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Maintenance Manual of Chery A113_Chassis

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3. Fan motor 1 Ground B Horn 1 Horn 2 Ground C e Right front combined Gli Right l o toni headlight O O turning light ER TNT i ia 360 6720 090 Engine E el 3130 oo 672 09 n compartment 0 E j contact switch R Washine fluid pi Fan motor 2 NE 15 S asnin uid pipe 3 D 674e 10 E 2 0 0 0 d ER 4 g ot RF wheel ABS B sensor 2 120 un 9
4. Sa e E a lel e gs 8 Y S a Sa 9 233 3 sis e E o Na BS vaJe 0 d TE GRESS e nd l gt a 2 d gt a NS Bags ATED Ek BES D SA 5 5 C CU gt oun CO o O E C e o gt CO E E gt LO CU SERA LJ al EN lt JEO NDE g p B Ss Q gt qD0e0 SC Headlamp SC gt 88 m du EJE JIMAP 021 ps JOUUaLXd Un 9 3 z 5 SSES x Fuel gt E Interior instrumentA 7 REENEN 6 o Un UNT MACO Instrument engineA 7 eO rem EE bz NO e l 0 En Interior
5. p herd Audio Cluster gauge Wu Se MOLEX 51128 1601 I O circulation TN L 50350 9001 50535 90 motor CIRCLE MOTER SE 7 g HS G THB DJ7072 3 21 95 4i6 er 020 6080 6080 48 47 46 450 4a 430 420 615 M L DJ621 F3 06 53 ald 325q 93 feat 5l 49 41 aea 50 Vis 6813 Y 7 9 16 4504 Ge 167 Blower relat Brake switch m amp Ge EES HS G THB D7051 63 21 bracket should be Fog light switch EEN MO thermostat Right loudspeaker gt Blower power fitted together with the l Nightlight switch BREAK SWITCH HOY THB DUVT EI 2 8 electric box the torque SC IH n pee e e 10 TML 1621 62106 IP SPEAKER BLIVER MIR Left loudspeaker MANN G SS lr il t e HS G THB 2J70910
6. e e e Ld E SES KS ca 30 10 C A C switch E D 11 E 10 E amp oa Instrument front Y z fe Pa B4 d Z 4 O S 3 V Z L Ly N Qu z VA d Air conditioner E Bi a BT relay Sir Ce 5S M 6 9 amp E e gt SS s JD Q A C switch 3 P y SEE Bs 3 ea E 0 89Brk n le Lf c AInstrument UJ of ea mi a 2 p LO LO LJ plug e Interior ce e circulation switch S fs 2 0BrG f E Ji z Instrumept front B Blower M A 1 8 e O E CH z fa o O gt OU 3 3 4 l a 73 Instrument g 5 a In DP Si plug10 e ES gt e E G gt 5 GE ES 3 EU X a CO C ea 6 P e C OU c QJ 3 e High lo S w 1 rN ee S EE a e E S i rN Instrument T ch resistor i S swithc plugl E CO y O K S C SS 2 M AN Interiovluggage ea SS Y boot door a CO 4 Lar E a Blower S E e E y J i Relay Fr
7. XIII BCM System
8. Sa lt a Interior left front E OSVB e v OSBrB B7 ae Interior left front Interior left Mterior lettfront SFR p E el al SL a Bop inten e 519 104 Left Front Window DSL R Ceta Y SUA SB 154 Brake right front left rear right rear lam p 13 P e window window window Switch switch switch switch To alarm lamp switch Air o O O O R Y O gt M conditioner Se fa relay DA UP g c me O O O O e O O e Di nti deterrent V IAN IAN VA KY me IN M oe module e e e 9 o 9 e e e S e e e s Instrument front S antenna 14 TNR O gt e S O O G O 4 z gt OWN m E S An z m i O O O O O O O ES le S Cr c MA 9 e c5 ds tv CU ol ay o y E AN Introrrght 0 Ob Interior left rear Interior right rar UN Interior left frontA2 a5 O gt D e fron B6 o FAN Interior instrument E Ana ca Interior left frontA6 Lj gt e C e 25 O 10 O Interior left 15 eo Interior left A Interior left frontB13 Cc QcC T frontB8 S frontB Al B
9. 16 J 8 Diagnosis Access spare Spare E rie KEE EE CEIS ORIG ETE OEA EI REO amp Rel Fee osa gi0A i04 EU ISA OA SA JIOA Jonn Jon 30c 30d n Blower Relay INGI ING ALE E yn Sue NE PR F5 F6 F9 F10 87 D A g105 IA 10A 154 410A 195 45A LOE ls i US d 85 PULLER m f 15 Beete 5 8 1 53s 31 f S IS 5 rent tees 490 Sam d gj 8d 30 nie E B i 49 2 20 Front wiper relay Integrated relay plug The instrument relay box is located within the left cover plate of the dashboard with the detailed function instructions of the fuses are as follows No Specification Functions No Specification Functions 22 CUA Rear defroster FII Vacant al CUA rei FO 108 Racio player control T 10A Lamp switch instrument 2 er Jigar i
10. LO 1245 2 917 gt Y e gt gt s e A Wiper combined switch co d T 00 o D O O A Terminal number 6 4 9 E 3 c Front washer 3 gt E 61 9 E O fe B N 040 o O oO lt O Kai O O O H Lo o ms Ke DO E a Rear washer v o 0 a OFF CT EZ LI O O O f 083W CO O 9 W Inte OE A21 44 Instrument front WiInterior instrumen W Instrument front A23 A22 oe Es A26 T E 00 fe O 00 i59 E Y I v IInterior luggage boot door5 ZN 53M gt gt Ve Instrument front Al LJ 19 Instrument front 19 CO 335 A 2 00 O I E nad O VW Inte T OY 31 boo vv IInstrument front wer Z 4 Bl d S Ee Ze es Rear Front p i 5 4 washer o washer i3 B4 H co motor motor lt 2 Ca gt 2 5 P oo i e 3 n Rear Wiper 19 Front wiper motor 00 Motor ma X Turn Signal Lamp System
11. 38 30 300 19 150 Ka XV 473 Engine and Liandian Electric Injection System Engine speed sensor x i q E Se a Ir omm amp H B ed 9 m GE JASO _ Lis E Ss 3 E S e asol T 2B HALISG x Accelerator E 5 E o O LJ eu n 79S 0 a gs80 es Ea We CY Cu a S e E E qSsou eS 3 wg s SCHO Ms D ADS O E e SCH o Em cu gG80 y E 5 eso e e cg d hz T CO ges Electronic Throttle Valve S 39S 0 S KNOCK SENSOR E E L E C o B mm gt u g o lt qe tt Y us za Ene ECOS 6o Ze ON engine ECU33 E IG 0 7 cxx O sS 0 2 SOLENOID VALVES 3 A engine E CUTS 5 C e 2 H z s co IS engine ECU a j LJ a SEN qa Sea F LA 259 engine ECU34 _ S i E 3 X aso VA 8T SES e No D S GE Evaporator temperature oie ES sensor zi IS 0 To camshaft position sensor CU m 3 P Injector 3 de AS O a 1680
12. 15 e 15a Ka F4 104 Left side Right side PAB switch xd ASE Y po z E Fy ES gt gt Airbag indicator lamp PAB indicator lamp BC M A e Diagnosis Access f Je al S IT 37 A EH __ Instrument airbag gt e Y OS plug e O O LA X z _ T In C O C E m 6 S 7 34 37 3 8 15 20 el 22 e3 Air Bag GT tof ul asf 141 18 leif 1 1 2f 3f 41 gt lt m gt ea Y 5 2 9 3 2 m OUR E n S 9 S E o o5 S Tep CD NY NM No M No NY YY M dl y i kl X Driver airbag Driver side Passenger sifhtiver seat Passenger seat Passenger airbagairbag airbag belt switch belt switch Special earth point of 30 C airbag IV Backup Radar PES 512 2006 circuit diagram backup radar 30 30a 15 15a ds Display Hl Engine ECU26 Ter gt LN Backup radar control To gear switch p module 9 Engine ECU27 ch ECU Front 4 AN Interior front 2 ZNI 0 5B 0 5W OS Probe Probe 204 G202 Ld e V Electric Rear View Mirror 30 3
13. 30 30a 15 e 15a Ka ls F mu 10A 15A To running relaye CC e To BCM24 O Ss O O L 9 Alarm BL IF Be IL TB TR Sh s S N oo o 00 2 E l 2 3 Creve NE LJ 22 Flash p e dt E relay CO ay Le K u C S L O83LY n E Te Turning D co L Switch Interior instrument 6 E ul RE Instrument24 3 9 Interior instrument 5 ii B E M A i S Instrument 7 gt bd 4 BCM A225 e o e e e e e oi i iL T D oF let Left P Right L Right turn rear turn rear lamp turn lamp turn lamp lamp Q9 OS aa aa aa pa ea le Ip an ea fe fe ea fe ea j 0D O0 co ol o f C C O O O O CD O 30 6207 Glo coy cog ol oi cog om o Geog XI Radio Player Horn Cigarette Lighter 38 9 3 300 v IN 190 Ka j E To antenna F10 152 085RLg R 104 AH r2 Torear 194 o fog lamp q
14. Charging Cenerator IA pressure sensor T connector connector E ab 4 1 C eo J ole Camshaft sensor connector E ia Ignition coil connector Rear oxygen Carbon agr Le CODE sensor connector canister ZE Sal el Se l Electronic throttle ae 5 Zb Econnector 228 282 2360 255 50 270 80 WJS igonnestar fr e 4 L 30 2178 B 3 2 1 1 E CO 70 Ol oo To injection nozzle SI acu ie Vehicle speed arness connector d e a sensor Ep r A us o Engine RPM sensor i Ola teg Am Al ne DOLAR D Front oxygen sensor ol Starter control connector ces Reverse light E cs O X Beo t connector LA 70 4 O O RPM 248 2820 2361 218 so 4 22 8 4 AA Knock sensor Jee __ te 0 peo PEE ES do connector EU Oil pressure C esie 606 To ECU harness L Compressor Switch anta 5 connector ES e Batter positive and negative Power steering EE Een pump switch E E Plain washer and plain cushion 120 II Instructions on Harness Connectors 3 8 Connector Name Pins Recharging display connector Intake pressure sensor Connection Ground To ECU harness connector To ECU harness connector To ECU harness connector To ECU harness connector Carbon canister solenoid valve connector Cams
15. door it E l 13 ad oT ll es ood aen am aus am ain 27a 310 3094 301 302 304 305 3050 307 622c 6220 310 311 312 313 Wee 32 a dad aal ae se se al 314 315 316 318 317 3050 320 622s 323 322 324 325 14 29 6434 3068b 27lb 32 3llb 20 S t b It it h eat belt switc E LR group tail lamp NP 3 LF door contact PME 2 6 1 dn TUBE e D SES switch e 2 3 2 160 une i5 E F e a j Les A oue a Butt joint with back de J 2 3 oe 48d 350 y 2 Dp 2 E License plate lamp 1 m sl Js door bo e Ground ct y cl wiel i EXC amp o 5 g 62 100 100 e 210 200 50 z 50 140 e 80 170 230 i 420 z 170 4 80 y 220 gt 220 gt 9 P 5 b 70 z 30 00 160 n S 170 300 gt 350 100 50 pa 100 gt 220 220 90 b 160 gt 460 330 160 0 240 0 MOs NUR NU TO F TO P T OTOTOT O v9 E OS O e 0070707070 F 6 w 671090 s oo soo TO o O6 A A ipo d dei ob Fo d o ob D a Rear loudspeaker ada 9 2 l 11 B E EK bo T x ms 3 ED m Hand brake switch 20 5 Trunk lig ONSE z 3 E 3i 8 ele i3 m Ground o mo A 3 S i l GE T Go E Abut joint zm Ground ko E CH RR door contact NC Gy VR E Jo with e Bei EE E switch Gr ound Reverse radar 314 Ss A instrument KE 2 J amp
16. LO a 85 86 B Ei a LX E SS E ES E 87 0 ASM AST own own he S 2 E 30 E gt o 3 E E 85 86 zm E Erte 2 es 86 3 X DA E O O A 85 86 ELAN EELS g E E 15A DA e SU EF EEA 5 a D Ea LJ LJ 10A os e E E d EF LONE 5 5 z z Mu EAR LEE LS 3 d 8 30 lu DA aa 3 87 2 86 ERAN rr E LJ 30 E SA o El E 3 CC 0A amp c5 87 Re iln EE 2 SEH 0A EM 85 86 F gt ERE B X 3 86 30 EF z K z SA le a S amp 83 m V D 7985 EFL E WS Ge 3 SA 30 C 20A 30 E The front compartment relay box is located near the front compartment battery with the detailed function instructions of the fuses are as follows Capacity Function SFI 30A Fan high speed EF6 10A Compressor E EE NEM NEM ISA Oxygen sensor SF3 A A C Vacant Vacant SF4 Instrument electric ISA Ignition coil box SES 30A ABS TI EFIO 10A Backuplamp EF4 15A Fuel pump EF15 10A Right low beam Primary relay EFI6 10A Left low beam 2 2 Instrument Relay Box Fuse
17. S eL I I Mm lee Starter Battery Battery body transmission earth earth Body Body earth earth S s 30A LAE SO 3065 Instrument 4 dale E ADE O Instrument frontA 9 Diagnosis Access f C S80 A 180 Instrument front 1 t G0 86 NIJ lt dE Instrument engine A10 PE 1045 dac 0 14 LOA mem II ABS Control System c c Lei en 3 OC NO scat E O 0 5 O Instrument frontH gt 16 18 24 G100 qoc G100 UD e ES Instrument front 11 eG EE Instrument front 10 as O Instrument front 9 qG 0 ABSsii onti lock brake system 13 SS Instrument fronts 20 gs O JS 0 IG Brake lamp Switch ASO lt le Lu Instrument engine pr 13 AG Interior instrument na Ale AS80 A X R R R L FR 249 Gede AG 0 aX CO High mount brake light AGO G204 x Right Brake Lamp 4680 AGO Ge02 ne Co Left Brake Lamp 30 30 30a III Airb ag
18. 10 Instrument engine B plug B of instrument harness and engine Instrument tront A plug A of instrument harness and front compartment harness EZE 9110111112 18 19 22123 242320 Instrument front B plug B of instrument harness and front compartment harness AS il BUM B 6171819 101 112 1 1415 1811912012112223 24 2320 COMBINED INSTRUMENTS MA E Ee s E 3 ge Ps AS Et el ee ci eA 6 24 zee J 2 43 o9 06 27 28 29 30 3 30 33 M 35 36 37 38 39 40 4 42 43 44 45 46 47 48 49 50 59 50 DW 55 56 37 58 99 00 6l 6 44 62 C 63 8l 63 6 65 66 608 69 A Dh p BMH D 7 sin e a8 ABS pin definition N T a 9 8 l 16 10 25 24 p 7 M P S AN NS x BCM A 16 15 14
19. Rear door Rear fende 2 10 Clearance between rear door and rear fender side wall at 14 14 0 mm C pillar Trunk door 4 y 2 11 Clearance between rear door and C pillar at 15 15 mm Rear door 2 12 Clearance between rear windscreen and C pillar at 16 16 5 1mm Rear windscreen Bor 100 2 13 Clearance between gas tank cover and rear fender side wall at 17 17 and 18 18 4 Ge mm m Rear fender Rear bumper Rear fender 101 pu v d i es E Gas tank cover RD p 2 15 Clearance between front fender and sill decorative board side wall at 20 20 25 mm C Front fender i T V decorative board 2 16 Clearance between front door and sill decorative board side wall at 21 21 641mm Front door Sill decorative board 102 3 Back View 22 23 ES 24 24 103 3 1 Clearance between vehicle roof and trunk door at 22 22 7 1mm Vehicle roof J 4 Trunk door Til gt qos MN d Rear windscreen he 3 2 Clear
20. Interior airbag plug of interior harness and airb harness DOG OD II Definition of Body Earth Points 1 Earth Definition G100 Body earth ABS earth G101 Left front compartment earth radiator fan low beam high beam position lamp turn signal lamp front fog lamp wiper brake liquid level anti deterrent horn G102 Right front compartment earth high beam low beam position lamp turn signal lamp side turn signal lamp front fog lamp horn G200 G201 G202 G203 G204 G206 G207 G208 G209 G210 Power train fuel position sensor left front door left rear door front ceiling lamp Electric sunroof Tail lamp backup radar oil pump rear wiper motor Luggage boot door rear wiper high mount brake lamp Tail lamp earth BCM seat belt switch Cigarette lighter fan instrument electric box Audio equipment combined instrument various control switches diagnosis socket Engine ECU earth Engine ECU earth 2 Distribution of Various Earth Points and Main Modules Front compartment electric box fo LL G204 Ga eg EES Gepo Lo 206 Ge0s KC aGe Sitz BCM is located under the driver s Instrument electric box eat Engine ECU Diagnosis socket The backup r
21. 2 Bt gt iu IGWO0s i S ai x Coolant Temperature Sensor MES 9 es Injector 4 5 SE S 5 AA g im cu x X 3 E ga DS 0 gt CY 7 D e Ss 37380 Injector 4 SEDE 5380 e X Intake temperature pressure S S sensor eu o al Injector 1 H 23asso e RET 31580 z lt MOS o ee UA CH X a Se a 3 pa se 93 OLS Beg 27 Zx El mai eel Ss TIGEL S B esoe P 2 2 MASSO E E CE Y Fa e ISO 4 o d E p 5S0 reds E DE Eje LL qf 5 d Li WwW 5 one 2 5 CO v E 31580 Sol E SUE ot n23 ulsuo OL e Rear oxygen sensor ON SETS ed a Qo Ps QU Bur we ms Zeen Y ies Ss el a acgo 7 3 RECHTS jie a i is so E a 3 s 5 gG80 MGO xd Aso P a o gt I O MASU Clutch switch 5 cu D E y ASZT r D O P E II AS 0 B Power steering switch E e a MdG O0 8 gt O e gt e OT MKS O Mose 6 2a VY S5 3 s 3 5 E amp g i aco E ES C in 5 HI LJ E ME m 5 ECU Instrument 6 OK e C mE 3 Y 3 LN ECU7 Instrument 4 a MADE ON NB y az U 7 Instrumen z ddeg ECU Instrument 5 E Se co E z P 8S0 ECU Instrument 2 Z 5 aaa Si ose 3580 kees d pe E E B Ll ECU7 Instrument 7 oul a gt Co El 32 MISO 90 ECU Instrument 13 LJ eo fe 2 KR S St 23380 No 15850 ECU Instrument 1 Ly ES fe e gt c B 21380 St Dn S80 ECU y Instruments To lamp control switch a 312 E a aoc 680 ON OO 2 get ep Ch D SN
22. Take the left side as an example 3 1 Open the Front Hood 3 2 Remove the headlights See Removal and Installation of Headlights 3 3 Use accross head screwdriver to loosen off the four screws on the grid fence 3 4 Use a 8 sleeve wrench to loosen off the two bolts on the bumper and the left wing sheet Torque 11N m 3 5 Use a cross head screwdriver to loosen off the 7 screws on the bumper and the front compartment member 3 6 Use a 8 sleeve wrench and a cross head screwdriver to loosen off the screws and fixing screws below the mud fender and the bumper Installation Torque 2 0 5 Nm 3 7 Raise the vehicle with a hoister 3 8 Use a cross head screwdriver and 8 sleeve to loosen off the fixing bolts and the screws below the mud fenderand the bumper Installation Torque 2 0 5N m 3 9 Pull off the fog lights connector 3 10 Remove the bumper Masia a 4 Installation Steps The installation steps are reverse to those for removal II Removal Installation amp Maintenance of Rear Bumper 1 Preparations Tools cross head screwdriver flat head screwdriver No 8 sleeve Spare parts disposable clips 2 Notes 2 1 Please wear necessary labor protection supplies to avoid accidents 2 2 Try to avoid scratching the painted surface of the bumper when removing it 2 3 When removing the bumper in colder environment operate gently to avoid damaging it 3 Removal Steps 3 1
23. ooa harness tapo e Yes i Check and replace th Check warning lamp power wiring of harness sid circuit and grounding circuit connector pin 16 S CT Repair p connector Check and replace warning lamp drive component Page 25 of 38 Table 2 oe The ABS warning lamp constantly illuminates after the vehicle start Evidence Possible Cause Damage of ABS warning lamp control Open circuit of ABS warning lamp control circuit ECU damage of ABS Troubleshooting Flow After the harness side connector is removed confirm if it s powered between the harness side pin 16 and warning lamp drive component Ln Check and replace Is it powered pl wiring of harness side Pd pin 16 E c Connect the harness side pin 16 to the grounding wire when the entire vehicle circuits are on _ as Check and replace Is warning lamp off warning lamp drive SQ ee component __ Replace HECU Page 26 of 38 Table 3 To uw Abnormal functioning of ABS Evidence Possible Cause e Damage of sensor e Improper installation of sensor e Problem of sensor harness e Impurity adherence on sensor Is the sensor correctly installed Re install the sensor with correct method Troubleshooting Flow X Ze gt Is Probl em 3 hecki let e Replace sensor Pau _ Is problem E still present 7 T Yes sy S Check if the ABS ECU socket and connector are norma
24. 9 1 2 Use a flat head screwdriver to pry open the C pillar upper shield 9 1 3 Remove the C pillar upper shield 9 1 4 Please follow the removal steps of left C pillar upper shield for that of the right C pillar upper shield 9 2 Installation Steps The installation steps are reverse to those for removal 10 Removal and Installation of Vehicle Ceiling 10 1 Removal Steps 10 1 1 Disassembling the left right front sun visors See Removal and Installation of Sun Visor 10 1 2 Disaasembling the front ceiling light Refer to removal and installation of front ceiling light 10 1 3 Disassembling all interior ceiling armrests See removal and installation of ceiling armrest 10 1 4 Disassembling A B C pillar shield See removal and installation of A B C Pillar Shield 10 1 5 Use a flat head screwdriver to loosen off the vehicle ceiling clip 4 in all 10 1 6 Disassemble the four doors weather strip by hand 10 1 7 Open the trunk and disassemble the vehicle ceiling 10 2 Installation Steps The installation steps are reverse to those for removal Chapter VII Removal and Installation of Instrument Panel A Instrument Panel Crossbeam I Removal of Instrument Panel Tools 8 sleeve extension bar Kix MS1 cross head screwdriver flat head screwdriver etc 1 Removal Steps 1 1 Open the storage box over the console and use a cross head screwdriver to loosen off the two screws Then
25. Chapter X Harness Section I Battery Negative Harness I Harness Sketch Hole type Connector Vehicle body earth e II Instructions on Main Connectors No Connector Name Pins Hole type joint Battery Negative Vehicle body Vehicle body Below left front ground fender 109 III Removal and Installation of Battery Harness Part number S12 3703010AC I Preparations Tools 10 13 wrench II Notes Make sure to disconnect the power supply when disassembling the electrical components and harnesses Ignition switch must be OFF III Removal Steps 1 Removal 1 1 Use a 10 wrench to remove the battery positive 1 2 Use a 10 wrench to loosen off the battery negative 1 3 Use a 13 wrench to loosen off the battery negative harness Remove the battery negative harness at the vehicle body ground wire 2 Installation The installation steps are reverse to those for removal 110 Section II Front Compartment Harness I Harness Sketch
26. 10 Removal and Installation of Vehicle Ceiling occccccnccnnnonnnononnnoncnnconcnncnnnncnnnnnnnnnonononononnos 55 AN ee VAL Ste EE 35 OZ AnstallattOBS te DSi eec t RU Eda toi pide 56 Chapter VII Removal and Installation of Instrument Panel amp Instrument Panel crossbeam 57 Etranger 57 ly REMOVAL E 57 2 dl O PS AAA PP O 66 3 Methods for Clearing Instrument Maintenance Indeator oes eeeeeerresseses 66 II Removal of Instrument Panel crossbeam nor nornornon see ense serere ens 66 E e oc 66 2 cInstall tom SUC Stilo 68 Chapter VILAR Conditioning Syste TTE Cosaseot eis toe este N eT 69 BEER ASNO abi 69 Removal of Evaporator Assembly rescrie a te Reb SU neue o deste tea polea ed istecu atta edu 69 Preparatoria 69 2 Removal and Installation Steng 69 3 Installation of Evaporator Assembly sese nennen eene eene 12 4 Removal and Installation of Interior Evaporator esee 12 k Replacement or e EE 12 2 Removal and Installation of Blower Speed Regulation Module 74 3 Removal and Installation of Heater Exchange 74 4 Removal and Installation of Mode Throttle Related Mechanism 76 5 Removal and Installation of Blend Throttle Related Mechanism T 6 Removal and Installation of Int Ext Throttle Motor amp Related Mechanism 78 7 Removal and Installation of Bvaporator eese 79 E POU IG S HOO DEP ss tada bue cu M
27. 13 12 LUOS JS TS 4 22 91 30 29 20 21262524023122 Jl 20 19 18 1 Interior left front A plug A of interior harness and left front door harness Ke 314 316 7 18 910 Interior right front A plug A of i harness and right front door harne m y l 2 34 FFE Interior right rear plug of interior harness and right rear door harness m 9 10 Interior ceiling lamp plug interior harness and ceiling lamp harness E 2 31451516 Interior rear bumper plug of inter harness and rear bumper harness 22 1 6543 Interior left front B plug B of interior harness and left front door harness l 2 3145 6 7 6 9 10 121314 Interior left rear plug of interior harness and left rear door harness Ke 314 Interior right front B plug B of interic and right front door harness WP 314 3 16 7 81910
28. 7 Removal amp Adjustment of of Hood Cable sese 8 TL Removal Adjustment Steps A nee AAA 8 1 2 MIStAl ALON SUC DS oso eraser O O A eu 9 II Removal and Installation of Rear Trunk Cover 9 ER Ge EE IT 9 2 Removal of Rear Decoration Plate 9 3 Removal and Installation of Trunk Lock eese 10 DL ROMO VAL SEG EE 10 Jesa tOn SED e e A 11 4 Removal ot Trunk Lock Cylinder aces estote bes lever rae entgehen pae Prae pe EE SUA 11 A NOS date Sos 11 7 2 Ee er E 11 s Removal or Rear Wiper NOZZE Sd 12 ML REMOVAL SUED ee 12 2 2 A aoe ee ee ee cosas eee oleae 13 6 Removal of Rear Wiper Motor idad dad 13 OX ee ii dieta 13 6 2 nStalTaltOn Ste DS 25u ee Eege 14 Chapter II Removal and Installation Of Trims 2 0 0 cceessessseseeseeseeceeceeceeceeceeceeaeeaeeeasessessseseeseeseees 15 I Removal and Installation of Seat Belt 15 PPLE PALA ONS DENT E I RTI 15 PM M P 15 3 Removal Steps Take Driver s Seat belt as an Eksample 15 Eer eo cesser iq uM oU LE 17 IL Removal and Installation Of Seals ee e ts a T 17 l Retnovaloft PLONE Seals A ecd habito a Race EA 17 2 Removal o Rear Sedis A A A reet 18 Neen Bt iia uis uui ean uma usi in DO Duae a 19 III Removal and Installation of Auxiliary Instrument Panel 19 A e lese e d Derbi urban nva Capite Stet Ee 19 2 Installattotr EE 22 IV Removal and Installation of Vehicle Cam
29. me me bech m OO DiaulBjuUy nN O O 0O0 I D M Ba Dw IN c Alarm switch engine connector C211 19 C209 instrument to 1 Instrument panel to plug engine connector 5 Instrument panel to plug pn Instrument panel to plug Instrument panel to plug Headlight switch Nightlight switch Brake light switch Air conditioner thermostat Air conditioner thermostat Brake light switch Anti sheft module connector Ground Ignition switch IGN1 C209 instrument to engine Failure diagnosis socket instrument panel plug C20 instrument to engine C200 instrument to interior C100 instrument to front compartment Ignition switch IGN2 C100 instrument to front compartment C100 instrument to front compartment 2 3 RHET EN Wiper relay EE NN NEN Wiper switch connector Wiper relay Ignition switch IGN2 C100 instrument to front compartment Speaker button 23 l Ignition switch C100 instrument to front connector compartment 4 ACC auxiliary electrical equipment bus Ignition switch IGN2 px Ground Ignition switch IGN2 C200 instrument to interior Headlights switch connector Rear wiper handle switch connector Dimmer steering switch connector Ground C100 instrument to front compartment 7 C100 nstrument to front Dimmer steering switch connector Dimmer steering switch connector Alarm switch 1 connector 2
30. 3 2 The brake liquid is one toxic liquid In event of contact with the skin or eyes due to carelessness flush with a great amount of water and if necessary call for medical treatment timely 3 3 The scrapped brake liquid should be accommodated in the container It s prohibited to drain it into the sewage system or stack with other household garbage 3 4 Do not depress the brake pedal nor move the vehicle during the removal installation operation 3 5 Do not make the friction lining or brake disc come contact with the oil substances which will impair the braking effects 4 Removal and Overhaul 4 1 Remove the protective cover from the tire rim with slotted screwdriver 4 2 Remove the tire fixing nuts with 19 torque wrench or vehicle attached tool and remove the tire Torque 110410 Nm 4 3 Lift the vehicle with elevator 4 4 Remove the 2 nuts upper and lower from the brake calliper and steering joint with 18 wrench 4 5 Remove the nuts from brake hose with 13 wrench Notice The brake liquid is one toxic liquid Do not splash the brake liquid to the clothes or skin during the removal of the brake hose Torque 16 3 Nm 4 6 Pull out the brake disc with hand 4 7 Measure the thickness of friction lining If below 3mm replace timely in pairs 4 8 Remove the brake calliper and brake pump with 14 wrench 4 9 Remove the dustproof seal and check for the damage of the dustproof seal If necessary renew the dus
31. 4 8 Pull of the vehicle alarm connector 4 9 Remove the shield inside the door 4 10 Pull off the power window up down switch connector 4 11 Use a cross head screwdriver to loosen off the two screws of the front door handle fixing mount 4 11 Tear off the anti water plastic sheeting on the left front door 4 12 Connect the battery and plug in the window up down switch plug lower the window glass to a proper position and loosen off the two screws that fix the glass 4 13 Take out the glass carefully 4 14 Use a 10 sleeve to loosen off the five screws that fix the window glass up down regulator 4 15 Loosen off the screws and then pull off the window glass up down motor connector to take out the window glass up down regulator assembly 4 16 Use a 10 sleeve wrench to loosen off the two fixing screws and remove the lock outside the door 4 17 Use a cross head screwdriver to loosen off the three screws fixing the lock core and remove it 4 18 Use a 13 sleeve wrench to loosen off the four fixing screws at the hinge that fixes the vehicle door and then the vehicle door can be disassembled 5 Installation Steps The installation steps are reverse to those for removal Note The removal steps for the right front door are the same as those for the left front door II Removal amp Installation of Rear Doors 1 System Constitution Diagram 2 Preparations Tools flat head screwd
32. Confirm if the bolts 3 pcs are tightened to 80 100 kgf cm with special tool or torque wrench 3 Notices for Installation of HECU and Bracket Assembly During the installation to vehicle body U Attach the components of brake hose and bracket to the HECU and install to the vehicle body with the body fixing bolts U Confirm if the body fixing bolts are tightened to 190 260 kgfcm with special _ tool or torque wrench U Again confirm if the pipeline installation of general pump and wheel branch pump is correct General pump MCP MCS Wheel branch pump FR FL RR RL U Tighten the brake hose not fully tightened to the specified torque 120 160 kgf cm with special tool or torque wrench 4 Other Notices Find out the trouble cause with diagnosis instrument before repair The package of the spare parts should be unwrapped only before the installation Only use the parts supplied by the original manufacturer Notice the cleanliness during removal and only use the non fuzz cloth for cleaning Use the detergent not containing the mineral oil to clean the appearance before removal Do not use the compressed air or move the vehicle when the system is opened C C C C C C C After the removal of the ABS assembly plug various hydraulic outlets with plugs as soon as possible Remove other components interfering the operation Use DOT 3 brake liquid Immerse the seals with brake liquid instead of engine oil
33. DEPENDA ASA 113 TD NOS dada 113 CIID REMOVAL EE 113 Section III Removal and Installation of Electronic Fuel Injection Harness 000000seeeeeeeeeen 120 BAP NESS SK CLC Hase eiunietet diia 120 II Instructions on Harness Connectors eene nnne nnns 121 III Removal and Installation of Harness missie aiin 123 GS scii uiu ipi vene EN E A ETS 123 2 EEGEN e 128 Section IV Indoor MES sami 129 E Eltere EE 129 III Removal and Installation of In door bharmness no nocnon 131 D EREECHEN 131 MINO pta 131 UE Removal STPS io 131 Section V Removal and Installation of Instrument Panel Harness eene 141 LJ Tarness e BEE 141 II Instructions on Main Connectors oocnncccnicnnnccnnocnnnconunononccnnnononicnonennoronononenccnnncnnoronanonoss 142 III Removal and Installation Instrument Panel Harness eee 151 D Preparation OE TOOLS EE 151 AIR e Susa dt Atos 151 III Removal and Installation of instrument panel Harness oooooocnnnnncnnccnnnnnnnnnnnnnnnos 151 Section VI LeH tront o ii 154 o A hice vaccum wsnceoecistussatena iad ouncbouedaisa ia iad pP ADD r E EG 154 IL Instructions on Mam CODDGGCEOLS eet Ee SEAN eae pes 155 III Removal and Installation of Left Front Door In door harness s 155 D Prepar dto uio de omia ts i tu bl iG em A ease eu equ E 155 SIM I REC iS Oo ds 155 GIID Removal Ste DS accom oce re eed bra e 155 Section VILRI sht ront Door Elie deeg lc 158
34. To in door harness connector 6 In door harness 3 2 4 To defroster positive harness Defroster positive harness connector 2 High mount brake light 2 High mount brake light connector Rear wiper motor connector 3 Rear wiper motor dl ken AE Vehicle body plate work On the tail door plate work III Removal and Installation of Tail Door In door harness Part number S12 3724160 I Preparations Tools sleeve wrench cross head screwdriver flat head screwdriver ID Notes 1 Do not use too much force when getting the harness through the hole in the vehicle body plate work or the harness may get damaged and result in short circuit 2 When disassembling the electrical components and harness please disconnect the power supply 3 The ignition switch must be OFF III Removal and Installation Steps Removal 1 1 1 Use a cross head screwdriver to remove the left C pillar inner shield See Removal of Vehicle Body Accessories Wy j d d AER 1 1 2 Unplug the harness plug forming abutt joint with the in door harness 1 1 3 Disassemble the high mount brake light shield by hand 1 1 4 Unplug the harness plug connecting the high mount brake light 1 1 5 Use a flat head screwdriver to disassemble the tail door shield 1 1 6 Unplug the rear defroster positive harness plug 1 1 7 Unplug the trunk switch plug 1 1 8 Unplug the rear wiper motor plug 1 1 9 Disassemble the veh
35. Y m uy ea de ll Pe al E EN Md a Sue E eo T S ee E ea uH s o E E E E Interior instrument7 al 5 5 la 3 SS SS olg Sg Ee Tan n ZA ep cu CG Lo xt lt r Lj guasa qu gt dm Ler eS gt CY T X o o 28S21 gt SE E a 1E 0 de Li Electric Fuel Pump MD T Lo d L E M E gt oN o a H a q D358 0 x59980 ED in e ge a 1S0 sica L Compressor Air conditioner relay 7 A QJ E E Ins as 0 LAIA 5 5 5 ni Sg El E i Tao E a 10 TAE p Main relay A 3 W No MO E al AMO E g SAME E QU d aso neues SEO SI CH doc Fan High Speed Relay Ps JME a LJ CU a ale lU Ee j vy save 376 0 nom Fan Low Speed Relay 30 CONTENT Common Abbreviations and Acronyms in This Manual ENEE ENEE 2 L Product Instruction 3 Mis SAPS RE TEE 3 LI Syst m BunctiOlnc ioo Seve veo ue eeu s v tea cer aorta d spe Que T eee TTO TUE EID NT CREER 3 1 2 Comparison between with and without ABS braking effects 3 2e SYSE SUCUT ce T AAA 5 3 System Functioning TIeOEy SA 6 S T ABS Control Th 0Ey 2 des tex ea costco ERO E UR MER m EU ANE ODE RIA OTT EE PUE 6 SEP NEM LEN 6 5 3 EBD Control Mode Zeene dies 9 IL Removal and Installation lt a e do Doe e EE a e HER e ode vaTE 10 1 Spare Part Supply SEAS si SA sa cand P S LEER obse Baek 10 2 Notices for Removal and Installation ececeeeeeeeeeee EEN 10 35 HECU Replacement A hor Ice ED e cS 12 III Trouble
36. 130 120 m 6 a9 LU 50 180 120 10 190 bh a ewm f a e e e e e e 9 amp e C To in door harness elle i 1 Sit z 210 T 20 V 8 z C 308 13 03 gi 30 318d 3254 406 i l o N a Left turning light z 2 Ss e 3 dd hs a a O i Ground A 8 9 E o a i Sa Washing fluid pipe Kaea E yy SES Rear washer 3 og light EE O motor A C high low 0 67 s 20 i pressure switch 3 Y n 160 al 150 90 30 J 150 150 120 7 Jaiml 407 dief e 36 20 eto te Gr 66 8 e e a e 8 Front washer y e 69 57 95 159 9 9 9 gt motor Dim o i al 2 2 To instrument teh berg 3 S w ie 10 ss allze ni ABS controller 36b 652c Da harness A e t ront com ine oh 210 4 230 10 121 n i i headlight 32850 030 652 0 08 E E l 3 g ie Sal 03 423 422 420 A 4180 by 3l la e i 0 25 24 DETAIL A o E j amp 15 2 V FUSE amp RLY BIK 50 T To batter y To instrument O J0 harness B 3 i E ME JJ Anti theft horn ar 0 T To engine harness a s s oo hs 20 ho I6 M rs eso feo oso tio 15e 3 9 Ir r3 2 NG DN a LF wheel ABS J sensor Brake fluid sensor de q Front wiper motor 66 67 60h a 111 II Instructions on Main Connectors No A AA HAN NNNM connector 3 Instrument harness B Instrument harness B connector 1 Washing fluid pi
37. 28 21 DyINee 6 3 el Ze 1NM TWL Ulli HS G THB DUTO6L 2 3 21 d KE 4 y THL DIRAG mb Var ee Wegen NE SPEAKER IP e om o AL EH e de HSG THB DJ70210 2 8 21 sael lens Pi te lat Zr HS G ANP 6260621 iy D l6 VW WICH 2 iz THL THB DJ621 2 8x084 lib ME Tb ck age m E l Antenna power S e 200 H E P E o 20 1 UD 394 AN S ella ge 7 D 4 mags A Air conditioner 5 0 speed resistor SPEED RESISTIR oe len lite MUN SS SC Nerei Hare re oy HS G THB DJTO42 6 3 21 HK H7 Fel Fee IL i E y SS y m WA gt T A d S N aN in 1 80 in sl o M i ent d Ile d 2l UI MH Blower relay A A 1 a 1 A dE y O Instrument to Se 9 160 D 9 BLOWER RL INNOBILZER M compartment nstrument s AS 380 97 724 V P Wt il one UD Tu i A 180 OE E HS WAN to interior pp Ne 4 THB 0 708 1 Na f 156 i TML ST740255 3 1 3 Cn Cn Cn ML Moe i0 VPVATOFRILWH 1 VP V A TOENGING V A Pa i F F 87 m l Ss ya E u RE p 33 pei PS NGG LR pugmmA3 kb mm ell gi W Tos TEST Ln JI Anti theft wa es Wi Se a te m CA Instrument m m iE Blower switch F BURG e5 05LR 320 05PB 404 0 L lg HA 1150 085Bry 1 S ii Bourg KR SR SEM d T730269 3 Y Vi Al de to engine 4 9 0 9 l 46 wn inset dine t Ci mge lighter Turning relay Em A BLOVER SW in ey 5 dP a dr I m d USA m HS Un A1 9 LASHRLY a al 90 ae v TNL DJ62PB A63 Wu DJeete t63 ao 180 n
38. Abbreviations and Acronyms in This Manual FL Front Left FR Front Right RL Rear Left RR Rear Right ABS Anti lock Brake System EBD Electronic Brake Distribution ECU Electronic Control Unit HU HCU Hydraulic Control Unit HECU ECU HCU LPA Low Pressure Accumulator MCP Master Cylinder Primary one of two outlet of master cylinder P refers to primary MCS Master Cylinder Secondary one of two outlet of master cylinder S refers to secondary SDL Serial Data Link Page 2 of 38 I Product Instruction 1 ABS Overview 1 1 System Function D Promotion of vehicle stability 2 Guarantee of vehicle steering ability 3 Guarantee of shortest brake distance 1 2 Comparison between with and without ABS braking effects gil LUS H 2XTITe To A O la e ds he m wm K al i ERO ka i d Sr ar i Zei E T SE zb 3 gt im p j 5 la a Se bo 4 a 4 Ee iai TT pr p P la UN LI We zw 17 fife Braking on Bisectional Roads Split Mea a tic v a F 2 IS Evading the obstacles during braking Page 3 of 38 1 3 Tire Dynamic Characteristics Slip Ratio Brake Force Steering Force Slip Rate Page 4 of 38 2 System Structure Including Electronic Control Unit The sensor will calculate the speed and acceleratio
39. BCM module and then disassemble the ground wire 33 Use a cross head screwdriver to remove the left vehicle ceiling handle and then disassemble the ground wire 34 Removal of sunroof controller harness 34 1 Disassemble the left vehicle ceiling See Removal and Installation of Vehicle Ceiling 34 2 Remove the sunroof controller harness plug Note Optional for some vehicle types and the sunroof controller connectors are reserved for this vehicle type 35 Installation of In door harness The steps are reverse to those for removal Outgoing EN I Harness sketch Section V Removal and Installation of Instrument Panel Harness
40. Case 5 The comprehensive trouble of Case 2 and Case 4 The status necessary for repetition Case 6 The status similar to Case 5 but it may cause the status incapable of repetition when the leakage 1s really severe 5 Measures in Event of Troubles during Air Discharge and Oil Refill for internal dry status of brake system D Implementation of trouble determination It s required to determine the connection portions of all components from the general pump to the wheel branch pump HECU hole portion connection portion of brake pipe connection portion of brake hose brake caliper and the air discharge screw portion of brake and etc 2 After the determination of the trouble re assemble in accordance with the provisions in order to avoid the further occurrence of leakage 3 Connect the repetition device to the 25 pin connector of the ECU or connect the checking device to the line K pin 7 Use the specific wiring to connect to the connectors During the connection to line K pin 7 make the vehicle at power on or start status The oil reservoir of the general pump is connected with the device for continual supply of brake oil or it s required that the oil reservoir should have enough oil during the supply of brake oil Page 31 of 38 4 Check the HECU with repetition device or checking device and determine the existence of trouble code If with trouble code firstly conduct the operation for deletion of the trouble code if the
41. Diagnosis and Troubleshooting eee EEN 14 I Eheckino Sequence is dos 14 2 Common Trouble Diagnosis and Troubleshooting of MGH 25 ABS 14 2 1 Checking of ABS and EBD Warning Lamp cc ceeeeeeee eee nne 14 2 2 Table for Common Troubles o 20 iiss chase ces eS ee rre eE 14 2 3 Trouble Code Readout and Deletion without Trouble Diagnosis Instrument 15 2 4 Trouble Checklist of Trouble Code ee ENNEN ENEE EE 17 2 5 Trouble Checklist without Trouble Code eee eene 25 IV Aw Discharge and Oil Reli i AAA ARSS 30 1 Regular Operation Procedure iii iia 30 SE ENER A tantam uova edet udine be PM ONU US 30 3 Notices for Air Discharge and Oil Ref EE ENEE 30 4 Determination Method for Vehicles with Air Discharge Trouble 31 5 Measures in Event of Troubles during Air Discharge and Oil Refill for internal dry status of brake system cccccsscccccccccccssscccssscccsssssesccsseees 31 6 Measures in Event of Trouble during Checking and ABS Functioning Test for internal wet status of brake system e ENEE 32 Annex I Malfunction Cases and Incorrect Repair Cases e 34 Annex Il ADS Basi eg ee 36 Annex III ABS Internal hydraulic Flow Diagram eee eee eee enne 37 Annex IV Connector Pin Layout of MGH 25 ABS ECU EN 37 Page 1 of 38 Common
42. Diagnosis and Troubleshooting 1 Checking Sequence Regular checking ECU ID determination ECU trouble code determination Warning lamp status determination determination Checking of wheel speed sensor Sensor air gap determination Sensor assembling status Checking of valve and terminal Valve status determination Pipeline assembling status determination 2 Trouble Diagnosis and Troubleshooting of MGH 25 ABS 2 1 Checking of ABS and EBD Warning Lamp Check if the ABS and EBD warning lamps are illuminated in accordance with following 1 Rotate the vehicle key to turn on the power The ABS warning lamp will illuminate and then go off in 3s Record checking result Trouble code determination e Trouble code record 2 It indicates the trouble if the status mentioned in I is not present and it s necessary to check the trouble code with reference to the trouble code checklist 3 If the warning lamps are completely not illuminated please refer to the trouble checklist without trouble code 2 2 Table for Common Troubles Position Cause Structure Warning lamp ABS EBD Incorrect assembling of brake hose installation Vehicle harness Locked wheels and brake off tracking Poor start of ABS and EBD Brake failure Deteriorated ABS performance ABS start failure Poor grounding of ECU ECU trouble Motor Motor trouble Trouble of ECU power line Trouble
43. Plate iglesia ott a che oe 46 7 Installation amp Adjustment of Headlights oooocccnccncccnnncnncnnnonononoonconcnnconocnnnnnnnnnnnnnnnnnnnnnnonos 47 8 Installation amp Adjustment of Front Fog Lights 48 Orcas alata OT ob Tan Lie EE 48 Chapter VI Removal and Installation of Vehicle Ceiling eee 49 IBN P ICI REESE UU D ahora es een edu 49 D mE 49 3 Removal and Installation of Sun Visor esses ener nennen nennen nne 49 Dale Removal EE 49 23 5 d stallatiot Ste EE 49 4 Removal and Installation of Vehicle top Armrest enm 50 dte REMOVA ES 50 aE EE EE EE 50 5 Removal and Installation of Front Ceiling Debt 31 5 d REMO VAS ES ties nu E etus ud AS MM EIE ED E MEE 51 een 51 6 Removal and Installation of Reverse Radar Display sees 52 6 1 Removal Steps EE 52 6 2 AMSA AU ONGS C6 62 iicet dc 532 7 Removal and Installation of A pillar Shield ococccccnnncnnncnnnonooononconcnncnnnnonccnnnnnnnnnnnnnononnnnos S T Removal EDS ad dea ed 252 152 T Sta AMON C6 E 53 8 Removal and Installation of B pillar Shield cc eccccccceeceeeseesesseesseeeescescesceeeeeeeeeeeeees 53 REMO VAIS OLE ORI isis 53 5 2 MISA ALOE SS A TA ea AE AA 53 9 Removal and Installation of C pillar Shield ococcccncnncnnncnnnononooncnncnncnnnconncnnnnnnnonononononnnnos 54 Ol Removal Steps erene e a e a e 54 92s IAS tao PS a edd A a a medic 54
44. a cross head screwdriver to remove the pre tension belt assembly 4 Installation Steps The installation steps are reverse to those for removal Note 4 1 Keep the seat belt clean and free of oil and check it for any damage 4 2 The pillar shield should fit securely with the vehicle body without any looseness and it should also fit well with the vehicle ceiling and weather strip s 4 3 The seat belt adjusting slide baffle of the upper B pillar shield should be able to move freely and won t affect the adjustment of the seat belt and its fitting clearance with the lower shield should be consistent and less than 1mm 4 4 The fitting clearance between the lower B pillar shield and the front rear sill plate should be consistent and less than 1mm II Removal and Installation of Seats Preparation of Tools sleeve wrench 1 Removal of Front Seats 1 1 Move the seat by pulling at the movable handle below it and when the fixing bolts are shown use a 13 socket wrench to remove the bolts 1n the seat Torque 25 3Nm 1 2 Pull off the seat connector and raise the seat 2 Removal of Rear Seats 2 1 Use a 13 socket wrench to remove the fixing bolts in the rear seat cushion Torque 25 3Nm 2 2 There are two rear seat cushions a left one and a right one secured by four bolts respectively Torque 25 3Nm 2 3 The cushion can be dismounted when the four fixing bolts are removed 2 4 Pull up the pull button in t
45. and seal sleeve Attach the seal ring onto the circular groove at the rear of the brake cylinder Attach the dustproof seal ring onto the front circular groove and press it in completely 4 14 The area between the dustproof seal ring and the brake clamp housing must be kept dry It should be kept away from the brake cylinder cream or the brake liquid in order to ensure the correct position of dustproof seal ring 4 15 Secure the brake piston with the reinforcement parts available in market and press it onto the dustproof seal ring slightly Blow the dustproof seal ring with compressed air up to 3 0bar to attach the piston ring onto the piston Notice Dip the dustproof seal ring and piston with brake liquid to facilitate the passing of the seal ring 4 16 Checking of brake disc Check the thickness of brake disc Replace the brake disc 1f the thickness is less than the min thickness Notice The two brake discs at the same axle should be replaced at a time The friction linings must be replaced following the replacement of the brake discs 4 17 Check the max run out of the end surface of brake disc with dial gage If above 0 03mm replace it Provided that the brake disc thickness is guaranteed it may conduct the proper machining to meet with the max run out 4 18 Installation of other portions with reference to the Removal Procedure III Removal Installation and Overhaul of Rear Brake 1 System
46. axle IV Tire Installation and Air Pressure Adjustment 1 Installation of Air Valve Prior to installing tire valve firstly check the valve port to ensure whether it is smooth and free from burr and then apply glycerol on the rubber body surface or soak the tire valve into glycerol Pull or press 200 400N using special tools to make the locating ring of the valve can go through the wheel holes to this point the assembly is completed soap water is allowed to substitute glycerol 2 Tire Assembling Before fit the tire apply glycerol or soap water along the cycle of tire bead meanwhile note that 2 1 When there is colored dot on the wheel rim align the uniformity testing mark of tire to the colored dot mark of wheel rim 2 2 When without colored dot on the wheel rim align the dynamic balance testing mark of tire to valve position 2 3 When without colored dot on the wheel rim additionally there is no dynamic balance testing mark however static balance testing mark is available at this point align the tire valve to the static balance testing mark 2 4 The description concerning the uniformity dynamic balance and static balance testing marks for tires will be additionally provided in writing by the product division of Chery Company or suppliers In addition this kind of descriptions will clearly be indicated on process sheet 2 5 Carry out tire inflation strictly in accordance with specified pressure During
47. inflating process air pressure shall not exceed 10 of rated pressure When performing separate packaging to spare wheel assembly the rated inflation pressure shall be 3 0bar and the spare wheel assembly shall be stored separately from four wheels Before the four wheel alignment check the air pressure of all wheels and adjust the air pressure 2 3bar for front wheels and 2 1bar for rear wheels 3 Tire Inflation After completion of tire inflation screw up the protective cap of valve and then carry out dynamic balancing test Fit appropriate balance weight at the internal and external fringe of wheel rim as required It is required that the unbalancedness of the final assembly shall be less than 100g cm which is approximately equivalent to a 5g balance weight at the internal and external fringe of wheel rim Note each wheel and each side can use only one balance weight Additionally its maximum mass shall not be more than 70g During assembling process never hit the balance weight too heavy Otherwise replace balance weight in time In addition never use the replaced balance weight again 4 Installation of Wheel and Tire Assembly When fixing wheel and tire assembly first manually screw up the wheel bolt onto the hub for pretension after that use special tools for tightening in accordance with diagonal process Tightening torque shall be 110 10N m It is prohibited to use impact wrench to prevent from wheel damage over lo
48. instrumentA 7 c Se Vehicle speed Y signal output DNI T E E E 9 amp Instrument engine 6 QU N E Pe Vehicle speed Instrument engineAl Fuel warning light a o AGE ELIO gt 0 AE O uc S dq z Instrument engineA 3 a E Coolant warning light E A i CO 3 amp uooo de 0 A amp q 0 oi 3 Coolant temperature NOI a 3 TE x o Brake warni ig ht S E u x E m T 3B kfK cac E z LJ MA dE 0 O i oo 8 R Instrument engineA 1 Engine oil pressure alarm lamp AS D de qi S E a ee E LIODO ADE D 29 e E Instrument engineA 4 Engine self examination lamp S gt 5 Ez TE NE Instrument engine 3 Power supply indicator light NN C se 4 Ac U Seat belt warning light S BEER ET 5 Interior instrumentA1 dau Sos OC 0 C BH e E S S 2 Interior instrument l1 NES 7 Door indicator Limp e a a Sei of 5 D am SEE BERK S JEO AIR BAG WARNING LIGHT aS GB D gt x Sag X IAE x E i E Nn A Coolant alarm lamp um Q SC 2 A O d Interior instrument A10 2 AMAE O 3S Position light e 8 Je e A FL E E E O 1 Tarman AJEO E ADE O ABS WARNING LIGHT Ba 3 d 3 EC aa d ssenger side airbag alarm lamp 3 SS gt d Diagnose o N 8 un E e E O Q a DEO N E e wm E un Mr O o 5 E must Ba 9S 0 a in i gs0 ov AIS O e ee A O e CN ME ee eC A TONO qS0 gga D AS O N Y C lt o E C C3 Ore We x E249 OR cs E S
49. is gradually exhausted from the oil reservoir In this process with the drop of oil level continuously supplement hydraulic fluid until the oil comes to specified level 3 Regularly check and adjust the tension of power steering belt vertically apply a 100N force at the middle of the belt the max deflection of belt shall be less than 5 mm otherwise adjust the belt tension until meet the above requirement via adjusting tension bolt 4 When in service 1t is prohibited to turn the steering wheel to limit position even 1f 1t has to do so never maintain at this position over 10 seconds It is strictly prohibited to use power steering pump without oil If the driver suddenly feels the steering heavy in service immediately stop the vehicle dismantle and repair accordingly Maintenance Manual of Chery A113 Body Accessories amp Dimensions After Sales Service Department of Chery Automobile Sales Co Ltd CONTENT Chapter T Eront Hoods Trunks 6 I Removal and Installation of Front Hood 6 A LEE 6 e 6 3 Removal and Installation of Front Hood Accesgortes sese 6 9S1 REMOVAL MEP A e ls 6 3 2 TASA MAIS ESOS AS e adco eL Com dtes Led o EEUU 6 4 Removal amp Adjustment of of Front Hood Assembly esee 7 5 Removal and Installation of Air Inlet Grid Assembly eee 7 IREMOS A 7 FLAO SE E 7 6 Removalof Front Hood ek 8 0 1 Removal Ste EE 8 6 2 WS TAO Ste DS lic 8
50. o 3 y TA allo bl dE dir f D 1 OM Q Q 4B 2 22 Beh atc juar is Jeck bei S a 2 m 14 8 P501 silly d Ge A Ee H 2h 15 d 1 8 asumen to front ig Air conditioner 9 gt RELAYANP 3735085 DEER d compartment i aA switch 4 m Air ME To instrument 27 Kap WI Boy 13 VP V H TOENGINE Alarm HS G ANP 174046 2 i iN connector Am Wiper relay dd electric box 66 67 18 2m cd 36 22 Mill 404 aseen 42 43 44 45 93 elc en 79 3H as te KS MP 936209 switch MK HS C THB JTII 23 21 Can A aea o pum O 157 68 69 65 60 d6 sorge 91 48 47 l te 70 49 02 se 5 3t dipl fo Wi Leal 23406 Ground vw Wo Ge nd ND Y 1 do I 7 TMLTHB DJ431 68 oer r UP V H TO ENGINE ROOM W H UP V H TOFROOL W H 62080605 608 7 HS G AMP 936098 2 HS G AMP 936098 1 Q Q ENEE E EE RECTE l E ees The bracket should be Wiper enr T can Instrument fitted together with the switch 2680851 0345 Dimmer to interior electric box the torque 1 turning switch ue To 68 X bla 69 H 325 320 X 1313 COMBI SV T SIG is 7 E INM s 8 B 8 g i T CH 0 J p HS G THB e TWL Dube F3x06 4 WIPER amp WASHER SV Rear wiper HS G THB DU7091 3 21 n M TML DJ621 F 3x06 handle switch Horn button KA En dan HORN SW Hi THB DJ3O114 4 21 TWL DJ221 4 w x i UY v ug 188 0J7091 23 21 TWL DJeol G2 306A Headlight gt dn switc
51. of front propelling rod and control arm with 15 wrench Torque 75 5 Nm 4 2 3 Remove the ball joint fixing bolts from control arm and steering universal joint with 18 socket and 18 ring wrench Torque 100 10 Nm 4 2 4 Remove the connection bolts of control arm and front axle with 18 socket to remove the control arm assembly Torque 150 10 Nm 4 3 Removal of Front Axle Assembly 4 3 1 Remove the fixing bolts from the chassis mud guard to remove the mud guard assembly Torque 3 0 5 Nm 4 3 2 Remove the front bracket bolts of the transmission from the secondary vehicle frame with 19 socket Torque 110 10 Nm 4 3 3 Remove the rear bracket bolts of the transmission from the secondary vehicle frame with 19 socket Torque 110 10 Nm 4 3 4 Remove the two connecting bolts of front exhaust pipe with 15 socket Torque 50 5 Nm 4 3 54 Remove the two connecting bolts of front exhaust pipe and rear muffler with 15 socket Torque 50 5 Nm 4 3 6 Remove the fixing bolts at the right side of the booster steering gear with 13 wrench Torque 75 5 Nm 4 3 7 Remove the fixing bolts at the left side of the booster steering gear with 15 wrench Torque 75 5 Nm 4 3 8 Remove the fixing bolts of propelling rod and secondary vehicle frame with 19 socket Torque 105 10 Nm 4 3 9 Remove the fixing bracket of the A C pipeline from the secondary vehicle frame with 10 wrench Torque 25 2 5 Nm 4 3 10 Remove th
52. of limit brake pad thickness shall be not less than 1mm Standard thickness of rear brake lining shall be 5 mm application limit shall be 1 mm and the remaining thickness of limit brake pad thickness shall be not less than 1 mm 4 Checking of brake disc run out Use dial gauge to check the face runout of brake disk the application limit of front disk shall be 0 03mm the application limit of rear disk shall be 0 03mm otherwise replace it Important notice After completion of replacing friction lining or brake disk apply the brake for several times to enable breaking in between brake lining and brake disk Always ensure safety After replacing brake lining check brake fluid level to ensure it is between MIN and MAX II Removal Installation and Overhaul of Front Brake and Brake Calliper 1 System Structural Diagram Structural Diagram of Front Brake Assembly 1 Brake disc positioning bolt 3 Wheel hub bearing unit 5 Dust cover 7 Fixing bolt 9 Friction lining thickness sensor plug 11 Brake calliper assembly 2 Brake disc 4 ABS speed sensor plug 6 Steering joint 8 Friction lining 10 Brake bracket 12 Fixing bolt 2 Preparations Tools Ratchet wheel ratchet lever 13 14 5 16 18 194 8 30 socket 10 13 14 16 ring wrench vice torque wrench measure ruler Accessories brake fluid 3 Notices 3 1 Please wear necessary labor protection supplies to avoid accidents
53. of valve power line ECU Trouble of motor wire line Sensor open circuit short circuit Speed sensor Gear ring trouble sensor interference trouble air gap trouble Page 14 of 38 Start failure of ABS and EBD Start failure of ABS and EBD Start failure of ABS and EBD Start failure of ABS and EBD ABS start failure In event of whichever trouble ABS start failure In event of both troubles Start failure of ABS EBD In event of whichever trouble Incorrect start of ABS In event of both troubles Start failure of ABS EBD 2 3 Trouble Code Readout and Deletion without Trouble Diagnosis Instrument I Purpose and condition of trouble code readout without trouble diagnosis instrument If without the trouble diagnosis instrument 1t may display the trouble status of the ABS via the ABS warning lamp and read out the trouble code to facilitate the trouble determination and troubleshooting In such case the trouble code will be displayed in 2 digit number Please refer to the numbers in parentheses in the trouble checklist of trouble code in succeeding section 2 4 The service conditions are as follows U Vehicle speed below 2km h Without connection of trouble diagnosis instrument The line L namely the pin 7 of interior diagnosis socket should be always grounded during the diagnosis process In addition at finish of the trouble code readout restore the ECU status of the ABS to the normal mode previously it s t
54. of which this function is fulfilled by the pressure reducing valve P Valve The special pressure reducing valve is not required for the vehicles equipped with ABS as the procedure supplemented to the ABS will fulfill the control function on the braking pressure of the rear wheels so as to effect the improvement of vehicle operation stability Page 9 of 38 II Removal and Installation l Spare Part Supply Status D Differentiation between Dry Type HECU and Wet Type HECU The biggest differentiation between the dry type HECU and wet type HECU is that the no air discharge is conducted in the 2nd circuit namely the circuit from the normal close valve to the general pump of the dry type HECU Therefore when the spare part is of wet type HECU it s only necessary to conduct the air discharge and oil refill in accordance with the regular brake system after the replacement When the spare part is of dry type HECU besides that the air discharge and oil refill are required in accordance with the regular brake system after the replacement it s necessary to conduct the air discharge and oil refill to the 2nd circuit of the HECU In addition for the appearance the wet type HECU has the bolts for sealing purpose and the dry type HECU has the protection film The product label located on the motor is marked with the part number of the products through which the dry type HECU and wet type HECU can be differentiated Take the 521 model for instance the d
55. or braking ointment Ci Q Ce C Check all hydraulic connectors for leakage Page 11 of 38 3 HECU Replacement 1 When the vehicle is stopped remove the 25 pin connector and harness wiring of the HECU located within the engine compartment 25 Pin Connector Used in MGH 25 ABS P No AMP 368482 1 2 Screw off in counter clockwise direction the 6 bolts M10x1 0 connected to the HECU brake hose with 11mm tool wrench rotate in clockwise direction during refit The tightening torque for the brake hose is 120 160 kgf cm 3 Screw off in counter clockwise direction the 3 bolts or nuts connected to the bracket with 12mm tool wrench rotate in clockwise direction during refit The tightening torque for the fixing bolts or nuts of the bracket is 190 260 kgf cm 4 After the removal of the product screw off in counter clockwise direction the 3 embedded bolts M6x1 0 attached to the HECU with 5mm tool hex wrench see the figure in next page Page 12 of 38 5 Screw off in counter clockwise direction the 6 bolts from the after service HECU with 6mm tool hex wrench 8 Screw on in clockwise direction 3 embedded bolts to assemble the after service HECU and the bracket with 5mm tool hex wrench The tightening torque for the embedded bolts is 80 100 kgf cm CO With reference to above item D 3 install the replacement after service HECU to the vehicle in reverse order Page 13 of 38 III Trouble
56. peres atom Md ttes iet ect p RU DAE 168 Rl for T a 168 CUD Re fmoyal ep iaa 168 EV nstallati on Steps occae cote eoo PM eter ivt ene tati A iiid iode aeu ees 169 Chapter I Front Hood amp Trunk I Removal and Installation of Front Hood 1 Preparations Tools Flat head cross head screwdriver socket wrench snipe nose pliers 2 Notes 2 1 During removal and installation be particularly careful to apply proper strength and no abrupt or violent operation is allowed 2 2 During removal and installation of the trims be particularly careful to avoid surface scratch of them 3 Removal and Installation of Front Hood Accessories 3 1 Removal Steps 3 1 1 Pull off the detergent hose 3 1 2 Press down the water nozzle clip from under the front hood and then push it up while removing the noozle outward 3 2 Installation Steps The installation steps are reverse to those for removal 4 Removal amp Adjustment of of Front Hood Assembly Preparation of Tools 13 sleeve wheel wrench and extension bar 4 1 Turn and remove the four adjusting bolts off the front hood and then the front hood can be taken down And the positing of the front hood can be adjusted in all directions by loosening the four adjusting bolts 4 2 Installation of Front Hood Assembly The installation steps are reverse to those for removal Installation torque is 29 3Nm 5 Removal and Installation of Air Inlet Grid Assembly 5 1 Rem
57. period 3 The inside of after service HECU is at moisture status therefore it may not conduct the air discharge mode operation see succeeding item 56 for the definition of air discharge mode but directly conduct the air discharge operation on all wheels However in order to meet with the performance and pedal comfort it s preferable to conduct the air discharge mode operation 4 During the air discharge mode operation the voltage supplied to HECU is preferably at 10 12V However during the use of checking devices it will be OK to use the vehicle amounted battery The repeated air discharge mode operation with high voltage may damage the coil of ECU components 4 Determination Method for Vehicles with Air Discharge Trouble ECU functioning or E E iot Excessive Minor Category leakage leakage repetition required repetition required repetition required repetition required repetition required repetition required Case The status at finish of normal functioning Case 2 The status that the connection of brake HECU hole portion brake pipe brake hose 1s poor and therefore needs rework Case 3 The status same with Case 2 but it may cause the status incapable of repetition when the leakage is really severe Case 4 Internal circuit air discharge trouble of HECU It s the status necessary for repetition as the ABS may cause the sponge phenomenon after functioning for one time C cc E
58. ring or sensor Occurred when installed with non standard specification gear rings Table 3 Note D The sensor signal is not uniform when the gears are adhered with engine oil and the impurities such as slag 2 The air gap refers to the air gap between the gear ring and the sensor 3 If the malfunctions corresponding to more than 2 trouble codes can be determined after the trouble codes are deleted erasable trouble codes drive the vehicle to above 40km h to determine the malfunctions to that the trouble codes correspond and check in accordance with the registered trouble codes determine the same one trouble code Replace sensor Y ain af Wan No Isproblem lt mb om la Checking complete ben it EE Sep Replace HECU Page 20 of 38 Table 4 Note If the malfunctions corresponding to more Code than 2 trouble codes can be determined after the Possible Abnormal battery voltage trouble codes are deleted erasable trouble codes Cause Occurred when the voltage is too high or too drive the vehicle to above 40km h to determine the low malfunctions to that the trouble codes correspond and check in accordance with the registered trouble codes determine the same one trouble code Remove harness side connector and measure the voltage between pin 4 and 8 and between pin 4 and 24 when the entire vehicle circuits are On Is between _ D Measure the volta
59. s necessary to check the brake drum bearing remove the po lock nuts shown in the figure with 30 socket and torque wrench and remove the brake drum bearing Torque 250 10 Nm 4 7 Remove the handbrake cable with calliper 4 8 Remove the upper return tension spring with calliper 4 9 Remove the lower return tension spring with calliper 4 10 Depress the spring strip of the brake shoe positioning tie rod with calliper and then rotate clockwise or counter clockwise for 90 to remove two brake shoe position tie rods 4 11 Pull out two brake shoes 4 12 Remove the tension spring to separate the brake shoe 4 13 In the event of detection of over tight rear brake 1t may adjust the length of the push rod Rotate clockwise to eliminate the friction 4 14 Remove the three bolts shown in the figure with 10 ring wrench 4 15 Remove the branch pump and break it down for checking of intactness 4 Installation Procedure Refer to removal procedures IV Adjustment and Replacement of Handbrake 1 System Composition Illustration To right rear brake assembly To left rear brake assembly 1 Handle 2 Fixing bolts 3 Cable 4 5 Left Right rear wheel cable 2 Preparations Tools Ratchet wheel ratchet lever 10 13 14 16 socket 10 13 14 ring wrench vice torque wrench slotted screwdriver 3 Notices 3 1 Please wear necessary labor protection supplies to avoid accidents 3 2 Dur
60. shield push down the connector plastic lock that fixes the right front door harness butt joint 2 See Removal of A pillar Inner Shield 26 2 Unplug the plug of Right front Door harness butt joint 1 27 Removal of right front door contact switch harness 27 1 Use a cross head screwdriver to loosen off the screws that fix the right front door contact switch and then remove the right front door contact switch 27 2 Unplug the right front door contact switch plug 28 Removal of left front door contact switch harness 28 1 Use a cross head screwdriver to loosen off the screws that fixes the left front door contact switch and then remove the left front door contact switch 28 2 Unplug the left front door contact switch plug 29 Removal of the harness butt jointed with the left rear door harness 29 1 Disassemble the left B pillar inner shield See Removal and Installation of B pillar Inner Shield 29 2 Push down the plastic clips that fixes the harness connector butt jointed left rear door harness and then unplug the harness plug that butt joints the left rear door harness 30 Removal of the Interior and right rear door butt jointed harness 30 1 Disassemble the right B pillar inner shield See Removal and Installation of B pillar Inner Shield 30 2 Unplug the harness plug butt jointed with the interior and right rear door 31 Disassemble the ground wire 32 Disassemble the screws that fix the
61. side 3 When spot welding make sure zinc coating is used 4 Before air tight sealing the welded parts apply a layer of filling coating to the inner side and outer side 5 Before protecting the chassis with paint apply protective coating to protect the chassis from rock bumping 6 When the coating is sprayed all opening parts at this position should be secured with fasteners In some cases the vehicle must be placed on a hoister platform for removal of spare parts may affect the distribution of various parts in the vehicle body Before spot welding make sure the battery connector is unplugged and check if the ventilation is good enough before welding In maintaining the vehicle body in a certain area take care to protect other vehicles in this area Be particularly careful when spraying sand or welding near the oil tank or fuel system and disassemble them if the safety can not be assured When maintaining or spray painting the vehicle body take all possible measures of preventing accidents When welding galvanized steel sheets the spot welding current should be raised by 30 and the electrodes should be pointed and the clamping force of the electrodes should be increaded and when doing gas shielded welding the welding current should be further intensified Do not weld the air conditioning parts or try to weld the parts on the vehicle whose temperature are easily raised When spray painting the vehicle frame the temperature e
62. 07b 2l6b 18lb 180b Section VII Right front Door Harness ra 397 3990 234b 308k 303b 271g 1860 ERR ad Right front window Right front window witch motor Je EE 3 279 a 173 A 1860 180 18lb 6 216b 207 po RS Right front door lock gt l 6 2 357 3550 356 303b 234b 202 209 Power rearview mirror Right front loudspeaker motor Right turning light II Instructions on Main Connectors No Connector Name Pins Connection Remark I Right front door in door harness 16 In door harness connector Right front window motor connector Right front window motor Right front window switch connector Right front window switch Right front door lock connector Right front door lock Right front speaker connector Right front speaker Power rearview mirror motor right Power rearview mirror motor turning light connector right turning light III Removal and Installation of Right front Door In door Harness Part number S21 3724080 1 Removal See Removal of Left front Door In door harness 2 Installation The installation steps are rever
63. 0a 15 15a Ka 9000 Interior left front B 3 USB US WV l Ei of lel le m i S Q Electric rearview mirrors R _ P DN D D e D 0 L R Lekt NW b 1 E RIGHT Q dp Q 6 3 e 2 4 E Interior left frontB10 zr rN Interior left frontE 4 O Interior left frontB 9 A Interiot right f front 1 o Interior right AN Interior right trono front 3 S gt UL C j 3 O O p Es O C9 C f O O O 3 2 3 1 ai E O lt z Q A a Engine Anti Deterrent 30 30a 15a Ka EC X 2 za ENS LOA 104 NIA NIB GND Q F B Q OR 450093 M M Anti deterrent module ECUI1 ECU71 ha 4 cac Aa E ee 5 LV A Q x UJ znl Instrument engine Ale A Instrument engine A14 ta I O 7 Diagnosis Access an f 7 1G208 30a 15a 98k VII A C Defroster System
64. 5 The operation in item 3 air discharge should be repeated for all wheels 6 Measure the brake pedal travel If not meet with the provisions repeat the operations in item 4 air discharge mode and item 3 air discharge If the brake pedal travel doesn t meet with the provisions after the air discharge mode and air discharge are repeated for above 10 times replace with after service HECU wet type and then repeat the operations from the beginning Connect the repetition device and checking device to the HECU and again determine the existence of trouble code If with trouble code delete the trouble code and then disconnect the repetition device or checking device Page 33 of 38 Annex I Malfunction Cases and Incorrect Repair Cases 1 HECU Incorrect Repair Cases D HECU replacement relating to ABS functioning noise The HECU replacement case that deemed the noise of electromagnetic valve and motor as the malfunction during the functioning of the ABS U During the functioning of ABS the noise generated during the relieving or enhancing of the braking pressure on various wheels is of normal functioning status The noise level will vary depending on the braking pressure applied on various wheels other than the product malfunction Therefore we should persuade the customers to understand that When the vehicle reaches 10km h speed at the first time after vehicle start the sensitive customers may hear the noise at the
65. 8 fixing nuts that fix the evaporator assembly on the plate work from the front compartment See the following figures for detailed positions 2 8 Take the evaporator assembly from the driver s cab 3 Installation of Evaporator Assembly The installation steps are reverse to those for removal 4 Removal and Installation of Evaporator Interior Preparation of Tools cross head screwdriver sleeve wrench 1 Replacement of Blower 1 1 Removal Steps 1 1 1 Disassemble the blower motor relay and motor speed regulation module plug 1 1 2 Remove the blower cooling jacket 1 1 3 Push down the clip and drag out the blower clockwise 1 2 Installation Steps The installation steps are reverse to those for removal 2 Removal and Installation of Blower Speed Regulation Module 2 1 Removal Steps 2 1 1 Pull out the speed regulation module plug 2 1 2 Use a cross head screwdriver to loosen off the 2 fixing screws on Speed Regulation Module 2 1 3 Pull out the speed regulation module 2 2 Installation Steps The installation steps are reverse to those for removal 3 Removal and Installation of Heater Exchanger 3 1 Removal Steps 3 1 1 Disassemble the evaporator assembly See Removal of Evaporator Assembly 3 1 2 Disassemble the air conditioner harness See Removal of Air conditioner Harness 3 1 3 Loosen off the two fixing screws and remove the heater exchanger shield 3 1 4 Unplug the pl
66. Disassemble the tail lights See Removal and Installation of Tail Lights 3 2 Open the trunk cover and use a cross head screwdriver to loosen off the four fixing clips on the rear bumper 3 3 Use a cross head screwdriver to loosen off the three clips fixing the rear bumper bottom and the vehicle body Note Raise the vehicle with a hoister 3 4 Use an 8 torque wrench to loosen the screws connecting the wing sheet and the bumper Note Two fixing screws on either side 3 5 Pull off the connector of the rear license plate lights 3 6 Disassemble the connector of the reverse radar and remove the rear bumper assembly 3 7 Unplug the reverse radar 3 8 Use a cross head screwdriver to loosen the clip seat of the reverse radar 4 Installation Steps The installation steps are reverse to those for removal Chapter V Removal and Installation of Headlights Fog Lights amp Tail Lights 1 Preparations Tools 10 open ended wrench cross head screwdriver 2 Notes 2 1 Please wear necessary labour protection supplies to avoid any accidents 2 2 Try to avoid scratching the painted surface of the bumper when removing it 2 3 When removing the bumper in colder environment operate gently to avoid cracking it 2 4 When disassembling the headlights violent operation may damage their clips on the bumper so operate properly 2 5 Pay attention not to scratch the headlight surface when disassembling and placing i
67. E E O A tras siete hare II ert i Ata O A eO 158 II Instructions on Main Connectors ooocnocccnccnnnccnnacnnuconnnononicnnncnnoronononnnrononononronancnnoronanenoss 159 III Removal and Installation of Right front Door In door harness 159 Section A UE Rear Door FIatness ee 160 I PHar ess CC AAA A A 160 II Instructions on Main Connectors ccccccecccecccsscccecccscccussceecccuseceucceuseseescsessceecceuseseuss 161 III Removal and Installation of Right rear Door In door harness 161 D Prep ALAMOS ge 161 CY o c C 161 CIID Removal SEPSA runi Socks esta Ora needs 161 Section ES Tal Door H Ele su tasse petet tacts endear a uasa t ebrium 163 AN Ee SES EGG AA A t et et tm Mata e Ede M 163 II Instructions on Main Connectors eese eee eene eee hh nen herren esr nnn ee 164 III Removal and Installation of Tail Door In door harness emm 164 CD Preparations anena a qom do males DA E 164 ED Tor cH cc rs 164 III Removal and Installation Steps oooooonnnccnnccnnnnnnnonnnononononnnonnonconcnnccnncnnncnnonnnnnnos 164 SECHOM A De rosera NESS ao sette notae laicidad 167 o ieee EE 167 II Instructions on Main Connectors ccccccecccesccsscccesccscccesccesccessceucceussseecceuseseesceuseseuss 168 III Removal and Installation of Rear Defroster Harness eee 168 CD Preparations soo sene
68. Front Axle and Suspension System 2 Preparations Tools 8 15 18 194 socket 10 27 134 15 wrench 3 Notices 2 1 Please wear necessary labor protection supplies to avoid accidents 2 2 When carry out maintenance and repair to chassis please note that whether the safety lock of lifting machine is locked 2 3 When carry out removal installation to shock absorber spring prevent spring ejection from being injured 2 4 It s prohibited to conduct the welding and correction on the bearing components of the wheel suspension and the guiding components of the wheels 2 5 During the removal of the chassis component renew the self lock nuts and rusted nuts so as to guarantee the safety 4 Removal Installation Procedure 4 1 Removal of shock absorber assembly 4 1 1 Remove the tire fixing nuts with 19 socket or vehicle attached wrench to remove the tire take left side for instance Torque 110410 Nm 4 1 2 Remove the ABS pipeline from the fixing seat with hand 4 1 3 Remove the fixing bolts of steering joint and shock absorber with 18 socket Torque 110 10 Nm 4 1 4 Remove the three fixing bolts of shock absorber assembly from the vehicle frame with 13 socket Torque 60 5 Nm 4 1 5 Remove the shock absorber assembly 4 2 Removal of Control Arm Assembly 4 2 1 Remove the fixing bolts of front connecting rod assembly from the control arm with 15 socket Torque 100 10 Nm 4 2 2 Remove the connecting bolts
69. Interior and right front door butt joint 2 6 butt joint 2 Right front door contact switch connector Right front door contact switch harness Left front door contact switch connector Left front door contact switch harness Connected with ground wire Connector to front door harness butt joint 1 Connector to front door harness butt joint 2 10 14 0 Forming butt joint with left rear door 29 harness harness Interior forming butt joint with right rear 10 Interior forming butt joint with right rear door door Forming butt joint with left rear door In the carpet under below left A pillar Ground 1 Connected with ground wire On the left of BCM module box Ground 1 Connected with ground wire In the left ceiling handle 34 Dormer controllerconnector ES Sunroof controller harness Ground 1 Comnected with ground wire n 20 21 n 30 31 m III Removal and Installation of In door harness Part number S12 3724050 I Preparations Tools sleeve wrench cross head screwdriver flat head screwdriver II Notes When disassembling the electrical components and harness make sure to disconnect the power supply The ignition switch must be OFF III Removal Steps 1 Removal of license plate light harness 1 1 Disassemble the rear bumper assembly See Removal and Installation of Rear Bumper 1 2 Unplug the plug of the license plate light harness 2 Removal of left rear group tail Llights harness 2 1 Disa
70. Left rear speaker connector Left rear speaker harness 5 Fuel pump connector 4 Fuel pump harness 6 Right rear speaker connector Right rear speaker harness Right rear combination tail tights connector 6 Right rear combination tail lights harness BCM Module A connector BCM Module A harness BCM Module B connector BCM Module B harness Hand brake switch connector Hand brake switch harness Ceiling light connector Ceiling light harness Seat belt switch connector Seat belt switch harness Connect the instrument harness butt joint Butt jointed with instrument harness Butt jointed with instrument harness Butt jointed with instrument harness To front compartment harness connector To front compartment harness Left rear wheel ABS sensor connector Left rear wheel ABS sensor harness Right rear wheel ABS sensor connector 2 Right rear wheel ABS sensor harness Reverse radar power harness Reverse radar power connector Butt jointed with tail door harness Butt jointed with tail door harness Inside the left C pillar Ground inner shield Connected with ground wire Left rear door contact switch connector 1 Left rear door contact switch harness Right rear door contact switch connector 1 Right rear door contact switch harness 19 Inside the right C pillar inner shield Front door harness butt joint 1 Front door harness butt joint 2 iO A SE Interior and right front door butt joint 1 5 butt joint 1 ee PE EE 1
71. Maintenance Manual of Chery A113 Chassis Chery Automobile Co Ltd CONTENT Chapter EE Drake System roar a rios 4 System Checking Parameters iiniita ias Nee eege 4 Chet brake EE 4 Ne EIA NA x 4 3 Checking of brake friction lining thickness eese 4 HC Me CkKAN GOL Drake CISC TUN OUE anda 4 II Removal Installation and Overhaul of Front Brake and Brake Calliper 5 LS vstem structural Diaria 5 2 EE NN 6 Dis NOTES das 6 A RemovalandOverhaulzs aes und e reor UR Orne ic oe detinet t Ven iie ree eo dem ER coda 6 III Removal Installation and Overhaul of Rear Brake eese esee ee eee eee eee 10 System Structural Dir As 10 2g PLE PALAOS td dd roses 10 SA o RO 10 4 REMOVA PLC ULSA oia 11 As InstallattoB Procedir Gerena r N 13 IV Adjustment and Replacement of Handbrake esseeseecoescososssssseseecececocecoesoesossssssssssssseesoe 14 1 System Composition Illustration ooooononnnnnnnnnncnnnnnnnnnnnnnonononononnnoncnncnnnnnnnnnnnnnnnnnonnnnnonnnnnnnnos 14 2 ee Te EE 14 A A E 14 4 Removal Installation Procedure esses eene enne nnn nennen rrr nnns 14 Chapter 2 Adjustment of Suspension System and Four Wheel Alignment 18 I Removal Installation and Overhaul of Front Axle and Suspension 18 ll System str ctural Dott ais 18 De POPA Te EE 20 E EE 20 4 Rem
72. Removal Installation and Overhaul of Steering System eese 33 I Removal Installation of Steering Gear sesssssssssecsccccceccecceocosossosssessecececocesoesoesossssssssssessessoe 33 1 System Compositron ITUSEFat idas 33 DE A ts ao 34 Ee E 34 4 RemovalInstallauon ee 35 erte 36 II Removal Installation of Steering Column 4 eee ee eee eee eee eee eee eee neon sess easet eaae eoe 37 System Composition TMUSt SUO uico ios rro iria ka ea Pepe p bou pua 37 Dis PES PALAOS euet na D Du eco A ETS MU EM 37 IN eege 37 4 Removal e EE 38 Ss dnstallatton Procedure EE 43 III Adjustment of Steering Gear Clearance ccccccccsscsssssssssssssssssccsccscssccsccecccccsssscssscssscssess 44 IV Adjustment of Power Steering System e c eee ee eee eee eee eee eee eee eee s oe RER sss KEE EEE Een 44 Chapter 1 Brake System I System Checking Parameters 1 Check brake disc The friction surface of brake disc should be flat and has no apparent grooves otherwise brake disc should be replaced 2 Thickness checking The standard thickness of front disc ventilation disc is 17 mm with its operating limit of 15 mm when exceeding the operating limit the front disc should be replaced 3 Checking of brake friction lining thickness Standard thickness of front brake lining shall be 10 mm application limit shall be 1 mm and the remaining thickness
73. S 36 B19B20 A1648 Ala Alo A10 All Ale A13 B24 Ae B C M High potential lock High potential unlock B2 A4 B10 B4 E11 B12 BS jo Bel AS B1 B14 B15 316 Bee ME B R18 sen B13 A AS A6 a9 e Interior front 2 gt Ve Interiolr instrument Interior right na 3 2 z compartments S T T E le SES Interior left frontA3 front D Interior right rearB s SI d gt o9 lo ES fe un Interior left CU CU ou vz y wl fw y y vz fe id un P D T frontB5 Th ES SS Interior left Interior right Interior right rears c O gt 5 f t 9 frontH9 Ww lInterior left rear3 Instrument intetior et q AS Ts Airbag im Interior left Q ren ee ee bp Ta aj Ss o signal rear ae turn Interior luggage boot e PU O Ho signal signal doof 5 cg lamp lamp x 5 Starter DN e Z ds 3 O Q di Ke O R T gt hi lt S O Ge Es z d 2 mez gt gt D 5 S 21 8 g S e fe CO d fei fe Ya T at S e S S oq a a w o o o ajej 5 3 Dod m d n D D d S 2 g o gt ES c C C gg 3 s el 4 1 de T gt E E E c S sg bert 3 s a 3 front a G gt door e i S lock S 3 o c 3 e gt 5 gt a 3 L_ L BW L Gei O m Left front right front left rear window right rear window motorwindow motormotor window motor dE ec c 00 ec 101 ec 00 eccls eullec e 2c90 c01 XIV Instrument System
74. Steering System 1 Correctly connect power steering oil pipe where the tightening torque for the connector between oil return pipe high pressure oil pipe and steering gear shall be 35 3N m the tightening torque of hollow bolt connecting high pressure oil pipe and power steering pump shall be 45 3N m When filling power steering oil it is recommended to use special purpose vacuum pumping oil The specifications for filling power steering hydraulic fluid and exhaustion are described as below Fill power steering hydraulic fluid into steering reservoir assembly to the maximum level start engine at low speed idle speed to drive the steering pump the steering system will be quickly full of hydraulic fluid In the oil filling process only let engine run at idle speed to drive vane pump Meanwhile continuously add hydraulic fluid to prevent vane from sucking air due to oil level drops 2 When hydraulic fluid in the oil tank presents emulsification state or the pump emits excessive noise under normal condition max noise shall be 80 db 1t must carry out exhaustion process The exhaustion procedure 1s described as below Jack the front part of the vehicle till two front wheels are hung up start the engine turn the steering wheel to right and left till reach limit position caution after come to the limit position try not to stop even if stop never maintain over 2 seconds Repeat above action for several times until the air in the system
75. Steering rela Instrument electric box AA E A Blower switch connector Blower relay ir conditioner reconditionang Air conditioner reconditionang 5 6 l 5 NEC NEN 5 6 El IE EOS al MECO Aur conditioner switch connector Blower switch air conditioner reconditionang Inside outside circulation motor 4 Inside outside circulation motor C100 nstrument to front compartment Blower relay Ground C200 instrument to interior Ignition switch IGN2 To instrument electric box Cigar lighter Air bag connector Trouble diagnosis socket 7 9 10 11 12 13 14 15 16 1 Ground wire Ignition switch ACC C200 instrument to interior Ignition switch IGN 1 Instrument panel plug Instrument panel plug C200 instrument to interior Trouble diagnosis socket Ground Anti sheft module connector Instrument panel plug C200 instrument to interior C100 nstrument to front compartment Air bag Wiper relay To instrument electric box connector C100 instrument to front compartment Air conditioner temperature switch connector C211 instrument to interior Fog lights switch connector Ignition switch IGN2 Instrument electric box C105 instrument to front compartment 14 Ground Speaker button Blowerrelay IL LX L MEA 5 po a C105 eR to front compartment i Ignition s
76. Structural Diagram 1 Rear brake assembly 2 Brake drum 3 Rear wheel hub bearing assembly 4 Oil seal 5 End cap 6 Bolt 7 Rear wheel sensor 8 Rear brake hose retaining clip 9 Dual port pipe clip 10 Tie rod 11 Rear shoe pressure spring plate 12 Rear shoe pressure spring 2 Preparations Tools Ratchet wheel ratchet lever 10 19 32 socket 10 ring wrench vice torque wrench slotted screwdriver Accessories brake fluid 3 Notices 3 1 Please wear necessary labor protection supplies to avoid accidents 3 2 The brake liquid is one toxic liquid In event of contact with the skin or eyes due to carelessness flush with a great amount of water and if necessary call for medical treatment timely 3 3 The scrapped brake liquid should be accommodated in the container It s prohibited to drain it into the sewage system or stack with other household garbage 3 4 Do not depress the brake pedal nor move the vehicle during the removal installation operation 3 5 Do not make the friction lining or brake disc come contact with the oil substances which will impair the braking effects 4 Removal Procedure 4 1 Remove the rear wheels see the removal procedure of front wheels 4 2 Remove two position bolts from the brake drum with the cross screwdriver 4 3 Remove the bearing dust cap with slotted screwdriver 4 4 Vibrate the brake drum to remove it 4 5 Observe the rear braking structure 4 6 If it
77. adar module is located within the left guard plate of luggage boot 3 Photos of Earth Points G100 Below battery we G20 G206 near BCM G204 below right pillar CH III Instruction of Main Circuit Symbols Symbol Symbol Meaning HE 7 Fuse position and GN VM ES TOA specification Relay RAT Switch control Shield wire Resistance unit Electromagnetic coil This part is not covered within this system Note Please validate specifically the real articles with the circuits for other symbols IV Auxiliary Instruction of Circuit Diagram 1 Instruction of Power Supply and Earth Wire 30 Primary live wire from the battery 30a Primary live wire from the battery 15 From the ignition switch IGNI 15a From the ignition switch IGN2 Ka From ignition switch ACC disconnect at start 58b RHEO power supply for noctilucence illumination 30 GROUND J Earth wire from cathode terminal of the battery 2 Wire Size and Color R Red ranges W White B Black Y Yellow V Purple a Green L Blue Br Brown Gr Grey P Pink Lg Light green oe SONA d Secondary color Primary color Lead wire size mm 3 Definition of Main Controls This circuit control theory diagram uses instrument plug to in
78. adjusting knob by hand and let it stay there when you turn the key to II position 3 Push down the mode adjusting knob and keep it there for about 20 seconds before you release the knob and then the maintenance indicator will be cleared II Removal of Instrument Panel crossbeam 1 Removal Steps 1 1 Disassemble the Instrument Panel assembly See Removal of Instrument Panel 1 2 Use a 13 sleeve combined wrench to loosen off the two nuts and four bolts that connect the Instrument Panel crossbeam with the left right A pillars 1 3 Use a 13 wrench to loosen off the bolts at the place as shown in the figure 1 4 Use a 10 wrench to loosen off the four bolts at the places as shown in the figure 1 5 Use a 10 wrench to loosen off the four bolts at the places as shown in the figure 1 6 Use a 10 wrench to disassemble the two bolts of the ground wire earth at the places as shown in the figure 1 7 Loosen off the single bolt and four nuts on the side pillars See Chassis Maintenance Manual side pillars and then relase the side pillar 1 8 Disassemble all harness plugs that are connected with the Instrument Panel crossbeam For example the harness plug of the brake light switch 1 9 Take out the Instrument Panel crossbeam 2 Installation Steps The installation steps are reverse to those for removal Chapter VIII Air Conditioning System I System Constitution Air adjustment and dist
79. ake sure to protect the decoration parts from being scratched 3 Removal and Installation of Sun Visor 3 1 Removal Steps 3 1 1 Use a cross head screwdriver to loosen off the screws in the sun visor on the left of the driver s cab and disassemble the sun visor As shown in the figure Torque 3 1Nm 3 1 2 The removal steps for the right sun visor are reverse to those for removal of the left one 3 2 Installation Steps The installation steps are reverse to those for removal 4 Removal and Installation of Vehicle top Armrest 4 1 Removal Steps 4 1 1 Open the ceiling armrest screw cover over the co driver s seat by hand and then use a cross head screwdriver to loosen off the left and right fixing screws As shown in the figure Torque 9 3Nm 4 1 2 Remove the ceiling armrest 4 1 3 The removal of other ceiling armrests can follow the above steps 4 2 Installation Steps The installation steps are reverse to those for removal 5 Removal and Installation of Front Ceiling light 5 1 Removal Steps 5 1 1 Align a flat head screwdriver with the groove along the ceiling light edge to pry it open as shown in the figure Note Do not scratch part surface 5 1 2 Remove the three fixing screws of the the front ceiling light Torque 1 5 0 5Nm 5 1 3 Unplug the harness and disassemble the front ceiling light assembly 5 2 Installation Steps The installation steps are reverse to those for
80. ance between rear windscreen and trunk door at 23 23 4 1mm Rear windscreen Trunk door 104 3 3 Clearance between trunk door and rearbumper at 24 24 21 1mm Trunk door SE on bumper 3 3 Clearance between rear windscreen and tail light at 25 25 521mm No Rear fender Rear windscreen Tail light 105 3 4 Clearance between tail lights and rear fender side wall at 26 26 4 1mm Rear fender Tail light i 4 Rear fender Ss 3 5 Clearance between tail light and rear bumper at 27 27 2 1mm Tail light LO E Rear bumper 106 III Engine Compartment Dimensions NS MG Uf ES SR i E t ML Par Mn LE d EST ge SE Diameter Front bumper crossbeam mounting hole C D E F Headlight mounting hole O11 Q7 O13 Engine right suspension bracket mounting hole G H DS 076 Installation of fender Shock absorber mounting hole 107 IV Various Opening Dimensions pn Ta a ae T tt RN P d l Corner eme Up turning where the point of the roof cover rear and side windshield wal join right left right left of the rear windshield right left upper cover assembly and Inner A pillar plate right and left are the same 108
81. anism 5 1 Removal Steps 5 1 1 Remove the blend throttle bar and use a cross head screwdriver to loosen off the screws on the control panel 5 1 2 Use a flat head screwdriver to pry off the control arm 5 1 3 Remove the blend throttle 5 2 Installation Steps The installation steps are reverse to those for removal 6 Removal and Installation of Int Ext Throttle Motor amp Related Mechanism 6 1 Removal Steps 6 1 1 Unplug the motor plug 6 1 2 Loosen off the 4 fixing screws to remove the shield 6 1 3 Loosen 3 screws of inside outside circulation ventilator motor and disassemble the motor 6 1 4 Use a flat head screwdriver to pry off the plastic parts that fix the inside outside circulation ventilator 6 1 5 Remove the inside outside circulation ventilator 6 2 Installation Steps The installation steps are reverse to those for removal 7 Removal and Installation of Evaporator 7 1 Removal Steps 7 1 1 Disassemble the evaporator assembly See removal of Eevaporator assembly 7 1 2 Remove the air conditioner harness See removal of air conditioner harness 7 1 3 Disassemble evaporator water thermostat Refer to removal of evaporator water thermostat 7 1 4 Disassemble mode ventilator connection rod Refer to removal of mode ventilator motor 7 1 5 Remove the temperature control throttle bar 7 1 6 Loosen off the 9 screws on the evaporator shield and use a flat head screwdriver to pry off
82. at the presence of trouble code 0 5s For differentiation of the interval of various digits of trouble code during the display of certain trouble code for this interval the first digit is for tens digit and the second digit is for ones digit Take the process shown in above figure for instance Within the display span of the first trouble code before the presence of T4 namely 1 5s before the off of the warning lamp since the warning lamp flashes twice the duration for each on and off is both T3 namely 0 5s the first digit of the 2 digit trouble code tens digit is at 2 after the presence of T4 namely 1 5s after the off of the warning lamp since the warning lamp flashes once the second digit of the 2 digit trouble code ones digit is at 1 After that the warning lamp will be off for 3s namely T2 duration Therefore the display of first trouble code is completed with the trouble code of 21 The detailed description of the trouble is shown in the trouble code checklist in section 2 4 Also the second trouble code of 22 can be obtained 8 Deletion of trouble code without trouble diagnosis instrument After the trouble code readout and troubleshooting based on the trouble code checklist it s necessary to delete the previous trouble code before the re checking of the trouble code The condition for trouble code deletion is same with that of the trouble code readout The detailed operation method is as follows Line L 7 Igni
83. blem ke D EE P EA P Replace HECU Table 1 Note If the malfunctions corresponding to more than 2 trouble codes can be determined after the trouble codes are deleted erasable trouble codes drive the vehicle to above 40km h to determine the malfunctions to that the trouble codes correspond and check in accordance with the registered trouble codes determine the same one trouble code Harness Sensor Head Correct the pins and assemble the connector Determine and repair wiring broken portion or replace wiring Page 18 of 38 Table 2 C1 202 13 CT 205 23 Note The air gap refers to the gap between C1208 33 Cl 211 43 the gear ring and the sensor Possible Case Air gap error 2 If the malfunctions corresponding to more Air gap too big or self short circuit than 2 trouble codes can be determined after of sensor resistance value at 0 that the trouble codes are deleted erasable trouble results no signal or the gear ring codes drive the vehicle to above 40km h to not properly installed determine the malfunctions to that the trouble codes correspond and check in accordance with the registered trouble codes determine the same one trouble code Troubleshooting Flow Replace sensor Y a Is GEES No T i presen gt j GE Replace HECU Page 19 of 38 Trouble Code Possible Cause Troubleshooting Flow C1201 12 C1 204 22 C1 207 32 C1210 42 Interference of gear
84. ch Instrument electric box Instrument electric box connector instrument electric box Headlight switch Nightlight switch C100 instrument to front compartment connector C200 instrument to interior Instrument electric box Ground Brake light switch Instrument electric box connector Ignition switch IGNI C200 instrument to interior C209 instrument to engine Ground C200 instrument to interior Speaker Speaker Audio system connector Speaker Speaker C200 instrument to interior C200 instrument to interior C200 instrument to interior ANT C200 instrument to interior C200 instrument to interior ANT Antenna power connector C209 instrument to engine Air conditioner thermostat connector Right loudspeaker connector C209 instrument to engine Audio system C200 instrument to interior C200 instrument to interior Audio system bech 10 11 12 Blower power supply connector 13 14 15 Inside outside motor connector Blower relay connector Air conditioner reconditionang connector C105 instrument to front compartment connector C100 instrument to front compartment connector 1 2 Nu 3 A C switch 4 Ignition switch IGN2 5 Ground 6 A c switch 7 A 1 Ground 2 Blower switch 3 Speaker resistor 4 Ground 1 Air conditioner reconditionang 2 Blower
85. ch case the ECU will transmit the code for wheel pressure increment to the HCU namely turn on the normal open valve and turn off the normal close valve to increase the pressure of wheel branch pump During the implementation of the pressure reduction the brake liquid stored in the low pressure accumulator LPA will continue to rotate the motor to drain the brake liquid under the pressure increment status In such case the brake liquid is supplied to branch pump of various wheels via the general pump and normal open valve The brake liquid will return to the high pressure accumulator HPA in the pipeline and reduce the high pressure pulse generated by the running of the oil pump by means of the orifice hydraulic resistance Solenoid Valve Solenoid Valve Status Normal Open Valve NO Valve ot Open Normal Close Valve NC Valve OFF Close Page 8 of 38 3 3 EBD Control Mode With P Valve With EBD F Fixed Distribution Ideal Distribution Ideal Distribution In order to guarantee the operation stability the EBD function is designed in such manner that front wheels are stopped ahead of the rear wheels As the front brakes undertake more works than that of the rear brakes it will cause that the rear wheels will be stopped firstly when apply with same braking pressure In order to preventing the occurrence of above thing a device to reduce the braking pressure applied on the rear wheels under certain pressure is required
86. ctor 122 III Removal and Installation of Harness Part number S12 3724180 Tools flat head screwdriver cross head screwdriver sleeve wrench Notes 1 The ignition switch must be OFF 2 When disassembling the electrical components and harnesses disconnect the power supply 3 When disassembling common plugs connectors first press down the locking device and then separate the plug and socket by force Be careful not to pull at the wires so as not to damage the wires and connectors 1 Removal Steps 1 1 Removal of battery and air filter 1 1 1 Disconnect the battery negative 1 1 2 Loosen off the battery positive and remove the battery assembly 1 1 3 Use a sleeve wrench to loosen off the air filter fastening nuts 123 1 1 4 Use a sleeve wrench to loosen off the inlet air filter fastening nuts 1 1 5 Pull out the hose that connects the air filter and engine inlet manifold by hand 1 1 6 Remove the air filter 1 1 7 Disassemble the battery fixed mounting 1 2 The installation steps are reverse to those for removal 2 Removal of harness 2 1 Disassemble the joints of all connectors of the engine harness 2 1 1 Disassemble the connector that connects the electronic fuel injection harness with the ECU wiring harnes The removal can be carried out by pulling out the clip as shown in the figure and then the connector can be removed 124 2 1 2 Disassemble the electronic th
87. d smooth the live wrinkles from the inner side outward The hammered spots should be near the most convex part of the live wrinkles At the same time make sure the platform can support every beaten spot When the wrinkles in one side of the plate are almost smoothed turn it over to beat the other side till all wrinkles are completely spread out 4 Measure with a templet and at the same time heat and beat the convex concave part to restore it to its original shape 5 When the vehicle body is assembled test with a templet again and make finer correction to achieve the final requirements 6 The seriously damaged wrinkles that can not be restored can be excised and repaired 4 5 Welding of Four Doors and Two Covers When welding the door panel choose proper welding methods gas welding oxygen and acetylene welding CO2 shielded welding manual arc welding resistance spot welding braze welding and so on Besides in order not to reduce the original strength and durability of the vehicle body try to adopt the welding methods used in manufacturing the door panels and the dimensions and types of all weld joints should be similar to those used by the original manufacturer As for appearance and quality no burnt through spots half points cracks a lot of burrs or other defects should exist at the welded parts The welded surface should be smooth and nice looking no obvious twist or deformation is allowed and the indentation de
88. dicate the integrated relay plug of the instrument electric box This circuit control theory diagram uses ECU to indicate the engine control unit This circuit control theory diagram uses BCM to indicate the body control module 4 Pin Definition Explanation The pin definition explanation of the circuit theory diagram For instance as follows 4 Instrument interior A 6 EE of pin number indicate the differentiation of plugs with same name Indicate the name of the harness to be connected Indicate the name of the connecting harness Instrument nterior A 6 indicates the 6 pin of plug A of instrument harness and interior harness connectors 4 2 To anti deterrent module A5 indicates to 5 pin of plug A of anti deterrent module 4 3 To ECU25 indicates to 25 pin of ECU V Fuse Definition 1 Fuse Number The fuse number within the front compartment relay box is expressed by EF number and SF number The fuse number within the instrument relay box 1s expressed by F number 2 Fuse Position and Function Instruction 2 1 Front Compartment Relay Box Fuse
89. e BE 3 S QU e o e E QJ 14 I 16 15 42 E i j lt Audio d D o Y y O P V C e ME B Gm ES 8 d 9 6 L H fi e i X BINB FP gs CH L d SE 4 5 EM AH Ee O G I T CS 3 C 9 4 4 es es Q S c ue E ME E ee aO za ud da SO E das 4n rente ier m e p ye Ss Schei ch 7 Map nse EE P Interiar lefi Interior left Interiov right Irteriovright D Q frontA7 AN AN fro fronA7 EA awe o Left front Right front Left Peor m 2 Left instrument panel Right instrument panel 7 208 30 G20 e XII Headlamp Fog Lamp System D 30a e 15 15a Ka 58 e La E de SE o 16 L C To instrumentl 1 P 0 5RBr Hon e 0 96 5 Jj gt cu al El g S s d Instrument 5 de d 054 Instrument engineAS Instrument gt da S Em 0 S9RBr plug 11 To T E ES us aa 1 E 3 1 Al 1 SS ea Lam ceiling z E Ta p 6 2 3 4 e o control c lamp d switch Off me O S A 4 5 oo Fog lt Clearance Yes VAN CO lam p UD 0 96 O E S witch Ce R A Eo Swite Headlamp O O O p e S x 1 Ei 7 geng 10 Sr j R o o 20 OF p e P Q o L Oo Clearance N Front lamp O fog Rear zD O O relay lamp oe l D s Noctilucence 0 e ES Se adjustment switch e Da G r E PASS eL l nstrument 28b de 0 5GBr O 5GBr Instrument front Z v EST Instrum ent front 4 Bi 2 Instrument 0 ES E G Instrument front A6 0 89GBr S d AS ES Instrument front FA LO ZA YA ca Te SIS A S fe ce e F
90. e S NA e lane Am Je ER g ower mx harness pe RR door Fuel pump A A To front Hh gp q ae am m MM Se RR wheel SE s a a 46 3250 313d mim 030 13 Lan compartment 15350 35 h oor contact 5 6 26h r o y 4 e asa asc 290 423 o us AE HE 3 Switc RR rou tail lam p switch ABS i wc Abut joint with Harness is H 1 an group p 641 8094 42 43 314 3110 i E LR loudspeaker gt left front harness Je 2 13 4 3124 418 plan 79 3200 24 93 45 44 43 42 2713154 E 1 oO 37 312 Le Yay 150 186c 305 c 2e set 02 49 7o et 47 a8 ot E atadasa d 4 kb jen 31a je di a ge iR T 31 od pl 204 5 o 207 fp Abut Joint with It 2 38 ge d E 6420 anigo 271e aie ac RR heel ABS D a b 8o NE sw x left front harness o oo g To abut E with SE 9 JE 5 E 2 ae Cab interior sensor instrument harness g s opd ap mis ps ato A LE DT O abut joint with ae A C207 Edi mra Ceiling light E 2154 right rear door Lo 868 edr Cab interior Cab interior bo 1 T abut joint abut joint de with right with right SPECIFICATION Be S front door front door bo 1 2 d om Dormer Poo Ground controller 20 3 G lt 6 al 190 aa 102 629 308ta 260 555 556 dE III Instructions on Main Connectors Connection Remark 3 Trunk light connector 2 Trunk light harness
91. e band drum assembly 4 4 3 Remove the handbrake cable with priers 4 4 4 Remove the lock nuts from the rear brake band drum assembly with 30 socket to remove the rear brake band drum assembly Torque 180 10 Nm 4 4 5 Remove the rear axle assembly 5 Installation Procedure The installation procedure is reverse to that of removal III Adjustment of Four Wheel Alignment Please conduct the measurement and adjustment of parameters on the four wheel alignment instrument recommended by Chery Auto 1 Adjustment of Front Wheel Toe In The toe in can be adjusted by means of the optical testing instrument or mechanical toe in adjustment instrument 1 1 Depending on the requirements of the testing instrument conduct the pre adjustment preparations for the wheel alignment 1 2 Loosen the lock nuts of right steering track rod and the spring clips of protective sleeve Based on the demands rotate the toe in adjustment rod to adjust the length till reach the specified value Toe in value 6 6 1 3 Tighten the lock nuts and install the spring clips of the protective sleeve Check 1f the lock nuts are properly tightened and the protective sleeve is in right position Torque 35 3 Nm 1 4 At the finish of toe in adjustment of front wheels check the steering wheel for levelness Otherwise loosen the lock nuts of the steering wheel adjust the steering wheel to level position and then tighten the lock nuts of the steering w
92. e corrected If the backs of the metal panels are accessible hand hammers and underlay irons or spoon shaped irons tommy bars flat punches and so on can be used for primary repairs For enclosed metal panels or parts that are difficult to access from the backs other tools can be used for repairing such as slide hammers and pointed hammers Here are some common ways of dent reconditioning 1 Repair the dents with underlay irons and hand hammers the commonest practice is to beat the damaged metal panels with underlay irons and hand hammers Both sides of the metal panel to be repaired must be accessible to the hand held underlay iron and there are two ways of using the underlay iron as the supporting piece for the hand hammer 1 Beat with a hammer from above the underlay rion This approach is suitable for correcting smaller and shallower dent or breaks 85 When beating with a hammer from above the underlay rion the hand held underlay iron should be placed against the back of the metal panels and then beat the convex part The beating of hand hammer can make the metal panel contract and finally smooth the metal panel 2 Beat with a hand hammer from other parts than from directly above the underlay iron The underlay iron is placed against the lowest part of the dent and then the higher parts near the dent are beaten with a hand hammer Generally when trying to repair the dent with a hand hammer and an underlay iron the convex sid
93. e fixing bracket of the condenser from the secondary vehicle frame with 13 wrench Torque 45 5 Nm 4 3 11 Remove the four connecting nuts of secondary vehicle frame and vehicle body with 18 socket to remove the front axle assembly Torque 150 10 Nm 4 3 12 Remove the fixing bolts and nuts from the rubber sleeve of the stabilizer rod with 10 wrench Torque 50 5 Nm 5 Installation Procedure Refer to the removal procedures of front axle and front suspension II Removal Installation and Overhaul of Rear Axle and Suspension 1 System Structural Diagram Rear trailing arm assembly 7 Rear shaft welding assembly 13 2 Bolt 8 Cross stay assembly 14 3 Rear shock absorber assembly 9 Rear spring cushion 15 4 Nut 10 Rear bumper block 16 5 Bolt 11 Rear coil spring 17 6 Bolt 12 Nut 18 Nut Nut Bolt Lock nut Rear brake band drum assembly Bolt Structural diagram of Rear Axle and Suspension System 2 Preparations Tools 11 13 152 164 16 194 304 socket Slotted screwdriver priers 3 Notices 3 1 Please wear necessary labor protection supplies to avoid accidents 3 2 Notice to lock the safety lock of the elevator during the repair of the chassis 3 3 When carry out removal installation to shock absorber spring prevent spring ejection from being injured 4 Removal Installation Procedure 4 1 Removal of Shock Absorber Assembly and Shock Absorber Spring 4 1 1 Remove the tire fixing nuts wit
94. e for looseness and counter clockwise for tightness can achieve the handbrake adjustment 4 11 The installation procedure should be conducted with reference to the removal procedure Chapter 2 Adjustment of Suspension System and Four Wheel Alignment I Removal Installation and Overhaul of Front Axle and Suspension 1 System Structural Diagram The front axle of Chery S21 model adopts the split steering drive axle with MacPherson independent suspension The upper end of the suspension is connected with the vehicle body as the lower end is connected with the secondary vehicle frame The front Macpherson suspension undertakes the dual functions of driving and steering Subframe connects with vehicle body via elastic element which improves diving stability and ride comfort 1 FS Pu ae n d Ki E 8 c WER CH d e DE T uoc ES 4 T F Fe T E 4 Ar L be Le d i 1 Structural diagram of Front Axle and Suspension System m o NY QN a tA A Q WN ER a Nut 9 Gasket 10 Rubber gasket I 10 Rubber gasket II 11 Left propelling rod weldment assembly 12 Right propelling rod weldment assembly 13 Nut 14 Bolt 15 Bolt 16 Nut Left control arm Right control arm Nut Secondary vehicle frame Front strut assy Nut Front connecting rod assy Front stabilizer bar 17 18 19 20 21 92 23 24 25 Nut Nut Bolt Bolt Clamp Rubber bush Bolt Bolt Bolt Composition List for
95. e hammer on the metal pull rod and impact the handle repeatedly so as to pull up the dent gradually Make more than one holes when necessary and fill the hole s by soldering and polish the spot s when the dent s is are smoothed Electrode welding Weld a peg or a flat gasket onto the dent with a special spot welder and then use a dent smoother to pull at the peg or flat gasket till the dent is smoothed More than one peg or flat gaskets can be welded when necessary so that the whole dented area can be dragged out Finally break the peg or flat gasket and polish the welded scar with a sand mill This method can avoid drilling the metal panels and prevent potential erosion so 1t is widely used 4 2 Restoration of Stretched Parts When the metal panel is impacted the dented area would be stretched At times even proper operations can not restore it the heating contracting method is sometimes used to achieve the desired repairing effect 2 Heated position and flame intensity The effect of flame correction depends on the heated position and the flame intensity Different heated spots bring about different effects and the heated position should be where the material is deformed the most and the metal panel is stretch the most or the furthest part outward that is bent and deformed Different flame intensities also lead to different correcting effects The intenser the flame is the faster the metal panel is heated and the more concentrated the
96. e high pressure side is higher than the specified value or is too high the pressure at the low pressure side is too high the air conditioner is under refrigeration the compressor makes exceptional sounds especially when just starts the engine When turning off the engine the pressure at the high pressure side slightly rises while the pressure at the low pressure side slightly falls the air conditioner is under refrigeration High pressure side is correct low pressure side is too low AC refrigerating correct sometimes the evaporator has ice even the refrigerant quantity is correct 1 High low pressure sides are correct AC refrigerating deficiency 2 High low pressure sides are correct compressor is abnormal especially when the engine is started AC refrigerating good The reservoir can not be used The refrigerant in the refrigerant pipelines is excessive The expansion valve fails or the compressor is disabled The compressor is disabled The expansion valve fails or the compressor is disabled The transmission oil in the air conditioner pipelines is excessive Puncture The sealed part is damaged Thread of fasten part is damaged outside air entering to system Evacuate the refrigerant O If the volume of the refrigerant is normal l Replace the expansion valve 2 Refill the refrigerant to the system 3 Test the pressure again O If the refrigerant is obviously excessive 1 Refill the ref
97. e is beaten with the hand hammer and the concave side is pressed against the underlay iron First do brief correction by beating the damaged part with a wooden hammer and then do finer repairing with an iron hammer For a larger area of dent the underlay iron should be placed against the place where the dent is shallower and the hand hammer should beat the higher parts Besides the wooden hammer and the iron one should be used alternatively according to the actual situation 2 Repair the dent with a shaping spoon or tommy bar Shaping spoons and tommy bars are commonly used tools for door panel maintenance and they are customized according the characteristics of the vehicle body They can reach the limited space between door panels to push up the dent This method is suitable for the narrow room between the door panels where it is inaccessible for the underlay iron or the hammer and the shaping spoon can act as a underlay iron to distribute the impact of the hammer over a larger area 3 Restore the dent with a dent smoother The dent smoother is applied to the inner side of the metal panel and it is used for the dents that are hardly accessible to other tools and it is usually operated in the following two ways 86 i Slide hammer Flat gasket Handle Slide hammer Handle Puncturing Drill a small hole in the dent with a hand power drill and then insert a pull rod with threaded head or hook shaped head into the hole Slide the slid
98. e vehicle body However even under such condition make sure to operate the steering wheel with car in order to avoid the occurrence of accidents The vehicle will present the slippery phenomenon before braking during the turning on the slippery road will the ABS function effectively when the brake pedal is depressed at that time U The ABS will function effectively to provide certain help depending on the vehicle speed However under most conditions the outward cornering force is really big due to the vehicle inertia and therefore the body correction will have limit even the ABS is functioning Generally the tires will be applied with two kinds of forces during cornering One is the force required by driving and braking another is the force required for vehicle steering and stability maintaining In fact the driving braking and steering of the vehicle are completed though the coordination of above two forces and the two forces are in reverse ratio Therefore during the braking at cornering the braking force will be increased and the force required for steering and stability maintaining will be reduced The vehicles equipped with ABS will best coordinate these two forces For the vehicles without the ABS the steering performance and the stability are really weak as these two forces are not in good coordination However under the condition that the above two forces are really small such as off tracking due to excessive speed during the v
99. e vehicle should be parked on level and smooth road or field 4 The matched mirror surface of the headlight should be fresh of dirt 5 The power supply should work normally and the bulb should be properly installed 8 3 2 Insert a cross head screwdriver into related adjusting hole to adjust the light 8 Installation amp Adjustment of Front Fog Lights 8 1 The installation of front light The installation steps of front fog light are reverse to those for removal 8 2 The adjustment of the front fog lights The front fog lights can be adjusted by turning the device with your hand or a cross head screwdriver 9 Installation of Tail Lights 9 1 Installation steps of the tail lights The installation steps of tail lights are reverse to those for removal 9 2 The functions of the tail lights 9 2 1 Front view See right figure 1 Left rear turning light 21w 2 Brake light 21w 3 Position light 5 21w 4 Rear Fog Light 21w See right figure 1 Right rear turning light 21w 2 Brake light 21w 3 Position light 5 21w 4 Reverse indicator 21w Chapter VI Removal and Installtion of Vehicle Ceiling 1 Preparations Tools sleeve wrench cross head screwdriver flat head screwdriver 2 Notes 2 1 During the removal and installtion make sure to apply proper force and no violent operation is allowed 2 2 During removal and installation of the inner decoration parts m
100. effects D Maintain the vehicle stability on roads during the braking 2 Capable of controlling the vehicle driving direction during braking in order to avoid the occurrence of the collision 8 Maintain the best braking pressure disregarding the driving skills of the driver Why is the ABS warming lamp illuminated U After the driver starts the vehicle the warning lamp will be off when the automatic diagnosis of ABS ECU shows no trouble If the warning lamp is illuminated during driving or the warning lamp is always on it indicates the trouble of ABS Please drive your vehicle to the designated service station for checking of ABS as soon as possible However when the warning lamp is illuminated that indicates the ABS trouble the brake system still has the basic braking capability Will there be free of accident when equipped with ABS U ABS is the one device capable of increasing the driving safety rather than the device used to avoid the accidents arising from the driving mistake or variation of traffic conditions Therefore insist on the safe driving all along rather than the excessive reliance on the ABS The vehicle will lean to one side during braking on the one side slippery road is this phenomenon caused by ABS This phenomenon is resulted from the different friction coefficients between the left and right wheels on the roads Under such condition the ABS will exert the special effects on the stability of th
101. ehicle skid the force for body correction is really small Therefore the ABS will not exert the effects In conclusion deceleration in advance and safe cornering is the best method Page 36 of 38 Annex III ABS Internal hydraulic Flow Diagram A _ m pria saii ies ess r E accumulator ie i i I i Normal Open Valve Normal Close Valve at Low Pressure pem Rear Accumulator Rear Front Annex IV Connector Pin Layout of MGH 25 ABS ECU Power supply 2 Power supply 1 A TEN K zd Grounding Grounding F d O Wire wire O K line i ve Ignition EN f Ld ry A l l l l Page 37 of 38 GO eeoeoes arness side G egeeeer 7 00 06996002060 Von den PGND O Smrr ee e Grounding wire GNO Damp E U Uer Gr E RR Gomm HL D Smm T I Rear left wheel sensor HL 5mm FR emm A r Ww Front right wheel sensor ER uimme E Peis Mome Y p Front left wheel sensor ES FL 0 5mm Wheel speed output FROUT VU 5mrmr Trouble ae A oO og e E SS 5 KZ DIAC line Line Omm MGH 25 ECU ABS EBD XT Drive circuit AESIEBD Warning lamp 0 5mm IS D 5mm Ignition switch anode Brake lamp Q T SE ENS gt oN m Motor module Brake switch Battery Note Ignition switch 1 refers to the status when the key is rotated to power on the vehicle but not to sta
102. ff the fixing screws from ignition lock with 5 inner hex wrench and remove the ignition lock assembly 4 14 Screw off the 4 fixing screws from the upper end cap with 6 inner hex wrench 4 15 Remove the outer caliper with the outer caliper pliers 4 16 Remove the retainer and spring with hand 4 17 Remove the upper end cap with hand 4 18 Remove the two upper fixing nuts from the steering column with 13 socket Torque 25 3 Nm 4 19 Remove the two lower fixing nuts from the steering column with 13 socket Torque 25 3 Nm 4 20 Remove the connecting nuts of steering column and steering universal joint with 10 socket to remove the steering column assembly Torque 25 3 Nm 4 21 Remove the connecting bolts of steering universal joint and steering gear with hand Take out steering universal joint assembly 5 Installation Procedure Refer to removal procedures III Adjustment of Steering Gear Clearance 1 Place the wheels at linear driving position 2 Rotate the steering wheel towards both sides 3 If heard noise of steering gear adjust the screw as shown in the diagram until no impinge noise 1s heard when turning steering wheel 4 Tighten the screws for further 1 8 turn approximate 45 5 Carry out the road test 6 If the steering mechanism can not return to the central position by itself then loosen the bolt for 15 7 Carry out the road test IV Adjustment of Power
103. ft rear door protecting film 1 3 Unplug right rear window connector 1 4 Unplug the door lock harness connector 1 5 Unplug the elevating motor connector 1 5 Disassemble the lower right B pillar shield See Removal and Installation of Door Shield 1 6 Unplug the connector that connects the inside door harness and in door harness 1 7 Unplug door contact switch connector 1 8 Pull out the inside door harness protective rubber jacket and take out the harness assembly from inside the door 2 Installation The installation steps are reverse to those for removal Note See Removal of Right rear Door Harness for details about the inside left rear door harness I Harness Sketch Section IX Tail Door Harness Rear wiper motor D c 70 Aa 6450 6 1 4180 6450 High mounted brake light Trunk switch To defroster positive harness gt Jug L To in door 58 harness L 210 140 iz J 320 CI 645 Je o 210 200 S N 330 s 20 4 690 z 40 P 210 x 10 10 z 40 3 4180 27 70 tc 6 Gi ci ct tt ji cl 1 cr i cl n tr i tt M6 Ground II Instructions on Main Connectors Connector Name Pins Connection Remark
104. functioning during the braking at low speed U During the braking at low speed the ABS may also function depending on the road conditions and braking pressure If the ABS is always functioning at each time it s necessary to check if the sensor air gap of various wheels is too large if it has interference with the gear ring and if the tooth shape of the gear ring is damaged U Air gap adjustment method For the improper air gap after the determination of the parts related to the problem replace or grind the installation surface junction portion of the sensor to the specified air gap in the event of interference place the thin gasket onto the sensor installation surface so as to adjust to the specified air gap 2 Incorrect Repair Cases for Wheel Speed Sensor D Open circuit and short circuit related to sensor The sensor replacement case without product checking when the ABS warning lamp is illuminated and the trouble code of the vehicle is determined U The ABS trouble code is prepared based on the ABS products Therefore during the open circuit or short circuit of the sensor it s necessary to conduct the problem checking such as confirm the connection status from the ECU to the wiring and connectors of the sensor measure the sensor resistance and etc During the malfunction checking of sensor it s preferable to use the tetrastyle jack which will facilitate the confirmation of short circuit problems such as the pinned wiring Pa
105. g of harness side pin 25 drive the vehicle to above 40km h to determine the malfunctions to that the trouble codes correspond and check in accordance with the registered trouble codes determine the same one trouble code Confirm if the harness side pin 25 and the terminal in the fuse box are connected zm a t j J hy e Is it on e ege pr E ai Yes T Confirm if the valve fuse 30A in the fuse box is broken Check and replace the wiring of harness side pin 25 X No Is fuse 30A 5 E Check and replace the valve lt normal BW M Yes d ES Confirm the assembling status and pin displacement of pin 25 of harness side connector em Bu ec m Adjust the connector pins and Is status good Be correctly assemble connector Forced drive the HECU with diagnosis instrument valve relay and motor start we n e i No e Is forced drive good Replace HECU M Si Re check from item 1 Page 23 of 38 Table 7 Note If the malfunctions corresponding to Possible Cause Malfunction of ECU internal circuit more than 2 trouble codes can be determined and valve coil after the trouble codes are deleted erasable trouble codes drive the vehicle to above 40km h to determine the malfunctions to that the trouble codes correspond and check in accordance with the registered trouble codes determine the same one trouble code Troubleshooting Flow Remove the ha
106. ge 9 4V 17V 5 between battery terminal gt and s a Yes I Confirm the assembling n Measure the resistance nd pin displacemen a PES between the harness side status and pin displacement Is below 9 4V of harness side connector pin connector pin 4 and 4 8 and 24 Be a battery terminal E No Check and replace ern e Soe Check and GE Is below 1 2 4 replace wiring Yes ts Adjust connector pins l j c Is status good Correctly assemble Confirm ma check grounding status of harnes connectors side connector pin 8 and 24 2 P s m Adjust status of Z Is status good grounding terminal 5 S P bn Ce o s K un D z E Measure the voltage between pin 4 and 8 and between pin 4 and 24 when the entire vehicle circuits are on 48 inc No Re check from e Is above 17V 4 item am Replace AC generator Page 21 of 38 Trouble Code C2 402 55 Possible Cause Malfunction of motor fuse motor Troubleshooting Flow 1 After the harness side connector is removed confirm if the harness side pin 25 and the grounding wire are connected t D S Isiton a S Table 5 Note If the malfunctions corresponding to more than 2 trouble codes can be determined after the trouble codes are deleted erasable trouble codes drive the vehicle to above 40km h to determine the malfunctions to t
107. ge 34 of 38 The union status of the sensor must be checked before the removal of the connectors of connecting wiring such as incomplete union pin displacement with impurity and etc After confirm that the sensor resistance and head are free of abnormalities centrally check the wiring and connectors 2 Notices for sensor checking Case of sensor head line break arisen from over pulling of sensor cable U When the connectors are removed during the checking of sensor the instantaneous pulling of cable under the condition that the sensor head is fixed will cause the falloff of the internal cable of the sensor head to cause line break problem Therefore during the checking of sensor do not pull the cable with the force above the specified one Sensor head cable It may be damaged when applied with above 12kgf tension force Cable at connectors it may be damaged when applied with above 4 5kgf tension force Page 35 of 38 Annex II ABS Basics Will the braking distance be shortened when equipped with ABS U The testing data show that the braking distance will be shortened on most road conditions approximately 5 20 However under some special road conditions such as snowy road non asphalt road and rough road the braking distance will be lengthened However the steering stability can be guaranteed What s the main objective of ABS U The main objective of ABS is to prevent the wheels to be locked which has following
108. gnter WS DA Alarm switch LOA Front wiper E gt H VA Clearance lamp ceiling lamp JA Steering power supply A C relay coil Se Vacant SCH oe S ELO LOA Horn foa lamp Ge Vacant 19 CUA Audio device E A Air Bag 14 104 Braking Lamp E DA ABS control GE LUA liagnosis Access ET OA Rear view mirror broke switch BCM Fle COA Start 1 IA MBINED INSTRUMENTS Chapter 2 Circuit Control Theory Diagram I Starter Charging System BS 512 2006 circuit diagram GA c ILL 08 30 Instrument front B2 40A T Sm nstrument front B3 IGNI 15 2 OP S4 E IGNe 15a va amp F18 cd S 104 e e E Instrument front D F103 g PI ji 20 o v REVERSE LAMPS e number Vehicle speed sensor 20130 115 15a ACC Ft ds 25A o instrument charging indicator FE amp ACC o o N O O O C Regulator 4 ST o o 0 O a Ignition Switch da AAA UN ZX ZN j 16 08 InstrumerPengine B1 gt gt lt gt AS ECU engine 2 SS on TX ZX TX Kam A m Interior instrumentB1 F a To mE B m BCM NM B M AA Motor SE ee
109. h fk LLIMBI LAMP AN oer HS G THB DU7061 2 3 2l 313 Ignition I switch HS C 2017001 TM L THB DJ623 E6 3 TNL DAeel Co306 II Instructions on Main Connectors Combination instrument connector Connection Instrument to interior Anti sheft module instrument to engine Ground Ground Fog lights c200 instrument to interior 10 11 12 13 C200 instrument to interior C209 instrument to engine C209 instrument to engine Instrument electric box Instrument to interior c200 Ignition switch IGNI 14 15 16 17 18 19 20 2 22 29 24 25 26 27 28 20 30 3l 32 Left loudspeaker connector Fog light switch connector C100 instrument to front compartment Trouble diagnosis socket C209 instrument to engine Air bag C209 instrument to engine C200 instrument to interior C209 instrument to engine C200 instrument to interior Headlight switch C209 instrument to engine Headlight switch C100 instrument to front compartment C100 instrument to front compartment C209 instrument to engine Instrument electric box C209 instrument to engine Air bag Fog lights switch instrument to front compartment Audio system C200 instrument to interior C200 instrument to interior Audio system Ground instrument to front compartment C200 instrument to interior C200 instrument to interior C100 Headlight swit
110. h 19 torque wrench or vehicle attached wrench to remove the tire take left side for instance Torque 110 10 Nm 4 1 2 Remove the connecting bolts of shock absorber assembly and rear axle with 18 socket Torque 100 10 Nm 4 1 3 Remove the connecting bolts of shock absorber assembly and vehicle body with 18 socket to remove the shock absorber assembly Torque 100 10 Nm 4 1 4 Pry out the rear coil spring with screwdriver 4 1 5 Vibrate from side to side with force with hand to remove the rear bumper block 4 2 Cross Stay Assembly 4 2 1 Remove the connecting bolts of cross stay and left side of vehicle body with 16 socket Torque 100 10 Nm 4 2 2 Remove the connecting bolts of cross stay and right side of vehicle body with 15 socket to remove the cross stay assembly Torque 100 10 Nm 4 3 Rear Trailing Arm Assembly 4 3 1 Remove the connecting bolts from the rear side of rear axle and trailing arm assembly with 13 socket Torque 100 10 Nm 4 3 2 Remove the connecting bolts from the middle side of rear axle and trailing arm assembly with 13 socket Torque 100 10 Nm 4 3 3 Remove the connecting bolts of trailing arm and vehicle body with 15 wrench to remove the rear trailing arm assembly Torque 100 10 Nm 4 4 Removal of Rear Axle Assembly 4 4 1 Remove the connecting bolts of brake pipeline and rear axle with 11 socket Notice the storage of brake liquid Torque 16 3 Nm 4 4 2 Remove the rear brak
111. haft sensor connector Oil nozzle harness connector Ground Ground To ECU harness connector To ECU harness connector To ECU harness connector Ground To ECU harness connector To ECU harness connector To ECU harness connector To ECU harness connector Ground To ECU harness connector Ignition coil connector To ECU harness connector To ECU harness connector To ECU harness connector To ECU harness connector Ground Electronic throttle 3 connector 4 121 To ECU harness connector To ECU harness connector To ECU harness connector Water thermostat Ground To ECU harness connector connector To ECU harness Engine rotation speed GE 8 P To ECU harness sensor connector connector 3 FE 1 To ECU harness connector Rear oxygen sensor Ground 11 connector Ground 4 To ECU harness connector 1 To ECU harness connector Front oxygen sensor Ground 12 connector 3 Ground 4 To ECU harness connector 1 To ECU harness connector 13 Vehicle speed sensor 2 To ECU harness connector connector 3 To ECU harness connector 14 Starter controller 1 To ECU harness connector connector 1 To ECU harness connector 15 Knock sensor connector 2 To ECU harness connector 16 Oil pressure switch To ECU harness connector connector 1 To ECU harness 17 Compressor connector connector 18 Power steering pump l To ECU harness switch connector connector l 1 Ground weee E E a connector conne
112. hat the trouble codes correspond and check in accordance with the registered trouble codes determine the same one trouble code Confirm if the harness side pin 25 and the terminal in the fuse box are connected Check and replace the wiring of harness side pin 25 um siton s o Check and replace the wiring of o EE harness side pin 25 Confirm if the valve fuse 30A in the fuse box is broken vw Ex Yes No Qm e Is A Check and replace the valve fuse f Confirm the assembling status and pin displacement of pin 25 of harness side connector ET Is status good Forced drive be Adjust the connector pins and correctly assemble connector the HECU with Is status good diagnosis instrument valve relay and motor start Yes a d Be D s T e Is forced drive good ke Replace HECU M No EL p Re check from item 1 Page 22 of 38 Trouble Code C2 112 54 Possible Cause Malfunction of valve fuse and relay a Broken of primary relay or fuse Table 6 Note If the malfunctions corresponding to more than 2 trouble codes can be determined after the trouble codes are deleted erasable trouble codes b Short circuit of primary relay Troubleshooting Flow 1 After the harness side connector is removed confirm 1f the harness side pin 25 and the grounding wire are connected p e Isiton D Check and replace the wirin
113. he diagnosis status of which the method is as follows At finish of the diagnosis operation disconnect the grounding status of the line L rotate the key to power off status and then re connect 2 Readout method of trouble code without trouble diagnosis instrument Read out the trouble code in accordance with following procedure when the service conditions for trouble code readout without trouble diagnosis instrument are met Line L Ignition Switch T3 T3 T3 T3 T3 T3 T3 T3 T3 T3 Mie RI err eh ord m lamp M 99 The display will be repeated without any new trouble code A D C L E P The steps in above figure are respectively A Rotate the vehicle key to power on position after the line L is grounded B When the ABS warning lamp illuminates and lasts for 3s it indicates the start of diagnosis C When the ABS warning lamp is off for 3s it indicates that it enters into the trouble code display phase D Trouble code display and readout E When the ABS warning lamp is off for 3s it indicates that it enters into next trouble display phase or circulated display phase F The display and readout of new trouble code and the circulated display of last trouble code Page 15 of 38 The meaning of symbols in the figure is as follows Code Symbol Description Duration For differentiation of the duration of various trouble codes during the display of multi trouble codes Flashing interval of warning lamp
114. he fixing screws of the shield 1 3 Use a flat head screwdriver to pry open the shield at the hand brake and gears Note Please pry carefully 1 4 Use a cross head screwdriver to remove the two fixing screws below the shield 1 5 Take out the gear selector shield upward by hand The shield and the auxiliary Instrument Panel are fixed with clips and no fixing screws are used 1 6 Use a cross head screwdriver to remove the front fixing screws of the auxiliary Instrument Panel One on the left and the other one the right 1 7 Use a cross head screwdriver to remove the rear fixing screws of the auxiliary Instrument Panel One on the left and the other one the right and then the suxiliary Instrument Panel can be dismounted 2 Installation Steps The installation steps are reverse to those for removal IV Removal and Installation of Vehicle Carpet Tools flat head screwdriver cross head screwdriver sleeve wrench 1 Removal Steps 1 1 Dismount the seats See Removal of Seat 1 2 Disassemble the auxiliary Instrument Panel See Removal of auxiliary Instrument Panel 1 3 Remove the seat belt shield See Removal of Seat belt 1 4 Remove the front rear sill plates B pillar and the lower shield 1 5 Use a flat head screwdriver to pry up the top cover of footrest plate 1 6 Use a 10 wrench to remove the footrest plate covers Installation Torque 7 1N m 1 7 Remove the rear seat cushion See Remova
115. he installation steps are reverse to those for removal I Harness Sketch SS in door harness B 233b 1711 1721 1840 1850 2070 1820 1810 1800 2lbo i Section VI Left front Door Harness Her REF 201 ent 186 353 To in door harness A Left front window motor l tate 1800 186 1850 1840 Left front window switch 1721 1711 308e e7iF 183a 1820 fe SN l6 9 q 17 72 f 1 2160 318g e e e 2070 201 3 Left front door lock Left front loudspeaker 352 355 353 302f 233k Power rearview mirror motor Left turning light II Instructions on Main Connectors Connector Name Pins Connection Remark To in door harness B connector MEM In door harness B Left front window motor connector EM Left front window motor Left front speaker connector EN Left front speaker 10 2 Left front window switch connector 16 Left front window switch To in door harness A connector In door harnessA 2 3 4 2 Power rearview mirror left turning Powe
116. he rear seat and the seat back can be released forward Take the left rear seat as an example 2 5 Use a 13 socket wrench to loosen off the two fixing bolts below the seat back Take the left rear seat as an example Torque 25 3Nm 2 6 Open the trunk and take out the trunk vehicle carpet 2 7 Loosen off the fixing seat of the spare tire and take 1t out 2 8 Use a 13 socket wrench to loosen off the fixing bolts in the rear seat back and then the rear seat back can be removed Torque 25 3Nm 3 Installation Steps The installation steps are reverse to those for removal III Removal and Installation of auxiliary Instrument Panel Preparation of Tools cross head screwdriver flat head screwdriver Removal Steps 1 1 Use a flat head screwdriver to pry open the shield at the hand brake and gears 2 6 Open the trunk and take out the trunk vehiclepet 2 7 Loosen off the fixing seat of the spare tire and take 1t out 2 8 Use a 13 socket wrench to loosen off the fixing bolts in the rear seat back and then the rear seat back can be removed Torque 25 3Nm 3 Installation Steps The installation steps are reverse to those for removal III Removal of auxiliary Instrument Panel Preparation of Tools cross head screwdriver flat head screwdriver Removal Steps 1 1 Use a flat head screwdriver to pry open the shield at the hand brake and gears 1 2 Use a cross head screwdriver to loosen off t
117. headlight switch connector ignition switch connector nightlight switch connector and fog light switch connector See Removal of Instrument Panel for detailed removal methods 1 1 3 When disassembling the combination instrument please disassemble the harness plug connectede with the combination instrument See Removal of Instrument Panel for detailed removal methods 1 1 4 Unplug the left right loudspeaker and the brake switch connector 1 1 5 When disassembling the instrument panel crossbeam please disassemble the inside outside circulation motor connector of the air conditioner evaporator blower power supply connector blower relay connector air conditioner reconditionang connector and anti theft module connector See Removal of Evaporator for detailed removal methods 1 1 6 Disassemble the two connectors of the instrument harness and the front compartment harness as shown in the right figures 1 1 7 Disassemble the two connectors of the instrument harness and the interior floor harness as shown in the right figures 1 1 8 Disassemble the two connectors of the instrument harness and the engine wiring harnes as shown in the right figures 1 1 9 Unplug the blower relay steering relay and wiper relay as shown in the right figures 1 1 10 Unplug the instrument electric box connector as shown in the right figures 1 1 11 Here is the failure diagnosis socket 2 Installation of instrument panel harness T
118. heat is and then the stronger the contracting capability is The low carbon steel panel for example should be heated till it gets cherry red 600 C 800 C 2 Heating ways normally adopted for flame correction in the vehicle body maintenance are 1 Spot heating The heated area is a round spot of a certain diameter which is usually 15 30mm One or more spots can be heated according to the actual deformity situation When more than one spot is heated the spots are arranged in a plum pattern And this way 1s often used for contracting the convex area in the middle of the panel 2 Triangle heating The heated area resembles a triangle and this way is often used for correcting strip shaped materials and deformed panel edges 87 Stretched area Triangle heating 3 Cooling contracting way When the flame is taken away proper cooling ways should be chosen according to the stretched degrees of the metal panels Different cooling ways bring about different contracting effects 1 Natural cooling contracting or cooling in the air naturally which is suitable for smaller areas of deformities 2 Water cooling or covering the heated area with wet cotton cloth to make it cool suddenly The contraction of metal plate cooled in this way 1s larger than that of the naturally cooled one but 1t may make the steel panel fragile 3 Natural cooling and hammering usually operated with a hand hammer and a underlay iron During the opera
119. heel to the specified torque 2 Adjustment of Front Wheel Camber Angle 2 1 Under normal conditions it s unnecessary to adjust the camber angle after the assembling of independent suspension and wheel steering joint In case the wheel camber angle is out of the tolerance scope due to other reasons it may be calibrated by means of the connecting bolts of independent suspension and steering joint Front wheel camber angle 0 87 50 2 2 Before the calibration check visual observation the driving system components for damage and replace the damaged parts 2 3 In case the front wheel camber angle is out of tolerance loosen the connecting bolts of front shock absorber and steering joint and move the wheels for correction 3 Adjustment of Caster Angle and Kingpin Inclination The caster angle and the kingpin inclination are guaranteed by the designed structure and are free of adjustment during use Caster angle 3 4 30 Kingpin inclination 12 7 If the parameters are out of the specified range replace the steering joint 4 Adjustment of Rear Wheel Alignment Parameters All of the rear wheel positional parameters shall be guaranteed through design process 4 1 Rear wheel camber angle 0 30 4 2 Rear wheel toe 1n 0 10 4 3 If the deformation of rear shaft arising from the great impact force causes the change of rear wheel alignment parameters that out of the specified range correct the rear axle or replace the rear
120. hort circuit of left rear 11 front sensor 31 sensor C1 201 Interference of left front sensor or Cl 207 Interference of left rear sensor or gear 12 gear ring 32 ring ON Air gap error of left front sensor SC Air gap error of left rear sensor C1 203 Open circuit short circuit of right Cl 209 Open circuit short circuit of right rear 21 front sensor 41 Sensor Interference of right front sensor Interference of right rear sensor or Or gear ring gear ring Air gap error of right front sensor Air gap error of right rear sensor Battery voltage too high above Trouble of electromagnetic valve fuse 17V or electromagnetic relay C1 102 Battery voltage too low below C2 402 52 9 4V 55 Trouble of motor fuse or motor C1 604 Trouble of ECU internal circuit or 53 electromagnetic valve coil Page 17 of 38 2 Trouble checklist of trouble code Trouble Code Possible Case C1 200 11 C1 203Q1 C1 206 31 C1 209 41 Open circuit short circuit of sensor At short circuit or open circuit of battery anode or cathode of sensor Remove the connector from the harness and sensor confirm the assembling status and check the pins for deviation ui No Is status good a a a Ch m a Determine if the two lines between harness side pin A and connector B of sensor assembly are powered Troubleshooting Flow i No Is powered onm S S gt Is the pro
121. icle body ground wire On the tail door 1 1 10 Removal of tail door in door harness 2 Installation The installation steps are reverse to those for removal and special auxiliary tools thin steel wire can be used to accomplish it Section X Defroster Harness I Harness Sketch Rear defroster Harness to tail door negative Loi 40 158 AN j Ground Rear defroster negative 645c II Instructions on Main Connectors No Connector Name Pins Connection Remark Defroster positive Defroster positive connector Defroster negative Defroster negative connector Tail door harness Tail door harness connector Vehicle body ground wire DR Vehicle body On the tail door IIl Removal and Installation of Rear Defroster Harness Defroster harness positive part number S12 3724530 Defroster harness negative part number S12 3724540 D Preparations Tools sleeve wrench cross head screwdriver flat head screwdriver II Notes When disassembling the electrical components and harness disconnect the power supply The ignition switch must be OFF III Removal Steps 1 Unplug the defroster harness connector 2 Unplug the left rear defroster connector 3 Unplug the right rear defroster connector IV Installation Steps The installation steps are reverse to those for removal Mai
122. iew 2 1 Clearance between front bumper and front fender at 5 5 Oo mm Bumper Front fender 2 2 Clearance between front hood and front fender at 6 6 4mm I Front compartment cover E m g Front fender Ol WE O O Qu sl 4 25 2 3 Clearance between front fender and A pillar side wall at 7 7 3mm A pillar N Front fender No o o 1 2 4 Clearance between front fender and front vehicle doors at 8 8 mm ep Front fender y i SCH um N Front door 96 2 5 Clearance between front door and A pillar Side wall at 9 9 5 1mm Vehicel roof A pillar ze V o e Front door Front door 97 2 7 Clearance between front door and rear door at 11 11 CH em A J S o Front door d JL 2 8 Clearance between front door and rear door at 12 12 CH mmi H Rear door UN e L J O O ll A JI Fr nt door P I Rear door 2 9 Clearance between rear door and rear fender side wall at 13 13 0 mm
123. ing pressures and then shape it and polish the seam with a grinding machine 4 4 Restoration of Wrinkled Parts Depending on the damage extent of the plate work pieces the wrinkles are divided into live wrinkles and dead wrinkles The live wrinkles are slight ones and can be directly removed by beating the convex part with a hammer The dead wrinkles refere to seriously damaged parts Since the wrinkles are folded and pressed against each other so if you hammer the most convex part the wrinkles would get even more seriously and harder to release hence the name dead wrinkles The principle of correcting the wrinkles is to spread dead wrinkles first so that they become live wrinkles and then live wrinkles are converted into convex concave shape and finally restore the damaged parts just as you deal with convex concave damages The repairing steps are as follows 1 First use support draw method to apply a correcting force in the direction opposite to that of the impact at the wrinkled part of the plate work and then spread and ease the wrinkles 2 Remove the wrinkled plate work and lay it on a platform and then beginning with the inner side of the wrinkled area pry up the wrinkles with a proper prying tool and heat the dead wrinkles one by one with a welding torch at the same time Finally all dead wrinkles are pried up and eased and converted into live wrinkle 3 Beat an
124. ing the removal installation of the spring parts enough cautions should be taken to prevent the ejection of such parts from causing body injuries 3 3 The removal installation at the vicinity of the exhaust pipe must be conducted only after the temperature of the exhaust pipe is lowered to normal temperature so as to prevent scald 4 Removal Installation Procedure 4 1 With reference to the removal installation of the rear brake loosen the handbrake cable of the rear wheels 4 2 Remove the handbrake clip with priers Notice It s under the rear wheels 4 3 Remove the fixing bracket bolts of the handbrake cable shown below with 8 ring wrench Torque 9 12 Nm 4 5 Pry out the protective cover at the handbrake and gear position with slotted screwdriver 4 6 Remove all fixing screws from the secondary instrument panel assembly with ring screwdriver to remove the secondary instrument panel assembly 4 7 Remove the handbrake adjustment nuts with 10 wrench 4 5 Loosen the two handbrake cables with hand 4 9 Pull out the handbrake cable from the underside of the vehicle body Notice Remove the handbrake cable at another side in accordance with the same method 4 10 Handbrake adjustment The length of the handbrake cable equipped on this model is designed to be the fixed length To adjust the handbrake effects refer to the part removal of rear brake The adjustment of the ejector rod length clockwis
125. is removed confirm if it s powered between the harness side pin 7 and vehicle diagnosis connector pin 7 Check and replace wiring of harness side pin 7 Confirm if the ABS ECU fuse 10A in the fuse box is burnt i i No l Is fuse 10A Check and replace ABS Cf normal EC U fuse LT i uc UU d Yes Correctly connect the harness side connector and confirm the communications e With Check and replace communications diagnosis instrument wi Yes ki Qu E After the trouble number is determined take measures based on the troubleshooting for various trouble numbers Page 29 of 38 IV Air Discharge and Oil Refill 1 Regular Operation Procedure Add brake fluid On e Off 20 bar 100 pai Vacuum On Off Motor On Off Normal Close Valve On Off Procedures The regular operation procedure of air discharge and oil refill is shown in the figure of which Move the vacuum device and brake oil refill device Start after connected with vacuum and brake oil refill device and SDL Drive normal close electromagnetic valve and apply the 1 vacuum Excessive leakage test Minor leakage test after the 1 vacuum cut off Applicable for 2 vacuum and drive motor After the oil refill and maintaining of pressurization on the brake oil relieve the brake oil pressure stop the normal close electromagnetic valve and motor and adjust the brake oil level H Disconnect the vacuum de
126. itch 20 2 Unplug the right rear door contact switch plug 21 Removal and removal of left rear door contact switch harness 21 1 Open the left rear door and disassemble the crews that fix the contact switch with a cross head screwdriver and then remove left rear door contact switch 21 2 Unplug the left rear door contact switch plug 22 Disassemble the rigth C pillar inner shield and then disassemble the ground wire 23 Removal of left front door harness butt joint 1 23 1 Disassemble the left A pillar inner shield and push down the plastic lock that fixed the connector of the left front door harness butt joint 1 See Removal of A pillar inner shield 23 2 Unplug the plug of the left front door harness butt joint 1 24 Removal of the left front door harness butt joint 2 24 1 Disassemble the left A pillar inner shield push down the plastic lock that fixes the connector of left front door harness butt joint 2 See Removal of A pillar Inner Shield 24 2 Unplug the plug of left front door harness butt joint 2 25 Removal of interior and right front door butt joint 1 25 1 Disassemble the right A pillar inner shield and push down the plastic lock that fixes the right front door harness butt joint 2 See Removal of A pillar Inner Shield 25 2 Unplug the plug of right front Door harness butt joint 1 26 Removal of interior and right front door butt joint 2 26 1 Disassemble the right A pillar inner
127. ither in the drying oven or the pre heating oven should not go beyond 80 C Take the following measures during welding operation to prevent shaking the electronically welded equipment 1 Connect the grouding of the electronic welding equipment directly to the welded parts And check to make sure no other parts or insulative parts exists between the ground wiring connector and the spot welded parts 2 First disassemble the ECU and prevent the electronic device or circuit from contacting the ground wiring connector or welding wire Corrections The vehicle body and the chassis are manufactured off the production line by low temperature tempering and cold die casting Therefore when the metal parts are damage in any accident the same processes must be used to restore them and no heating is allowed If they are damaged very seriously and can not be restored the damaged parts must be removed after the connecting surface is corrected The car bodies are made up of various members pressing panels and other parts of which the doors are the most complexly processed parts of the vehicle body They involve processes like part stamping and welding assembly of spare parts and assemblies for which the dimensional fits and technical requirements are quite 82 strict so the car doors are difficult to maintain and the quality requirements are fairly high and only the service personnel understand the structure of the car doors thoroughly and are qualified f
128. itions of the door panels as related to other assemblies of the vehicle body as well as the dimensions of their tolerance clearances should be tested 83 2 Clean the vehicle doors Use fresh water or detergent to clean the dirt and greasy spots on the door panels and let them thoroughly dry for tests 3 Maintenance appraisal Appraise the scope and degree of damage to the door panels by testing and decide the maintenance methods 4 Clear the old paint Before cleaning or maintenance get rid of the old paint according to the actual situation especially when there exists obvious rust cracks or dents The paint can be got rid of in manual heating mechanic or chemical metchod s Painted Welding torch surface Scraper 5 Tests after the removal including the measurements of the geometric dimensions between various plate work pieces tests of specific damage spots of various plate work pieces recognition of damage types analyses of damage causes and choices of maintenance schemes 3 Main Contents of Door Panel Maintenance Generally speaking the causes of door panel damages are related to the following 4 aspects structure design defects manufacturing defects chemical erosion and physical damage And the most common damage causes can be classified as the following types 1 Abrasion The surfaces of plate work pieces may contact each other and relative movements will take place and cause surface friction which
129. l Yes Replace harness connector or HECU e Damage of gear ring e Damage of wheel bearing e HCU damage of ABS e ECU damage of ABS bg Checking complete Replace HECU or connector Page 27 of 38 Table 4 Trouble Brake pedal travel too long Possible Cause e Improper adjustment of handbrake e Leakage of brake liquid e Severe wearing of brake friction disc e Leakage of normal close valve e Air in the system Troubleshooting Flow Check hydraulic pipe connector for leakage Ea No Having leakage bn ue Yes y Tighten pipe connector to _ 120 160kgf cm m Check wearing of brake disc No _Is it normal Replace brake disc EA Yes Y Check handbrake regulator X No E a _Is it normal 5 s Replace handbrake regulator on d W Le E E M Yes Air discharge checking e Isi normal Re conduct the air MARC discharge E E E a Yes Ba Page 28 of 38 Trouble Evidence Possible Cause Troubleshooting Flow Table 5 Without diagnosis code output communication failure with trouble diagnosis instrument e Problem of diagnosis instrument e Burn of fuse e Broken of diagnosis line or loosening of connector e ECU damage of ABS Confirm the connection between the diagnosis instrument connector and vehicle diagnosis connector vu zd T lt s it normal2 Correctly install the MM connector After the harness side connector
130. l of Seats Use a cross head screwdriver to remove the left shield of the rear seat cushion 1 8 Take down the vehicle vehicle carpet by hand 2 Installation Steps 2 1 Put the vehicle vehicle carpet inside the vehicle and take out the harness connected with the seats and then press the vehicle vehicle carpet besideds the middle passage tightly 2 2 Keep the seat holes visible 2 3 Spread the vehicle vehicle carpet till it gets to the footrest plate and press it tightly 2 4 Spread the left rear part of the vehicle vehicle carpet according to the shape of the vehicle floor keep the installation holes of the left rear seats visible and spread and press the rear part of the vehicle vehicle carpet according to the shape of the vehicle floor V Removal of Damping Mat 1 Removal Steps 1 1 Remove the vehicle vehicle carpet See Removal of Vehicle Vehicle carpet 1 2 Take down each damping mat 2 Installation Steps 2 1 The installation steps are reverse to those for removal 2 2 Notes When installing sort out the harness and at the same time the damping mat should fit well with the vehicle body plate work Chapter III Removal amp Maintenance of Vehicle Doors I Removal Installation amp Maintenance of Front Doors 1 System Constitution Diagram 2 Preparations Tools flat head screwdriver cross head screwdriver 10 13 sleeve wrench and pliers 3 Notes 3 1 Please wear neces
131. le the Instrument Panel See Removal and Installation of Instrument Panel 12 2 Unplug the instrument harness butt joint 13 Removal of instrument harness butt joint 13 1 Disassemble the Instrument Panel See Removal and Installation of Instrument Panel 13 2 Unplug the instrument harness butt joint 14 Removal of front compartment harness connector 14 1 Disassemble the Instrument Panel See Removal and Installation of Instrument Panel 14 2 Unplug the front compartment harness plug 15 Removal of left rear wheel ABS sensor harness 15 1 Raise the vehicle by hoister Take care of your safety 15 2 Unplug the left rear wheel ABS sensor connector 16 Removal of right rear wheel ABS sensor harness 16 1 Raise the vehicle by hoister Take care of your safety 16 2 Unplug the right rear wheel ABS sensor connector 17 Removal of reverse radar power harness 17 1 Use a cross head screwdriver to remove the left C pillar inner shield 17 2 Unplug the reverse radar power plug 18 Removal of the tail door harness butt jointed harness 18 1 Disassemble the left C pillar inner shield 18 2 Unplug the tail door harness butt jointed harness 19 Disassemble the ground 20 Removal of right rear door contact switch harness 20 1 Open the right rear door and disassemble the crews that fix the contact switch with a cross head screwdriver and then take off the right rear door contact sw
132. lehal Lamy SM a 23 XL Radio Player Horn Cigarette Lighter iii praeter pee ete gege 24 KIT Headlamp boe Lamp Mit ti 25 PUT SES CNS E E 26 ALY neng EE 27 XV 473 Engine and Electric Injection SysteM snenia a a aa 28 Chapter 1 Illustration Instruction I Definition of Main Harness Inserters Engine ECU inserter of engine harness and ECU harness 1o E ce die e SE Ee A T9539 S ECU front plug of ECU and front compartment harness H i 0 4 3 2 16 15 14 13 1j 11 10 9 zCU instrument plug of ECU and instrument harness V 2 3 4 J 0 1 9 10 11 K 13 14 Interior instrument A plug A of interior harness and instrument harness IE wh EE IA doses E E VA A Ia ad Interior instrumentB plug B of inte harness and instrument harness gt l 4 3 Interior tront plug of interior harness and front compartment harness 14 12 ii 10 Instrument engine A plug A of instrument harness and engine 7 6 1 j 2 14 13 12 11
133. llustration Steering Wheel Steering universal joint assembly 1 Steering wheel 2 Steering column assembly 3 Steering universal joint assembly 2 Preparations Tools Cross screwdriver 5 6 inner hex wrench 10 13 22 socket wrench 3 Notices 3 1 Please wear necessary labor protection supplies to avoid accidents 3 2 Avoid steering fluid to contact with skin or eyes when disassembling steering system 3 3 Before disassembling steering wheel disconnect negative of battery cell to avoid airbag ejection 4 Removal Procedure 4 1 Loosen the two screws under the steering wheel with 5 inner hex wrench 4 2 Remove the horn cover from the steering wheel 4 3 Remove the fixing nuts of the steering wheel with 22 socket wrench 4 4 Remove the steering wheel after screw off the nuts 4 5 Screw off the two screws from the front surface of combined switch guard plate with cross screwdriver 4 6 After screw off the screws open upward to remove the upper protective cover 4 7 Screw off the three screws from the lower side of combined switch guard plate with cross screwdriver 4 8 Remove the lower protective cover after screw off the screws 4 9 Remove the two fixing screws from the combined switch with cross screwdriver 4 10 Pull out all plugs from the combined switch Total 5 plugs 4 11 Remove the combined switch 4 12 Pull out the plug of ignition switch 4 13 Screw o
134. move the pull rod off the upper lock 3 1 2 Pull off the connector on top of the upper lock 3 1 3 Use a cross head screwdriver to remove the three screws on the upper lock 3 1 4 Remove the trunk lock 3 2 Installation Steps The installation steps are reverse to those for removal Installation notes Is the lock column deformed Is the riveting adequate Is the lock jacket on the trunk in good condition Or can the lock tongue open and shut freely 4 Removal of Trunk Lock Cylinder 4 1 Removal Steps 4 1 1 Disengage the hitch bar from the lock core 4 1 2 Pry open the clip on the lock core with a flat head screwdriver 4 1 3 Push up the lock core to take it out Note Do not throw away the washer of the lock core 4 2 Installation Steps The installation steps are reverse to those for removal Pay attention to assemble it to its correct position and joint to door plate work 5 Removal of Rear Wiper Nozzle 5 1 Removal Steps 5 1 1 Pry open the shield of the high mount ceiling light with a flat head screwdriver 5 1 2 Pull off the connector and then use a cross head screwdriver to remove the two screws on the high mount ceiling light and take it down 5 1 3 Remove the two nuts on the spoiler with 10 sleeve 5 1 4 Remove the spoiler 5 1 5 Pull off the rear water nozzle You can pry with a flat head screwdriver but try to avoid any paint scratch and then pull off the wate
135. mp Trunk 1 23 Use a cross head screwdriver to loosen off the two screws on the console 1 24 Pull off the central switch box shield to the left Instrument Panel 1 25 Use a 8 wrench to disassemble the bolts to the left and right of the Instrument Panel with 3 bolts for the top middle bottom part respectively i e 9 in total 1 26 Use a 8 sleeve wrench to loosen off the four bolts that connect the console and the instrument beam and another bolt behind the instrument panel 1 27 Unplug the harness plugs of the left and right loudspeakers 1 28 Take out the Instrument Panel Notes 1 Disconnect the battery negative before disassembling the electrical equipment 2 Don t wait until all the Instrument Panel bolts are disassembled before you disassemble the ones on the other side or the Instrument Panel are likely to get deformed 2 Installation Steps 2 1 The installation steps are reverse to those for removal 2 2 Notes D Double wind channels should agree with the air conditioner outlet connector and be installed properly without any air leak and the Instrument Panel air channel should not conflict with the Instrument Panel crossbeam the evaporator and other parts or the Instrument Panel and its accessories will not be installed properly 2 The Instrument Panel should not interfer with the front windscreen or affect its installation and an even clearance should exist between the Ins
136. n deceleration of four wheels and judge the skid status of the wheels and therefore drive the electromagnetic valve and motor control the pressure increment and pressure reduction maintain the status and etc Hydraulic Unit The basic hydraulic circuit is comprised of the 1 circuit and the 2 circuit that is active only when the ABS is functioning and is the integral part that controls the hydraulic parts transmitted to various wheels Depending on the transmitted signal output of the sensor the ECU performs the calculation and judges the skid status to determine if it s necessary to run the ABS Therefore depending on the control procedure of the ECU the electromagnetic valve and the motor will be started to control the pressure increment and pressure reduction maintain the status and etc In order to make the ECU to calculate the speed and acceleration deceleration of the four wheels it always transmits the revolution measurement of the gear ring to the ECU When the ABS is functioning the motor will rotate following the ECU signal and convert the rotation movement into linear reciprocated movement via the bearing to circulate the brake oil Page 5 of 38 3 System Functioning Theory 3 ABS Control Theory ABS Control Range Start GE Start t s Body Speed Wheel Speed Pressure Pressure d y Sp D Increment Reduction TO A Body Speed d __Tire braking force us Tire transversal friction force
137. ns repeat the operations in item 6 air discharge mode and item air discharge If the brake pedal travel doesn t meet with the provisions after the air discharge mode and air discharge are repeated for above 10 times replace with after service HECU wet type and then repeat the operations from the beginning 9 Connect the repetition device and checking device to the HECU and again determine the existence of trouble code If with trouble code delete the trouble code and then disconnect the repetition device or checking device During the use of other repetition devices the equipment capable of vacuum formation and liquid refilling the implementation method is as follows U Conduct in accordance with the contents in above item G U When the vacuum pump is sufficiently driving for approximate 60s the inside of brake system will form the vacuum status C Start the operation of air discharge mode in above item 10s before the vacuum cut off C Without the repeated operations of pedal depressing and pedal releasing U Conduct the brake liquid refilling operation above 7bar 100Psi for above 20s at the same _ time of vacuum cut off U Complete the brake liquid refill and air discharge mode U Conduct the operation based on the contents in above item 8 6 Measures in Event of Trouble during Checking and ABS Functioning Test for internal wet status of brake system D Connect the repetition device o
138. ntenance Manual for Chery A113 Circuit Diagram Content Chapter Diustration Instruccion sata T 3 I Definition of Main Harness Inserters ooccccccnccnnnnoncnonononoononnconcnncnnncnnnnnnnnnnnnnononononnnonannnnnns 3 IL Definition Body Earth e EE 7 Earth DG Til ON 26522 tUm 7 2 Distribution of Various Earth Points and Main Modules oooooonnonnncnncnnnccnncnnononnnnnonnnnnos 7 SS Eet OF Earth POH S oss aa D DUREE 8 HE Instruction of Main Circuit SAMOA ds 9 IV Auxiliary Instruction of Circuit Diagram cc ccccessessesssesseeeescescesceeceeceeceeceeneeaeeageeseeees 10 1 Instruction of Power Supply and Earth Wire essen 10 2 WIFE size and Color coe niece or pere then anes o adea utere ceo e ie 10 3 Dehnitonmnotn Marie ontlolst oto aiuta a ed 10 T Pin Detuitron EXPONE a 10 Y HR TEE 11 ks RUSE IN ee ee 11 2 Fuse Position and Function Instructpon nennen 12 2 1 Front Compartment Relay Box Fuse 12 22x Instrument Relay BOX FUSE isistato eendeitege 13 Chapter 2 Circuit Control Theory Diagram eeeeeeseeessssssssssosseesreerrerressrssssssssssssessesseeeresresssssess 14 Starter Charmed didas 14 LABS COMMONS SM EE dE 15 HANDAS id iia 16 IV Backup NEE 17 M Electric Rear Vien MITO omiran anene ida 18 VT Pine inie Ants RE EE 19 VEAC Deroster Syste AA A E TE 20 VIII Ceiling Lamp Luggage Boot Lamp and Sunroof System oooocnnnnnnnnncnnnnnnnnnnnnnnnnnnnononnos 21 IX Front Rear Wiper SVSIe EE 22 Xs Turno
139. o connectors to the speaker 1 1 23 Disassemble the front compartment contact switch 117 1 1 24 Unplug the connectors of the front rear washing motors 1 1 25 Disassemble the ground wire Washing fluid tank on the right front side member 1 1 26 Use a flat head screwdriver to pry open right front turning light 1 1 27 Unplug the plug of the right front turning light 1 1 28 Unplug the right headlight connector 118 f a KC Bl V K Wi dz ve me s Ff Ze KA ef j iu o D LUT nun wat E d vli 1 1 29 Unplug the right front fog light connector 1 1 30 Unplug the high low voltage switch plug of the air conditioner 1 1 31 Unplug the right front wheel ABS sensor plug 2 Installation The installation steps are reverse to those for removal 119 Section III Removal and Installation of Electronic Fuel Injection Harness I Harness Sketch
140. odos eene di 80 Chapter Body DIMENSION Sa A Cota dene pena seumin eee Aerie teens 82 I Basic Instructions on BIW Maintenance oooocnnnnnncnncononnnnnnnnnnnnnnnnnnonnonnconcnncnnnnnnncnnnnnnnnnnnnnnnnnnnnos 82 Vehicle Eege 83 Z Doot EIERE EE ee edel cd 83 3 Main Contents of Door Panel Maintenance ooooonnnnnnncnncnnnnonnnnnnnnnnonononoonnnconcnncnnnnonncnnonoss 84 4 Basic Methods for Door Panel Maintenance essen 85 SEET MD oiu TTE 85 4 2 Restoration of Sitretehed Parts canti 87 4 3 Restoration of Cutting amp Patching sese 88 A RESTORATION OF Wemklcd Pais ahaa aaa austen ean seers 89 4 5 Welding of Four Doors and Two Coverg 89 II Vehicle Body Assembly DIMENSIONS A iii 90 A Pr 90 UN OS AA O A A O 94 o AC Ke WCW APRO CO E NS 103 TH Engine Compartment DIA iia 107 TV Various Opening DIMENSIONS EE 108 Vc Wifidscree RR ee aiii ii cali 108 Chapter SEENEN dE dU Le dandos 109 section T Battery Negativo Harness a ruo ied Sege 109 T Harness Eel D uec tU b A sn esr ap unu mu LSU 109 II Instructions on Main Connectors esessessesseseeeeeeeeeenn enne enne nnne nnn nnn nnns 109 III Removal and Installation of Battery Hames 110 CD e ON 110 UA A AI Te ee en ee eS 110 CHD REMOVALS E 110 Section IL Eront Compartment Harness ii 111 V HARNESS ECM ee E E 111 IL Instructions on Main Connectors vecs Leuten ri aos 112 III Removal and Installation of Front Compartment Harmess 113
141. ont 11 E ACi vo wd d O F X up ECU Front 3 fab zi E o Pal os ECUGO EG 3 PEE S ECu75 O O O i ere o ed i Blower switch a ea O OU Geode 6207 6207 M G207 3807 30 e goat Ld eo e VIII Ceiling Lamp Luggage Boot Lamp and Sunroof System 14 30 30a e e 15 15a Ka I F18 F6 EN 10A 154 FUS FEI d LOAC 20A E 7 Interior instrument AS d e E a lo L9 LN lf QU aa a C Ce us E i x AN Interior instrument 4 1 rNInterior mn Front Go B3 x ceiling S lamp Ceiling lamp switch d Interior luggage AY Q boot door N 9 g DOOR a D 6 oer 3 5 0 9W S O DPB d a 4 1 mo m ag 0 5L Y5 tit Automatic off da 0 5G 6 ES Sunroof o BCM e S 3 2 B14 8 al Get gt e o 4 gd gt Bl To instrument LO fe fe IN O C D D D y Jd y AN Interior instrument z 3 J 3 Speed Signal e 8 S e o 3 Q Q 3 c O 3 E JC z OV B p es v z e 3 8 D gt zi 6 gt ea gt 2 Self Self Self Self E earth earth earth earth 6203 G200 G201 e e de e 8 e 30 IX Front Rear Wiper System 30 30a 15a Ka Ae Y JodtAA
142. or the maintaining operations 1 Vehicle Door Structure Generally speaking the vehicle doors consist of outside plates inside plates window frames glass guide rails hinges locks and window accessories and so on The inside door plates are equiped with accessories including glass lifter locks and so on To secure the assembly some parts of the inside door plates need to be fortrified To increase safety level the inner parts of the outside plates are usually equipped with impact bars The outside plates and inside plates are connected by flanging adhesion seam welding and so on Depending on different bearing capabilities the outside plates should be light and the inside plates should have higher rigidity and be able to stand stronger impact The BIW vehicle door assemblies have relatively fewer components and usually consist of inside plates outside plates glass guide rails window frame reinforcing plates lock mounting plates hinges reinforcing plates impact bar assemblies and so on The figure below is a typical structure drawing of a vehicle door Front glass guide rail Upper door glass guide rail hinge mounting l hi d LN Inside plate back Front impact bar connecting pla C 2 Door panel Maintenance Process Generally speaking the basic maintenance methods for car doors and hoods are the same as those for ordinary plate work and the following steps apply to both of them 1 Primary tests The pos
143. ose or over tight It is not allowed to apply grease on wheel bolt For new installed wheel and tire assembly the wheel bolts should be tightened at first running of 100km to guarantee the tightening torque The tightening torque checking of wheel bolts is one of the items of regular maintenance 5 Tightening Method of Wheel Nuts Tighten the fixing nut in a decussate way the tightening force shall be approximately equal then wheel shall be able to turn freely When carry out final tightening the wheel shall be on the ground 6 Installation of Decorative Cover Mount trim cover or place trim cover as required When fitting clip type trim cover place knock in position by hand or via rubber tools Chapter 3 Removal Installation and Overhaul of Steering System I Removal Installation of Steering Gear 1 System Composition Illustration 1 Booster steering liquid reservoir 3 Bracket fixing nut 5 Reservoir fixing bracket 7 Tensioner 9 Adjustment nut 11 Pipe clamp 13 Outlet pipeline 16 Fixing nut 2 Bracket fixing bolt 4 Outlet pipeline 6 Steering pump 8 Lock nut 10 Adjustment tie rod 12 Steering gear 14 15 Fixing bolt 17 Return pipeline The breakdown illustration of steering gear is shown below 1 Lock nuts 2 Trackrod 3 Input shaft 4 Left installation bracket 5 Right installation bracket The illustration of steering universal joint and protective sleeve is shown bel
144. oval Installation Procedure aviacion 20 4 1 Removal of Shock absorber assembly enne 20 4 2 Removal or Control Arm ASSeml E Z1 4 3 Removal ot Front Axle AsSembLy eene caceria dioses 22 S Installatton Procedure e ee 24 II Removal Installation and Overhaul of Rear Axle and Suspension 25 SYM structural DIANA AAA nieces IL QUU aes 25 A catheter etas sce ao tust N E E S E A ests ET Race 26 SEENEN 26 4 REMOVAL Installation Procedure A A a AR 26 4 1 Removal of Shock Absorber Assembly and Shock Absorber Spring 26 2 2 TOSS DAA E 27 4 3 Rear Trailing Arm Assembly eres ee tete A A ok elect A A 27 4 4 Removal of Rear Axle Assembly eerte be In ete liada cabida 28 Se St Al E A LU E EC M EL E D LE 20 III Adjustment of Four Wheel Alignment cce eee eee eee eee ee ee tees eese e eee esee ee EER KEREN 30 T Adjustment or Front Wheel TO6 In ns ba 30 2 Adjustment of Front Wheel Camber Ange 30 3 Adjustment of Caster Angle and Kingpin Inclination esee 30 4 Adjustment of Rear Wheel Alignment Parameters seen 3l IV Tire Installation and Air Pressure Adjustment ceeeee eee eee eee eee eee ee ee EEE Een 31 MST AMATI ONION Aut Valverde 31 Dees SS EE 31 A A EE 32 4 Installation of Wheel and Tire Assembly ENNEN 32 5 Tightening Method of Wheel Bolts orate as ait 32 6 Installaton or Decorative EE 32 Chapter 3
145. oval Steps 5 1 1 Use the wrench to remove the four fastening screws on the Air Inlet Grid assembly as shown in the picture 5 1 2 Remove the Air Inlet Grid 5 2 Installation Steps The installation steps are reverse to those for removal Installation torque is 5 0 5Nm 6 Removal of Front Hood Lock 6 1 Removal Steps 6 1 1 Turn and remove two screws off the front hood to take down 1ts lock 6 1 2 Remove the front hood lock cable off the front hood lock assembly 6 2 Installation Steps The installation steps are reverse to those for removal 7 Removal amp Adjustment of of Hood Cable 7 1 Removal amp Adjustment of Steps 7 1 1 Remove the plastic nut behind the front hood handle in driver s cab And you can also regulate the cable by adjusting this nut 7 1 2 Use snipe nose pliers to remove the front hood cable off the pull cover 7 1 3 Drag out the cable 7 2 Installation Steps The installation steps are reverse to those for removal II Removal of Rear Trunk Cover 1 Preparations Tools flat head screwdriver 13 sleeve wrench and cross head screwdriver Material s Clip 2 Removal of Rear Decoration Plate 2 1 Pry up the rear decoration plate with a flat head screwdriver before you take it apart 2 2 Installation of Rear Decoration Plate The installation steps are reverse to those for removal 3 Removal and Installation of Trunk Lock 3 1 Removal Steps 3 1 1 Re
146. ow S21 3404060 Steering universal knuckle protective sleeve assembly 2 Preparations Tools 13 19 socket wrench 12 13 17 non adjustable wrench Accessories power steering fluid 3 Notices 3 1 Please wear necessary labor insurance products in order to avoid the accidents 3 2 Avoid steering fluid to contact with skin or eyes when disassembling steering system 4 Removal Installation Procedure 4 1 Remove the fixing nuts at the both sides of steering ball joint with 19 socket Torque 40 5 Nm 4 2 Loosen the fixing nuts under the booster steering hose with 17 non adjustable wrench Torque 25 5 Nm 4 3 Loosen the fixing nuts above the booster steering hose with 12 non adjustable wrench Torque 25 5 Nm 4 4 Remove the fixing screws above the right bracket of power steering gear with 13 socket Torque 100 10 Nm 4 5 Remove the fixing screws under the right bracket of power steering gear with 13 socket Torque 100 10 Nm 4 6 Remove the fixing screws above the left bracket of power steering gear with 13 socket Torque 100 10 Nm 4 7 Remove the fixing screws under the left bracket of power steering gear with 13 socket Torque 100 10 Nm 4 8 Remove the fixing bolts of the steering universal joint with 10 socket wrench to remove the steering gear assembly 5 Installation Procedure Refer to removal procedures II Removal Installation of Steering Column 1 System Composition I
147. per 22 lke e al SUC PTT 22 2 Installatton SUC Eed Eet 24 V Removal of Damipin EE 24 T ue E E 24 PA Talat ASES A A ad 25 Chapter III Removal amp Maintenance of Vehicle Doors 26 I Removal Installation amp Maintenance of Front Doors 26 1 System Constitution Duageram esses enne nennen nennen eene senses nes nnne rna 26 7 SI e TI LEUR cios 26 SUI TM 27 NN Als UCI Sais duteiicu iiu etiem desean dee 27 2 InstallattOnd te D Sissi ane pereo petes asus iras esent ood tried pete drame E A EE S 31 II Removal amp Installation of Rear Doors 32 EE SEHR ege eege 32 A A tese Eea souder ie E 32 Ie NOUCS mm 33 7 Removal Steps ee 33 S TOS AMAS ES ia 36 Chapter IV Removal Installation amp Maintenance of Front Rear Bumper 37 I Removal Installation amp Maintenance of Front Bumper 37 E Goen 37 EH Ee 37 2 REMOVALS EE 37 Z Installatiofr A E EE ade E epus usta E A E 39 II Removal Installation amp Maintenance of Rear Bumper 39 ee EE 39 E EE 39 SEELEN 39 ls AA a O PO ale ic Aa n I eese ue ED AU LL E 40 Chapter V Removal and Installation of Headlights Fog Lights amp Tail Lights 4 LEN ee Lee RESTE ELTE dis 4 DIUI E e 4 So Removal steps OL Heads indica ede e e breue pe os vao fs let 4 Sob Tatst opemthe PrOnt EE 4 4 Removal oft Front Fog Ei DES sarria 44 Removal Or Tal IS ina 45 6 Removal ol License
148. ping 5 6 Ground A Vehicle body ABS on the left front side member headlights connector headlights 8 Fuse box Fuse box 9 Anti theft speakerconnector 2 Anti theft speaker 10 Connect the battery Battery 11 12 Brake fluid level sensor Brake fluid level connector sensor A MAA 14 Left front wheel ABS sensor Left front wheel ABS connector sensor 15 Left turning light connector Left turning light 16 Fan motor 1 connector Fan motor 1 17 EO EES O 18 Ground B Vehicle body Fan on the left front side M ul eene m S connector r peter 2er 2 fe 21 Speaker 2 connector Speaker 2 22 Front compartment contact Front compartment switch connector contact switch 23 Ground C Vehicle body Washer solution tank on the right front side member MAA EE connector connector 26 Rear washing motor Rear washing motor connector 27 Washing fluid pipe connector headlight connector combination headlight sensor connector sensor 3l Air conditioner high low Air conditioner voltage switch connector high low voltage switch 112 III Removal and Installation of Front Compartment Harness Part number S12 3724010 D Preparations Tools sleeve wrench cross head screwdriver flat head screwdriver II Notes Make sure to disconnect the power supply when disassembling the electrical components and harnesses The ignition switch must be OFF III Removal Steps 1 Removal 1 1 1 Remove the left down shield of the Inst
149. pth should be less than 1 5 of the plate thickness Flat spade and iron hammer can be used to carry out non destructive tests of the welded spots strength Insert the flat spade between two welded spots to see 1f they are 89 easy to separate and then beat the welded part with an iron hammer to restore 1t No welding spatter 1s allowed at the welded seam and the overlapped seam should be nice looking with no defects like air holes or cracks Defects like undercut welding beading and burning through are also not allowed II Vehicle Body Assembly Dimensions 1 Front View 1 1 Clearance between front hood and air inlet grid at C C 8 1 Latch supporting plate A Inner layer of front compartment cover Front compartment cover 64 IFG n ae WS gt x EA TI F 2 Front compartment cover seal strip 9 1 2 Clearance between front hood and headlamp at 2 2 5 1mm Front compartment cover Headlamp if d z a POR PULL Front bumper 92 1 3 Clearance between headlamp and air inlet grid at 3 3 1 1mm Air inlet grid E Headlamp 1 4 Clearance between the front windscreen and the vehicle roof at 4 4 641mm Vehicle roof Front windscreen 93 2 Left front V
150. pump is temporarily stored in the low pressure accumulator LPA The brake oil stored in the LPA will be sucked back to the general pump by the oil pump started following the rotation of the motor The brake liquid will return to the high pressure accumulator HPA in the pipeline and reduce the high pressure pulse generated by the running of the oil pump by means of the orifice hydraulic resistance Solenoid Valve Power Status Solenoid Valve Status Normal Open Valve NO Valve ON Close Normal Close Valve NC Valve 3 ABS Functioning Maintaining Status When the branch pumps of the wheels are applied with proper pressure via the pressure reduction or pressure increment the normal open valve and the normal close valve will be turned off to maintain the pressure of the wheel branch pumps For the operations mentioned in above 4 depending on that wheels are locked or not the ABS will function till the vehicle is fully stopped and therefore the safety and steering capability of the vehicle are guaranteed solenoid Valve Solenoid Valve Status Normal Open Valve NO Valve Normal Close Valve NC Valve OFF Close Page 7 of 38 MC MCP 4 ABS Functioning Pressure Increment Status During the implementation of the pressure reduction if the excessive brake liquid is drained or the friction coefficient between the wheels and the road is increased it s necessary to increase the pressure of various wheels Under su
151. r checking device The following conditions must be guaranteed U Use the specific wiring while connecting to the 25 pin connector of ECU U The vehicle should be at power on status or start status while connecting to line K pin 7 U The oil reservoir of the general pump is connected with the device for continual supply of brake oil or it s required that the oil reservoir should have enough oil during the supply of brake liquid Page 32 of 38 2 Check the HECU with repetition device or checking device and determine if it has trouble code If with trouble code firstly conduct the operation to delete the trouble code Ifthe trouble code can t be deleted implement with reference to section 2 4 trouble checklist of trouble code If the HU motor or ECU has trouble the inside of HECU can t conduct the air discharge and oil refill 3 After the brake pedal is depressed open the air discharge screw attached on the wheel brake caliper or drum brake to discharge the internal air It s required to conduct this operation on all wheels till that the brake oil discharged from the air discharge screw is free of air and the brake pedal is properly rigid 4 Conduct the air discharge mode by means of the repetition device or the checking device If there has no reaction force when the brake pedal is depressed then repeat the operation of pedal depressing and pedal releasing till the air discharge mode is completed
152. r nozzle hose 5 2 Installation Steps The installation steps are reverse to those for removal Note Water injection opening should be opposite to wiper motor steering shaft 6 Removal of Rear Wiper Motor 6 1 Removal Steps 6 1 1 Remove the rear wiper shield by hand 6 1 2 Use a 10 sleeve wrench to loosen off the nut above the motor and remove the rear wiper blade Installation torque is 12 2Nm 6 1 3 Remove the three fixing bolts on the rear wiper motor Installation torque is 12 2Nm 6 1 4 Remove the motor 6 2 Installation Steps The installation steps are reverse to those for removal Chapter II Removal of Trims I Removal and Installation of Seat belts 1 Preparations Tools flat head screwdriver wrench sleeve wrench Spare parts disposable clip 2 Notes Keep the seat belts clean and free of oil and check them for any damage 3 Removal Steps Take Driver s Seat belt as an Example 3 1 Carefully pry up the front sill plate with a flat head screwdriver 3 2 Remove the front door weather strip by hand 3 3 Remove the B pillar plate with a flat head screwdriver 3 4 Remove the decorative covers at the upper and lower ends of the seat belt with a flat head screwdriver 3 5 Use a 17 wrench to loosen the upper and lower fastening nuts before you remove the seat belt Installation Torque 350 5Nm 3 6 Pull off the seat belt warning light connector by hand 3 7 Use
153. r rearview mirror left turning light connector light Left front door lock connector Left front door lock Left front door remote control Left front door lock connector III Removal and Installation of Left front door in door harness Part number S21 3724070 I Preparations Tools sleeve wrench cross head screwdriver flat head screwdriver II Notes When disassembling the electrical components and harness please disconnect the power supply The ignition switch must be OFF III Removal Steps Removal 1 1 Disassemble inside door shield See Removal of Inside Door Shield 1 2 Remove the inside door protecting film 1 3 Unplug the left front door remote control connector 1 4 Unplug the door lock connector See Removal of Door Lock 1 5 Unplug the outside left front door rearview mirror harness connector 1 6 Unplug the left front door speaker connector 1 7 Unplug the two connectors that connect the left front door in door harness and interior floor harness See Removal of In door harness 1 8 Unplug the left front window switch connector 19 Unplug the left front door lock connector 2 0 Unplug the elevating motor connector 21 Unplug the inside door harness shield and then remove the harness 2 Installation The installation steps are reverse to those for removal I Harness Sketch Right front door to in door harness 209 ele 2
154. relay Blower switch 2 Blower switch 3 Blower switch 4 Blower power supply Blower relay connector 1 Ignition switch 2 Ignition switch 3 Ignition switch 4 Blower relay Windshield washing switch 2 Windshield washing switch 3 E 4 Fog light switch 5 To Instrument electric box connector 6 Headlight switch 7 Nightlight switch 8 Headlight switch 9 Instrument panel plug 10 Trouble diagnosis socket 11 Brake light switch 12 Ignition switch IGN 1 13 14 15 16 17 18 AV switch 19 Instrument panel connector 20 22 To instrument electric box connector 23 Wiper switch 24 Wiper switch Wiper switch Ignition switch IGN 1 To instrument electric box connector C212 instrument to engine Ignition switch acc Instrument electric box Trouble diagnosis socket Ground Left loud speaker Left loud speaker Right loud speaker Right loud speaker Instrument panel plug Instrument panel electric box Ignition switch IGN 1 Instrument panel plug Instrument panel plug Brake light switch Air bag Audio system Light group switch Light group switch Instrument panel plug Instrument panel plug Audio system Audio system Ignition switch IGN2 Wiper switch Audio system Fog light switch bh UA C211 instrument to interior connector C200 instrument to front compartment connector NININILILININ
155. removal 6 Removal and Installation of Reverse Radar Display 6 1 Removal Steps 6 1 1 Use a cross head screwdriver to loosen off the screws of the reverse radar display 6 1 2 Unplug the harness and remove the reverse radar display 6 2 Installation Steps The installation steps are reverse to those for removal 7 Removal and Installation of A pillar Shield 7 1 Removal Steps 7 1 1 Use a flat head screwdriver to pry open the weather strip of the left A pillar shield and then take out the left A pillar shield by hand 7 1 2 Take out the left A pillar shield 7 1 3 Follow the the removal steps of the right A pillar shield for that of the left one 7 2 Installation Steps The installation steps are reverse to those for removal 8 Removal and Installation of B pillar Shield 8 1 Removal Steps 8 1 1 Disassemble the shield below the left B pillar See Removal and Installation of Seat belt 8 1 2 Use a flat head screwdriver to pry open the B pillar shield Note protect the trim part surface from scratching 8 1 3 Follow the removal steps of the left B pillar shield for removal of the right B pillar shield 8 2 Installation Steps The installation steps are reverse to those for removal 9 Removal and Installation of C pillar Shield 9 1 Removal Steps 9 1 1 Use a sleeve wrench to loosen off the seat belt bolts See Removal and Installation of Rear Seats amp Seat belts
156. ributing system HVAC air mixing and distributor part inside outside circulation air inlet air outlet outside circulation air filter Control system control panel assembly micro motor blower speed regulating mode high low voltage switch AC thermostat Heating system heating water tank hot water pipe and engine cooling water system Cooling system compressor condenser reservoir dryer expansion valve evaporator and pipe II Removal of Evaporator Assembly 1 Preparations Tools cross head screwdriver vehiclep pliers socket spanner Auxiliary material refrigerant antifreeze sponge rubber strip 2 Removal Steps 2 1 Use coolant recycling machine to recycle the coolant Note 1 Don t deal with the coolant in any closed place or near flame 2 Do not splash the refrigerant into eyes and skin 2 2 Disassemble the Instrument Panel assembly and the front crossbeam and unplug the related electrical equipment connector See Removal and Installation of Instrument Panel 2 3 Use a sleeve wrench to loosen off the fixing bolts of the high low pressure pipes 2 4 Loosen the fastening nuts of the high low pressure pipes and then pull them out 2 5 Loosen off the three nuts fixed on the plate work 2 6 Use pliers to remove the inlet outlet water pipes of the evaporator and pull out the pipes Note Coolant will flow out from the water pipe pay attention to recycle the coolant 2 7 Loosen off the
157. rigerant to the system 2 Test the pressure again Note If the system is still off normal after retesting the pressure install the expansion valve have it replaced and dredge the pipelines with compressed air and nitrogen and then further replace the compressor and the fluid reservoir and drying chamber Dredge the pipelines with compressed air and nitrogen Replace the compressor and the fluid reservoir and drying chamber Replace the expansion valve Refill the refrigerant to the system Test the pressure again Note If the system is still off normal after retesting the pressure install the expansion valve have it replaced and dredge the pipelines with compressed air and nitrogen and then further replace the compressor and the fluid reservoir and drying chamber Evacuate the refrigerant O Dredge the pipelines with compressed air and nitrogen Note Adjust the volume of the lubricant when replacing such component of the air conditioner system as the compressor Replace CHAPTER IX Body Dimension L Basic Instructions on BIW Maintenance Vehicle body maintenance should be carried out by professionals according to the requirements of the manufacturer and only in this way will the promises of rust free and paint defect free be effective 1 Only adopt the materials specified by the manufacturer 2 When welding the outside metal of the vehicle body make sure protective coating is applied to the inner
158. river cross head screwdriver and 10 13 sleeve wrench 3 Notes 3 1 Please wear necessary labor protection supplies to avoid accidents 3 2 Disconnect the battery so as to avoid damaging the eletrical equipment 3 3 Take correct steps during removal and installation of glass to avoid any damage 4 Removal Steps 4 1 Disassemble the right rear door weather strip The fixing clip of the vehicle door weather strip are shaped and when disassembling it press the weather strip downward and then push the weather strip to one side till you can see part of the clip And go on to push it to the opposite direction till another corner of it is exposed Don t pull the weather strip vertically so as not to damage the weather strip 4 2 Use a cross head screwdriver to loosen off the four screws that fix the shield inside the door 4 3 Use a flat head screwdriver to pry off the plastic cover of the screws that fix the handle inside the vehicle door 4 4 Use a cross head screwdriver to loosen off the screws that secure the handle inside the door and then disassemble it 4 5 Use a cross head screwdriver to loosen off the screws that secure the handle inside the vehicle door and then disassemble the handle inside the door 4 6 Disassemble the shield inside the door by hand 4 7 Pull off the power window up down switch connector 4 8 Use a cross head screwdriver to remove the two fixing screws in the mount tha
159. rness side connector and measure the resistance between the harness side connector pin 8 and grounding wire and between the pin 24 and grounding wire N M e Confirm and check the grounding p status between the harness side connector pin 8 and 24 1 grounding terminal lt Isit below 197 Replace HECU Page 24 of 38 2 5 Trouble Checklist without Trouble Code Table 1 ns BE The ABS warning lamp doesn t illuminate when the engine is started Evidence Possible Cause e Burn of fuse e Burn of ABS warning lamp bulb e Open circuit of power line e Damage of ABS warning lamp control Troubleshooting Flow Check ABS warning lamp fuse in fuse box D m E Is fuse normal Replace fuse Check fuse socket of fuse box P oll No Is socket normal y Repair fuse socket E E Remove the harness side connector and check the ABS warning lamp when the entire vehicle circnits are on X No Does ABS Check if the AB o Ts Bulb Yes m if ali warning lamp M0 warning lamp bulb i a damaged gt Replace bulb illuminate damaged in E No ina E After the harness side connector Check if l is removed check for short SES IE warning tamp circuit between the harness side power circuit of ABS pin 16 and warning lamp drive harness and grounding component Wire are disconnected Y w ee a Za 8 No AL _ Is it normal Replace Short circuit s
160. ront 2 3 A L Low d High d 7 E Lamp Beam Beam 26b s Yo O Relay Relay l Sech ees SKI S instrument T 3 6 LOA 10A L2 6 ea E S AR L7 Y s zi SR 7 3 S fe c 4 ce UE CU ES Instrument front E e e e z 7 Instrument front Instrument sont e iS ea E 3 E a 1 E S fe ea ea OO ER LD L7 AW ca CO fe LN uU 2 An LO LU 19 y B BEA Fi sens pe C 3 e e Interior instrument D ES EF1 E E S P 10A a 10A S F o S 2 S CY gt zm Left AN 8 1e D fe fs DowG E 3 Se EE S CU OU eth d OU em 3 l T Co q E 3 s ER gt O OWL ES SC 0 5RB Left E 3 5 a amp e S e 9 7 9 4 el 8 4 o clearance CS ET CS S d s CS eo Gi x e Left l lamp 9 Ha 2 R d Ge R 1 1 y S E io M gt License 5 i d 5 3 cu headlamp Plate E Ca 5 Sei LO Aa An 5 6 6 Lamp LQ ES LN LO 5 0 5 5 gt S ce CO fe ae CO e E LO E e S S de d e E E o CO de cd G208 sif ac 01 aco Ue ecc 08 ec 08 peste e 101 acc Q202 4 604 quite 620 di awl y al02 e 201
161. rottle connector 2 1 3 The ignition coil connector can be diassembled by pressing at the place shown in the right figure 2 1 4 Disassemble the camshaft sensor connector 2 1 5 Disassemble the carbon canister solenoid valve connector 125 2 1 6 Disassemble the inlet pressure sensor connector 2 1 7 Disassemble the recharging display connector 2 1 8 Disassemble the generator connector 2 1 9 Disassemble the starter connector 2 1 10 Unplug the air conditioning compressor connector 126 2 1 11 Disassemble the power steering pump connector 2 1 12 Disassemble the knock sensor connector 2 1 13 Disassemble the reverse light switch connector 2 1 14 Disassemble the water thermostat connector 2 1 15 Disassemble the front rear oxygen sensor connector Simply pull out the red lid on the connector as shown in the figure 127 2 1 17 Disassemble the vehicle speed sensor connector Use a flat head screwdriver to pry open the clips on the connector and then pull 1t out 2 1 18 Disassemble the engine rotation speed sensor connector 2 1 19 Take out the electronic fuel injection harness assembly 2 Installation of harness The installation steps are reverse to those for removal 128 Section IV In door Harness I Harness Sketch Butt joint with LR BCM module A BCM module B
162. rt the engine Page 38 of 38
163. rument Panel See Removal and Installation of Instrument Panel 1 1 2 Unplug the in door harness connector 1 1 3 Unplug the connector of instrument harness A 1 1 4 Unplug the connector of instrument harness B 113 1 1 5 Unplug the washing fluid piping connector 1 1 5 Disassemble the battery See Removal and Installtion of Battery 1 1 6 Unplug the ABS plug 1 1 7 Remove the ground wire ABS on left front side member 1 1 8 Unplug the connector to left headlight 114 1 1 9 Unplug the connector of left front fog light 1 1 10 Unplug the engine harness connector 1 1 11 Use a sleeve wrench to loosen off the lower fixing screws of the fuse box 1 1 12 Use a sleeve wrench to loosen off the upper fixing screws of the fuse box 1 1 13 Unplug the connector to the anti theft speaker 115 1 1 14 Unplug the connector to the brake fluid level sensor 1 1 15 Unplug the connector to the wiper motor 1 1 16 Use a flat head screwdriver to pry out the left front wheel ABS sensor plug fixed on the vehicle body Near ABS 1 1 17 Unplug the left front wheel ABS sensor plug 1 1 18 Use a flat head screwdriver to pry open the left front turning light rm LOUP TNT 116 1 1 19 Unplug the plug of the left front turning light 1 1 20 Unplug the two connectors of the fan motor 1 1 21 Loosen off the ground wire on the side member Fan 1 1 22 Unplug the tw
164. ry type Mando product number is BH601 086 00 and the wet type Mando product number is BH602 386 00 Dry Type Wet Type 2 Notices If the bolts on the wet type HECU are fallen off such as during the transportation besides that the air discharge and oil refill must be conducted for 1st circuit maybe it s necessary to conduct the air discharge and oil refill to the 2nd circuit 2 Notices for Removal and Installation D Notices for HECU Assembling During the assembling of brake pipeline Remove the protection film attached onto the HECU before the operation Confirm the pipeline of general pump and wheel branch pump before the operation General pump MCP MCS Wheel branch pump FR FL RR RL Confirm if the brake hose is tightened to 120 160 kef cm with special tool or torque wrench Notice to keep away the impurity ingress into the HECU hole and brake hose during operation Page 10 of 38 2 Notices for HECU Bracket Assembling During the assembling of HECU bracket U During the tightening of the bolt 3 pcs it may cause the incorrect assembling due to the friction a resistance of the cushion pad It s Installation bolt preferable to use the lubricating oil Mix 1 with the physical properties that will not impair the cushion pad Bumper block Insert the bolts 3 pcs onto the cushion pad installed onto the bracket before install to the HECU which will help the operation
165. sary labour protection supplies to avoid any accident 3 2 Disconnect the battery to avoid damaging the eletrical equipment 3 3 Use the correct method to disassemble and assemble the glass to avoid damage 4 Removal Steps 4 1 Remove the left front vehicle door weather strip The fixing clip of the vehicle door weather strip are shaped and when disassembling it press the weather strip downward and then push the weather strip to one side till you can see part of the clip And go on to push it to the opposite direction to show another part of it Don t pull the weather strip vertically so as not to damage the weather strip 4 2 Use a flat head screwdriver to pry up the plastic decorative block fixing the rearview mirror outside the vehicle door 4 3 Use a 10 sleeve wrench to loosen off the two screws fixing the outside rearview mirror 4 4 Pull off the electrically adjustable outside rearview mirror harness connector and take off the outside rearview mirror assembly 4 5 Use a cross head screwdriver to loosen off the four screws that fix the shield inside the door 4 6 Use a cross head screwdriver to loosen off the screw that fixes the handle inside the vehicle door 4 7 Use a flat head screwdriver to pry off the plastic cover of the screw hole for the handle inside the vehicle door and then remove the fixing screw with a cross head screwdriver so as to disassemble the lock assembly inside the door
166. se to those for removal I Harness Sketch To in door harness B A ef WW H ern X 2074 216d 178 177 186c 18 1846 Section VIII Rear Door Harness To in door harness A a Right rear switch window 308d 7 n 186c 184b 185b Right rear door lock el6d 204 ru co Right rear loudspeaker 207d NEN 3 Rear window motor II Instructions on Main Connectors Remark Right rear window switch connector Right rear window switch Right rear door lock connector Right rear door lock To in door harness connector A In door harness A Rear window motor connector III Removal and Installation of Right rear Door In door Harness Part number S21 3724180 I Preparations Tools sleeve wrench cross head screwdriver flat head screwdriver II Notes When disassembling the electrical components and harness please disconnect the power supply The ignition switch must be OFF III Removal Steps Removal 1 1 Disassemble the rear inside door shield See Removal of Inside Door Shield 1 2 And then remove the inside le
167. ssemble the left rear group tail lights assembly See Removal and Installation of Left rear Combination Tail Lights 2 2 Unplug the plug of the left rear combination tail lights harness 3 Use a flat head screwdriver to pry off the luggage light and unplug the luggage light harness 4 Unplug the plug of the left rear speaker harness 5 Removal of fuel pump harness 5 1 Pull off the right rear seat and take down the plastic cover on the fuel pump 5 2 Unplug the fuel pump harness plug 6 Unplug right rear speaker harness plug 7 Disassemble the right rear combination tail light harness 7 1 Disassemble right rear combination tail lights assembly See Removal and Installation of Right rear Combination Tail Lights 7 2 Unplug the right rear combination tail lights harness plug 8 Removal of BCM MODULE 8 1 Open BCM module box 8 2 Unplug the BCM module A plug 8 3 Unplug the BCM Module B plug 7 CECR CR NS 9 Removal of hand brake harness 9 1 Disassemble the auxiliary Instrument Panel assembly See Removal and Instalaltion of Auxiliary Instrument Panel 9 2 Unplug the hand brake harness plug 10 Removal of ceiling light harness 10 1 Disassemble the ceiling light See Removal and Installation of Ceiling Light 10 2 Unplug the ceiling light harness plug 11 Unplug the seat belt switch harness plug 12 Removal of instrument harness butt joint 12 1 Disassemb
168. t 3 Removal Steps of Headlights 3 1 First open the front hood 3 2 Use a 10 open ended wrench to loosen off the three fixing screws of the right headlights on the front compartment member A MA d 1 Fa DN 3 3 Hold the headlight with both hands and apply a forward force to loosen off the right headlights 3 4 Unplug the right headlights harness to take out the right headlights assembly 3 5 Turn open the the high beam headlight holder shield by hand 3 6 Press down the bulb fixing clip by hand and turn the clip over to take out the bulb 3 7 Unplug the right front position light harness to take out the bump 3 8 Turn open the low beam light holder shield by hand 3 9 Unplug the low beam light harness 3 10 Press down the bulb fixing clip by hand and turn the clip over to take out the bulb 3 11 Turn the right front turning light shield counterclockwise to disassemble the bulb See the above steps for removal of the left headlight 4 Removal of Front Fog Lights 4 1 Diassemble the bumper assembly Refer to removal of bumper 4 2 Unplug the right front fog lights harness connector 4 3 Use a cross head screwdriver to loosen off the three screws that fix the front fog light and then disassemble the right front fog light assembly 4 4 Turn the right front fog light holder and remove the bulb See the above steps for removal of left front fog lights 5 Remo
169. t fixes the rear door handle cover 4 9 Tear off the anti water plastic sheeting on the rear door 4 10 Connect the battery lower the window glass to a proper position and loosen off the two screws that fix the glass and then carefully diassemble the glass 4 11 Use a 10 wrench to loosen off the five screws that fix the window up down regulator and remove it 4 12 Use a 104 sleeve wrench to loosen off the screw that fix the handle outside the rear door and then remove it 4 13 Use a cross head screwdriver to loosen off the three screws that fix the rear door lock core and then remove it 4 14 Use a 13 sleeve wrench to loosen off the four screws at the hinge that fix the right rear vehicle door and then remove it 5 Installation Steps The installation steps are reverse to those for removal Note Removal of the left rear door is similar to that of the right rear door Chapter IV Removal Installation A Maintenance of Front Rear Bumper I Removal Installation A Maintenance of Front Bumper 1 Preparations Tools 8 wrench 8 sleeve cross head screwdriver flat head screwdriver Spare parts disposable clips 2 Notes 2 1 Please wear necessary labor protection supplies to avoid accidents 2 2 Try to avoid scratching the painted surface of the bumper during the removal operation 2 3 For removal in colder environment operate gently to avoid damaging the bumper 3 Removal Steps
170. the Instrument Panel and unplug the harness when removing the lighter 1 13 Use a cross head screwdriver to loosen off the three screws that connects the ashtray with the Instrument Panel and take out the ashtray Note When disassembling the console the operations should be carried out from top to bottom and you should disassemble the air conditioner switch before disassembling the audio system 1 14 Disassemble the steering wheel combination switches and ignition switch 1 15 Use a cross head screwdriver to loosen off the two screws on the instrument panel shield and the Instrument Panel and then pull it out with both hands 1 16 Use a cross head screwdriver to loosen off the four screws on the instrument panel and the Instrument Panel 1 17 Use a flat head screwdriver to pry up the red clip and the instrument panel harness plug can be taken out before the instrument panel is taken out 1 18 Push out the two harness plugs from behind the fog light switch 1 19 Disassemble the left front and the right front door seal strip 1 20 Disassemble the decorative shields of the left and righte A pillars See Removal of Vehicle Ceiling for details 1 21 Open the storage box to the lower right of the Instrument Panel use a cross head screwdriver to loosen off the four screws on the storage box and disassemble the storage box 1 22 Disassemble the front hood cord switch See Removal of Front Hood a
171. the two clips to disassemble the evaporator shield Note The sponge seal around housing is for single use only 7 1 7 Remove the evaporator assembly 7 1 8 Use a wrench to disassemble the expansion valve 7 2 Installation of the Evaporator Assembly The installation steps are reverse to those for removal After the installation the system should be evacuated proper pressure should be maintained and anti freeze agent should be filled to check for any leakage Check if the radiator is blocked and pressure air can be used to get it through if it is III Trouble Shooting Types of pressure deviation Possible causes TH ALDO i mit Wee m o wm vi T f EE i Es A Ergo I 7 TIT AIT HIJA RE 8 8 E Re MATT i T2013 T4 ida 1 o L D I CG 1 i a UA T sr c miri hi Bi Ni Fn ge a A d B E l E T wm T VREREELEL Ch Method for troubleshooting The pressure at the high pressure side remains unchanged or just slightly rises compared with the value when the engine stalls the pressure at the low pressure side is within or under the range as shown the air conditioner is under refrigeration The pressure at the high pressure side is normal the pressure at the low pressure side is within the range as shown the air conditioner is under refrigeration The pressure at the high pressure side is higher than the specified value the pressure at the low pressure side falls rapidly to within or
172. time when the ECU diagnoses the motor drive which is also the normal functioning of the ABS 2 HECU replacement relating to EBD functioning noise The HECU replacement case that deemed the clattering noise of rear wheels that other than the ABS functioning noise during the braking as the malfunction U The ABS is also equipped with EBD function which will effect the relieving of braking pressure on the rear wheels when the rear wheels are locked ahead of the front wheels The noise generated during the above mentioned process is of normal functioning status 3 HECU replacement relating to braking off tracking HECU replacement case due to the vehicle braking off tracking towards one side during the braking U ABS is the braking assisted device that functioning in such manner that the ECU will calculate the speed of various wheels in order to maintain the best braking force and control stability during the braking In the event of malfunction of the HECU the ECU will illuminate the warning lamp by means of the diagnosis Therefore in the event of braking off tracking without the illumination of ABS warning lamp it s necessary to check other braking hydraulic devices Inthe event of incorrect assembling of the braking hose the braking off tracking may occur during the functioning of the ABS 4 Replacement case that the ABS is functioning during barking at low speed below 40km h HECU and sensor replacement case that the ABS is always
173. tion beat around the heated area quickly to increase the compressing stress and the contraction till that area is smoothed The wooden hammer is preferred and do not use too strong a force or the metal panel may get re stretched 4 3 Restoration of Cutting amp Patching When any part of the metal door panel is eroded or damaged beyond repair it should be removed and replaced with a new piece by welding The repairing methods include patching repair and cutting Steps for cutting repair are as follows 1 Check the damaged part and determine the repairing area 2 Make a paper model according to the determined area 3 Draw lines on the metal plates and cut material according to the paper model and leave proper processing allowance 4 Select proper processing and shaping methods so that the patch matches well with the 88 part to be removed 5 Apply the patch to the intended position and press it tightly draw a line along the edge of the part to be removed and cut it out using methods like gas cutting or excising according to the actual situation and then align the patch with the excised area 6 Weld the seam by gas welding or carbon oxide protection welding Spot weld it at a pace of 30 50mm to fix it and then weld it again in a certain order after beating it smooth For seams requiring welding of higher strength doulble sided welding is prefered 7 Smooth the welded seam by beating it with flat hammer release the weld
174. tion switch Brake pedal Pedal depressing Pedal releasin ABS warning lamp Deletion period The steps in the above figure are respectively as follows A After the brake pedal is depressed ground the line L and rotate the vehicle key to the power on position B The ABS warning lamp illumination and go off in 3s C Start to release the pedal within 1s after the ABS warning lamp goes off D After the pedal is released for approximate 1s re depress the pedal for approximate Is Repeat the above operation for 5 times During this operation the warning lamp will not be illuminated E The ABS warning lamp illuminates and lasts for 3s During this period the trouble code within this process will be deleted At the finish of the trouble code deletion restore the ECU status of the ABS to the normal mode Page 16 of 38 of which the operation method is same with that of the trouble code diagnosis In addition when the ECU of the ABS has no trouble code ground the line L and rotate the key to the power on position The flashing of the ABS warning lamp is conducted in accordance with the type in following figure of which the symbol meaning is same with the foregoing section Line L Ignition Switch T3 T8 T mmm ABS warning lamp 2 4 Trouble Checklist of Trouble Code ID Contents of Trouble Code la Contents OS Contents code code C1 200 Open circuit short circuit of left Cl 206 Open circuit s
175. tproof seal Clean the contact surface of the brake piston and apply with one film of silencing grease Notice It s prohibited to make the dustproof seal come contact with the silencing grease which will cause the swelling of the dustproof seal 4 10 Remove the piston Prepare one wood board to hold the piston and place the wood board between the piston and the wall of the brake calliper Press out the piston with the compressed air carefully through the connecting bore Place the guard plate such as hard wood at the notch of the brake calliper to protect the piston Notice Do not hold the piston with fingers danger of clamping The brake calliper piston is prohibited from removal at will and should be removed installed only by professionals or under the guidance of the professionals 4 11 Check the guide sleeve The guide sleeve should move smoothly and freely when pushed with hand Replace the guide sleeve in event of jamming or stiffness Notice Apply the lubricating grease onto the guide sleeve during assembling 4 12 Remove the seal ring carefully with the plastic needle clean the brake cylinder and components with alcohol and blow dry with compressed air Carefully check the surfaces of brake cylinder piston and flange It s prohibited to conduct the machining process on the brake cylinder and piston 4 3 Installation of brake branch pump Apply one film of brake cylinder cream onto the cylinder body plunger
176. trouble in above item D is not determined it s necessary to determine the existence of trouble code When the trouble code can t be deleted operate with reference to the Trouble Checklist of Trouble Code in section 2 4 In case of trouble of HU motor and ECU the air discharge and oil refill can t be conducted at the inside of the HECU 5 After the brake pedal is depressed open the air discharge screw attached onto the wheel brake caliper or drum brake to discharge the air Conduct this operation on all wheels till that the brake oil discharged from the air discharge screw is free of air and the brake pedal is properly rigid Refer to the operation in item in using the repetition device capable of vacuum formation and refilling of brake liquid 6 Conduct the air discharge mode by means of the repetition device or the checking device If there has no reaction force when the brake pedal is depressed then repeat the operation of pedal depressing and pedal releasing till the air discharge mode is completed air discharge mode repeat the start in 2s interval stop the normal close valve of HECU for 1 min and continually drive the motor The repeated operation of pedal depressing and pedal releasing is conducted within the period of normal close electromagnetic valve and motor drive f The operation in item air discharge should be repeated for all wheels Measure the brake pedal travel If not meet with the provisio
177. trument Panel and the windscreen 3 The clearances between the Instrument Panel and either sides of the vehicle body should be consistant and meet the requirements for assembling the door weather strips 3 Methods for Clearing Instrument Maintenance Indicator 1 Clearing with diagnosis equipment D Using the X431 diagnosis equipment Select the OBD II diagnosis connector and connect it with the diagnosis interface below the instrument panel turn on the ignition switch and start the diagnosis equipment choose the latest edition and select the instrument panel system select ATECH Instrument System and then Action Testing select Maintenance and service requirements and then click confirm to clear the instrument maintenance indicator and then exit the diagnosis equipment 2 Using K81 K61 diagnosis equipment Select the MITSUBISHI diagnosis connector and connect it with the diagnosis interface below the instrument panel turn on the ignition switch and start the diagnosis equipment choose the latest edition and select the instrument panel system select Instrument System ATECH and then Action Testing select To clear maintenance requirement indicator and then press enter to clear the instrument maintenance indicator and then exit the diagnosis equipment 2 Clearing by the adjusting knob as follows 1 Insert the key into the ignition switch and get it to the position ec ji 2 Press the mode
178. ug of the evaporator thermostat 3 1 5 Disassemble the mode throttle hitch bar 3 1 6 Remove the temperature control throttle bar 3 1 7 Loosen off the 8 screws on the heater shiled and disassemble the evaporator shield Notes The sponge weather strips around the shield are for single use only 3 1 8 Use a flat head screwdriver to pry off the clips that fix the air conditioner cover plate assembly 3 1 9 Remove the air conditioner cover plate assembly 3 1 10 Tear open the sponge around the inlet outlet water pipes and remove the fixing clips 3 1 11 Remove the heater exchanger 3 2 Installation Steps The installation steps are reverse to those for removal After the installation the system should be evacuated proper pressure should be maintained and anti freeze agent should be filled to check for any leakage Check if the radiator is blocked and pressure air can be used to get it through if it is 4 Removal and Installation of Mode Throttle Related Mechanism 4 1 Removal of Steps 4 1 1 Remove the mode throttle hitch bar use a cross head screwdriver to lossen off the fixing screws on the control panel to disassemble 4 1 2 Loosen off the three screws and washers behind the control panel that control defroster blowing head blowing foot and control arm 4 2 Installation Steps The installation steps are reverse to those for removal 5 Removal and Installation of Blend Throttle Related Mech
179. under the range as shown the air conditioner 1s under refrigeration Initially the pressures at the high and low pressure sides are normal but after a period of time the pressure at the high pressure side is higher than the specified value and the pressure at the low pressure side is within or under the range as shown the air conditioner 1s under refrigeration Lack of refrigerant or the expansion valve fails The blockage or throttling occur somewhere in the refrigerant pipelines The expansion valve fails The expansion valve fails There exists vapor in the refrigerant pipelines Evacuate the refrigerant O If the volume of the refrigerant is normal l Replace the expansion valve 2 Refill the refrigerant to the system 3 Test the pressure again If the volume of the refrigerant is short 1 Check if there is leaking if there is fix it 2 Refill the refrigerant to the system 3 Test the pressure again Touch the pipelines to feel the temperature change O If there exists temperature differences on several parts of a certain component 1 Dredge the pipe with compressed air and nitrogen and replace the expansion valve 2 Replace the blocked parts O If no trouble found 1 Dredge the pipelines with compressed air and nitrogen 2 Test the pressure again Check for dirt or rust in the expansion valve and replace 1t when necessary O Dredge the pipelines with compressed air and nitrogen The pressure at th
180. us d Skid Ratio AL 100 Ac 0 The status that the brake is A 100 The rn eg the wheels not functioning are locke 3 2 ABS Control Mode 1 Functioning Status of General Brake For the vehicles equipped with ABS if the braking pressure applied onto the wheels is not enough to lock the wheels the pressure generated by the general pump will transmit to the wheel branch pump via the normal open valve to obtain the braking effects When it s unnecessary for further braking the driver will reduce the pressure on the brake pedal and then the brake liquid of various wheels will return to the general pump to reduce the braking pressure Solenoid Valve Solenoid Valve Status Normal Open Valve NO Valve Normal Close Valve NC Valve CLER Y CIR ASL y SGI y y i E NO MO oi NO HG Se d xli GUR air aii NC NC NC NC E F zm d H zm k RL j ER LPA MA Ve el ar __ A E Page 6 of 38 2 ABS Functioning Pressure Reduction Status For the vehicles equipped with ABS if the applied braking pressure is too big the wheels will have rapider deceleration than that of vehicle body which will be ready to result the lock of the wheels Under such case the ECU will transmit the code for wheel pressure reduction to the HCU namely turn off the normal open valve and turn on the normal close valve to reduce the pressure of wheel branch pump In such case the brake oil released by the wheel branch
181. use a flat head screwdriver to pry open the storage box See the right figure 1 2 Use a cross head screwdriver to loosen off the two screws than connect the emergency switch with the Instrument Panel as shown in the figure 1 3 Pull out the top part by hand and then use a flat head screwdriver to pry open the lower part Unplug the harness when removing it as shown in the figure 1 4 Use a flat head screwdriver to pry open the control panel of the airconditioner switch and take it out 1 5 Use a cross head screwdriver to loosen off the four screws that connect the airconditioner switch and the Instrument Panel 1 6 When taking the airconditioner switch unplug the two harness plugs behind it and disassemble the two cables behind the switch 1 7 Use a 8 sleeve wrench to loosen off the four fixing bolts that connect the audio system with the Instrument Panel 1 8 When taking out the audio system unplug the antenna and harness 1 9 Use a cross head screwdriver to loosen off the two screws that connect the cup holder and the Instrument Panel and then take out the cup holder 1 10 Disassemble the auxiliary Instrument Panel See Chapter I Removal Installation amp Adjustment of of the Brake System 1 11 Use a cross head screwdriver to pry open the decoration sheet on the ash tray and take it out 1 12 Use a cross head screwdriver to loosen off the four screws that connect the cigarette lighter with
182. val of Tail Lights 5 1 Open the rear door 5 2 Use a cross head screwdriver to loosen off the screws fixing the left tail light 5 3 Remove the left tail light unplug the left tail light harness connector and then disassemble the left tail light assembly 5 4 Use a cross head screwdriver to loosen off the four screws that fix the tail light holder and open it 5 5 Turn the bulb counterclockwise by hand and then the bulb can be removed 6 Removal of License Plate Lights 6 1 Use a flat head screwdriver to pry off the license plate light 6 2 Unplug the harness plug to disassemble the license plate light 7 Installation amp Adjustment of Headlights 7 1 Installation Steps for the Headlights The installation steps of headlights are reverse to those for removal 7 2 Functions of Headlights 7 2 1 Front view See right figure 1 High beam light 2 Position light 3 Low beam light 4 Turn light 7 2 2 Back view High beam light holder High beam adjusting nut Low beam light holder Nm E UN ra Low beam adjusting nut High beam low beam position and turning light plugs Turning light holder 8 3 Adjustment of Headlights 8 3 1 Pay attention to law and regulations and verify the following items before adjustment 1 The tire air pressure should comply with the related standard 2 Vehicle is unloaded except for spare tire and equiping tools and include driver s weight for sedan 3 Th
183. vice and brake liquid refiller I Screw on the oil reservoir lid disconnect the SDL J Transfer to next step Gangan 2 Checking Device 1 The vacuum supplied to the oil reservoir should be as lower as possible provided that the oil gun must supply at least below 1mm Hg vacuum 2 Confirm if the air discharge screw portion of the rear wheel hydraulic device drum brake or brake caliper forms the vacuum within the specified period It should be below 5 10mm Hg after connected with vacuum for 20 25s 3 Confirm if the working voltage supplied to the HECU is at specified 10 12V 4 Confirm the circulation time C T Confirm the working time setting of the electromagnetic valve meets with the specified value C T 90 Run the electromagnetic valve continuall y 90 lt C T 180 Start the electromagnetic valve for 2s and stop the electromagnetic valve for 2s continually repeat above cycles C T gt 180 The total running period setting of the electromagnetic valve is below 90s 3 Notices for Air Discharge and Oil Refill Page 30 of 38 D During the refilling of brake oil if the refilling pressure is not maintained for certain period or above the oil level within the oil reservoir will lower at the finish of the refilling Therefore it s required to refill more brake oil or maintain the refilling pressure for certain period 2 The time period marked in the regular operations refers to the general circulation
184. will lead to abrasion For example the long time friction between the hinge hole and the shaft of the vehicle door hinge will increase their tolerance clearance and cause to vehicle doors to drop 2 Erosion This is generally due to the oxidation caused by the mud deposit and dirt or the rust caused by lack of anti erosion processing after welding or erosion caused by chemicals This type of damage usually occurs between the plate work pieces in overlapped parts of spot welded pieces and at other similar places 84 3 Cracks or breaks The metal plates may develop fatigue under repeated inner outer stress where the stress concentrates and the structure 1s the weakest causing cracks and even breaks 4 Dents or wrinkles Dents develop because the door panel is subjected to bumping or pressing leading to elastic or plastic deformations 5 Bends or twists They are mainly caused by too much load the door panel receives in use or the plastic deformation due to bumps 4 Basic Methods for Door Panel Maintenance The basic maintenance methods for the above door panel damage types include dent reconditioning flame correction welding repairing and mending wrinkle spreading and so on 4 1 Reconditioning of Dents For convex concave damages in the outside door panels if they are indirectly caused by structural pieces or reinforcers the structural pieces should be corrected first and then the outside panel breaks or dents are to b
185. witch IGN2 Alarm switch Alarm switch Audio system C200 instrument to interior III Removal and Installation of Instrument Panel Harness I Preparation of Tools Tools 10 13 sleeve wrench cross head screwdriver flat head screwdriver ID Notes 1 When disassembling the electrical components and harness the power supply should be disconnected 2 Make sure the ignition switch is OFF 3 When disassembling common connectors push down the latch device on the connector and then separate the plug from the socket by force but do not pull at the wires so as not to damage the wires and connectors III Removal and installation of instrument panel harness 1 1 Removal of Instrument harness 1 1 1 Disassemle the auxiliary instrument panel and when disassembling the instrument panel the cigarette lighter connector blower switch connector air conditioner switch connector air conditioner thermostat connector audio system connector antenna power supply plug alarm switch connector and safety airbag socket will also be disassembled The safety airbag socket is a reserved function and there are 2 grounds under the console which can be disaasembled with a 10 sleeve See Removal of Instrument Panel for detailed removal methods 1 1 2 Removal of the steering wheel will also involve removal of speaker button connector wiper switch connector dimmer steering switch connector rear wiper switch connector

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