① With obviously low tone, the current voltage may be too high and the circuit check is required. If the
circuit is normal, replace the horn assembly. Refer to “Replacement of Horn”.
② With obviously high-pitched and weak tone, the horn may have foreign substances on it. Dismantle
the horn assembly and check whether there are any foreign substances on it. Refer to
“Replacement of Horn”.
③ Wipe off the adhesive foreign substances and re-install the horn assembly.
④ If any adhesive foreign substances are found or such substances can’t be wiped off, replace the
horn assembly.
4) Press the horn button and check that the concerned items have been rehabilitated. Refer to “Check
of Horn”.
V. Replacement of Horn
Precautions:
■ Strictly comply with the precautions for operation of the airbag system. Refer to “Airbag System”.
① Open the engine hood and dismantle the front bumper. Refer to “Replacement of the Front
Bumper”.
② Dismount the fixing bolt of the horn.
Fig.1.8.004
③ Disconnect the connector of the horn. Fig.1.8.005
④ Dismantle the horn assembly.
① Install the horn assembly.
■ Tightening torque: 5 N•m
167
② Connect the connector of the horn assembly. Fig.1.8.006
③ Close the engine hood.
VI. Replacement of Horn Button
① Dismantle the negative pole of the storage

battery.
② Turn the ignition switch to the “OFF” position.
③ Dismantle the fixing bolt of the driver airbag

module.
■ Rotate the steering wheel with its center as

the axis so as to take off the second screw.
④ Remove the driver airbag module and Fig.1.8.007

disconnect the connector of the module
electrical appliance.
⑤ Disconnect the connector of the horn button Fig.1.8.008

on the steering wheel.
⑥ Dismount the fixing screw of the left and right

horn buttons.
⑦ Take off the horn button assembly.
168
① Place the horn button assembly in.
② Connect the connector of the horn button on the steering wheel.
③ Install the left and right fixing screws of the horn button (four screws).
■ Tightening torque: 2 N•m.
Fig.1.8.009
Attention:
■ L refers to left side and R, right side.
④ Put in the driver airbag module. Connect the
connector of the module electrical appliance.
While installing, make sure that the circuit
installation is correct and reliable.
⑤ Install the fixing screw of the driver airbag
module.
■ Tightening torque: 2 N•m Fig.1.8.010
⑥ Install the negative pole of the storage battery.

⑦ Check the following components:
■ Horn
■ Steering wheel
■ Airbag system
169
VII. Cigar Lighter

Light the cigar after the cigar lighter is heated. Press the cigar lighter into the socket of the cigar lighter
and while the cigar lighter rebounds, light the cigar.
1. Schematic Diagram
Connect the storage battery
Small lamp relay
Cigar
lighter
Schematic Diagram of the Cigar Lighter

2. Trouble Diagnosis
1) Check of the cigar lighter system
Step Measure Normal Result Abnormal Result

Press the cigar lighter into the socket While the negative pole is electrified,
The cigar lighter is
1 of the cigar lighter until the click the cigar lighter will jump to the edge
out of work.
sound is heard. of the cigar lighter.
The lamp of the cigar lighter is The cigar lighter is
2
lighted. off.
2) The cigar lighter is out of work.
Step Measure Yes No

Check the fuse
Is the fuse broken?
Connect the positive pole and the negative pole of the
2 cigar lighter with a test lamp and check whether there To step 5 To step 3
is current and whether the test lamp is lightened?
3 Is the cigar lighter lightened? To step 6 To step 7
4 Replace the fuse - To “Check of System”
5 Replace the cigar lighter - To “Check of System”
6 Replace the lamp of the cigar lighter - To “Check of System”
7 Repair connections of bad contact - To “Check of System”
170
Section IX Audio System

I. Location Plan of Elements
1. Main machine of audio 2. Rear loudspeaker
II. Basic Diagram of Audio System
Small lamp relay
CD player Antenna
Left high
loudspeaker
loudspeaker
loudspeaker
Right door
Right high
loudspeaker
loudspeaker
Left rear
pitch
Right rear
Left door
pitch
loudspe
aker
Basic Diagram of Audio System
171
III. Illustration of Audio Changer
Illustration Table of Audio Changer
No. Function No. Function

1 Automatic antenna (+) 9 Illumination (+)
2 Left rear loudspeaker (+) 10 Right rear loudspeaker (-)
3 Left front loudspeaker (+) 11 Right front loudspeaker (-)
4 Right front loudspeaker (+)) 12 Empty
5 Right rear loudspeaker (+) 13 Empty
6 Empty 14 Left front loudspeaker (-)
7 Ignition switch 15 Left rear loudspeaker (-)
8 Memory power supply (+) 16 Grounding
IV. Replacement of Audio Changer and Antenna Fig.1.9.001
1. Replacement of Audio Changer
① Disconnect the negative pole of the storage

battery.
② Dismantle the cover plate of the middle console.
Precautions:
■ Only the comparison of front loudspeaker with

other front loudspeakers, and the rear
loudspeaker with other rear loudspeakers can be
carried out. Don’t compare front loudspeakers
with rear loudspeakers, for the front loudspeaker
and the rear loudspeaker may be of different
types and their different installation
environments may lead to different sound
effects.
172
③ Dismantle the glove box with two fixed bolts. Fig.1.9.002
④ Unscrew the nuts of the audio changer. Fig.1.9.003
⑤ Pull out the audio changer forward, disconnect

Fig.1.9.004
the electrical connector and dismantle the
audio changer assembly.
2) Install in reverse order with dismantlement, and check whether the audio changer works normally.
2. Replacement of the antenna signal cable
① Remove the right-side carpet located in front of the front passenger and dismantle the interior plate
of the door. Refer to “Replacement of the Trimming Plate—Carpet and Interior Plate in Interior
Trimming”.
173
② Disconnect the antenna signal cable from the lead of the antenna amplifier. Disconnect the antenna
signal cable at the back of the audio changer. Refer to “Replacement of the Audio Changer”.
Fig.1.9.005
2) Installation steps: Fig.1.9.006

① Install the antenna signal cable.
② Connect the antenna signal cable at the back

of the radio and install the radio. Please refer
to “Replacement of the Radio”. Connect the
antenna signal cable with the lead of the
antenna amplifier.
③ Install the insulator of the right console. Refer to “Replacement of the Console”.
V. Replacement of Rear Loudspeaker of Fig.1.9.007

Three-carriage Car
1) Dismantle the trimming plate of the rear

window. Refer to “Replacement of the
Trimming Plate”.
2) Disconnect the electrical connector of the rear

loudspeaker.
174
3) Dismantle the 6 bolts for the rear loudspeaker, including 3 ones on the left and 3 ones on the right.
Fig.1.9.008
4) Dismantle the rear loudspeaker
1) Mount 6 bolts of the rear loudspeaker.
2) Connect the electrical connectors of the rear loudspeaker.
3) Install the rear trimming shelf panel. Refer to “Replacement of the Trimming Plate—Rear Shelf
Panel in the Interior Trimming”
VI. Replacement of Rear Loudspeaker of Two-carriage Car
1) Dismantle the lateral trimming plate. Refer to “Replacement of the Inner Trimming Plate at Boot’s
Side”.
2) Dismount 6 fixed bolts for the rear loudspeaker.
3) Gently lift the rear part of the loudspeaker outward.
4) Disconnect the electrical connector of the rear loudspeaker.
5) Dismantle the rear loudspeaker.
1) Connect the connector of the rear loudspeaker.
2) Install 6 bolts of the rear loudspeaker.
3) Dismantle the lateral trimming plate. Refer to “Replacement of the Inner Trimming Plate at the
Boot’s Side”.
175
VII. Replacement of Front Door Loudspeaker
1) Dismantle the inner trimming plate of the front door. Refer to “Replacement of the Inner Trimming
Plate of the Front Door”.
2) Disconnect the electrical connector of the front Fig.1.9.009

door loudspeaker.
3) Dismount the bolts for the front door Fig.1.9.010

loudspeaker.
4) Dismantle the front door loudspeaker. Fig.1.9.011

1) Put the front door loudspeaker in.
2) Mount 3 bolts for the front door loudspeaker.
3) Connect the electrical connector of the front door loudspeaker.
176
Fig.1.9.012
4) Install the inner trimming plate of the front door. Refer to “Replacement of the Inner Trimming Plate
of the Front Door”.
177
Section X Parking Auxiliary System

Parking auxiliary system (reversing radar) consists of sensor, control module and warning device. On
the basis of ultrasonic ranging principle and computer data fuzzy processing technology, the parking
auxiliary system can judge whether there are any obstacles in the reversing direction of vehicle, and
suggest the distance from the nearest obstacle. When the gear is shifted to reverse, the reverse switch
is turned on, and the reversing light goes on. After the controller receives the reversing signal, it will
command the ultrasonic sensor to send out ultrasonic signal, then based on the self-transmitting and
self-receiving and multiple transmitting and single receiving principles, the echoed signal is completely
and accurately transmitted to the controller. Upon the echoed signal is analyzed and processed by the
controller, it will determine whether there’s any obstacle in the detection range, and the distance from the
nearest obstacle, and then it communicates with the buzzer, gives out the warning tones of different
frequencies according to different distance ranges, to suggest the distance from obstacle, and realize
the function of safety warning.
Location Plan for Elements of Parking Auxiliary System
1- Sensor of parking auxiliary system 2- Parking auxiliary system Module 3- Buzzer
178
II. Basic Diagram
Sensor Sensor Sensor
Buzzer
Power supply
Controller
Assembly
Ground
Basic Diagram of Parking Auxiliary System
III. Testing of Elements
1. Check whether the power supply of parking auxiliary system sensor is working normally (9V〜16V).
2. The parking auxiliary system connects the control module assembly, sensor assembly and buzzer
assembly together through the wire harness; the terminals of each assembly are defined as follows:
Definition List of Sensor Terminals
Connector Diagram Pin Number Signal Name Note
1 Signal Probe signal
2 GND Ground
179
Definition List of Terminals of Buzzer Assembly
1 BUZ Driving signal
2 GND Ground
Definition List of Terminals of Parking Auxiliary System Module

Power supply of
l R_shift
reverse gear
2 NC
3 NC
4 NC
5 NC
6 NC
7 S_L Left probe
8 S-CL Middle probe
9 NC
10 NC
11 NC
12 NC
13 NC
14 BUZ Buzzer control
15 S-R Right probe
16 GND Ground
180
IV. Replacement of Control Module of Parking Auxiliary System
1. Steps of dismantlement
1) Cut off the negative pole of storage battery.
Fig. 1.10.001
2) Dismount the inner trimming plate of boot.
See also “Dismantlement of Interior and Exterior

Trimmings”.
Fig. 1.10.002
3) Dismount the fixing bolts of parking auxiliary

system module.
Fig. 1.10.003
181
4) Disconnect the connetors. Fig. 1.10.004
5) Take out the parking auxiliary system module. Fig. 1.10.005
V. Replacement of Buzzer of Parking Auxiliary System
1. Cut off the negative pole of storage battery. Fig. 1.10.006
2. Dismount the lower trimming plate of steering wheel. See also “Dismantlement of Consoles of
Interior and Exterior Trimmings”.
182
3. Dismount the clamping screws of buzzer.
Fig. 1.10.007
4. Disconnect the connectors, and take out the buzzer.
VI. Replacement of Sensor of Parking Fig. 1.10.008

Auxiliary System
1. Cut off the negative pole of storage battery.
2. Dismount the rear bumper. See also “Replacement of Rear Bumper”.
3. Dismount the sensor, and disconnect the connectors.
Fig. 1.10.009
183
4. Install in the reverse order with

Fig. 1.10.010 Lock catch
dismantlement.
Adjusting
plate
Sensor body
VII. Common Troubles and Maintenance Methods
1. The system is unworkable
Concrete symptom: when the vehicle is shifted into reversing condition, the buzzer gives out no warning
tone.
Trouble cause: the parking auxiliary system is unworkable, and this is usually caused by the
disconnection of working power supply, generally speaking, if the vehicle storage battery is working
normally, the cause should be the poor contact of power cord.
Maintenance method: Check whether the DC+12V power supply is connected into the control module,
this circuit of power supply is the same as the power supply circuit of vehicle reversing light; if the power
supply is working normally, please replace the control module.
2. The sensor is unworkable
Concrete symptom: when the vehicle is shifted into reversing condition, one of the sensors can not
detect the obstacles all the time.
Trouble cause: the parking auxiliary system is working, but one of the sensors is unworkable.
Maintenance method: when the vehicle is shifted into reversing condition, put your ear close to the
surface of sensor, listen carefully to judge whether the there’s slight “click” from it (by contrast with a
normal one); if the sound is normal, it means that the power supply of sensor is working normally, hence,
please check whether the connection of signal wire between the sensor and controller is normal; in case
the signal wire is normally connected, please replace the sensor.
3. The performance of sensor is poor
Concrete symptom: when the vehicle is shifted into reversing condition, the detection performance of
one of the sensors is always poor.
Trouble cause: the parking auxiliary system is working, but the detection performance of one of the
sensors is poor.
Maintenance method: please clear the foreign matters on the surface of the sensor.
184
When the reverse running is performed on rough roads, it is normal that the system gives an alarm
occasionally.
When the reverse running is performed on narrow laneways, it is normal that the system gives an
alarm occasionally.
VIII. Trouble Diagnosis Procedure
There’s no reminder for starting The main frame is damaged,

up when the vehicle is in replace the main frame
reverse gear
Check if the voltage of Whether the harness

main frame terminal is is correctly
12 V connected
The voltage is not 12 V Connect up the harness

through again
Whether the
connectors of main Reconnect the connectors
frame is connected of main frame
correctly
The connectors of main

frame is connected well
Whether the harness is Replace the

damaged harness
The harness is good,

recheck it
185
When the vehicle is in reverse gear, the

main frame gives two beeps, and the
sensor indicator lamp on the display
goes on
Whether the connectors Reconnect the connectors

of main frame is of main frame
connected correctly
The connectors of main frame

has been connected well
Whether the harness is Replace the

damaged harness
The harness is
good
Whether the sensor is Replace the

damaged sensor
Shift into reverse gear Replace the

again, and see whether it is main frame
working normally
Continue using it
186
IX. Trouble Maintenance Methods
List of Trouble Maintenance Methods
Maintenance Methods and

Number Trouble Symptom Trouble Causes Remarks
Techniques
The system is 1. Poor connection 1. Check whether the harness is
unworkable during between the harness correctly connected to the
the reverse running. and the main power power supply.
1
supply. 2. Reconnect all the sockets
2. Incorrect socket correctly
connection
The indicator lamp The position of socket is Reconnect all of the inductor sockets
of power supply incorrect, so that the correctly.
2 lighting, but the inductor is unworkable.
system is
unworkable.
The buzzer is 1. The body or ground 1. Install the inductor correctly
continuously giving is detected by according to the instruction, and
warnings, while the system. turn to professional technician
display showing a 2. Incorrect installation for instruction and inspection if
same data, but of inductor, or necessary.
3 there’s no obstacle inductor falling off 2. If the inductor is damaged,
behind the vehicle 3. The inductor is please replace it in a timely way.
damaged. 3. Check whether the harness is
4. The connecting wire free from damage.
of inductor is
damaged.
It can not correctly 1. The voltage of 1. Check whether the voltage of
display the distance storage battery is storage battery is normal.
from obstacles. abnormal. 2. Shut off the system, and
2. The socket position correctly reconnect all the
4 is incorrect. sockets.
3. The inductor 3. Check whether there’s any
harness is disturbed. contact between the connecting
wire of inductor and the exhaust
pipe and muffler.
There’s no reminder 1. The buzzer is 1. Check the buzzer connecting
for starting up, but misconnected. wire and socket, and reconnect
the other parts are 2. The buzzer is the buzzer correctly.
5
working normally damaged. 2. Replace the buzzer.
without warning
tone.
187
Section XI Rear View Mirror

With internal rear view mirror and external rear view mirrors in kind which are fixed on the upper part of
front wind shield, left and right sides of the outer vehicle body respectively, rear view mirror is used for
observing the situation inside the carriage and behind the vehicle. It consists of mirror, fixing parts,
direction adjusting parts and mirror seat, etc.
1. Electric Rear View Mirror Assembly

Fig. 1.11.001
2. Electric Rear View Mirror Switch

Fig. 1.11.002
188
II. Basic Diagram
ACC/ON Power
Console of rear
UP/DOWN Switch LEFT/RIGHT Switch view mirror switch
Option switch of left and right

exterior rear view mirror
Left exterior rear Right exterior rear

Grounding
view mirror view mirror
Basic Diagram of Electric Rear View Mirror
III. Testing for Elements
1. Check of Electric External Rear View Mirror

Fig. 1.11.003
1) After pressing the left/ right direction adjusting
buttons of rear view mirror, the mirror shall
move leftward or rightward smoothly.
2) After pressing the up/down direction adjusting

button of rear view mirror, the mirror shall
move upward/downward smoothly.
If it doesn’t meet the requirement, continue the

check.
189
2. Check of Electric Rear View Mirror Switch
Check the conductivity state between terminals of lead connector according to the following diagram. If it
is not the same as what is listed in the diagram, please replace the switch.
Wiring
terminal
Gear
Upward
Downward
Left Leftward
Rightward
Upward
Downward
Right Leftward
Rightward
Terminal Diagram of Electric Rear View Mirror
3. Check of Electric Rear View Mirror Motor
1) Dismount the lead connector of electric rear view mirror actuator.
Up Left
Down Right
Circuit Diagram of Rear View Mirror Motor
2) Connect the storage battery (12V) between terminals according to the following table, and check
whether the actuator works normally. If not, replace the actuator.
190
Terminal
Position
Up
Down
Left
Right
Testing Diagram of Electric Rear View Mirror Motor
IV. Replacement of Internal Rear View Mirror
1. Dismantlement Steps
Fig. 1.11.004
■ Dismantle the internal rear view mirror from
the internal rear view mirror bearer with a
small right-angled screwdriver.
Fig. 1.11.005
191
2. Installation Steps
Fig. 1.11.006
1) Clip the internal rear view mirror into the rear
view mirror bearer, and make sure that it is
fixed firmly.
2) Mount the internal rear view mirror.
Attention:
■ Internal rear view mirror is fixed on the internal rear view mirror bearer which is glued on the wind
shield by plastic polyvinyl-butyral adhesive. The following objects are needed while mounting an
independent rear view mirror or a new spare part:
■ Loctite™ instant adhesive 312.
■ (According to the installation step 4 and 5, prepare) original internal rear view mirror bearer, or
replace it with new internal rear view mirror bearer.
■ Waxy marker pen or wax crayon.
■ Isopropyl alcohol.
■ Cleaning paper towel.
■ Fine emery cloth or abrasive paper (320 or 360).
1. Measure the dimension from the upper part (1) to internal rear view mirror bearer (2), and the
dimension is 70 mm.
Schematic Diagram 1 of Mounting Internal Rear View Mirror
2. Make a mark on the exterior surface of wind shield. Draw a big circle on the exterior surface (3) of
wind shield along the circle of rear view mirror bearer.
192
Schematic Diagram 2 of Mounting Internal Rear View Mirror
3. Use the paper towel that has been soaked in the glass cleanser of general type (general part number)
or polishing agent to clean the glass marked with the big circle on the interior surface of wind shield
until it is completely clean and dry. Then clean it with the paper towel moistened with isopropyl
alcohol to remove the cleaning powder or the mark left by cleaning agent.
Precautions:
■ If the original internal rear view mirror bearer is reused, clean all marks of adhesive left by plant
installation before its reinstallation.
4. Use a fine (320 or 360) emery cloth or abrasive paper to polish the new internal rear view mirror
bearer or the original adhesive surface of internal rear view mirror bearer left by plant installation.
5. Use the paper towel soaked with isopropyl alcohol to wipe the sanded internal rear view mirror
bearer clean, and then let it dry in air.
6. Before mounting on the wind shield, prepare the internal rear view bearer according to the illustration
for components provided by the manufacturer.
7. Place the internal rear view mirror bearer on the marked position beforehand correctly, and prevent
the round hole of rear view mirror from pointing upward; Press the internal rear view mirror bearer on
the wind shield for 30s to 60s with constant force.
8. After 5 minutes, use the paper towel soaked with isopropyl alcohol or window cleaning agent to
remove redundant adhesive.
9. Remount internal rear view mirror. Refer to the “Replacement of Internal Rear View Mirror”.
193
V. Replacement of External Rear View Mirror
Mirror casing
Base plate (201x75x68)

Retainer ring
Machine core
Mirror bracket
Pressure spring
Rotary shaft (ø72 x 43)

Triangle seat
Screw Inserted nut
Mirror
Disassembly Schematic Diagram of External Rear View Mirror
Attention:
■ Make sure that the washer is placed correctly.
1) Cut off the negative pole of storage battery.
2) Pry up the cover plate of rear view mirror carefully with a right-angled screwdriver.
Fig. 1.11.007
194
3) Cut off the connector of rear view mirror.

Fig. 1.11.008
4) Dismount the three fixed nuts of rear view

Fig. 1.11.009
mirror.
5) Dismount the rear view mirror assembly.

Fig. 1.11.010
2. Installation Steps Fig. 1.11.011

1) Place the rear view mirror assembly in.
195
2) Mount the three fixed nuts of rear view mirror.

Fig. 1.11.012
3) Connect the connector of rear view mirror.

Fig. 1.11.013
4) Mount the cover plate for rear view mirror of front
door.
5) Mount the negative pole of storage battery.
VI. Replacement of Electric Rear View Mirror Switch Fig. 1.11.014

1. Pry up the electric rear view mirror switch along the
edge of switch plate to loosen the grab and clip.
196
2. Cut off the switch of the side window in the

Fig. 1.11.015
cab and the connector for electric rear view
mirror.
3. Dismount the switch assembly.
4. Mount the switch of electric rear view mirror in

reverse order with dismantlement.
197
Section XII Central Control Door Lock

I. Basic Diagram
Lock or unlock all doors by key lock core. The ETACS control module controls the central control
lock relay after receiving the unlock or lock signal to make the door lock motor open or close. In
spite of the location of the ignition switch, the electric door lock is in operational state.
When the vehicle runs in a speed of higher than 40km/h, all doors are closed and the acceleration
pedal is stepped down, the ETACS control module automatically locks all doors. After the engine
cuts out and the ignition switch is shut down, the central control door lock automatically opens.
The doo lock motor is controlled by the central controller. The positive and negative poles of the storage
battery are connected to the two terminals of the motor to make the motor rotate toward one direction.
The current is opposite and the rotation speed of the motor is opposite.
II. Replacement of Outside Handle of Door
1. Pry off the lock core trim cover of the door

Fig. 1.12.001
outside handle.
2. Dismount the outside handle of the door and

Fig. 1.12.002
install the fixing bolt of the bracket.
198
3. Disconnect the outside handle of the door

from the mounting bracket and then take off Fig. 1.12.003
the washer.
4. Dismount the outside handle of the door.

Fig. 1.12.004

dismantlement.
III. Replacement of Door Lock Assembly

1. Dismount the inner trimming plate of door.
Refer to “Replacement of Inner Trimming
Plate of Door”.
2. Dismount the waterproof membrane. Refer to
“Replacement of Waterproof Membrane”.
3. Dismount the sealing strip of window glass.
Refer to “Replacement of Sealing Strip of
Window Glass".
4. Dismount the window glass. Refer to
“Replacement of Window Glass”.
5. Dismount the glass regulator. Refer to

Fig. 1.12.005
“Replacement of Glass Regulator”.
6. Pry off the lock core trim cover of the outside
handle of the door.
199
7. Dismount the outside door handle and install

the fixing screw on the bracket. Fig. 1.12.006
8. Disconnect the outside handle of the door

Fig. 1.12.007
from the mounting bracket on the outside door
handle, and take off the washer.
9. Dismount the outside handle of the door.

Fig. 1.12.008
10. Dismount another screw on the mounting

Fig. 1.12.009
bracket of the outside handle of the door.
200
11. Loosen the tie rod on the outside handle of the Fig. 1.12.010
door and lock core tie rod.
12. Take off the fixing bracket of the outside

Fig. 1.12.011
handle of the door.
13. Dismount the fixing screw of the door lock

Fig. 1.12.012
body.
14. Cut off the connector of the door lock motor Fig. 1.12.013
and take off the door lock body assembly.
201
15. Cut off the tie rod on the lock body, and take
Fig. 1.12.014
off the lock body.

dismantlement.
Notes:
■ Install in the original locations.
■ Check the door switch for being normal and

the door lock for being reliable after the
installation. If it is abnormal or unreliable,
re-install or re-adjust it.
IV. Replacement of Actuator of Trunk Door

Fig. 1.12.015
Lock
1. Open the trunk door.
2. Dismount the trunk door sill plate. Refer to “Replacement of Trunk Door Sill Plate”.
202
3. Plug off the connector of the actuator harness.

Fig. 1.12.016
4. Loosen the fixing screw of the actuator by

Fig. 1.12.017
screwdriver.
5. Cut off the pull wire of the actuator.

Fig. 1.12.018
6. Dismount the actuator.
Notes:
■ After the assembly, open and close the rear cabin cover to validate the lock body function.
■ Suppose the meshing of the lock body and hook offtracks, loosen the two fixing bolts of lock hook,
adjust the lock hook to an appropriate location and then tighten the fixing bolt.
203
V. Replacement of Controller of Trunk Door Lock
1. Open the trunk.
2. Cut off the negative terminal of the storage battery.
3. Dismount the inner trimming plate of the trunk lid. Refer to “Replacement of Inner Trimming Plate of
Trunk Lid”.
4. Dismount the bolts for fixing the trunk lock controller.
■ Tightening Torque: 24±4 N•m
Fig. 1.12.019
5. Cut off the tie rod and then take off the trunk
Fig.
lock controller.
Lock body of
trunk

dismantlement.
204
VI. Analysis for Troubles
Analysis Table on Troubles of Central Control Door Lock
Step Troubleshooting Yes No

1 Check the fuse for being in good state? To Step 2 To Step 3
2 Replace the damaged fuse. To Step 3
Check the fuse for being in good state according to the circuit To Step 4
3 To Step 5
diagram.
4 Replace the damaged fuse with new fuse. To Step 5
Separate the connector between the instrument panel and To Step 7
rear body lead harness; measure the voltage at the
5 To Step 6
instrument lead harness side by digital multimeter. The
voltage is normal or not?
Check and repair the instrument panel lead harness from fuse To Step 7
6
to connector. Make sure it is ok.
Measure the voltage of the connector (at the instrument panel To Step 9
7 lead harness side) by a digital multimeter to see the voltage To Step 8
for being normal?
Check and repair the instrument panel lead harness from the To Step 9
8
fuse to the connector, and make sure it is ok.
Dismount the central door lock module, dial the ignition To Step 11
device to the ON position and the wiper switch to the inner
9 To Step 10
gear position. Measure the voltage by a digital multimeter to
see the voltage for being normal?
Check and repair the rear vehicle body lead harness from the To Step 11
10 connector to the central door lock module in accordance with
the circuit diagram and make sure it is ok.
Replace the central door lock module with a new one to see
11 To Step 12
the system for being normal?
Measure the grounding wire of the central door lock module To Step 13
12 by a digital multimeter to see the grounding for being in good To Step 14
state?
Separate the connector between the rear vehicle body and To Step 16
left front door (right front door and tail trunk lid) lead harness,
13 To Step 15
and measure the grounding wire by a digital multimeter to see
the grounding for being in good state?
Repair the grounding wire of the rear body lead harness to To Step 13
14
see the system for being normal?
Repair the grounding wire at connector to make sure its To Step 16
15
grounding is in good state.
Cut off the connector of the central door lock motor and
switch connector of doors; test or check the lead harness of
rear vehicle body, left and right front vehicle doors, rear
16 vehicle door as well as tail trunk lid by a digital multimeter in To Step 17
accordance with the circuit diagram. If necessary, repair the
lead harness. Make sure the lead harness is ok and the
system is normal?
Check the inner structure of the central door lock switch and
17 door lock motors of door locks. When necessary, replace or
repair them. The system is in good state.
205
Section XIII Electric Window
Electric window system could raise or lower the window glass electrically via operation of switch on each
trimming plate of door. The main switch on trimming plate of driver side front door could not only help the
driver to raise or lower the passenger side window glass, but also could lock every separate switch on
the side door. Only when the ignition switch is located at “on” position, the electric window system could
receive the voltage of storage battery via circuit breaker in junction box. The electric window system
includes the electric window switch on the trimming plate of door, ETACS control module and electric
window motor in each door. The window motor together with the glass frame riser is an assembly. If the
window motor needs to be replaced, the glass frame riser should be replaced as well.
I. Illustration on Elements
1. Electric Window Switch
The electric window is controlled by window/door interlock switch on the trimming plate of front door. The
driver side window/door interlock switch could help the driver control all of the window glasses. The
passenger side windows could receive the electricity from storage battery and grounding power supply
via the window/door interlock switching circuit. The power supply for the electric window switch of every
separate passenger side door from storage battery would be cut off when the interlock switch of electric
window is located at “lock" position.
2. Electric Window Motor
Permanent magnet reversible electric motor could drive the movement of glass frame riser via integrated
gear box mechanism. The positive and negative poles of storage battery are connected to the two
terminals of motor and enable the motor to turn round in one direction. The counter current flowed
through the two same junctions would enable the motor to turn round in the reverse direction. Moreover,
every electric window motor is equipped with an integrated self-reset circuit breaker to avoid the
over-load.
II. Illustration on Functions
1. Elevation of Electric Window
The electric window could be operated by the elevating button on the door. The elevating operation of
electric window would be allowed when ignition switch is located at “on” position. The operation of rear
windows is invalid after pressing the child lock at any time. The electric window could be operated after
shutdown of ignition switch as well unless the following situations occur:
1) The closing time of ignition switch is over 10 minutes.
2) Any door is opened.
3) The door is locked from the outside.
206
2. Child Lock Button
Child lock button could lock the electric window buttons on the right front door and left & right rear doors.
When the child lock button is locked, the window buttons on the driver’s door that control the right front
window, right & left rear windows are valid as well.
3. Operation Mode
Operation modes of electric window: manual elevation, and auto drop.
Manual rise: press the “up” button of window over 300ms, the corresponding window would be raised
and the rising of the electric window would be stopped by releasing the button.
Manual drop: press the “down” button of window over 300ms, the corresponding window would be fallen
and the dropping of the electric window would be stopped by releasing the button.
Auto drop: press the “down” button less than 300ms, the corresponding window would drop to the
bottom or to the position till pressing the “down” button of the electric window again.
207
III. Basic Diagram
Electric Window
Relay
Main Switch of Window
Elevation
Left Front Electric Right Front Left Rear Electric Right Rear
Motor Electric Motor Motor Electric Motor
Elevation Switch of
Right Front Window Elevation Switch of Elevation Switch of
Left Rear Window Right Rear Window
Ground of
Combined
Wiring Joint
Electric Power
Source of Combined
Wiring Joint
208
IV. Replacement of Element
1. Replacement of Switch of Electric Window Glass Frame Riser
1) Prize up the switch of glass frame riser by flat

Fig. 1.13.001
head screwdriver.
2) Cut off the harness connector of the switch.

Fig. 1.13.002
3) Dismount the switch of the electric window

glass framer riser.

dismantlement. Attention:
■ Check if the function of buttons is normal after

installation.
■ Reinstall and replace the switch if it’s

abnormal or it doesn’t work.
2. Replacement of Front Window Glass
1) Dismantlement
① Dismount the inner trimming plate of door. Refer to “Replacement of Inner Trimming Plate of Door”.
② Dismount the waterproof membrane. Refer to “Replacement of Waterproof Membrane”.
③ Dismount the sealing strip of window glass. Refer to “Replacement of Sealing Strip of Window
Glass".
④ Reinstall the switch of window glass frame riser and adjust the height of window glass to a suitable
position so as to dismount the fixing screw of window glass.
209
Fig. 1.13.003
⑤ Dismount the fixing screw of window glass.

Fig. 1.13.004
⑥ Take off the window glass.

3. Replacement of Front Window Glass Frame Riser
1) Dismount the inner trimming plate of door. Refer to
“Replacement of Inner Trimming Plate of Door”.
2) Dismount the waterproof membrane. Refer to
3) Dismount the sealing strip of window glass. Refer to
“Replacement of Sealing Strip of Window Glass".
4) Dismount the window glass. Refer to “Replacement
of Window Glass”.
5) Dismount the fixing nut of glass support.
Fig. 1.13.005
210
6) Dismount the fixing nut of electric motor of

glass frame riser. Fig. 1.13.006
7) Cut off the connector on electric motor of

glass frame riser. Fig. 1.13.007
8) Take out the glass frame riser.

Fig. 1.13.008
4. Replacement of Rear Window Glass
1) Dismount the inner trimming plate of door. Refer to ““Replacement of Inner Trimming Plate of Door”.
2) Dismount the waterproof membrane. Refer to “Replacement of Waterproof Membrane”.
3) Dismount the sealing strip of window glass. Refer to “Replacement of Sealing Strip of Window
Glass".
211
4) Connect the switch of glass frame riser and

lower the glass to a suitable position. Fig. 1.13.009
5) Dismount the glass sealing strip on the door.

Fig. 1.13.010
6) Screw off the fixing screw in the locating slot

Fig. 1.13.011
of quarter window glass.
7) Dismount the locating slot of quarter window

glass. Fig. 1.13.012
8) Dismount the quarter window glass.
212
9) Connect the switch of glass frame riser and

lower the glass to a suitable position. Fig. 1.13.013
10) Dismount the fixing screw of window glass.

Fig. 1.13.014
■ Tightening torque: 7.5N • m
11) Take off the window glass.

Fig. 1.13.015

dismantlement.
213
5. Replacement of Rear Window Glass Frame Riser
1) Dismount the inner trimming plate of door. Refer to

“Replacement of Inner Trimming Plate of Door”.
2) Dismount the waterproof membrane. Refer to

3) Dismount the sealing strip of window glass. Refer to

“Replacement of Sealing Strip of Window Glass"
4) Dismount the window glass. Refer to

“Replacement of Window Glass”.
5) Dismount the fixing nut of glass frame riser support.

Fig. 1.13.016
■ Tightening torque: 7.5N • m
6) Dismount the fixing nut on electric motor of glass

Fig. 1.13.017
frame riser.
7) Cut off the connector on glass frame riser and take

out the whole body of glass frame riser. Fig. 1.13.018
214
V. Trouble Diagnosis
See table below for the trouble diagnosis on electric window control system.
Trouble Diagnosis Table on Electric Window Control System
Trouble Possible Cause Trouble Shooting
Replace the fuse and check for

Breakage of fuse
short-circuit
All of the electric windows are
Trouble of main relay of power
out of work Check the relay
source
Trouble of wiring or grounding Repair as required
Main control electric window Trouble of door lock control relay Check the relay
is out of work
Trouble of wiring Repair as required
One-way trigger electric Trouble of main switch of electric

Check the switch
window is out of work window
215
Maintenance Manual of Tojoy Sedan Structure of Vehicle Bodyy
Chapter II Structure of Vehicle Body

Section I Engine Hood and Door
I. Engine Hood Assembly
Precautions:
■ Wrap the right-angled screwdriver blade with cloth,when dismantling the metal clip from trimmings.
1. Replacement of Heat Insulating Mattress of

Fig. 2.1.001
Engine Hood
① Open the engine hood.
② Dismount the snaps-in on the heat insulating

mattress of engine hood. Fig. 2.1.002
216
③ Dismantle that heat insulating mattress. Fig. 2.1.003
2) Installation steps: Fig. 2.1.004

① Place the heat insulating mattress onto the
engine hood.
② Align the hole position for fixing the engine

hood to that on the engine hood.
③ Mount and fix the heat insulating mattress of

engine hood.
④ Cover the engine hood properly.
2. Replacement of Support Bar of Engine Hood
Precaution:
■ When dismantling and installing the support

bar of engine hood, additional support bar
must be adopted to avoid possible vehicle
damage and personnel injury.

① Open and support the engine hood.
217
② Lift the retaining clip on the support for fixed

Fig. 2.1.006
support bar of engine hood.
③ Dismount the engine support bar from the

retaining clip. Fig. 2.1.007
2) Installation steps Fig. 2.1.008
① Pull the support bar of engine hood through

the retaining clip and then lock the clip.
② Dismantle the additional support of engine

hood.
③ Cover the engine hood properly.
218
3. Adjustment of Engine Hood
The engine hood is fixed on the hinges of engine hood by bolts. The longitudinal adjustment of the hood
can be achieved by the movement in hinge holes. Through adjusting the length of the long and short
buffer bumper and the major latch on the engine hood, the engine hood can be adjusted vertically. The
tolerance clearance is 4.0 mm±1.0 mm, and the smoothness tolerance is 0 mm to 1.0 mm.
Fig. 2.1.009
1) Open the engine hood.

Fig. 2.1.010
2) Loosen the bolts between engine hood and 图 2. 1.008

Fig. 2.1.011
hinges.
3) Adjust the position of engine hood and front

fender.
4) Cover the engine hood properly.
219
5) Check the alignment.

Fig. 2.1.012
6) Open the engine hood and adjust it to the
qualified position.
7) Adjust the buffer stopper of engine hood

accordingly.
8) Check the alignment.
9) Adjust the engine hood lock body. Refer to the

“Replacement of Engine Hood Lock”.
10) Fasten the bolts between engine hood and

Fig. 2.1.013
hinges.
■ Tightening torque: 25N·m
11) Cover the engine hood properly.

Fig. 2.1.014
4. Replacement of Engine Hood
② Place the protective liner board on the vehicle

body and the glass near the engine hood.
220
Precautions:
■ When dismantling and installing the support device of engine hood, alternative support must be
adopted to avoid possible damage on vehicle and personnel injury.
③ Dismount the cleaner nozzle and hose.

Fig. 2.1.015
Refer to the “Replacement of the Solvent Tank for
Solvent Tank of Cleanser, Spray Nozzle of Pump
and Hose”.
④ Dismantle the fixed bolts on the engine hood

Fig. 2.1.016
with the help of the assistant.
⑤ Dismantle the engine hood with the help of the

Fig. 2.1.017
assistant.
221
⑥ Dismount the heat insulating mattress of Fig. 2.1.018

engine hood, and please refer to the
“Replacement of Heat Insulating Mattress of
Engine Hood”.
⑦ Dismount the rubber buffer stopper on the

engine hood.
⑧ Dismount the lock loop of support bar of

engine hood.
① Mount the lock loop of support bar of engine hood.
② Mount the rubber buffer stopper of the engine hood.
③ Mount the heat insulating mattress of engine hood, and please refer to the “Replacement of Heat
Insulating Mattress of Engine Hood”
④ Place the engine hood on the position of vehicle body with the help of the assistant.
⑤ Mount the bolts between engine hood and hinges with the help of the assistant.
⑥ Check the matching of engine hood and vehicle body and adjust the engine hood as per required.
Please Refer to the “Adjustment of Engine Hood”.
⑦ Mount the cleaner nozzle and hose. Please Refer to the “Replacement of the Solvent Tank of
Cleanser, Spray Nozzle of Pump and Hose”
⑧ Fasten the bolts of engine hood hinges.
⑨ Remove the protective liner board.
⑩ Cover the engine hood properly.
II Fender
Precautions:
■ Use cloth to protect the dismounted spare parts from being damaged and scratched when
dismantling and installing the elements,
■ Wrap the right-angled screwdriver blade with cloth,when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly installed into the plate hole of the body before installing body
222
■ Please don’t scratch the exterior surface of vehicle body during the assembly process.
■ Dismount the front bumper before the dismantlement of fenders. Refer to the “Replacement of Front
Bumper”.
■ Dismount the door assembly before the dismantlement. Refer to the “Replacement of Door
Assembly”.
■ It is better to dismount the engine hood to facilitate the dismantlement of fender. Refer to the
“Replacement of Engine Hood”.
① Dismantle the front bumper. Refer to the “Replacement of Front Bumper”.
② Dismantle the clamping screws on the front end of the fender.
Fig. 2.1.019
③ Dismantle the clamping screws on the rear

Fig. 2.1.020
part of the fender.
223
④ Dismantle the clamping screws of the fender

and those of the front wheel cover. Fig. 2.1.021
⑤ Dismantle the clamping screws on the upper

Fig. 2.1.022
part of the fender.
⑥ Take off the fender and pull out the turn light Fig. 2.1.023
connector.
① Put in the fender and connect the turn light

connector.
② Mount the clamping screws on the upper part

of the fender.
224
③ Mount the clamping screws of fender and those of front wheel cover.
④ Mount the clamping screws on the rear part of the fender.
⑤ Mount the clamping screws on the front end of the fender.
⑥ Mount the front bumper. Refer to the “Replacement of Front Bumper”
Precautions:
■ Check the following items after installation: check for the fender being mounted on the right position;
check for the proper fit clearance between the fender and the vehicle body, and if not, the fender
should be adjusted and reinstalled.
■ The replacement steps of left fender or right fender are the same.
225
III Replacement of Front Door Assembly
Precautions:
■ The dismantlement/installation methods of each door assembly are the same
■ Protect door and vehicle body with cloth when dismantling and installing the front door assembly.
■ Make sure carry out the assembly adjustments during the dismantlement /installation of the front
door assembly.
■ After installation, re-coat some paint (the color of vehicle body) on the head of mounting bolt for
hinges.
■ Check the rotation parts of hinge for lubrication. Apply some “lubrication grease” when necessary.
■ This element is heavy, so two workers are needed for handling it.
■ After installation, check for normal open/close of the front door.
1. Replacement of Front Door
① Dismantle the clamping screws of front door Fig. 2.1.024

stopper.
② Dismantle the clamping screws of door assembly.

Fig. 2.1.025
226
Precautions:
■ The dismantlement of the screws should be carried out by several times. Please don’t loosen them
in one time.
■ The door should be dismantled from down to up.
■ Carry out the dismantlement steps with the help of the assistant.
③ Pull out the rubble sleeve of door wire Fig. 2.1.026

harness.
④ Cut off the door electrical connector.
⑤ Lift the door and place it on the proper place

with the help of the assistant. Fig. 2.1.027
① Move the door to the proper position with the help of the assistant.
② Connect the door electrical connector.
③ Reinstall the rubble sleeve of door wire harness.
④ Align to the mounting hole of clamping screw and mount the clamping screw of door assembly.
⑤ Mount the clamping screw of front door stopper.
Precautions:
■ Tighten the clamping screw of front door assembly, with the tightening torque: 25N·m.
■ Tighten the clamping screw of front door stopper, with the tightening torque: 5N·m.
227
■ The screws should be tightened by several times. Please don’t tighten them in one time.
■ Carry out the whole process with the help of the assistant.
2. Replacement of Outer Rear-view Mirror
② Open the door and pry out the inner trimming plate of rear-view mirror with right-angled screwdriver.
Fig. 2.1.028
③ Cut off the electrical connector of outer

Fig. 2.1.029
rear-view mirror.
④ Dismount the clamping screws on the outer

Fig. 2.1.030
rear-view mirror.
228
⑤ Take off the outer rear-view mirror. Fig. 2.1.031
① Align to the mounting hole for clamping screw and mount the rear-view mirror.
② Mount the clamping screw of outer rear-view mirror, with the tightening torque: 10 N·m.
③ Connect the electrical connector of outer rear-view mirror.
④ Align to the snap-in mounting hole and mount the inner trimming plate of rear-view mirror.
⑤ Reinstall the negative pole of storage battery.
3. Replacement of Inner Trimming Plate of Front Door
② Open the door and pry out the inner trimming plate of rear-view mirror with right-angled screwdriver.
Fig. 2.1.032
229
③ Cut off the electrical connector of outer Fig. 2.1.033

rear-view mirror.
④ Dismount the clamping screw on the inner

Fig. 2.1.034
door handle.
⑤ Pry out the wiredrawing of inner door handles Fig. 2.1.035

and take off the inner door handle.
230
⑥ Pry out the glass frame riser switch with Fig. 2.1.036
right-angled screwdriver.
⑦ Cut off the electrical connector of glass frame

Fig. 2.1.037
riser switch and take off that switch.
⑧ Dismantle the clamping screws on the inner

Fig. 2.1.038
trimming plate of the door.
231
⑨ Pry out that inner trimming plate.
Precaution:
■ During the dismantlement of inner trimming plate, please pay special attention to the snap-in, which
would easily cause the damage of the inner trimming plate.
Fig. 2.1.039
⑩ Cut off the electrical connector of front door Fig. 2.1.040

light
⑪ Take off the inner trimming plate of left front Fig. 2.1.041
door.
232
① Connect the electrical connector of front door light.
② Align to the snap-in mounting hole of front door inner trimming plate and mount the inner trimming
plate of left front door.
Precautions:
■ During the installation of inner trimming plate, please pay special attention to the snap-in, which
would easily cause the damage of the inner trimming plate.
③ Mount the clamping screw of front door inner trimming plate. Tightening torque: 2N•m.
④ Connect the electrical connector of glass frame riser.
⑤ Align to the right position and mount the glass frame riser switch.
⑥ Connect the pull rod of inner handle and mount the inner door handle.
⑦ Mount the clamping screws of inner door handle, with the tightening torque: 2N•m.
⑧ Connect the electrical connector of rear-view mirror.
⑨ Align to the snap-in mounting hole for the inner trimming plate of rear-view mirror and mount that
plate.
⑩ Reinstall the negative pole of storage battery.
4. Replacement of Waterproof Membrane of Front Door
1) Dismount the door inner trimming plate. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
2) Pry out the fixed snap-in of wire harness. Fig. 2.1.042
3) Disconnect and take off the waterproof Fig. 2.1.043

membrane.
233
4) Assemble in the reverse order with dismantlement..
Precautions:
■ Don’t touch the adhesive surface to avoid weakening the re-adhesive effect.
■ Scale off the waterproof membrane with plastic knife.
■ Be careful to fetch the waterproof membrane in order not to damage it.
5 Replacement of Loudspeaker on Front Door
1) Dismount the door inner trimming plate. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
2) Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
3) Pull out the loudspeaker connector.
Fig. 2.1.044
4) Dismantle the clamping screw of loudspeaker

on front door. Fig. 2.1.045
234
5) Take off the front door loudspeaker.

Fig. 2.1.046
① Mount and tighten the clamping screw of loudspeaker on front door.
■ Tightening torque: 2N•m
② Connect the electrical connector of loudspeaker.
③ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
④ Mount inner trimming plate of the door. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
6. Replacement of Weather Seal on Front Window Glass
① Dismount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
Fig. 2. 1.047
③ Pry out an end of the weather seal with right-angled screwdriver and take off the inner side of the
seal slowly from that end.
235
④ Dismount the clamping screw at the outer side

Fig. 2.1.048
of the outer glass weather seal.
⑤ Take off the outer glass weather seal slowly from one end.
Precautions:
■ Don’t use too much force during dismantling, for too much force will cause the damage of the spare
parts.
■ Visually inspect the drip moulding after the dismantlement. Please replace it when distortion occurs.
① Align the mounting slot of outer glass weather seal to the vehicle body, and mount the seal to the
right position slowly from one end.
Fig. 2.1.049
② Tighten the outer clamping screw of outer glass weather seal, with the tightening torque: 2N • m.
③ Align the mounting slot of inner glass weather seal to the body, and mount the seal to the right
position slowly from one end.
④ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑤ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
236
7. Replacement of Front Window Glass
Front Door”.
Door”.
③ Dismount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window
Glass”.
④ Reinstall the glass frame riser switch and regulate it to the proper position to facilitate the
dismantlement of the clamping screws of front window glass.
Fig. 2.1.050
⑤ Dismount the clamping screws of front window

Fig. 2.1.051
glass.
⑥ Take off the window glass.
① Reinstall the glass frame riser switch and regulate it to proper position to facilitate the installation of
the clamping screws of front window glass.
② Put the window glass into the door and align to the mounting hole.
③ Mount the clamping screws of front window glass, with the tightening torque: 7.5N•m.
237
④ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑤ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑥ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
8. Replacement of Glass Frame Riser of Front Window
Front Door”.
Door”.
Glass”.
④ Dismantle the window glass. Refer to the “Replacement of Front Window Glass”.
⑤ Dismount the fixed nuts of window glass support.
Fig. 2.1.052
⑥ Dismount the fixed nuts on the motor of glass Fig. 2.1.053

frame riser.
238
⑦ Cut off the electrical connector on the motor of Fig. 2.1.054

glass frame riser.
⑧ Take out the glass frame riser. Fig. 2.1.055
① Connect the glass frame riser connector of front window and put in the glass assembly.
② Mount the fixed nuts of front window glass support. Tightening torque: 7. 5N•m.
③ Mount the fixed nuts on the motor of front glass frame riser. Tightening torque: 7.5N•m.
④ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑤ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑥ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑦ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
9. Replacement of Lock Core of Front Door
① Dismantle the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
Door”.
Glass”.
239
⑤ Dismantle the glass frame riser. Refer to the “Replacement of Glass Frame Riser of Front Window”.
⑥ Pry out the decorative cap of lock core of the outer handle of the front door.
Fig. 2.1.056
⑦ Dismount the clamping screws on mounting

Fig. 2.1.057
base support of the outer handle of the front
door.
⑧ Disconnect the outer handle from the fixed

Fig. 2.1.058
support for outer handle of the front door and
then take off the gasket.
240
⑨ Dismount the outer handle of the front door. Fig. 2.1.059
⑩ Dismount another screw on the mounting Fig. 2.1.060

support for outer handle of the front door.
⑪ Loosen the outer handle pull rod and lock core Fig. 2.1.061
pull rod of the front door.
241
⑫ Take off the fixed support of the front door Fig. 2.1.062
handle.
⑬ Pry out the fixed snap-in of door lock core. Fig. 2.1.063
⑭ Replace the door lock core. Fig. 2.1.064
242
① Fix the door lock core on the fixed support of the door handle.
② Mount the fixed support of the front door handle.
③ Connect the outer handle pull rod and lock core pull rod of the front door.
④ Mount the clamping screw on the mounting support for the outer handle of the front door. Tightening
torque: 2.5N•m.
Fig. 2.1.065
⑤ Mount the outer handle of the front door
⑥ Mount the gasket and connect the outer handle from the fixed support of outer handle.
Fig. 2.1.066
⑦ Mount the clamping screws on fixed support for the outer handle of the front door. Tightening torque:
2.5N•m.
⑧ Mount the decorative cap of lock core of the outer handle of the front door.
⑨ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑩ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑪ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑫ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
10. Replacement of Front Door Lock Assembly
① Dismantle the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
243
Door”.
③ Dismantle the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window
Glass”.
⑤ Dismantle the glass frame riser. Refer to the “Replacement of Glass Frame Riser of Front Window”.
⑥ Pry out the decorative cap of lock core of the outer handle of the front door.
Fig. 2.1.067
⑦ Dismount the clamping screws on mounting

Fig. 2.1.068
support for the outer handle of the front door.
⑧ Disconnect the outer handle from the fixed

Fig. 2.1.069
support of outer handle of the front door and
then take off the gasket.
244
⑨ Dismount the outer handle of the front door.

Fig. 2.1.070
⑩ Dismount another screw on the mounting Fig. 2.1.071

support for outer handle of the front door.
⑪ Loosen the outer handle pull rod and lock core Fig. 2.1.072
pull rod of the front door.
245
⑫ Take off the fixed support of the front door Fig. 2.1.073
handle.
⑬ Dismount the clamping screw on the lock of Fig. 2.1.074

front door.
⑭ Cut off the connector and take out the door Fig. 2.1.074
lock assembly.
246
⑮ Dismount the lock and its pull rod.
Fig. 2.1.076
① Put in the front door lock and connect its pull rod.
② Connect the connector from the lock assembly and put the lock assembly into the door.
③ Mount the clamping screw on the lock of front door. Tightening torque: 5N·m.
④ Mount the mounting support of the front door handle.
⑤ Connect the outer handle pull rod and lock core pull rod of the front door.
⑥ Mount the clamping screw on the mounting support for the outer handle of the front door. Tightening
torque: 2.5N·m.
⑦ Mount the outer handle of the front door.
Fig. 2.1.077
247
⑧ Mount the gasket and connect the outer handle from the mounting support for the outer handle of
the front door.
Fig. 2.1.078
⑨ Mount the clamping screws on fixed support for the outer handle of the front door. Tightening torque:
2.5N•m.
⑩ Mount the decorative cap of lock core of the outer handle of the front door.
⑪ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑫ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑬ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑭ Mount the inner trimming plate of the door. Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
Precautions:
■ During the installation, the lock must be mounted as per the original position.
■ After installation, check for the normal open/close of the door; check for the firm locking. If not,
please carry out the re-installation or proper adjustment.
11. Replacement of Front Door Latch Fig. 2.1.079

248
① Mark the current position of the latch.
② Dismantle the clamping screw of latch.
③ Dismantle the latch.
④ Dismantle the washer as per the actual configuration.
① Mount the dismounted washer
② Mount the lock latch to the marked position.
③ Mount the screw. Tightening torque:25N•m.
④ Check the latch and the lock for being engaged. Refer to the “Replacement of Front Door Latch” if
some adjustments are needed.
12. Adjustment of Front Door Latch
1) Adjust the latch accordingly.
Fig. 2.1.080
① Loosen the latch screw.
② Move the latch to the required direction accordingly.
③ Fasten the screw to the tightening torque of 25N•m.
249
2) Adjust the latch frontward or rearward.
Fig. 2.1.081
① Apply some clay or joint sealer of vehicle body on the opening of door lock.
② Close the door from enough distance, enabling that the latch can press the joint sealer.
③ Leaving the door closed for a long time may cause the difficulty of removing the clay or joint sealer.
④ Open the door and check for the latch indentation being in the middle of the lock opening.
⑤ Carry out the following steps if adjustments are needed:
■ Dismount the latch.
■ Adjust and reinstall the latch.
■ Fasten the latch screw to the torque of 25Nm.
⑥ Apply paint on any exposed area and any area without paint after installing the latch.
Attention:
The replacements for the components of left or right front door are the same.
250
IV Replacement of Rear Door Assembly
1. Replacement of Inner Trimming Plate of Rear Door
① Dismantle the screw cover for the recessed frame of rear inner door handle.
Fig. 2.1.082
② Dismantle the screw cover for the trimming Fig. 2.1.083

plate of rear door.
③ Push the inner handle toward the direction of

hinge, pry out the pull rod and dismount the
inner handle of rear door.
④ Dismount the safety lock button. Fig. 2.1.084
251
⑤ Dismount the clamping screw for the switch of Fig. 2.1.085

rear glass frame riser.
⑥ Pry out the switch of rear glass frame riser.

Fig. 2.1.086
⑦ Cut off the switch connector of rear glass

Fig. 2.1.087
frame riser.
252
⑧ Dismount the clamping screw for inner

Fig. 2.1.088
trimming plate of rear door.
⑨ Pry out the snap-in for inner trimming plate of

Fig. 2.1.089
rear door.
Precautions:
would easily damage the inner trimming plate.
⑩ Take off the inner trimming plate of rear door.
图 2. 1.090
① Align to the snap-in mounting hole for inner trimming plate of rear door and mount the trimming
plate.
Precautions:
would easily damage the inner trimming plate.
253
② Mount the clamping screws of inner trimming plate of rear door. Tightening torque: 5N·m.
③ Connect the electrical connector for the switch of rear glass frame riser.
④ Align to the proper position and mount the switch of rear glass frame riser.
⑤ Mount the safety lock button of rear door.
⑥ Connect the pull rod for the inner handle of rear door and mount the handle.
⑦ Mount the clamping screw for inner handle of rear door. Tightening torque:
⑧ Mount the screw cover for the trimming plate of rear door.
⑨ Mount the screw cover for the recessed frame of rear inner door handle.
Precautions:
■ Before installing rear door trimmings, make sure the snaps-in are firmly installed into the plate hole
of the body, and then pressed the trimmings into the body.
2. Replacement of Waterproof Membrane of Rear Door
1) Dismantle the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
2) Disconnect and take off the waterproof membrane.
Fig. 2.1.091
Precautions:
■ When installing the waterproof membrane, don’t let it cover the mounting hole for the cramp of
trimming plate.
■ Don’t touch the adhesive surface to avoid weakening the re-adhesive effect.
■ Scale off the waterproof membrane with plastic knife.
3. Replacement of Weather Seal on the Rear Window Glass
① Dismantle the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
254
② Dismantle the waterproof membrane. Refer to

Fig. 2.1.092
the “Replacement of Waterproof Membrane of
Rear Door”.
③ Take off the inner glass weather seal of rear

door.
④ Take off the outer glass weather seal of rear

Fig. 2.1.093
door.
① Align the mounting slot of outer glass weather seal to the body, and mount the seal into the right
Fig. 2.1.094
255
② Align the mounting slot of inner glass weather seal to the body, and mount the seal into the right
Fig. 2.1.095
③ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
④ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
4. Replacement of Rear Window Glass
of Rear Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
③ Dismantle the inner glass weather seal of rear door. Refer to the “Replacement of Weather Seal on
the Rear Window Glass”.
④ Connect the switch for rear glass frame riser and adjust rear window glass into the proper position.
Fig. 2.1.096
256
⑤ Dismount the weather seal for the upper part

Fig. 2.1.097
of rear window glass.
⑥ Dismount the clamping screw for locating slot

Fig. 2.1.098
of quarter window glass of rear door.
⑦ Dismount the locating slot of rear quarter

Fig. 2.1.099
window glass.
⑧ Dismount quarter window glass of rear door.
257
⑨ Connect the switch for rear glass frame riser

and adjust the rear window glass into the Fig. 2.1.100
proper position.
⑩ Dismount the clamping screw for rear window Fig. 2.1.101

glass.
■ Tightening torque: 7.5N•m.
⑪ Take off the rear window glass. Fig. 2.1.102
258
① Mount the switch for rear glass frame riser and adjust the rear window glass into the proper position
to facilitate the installation of clamping screw for rear window glass.
② Place the rear window glass into the door and align the glass to the mounting hole.
③ Mount and tighten the clamping screw for rear window glass
④ Reinstall the switch for rear glass frame riser and adjust the rear window glass into the proper
position to facilitate the installation of quarter window glass of rear door.
⑤ Mount the rear quarter window glass
⑥ Mount the locating slot of rear quarter window glass.
⑦ Mount and tighten the clamping screw for locating slot of rear quarter window glass.
⑧ Mount the weather seal for the upper part of rear window glass. Reinstall the switch for rear glass
frame riser and rise and lower the glass to check if the installation is qualified.
⑨ Mount the rear window glass. Refer to “Replacement of Weather Seal on the Rear Window Glass”.
⑩ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
⑪ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
5. Replacement of Glass Frame Riser of Rear Window
① Dismantle the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
Door”.
③ Mount the inner glass weather seal of rear door. Refer to the “Replacement of Weather Seal on the
Rear Window Glass”.
④ Dismantle the rear window glass. Refer to the “Replacement of Rear Window Glass”.
259
⑤ Dismantle the fixed bolts for the support of Fig. 2.1.103

rear glass frame riser
⑥ Dismount the retaining nut for the motor of Fig. 2.1.104

rear glass frame riser.
⑦ Cut off the connector for rear glass frame riser Fig. 2.1.105
and take out the glass frame riser assembly.
260
① Connect the connector for rear glass frame riser and put in the glass frame riser assembly.
② Mount and tighten the retaining nut for the support of rear window glass.
③ Mount and tighten the retaining nut for the motor of rear glass frame riser.
④ Mount the rear window glass. Refer to the “Replacement of Rear Window Glass”.
⑤ Mount the weather seal on the rear window glass. Refer to the “Replacement of Weather Seal on
⑥ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
⑦ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
6. Replacement of Door Lock Assembly
of Rear Door”.
Door”.
③ Dismantle the weather seal on rear window glass. Refer to the “Replacement of Weather Seal on
④ Dismantle the rear window glass. Refer to the “Replacement of Rear Window Glass”.
⑤ Dismantle the glass frame riser of rear window. Refer to the “Replacement of Glass Frame Riser of
Rear Window”.
⑥ Dismantle the decorative cap on the outer handle of the rear door.
Fig. 2.1.106
261
⑦ Dismantle the clamping screw for outer handle and take the handle off.
Fig. 2.1.107
⑧ Dismantle the connecting pull rod for outer Fig. 2.1.108

handle.
⑨ Dismantle the mounting support for outer

handle of rear door.
⑩ Cut off the inner handle pull rod and the pull Fig. 2.1.109
rod of locking button.
⑪ Dismount the clamping screw for rear door lock.
262
⑫ Take out the rear door lock and cut off the electrical connector for the lock.
Fig. 2.1.110
① Put the door lock in and connect the electrical connector of it.
② Mount the clamping screw for rear door lock. Tightening torque: 7.5N•m.
③ Connect the inner handle pull rod and the pull rod of locking button.
④ Mount the mounting support for outer handle of rear door.
⑤ Mount the connecting pull rod for outer handle.
⑥ Mount the clamping screw for outer handle and mount the outer handle.
⑦ Mount the decorative cap on the outer handle of the rear door.
⑧ Mount the glass frame riser of rear window. Refer to the “Replacement of Glass Frame Riser of
Rear Window”.
⑨ Mount the weather seal on rear window glass. Refer to the “Replacement of Weather Seal on the
Rear Window Glass”.
⑩ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”
⑪ Mount the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
Attention:
The replacements for the components of left and right rear door are the same.
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V. Boot Cover
1. Replacement of Boot Cover Assembly
Precautions:
■ Two workers are needed for the handling of boot cover because of its heavy weight.
■ Don’t scratch the paint surface during the dismantlement or installation.
1) Assembly Breakdown Drawing
Breakdown Drawing of Boot Cover Assembly
1- Torsion bar of boot 2- Boot cover 3- Lock core of boot cover 4- Boot cover lock 5- Adjusting pad
of boot cover
6- Weather seal of boot 7- Boot cover Latch
264
① Dismantle the buffer stoppers on both side of the boot.
Fig. 2.1.111
② Dismantle the boot top trimming plate. Refer Fig. 2.1.112

to the “Replacement of Top Trimming Plate of
the Trunk”.
③ Cut off the wire harness connector of the boot Fig. 2.1.113
cover lock.
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④ Dismantle the clamping screws on the boot cover with the help of the assistant.
Fig. 2.1.114
⑤ Lift the boot cover assembly down with the help of an assistant.
① Mount the boot cover assembly with the help of an assistant.
② Mount the clamping screws on the boot cover with the help of the assistant. Tightening torque:
25N•m.
③ Connect the wire harness of the boot cover lock.
④ Mount the boot top trimming plate. Refer to the “Replacement of Top Trimming Plate of the Trunk”.
⑤ Mount the buffer stoppers on both side of the boot.
2. Replacement of Weather Seal of the Boot Cover
① Pry out the weather seal with tools.
② Dismantle the weather seal slowly.
Fig. 2.1.115
Precautions:
■ Pull the weather seal moderately during the dismantlement.
■ Knock the weather seal moderately with the rubber hammer during the installation, to protect the
seal from being damaged.
266
① Mark the original mounting position of the weather seal and mount it according to that position.
② Fix manually the guide slot on the seal to the vehicle body.
③ Knock the weather seal into the required position with rubber hammer.
3. Check and Adjustment of Boot Cover
1) Check if there exists surface difference between the upper surface and the side walls of the boot
cover. If there exists, the surface difference can be eliminated by adjusting the height of buffer
stopper of boot cover.
Fig. 2.1.116
2) Check for uniform gap between the boot cover and side wall exterior panel.
Precautions:
■ If the gap is not uniform but just with little deviation, knock the boot cover latch with a little hammer
and close the cover to re-check the uniformity of the gap.
■ If the gap offtracks a lot, loosen the cover hinges and 4 clamping screws, and then move the cover
upward/downward or leftward/rightward to make the gap uniform; then pre-tighten the four screws
and tighten them until the boot cover has been adjusted to proper position.
■ Check for the flexibility of the opening/closing of the boot cover. If it is not flexible, adjust the latch
frontward/rearward or leftward/rightward to achieve the flexibility after loosening the clamping
screws of the latch.
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4. Replacement of Spare Tire Cover Plate
Fig. 2.1.117
② Lift the spare tire cover plate and tow out two Fig. 2.1.118
right-angled grabs.
③ Take off the spare tire cover plate. Fig. 2.1.119
① Place the spare tire into the boot properly.
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② Press the two right-angled grabs on the spare tire cover plate into the corresponding holes on the
boot door sill fender.
③ Close the boot cover.
5. Replacement of Spare Tire
① Dismantle the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
② Dismantle the fixture of spare tire.
Fig. 2.1.120
③ Take off the spare tire. Fig. 2.1.121
① Place the spare tire into the carriage without damaging other components.
② Mount the fixture of spare tire.
③ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
6. Replacement of Coatrack
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① Dismantle the clamping screws on the

Fig. 2.1.122
coatrack.
② Pry out the snaps-in on the coatrack. Fig. 2.1.123
③ Cut off the electrical connector for the high

Fig. 2.1.124
position brake lamp.
④ Take off the coatrack.
① Connect the electrical connector for the high position brake lamp.
② Mount the snaps-in on the coatrack.
③ Mount and tighten the clamping screws on the coatrack. Tightening torque: 2N•m,
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7. Replacement of Front Trimming Plate
① Dismantle the coatrack. Refer to the “Replacement of Coatrack”.
② Pry out the fixed snaps-in on the front trimming plate.
Fig. 2.1.125
③ Take off the front trimming plate.
8. Replacement of Trunk Door Sill Fender
② Dismantle 3 outer fixed snaps-in on the door sill fender.
Fig. 2.1.126
③ Pry out 3 snaps-in on the back of the sill fender.
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④ Take off the boot door sill fender.
Fig. 2.1.127
① Align to the mounting hole for snaps-in on the back of the door sill fender and mount the fender.
② Mount the outer fixed snaps-in on the door sill fender.
③ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
9. Replacement of Side Protecting Plate of the Trunk
② Dismantle the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
③ Dismantle the protecting plate of rear tail lamp in the boot.
Fig. 2.1.128
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④ Dismantle the clamping screws on the protecting plate of boot.
Fig. 2.1.129
⑤ Dismantle the snaps-in on that protecting

Fig. 2.1.130
plate by sequence.
① Put the boot protecting plate into the carriage and mount the fixed snaps-in on the plate by
sequence.
② Mount and tighten the clamping screws on the protecting plate by sequence. Tightening torque:
2N•m.
③ Mount the protecting plate of rear tail lamp in the boot.
④ Mount the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
⑤ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
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10. Replacement of Top Trimming Plate of the Trunk
Fig. 2.1.131
② Pry out the fixed snaps-in on the trimming

Fig. 2.1.132
plate by sequence.
Place the plate properly; press the snaps-in of the trimming plate into the mounting hole and clamp
tightly.
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VI. Oil Filler of Fuel Tank
1. Replacement of Oil Filler Door
① Open the oil filler door.
Fig. 2.1.133
② Dismount the connection between the cap and

Fig. 2.1.134
the oil filler door.
③ Dismantle the clamping screws for the oil filler Fig. 2.1.135
door.
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④ Dismantle the oil filler door.

Fig. 2.1.136
① Align the oil filler door to the mounting hole.
② Mount the door to the side shroud with screws. Tightening torque: 0.6-1.0N•m.
③ Connect the wire between the oil filler cap and the oil filler door.
④ Close the oil filler door.
Fig. 2.1.137
2. Replacement of Oil Filler Cap Fig. 2.1.138

① Open the oil filler door.
276
② Dismantle the connection between the cap

Fig. 2.1.139
and the oil filler door.
③ Dismantle the oil filler cap.

Fig. 2.1.140
① Mount the oil filler cap.
② Mount the connection between the cap and the oil filler door.
③ Close the oil filler door.
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VII. Replacement of Locking System Fig. 2.1.141

1 Replacement of Engine Hood Lock Body
② Dismantle the front bumper. Refer to the “Replacement of Front Bumper”.
③ Dismantle the bolts for the lock body.
Fig. 2.1.142
④ Cut off the lock body connecting wire and take Fig. 2.1.143
off the lock body of engine hood.
① Connect the lock body connecting wire and mount the lock body of engine hood.
278
② Mount and tighten the clamping screws for the lock body. Tightening torque: 5N•m.
③ Mount the front bumper. Refer to the “Replacement of Front Bumper”.
④ Close the engine hood.
2. Replacement of the Switch Handle of Engine Hood
① Dismantle the bottom part of the instrument panel at the driver’s side.
Fig. 2.1.144
② Dismantle the clamping screws for switch handle of engine hood.
Fig. 2.1.145
③ Cut off the wiredrawing for the engine hood Fig. 2.1.146
handle.
279
④ Take off the wiredrawing of the handle.
Fig. 2.1.147
① Connect the wiredrawing for the engine hood handle.
② Mount and tighten the clamping screws for switch handle of engine hood. Tightening torque: 2N•m.
③ Mount the bottom part of the instrument panel at the driver’s side.
3. Replacement of the Trunk Door Actuator
Fig. 2.1.148
① Open the boot door.
② Dismantle the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
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③ Cut off the actuator connector. Fig. 2.1.149
④ Dismantle the clamping screws of actuator Fig. 2.1.150

with cross screwdriver.
⑤ Cut off the wiredrawing of actuator. Fig. 2.1.151
⑥ Take off the actuator.
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① Connect the wiredrawing of actuator.
② Mount and tighten the clamping screws of actuator with cross screwdriver.
③ Connect the actuator connector.
④ Mount the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
⑤ Close the boot door.
Precautions:
■ Open the after-closed boot lock body check function after finishing the assembly
■ If the engagement between lock body and latch offtracks, loosen 2 fixed bolts of latch, and tighten
the bolts after adjusting the latch to the proper position.
4. Replacement of the Switch Handle of Trunk Lock
① Dismantle the clamping screws for the switch handle.
Fig. 2.1.152
② Cut off the connecting wire of switch handle.

Fig. 2.1.153
③ Dismantle the switch handle.
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① Connect the connecting wire of switch handle.
② Mount the clamping screws for the switch handle.
5. Replacement of boot cover Lock Latch
Fig. 2.1.154
② Dismount the fixed bolts for boot cover lock latch.
■ Tightening torque: 5N•m.
Fig. 2.1.055
③ Pull out the latch and cut off the pull rod of boot cover lock latch.
① Connect the pull rod of boot cover to the latch.
② Pull out the latch and its pull rod of boot cover lock.
③ Mount and fasten the bolts for the boot cover latch.
④ Close the boot cover.
283
6. Replacement of Wire Harness of Boot Cover
① Dismantle the inner trimming plate of boot cover. Refer to the “Replacement of Inner Trimming Plate
of Boot Cover”.
② Cut off the electrical connector between the wire harness of rear body and the wire harness of boot
cover.
Fig. 2.1.156
③ Cut off the fastening band for wire harness of boot cover.
④ Pull out the clip.
⑤ Pull out the wire harness of boot cover from the vehicle body.
① Lay wire for the wire harness of rear boot from the door of the boot cover.
② Insert the clips to the hole on the body.
③ Fix the wire harness of boot cover with fastening band as per required.
④ Connect the electrical connector between the wire harness of rear body and the wire harness of
boot cover.
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Section II Interior & Exterior Trimmings

I. Precautions
■ During dismantlement and installation of elements, use a cloth to protect the spare parts to be
dismounted from damage.
■ When dismounting the metal clip from trimmings, use a cloth to cover the blade of slotted screw
driver.
■ Don’t damage the elements of body.
■ When installing body trimmings, make sure the clip is firmly installed in the stamping hole of body
and then carefully press them in.
■ When it is impossible to dismantle and install some elements by one person, two people shall work
together to prevent the elements from falling.
■ When dismantling and installing some trimmings, please don’t press too hard as it may result in
II. Replacement of Front Bumper
Attention:
■ The trimming plate of bumper is made from resin material. Please don’t apply great force on it and
keep it away from oil.
■ When dismantling the trimming plate of bumper, it is necessary to operate by two people to prevent
it from falling.
■ For the convenience of dismantlement and installation, put the vehicle on lifter to lift the vehicle at
any time.
1. Lift the vehicle to an appropriate height and dismount the clamping screw of front bumper base
board.
■ Tightening torque: 5 N.m
Fig. 2.2.001
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2. Take off the snap fasteners at the two sides connecting the front bumper and mudguard.
Fig.2.2.002
3. Dismount the clamping screw connecting the rear end of front bumper and mudguard.
Fig. 2.2.003
4. Dismount the screw at the two sides connecting the front bumper and fender.
5. Dismount the screw connecting the front bumper and fender.
Fig. 2.2.004
286
6. Remove the front bumper and cut off the connectors of front fog lamp.
Fig. 2.2.005
7. Take off the front bumper and take out the percussion absorption pad.
Fig. 2.2.006
Fig. 2.2.007
Attention:
■ During assembly, don’t scratch the outside surface of bumper body.
■ After installation, check if it is installed properly and if the fitting clearance between other
components is right.
287
III. Replacement of Front Bumper Frame
1. Dismount the fixed nut of upper frame.
Fig. 2.2.008
2. Take off the upper frame.
3. Dismount the fixed nut of lower frame.
Fig. 2.2.009
4. Take off the lower frame.
Attention:
■ For the upper frame, fix the upper frame of front bumper to the body with 8 nuts. The tightening
torque is 12~15 N.m.
■ For the lower frame, take the projection welding nut in the center of body as locating hole. Use 5
nuts to fix the lower frame of front bumper to the body. The tightening torque is 5~6 N.m.
■ Finally, take the circular hole in the center of the upper frame of front bumper as datum hole. Align
the datum hole and set the front bumper percussion absorption pad to the upper frame of front
bumper.
288
Disassembly Diagram for Front Bumper
1-Datum hole for assembling percussion absorption pad 2-Upper frame 3-Lower frame
4-Percussion absorption pad 5-Datum hole for assembling lower frame
IV. Wheel Cover
1. Replacement of Front Wheel Cover
For the convenience of dismantlement, lift the vehicle up to dismount the tire.
1) Dismount the clamping screw at the outside of front wheel cover.
Fig. 2.2.010
2) Dismount the fixed snap-in and clamping screw of front wheel cover.
3) Screw off the fixed nut of front wheel cover.
4) Take off the front wheel cover and check it for crack. If any, replace it.

289
Attention:
■ Before installation, check if there is defects such as crack of front wheel cover and omission of fixed
snap-in of wheel cover.
■ After installation, make sure the wheel cover is fitting properly with the fender and front bumper.
Align the hole and tighten the screw.
2. Replacement of Right Rear Wheel Cover
1) Dismount the 3 snap fasteners fixing the rear wheel cover in turn.
Fig. 2.2.011
2) Dismount the fixed nut of rear wheel cover.
Fig. 2.2.012
3) Dismount the clamping screw of rear wheel cover.
4) Take off the rear wheel cover.
Fig. 2.2.013
290
Attention:
■ Before installation, check if there is defects such as crack of rear wheel cover and omission of fixed
snap-in of wheel cover.
■ After installation, make sure the wheel cover is fitting properly with the body and rear bumper. Align
the hole and tighten the screw.
V. Replacement of Ceiling Stripe
1) Pry out the ceiling stripe at the welding part of car roof with plastic flat-edge tools.
2) Dismount the ceiling stripe from the guide slot of car roof.
Attention:
■ Don’t damage the clip on the ceiling stripe. Otherwise, it is required to replace it.
Fig. 2.2.014
1) Align the front end of the stripe with the fixed snap-in at the front end of guide slot.
2) Set the stripe in properly.
3) Use the rear end of stripe to cover the weather seal of rear window.
Fig. 2.2.015
291
VI. Replacement of Rear Bumper
Attention:
■ The trimming plate of bumper is made from resin material. Please don’t apply great force on it and
keep it away from oil.
■ When dismantling the trimming plate of bumper, it is necessary to operate by two people to prevent
it from falling.
■ Before dismantlement, dismount the rear tail lamp first.
■ During installation, don’t scratch the outside surface of bumper.
1. Dismount the rear wheel cover. Refer to “Replacement of Rear Wheel Cover”.
Fig. 2.2.016
2. Put the vehicle on the lifter and lift it to an appropriate height. Dismount the clamping screws at the
lower part of rear bumper in turn.
3. Dismount the screw, at the left and right sides, connecting the rear bumper and fender.
Fig. 2.2.017
292
4. Dismount the clamping screw at the upper part of rear bumper in turn.
Fig. 2.2.018
5. Cut off the electric connectors of sensors of auxiliary parking system.
Fig. 2.2.019
6. Take off the rear bumper.

VII. Replacement of Rear Bumper Frame
Disassembly Diagram for Rear Bumper

1-Frame 2-Percussion absorption pad
3-Datum hole for assembling percussion absorption pad 4-Body
293
1. Take off the percussion absorption pad.
2. Pry out the wiring clip fixing the wire harness on the rear bumper frame.
Fig. 2.2.020
3. Dismount the nuts fixing the lower frame and body in turn.
Fig. 2.2.021
4. Take off the frame and re-install the nut.

5. Dismount the clamping screw on the left and right connection supports at the lower part of rear
bumper.
The left and right connection

supports at the lower part
Diagram for Left and Right Connection Supports at the Lower Part

294
VIII. Replacement of Sun Visor
1. Dismount the clamping screw on the sun visor.
■ Tightening torque: 1.4 N.m
Fig. 2.2.022
2. Take off the sun visor.
3. Dismount the screw on the hook of sun visor with cross screw driver.
Fig. 2.2.023
4. Install in the reverse order with dismantlement of sun visor.
Note: The replacement steps for left and right sun visors are the same.
295
IX. Replacement of A-pillar Trim Board
1. Pry out the fixed snap-in of A-pillar trim board with slotted screw driver.
Attention:
■ Don’t scratch the trim board.
Fig. 2.2.024
2. Dismount the A-pillar trim board.
Fig. 2.2.025
3. During installation, align the snap-in of trim board with hole, press it in with force and make it seized.
X. Replacement of Front Door Pedal
1. Use a slotted screw driver to pry out the metal fixed snap-in of front door.
Attention:
Fig. 2.2.026
■ Don’t scratch the pedal.
296
2. Dismount the front door pedal.
3. During installation, align the snap-in of pedal with hole, press it in with force and make it seized.
XI. Replacement of A-pillar Lower Trim board
1) Dismount the front door pedal at first. Refer to “Replacement of Front Door Pedal”.
Fig. 2.2.027
2) Hold the A-pillar lower trim board and pull it out, disconnect the snap-in and dismount the lower trim
board.
Fig. 2.2.028
3) Install in the reverse order with dismantlement. During installation, align the snap-in of trim board
with hole, press it in with force and make it seized.
297
XII Replacement of Rear Door Pedal
1. Screw off the clamping screw of rear door pedal.
■ Tightening torque: 1.4 N•m
Fig. 2.2.029
2. Use slotted screw driver to pry out the rear door pedal.
Attention:
■ Don’t scratch the pedal.
Fig. 2.2.030
3. During installation, align the snap-in of pedal with hole, press it in with force and make it seized.
Then tighten the clamping screw.
298
XIII. Replacement of B-pillar Trim board
1) Adjust the front seat to an appropriate position.
Fig. 2.2.031
2) Dismount the front door pedal. Refer to “Replacement of Front Door Pedal”.
Fig. 2.2.032
3) Dismount and replace the rear door pedal. Refer to “Replacement of Rear Door Pedal”.
Fig. 2.2.033
299
4) Dismantle the trim strip of door edge at both

Fig. 2.2.034
sides of B pillar.
5) Dismount the fixed bolt at the bottom of safety

Fig. 2.2.035
belt.
6) Pry out the fixed snap-in of B-pillar lower trim

Fig. 2.2.036
board.
300
7) Take off the B-pillar lower trim board.

Fig. 2.2.037
8) Pry out the anchor seat cover of front safety

Fig. 2.2.038
belt.
9) Dismount the clamping screw of anchor seat

Fig. 2.2.039
of front safety belt.
301
10) Dismount the clamping screw of B-pillar upper trim board.
Fig. 2.2.040
11) Take off the B-pillar upper trim board.
1) Install the B-pillar upper trim board and tighten its clamping screw.
2) Install the clamping screw of anchor seat of front safety belt.
3) Install the anchor seat cover of front safety belt.
4) Align the installation hole and fix the B-pillar lower trim board properly.
5) Install the clamping screw at the rear end of safety belt.
6) Install the rubber strip of door edge at both sides of B pillar.
7) Install the rear door pedal. Refer to “Replacement of Rear Door Pedal”.
8) Install the front door pedal. Refer to “Replacement of Front Door Pedal”.
9) Adjust the front seat to an appropriate position.
Attention:
■ Before installation, check if there is damage or omission of snap-in.
■ Align the snap-in of trim board with hole, press it in with force and make it seized.
■ As the snap-in is fragile, please don’t install it forcibly.
302
XIV. Replacement of C-pillar Trim board
1) Dismount rear seat. Refer to “Replacement of Rear Seat”.
2) Dismount rear door pedal. Refer to “Replacement of Rear Door Pedal”.
3) Dismount the trim strip of rear door.
Fig. 2.2.041
4) Screw off the fixed bolt at the rear end of safety belt of rear seat.
Fig. 2.2.042
5) Pry out the guider cover of safety belt on the

Fig. 2.2.043
C-pillar upper trim board.
303
6) Pry out the fixed snap-in of C-pillar upper trim board.
Fig. 2.2.044
7) Take off the C-pillar upper trim board.

Fig. 2.2.045
8) Dismount the coatrack. Refer to “Replacement

Fig. 2.2.046
of Coatrack”.
9) Dismount the clamping screw of C-pillar lower

trim board.
10) Pry out the fixed snap-in of C-pillar lower trim board.
11) Dismount the C-pillar lower trim board.
304
Attention:
■ Before installation, check if there is damage or omission of snap-in.
■ Align the snap-in of trim board with hole, press it in with force and make it seized.
■ As the snap-in is fragile, please don’t install it forcibly.
XV. Replacement of Auxiliary Handle
1. Use slotted screw driver to pry out the screw decorative cap of auxiliary handle.
Fig. 2.2.047
2. Use cross screw driver to dismount the

Fig. 2.2.048
clamping screw of auxiliary handle.
3. Take off the auxiliary handle.

Fig. 2.2.049
305
XVI. Replacement of Ceiling
1. Dismantlement Steps:
Fig. 2.2.050
1) Dismantle the sun visor. Refer to “Replacement of Sun Visor”.
2) Dismantle the reading light. Refer to “Replacement of Reading Light”.
3) Dismantle the auxiliary handle. Refer to “Replacement of Auxiliary Handle”.
4) Dismantle the A-pillar trim board. Refer to “Replacement of A-pillar Trim Board”.
5) Dismantle the B-pillar trim board. Refer to "Replacement of B-pillar Trim Board".
6) Dismantle the C-pillar trim board. Refer to "Replacement of C-pillar Trim Board".
7) For the convenience of removing ceiling, rotate the right front seat backrest to horizontal position.
8) Dismantle the fixed snap-in at the back of ceiling interior trimming with special tools.
Fig. 2.2.051
9) Dismantle the ceiling interior trimming from the weather seal of door.
10) Remove the ceiling interior trimming from right front door.
2. Installation Steps:
1) Put the ceiling interior trimming in from right front door.
2) Install the ceiling interior trimming from the weather seal of door.
3) Install the fixed snap-in at the back of ceiling interior trimming.
306
4) Adjust the right front seat backrest to the original position.
5) Install the C-pillar trim board. Refer to "Replacement of C-pillar Trim Board".
6) Install the B-pillar trim board. Refer to "Replacement of B-pillar Trim Board".
7) Install the A-pillar trim board. Refer to "Replacement of A-pillar Trim Board".
8) Install the reading light. Refer to “Replacement of Reading Light”.
9) Install the auxiliary handle. Refer to “Replacement of Auxiliary Handle”.
10) Install the sun visor. Refer to “Replacement of Sun Visor”.
Attention:
■ During installation, don’t bend the ceiling interior trimming too much.
■ When installing ceiling interior trimming, align the holes of sun visor on the ceiling interior trimming
and the two holes at the back of ceiling interior trimming with the correspondent holes on the body.
XVII. Replacement of Carpet
Attention:
■ The carpet is a single layer of molded carpet covering the front/rear floor. Replace the carpet
according to the following steps:
1) Dismantle the rear seat backrest. Refer to “Replacement of Rear Seat”.
2) Dismantle the rear seat cushion. Refer to “Replacement of Rear Seat”.
3) Dismantle the front seat. Refer to “Replacement of Front Seat”.
4) Screw off the fixed bolt of front seat safety belt retractor.
5) Dismantle the front and rear door pedals.
7) Dismantle the central console of front floor.
8) Dismantle the auxiliary facia console assembly. Refer to “Replacement of Auxiliary Facia Console”.
9) Dismantle the console. Refer to “Replacement of Console”.
10) Dismantle the sub-assembly of ECU.
11) Screw off the sub-assembly of carpet clamp holder.
12) Dismantle the carpet of carriage.
307
1) Put a carriage carpet.
2) Install the sub-assembly of carpet clamp holder.
3) Install the sub-assembly of ECU. Refer to “Replacement of ECU”.
4) Install the console. Refer to “Replacement of Console”.
5) Install the central console of front floor.
6) Install the auxiliary facia console assembly. Refer to “Replacement of Auxiliary Facia Console”.
7) Install the A-pillar lower trim board. Refer to "Replacement of A-pillar Lower Trim Board”.
8) Install the front and rear door pedals.
9) Tighten the fixed bolt of retractor of front seat safety belt.
10) Install the front seat. Refer to “Replacement of Front Seat”.
11) Install the rear seat backrest. Refer to “Replacement of Rear Seat”.
12) Install the rear seat cushion. Refer to “Replacement of Rear Seat”.
XVIII. Replacement of Front Trimming Plate of Coatrack
1. Dismount coatrack. Refer to “Replacement of Coatrack”.
2. Pry out the fixed snap-in on the front trimming plate.
Fig. 2.2.052
3. Take off the front trimming plate.
308
XIX. Replacement of Protecting Plate of Rear Boot Cover

Attention:
■ Fix the protecting plate to the outer panel of rear boot cover with 5 plastic snap-ins and 5
self-tapping screws.
■ During dismantlement, screw off the self-tapping screws in turn and take off the protecting plate of
rear boot cover.
■ During dismantlement, don’t scratch the outside surface of the protecting plate of rear boot cover.
1. Dismount the fixed self-tapping screws on the protecting plate of rear boot cover in turn.
Fig. 2.2.053
2. Take off the protecting plate of rear boot cover.

Disassembly Diagram for Protecting Plate of Rear Boot Cover

1-Plastic snap-in (5 pcs) 2-Fixed hole of rear boot cover (5 pcs) 3-Outer panel of rear boot cover
4-Self-tapping screw (5 psc) 5-Protecting plate of rear boot cover
Attention:
■ Before installation, check if there is any defect affecting appearance, such as scratch, shrinkage,
uneven gloss, etc.
■ Check if the 5 plastic snap-ins are firmly set to the outer panel of rear boot cover and if there is any
omission.
■ After installation, make sure the protecting plate of rear boot cover is fitting well with the edge of
outer panel.
■ During installation, don’t scratch the outside surface of protecting plate of rear boot cover.
309
XX. Replacement of Front Seat
1) Adjust the seat to an appropriate position to dismantle the clamping screw at the front end of seat.
Fig. 2.2.054
2) Dismount the clamping screw at the front end

Fig. 2.2.055
of seat.
3) Adjust the seat to an appropriate position

Fig. 2.2.056
again to dismantle the clamping screw at the
rear end of seat.
4) Dismount the clamping screw at the rear end

Fig. 2.2.057
of seat.
310
5) Adjust the seat backrest to an appropriate position to move it out.
Attention:
■ When moving the seat, pay attention to prevent the paint from scratch.
Fig. 2.2.058
6) Move the seat out and re-install the screws.
1) Adjust the seat backrest to an appropriate position to put the seat in.
2) Put the seat in.
3) Install the clamping screw at the rear end of seat. Tightening torque: 35~55 N•m.
4) Adjust the seat to an appropriate position again to install the clamping screw at the front end of seat.
5) Install the clamping screw at the front end of seat. Tightening torque: 35~55 N•m.
6) At last, adjust the seat backrest to an appropriate position.
XXI. Replacement of Rear Seat
1. Pull the fixed snap-in of rear seat cushion outwards.
Fig. 2.2.059
311
2. Lift the seat cushion and disconnect the snap-in.
Fig. 2.2.060
3. Take the seat cushion out.

Fig. 2.2.061
4. Press the switch of backrest latch and put the

Fig. 2.2.062
left rear seat backrest to an appropriate
position.
5. Dismount the left rear seat backrest.

Fig. 2.2.063
312
6. Press the switch of backrest latch and put the

Fig. 2.2.064
right rear seat backrest to an appropriate
position.
7. Slightly tilt the backrest and take it out.

Fig. 2.2.065
Attention:
■ When dismantling backrest, do dismantle from left to right.
■ Don’t get the seat dirty during dismantlement and installation.
313
XXII. Replacement of Name Plate
1) Before dismantlement, heat the name plate

in circle at 152 mm away from the surface
for approximately 30 s.
Fig. 2.2.066
Fig. 2.2.067
Fig. 2.2.068
2) Use tape to protect the installation surface.
314
3) Use plastic flat-edge tool to pry out or dismantle the name plate from the surface of panel.
Fig. 2.2.069
Fig. 2.2.070
Attention
■ Don’t damage the paint of body.
1) Clean the area on which the name plate is about to be installed and make the area completely dry.
2) Mark the tape with the dimension when the nameplate is located correctly.
3) Heat the installation surface to around 27~41℃.
4) Stick the adhesive foam tape to the back side of name plate and press the name plate to the correct
position.
Attention:
■ Try to stick the name plate in an environment without dust. Dust or other foreign substances may
lead to improper stickup.
5) Remove the protective tape from the installation surface.
315
XXIII. Replacement of Front Windshield
1) Open the engine hood.
2) Cover the surrounding area of front windshield to protect the paint and the interior ceiling lining.
3) Dismantle the wiper arm and wiper blade of front windshield. Refer to “Replacement of Wiper Arm”
in “Wiper and Wiper Cleaner System”.
4) Dismantle the air inlet grid. Refer to “Replacement of Front Wiper Driving Components”.
5) Dismantle the inside rear-view mirror. Refer to “Replacement of Inside Rear-view Mirror”.
7) Dismantle the stripe ornament of front windshield.
① Hold the lower corner of stripe ornament of windshield and slowly pull it out.
② If the stripe ornament of windshield is too tight, cut it along the windshield with multi-purpose knife to
dismantle it.
Attention:
■ When dismantling windshield, the only proper lubricant is clean water.
8) Use tools for dismantling glass sealing layer or static window glass to dismantle the windshield.
Diagram 1 for Dismantlement and Installation Methods of Windshield
9) Dismantle the front windshield from the vehicle with the help of assistant.
316
10) Check the following components which may lead to breakage of windshield:
① The edge of windshield frame.
② Stripe ornament of windshield.
③ Windshield.
11) Check the status of windshield frame and flanging of adhesive.
12) Clear all broken glass from the front cover plate, seat, floor and the duct of defroster.
13) Moisten a lint-free cloth with solution mixed by isopropyl alcohol and water (the volume ratio is 50/50)
to clean the edge of windshield’s inner surface.
After treating the windshield frame according to the requirement, conduct the following operations:
1) Shake the hold-down welding primer for at least 1 min.
2) Use new coating tools to coat the surface of binding part (1) with hold-down welding primer.
317
3) Wait for the primer to be dry for around 10 min. Make sure all the scratch and rubbing marks are
covered.
4) Install washer and filling strip of VIN plate.
5) Install stripe ornament of window at the edge of windshield. If the original stripe ornament of window
is damaged, replace it.
318
6) With the help of an assistant, fit the windshield and frame to confirm the correct way to locate the
front windshield in the frame.
7) Use tape (1) to mark the location of windshield in the frame.
8) Cut off the tape at the top edge of windshield.
9) With the help of an assistant, dismantle the windshield from frame with suction cup.
10) Put the windshield on a clean and safe surface, making the inside face upwards.
11) For using the original windshield repeatedly, get rid of all carbamate adhesive from the surface of
windshield with multi-purpose knife or shaver blade. However, leave a layer of film there.
319
12) Moisten a lint-free cloth with solution mixed by isopropyl alcohol and water (the volume ratio is 50/50)
to clean the edge of windshield’s inner surface.
Attention:
■ Don’t get rid of all marks of adhesive. Just get rid of all accumulated or scattered chips of carbamate
adhesive.
13) For long-term usage, get rig of all adhesive at the flanging of hold-down welding. However, leave
about 2 mm of adhesive there.
14) Shake the hold-down welding primer for at least 1 min.
15) Use new coating tools to coat the surface of the flanging of hold-down welding with primer.
16) Dry the clamping welding primer for around 10 min.
Attention:
■ Please take care when adding glass protective agent (transparent) to windshield. This primer may
become dry immediately. If coating unevenly, the visible area on windshield may be polluted.
17) Use new coating tools to coat along the edge of inside surface of window with 10~16 mm of glass
protective agent.
18) Coat the same position on the glass with a second layer of glass protective agent.
19) Use a clean lint-free cloth to wipe the position, coated with primer, clean immediately.
20) Shake the glass protective agent for at least 1 min.
21) Use new coating tools to coat the glass primer on the same place coated with glass protective agent.
The glass primer may be used in 8 hours after coating. The surface of glass for primer coating must
be clean.
320
22) Wait the glass primer to be dry for at least 10 min.
23) Cut out the coater nozzle to form a 6.0 mm of flanging.
321
24) Use barrel-type caulking gun to coat the flanging of glass glue evenly and continuously.
25) Coat glass glue on the existing glass glue of body.
26) With the help of an assistant, install the windshield in the frame with suction cup.
322
27) Align the windshield with the tape line (1) on the body.
28) Press the windshield properly.
29) Use tape to stick the windshield to the body to reduce moving until the glass glue is solidified.
30) Clear the remaining glass glue on the body.
Attention:
■ Don’t directly spray high pressure water on the glass glue which is just coated.
31) Conduct water-tightness test to windshield by moderate-pressure warm water jet.
32) Check if there is leakage of windshield.
33) If there is leakage, use plastic scraper to coat more glass glue at the leaking position.
34) When the glass glue is solidified, check for leakage of windshield again.
Caution:
■ It takes 24 h for the maintenance material to be solidified completely. Don’t interfere with the
maintenance part before it is completely solidified. Otherwise, the passenger without any protective
measures will fall out from the vehicle and get hurt.
35) Dismount the protective tape and covering from windshield area.
■ Replace the rear windshield according to the above steps.
323
Section III Console
I. Precautions
may be caused.
Dismount the negative pole of storage battery and wait for at least 1 min before dismounting the
II. Replacement of Driver Airbag Module
Refer to “Safety Airbag System”.
III. Replacement of Steering Wheel
1) Dismount the negative pole of storage battery.
Fig. 2. 3.001
2) Turn the ignition switch to “OFF”.
324
3) Dismantle the clamping screw of airbag module. Rotate the steering wheel along its central position
so as to take off the second screw.
Fig. 2. 3.002
4) Move away the driver airbag module and cut off the connector of airbag module at the driver’s side.
Fig. 2. 3.003
5) Cut off the connector of horn button and dismantle the clamping screw of horn switch.
Fig. 2. 3.004
6) Take off the horn switch assembly.
7) Mark out a location mark on the steering wheel hub and align this mark with the notch on steering
shaft.
325
8) Unscrew the steering wheel nut.
Fig. 2. 3.005
9) Use special tools to dismount the steering wheel from steering shaft.
Fig. 2. 3.006
10) Dismantle the steering shaft nut.
11) Remove the wiring of airbag module connector from the steering wheel.
2. Installation steps
1) Arrange the wiring of airbag module connector through steering wheel.
2) Align the mark on steering wheel with the notch on steering shaft.
3) Install the steering wheel.
4) Install the steering shaft nut.
■ Tightening torque: 41N.m.
326
5) Install the clamping screw of horn switch and connect the connector of horn switch.
Fig. 2. 3.007
6) Place the driver airbag module on steering wheel, connect the connector of driver airbag module
and ensure that the circuit is correctly and firmly installed during installation.
7) Install the clamping screw of airbag module.
Fig. 2. 3.008
8) Check if the operations of the following components are correct or not:
■ Horn
■ Steering wheel
■ Safety Airbag System
327
IV. Replacement of Trimming Cover of Steering Column
Fig. 2. 3.009
2. Dismount the steering wheel assembly. Refer to “Replacement of Steering Wheel”.
3. Dismount the clamping screw of lower cover of steering column.
Fig. 2. 3.010
4. Dismount the upper/lower trimming cover of steering column.
Fig. 2. 3.011
5. Install with the reverse order. Notice that the steering column should be placed at central position
and install the clamping screw of left lower protective cover of console.
■ Tightening torque: 1.4 N.m.
328
V. Replacement of Clock Spring of Safety Airbag
Refer to “Safety Airbag System”.
VI. Replacement of Lower Protective Cover of Console at Driver’s Side
1. Dismount the bottom cover of lower protective cover of console at driver’s side.
Fig. 2. 3.012
2. Dismount the handle of engine hood.
Fig. 2. 3.013
3. Cut off every connector seat connected with the lower protective cover of console at driver’s side.
Fig. 2. 3.014
329
VII. Replacement of Ignition Switch
Fig. 2. 3.015
2. Dismantle the driver airbag module. Refer to “Replacement of Driver Airbag Module”.
3. Dismantle the steering wheel. Refer to “Replacement of Steering Wheel”.
4. Dismantle the upper/lower protective cover. Refer to “Replacement of Trimming Cover of Steering
Column”.
5. Dismantle the clock spring of airbag. Refer to “Replacement of Clock Spring of Airbag”.
6. Dismantle the lower protective cover of console at driver’s side. Refer to “Replacement of Lower
Protective Cover of Console at Driver’s Side”.
7. Dismantle the combined switch. Refer to “Replacement of Combined Switch”.
8. Dismount the connector from the ignition lock module assembly.
Fig. 2. 3.016
9. Dismantle the assembling bolt of ignition

switch and key alarm switch assembly from Fig. 2. 3.017
ignition switch and key alarm switch assembly.
330
Fig. 2. 3.018
10. Dismantle the ignition switch and key alarm switch assembly from ignition lock module assembly.
Figure of Ignition Switch and Key Alarm Switch Assembly
11. Install in reverse order with dismantlement; ensure that the circuit is correctly and firmly installed
during installation.
VIII. Replacement of Glove Box
1. Dismount the two left/right bolts of glove box.
Fig. 2. 3.019
331
2. Pull out the glove box from the console opening.
Fig. 2. 3.020
3. Install in reverse order with dismantlement.
IX. Replacement of Auxiliary Fascia Console
1) Dismantle the lower protective cover of console at driver’s side. Refer to “Replacement of Lower
2) Dismantle the glove box. Refer to “Replacement of Glove Box”.
3) Dismantle the clamping screw of left/right trimming plate of auxiliary fascia console and slightly pull
out the trimming plate outward.
Fig. 2. 3.021
4) Dismantle the screw of front part assembly of

auxiliary fascia console. Fig. 2. 3.022
332
5) Dismount the protective sleeve of control lever.
Fig. 2. 3.023
6) Dismount the control lever housing.

Fig. 2. 3.024
7) Dismount the ash tray.

Fig. 2. 3.025
8) Dismantle the middle fastening bolt of front

Fig. 2. 3.026
part assembly of auxiliary fascia console.
333
9) Dismount the cigarette lighter assembly.
10) Dismantle the front part assembly of auxiliary fascia console.
11) Take off the rear fixed cup holder pad.
12) Dismantle the front/rear fastening bolt of rear part assembly of auxiliary fascia console and then
slightly pull out the rear part assembly of auxiliary fascia console forward.
Location Plan of Front/Rear Fastening Bolt of Auxiliary Fascia Console
2. Installation steps
1) Install the rear part assembly of auxiliary fascia console to the vehicle and fasten the front/rear
fastening bolt of auxiliary fascia console.
■ Tightening torque: 9N.m
2) Install the rear fixed cup holder pad.
3) Install the front part assembly of auxiliary fascia console.
4) Install the cigarette lighter assembly.
5) Install the middle fastening bolt of front part assembly of auxiliary fascia console.
Fig. 2. 3.027
334
6) Mount the ash tray.
Fig. 2. 3.028
7) Install the control lever housing.

Fig. 2. 3.029
8) Install the protective sleeve of control lever.
9) Install the screw of front part assembly of auxiliary Fig. 2. 3.030

fascia console.
10) Slightly insert left/right trimming plate of auxiliary

fascia console inward and fasten the bolt.
11) Install the glove box.

Fig. 2. 3.031
Refer to “Replacement of Glove Box”.
12) Install the lower protective cover of console at

driver’s side.
Refer to “Replacement of Lower Protective Cover of

Console at Driver’s Side”.
335
X. Replacement of Steering Column
1. Dismantle the negative pole of storage battery.
2. Dismount the steering wheel. Refer to “Replacement of Steering Wheel”.
3. Dismount the trimming cover of steering column. Refer to “Replacement of Trimming Cover of
Steering Column”.
4. Dismantle the clock spring of Airbag. Refer to “Replacement of Clock Spring of Airbag”.
6. Dismantle the combined switch assembly. Refer to “Replacement of Combined Switch”.
7. Dismantle the ignition switch assembly. Refer to “Replacement of Ignition Switch”.
8. Dismount the fastening bolt connected with intermediate steering shaft and steering gear.
Fig. 2. 3.032
9. Dismantle the upper/lower fastening bolt of

Fig. 2. 3.033
steering column and take off the steering
column assembly.

Fig. 2. 3.034
■ Tightening torque of bolt connected with
intermediate steering shaft and steering gear:
25 N.m.
■ Tightening torque of upper/lower assembling

bolt of steering column: 35 N.m.
336
XI. Replacement of Combined Device
1. Dismantle the negative pole of storage battery.
Fig. 2. 3.035
2. Dismantle the clamping screw of outer cover Fig. 2. 3.036

plate of combined device.
■ Tightening torque: 1.4N.m.
3. Carefully take off the outer cover plate of Fig. 2. 3.037

combined device.
4. Dismount the clamping screw of combined

device.
■ Tightening torque: 1.4N.m.
337
5. Cut off the connector of combined device and dismount the combined device.
Fig. 2. 3.038
XII. Replacement of Control Panel of Air Conditioner

Fig. 2. 3.039
2. Dismount the cover plate of central control

Fig. 2. 3.040
panel group.
338
3. Dismount the glove box.
Fig. 2. 3.041
4. Unscrew the clamping screw of control panel Fig. 2. 3.042

of air conditioner.
5. Pull out the control panel of air conditioner

Fig. 2. 3.043
forward, cut off the relevant connector and
take off the control panel of air conditioner.
7. Check if the air conditioner system is normal or not.
339
XIII. Replacement of Console
Fig. 2. 3.044
2. Dismount the steering wheel assembly. Refer to “Replacement of Steering Wheel”.
3. Dismount the trimming cover of steering column. Refer to “Replacement of Trimming Cover of
Steering Column”.
4. Dismantle the clock spring of Airbag. Refer to “Replacement of Clock Spring of Safety Airbag”.
Protective cover of Console at Driver’s Side”.
6. Dismantle the combined switch assembly. Refer to “Replacement of Combined Switch”.
7. Dismantle the ignition switch assembly. Refer to “Replacement of Ignition Switch”.
8. Dismantle the steering column assembly. Refer to “Replacement of Steering Column”.
9. Dismantle the lamp of glove box. Refer to “Replacement of Glove Box Lamp”.
Fig. 2. 3.045
10. Dismantle the glove box. Refer to “Replacement of Glove Box”.
11. Dismantle the passenger airbag module.
12. Dismantle the ash tray.
13. Dismantle the auxiliary fascia console assembly. Refer to “Replacement of Auxiliary Fascia
Console”.
340
14. Dismantle the combined device assembly. Refer to “Replacement of Combined Device”.
15. Dismount the cover plate of central control panel group.
Fig. 2. 3.046
16. Dismount the clamping screw of glove box Fig. 2. 3.047

and take off its element.
17. Dismount the control panel assembly of air Fig. 2. 3.048

conditioner. Refer to “Replacement of Control
Panel of Air Conditioner”.
18. Dismount the main frame of audio. Refer to

Fig. 2. 3.049
“Replacement of Main Frame of Audio”.
341
19. Dismantle the air conditioner’s internal

Fig. 2. 3.050
circulation switch and rear window glass
defrosting switch assembly.
20. Dismantle the hazard lamp switch assembly.

Fig. 2. 3.051
21. If the vehicle is equipped with automatic lamp,

Fig. 2. 3.052
dismantle the solar sensor.
22. Dismount the left/right pedal of front door.
23. Dismount the left/right trim strip of front door.

Fig. 2. 3.053
342
24. Dismantle the left/right pedal.

Fig. 2. 3.054
25. Dismantle the left/right trimming plate of pillar
A.
26. Dismantle the side trimming plate of console.

Fig. 2. 3.055
27. Dismount the clamping screw at the left side

Fig. 2. 3.056
of console.
28. Dismount the clamping screw at the right side

Fig. 2. 3.057
of console.
343
29. Cut off all electric connecting connectors.
30. Take down the console with the aid of the assistant.
XIV. Replacement of Console Support
1. Dismantle the console assembly. Refer to “Replacement of Console Assembly”.
2. Dismantle all of electrical appliances connected with console support.
3. Dismantle the wire harness of the console.
4. Dismantle the fastening bolt at the left side of console support.
Fig. 2. 3.058
5. Dismantle the fastening bolt at the right side of console support.
Fig. 2. 3.059
6. Take down the console support with the aid of the assistant.
344

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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body

Electrical Appliance & Structure Volume of Vehicle Body

Chapter I Electrical Appliance of Vehicle Body.................................................................................1

Section I Safety Airbag System ......................................................................................................1

III. Principles of Safety Airbag System..................................................................................3

IV. Safety Airbag Module at Driver’s Seat Side.....................................................................5

V. Safety Airbag Module at the Second Driver’s Seat Side..................................................7

VI. Safety Belt .......................................................................................................................9

VII. Pretensioner of Front Seat Safety Belt ..........................................................................15

VIII. Clock Spring of Safety Airbag ........................................................................................16

IX. Control Module of Safety Airbag (SDM) ........................................................................18

XI. Overhaul of Safety Airbag System.................................................................................22

XII. Disposal Methods of Safety Airbag System Components..............................................24

Section II Air Conditioning System................................................................................................28

III. Check of System ...........................................................................................................32

IV. Control of System..........................................................................................................35

V. Illustration on Function, Location and Check of System Elements ................................41

VI. Dismantlement and Installation of System (Evaporator\Warm air blower\3

VII. Filter of Air Conditioner ..................................................................................................64

VIII. Maintenance Data .........................................................................................................66

Section III Information and Time Electronic Control System (ETACS)..........................................67

II. Schematic Diagram of Elements ...................................................................................67

III. Illustration on Functions.................................................................................................68

IV. Definition of ETACS Control Module Terminals .............................................................83

V. Operation Illustration of ETACS Key Code ....................................................................83

VI. Replacement of ETACS Module and Alarm...................................................................84

VII. Technical Parameters ...................................................................................................87

Section IV Combined Switch ........................................................................................................88

II. Test of Elements ...........................................................................................................91

III. Replacement of Combined Switch ................................................................................91

Section V Lighting System............................................................................................................94

II. Headlamp ......................................................................................................................94

III. Front Fog Lamp...........................................................................................................104

IV. Tail Lamp.....................................................................................................................107

V. Highmounted Stop Lamp.............................................................................................115

VI. License Plate Lamp .....................................................................................................116

VII. Illuminating Lamp of Boot ............................................................................................118

VIII. Side Turn Signal Lamp ................................................................................................119

IX. Illuminating Lamp of Glove Box...................................................................................121

X. Reading Lamp .............................................................................................................123

XI. Maintenance Data and Specification ...........................................................................125

Section VI Combined Device ..................................................................................................... 127

II. Illustration on Connector Terminal of Combined Device ..............................................130

III. Replacement of Combined Device ..............................................................................130

IV. Speed Meter and Odometer ........................................................................................132

VI. Water Thermometer ....................................................................................................136

VII. Fuel Oil Meter..............................................................................................................138

VIII. Alarm Lamp of Engine Oil Pressure ............................................................................140

IX. Alarm Lamp of Braking System ...................................................................................141

X. Alarm Lamp of Door Open...........................................................................................141

Section VII Windscreen Wiper and Its Cleanser .........................................................................142

I. System Composition ...................................................................................................142

II. Precautions .................................................................................................................142

III. Front Windscreen Wiper..............................................................................................142

IV. Rear Windscreen Wiper ..............................................................................................152

V. Cleanser of Windscreen Wiper....................................................................................155

VI. Overhaul for Trouble ...................................................................................................159

Section VIII Horn and Cigar Lighter ............................................................................................164

I. Location of Elements ...................................................................................................164

II. Basic Diagram .............................................................................................................164

III. Check of Horn .............................................................................................................165

IV. Overhaul for Trouble....................................................................................................165

V. Replacement of Horn ..................................................................................................167