Professional Documents
Culture Documents
I. Precautions .....................................................................................................................1
II. Preparation......................................................................................................................2
X. Trouble Diagnosis..........................................................................................................20
I. Precautions ...................................................................................................................28
II. Preparation....................................................................................................................30
I. Precautions ...................................................................................................................67
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
I. Illustration ......................................................................................................................88
I. Precaustions:.................................................................................................................94
I. Illustration on Functions...............................................................................................127
V. Tachometer .................................................................................................................134
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
II Fender .........................................................................................................................222
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
I. Precautions .................................................................................................................285
I. Precautions .................................................................................................................324
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Warning:
■ During maintenance, if the proper processes aren’t followed, the airbag system may be ignited
accidentally, which will result in serious accidents.
■ The mistakes during maintenance will make the airbag incapable of ignition when it is required to,
which will result in serious accidents.
■ Before the maintenance (including dismantlement, installation, check or replacement of spare parts),
do carefully read the following notes, and operate according to the proper process defined in the
maintenance manual.
1. Don’t disassemble the safety airbag components such as safety airbag assembly at driver’s seat
side and safety airbag assembly at the second driver’s seat side.
2. Don’t repair the following parts but use the replacements to replace them.
1) Safety airbag at driver’s seat side.
2) Safety airbag at the second driver’s seat side.
3) Safety belt tensioner.
4) Control module of safety airbag.
5) Clock spring.
3. Don’t make the airbag exposed to the high temperature or flame.
4. Immediately use a dry cloth to wipe if the liquid exists on the airbag such as butter, detergent,
engine oil or water.
5. Don’t make the airbag fall and the fallen airbag is not allowed to use.
6. The original replacements shall only be obtained from the authorized dealer.
7. After disassembling the airbag, store it in a stable place with its face upwards. Don’t put any articles
on its top.
8. Check whether the replacement part number is correct. Don’t use the parts of other vehicles as the
replacement of this vehicle.
9. Even if the airbag is not ignited in light impacts, the pad surface and airbag sensor shall be checked.
If the situations such as sunken, crack or deformation are found, a new airbag assembly shall be
used.
10. When the vehicle or airbag is discarded, the airbag shall be dealt with first.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
11. After the airbag is ignited, the inflation device will become very hot, so, it shall be handled after
natural cooling. Don’t use water to cool it.
12. It is not allowed to measure the circuit resistance of airbag module, for it will result in the ignition of
airbag.
II. Preparation
General tools and special tools are required to use during maintenance.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Diagram for the Impact Angle Which may Result in the Openness of Airbag
The airbag will open if the frontal impact happens within the 30°away from the center line of vehicle and
impact force is big enough.
1-airbag at driver’s seat side 2-airbag at the second driver’s seat side
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
The impact will result in the rapid change of vehicle speed. Due to the inertia, the passenger keeps on
moving forward, and then the impact between passenger and inner structures happens. And the function
of occupant restraint system is to avoid or alleviate the hurt caused by the impact between passenger
and inner structures through restraint system (including seat, safety belt, airbag and so on).
Airbag system
Control
Impact sensor Ignite Airbag
/Diagnosis
system
Restrain
Pretensioner Restrain
Safety belt
Driver/the
second driver
Load restriction
Before the impact between passenger and inner structures, an airbag inflated with air is quickly inserted
between them. Through the breathability of airbag itself and exhaust throttle function of discharging hole,
the kinetic energy of passenger is absorbed to alleviate the fierce impact and the passenger is separated
from the inner structures, so that the passenger is protected.
Fig.1. 1.001
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
First of all, frap in time, that is, at the first moment of accident, with the help of impact acceleration,
incline angle of vehicle and acceleration created by mesh belt, the safety belt “presses” the passenger
on the seat; then, relax properly, that is, when the impact force peak is over or passenger has been
already protected by airbag, the safety belt relaxes properly.
1. Element
Fig.1. 1.002
The safety airbag module at driver’s seat side
locates on the steering wheel.
2. Specification:
■ Airbag Volume: 50 L
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Attention:
Fig.1. 1.003
■ When the safety airbag module at driver’s seat
side is dismantled or the new safety airbag module
at driver’s seat side is mounted, the face of pad
shall be upward.
Correct Placement
3. Dismantlement steps:
Fig.1. 1.005
1) Disconnect the negative pole of storage battery
for over 3 minutes.
Warning:
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
4. Installation steps:
Attention:
2. Specification:
■ Airbag Volume: 90 L
Attention:
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
4. Installation
Attention:
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Attention:
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
■ If the spare parts and components of safety belt assembly have any problems, they shan’t be
repaired. Directly replace the assembly.
■ If the safety belt has defects such as rupture, abrasion or damage, replace the safety belt assembly.
■ When the safety belt assembly is replaced, authentic JAC safety belt assembly shall be used.
Attention:
■ Before the installation of front seat safety belt, the B-pillar upper trim board is required to install
eudipleurally. And the mortise lock of safety belt buckle shall be mounted on the seat.
■ Make sure that the connection of safety belt pretensioner connector is reliable.
■ Put the safety belt body into the space corresponding to B pillar and make it aim at the mounting hole.
Use the bolt of 7/16 British System to make it fastened to B pillar with the tightening torque of 40〜55
N•m.
■ Make the bolt of 7/16 British System go through the upper protecting plate of B pillar to fasten the
guide components of safety belt to the sheet metal of B pillar with the tightening torque of 40~55
N•m.
■ After the installation of B-pillar lower trim board, use the bolt of 7/16 British System to fasten the end
of safety belt to the vehicle body sheet metal with the tightening torque of 40~55 N•m.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Attention:
■ Align the locating pin hole with bolt hole and use the bolt of 7/16 British System to fasten the safety
belt body with the tightening torque of 40〜55 N•m.
■ Use the bolt of 7/16 British System to fasten the guide components to the sheet metal of C pillar, then
go though the upper trim board of C pillar. The tightening torque is 40〜55 N•m.
■ Use the bolt of 7/16 British System to fasten the mounting point below C pillar and the mounting point
is at the end of safety belt. The tightening torque is 40〜55 N•m.
■ Use the bolt of 7/16 British System to eudipleurally fasten the 3 safety belt latch assemblies and 1
middle 2-point safety belt to the floor. The tightening torque is 40〜55 N•m.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
1. Specification
Attention:
■ Using the safety belt and supplemental restraint system such as airbag and pretensioner of safety
belt at the same time is helpful for driver and passenger at the front seat to reduce the danger of
injury when impacts happen.
■ In order to avoid increasing danger of personal casualty caused by the failure of airbag when impacts
happen, all of the maintenance operations shall be conducted by authorized JAC service centers.
■ The improper maintenance, including wrong dismantlement and installation of safety belt
pretensioner may result in the wrong behavior of system so that accidental personal injuries happen.
■ It is not allowed to use electrical test devices to test any circuit of airbag system except the
operations specified in this manual.
Attention:
■ Before the dismantlement or installation, make sure that the ignition switch is shut and negative pole
of storage battery is disconnected, and then, wait for over 3 minutes.
■ Don’t use electrical test device to check the pretensioner of safety belt.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Attention:
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
■ Take the clock spring of safety airbag out from the package and check whether it is intact and
whether the anchor pin is on the spare part.
■ Open the gland bush of connector, insert the airbag wire harness connector into the jack and then
fasten the gland bush.
■ Before the installation of clock spring of safety airbag, first make sure that the front wheel direction is
in the middle (towards).
■ Before the installation of clock spring of safety airbag, make sure that the clock spring is in the middle
(clockwise rotating to the end and then rotating reversely for 2.5 turns).
2) To ignite the airbags both at driver’s seat side and the second driver’s seat side.
3) To ignite the safety belts with pretensioners both at driver’s seat side and the second driver’s seat
side.
5) To report the airbag system state to driver through warning indicator light: ready or in trouble.
6) To conduct the diagnosis maintenance for airbag system through the serial diagnosis communication
port.
7) To record the working state of each component of airbag system and relevant impact information
data.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
3. Dismantlement steps
Fig.1. 1.0037
1) Shut the ignition switch, disconnect the
negative pole of storage battery and wait for at
least 3 minutes until the discharge of reservoir
capacitance inside the SDM is finished.
3) Loose and pull out the connector of SDM wire harness, dismount 4 bolts which are used for fixing
SDM and take out SDM. Attention:
4. Installation
Attention:
■ When installing it, pay attention to the direction of SDM, and make sure that the arrowhead marked
on SDM is in accordance with the travel direction of vehicle.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
X. Trouble Diagnosis
After the ignition switch is shifted to “ON” position, the airbag indicator light on the console will twinkle for
a few seconds and go out, which means the airbag is in the normal working state, if it doesn’t light or
keeps lighting, then the airbag system has troubles. In order to further confirm the reason for trouble, a
special trouble diagnosis apparatus shall be used to diagnose.
■ After the trouble is eliminated, the diagnosis apparatus shall be used to delete the trouble code
stored in the system.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Attention:
■ The safety belt assembly of all the seats shall be checked after any impact, including retractor and
other metallic spare parts and components.
■ It is suggested by our company that all the safety belt assemblies used during impact shall be
replaced. Or else, serious personal injuries may happen in an accident. For example, the frontal
impact which results in the ignition of airbag happens, even if the safety belt is not used, the
pretensioner of safety belt shall be replaced.
Please replace the safety belt assembly (including the fastening bolt) if the following conditions happen:
■ The safety belt is used when the impact happens (except that the impact is very light and safety belt,
retractor and snap ring are not damaged and their functions are normal).
■ The safety belt is damaged entirely during an accident. (That is, the safety belt is broken; retractor
bends or slide groove appears).
■ The fastening point of safety belt is entirely damaged during an accident. Before the installation of
new safety belt assembly, whether the fastening area of safety belt is damaged or deformed shall be
checked and repair it when necessary.
2. If the airbag is not ignited when the vehicle impacts in low speed, and a side impact, a side-rollover
or pileup happens, the following items shall be checked:
■ Check whether the SDM shell and installation support have dints, cracks or deformations.
■ Check whether the installation bolt and grounding wire are in good condition.
1) Airbag module
② Check whether the connector is damaged, whether the terminal is deformed and whether the wiring
is stuck.
③ Check whether the air generator shell of airbag has dints, cracks or deformations.
④ Install the airbag sub-assembly to the steering wheel and check the matching and alignment
condition.
2) Clock spring
① Check whether the clock spring connector and protecting sleeve are damaged and whether the
terminal is deformed.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Before the airbag or vehicle with airbag is discarded, the following disposal methods shall be
used to ignite them.
1) If the vehicle is discarded, the airbag shall be ignited inside the vehicle. And if the vehicle will still be
used and only the airbag is discarded, the airbag shall be ignited outside the vehicle.
2) There will be a lot of smoke caused by the ignition of airbag, so, you shall be careful of not breathing
in. Otherwise, it will irritate the throat and may result in asphyxia. Therefore, the resident area shall
be avoided as much as possible.
3) Due to the loud noise caused by the ignition of airbag, the resident area shall be avoided as much
as possible. If someone is around, a warning for the imminent noise shall be given to him.
5) When the airbag module and safety belt pretensioner are ignited, the person shall be at least 10 m
away from the ignited component.
6) Due to the high temperature, the airbag module shall be placed at least 30 minutes after ignition.
7) The person in charge of this mission or persons in site shall wear proper protective articles for ears.
2) Disconnect the positive and negative cables from the terminals of storage battery, and then
dismount the storage battery from vehicle.
Attention:
■ After the negative pole of storage battery is disconnected, at least 3 minutes shall be waited for until
the next step.
② Disconnect the connection between pin connector of clock spring of safety airbag and harness
connector of body airbag.
Attention:
■ After the connector of clock spring of safety airbag is disconnected from the harness of airbag of
vehicle body, the pole of connector of clock spring will automatically create a short circuit to prevent
the accidental ignition of airbag due to static and so on.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
4) Connect 2 wires with a length of over 10 m to the 2 lead wires of airbag adapter wiring, and use the
insulating tape to pack the joint. Besides, the other end of these two wires shall be connected each
other (short circuit) to prevent the sudden and accidental ignition of airbag.
5) Connect the pin connector of airbag to the airbag adapter wiring, and extend the wire used for
ignition outside the vehicle.
6) In order to restrain the ignition noise as much as possible, all the doors and windows shall be shut
and a vehicle cover shall also be used.
Attention:
■ If the window glass has any trace of damage, it will fall to pieces during ignition. Therefore, a vehicle
cover is required to be used.
7) Disconnect the 2 connected wires in the place which is far away from the vehicle as much as
possible, and then connect them to 2 terminals of storage battery (this battery has already been
dismounted from the vehicle) to ignite the airbag.
Attention:
■ Before using this method to ignite the airbag, first check and make sure that nobody is around or
inside the vehicle.
■ The aerator is very hot immediately after ignition, therefore, it shall be moved at least 30 minutes
later. Although the gas created by the ignition of airbag is innoxious, it can’t be breathed in. And
please refer to disposal methods of ignited airbag components for the move rules of airbag after
ignition.
■ If the airbag sub-assembly can’t be ignited according to the above methods, don’t walk towards it.
Please contact local dealers.
8) After ignition or operation, please dispose this airbag sub-assembly in accordance with the disposal
methods for ignited airbag sub-assembly.
1) This ignition shall be conducted in an open even ground where is away from barriers and persons
over 10 m.
2) The ignition can’t be conducted outside in windy days. Even if in breezy days, the airbag module
shall be ignited on the lee of storage battery.
① Disconnect the positive and negative cables from the terminals of storage battery, and then
dismount the storage battery from the vehicle.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Attention:
■ After disconnecting the cables of storage battery, at least 3 minutes shall be waited for until the next
step.
Attention:
■ The airbag sub-assembly shall be put on an even ground with its lining cover upward. And no
articles shall be put on its top.
Connect 2 wires with a length of over 10 m to the 2 lead wires of airbag adapter wiring, and use the
insulating tape to pack the joint. Besides, the other end of these two wires shall be connected each other
(short circuit) to prevent from the sudden and accidental ignition of airbag.
① Hold the airbag adapter wire connected with the above wire, make it cross the underside of old tire
assembly prepared and connected it to the airbag module.
② Make the thick wire go through the mounting hole of airbag sub-assembly, and then fasten the
airbag sub-assembly to the old tire of wheel with the pad upward.
Attention:
■ Leave a little space for the adapter wiring under wheels. If not, the counterforce caused by ignition
of airbag may destroy the adapter wiring.
③ Lay three old tires without hubs on the top of tire which fixes the airbag sub-assembly.
④ Disconnect the 2 connected wires in the shielded place which is far away from the airbag module as
much as possible, and then connect them to 2 terminals of storage battery (this battery has already
been dismounted from the vehicle) to ignite the airbag.
Attention:
■ The ignited gas generator is very hot, therefore, it shall be moved at least 30 minutes later. Although
the gas created by the ignition of airbag is innoxious, it can’t be breathed in. And please refer to
disposal methods of ignited airbag components for the move rules of airbag after ignition.
■ If the airbag sub-assembly can’t be ignited according to the above methods, don’t walk towards it.
Please contact local dealers.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
■ After ignition or operation, please dispose this airbag sub-assembly in accordance with the disposal
methods for ignited airbag sub-assembly.
After the ignition of airbag, it shall be disposed as other spare parts, and the followings shall be
especially paid attention to:
1) The gas generator is very hot after ignition, therefore, it shall be moved at least 30 minutes later.
3) The substance which will irritate eyes and skin may adhere to the ignited airbag sub-assembly,
therefore, gloves and eyeglasses shall be worn when the ignited airbag sub-assembly is being
moved.
Attention:
■ If any substance still enters eyes or adheres to skin after these attentions are obeyed, abundant and
clean water shall be used immediately to wash. And if the skin or other physical parts rankle,
medical cares shall be obtained.
4) Tightly seal the powerful PVC bag which contains the discarded airbag sub-assembly.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Caution:
■ The following precautions must be complied with when checking and repairing air conditioning
system. Otherwise, it may lead to damage of vehicle and physical injury.
Attention:
■ As the refrigerant is of low freezing point and high volatility, do wear gloves and glasses to avoid
chilblain, blindness, etc. when the skin contacts with refrigerant.
■ If the eye or skin contacts with refrigerant, wash it with water immediately and see an oculist or
dermatologist. Don’t rub the eye with hands or handkerchief.
■ The site shall be ventilated when conducting operations related to refrigerant. Great emission of
refrigerant in a closed place will lead to oxygen deficit.
Excessive emission of refrigerant will lead to abnormality or allergy of heart and cardiovascular
system, immune system and respiratory system, or skin disease.
■ When conducting operations related to refrigerant, there shouldn’t be any foreign substances such
as moisture, dust in the surrounding environment. These foreign substances which flow into the air
conditioning system are harmful to the system.
■ When conducting operations related to refrigerant, it is necessary to prepare a gas leakage detector.
When the R-134a refrigerant contacts with high-temperature objects, it will produce harmful gas.
Thus, it is necessary to prevent gas leakage.
■ The refrigerant adopted for this model must be R-134a refrigerant. Otherwise, there will be harmful
effect for the components of system.
■ R-134a refrigerant is incompatible with R-12 refrigerant. Thus, even the amount is extremely small,
they can not be mixed together.
■ As the R134a container is under high pressure, it is definitely forbidden to put it under high
temperature. Meanwhile, check if the temperature of storage environment is lower than 52℃.
■ Generally, there is a dust guard to prevent the sewage, dust, moisture from flowing into the
components of air conditioner. The dust guard shall be removed before operation and sealed up
after operation.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
■ The synthetic (PAG) refrigerant oil which is applicable to R-134a is easier to absorb moisture than
R-12, and its absorption rate is 10 times higher than that of mineral (MINERAL) refrigerant oil. If the
moisture is too much, the compressor, lubricating function and endurance will be affected.
■ Since moisture is extremely harmful to the air conditioner, it is better to avoid operation in rainy
days.
■ When mounting the air conditioning system again after dismantlement, do coat the “O” ring with
refrigerant oil. Especially for the screw-type connecting parts, assemble them with 2 spanners after
manual installation.
■ When assembling flange-type connecting parts, connect the nut and bolt while gently pushing the
pipeline.
Push
■ It is forbidden to separate the air conditioning system before completely recycling the refrigerant.
Otherwise, refrigerant and refrigerant oil will be discharged under the system pressure and bring
pollution to the surrounding environment.
■ When replacing components of air conditioner, fill refrigerant oil (model: PAG56) when filling
refrigerant.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
II. Preparation
High Intensity
Digital Multimeter Invisible Light
Lamp
R-134A Manifold
Cable Removing
Measuring
Caliper
Instrument
R134A Tracing
Microthermometer
Paint
50-pound
Pressure Test
Rechargeable
Adaptor
Recycling Tank
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Spring Clamp
Spring Clamp Caliper
Caliper
Refrigerant
Passive Test
Recycling/Regenerating
Lamp
and Refilling System
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
3) Gradually open the high-pressure manual valve and discharge the refrigerant.
Attention:
■ If discharging too fast, the refrigerant oil of compressor will be discharged from the system.
4) Check if there is refrigerant oil on the cloth. If there is, slightly close the manual valve.
5) When the reading on the scale of filling device is lowered to 3.5 kg/cm2, slowly open the
low-pressure manual valve.
6) To reduce the system pressure, slowly open the high-pressure and low-pressure manual valves until
the reading on the filling scale is 0 kg/cm2.
Attention:
■ The system must be vacuumized after discharging the refrigerant so as to remove the air and
moisture flowing into the system. Conduct vacuumization for 15 minutes after mounting each
component.
2) Connect the filling device to the connecting position of compressor and close the two sides.
5) After operating vacuum pump, open the high-pressure and low-pressure valves of filling device.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
6) 10 minutes later, the reading on the scale of low pressure detector shall be more than 0.96 kg/cm2,
(vacuum). Otherwise, there is leakage of system. Repair it according to the following steps:
■ Find out the leakage position with leakage detector and repair it.
Low High
Fig. 1.2.003
Close
Close
Air
Vacuum pump
8) The reading on the scales of filling device at both sides shall be kept as 0.96 kg/cm2 (vacuum).
10) After 15 minutes of vacuumization, close the pressure valve of filling device, stop vacuum pump and
separate the pipeline from vacuum pump so as to fill refrigerant.
1) Before connecting the valve and refrigerant container, completely rotate the handle anticlockwise.
3) After connecting the central pipeline to the valve device, rotate the disk by hand clockwise.
4) Rotate the handle clockwise and drill on the upper part of sealing.
5) Unscrew the nut at the connecting pipeline of central connector of filling device.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Attention:
Refrigerant
the system.
2) Open the low-pressure valve and adjust it to make the reading on low pressure scale lower than 4.2
kg/cm2.
Attention:
■ Put the container vertically to prevent filling the liquid refrigerant into the compressor through air
suction port.
Attention:
Put it into water and heat it to
■ In any case, don’t heat the water to higher around 40℃.
Refrigerant
than 52℃.
Attention:
■ This operation is for filling by the device at high pressure side. In this case, the refrigerant container
shall be inverted to let the refrigerant flow into the system.
1) After vacuumizing the system, completely close the high-pressure and low-pressure valves.
Refrigerant
amount while weighting the refrigerant, and
then close the high-pressure valve.
1. Summary of System
Manual control air conditioning system is adopted for this model. The condenser is overcooling
condenser, so the refrigeration performance is improved. To improve defrosting performance, it will
automatically shift to external circulation mode when the mixed mode and defrosting mode are selected.
On the basis of different vehicle speeds, cooling water temperatures and refrigerant pressures, the fan of
condenser is controlled by low and high stages. The increase of air volume of blower and the air mixing
capacity will lead to improvement of heating and refrigeration performances.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
High-temperature Low-temperature
High-pressure Low-pressure
Gas Liquid
High-temperature Low-temperature
High-pressure Low-pressure
Liquid Gas
Condenser:
Condenser is
Evaporator:
mounted at the front When the vaporous refrigerant
part of vehicle. It is is changed into gas, the heat
used for transferring will be absorbed from the air
the gas refrigerant passing through the evaporator
into liquid refrigerant by the blower.
with high
temperature and
high pressure.
Blower:
It is for sending the air to
evaporator and sending the
Drying Bottle: Compressor: cooled air into the vehicle.
The gas refrigerant with low
It will absorb the
temperature and low pressure
moisture of refrigerant
will be transferred into
and keep the refrigerant.
high-temperature
high-pressure gas by belt Expansion Valve:
pulley of engine and then sent
It will expand the
to the compressor. It is
refrigerant quickly and
controlled by clutch.
transfer it into
low-temperature
low-pressure liquid.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Blower relay
Signal of
turning on of
A/C Blower
End of small
lamp relay Blower
switch switch
Speed regulating
End of resistance
dimming A/C
switch relay
Blowing mode
motor
Compressor Air
conditioning
control panel
Radiator fan
relay
Air intake
Radiator
mode motor
fan
Thermostat
Condenser fan
Basic Diagram for Control Circuit of Air Conditioning System and Illustration of Pin
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
The blower consists of motor and fan. It is for shifting inside/outside air mode by the air door motor at the
air suction port, and for suction of the inside or outside air.
The function of the air door motor at the air suction port is realized by the inside/outside air button on the
controller. When it is under internal circulation mode, air will be taken in from the two lateral air inlets;
when it is under external circulation mode, air will be taken in from the filter mounted on the front
protecting cover at the front of vehicle.
In this case, the air is taken in by the blower. After heat exchange by evaporator, the cooled air will be
sent into the vehicle.
When the refrigerant in the evaporator passing through the expansion valve, the low-temperature
low-pressure liquid will absorb the heat from the air coming from outside and be changed into gas
refrigerant to lower the temperature.
1-Air bellow-evaporator 2-Air bellow-upper part 3-Air bellow-lower part 4-Air intake motor 5-Cooling pipe
6-Blower 7-Speed regulating resistance 8-Thermistor (evaporator temperature sensor) 9-Air filter 10-Air filter
cover 11-Wire harness 12-Heat insulating trimming
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Temperature Temperature
Resistance (kΩ) Voltage (V) Resistance (kΩ) Voltage (V)
(℃) (℃)
30 1.977 6. 54 6. 54 6. 54 2. 37
25 2. 45 6. 87 6. 87 6. 87 2. 44
20 3. 063 6. 54 6. 54 6. 54 2. 50
15 3. 85 6. 87 6. 87 6. 87 2. 56
10 4. 876 6. 54 6. 54 6. 54 2. 63
5 6. 221 6. 87 6. 87 6. 87 2. 69
4 6. 54 6. 54 6. 54 6. 54 2.71
3 6. 87 6. 87 6. 87 6. 87 2. 82
1) Function
When connected in series with the blower, the speed regulating resistance may be used to regulate the
rotating speed of blower.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
3) Appearance
Fig. 1.2.009
4) Parameters
■ At 25℃, the specification of resistance is: HI-MH: 0.65Ω, HI-ML: 1.3Ω, HI-LO: 2.3Ω.
1) Function
It is mounted at the inside/outside air inlet duct of evaporator and blower and its function is realized by
controlling the inside/outside air selection button.
2) Location
Fig. 1.2.010
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Operation Method
Input Voltage Output Direction
(Reference for
Terminal ① Terminal ②
Installation)
+ - Outside Air
- + Inside Air
Diagram for Inside/Outside Air Door Motor Circuit and Detection Method
6. Blower Motor
1) Function
With the vehicle power, it may rotate the fan to generate air volume required by the system.
2) Specification
Fig. 1.2.012
Rotation direction: Clockwise (At the Location of the
Fan)
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
7. Expansion Valve
1) Function
The expansion valve is assembled at the inlet of evaporator. With releasing function, it may transfer the
liquid refrigerant with high temperature and high pressure which flows from the condenser into saturated
refrigerant steam with low temperature and low pressure, so as to help the evaporator to evaporate the
refrigerant.
3) Specification:
Type: H type
Capacity: 1.5 RT
Attention:
■ When the cover of expansion valve falls, the heat of engine will be transferred to the thermo-bulb,
thus the pressure of expansion valve will be increased and the refrigerant in evaporator will be
excessive. If the evaporator is not working normally, the liquid refrigerant will flow to the compressor
and result in damage.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
2) Installation Location
■ Detection:
When ① is connected to + pole and ② is connected to – pole, the motor operates towards the VENT
(face-blow) direction.
When ① is connected to – pole and ② is connected to + pole, the motor operates towards the DEF
(demist) direction.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
1) Function
It is mounted at the lower part of heat installation housing and controlled by the operational signal of
temperature switch on the air conditioning panel (FTAC). It starts the small motor to regulate the position
of temperature control air door. The variable voltage difference, when starting the motor, will be fed back
to the FATC which will judge the feedback signal. When the air door arrives at the specified position, the
motor will stop.
2) Installation Location
Fig. 1.2.017
■ Detection:
When ① is connected to + pole and ② is connected to – pole, the motor operates towards the COOL
(refrigeration) direction.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
When ① is connected to – pole and ② is connected to + pole, the motor operates towards the HOT
(heating) direction.
11. Condenser and Drying Bottle
1) Function
It may cool the gas refrigerant with high temperature and high pressure coming from the compressor at
ambient temperature. The cooling of condenser depends on the running air and the forcible air volume of
fan. The condenser for this model is of overcooling type and works with drying bottle. By overcooling, it
improves the refrigeration performance and reduces the amount of refrigerant required by the system.
Besides, the incorporation with drying bottle reduces the amount of components. In the past, when there
is pollution of system, it is required to replace the drying bottle. But for this model, after separating the
cover at the lower part of drying bottle, it is only required to replace the dryer.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
After comparing the input vehicle speed, the load of air conditioner and the cooling water temperature,
the engine ECM is divided into two stages (high/low) to control the rotating speed of cooling fan.
■ When there is trouble with speed sensor and cooling water temperature sensor, the engine ECM
drives the cooling fan to run at high rotating speed.
■ When the air conditioner compressor is shut down due to overheating, the starting temperature is
115℃.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Compressor relay
Fan relay
Pressure switch
Cooling fan
Fan relay
Fan relay
Fan
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Fig. 1.2.019
5) Specifications
■ Fan
■ Motor
1) Function
In the 3-phrase pressure switch, a medium pressure is added between the two end pressures of air
conditioner. When the system pressure increases, the pressure switch will be started and send signal to
engine ECM.
At that time, the engine ECM drives the cooling fan to run at high rotating speed to avoid lower
performances as a result of increased pressure. Besides, in this way, the air conditioning system may be
protected when the pressure is abnormal (high/low pressure).
2) Installation Location
Fig. 1.2.020
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3) Circuit Diagram
4) Specifications
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
1) Dismantlement
① Use special refrigerant recycling equipment to recycle the refrigerant in the system.
Fig. 1.2.023
③ Dismantle the console assembly. Please refer to “Dismantlement and Installation of Console” for the
dismantlement steps.
④ Open the engine cabin and dismantle the fixed bolt of expansion valve.
⑥ Cut off the connector of the circuit and take off the evaporator blower assembly.
2) Installation
Fig. 1.2.024
1) Dismantlement
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Fig. 1.2.025
② Dismantle the console assembly. Please refer to “Dismantlement and Installation of Instrument
Desk” for the dismantlement steps.
③ Open the engine cabin and cut off the joint of warm air blower water pipe.
Fig. 1.2.026
Fig. 1.2.027
⑤ Cut off the connector and take off the warm air blower assembly.
2) Installation
1) Dismantlement
Fig. 1.2.028
③ Cut off the connectors and dismantle the fixed bolt of temperature-controlled motor.
Fig. 1.2.029
Fig. 1.2.030
2) Installation
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
1) Dismantlement
Fig. 1.2.031
③ Cut off the connectors and dismantle the fixed bolt of mode air door motor.
Fig. 1.2.032
Fig. 1.2.033
2) Installation
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
1) Dismantlement
Fig. 1.2.034
③ Cut off the connectors and dismantle the fixed bolt of inside/outside air door motor.
Fig. 1.2.035
Fig. 1.2.036
2) Installation
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
1) Dismantlement
Fig. 1.2.037
③ Cut off the connectors of power amplifier wire harness and dismantle the two fixed bolts.
Fig. 1.2.038
Fig. 1.2.039
2) Installation
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Fig. 1.2.040
1) Pry out the trimming frame of air conditioning panel with slotted screw driver.
Fig. 1.2.041
2) Dismantle the fixed bolt of air conditioning panel and take the panel off.
Fig. 1.2.042
3) Installation
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2) Installation
Attention:
9. Compressor Assembly
Fig. 1.2.048
1) Disassembly of Compressor
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③ If there is leakage at A position, replace the high-pressure relief valve. If there is no leakage, the
valve still can be used.
④ If there is leakage at B position, please tighten the valve. If there is still leakage after tightening,
replace the seal gasket.
3) Installation
Fig. 1.2.051 Clearance Gauge
Attention:
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
1. Function
The air conditioner adopts particulate filter to remove the foreign substances and odor in the vehicle, so
as to keep a comfortable indoor environment. For convenience of replacement, a 2-plate filter is
adopted.
Fig. 1.2.052
2. Replacement Cycle
If the filter is not replaced for a long time, the filter will be blocked by foreign substances, the noise of
blower will be increased and the air outlet volume will be reduced, etc.
The replacement cycle is 5,000~12,000 km. It is necessary to check and replace the filter frequently in
region with serious air pollution or poor road condition.
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2) Push the glove box towards the two sides and push the air conditioner filter upwards to separate it.
Fig. 1.2.054
3) Hold the upper air conditioner filter and pull it Fig. 1.2.055
out.
Attention:
■ When replacing filter, the arrow shown at the front end shall points to the core body. Don’t assemble
constrainedly.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
I. Precautions
Strictly comply with the precautions for operation of SRS, or else, damage to vehicle and people
may be caused.
Dismount the negative pole of storage battery and wait for at least 1 min before dismounting the
connector of electrical appliance, or else, vehicle damage will be caused.
■ Use cloth to protect the dismounted spare parts from being damaged and scratched during
dismantling and installing the elements.
■ Wrap the right-angled screwdriver blade with cloth, when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly mounted into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
Alarm
ETACS module
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Ignition switch
Front/rear washing
switch
Front/rear wiper
T1: 0. 6 ± 0.1s T2: 2. 5—3. 8s T3: 0. 2—0. 6s (MAX) T4: One wiping period
When the ignition switch is turned to the “ON” position, after the washing switch is turned on for more
than 0.6s, the wiper will operate after T1 (0.6 ± 0.1s) of the wiper switch turns on until it is turned off, and
the wiper will wipe for another three periods T2 (that is 3 times); after the time of the washing switch
turned on is within 0.2 ~ 0.6s, the wiper will wipe once again.
Ignition switch
Front wiper
T3: when the speed = 0Km/h, it can be adjusted in the range of 2.6 ± 0.7s (VR = OKΩ) ~ 18. 0 ± 1 s (VR
= 50KΩ).
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
When the speed is more than 100Km/h, it can be adjusted in the range of 1.0 ± 0.2s (VR = OKΩ) ~ 10. 0
± 1 s (VR = 50KΩ). The ignition switch is at “ON” position, the pause switch has been turned on for T1
(0.3s) and then begins to act, and the wiper acts. The finished time of each wiping action is T2 (0.7 ±
0.1s), when the speed=0Km/h, the interval of each wiping action can be adjusted within the range of 2.6
± 0.7s (VR = 0KΩ) ~ 18.0 ± 1s (VR = 50KΩ. When the speed is more than 100Km/h, it can be adjusted in
the range of 1.0 ± 0.2s (VR = 0KΩ) ~ 10.0 ± 1s (VR = 50KΩ).
"L" end of
generator
Defrost switch
Defrost relay
T1: 20 ± 2ms
When the generator is in operation, turn on the defrost switch, the defrost relay begins to work and it will
last for T1 (20 ± 2ms). If the interval of pressing the defrost switch is less than T1, the defrost function will
be disabled when defrost switch is pressed for the second time.
When the ignition switch is the OFF position, any one of the left and right front doors can be open, the
ignition lock lighting is on, and it will be off after T1 (10 ± 1s) of the door closed; if the front door is open,
the lighting will be off after the ignition switch is turned to the “ON” position.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Ignition switch
IGN. S/W
Illumination of
ignition lock
hole
T1: 10 ± 1s
Set the front dome lamp in the DOOR position, the front door is open and the front dome lamp is on,
when the door is closed and after the ignition switch is at the ACC position, the front dome lamp will go
out gradually after T1 (5.5 ± 0.5s); and after the ignition switch is at the “ON” position, the front dome
lamp will go out directly.
Igniton switch
Illumination of front
dome lamp
T1: 5. 5±0.5s
When the ignition switch is at “ON” position and the parking handle is not released, after the speed is
more than17Km/h, the door bell will ring at the interval of T1 (0. 3 ± 0. 1s), and if the parking handle is
released at this moment, the door bell will stop ringing; and when the speed is less than17Km/h, the door
will not ring.
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Ignition switch
Parking brake
switch
Speed sensor
Harmonic bell
T1: 0. 3 ± 0. 1s
Ignition switch
Take off
Safety belt switch
Enable
Harmonic bell
When the ignition switch is at the “ON” position and the driver does not wear the safety belt, the safety
belt alarm lamp flashes with the duty cycle of 50% at the interval of T1 (0.3 ± 0.1Is), and the door bell will
ring at the interval of T2 (0.45 ± 0.1s) and with the period of T3 (6 ± 1s); when the driver wears the safety
belt, the alarm lamp will flash for one period and give out a warning tone; the alarm lamp will flash and
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give out a warning tone if the safety belt is unfastened, indicator lamp for not wearing safety belt will be
still on after flashing for one period, vise versa, the safety belt indicator lamp will go out after flashing for
one period.
When the ignition switch is at the “ON” position and the front door is closed, the electric window can
operate. When the ignition switch is at the LOCK or ACC position, the electric window can operate within
T1 (30 ± 3s); if the front door opens in T1 (30 ± 3s), the electric window can’t operate.
Ignition switch
Electric window
motor
T1: 30±3s
When the lamp switch (left switch of the combined switch) is turned to “ON” from OFF in any case, the
tail lamp will turn on.
1) The lamp switch (left switch of the combined switch) is turned from “ON” to OFF.
2) After the key is drawn out, the door at driver’s side will be open, and meanwhile the tail lamp will go
out; if inserting the key at this moment, the tail lamp will turn on.
Note: Here the tail lamp refers to the small lamp system.
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Insert
Ignition Key
Draw out
When the ignition switch is at the OFF position, the lamp switch is turned on (at the left side of combined
switch), and the front fog lamp switch is turned on, the rear fog lamp will not be lighted when the rear fog
lamp switch is turned on; when the ignition switch is at the “ON” position, the lamp switch is turned to the
gear of small lamp (at the left side of combined switch), and the front fog lamp switch is turned on, the
rear fog lamp will be lighted when the rear fog lamp switch is turned on, while the front fog lamp is turned
off at this moment, the rear fog lamp will be turned off at the same time; when the ignition switch is
turned to other lamp positions, the work of the rear fog lamp is not controlled by the front fog lamp, that is,
when the front fog lamp switch is turned off, the rear fog lamp switch can control the rear fog lamp
automatically.
Ignition switch
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
There is a central control door lock which can control the four doors at the driver’s side and passenger’s
side. When the door is shut at the driver’s side, the fastener outputs the lockout signal, and the door is
locked; when the door is opened at the driver’s side, the fastener outputs the unlock signal, and the door
is opened. The control process of door lock at passenger’s side is also the same with that of at driver’s
side.
Pull up
Pull up
Door switch at the
passenger’s side
Press
Door lockout
output
When the key is not removed and the door at driver’s side is open, the fastener output a signal, and the
door can not be locked; if the fastener switch is pressed continuously, the fastener outputs an unlock
signal, after that it outputs the unlock signal for 3 times; if the door at driver’s side is closed in T3 (0s
<T3<0.5s) of the fastener switch being pressed, the fastener switch is released, meanwhile, the fastener
will output an unlock signal, and the door is not locked.
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Insert in
Ignition key
Draw out
Turn on
Door switch at the
driver’s side Turn off
Lockout
Door lock switch
Unlock
Unlock the front
door
Output
When the collision occurs, the airbag will be unfolded, meanwhile the airbag control module will output
an OV signal to ETACS, and then the ETACS will output an unlock signal to the fastener, subsequently
the fastener will output an unlock action of T3 (5s) after T2 (40s). After that the door will be unlocked.
Unfolded
The airbag
unfolded condition
Folded
Airbag module
Collision signal
Unlock
The electric door is
open
Lockout
Output signal
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
When the ignition switch is at “ON” position and the door is not locked, if the vehicle travels with a speed
of more than 40Km/h for T1 (1 ± 0.3s), the door will be locked automatically; if the fastener unlocks
during traveling, the door will be locked automatically again after T1 (1 ± 0.3s).
Ignition switch
Speed sensor
Less than 40km/h
Unlock
Lockout switch of
the entire door Lockout
Lockout relay
T1: 1 ± 0. 3s
When drawing out the key under locked state of the vehicle door, the lockout relay will send an unlock
signal of T1 (0.5 ± 0.1s), after that the door will be unlocked.
Insert
Ignition switch
Remove
Unlock
Lockout switch of
the entire door Lockout
Lockout relay
T1: 0. 5 ± 0. 1s
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When the doors and the engine cover are closed, the door shall be locked with remote controller, the
hazard alarm lamp will flash for T2 (1.0 ± 0.2s), and the vehicle is in guard status; when there is door not
closed, it shall be locked with remote controller, after that the hazard alarm lamp will not flash, and the
vehicle is not in the guard status at the moment; when the doors are all locked, the hazard alarm lamp
will flash for T2 (1.0 ± 0.2s), and the vehicle is in guard status.
Open
Front cover of
each door Closed
Remote control
Lockout relay
Guard
Guard status
Guard release
Hazard alarm
lamp
T1: 0. 5 ± 0. Is T2: 1. 0 ± 0. 2s
When releasing guard with remote controller, the door is unlocked, and the hazard alarm lamp will flash
for T1 (0.5 ± 0.1s), and it will flash for another T1 after T2 (0.5 ± 0.1s). Moreover, when adopting the
remote controller to open the door, if the door is not open after 30s, the vehicle will be in guard status
automatically.
This function is set up to prevent the door from being opened accidentally.
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Remote control
opening the door
Unlock relay
Guard
Guard status
Guard release
Hazard warning
light
Illumination of the
driver’s dome lamp
Door switch DR
S/W
Lockout relay
When the vehicle is in guard status, after opening the door or the engine cover, the siren will alarm for Tl
(27 ± 2s) at one inteval of T2 (10 ± 1s). After repeating for 3 times, the vehicle is under guard status, the
hazard alarm lamp will flash for T3 (0.5 ± 0.1s) with the duty cyle of 50%, with same flash time as that of
the siren.
Guard
Guard status
Guard release
Open
Front cover of
each door Closed
Rear boot door
Siren
Hazard alarm
lamp
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Open
Front cover of
each door Closed
Rear boot door
Starter relay
Siren
Remote control
opening door
Unlock relay
Guard
Guard status
Guard release
Starter relay
Siren
Hazard alarm
lamp
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
T1: 0. 5 ± 0. 1s T2: 0. 5 ± 0. 1s
21. Lockout with Remote Controller When the Vehicle is in Guard Status and the Door is Locked
When the vehicle is in guard status and the door is locked, the remote controller shall be adopted for
lockout, the relay shall be started to deenergize, and the hazard alarm lamp will go out after flashing for
T1 (1 ± 0.2s). At this moment, the vehicle is in guard status.
Open
Front cover of each
door
Rear boot door is
closed
Remote control
locking door
Lockout relay
Starter relay
Hazard alarm
lamp
T1: 1 ± 0.2s
22. Lockout with Remote Controller When the Vehicle is in Guard Status and the Door is Unlocked
When the vehicle is in guard status and the door is unlocked, the remote controller shall be adopted for
lockout, and the lockout relay outputs a lockout signal, and the relay shall be started to deenergize; if all
the doors are locked, and the hazard alarm lamp will flash once for T1 (1 ± 0.2s). At this moment, the
vehicle is in guard status.
Remote control
locking door
Lockout relay
Starter relay
Hazard alarm
lamp
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T1: 1 ± 0.2s
When the vehicle is in guard status, after the igniton switch is turned to the “ON” position, the vehicle will
be guard released after 30s.
Insert
Ignition key
Remove
Ignition
switch
Siren
Guard
Guard status
Guard release
After the guard status, the door re-opens abnormally, the siren still sounds alarm, and the initial guard
status is repeated.
Starter relay
Siren
Hazard
alarm lamp
25. Dismantling and Mounting the Storage Battery in Guard Status and During Alarm
Mount the storage battery after dismounting the storage battery in guard status and during alarm, at this
moment the vehicle is still in guard status, and the siren sounds.
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Guard
Guard status
Guard release
Battery Mount
Starter relay
Siren
Dismantle the storage battery in guard status, and then mount it, at this moment the vehicle is guard
released.
Dismount
Battery
Mount
Guard
Guard
status Guard
release
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2. Press any key on the remote controller, and re-press it after 3s.
4. If there are several remote controllers to be memorized, the step1, 2, and 3 can be repeated, one
key can be memorized each time, and 6 keys in all can be memorized.
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Fig.1.3.001
Fig.1.3.002
4. Dismount the connectors of each connecting switch (front fog lamp switch, rear fog lamp switch,
combined device brightness adjustment switch, lighting distance adjustment switch of the front
headlamp).
Fig.1.3.003
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Fig.1.3.004
Fig.1.3.aa0
7. Cut off the ETACS module connector to dismount the ETACS module.
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Fig.1.3.006
Fig.1.3.007
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Item Specification
Operating volatage DC12V
Range of operating voltage DC9V ~ DC16V
Quiescent current MAX 10mA (at 12.8V)
Insultation resistance 100MΩ (DC500V megameter)
Operating temperature -40°C ~ 5°C
Storage temperature -55°C ~ 150°C
Front/rear wiper relay DC 12V, 200mA (relay load)
Defrost relay of rear windscreen DC 12V, 200mA (relay load)
Illumination of ignition key hole DC 12V, 1.4W (bulb load)
Illumination of dome lamp for driver DC 12V, 10WX2 (bulb load)
Acousto-optic device of safety belt DC 12V, 1.4W (bulb load)
Electric window relay DC 12V, 200mA (relay load)
Tail lamp realy DC 12V, 200mA (relay load)
Rear fog lamp relay DC 12V, 200mA (relay load)
Electric door relay DC 12V, 200mA (relay load)
Alarm DC 12V, 260mA (relay load)
Warning tone DC 12V, 350mA (relay load)
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
1. Lamp Control
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Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
4-Dipped headlamp 5-Small lamp 6-OFF 7-Overtaking lamp 8-High beam lamp
Control the signals of left/right turn lamp, headlamp, side turn lamp, and of overtaking lamp. In the mode
of headlamp, it can also realize two function options: shifting from high beam to low beam, or shifting
from low beam to high beam.
1) Turn Lamp
The turning signal level has two upwards (right turn) positions and two downwards (left turn) positions,
which are used for sending turning signal.
Put the level to the end upwardly or downwardly to send turning signal. When the turning movement is
fulfilled, the level will automatically return. One of the arrows on the combined device will flicker and
show the turning direction.
In order to send turning signal, you need only lift or press down the level until the arrow begins to filcher,
and hold the level there until the vehicle lane-changing is fulfilled. When you release the level, it will
automatically return. When you sending the turning signal, if the turning arrow flickers too fast, the signal
lamp maybe broken, and the other drivers can’t successfully notice the turning signal you send.
If some bulb is burned out, it shall be replaced, in case of traffic accidents. If the driver sends out turning
signal, but the arrow doesn’t flicker at all, you shall check whether the bulb is burned out, and then check
the fuse.
If you want to shift the headlamp from low beam to high beam, push the turning signal/ multi-functional
level in the direction deviating from you. When the high beam is powered on, if you turn on the ignition
switch, the combined device will display the high beam lamp signal.
If you want to shift the headlamp from high beam to low beam, you need pull the turning
signal/multi-functional level towards you.
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3) Overtaking Flash
This function can help the driver send overtaking signal to the vehicle in front of him by the usage of high
beam headlamp. For using this function, pull the turning signal/multi-functional level towards the driver
until the high beam of the headlamp is turned on, and then release the level to turn off the headlamp.
1) Operating Modes of Wiper Controlling (Washing, Interval, Low Speed, High Speed)
At the interim gear, the wiper has three different modes, viz. high, medium, and low modes for selection.
The front windscreen wiper is operated only when the ignition switch is powered on. Use the level at the
right side of the steering column to operate the front windscreen wiper.
HI (high): turning the level to this position can realize the high speed wiping function.
LO (low): turning the level to this position can realize the stable low speed wiping function.
INT (interim): turning the level to this position can choose wiping delayed for a cycle.
Turn the middle section of the wiper level towards the LO direction, and the delay is prolonged; while,
turn it towards the HI direction, and the delay is shortened. Only when the level is in the INT position can
the wiping speed be adjusted.
In order to wiping the front windscreen, pull the washing solution level of front windscreen wiper towards
you, with the ignition switch powered on, and the washing solution of the windscreen wiper will be
injected from the spray nozzle.
Attention:
■ In cold weather, the wiper is not allowed to be used until the front windscreen is preheated.
Otherwise, the washing solution will get frozen on the front windscreen and interfere with your view.
■ When you release the level, the washing apparatus will stop working, however, the wiper will
continue to work for other three cycles and then either stop or recover to the wiping speed you
select before.
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Inspect the on-state between each terminals of the lead wire connector according to the following charts.
If the on-state doesn’t confirm with the following charts, replace the switch.
Dipped headlight
Small light
High beam light
Big light
Overtaking
Terminal
Function
Interm
Low speed
High speed
Front washer
Intermission
time adjusting
Rear washer
Rear wiper on
Precaution:
Strictly comply with the precautions for operation of SAS, or else, damage to vehicle and people
may be caused.
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Dismount the negative pole of storage battery and wait for at least 1min before dismounting the
connector of electrical appliance, or else, vehicle damage will be caused.
■ Use cloth to protect the dismounted spare parts from being damaged and scratched during
dismantling and installing the elements.
■ Wrap the right-angled screwdriver blade with cloth, when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly mounted into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
1. Dismantlement Steps:
2) Dismount the steering wheel. Refer to the “Replacement Steps of Steering Wheel”.
3) Dismount the upper and lower covers of steering column cap. Refer to the “Replacement Steps of
Upper and Lower Cover of Steering Column Cap”.
4) Dismount the clock spring of safety airbag. Refer to the “Replacement Steps of Clock Spring of
Airbag”.
Fig. 1.4.002
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Fig. 1.4.003
2. Installation Steps:
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■ Use cloth to protect the dismounted spare parts from being damaged and scratched during
dismantling and installing the elements.
■ Wrap the right-angled screwdriver blade with cloth, when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly mounted into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
II. Headlamp
1. Location Plan of Element
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Power Power
supply supply
Relay of lower
Relay of beam lamp
upper
beam
lamp
Left lower beam
Right upper
beam lamp
Lower beam
lamp
lamp
lamp
Lower beam
Small lamp
Overtaking
2) Relay of headlamp
Less than 2Ω
Multimeter
Storage battery
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4. Replacement of Headlamp
1) Dismantlement steps:
① Cut off the negative pole of storage battery.
Fig. 1.5.001
Fig. 1.5.002
Fig. 1.5.003
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Fig. 1.5.004
Fig. 1.5.005
2) Installation steps:
① Connect the electrical connectors of headlamp
assembly.
② Mount the headlamp assembly and fixed bolt.
Tightening torque: 5N•m
Fig. 1.5.006
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Fig. 1.5.007
Fig. 1.5.008
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Dismantlement steps:
① Cut off the negative pole of storage battery.
Fig. 1.5.009
Fig. 1.5.010
③ Disconnect the connector from the rear of bulb and loose the snap-in.
④ Dismount the headlamp bulb carefully.
⑤ Don’t shake or screw the bulb during dismantlement.
2) Install in the reverse order with dismantlement.
Attention:
Don’t dismount the headlamp from reflector for a long time, or else, the performance of lamp may be
affected due to ingress of dust, moisture, smoke, etc. Once the bulb in reflector of headlamp is
dismounted, mount a new bulb as soon as possible.
6. Replacement of Turn Lamp Bulb of Headlamp
Attention:
Don’t dismount the headlamp from reflector for a long time, or else, the performance of lamp may be
affected due to ingress of dust, moisture, smoke, etc. Once the bulb in reflector of headlamp is
dismounted, mount a new bulb as soon as possible.
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The headlamp is of semi-closed beam type, and the replaceable halogen bulb is applied. The
replacement of bulb can be carried out in engine compartment after the dismantlement.
When dealing with the bulb, hold the plastic seat of bulb rather than touch the glass shell.
Don’t shake or screw the bulb during dismantlement.
1) Dismantlement steps:
① Cut off the negative pole of storage battery.
Fig. 1.5.011
Fig. 1.5.012
Fig. 1.5.013
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Fig. 1.5.014
Fig. 1.5.015
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Fig. 1.5.018
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Fig. 1.5.019
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Fig. 1.5.020
Fig. 1.5.021
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Fig. 1.5.024
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② Make sure the fuel achieves the full level or slightly below.
③ Stop the vehicle on level ground and keep a 1.52m distance with target screen.
④ Stop other operations carried out on the vehicle.
⑤ Rock the vehicle to make the suspension be available.
⑥ Cover the headlamp during the adjustment of beam of fog lamp.
2) Turn on the front fog lamp.
3) Insert the cross screwdriver through the space under front bumper to get close to the vertical
adjusting screw.
4) Adjust the fog lamp upward/downward to make the top edge of highlight area be 102mm lower than
the horizontal centerline (2). The area shown in target screen is the ground boundary (5) which is
0mm below the horizontal centerline (3).
5) Turn off the front fog lamp.
Fig. 1.5.025
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Fig. 1.5.026
Fig. 1.5.027
③ Dismount the trim strip of boot cover. Please refer to “Replacement of Trim Strip of Boot Cover”.
④ Take off the cover plate of spare tyre. Please refer to “Replacement of Cover Plate of Spare Tyre”.
Fig. 1.5.028
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Fig. 1.5.029
Fig. 1.5.030
Fig. 1.5.031
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⑧ Pull out the connector of tail lamp and take off the tail lamp.
Fig. 1.5.032
5-Stop lamp 6
3
6-Reversing lamp
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Fig. 1.5.034
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Fig. 1.5.036
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Fig. 1.5.037
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Fig. 1.5.038
Fig. 1.5.039
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Fig. 1.5.040
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Fig. 1.5.044
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Fig. 1.5.045
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Fig. 1.5.046
Fig. 1.5.047
2) Installation steps:
① Connect the electrical connector.
② Mount the side turn signal lamp on the fender.
4. Replacement of Side Turn Signal Lamp Bulb
1) Dismantlement steps:
① Dismount the side turn signal lamp. Please refer to “Replacement of Side Turn Signal Lamp”.
② Anti-clockwise screw the turn lamp seat out from the mounting hole.
③ Dismount the bulb from the side turn signal lamp seat.
④ Replace the bulb of side turn signal lamp.
2) Install in the reverse order with dismantlement.
Attention:
Check if the bulb is in good condition before installation.
Mount the bulb properly on the lamp seat.
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Carry out alignment for mounting hole during installation of lamp seat and mount it properly.
Conduct inspection after installation.
Don’t dismount the bulb for a long time, or else, the performance of lamp may be affected due to
ingress of dust, moisture, smoke, etc. Once the bulb is dismounted, mount a new bulb as soon as
possible.
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Fig. 1.5.051
Fig. 1.5.052
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X. Reading Lamp
1. Location Plan of Element
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Fig. 1.5.055
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4. Lighting Switch
Table of lighting switch parameters
2. Torque Specification
Table of Torque Specification
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Fig.1.6.001
1. Speed meter: the pointer moves according to the signals which are from speed sensor, showing the
travel speed of vehicle.
2. Tachometer: the pointer moves according to the rotate speed signals inputted by ECM of engine,
showing the rotate speed of engine.
3. Water thermometer: the pointer moves according to the signals which are from the coolant
temperature sensor, showing the temperature of engine coolant.
4. Fuel oil meter: the pointer moves according to the signals which are from the fuel oil sensor,
showing the amount of remained oil in the fuel tank.
5. Odometer: it calculates the total (accumulated) travel distance of vehicle through pulse signals
which are from speed sensor and it can switch short trips (subtotal).
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Input Mode of
No. Name of Indicator Lamp Symbol Color Remarks
Signal
Charge-discharge indicator
1 Red Low level LED
lamp
Alarm lamp of engine oil
2 Red Low level LED
pressure
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3
1
1) Dismantlement steps:
Fig.1.6.002
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Fig.1.6.003
Fig.1.6.004
2) Installation steps:
Fig.1.6.005
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Fig. 1.6.006
1. Principle
1 2
The crossed coil speed meter and odometer are used in this vehicle to indicate the vehicle’s traveling
speed and accumulated traveling mileage, and a digital odometer is also set. A magnetic-type structure
is adopted for measuring vehicle speed while a multifunctional LCD is used to control the recording of
mileage.
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When the speed meter doesn’t work, the pointer will be at the zero position. When the vehicle travels,
the lines of magnetic force of permanent magnet driven by a driving gear in the transmission to cut the
HALL vehicle speed sensor will make the HALL vehicle speed sensor produce pulse-width signals and
provide them for the cross coil speed odometer so as to drive the pointer of speed meter to move.
Meanwhile, it provides the control mileage for the multifunctional LCD which records the mileage.
2. Testing
1) Testing:
④ In order to prevent the vehicle from moving around, the left and right of vehicle shall be fixed.
⑤ In order to prevent the vehicle from rushing out, a chain or steel wire shall be used to fasten the rear
and make sure the ends of chain or steel wire are fixed tightly.
⑥ Check whether the indication of speed meter is within the range of standard value.
Comparison Table for Indicated Standard Range and Frequency of Speed Meter
Attention:
During test, don’t operate the clutch suddenly or increase and reduce the speed rapidly.
Check whether the circuit and plug resistance of combined device and speed sensor are conducted.
And the electrical resistance value shall be less than 0.5Ω.
Detect the waveform between input terminal of combined device and grounding of vehicle body, and
it shall be the rectangular wave with 12V.
Verify the change of frequency along with vehicle speed, that is, the frequency shall increase with the
times of 7.08 Hz when the vehicle speed is increased from 10 to 20 to 30 km/h.
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V. Tachometer
1. Principle
The tachometer of engine is used for indicating the running speed of engine. When the engine is running,
its rotating speed sensor will send rotating speed signals to ECM of engine. The ECM will send an
impulse square wave to the combined device according to the rotating speed of engine, then, the
combined device controls the pointer of tachometer of engine according to this signal in order to indicate
the actual rotating speed of engine.
Remarks:
It had better to use a fluxmeter type tachometer of engine to conduct the check. (Because the
fluxmeter only needs clipping on the high-voltage wire.)
2) Compare the reading of tachometer of engine with reading of tachometer in the vehicle under each
rotating speed of engine, and make sure that the difference between them is within the range of
standard value.
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Comparison Table for Indicated Standard Range and Reference Frequency of Tachometer
750 25Hz
1050 35Hz
1500 50Hz
3000 100Hz
4500 150Hz
6000 200Hz
7500 250Hz
Possible Cause
Repair it.
measure at the wiring’s side: abnormal. connector.
1. Measure whether there is a
pulsed voltage between #1
terminal of C and grounding part of
vehicle body when the engine is
running. Normal
Normal: there is a pulsed voltage.
2. Measure the continuity condition
between #2 terminal of B and
grounding part of vehicle body. Check the rotational speed
Normal: in conducted. sensor of engine, and repair it
if necessary.
Normal
2 is
abnormal. Check the wiring, and repair
Replacing the tachometer. it if necessary.
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An analog water thermometer (coolant thermometer) driven by stepper motor is used. And it is shown in
the following diagram.
The adopted coolant temperature sensor is a thermistor sensor, and its location is shown as the
following diagram:
During start and warm-up, the engine will work in this zone for a short time. And in this temperature zone,
the engine shall be prevented from running with a high rotate speed, at the same time its working load
shan’t be overlarge.
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Between C and H——Normal temperature zone The pointer shall be within this range when the
vehicle is traveling normally.
When the outside temperature is very high and load of engine is very heavy, the pointer may deviate
from this range. As long as the coolant alarm lamp doesn’t flash, the vehicle still can travel normally.
However, if it flashes to warn, the engine shall be shut and the cooling system shall be checked.
If the pointer enters this red zone, it means that the engine is overheated. Please safely stop the vehicle
immediately, shut down the ignition switch and find out the cause after the engine is cooled off.
Illustration:
If the auxiliary headlamp is mounted in front of cold air inlet which is under the front bumper, it will affect
the circulation of cooling air and be harmful for cooling of engine. If the outside temperature is very high
and engine is working with a heavy load, the engine is easy to be overheated. The front spoiler is also
helpful for guiding cooling air. If it is damaged or even ruptures due to impact, the overheating of engine
may happen.
If the electrical resistance value of coolant temperature sensor of engine is normal, the circuit of sensor
and water thermometer shall be checked. If not, the maintenance or replacement shall be conducted.
Please refer to “Maintenance Volume of Circuit”.
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The working condition of fuel oil meter is basically the same with the water thermometer, that is, an
analog instrument driven by stepper motor is used.
When the floater changes with the oil level in fuel oil tank, the sliding contact linked with floater rod
responds to change the electrical resistance value of thick-film resistor. Therefore, when the fuel oil tank
is filled with fuel oil, the electrical resistance value of thick-film resistor is the smallest, and the pointer of
fuel oil meter points to the maximum scale value F. On the contrary, when the fuel oil in fuel oil tank is
used out, its electrical resistance value is the largest, and the pointer points to the minimum scale value
E.
1. Testing Method
When the pointer reaches the empty position (E), there is fuel oil of about 10 L in the fuel tank. And it
leaves the full position (F) only when the vehicle has traveled for a distance after the fuel tank is filled.
With oil remained, the quantity of fuel oil that can be added will lower than the marked capacity when the
oil is added renewedly.
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Normal
Abnormal
Abnormal
1) Check whether the electrical resistance values among terminals of fuel oil meter sensor are within
the range of standard value when the floater of fuel oil meter sensor sub-assembly is at F position
(highest) and E(lowest) position.
Comparison Table for Electrical Resistance and Instrument Indication of Fuel Oil Meter Sensor
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When ignition switch is on, this indicator lamp shall light immediately and go out after the engine is
started. If this lamp doesn’t go out after engine starting or it lights when the rotating speed of engine
exceeds 2000 r/min during traveling, stop the vehicle immediately, switch off the engine and check the
oil level of engine oil. If the oil level is too low, add oil immediately.
Disconnect the connector from alarm lamp switch, and connect the connecting terminal in the end of
wiring to earth. Shift the ignition switch to “ON”, and alarm lamp shall light. If not, the bulb shall be tested.
Combined
device
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If the lamp is still on after the parking brake is released, then the oil level of brake fluid is too low.
Therefore, the brake fluid shall be added until its level is between MIN and MAX marks.
Disconnect the connector from the switch of alarm lamp of brake fluid, loose the parking brake, and start
the engine. At this moment, the alarm lamp shall turn on, if not, test the bulb and wiring.
Dismount the stock solution tank cover and strainer screen, disconnect the connector, and shift the
switch to “OFF” position (the floater floats). At this moment, the terminals shall not be conducted. Use a
siphon to suck out the liquid in stock solution tank and shift the switch to “ON” position (the floater falls).
And now, the terminals shall be conducted. At last, pour the liquid back in stock solution tank. If the
actual conditions don’t comply with the above conditions, the switch shall be replaced.
1. The alarm lamp shall light when any door or trunk is opened.
2. If the alarm lamp doesn’t light, disconnect the connector of courtesy lamp switch and connect the
terminal 1 at the end of wiring to earth. In this condition, it shall turn on, if not, check the bulb or
wiring.
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As the traveling safety will be affected when the dust and dirt on the windscreen is not cleared in time,
the wiper washing system is applied on the vehicle. This model of vehicle equipped the wiper with 2
speeds and intermittent working mode and consists of drive motor, worn gear mechanism, rocker arm,
wiper blade, etc.; the washing system consists of washer reservoir, motor, pipeline, spray nozzle and so
on.
II. Precautions
Before dismounting the electrical connecting wire of system, dismount the negative pole of storage
battery and wait for at least 1min, otherwise, it may cause physical injury.
■ Use cloth to protect the dismounted spare parts from being damaged and scratched during
dismantling and installing the elements.
■ Wrap the right-angled screwdriver blade with cloth, when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly mounted into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
The motor of front windscreen wiper, which is controlled by combined switch and timing relay of
windscreen wiper, can run at 2 speeds and connect with a limit switch for stop position.
When the ignition switch is set at “ON” position, the following 4 functions are available:
1) Shutdown.
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ETACS module
Windscreen wiper
switch
Terminal
Function
Intermittent
relay of front
windscreen
wiper
Intermittent
Low speed
High speed
Adjustment of
interval
1) Make the wiper arm and wiper blade run to the middle position.
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3) Connect the spring to one end of the wiper arm and measure the required torque for lifting the
wiper arm to normal working height when it is vertical to the windscreen (the specified value is
6~8N•m).
4) Replace the wiper arm when the measured value does not conform to the specified value.
5) Mount the wiper blade on the wiper arm.
4. Adjustment and Check of Wiper Blade Rubber Strip
1) Dismount the wiper blade from the wiper arm,
2) Check the length of rubber strip of wiper blade.
3) Replace the rubber strip of wiper blade when the rubber parts contacting with the windscreen is not
within wiper blade centerline ±15°.
4) Mount the wiper blade on the wiper arm.
5. Check of Front Windscreen Wiper Switch
During the application of the following 4 functions of front windscreen wiper switch: OFF, intermittent
operation, low-speed operation and high-speed operation, check if its conductivity complies with the
figure below. If not, replace the switch.
Terminal
Function
Intermittent
Low speed
High speed
Adjustment of
interval
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2) Connect the positive pole of storage battery with pin 4 of front windscreen wiper motor and connect
the negative pole with pin 2, so that the motor of front windscreen wiper will operate at high speed. If
not, please replace the motor of front windscreen wiper.
3) Connect the positive pole of storage battery with pin 4 of front windscreen wiper motor and connect
the negative pole with pin 1, so that the motor of front windscreen wiper will operate at low speed. If
not, please replace the motor of front windscreen wiper.
4) Connect the positive pole of storage battery with pin 4 of front windscreen wiper motor and connect
the negative pole with pin 1, so that the motor of front windscreen wiper will operate at low speed.
Then cut off the connection between pin 1 of motor terminal and negative pole of storage battery
during the operation of windscreen wiper motor. Check the conductivity between pin 4 and 5 with
multimeter. If the specification is not complied with, please replace the motor of front windscreen
wiper.
7. Replacement of Windscreen Wiper Arm
1) Dismantlement steps:
① Push it to the bottom of clamp of windscreen wiper blade and dismount the windscreen wiper blade
from the inner side of wiper arm.
② Take out the wiper arm from the opening of wiper blade.
2) Installation steps:
① Place the wiper blade claw groove inside the wiper arm claw.
② Pull the wiper blade claw groove into the wiper arm claw until the claw groove is fixed into the hook.
③ Actuate the windscreen wiper and check if it is working normally.
8. Replacement of Rubber Strip of Windscreen Wiper Blade
1) Dismantlement steps:
Attention:
If the rubber strip from windscreen wiper blade is dismounted, replace it with a new one.
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2) Installation steps:
Attention:
Keep the wiper blade claw in the slide track of rubber claw of wiper rubber strip, and do not let the
wiper blade claw contact with the metal groove of wiper rubber strip.
① Insert the opening end of rubber strip of wiper blade into the lower claw of wiper blade.
② Introduce the rubber strip of wiper blade into the sub-assembly of wiper blade claw.
③ Insert the lower claw of wiper blade rubber strip into the wiper blade notch.
④ Mount the wiper blade on wiper arm. Please refer to “Replacement of Windscreen Wiper Arm and
Blade”.
9. Replacement of Front Windscreen Wiper Arm
② Set the wiper switch at low-speed position and shut down the low-speed gear after the wiper motor
is actuated.
③ Turn off the ignition switch when the transmission system of windscreen wiper is stopped.
④ Mount the wiper arm on drive shaft of wiper transmission.
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⑤ Mount the nut on the drive shaft of wiper transmission and the wiper arm and tighten it.
Tightening torque: 10~12N'm
⑥ Mount the nut cap.
⑦ Operate the windscreen wiper to check if its operation is normal.
10. Replacement of Transmission Parts of Front Windscreen Wiper
Fig. 1.7.005
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Fig. 1.7.013
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2) Installation steps:
① Mount the driving rod assembly of windscreen
wiper.
② Mount the fixing screw for wiper transmission
system.
■ Tightening torque: 9~12N•m.
Fig. 1.7.014
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Fig. 1.7.017
Fig. 1.7.018
Fig. 1.7.019
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Fig. 1.7.022
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2. Circuit Diagram
windscreen wiper
Function
Rear windscreen
wiper ON
Rear windscreen
wiper OFF
Terminal
Function
② Connect the positive pole of storage battery with terminal 1 of rear windscreen wiper motor, and
then connect the negative pole with terminal 2, so that the rear windscreen wiper motor will be
actuated. If not, replace the rear windscreen wiper motor.
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③ Connect the positive pole of storage battery with terminal 1 of rear windscreen wiper motor and
connect the negative pole with terminal 2. Then cut off the connection between terminal 2 of motor
and negative pole of storage battery during the operation of rear windscreen wiper motor. Check the
conductivity between pin 3 and rear windscreen wiper motor with multimeter. If the specification is
not complied with, please replace the motor of rear windscreen wiper.
4. Replacement of Rear Windscreen Wiper Arm
1) Dismantlement steps:
① Set the ignition switch at “ON” position.
② Set the wiper switch at OFF position.
③ Turn off the ignition switch when the rear windscreen wiper arm is stopped.
④ Dismount the nut cap.
Fig. 1.7.023
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2) Installation steps:
① Mount the wiper blade on wiper arm. Please refer to “Replacement of Windscreen Wiper Arm and
Blade”.
② Mount the rear windscreen wiper arm on the motor shaft:
Set the ignition switch at “ON” position.
Set the rear windscreen wiper switch at OFF position.
Turn off the ignition switch when the transmission system of windscreen wiper is set at stop position
and doesn’t move.
Mount the rear windscreen wiper arm on the motor shaft.
③ Mount and tighten the washer and nut on motor shaft.
Tightening torque: 10.0~11.0N•m
④ Press down the cap.
⑤ Operate the rear windscreen wiper to check if its operation is normal.
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2. Schematic Diagram
EATCS module
Terminal
Function
Low speed
High
speed
Front
Rear windscreen
wiper ON
Rear
water Rear windscreen
motor
Terminal
Function
Intermittent
Low speed
High
speed
Front washing
Adjustment of
interval
Rear
washing
Rear
windscreen
wiper ON
Rear
windscreen
wiper OFF
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2) Installation steps:
③ Connect the nozzle and hose, and then mount the nozzle on engine hood.
⑥ Mount the solvent pump of cleanser at the right side in front of vehicle.
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1) Dismantlement steps:
③ Dismount the rear nozzle from rear lift gate and disconnect the rear hose on rear nozzle.
④ Dismount the claw grooves from rear lift gate and left side of vehicle.
⑤ Dismount the rear hose from the left side of vehicle body.
2) Installation steps:
④ Get the hose through claw groove and mount the rear hose in rear lift gate.
⑤ Mount the claw groove on rear lift gate and left side of vehicle body.
⑥ Connect the hose and rear nozzle, and then mount the rear nozzle on rear lift gate.
Out-of-level of blade Dismount the wiper arm for reinstallation to keep the blade leveled
1. Uncleanness of windscreen 1. Wash the windscreen to be
2. Severe abrasion of blade clean
Failure of wiping 2. Replace the blade (it is
recommended to replace it every
3 months)
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Trouble mode: the wiper and cleanser fail to work no matter of the position the wiper switch is set at
Make sure the wiper switch and connector of wire harness contact
properly. Disconnect the wire harness and wiper motor, check the
5 To step 6
console wire harness between wiper switch & fuse and wiper
motor according to circuit diagram and repair it when necessary.
Check the wiper motor and repair it when necessary. Make sure
6 the wiper motor is in good condition and the connector of wiper To step 7 -
motor contacts properly.
Check the earth wire of wiper motor at wire harness of console
7 To step 8
and repair it when necessary.
8 Check if the system is in good condition.
Check the console wire harness between wiper switch and wiper
4 motor and repair it when necessary.
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6) Trouble mode: the wiper blade does not stop at its original position
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Check the console wire harness between the fuse and wiper switch
4 To step 5 To step 6
and repair it when necessary.
Check the internal structure of wiper switch and replace or repair
5 the switch when necessary. Make sure the switch is in good To step 10
condition. Check if the system is in good condition.
Disconnect the connector from wiper motor, set the ignition switch
at “ON” position, turn the wiper switch to high-speed position and
6 To step 7 To step 10
check if the pressure measured at the connector pin (wire harness
side) with digital multimeter is normal.
Check if the console wire harness between wiper switch and wiper
7 To step 8 To step 9
relay is in good condition.
8 Check if the earth wire is earthed properly with digital multimeter.
Dismount the wiper motor and repair or replace it. The system is in
9 To step 10
good condition.
Check the console wire harness between wiper switch and wiper
motor according to circuit diagram; repair it when necessary and
10
make sure it is in good condition. Check if the system is in good
condition.
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2. Horn Fig.1.8.002
Bass horn
Horn
button
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1 2
3. Connect terminal 1 of the horn with the positive pole of the storage battery and connect terminal 2
with the negative pole of the storage battery, and then the horn will sound.
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3. Connect pin 4 and pin 8 of the relay with the test lamp.
Does the horn sound?
1. Install the horn relay again.
2. Disconnect the electrical system of the airbag.
3. Dismantle the lead of the horn switch from the steering
6 To step 7 To step 8
wheel.
4. Connect joint 1 and joint 2 of the horn button with the
test lamp. Does the horn sound?
To “Check of the
7 Replace the button horn -
Horn System”
1. Place the test lamp at the same position (between joint 1
and joint 2 of the horn button).
8 2. Connect pin 4 with the pin 8 of the horn relay terminal To step 9 To step 10
temporarily with a 5 A fuse.
Is the test lamp lightened?
To “Check of the
9 Replace the horn relay -
Horn System”
Check whether the grounding is good and connect the test
lamp:
10 1. Terminal 8 of the horn relay and the ground. To step 11 To step 12
2. Terminal 1 of the horn button and the ground.
Is the test lamp lightened?
To “Check of the
11 Repair lead of bad grounding _
Horn System”
To “Check of the
12 Repair circuits of poor contact _
Horn System
① With obviously low tone, the current voltage may be too high and the circuit check is required. If the
circuit is normal, replace the horn assembly. Refer to “Replacement of Horn”.
② With obviously high-pitched and weak tone, the horn may have foreign substances on it. Dismantle
the horn assembly and check whether there are any foreign substances on it. Refer to
“Replacement of Horn”.
③ Wipe off the adhesive foreign substances and re-install the horn assembly.
④ If any adhesive foreign substances are found or such substances can’t be wiped off, replace the
horn assembly.
4) Press the horn button and check that the concerned items have been rehabilitated. Refer to “Check
of Horn”.
V. Replacement of Horn
Precautions:
■ Strictly comply with the precautions for operation of the airbag system. Refer to “Airbag System”.
1) Dismantlement steps:
① Open the engine hood and dismantle the front bumper. Refer to “Replacement of the Front
Bumper”.
Fig.1.8.004
2) Installation steps:
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1. Dismantlement steps:
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2. Installation steps:
① Place the horn button assembly in.
② Connect the connector of the horn button on the steering wheel.
③ Install the left and right fixing screws of the horn button (four screws).
■ Tightening torque: 2 N•m.
Fig.1.8.009
Attention:
■ L refers to left side and R, right side.
④ Put in the driver airbag module. Connect the
connector of the module electrical appliance.
While installing, make sure that the circuit
installation is correct and reliable.
⑤ Install the fixing screw of the driver airbag
module.
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Cigar
lighter
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CD player Antenna
Left high
loudspeaker
loudspeaker
loudspeaker
Right door
Right high
loudspeaker
loudspeaker
Left rear
pitch
Right rear
Left door
pitch
loudspe
aker
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1) Dismantlement steps:
Precautions:
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2) Install in reverse order with dismantlement, and check whether the audio changer works normally.
1) Dismantlement steps:
① Remove the right-side carpet located in front of the front passenger and dismantle the interior plate
of the door. Refer to “Replacement of the Trimming Plate—Carpet and Interior Plate in Interior
Trimming”.
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② Disconnect the antenna signal cable from the lead of the antenna amplifier. Disconnect the antenna
signal cable at the back of the audio changer. Refer to “Replacement of the Audio Changer”.
Fig.1.9.005
③ Install the insulator of the right console. Refer to “Replacement of the Console”.
1. Dismantlement steps:
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3) Dismantle the 6 bolts for the rear loudspeaker, including 3 ones on the left and 3 ones on the right.
Fig.1.9.008
2. Installation steps:
3) Install the rear trimming shelf panel. Refer to “Replacement of the Trimming Plate—Rear Shelf
Panel in the Interior Trimming”
1. Installation steps:
1) Dismantle the lateral trimming plate. Refer to “Replacement of the Inner Trimming Plate at Boot’s
Side”.
2. Installation steps:
3) Dismantle the lateral trimming plate. Refer to “Replacement of the Inner Trimming Plate at the
Boot’s Side”.
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1. Dismantlement steps:
1) Dismantle the inner trimming plate of the front door. Refer to “Replacement of the Inner Trimming
Plate of the Front Door”.
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Fig.1.9.012
4) Install the inner trimming plate of the front door. Refer to “Replacement of the Inner Trimming Plate
of the Front Door”.
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Buzzer
Power supply
Controller
Assembly
Ground
1. Check whether the power supply of parking auxiliary system sensor is working normally (9V〜16V).
2. The parking auxiliary system connects the control module assembly, sensor assembly and buzzer
assembly together through the wire harness; the terminals of each assembly are defined as follows:
2 GND Ground
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2 GND Ground
3 NC
4 NC
5 NC
6 NC
9 NC
10 NC
11 NC
12 NC
13 NC
16 GND Ground
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1. Steps of dismantlement
Fig. 1.10.001
Fig. 1.10.002
Fig. 1.10.003
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2. Dismount the lower trimming plate of steering wheel. See also “Dismantlement of Consoles of
Interior and Exterior Trimmings”.
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Fig. 1.10.007
Fig. 1.10.009
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Sensor body
Concrete symptom: when the vehicle is shifted into reversing condition, the buzzer gives out no warning
tone.
Trouble cause: the parking auxiliary system is unworkable, and this is usually caused by the
disconnection of working power supply, generally speaking, if the vehicle storage battery is working
normally, the cause should be the poor contact of power cord.
Maintenance method: Check whether the DC+12V power supply is connected into the control module,
this circuit of power supply is the same as the power supply circuit of vehicle reversing light; if the power
supply is working normally, please replace the control module.
Concrete symptom: when the vehicle is shifted into reversing condition, one of the sensors can not
detect the obstacles all the time.
Trouble cause: the parking auxiliary system is working, but one of the sensors is unworkable.
Maintenance method: when the vehicle is shifted into reversing condition, put your ear close to the
surface of sensor, listen carefully to judge whether the there’s slight “click” from it (by contrast with a
normal one); if the sound is normal, it means that the power supply of sensor is working normally, hence,
please check whether the connection of signal wire between the sensor and controller is normal; in case
the signal wire is normally connected, please replace the sensor.
Concrete symptom: when the vehicle is shifted into reversing condition, the detection performance of
one of the sensors is always poor.
Trouble cause: the parking auxiliary system is working, but the detection performance of one of the
sensors is poor.
Maintenance method: please clear the foreign matters on the surface of the sensor.
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When the reverse running is performed on rough roads, it is normal that the system gives an alarm
occasionally.
When the reverse running is performed on narrow laneways, it is normal that the system gives an
alarm occasionally.
VIII. Trouble Diagnosis Procedure
Whether the
connectors of main Reconnect the connectors
frame is connected of main frame
correctly
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The harness is
good
Continue using it
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ACC/ON Power
Console of rear
UP/DOWN Switch LEFT/RIGHT Switch view mirror switch
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Check the conductivity state between terminals of lead connector according to the following diagram. If it
is not the same as what is listed in the diagram, please replace the switch.
Wiring
terminal
Gear
Upward
Downward
Left Leftward
Rightward
Upward
Downward
Right Leftward
Rightward
Up Left
Down Right
2) Connect the storage battery (12V) between terminals according to the following table, and check
whether the actuator works normally. If not, replace the actuator.
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Terminal
Position
Up
Down
Left
Right
1. Dismantlement Steps
Fig. 1.11.004
■ Dismantle the internal rear view mirror from
the internal rear view mirror bearer with a
small right-angled screwdriver.
Fig. 1.11.005
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2. Installation Steps
Fig. 1.11.006
1) Clip the internal rear view mirror into the rear
view mirror bearer, and make sure that it is
fixed firmly.
Attention:
■ Internal rear view mirror is fixed on the internal rear view mirror bearer which is glued on the wind
shield by plastic polyvinyl-butyral adhesive. The following objects are needed while mounting an
independent rear view mirror or a new spare part:
■ (According to the installation step 4 and 5, prepare) original internal rear view mirror bearer, or
replace it with new internal rear view mirror bearer.
■ Isopropyl alcohol.
1. Measure the dimension from the upper part (1) to internal rear view mirror bearer (2), and the
dimension is 70 mm.
2. Make a mark on the exterior surface of wind shield. Draw a big circle on the exterior surface (3) of
wind shield along the circle of rear view mirror bearer.
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3. Use the paper towel that has been soaked in the glass cleanser of general type (general part number)
or polishing agent to clean the glass marked with the big circle on the interior surface of wind shield
until it is completely clean and dry. Then clean it with the paper towel moistened with isopropyl
alcohol to remove the cleaning powder or the mark left by cleaning agent.
Precautions:
■ If the original internal rear view mirror bearer is reused, clean all marks of adhesive left by plant
installation before its reinstallation.
4. Use a fine (320 or 360) emery cloth or abrasive paper to polish the new internal rear view mirror
bearer or the original adhesive surface of internal rear view mirror bearer left by plant installation.
5. Use the paper towel soaked with isopropyl alcohol to wipe the sanded internal rear view mirror
bearer clean, and then let it dry in air.
6. Before mounting on the wind shield, prepare the internal rear view bearer according to the illustration
for components provided by the manufacturer.
7. Place the internal rear view mirror bearer on the marked position beforehand correctly, and prevent
the round hole of rear view mirror from pointing upward; Press the internal rear view mirror bearer on
the wind shield for 30s to 60s with constant force.
8. After 5 minutes, use the paper towel soaked with isopropyl alcohol or window cleaning agent to
remove redundant adhesive.
9. Remount internal rear view mirror. Refer to the “Replacement of Internal Rear View Mirror”.
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Mirror casing
Mirror bracket
Pressure spring
Mirror
Attention:
1. Dismantlement Steps
2) Pry up the cover plate of rear view mirror carefully with a right-angled screwdriver.
Fig. 1.11.007
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Lock or unlock all doors by key lock core. The ETACS control module controls the central control
lock relay after receiving the unlock or lock signal to make the door lock motor open or close. In
spite of the location of the ignition switch, the electric door lock is in operational state.
When the vehicle runs in a speed of higher than 40km/h, all doors are closed and the acceleration
pedal is stepped down, the ETACS control module automatically locks all doors. After the engine
cuts out and the ignition switch is shut down, the central control door lock automatically opens.
The doo lock motor is controlled by the central controller. The positive and negative poles of the storage
battery are connected to the two terminals of the motor to make the motor rotate toward one direction.
The current is opposite and the rotation speed of the motor is opposite.
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11. Loosen the tie rod on the outside handle of the Fig. 1.12.010
door and lock core tie rod.
14. Cut off the connector of the door lock motor Fig. 1.12.013
and take off the door lock body assembly.
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15. Cut off the tie rod on the lock body, and take
Fig. 1.12.014
off the lock body.
Notes:
2. Dismount the trunk door sill plate. Refer to “Replacement of Trunk Door Sill Plate”.
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Notes:
■ After the assembly, open and close the rear cabin cover to validate the lock body function.
■ Suppose the meshing of the lock body and hook offtracks, loosen the two fixing bolts of lock hook,
adjust the lock hook to an appropriate location and then tighten the fixing bolt.
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3. Dismount the inner trimming plate of the trunk lid. Refer to “Replacement of Inner Trimming Plate of
Trunk Lid”.
Fig. 1.12.019
5. Cut off the tie rod and then take off the trunk
Fig.
lock controller.
Lock body of
trunk
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Electric window system could raise or lower the window glass electrically via operation of switch on each
trimming plate of door. The main switch on trimming plate of driver side front door could not only help the
driver to raise or lower the passenger side window glass, but also could lock every separate switch on
the side door. Only when the ignition switch is located at “on” position, the electric window system could
receive the voltage of storage battery via circuit breaker in junction box. The electric window system
includes the electric window switch on the trimming plate of door, ETACS control module and electric
window motor in each door. The window motor together with the glass frame riser is an assembly. If the
window motor needs to be replaced, the glass frame riser should be replaced as well.
I. Illustration on Elements
The electric window is controlled by window/door interlock switch on the trimming plate of front door. The
driver side window/door interlock switch could help the driver control all of the window glasses. The
passenger side windows could receive the electricity from storage battery and grounding power supply
via the window/door interlock switching circuit. The power supply for the electric window switch of every
separate passenger side door from storage battery would be cut off when the interlock switch of electric
window is located at “lock" position.
Permanent magnet reversible electric motor could drive the movement of glass frame riser via integrated
gear box mechanism. The positive and negative poles of storage battery are connected to the two
terminals of motor and enable the motor to turn round in one direction. The counter current flowed
through the two same junctions would enable the motor to turn round in the reverse direction. Moreover,
every electric window motor is equipped with an integrated self-reset circuit breaker to avoid the
over-load.
The electric window could be operated by the elevating button on the door. The elevating operation of
electric window would be allowed when ignition switch is located at “on” position. The operation of rear
windows is invalid after pressing the child lock at any time. The electric window could be operated after
shutdown of ignition switch as well unless the following situations occur:
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Child lock button could lock the electric window buttons on the right front door and left & right rear doors.
When the child lock button is locked, the window buttons on the driver’s door that control the right front
window, right & left rear windows are valid as well.
3. Operation Mode
Manual rise: press the “up” button of window over 300ms, the corresponding window would be raised
and the rising of the electric window would be stopped by releasing the button.
Manual drop: press the “down” button of window over 300ms, the corresponding window would be fallen
and the dropping of the electric window would be stopped by releasing the button.
Auto drop: press the “down” button less than 300ms, the corresponding window would drop to the
bottom or to the position till pressing the “down” button of the electric window again.
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Electric Window
Relay
Elevation
Left Front Electric Right Front Left Rear Electric Right Rear
Motor Electric Motor Motor Electric Motor
Elevation Switch of
Right Front Window Elevation Switch of Elevation Switch of
Left Rear Window Right Rear Window
Ground of
Combined
Wiring Joint
Electric Power
Source of Combined
Wiring Joint
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1) Dismantlement
① Dismount the inner trimming plate of door. Refer to “Replacement of Inner Trimming Plate of Door”.
③ Dismount the sealing strip of window glass. Refer to “Replacement of Sealing Strip of Window
Glass".
④ Reinstall the switch of window glass frame riser and adjust the height of window glass to a suitable
position so as to dismount the fixing screw of window glass.
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Fig. 1.13.003
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1) Dismount the inner trimming plate of door. Refer to ““Replacement of Inner Trimming Plate of Door”.
3) Dismount the sealing strip of window glass. Refer to “Replacement of Sealing Strip of Window
Glass".
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V. Trouble Diagnosis
See table below for the trouble diagnosis on electric window control system.
Main control electric window Trouble of door lock control relay Check the relay
is out of work
Trouble of wiring Repair as required
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Precautions:
■ Use cloth to protect the dismounted spare parts from being damaged and scratched during
dismantling and installing the elements.
■ Wrap the right-angled screwdriver blade with cloth,when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly mounted into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
1) Dismantlement steps:
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Precaution:
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The engine hood is fixed on the hinges of engine hood by bolts. The longitudinal adjustment of the hood
can be achieved by the movement in hinge holes. Through adjusting the length of the long and short
buffer bumper and the major latch on the engine hood, the engine hood can be adjusted vertically. The
tolerance clearance is 4.0 mm±1.0 mm, and the smoothness tolerance is 0 mm to 1.0 mm.
Fig. 2.1.009
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1) Dismantlement steps:
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Precautions:
■ When dismantling and installing the support device of engine hood, alternative support must be
adopted to avoid possible damage on vehicle and personnel injury.
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2) Installation steps:
③ Mount the heat insulating mattress of engine hood, and please refer to the “Replacement of Heat
Insulating Mattress of Engine Hood”
④ Place the engine hood on the position of vehicle body with the help of the assistant.
⑤ Mount the bolts between engine hood and hinges with the help of the assistant.
⑥ Check the matching of engine hood and vehicle body and adjust the engine hood as per required.
Please Refer to the “Adjustment of Engine Hood”.
⑦ Mount the cleaner nozzle and hose. Please Refer to the “Replacement of the Solvent Tank of
Cleanser, Spray Nozzle of Pump and Hose”
II Fender
Precautions:
■ Use cloth to protect the dismounted spare parts from being damaged and scratched when
dismantling and installing the elements,
■ Wrap the right-angled screwdriver blade with cloth,when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly installed into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
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■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
■ Please don’t scratch the exterior surface of vehicle body during the assembly process.
■ Dismount the front bumper before the dismantlement of fenders. Refer to the “Replacement of Front
Bumper”.
■ Dismount the door assembly before the dismantlement. Refer to the “Replacement of Door
Assembly”.
■ It is better to dismount the engine hood to facilitate the dismantlement of fender. Refer to the
“Replacement of Engine Hood”.
1) Dismantlement steps:
Fig. 2.1.019
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⑥ Take off the fender and pull out the turn light Fig. 2.1.023
connector.
2) Installation steps:
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③ Mount the clamping screws of fender and those of front wheel cover.
Precautions:
■ Check the following items after installation: check for the fender being mounted on the right position;
check for the proper fit clearance between the fender and the vehicle body, and if not, the fender
should be adjusted and reinstalled.
■ The replacement steps of left fender or right fender are the same.
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Precautions:
■ Protect door and vehicle body with cloth when dismantling and installing the front door assembly.
■ Make sure carry out the assembly adjustments during the dismantlement /installation of the front
door assembly.
■ After installation, re-coat some paint (the color of vehicle body) on the head of mounting bolt for
hinges.
■ Check the rotation parts of hinge for lubrication. Apply some “lubrication grease” when necessary.
■ This element is heavy, so two workers are needed for handling it.
1) Dismantlement steps:
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Precautions:
■ The dismantlement of the screws should be carried out by several times. Please don’t loosen them
in one time.
■ Carry out the dismantlement steps with the help of the assistant.
2) Installation steps:
① Move the door to the proper position with the help of the assistant.
④ Align to the mounting hole of clamping screw and mount the clamping screw of door assembly.
Precautions:
■ Tighten the clamping screw of front door assembly, with the tightening torque: 25N·m.
■ Tighten the clamping screw of front door stopper, with the tightening torque: 5N·m.
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■ The screws should be tightened by several times. Please don’t tighten them in one time.
■ Carry out the whole process with the help of the assistant.
1) Dismantlement steps:
② Open the door and pry out the inner trimming plate of rear-view mirror with right-angled screwdriver.
Fig. 2.1.028
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2) Installation steps:
① Align to the mounting hole for clamping screw and mount the rear-view mirror.
② Mount the clamping screw of outer rear-view mirror, with the tightening torque: 10 N·m.
④ Align to the snap-in mounting hole and mount the inner trimming plate of rear-view mirror.
1) Dismantlement steps:
② Open the door and pry out the inner trimming plate of rear-view mirror with right-angled screwdriver.
Fig. 2.1.032
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⑥ Pry out the glass frame riser switch with Fig. 2.1.036
right-angled screwdriver.
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Precaution:
■ During the dismantlement of inner trimming plate, please pay special attention to the snap-in, which
would easily cause the damage of the inner trimming plate.
Fig. 2.1.039
⑪ Take off the inner trimming plate of left front Fig. 2.1.041
door.
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2) Installation steps:
② Align to the snap-in mounting hole of front door inner trimming plate and mount the inner trimming
plate of left front door.
Precautions:
■ During the installation of inner trimming plate, please pay special attention to the snap-in, which
would easily cause the damage of the inner trimming plate.
③ Mount the clamping screw of front door inner trimming plate. Tightening torque: 2N•m.
⑤ Align to the right position and mount the glass frame riser switch.
⑥ Connect the pull rod of inner handle and mount the inner door handle.
⑦ Mount the clamping screws of inner door handle, with the tightening torque: 2N•m.
⑨ Align to the snap-in mounting hole for the inner trimming plate of rear-view mirror and mount that
plate.
1) Dismount the door inner trimming plate. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
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Precautions:
■ Don’t touch the adhesive surface to avoid weakening the re-adhesive effect.
1) Dismount the door inner trimming plate. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
2) Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
Fig. 2.1.044
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2) Installation steps:
③ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
④ Mount inner trimming plate of the door. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
1) Dismantlement steps:
① Dismount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
Fig. 2. 1.047
③ Pry out an end of the weather seal with right-angled screwdriver and take off the inner side of the
seal slowly from that end.
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⑤ Take off the outer glass weather seal slowly from one end.
Precautions:
■ Don’t use too much force during dismantling, for too much force will cause the damage of the spare
parts.
■ Visually inspect the drip moulding after the dismantlement. Please replace it when distortion occurs.
2) Installation steps:
① Align the mounting slot of outer glass weather seal to the vehicle body, and mount the seal to the
right position slowly from one end.
Fig. 2.1.049
② Tighten the outer clamping screw of outer glass weather seal, with the tightening torque: 2N • m.
③ Align the mounting slot of inner glass weather seal to the body, and mount the seal to the right
position slowly from one end.
④ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑤ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
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1) Dismantlement steps:
① Dismount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
③ Dismount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window
Glass”.
④ Reinstall the glass frame riser switch and regulate it to the proper position to facilitate the
dismantlement of the clamping screws of front window glass.
Fig. 2.1.050
2) Installation steps:
① Reinstall the glass frame riser switch and regulate it to proper position to facilitate the installation of
the clamping screws of front window glass.
② Put the window glass into the door and align to the mounting hole.
③ Mount the clamping screws of front window glass, with the tightening torque: 7.5N•m.
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④ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑤ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑥ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
1) Dismantlement steps:
① Dismount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
③ Dismount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window
Glass”.
④ Dismantle the window glass. Refer to the “Replacement of Front Window Glass”.
Fig. 2.1.052
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2) Installation steps:
① Connect the glass frame riser connector of front window and put in the glass assembly.
② Mount the fixed nuts of front window glass support. Tightening torque: 7. 5N•m.
③ Mount the fixed nuts on the motor of front glass frame riser. Tightening torque: 7.5N•m.
④ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑤ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑥ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑦ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
① Dismantle the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
③ Dismount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window
Glass”.
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④ Dismantle the window glass. Refer to the “Replacement of Front Window Glass”.
⑤ Dismantle the glass frame riser. Refer to the “Replacement of Glass Frame Riser of Front Window”.
⑥ Pry out the decorative cap of lock core of the outer handle of the front door.
Fig. 2.1.056
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⑪ Loosen the outer handle pull rod and lock core Fig. 2.1.061
pull rod of the front door.
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⑫ Take off the fixed support of the front door Fig. 2.1.062
handle.
⑬ Pry out the fixed snap-in of door lock core. Fig. 2.1.063
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2) Installation steps:
① Fix the door lock core on the fixed support of the door handle.
③ Connect the outer handle pull rod and lock core pull rod of the front door.
④ Mount the clamping screw on the mounting support for the outer handle of the front door. Tightening
torque: 2.5N•m.
Fig. 2.1.065
⑥ Mount the gasket and connect the outer handle from the fixed support of outer handle.
Fig. 2.1.066
⑦ Mount the clamping screws on fixed support for the outer handle of the front door. Tightening torque:
2.5N•m.
⑧ Mount the decorative cap of lock core of the outer handle of the front door.
⑨ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑩ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑪ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑫ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
10. Replacement of Front Door Lock Assembly
1) Dismantlement steps:
① Dismantle the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
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② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
③ Dismantle the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window
Glass”.
④ Dismantle the window glass. Refer to the “Replacement of Front Window Glass”.
⑤ Dismantle the glass frame riser. Refer to the “Replacement of Glass Frame Riser of Front Window”.
⑥ Pry out the decorative cap of lock core of the outer handle of the front door.
Fig. 2.1.067
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⑪ Loosen the outer handle pull rod and lock core Fig. 2.1.072
pull rod of the front door.
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⑫ Take off the fixed support of the front door Fig. 2.1.073
handle.
⑭ Cut off the connector and take out the door Fig. 2.1.074
lock assembly.
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Fig. 2.1.076
2) Installation steps:
① Put in the front door lock and connect its pull rod.
② Connect the connector from the lock assembly and put the lock assembly into the door.
③ Mount the clamping screw on the lock of front door. Tightening torque: 5N·m.
⑤ Connect the outer handle pull rod and lock core pull rod of the front door.
⑥ Mount the clamping screw on the mounting support for the outer handle of the front door. Tightening
torque: 2.5N·m.
Fig. 2.1.077
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⑧ Mount the gasket and connect the outer handle from the mounting support for the outer handle of
the front door.
Fig. 2.1.078
⑨ Mount the clamping screws on fixed support for the outer handle of the front door. Tightening torque:
2.5N•m.
⑩ Mount the decorative cap of lock core of the outer handle of the front door.
⑪ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑫ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑬ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑭ Mount the inner trimming plate of the door. Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
Precautions:
■ During the installation, the lock must be mounted as per the original position.
■ After installation, check for the normal open/close of the door; check for the firm locking. If not,
please carry out the re-installation or proper adjustment.
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2) Installation steps:
④ Check the latch and the lock for being engaged. Refer to the “Replacement of Front Door Latch” if
some adjustments are needed.
Fig. 2.1.080
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Fig. 2.1.081
① Apply some clay or joint sealer of vehicle body on the opening of door lock.
② Close the door from enough distance, enabling that the latch can press the joint sealer.
③ Leaving the door closed for a long time may cause the difficulty of removing the clay or joint sealer.
④ Open the door and check for the latch indentation being in the middle of the lock opening.
⑥ Apply paint on any exposed area and any area without paint after installing the latch.
Attention:
The replacements for the components of left or right front door are the same.
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① Dismantle the screw cover for the recessed frame of rear inner door handle.
Fig. 2.1.082
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Precautions:
■ During the dismantlement of inner trimming plate, please pay special attention to the snap-in, which
would easily damage the inner trimming plate.
图 2. 1.090
2) Installation steps:
① Align to the snap-in mounting hole for inner trimming plate of rear door and mount the trimming
plate.
Precautions:
■ During the dismantlement of inner trimming plate, please pay special attention to the snap-in, which
would easily damage the inner trimming plate.
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② Mount the clamping screws of inner trimming plate of rear door. Tightening torque: 5N·m.
③ Connect the electrical connector for the switch of rear glass frame riser.
④ Align to the proper position and mount the switch of rear glass frame riser.
⑥ Connect the pull rod for the inner handle of rear door and mount the handle.
⑦ Mount the clamping screw for inner handle of rear door. Tightening torque:
⑧ Mount the screw cover for the trimming plate of rear door.
⑨ Mount the screw cover for the recessed frame of rear inner door handle.
Precautions:
■ Before installing rear door trimmings, make sure the snaps-in are firmly installed into the plate hole
of the body, and then pressed the trimmings into the body.
1) Dismantle the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
Fig. 2.1.091
Precautions:
■ When installing the waterproof membrane, don’t let it cover the mounting hole for the cramp of
trimming plate.
■ Don’t touch the adhesive surface to avoid weakening the re-adhesive effect.
1) Dismantlement steps:
① Dismantle the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
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2) Installation steps:
① Align the mounting slot of outer glass weather seal to the body, and mount the seal into the right
position slowly from one end.
Fig. 2.1.094
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② Align the mounting slot of inner glass weather seal to the body, and mount the seal into the right
position slowly from one end.
Fig. 2.1.095
③ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
④ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
1) Dismantlement steps:
① Dismantle the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
③ Dismantle the inner glass weather seal of rear door. Refer to the “Replacement of Weather Seal on
the Rear Window Glass”.
④ Connect the switch for rear glass frame riser and adjust rear window glass into the proper position.
Fig. 2.1.096
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2) Installation steps:
① Mount the switch for rear glass frame riser and adjust the rear window glass into the proper position
to facilitate the installation of clamping screw for rear window glass.
② Place the rear window glass into the door and align the glass to the mounting hole.
③ Mount and tighten the clamping screw for rear window glass
④ Reinstall the switch for rear glass frame riser and adjust the rear window glass into the proper
position to facilitate the installation of quarter window glass of rear door.
⑦ Mount and tighten the clamping screw for locating slot of rear quarter window glass.
⑧ Mount the weather seal for the upper part of rear window glass. Reinstall the switch for rear glass
frame riser and rise and lower the glass to check if the installation is qualified.
⑨ Mount the rear window glass. Refer to “Replacement of Weather Seal on the Rear Window Glass”.
⑩ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
⑪ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
1) Dismantlement steps:
① Dismantle the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
③ Mount the inner glass weather seal of rear door. Refer to the “Replacement of Weather Seal on the
Rear Window Glass”.
④ Dismantle the rear window glass. Refer to the “Replacement of Rear Window Glass”.
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⑦ Cut off the connector for rear glass frame riser Fig. 2.1.105
and take out the glass frame riser assembly.
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2) Installation steps:
① Connect the connector for rear glass frame riser and put in the glass frame riser assembly.
② Mount and tighten the retaining nut for the support of rear window glass.
③ Mount and tighten the retaining nut for the motor of rear glass frame riser.
④ Mount the rear window glass. Refer to the “Replacement of Rear Window Glass”.
⑤ Mount the weather seal on the rear window glass. Refer to the “Replacement of Weather Seal on
the Rear Window Glass”.
⑥ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
⑦ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
1) Dismantlement steps:
① Dismantle the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
③ Dismantle the weather seal on rear window glass. Refer to the “Replacement of Weather Seal on
the Rear Window Glass”.
④ Dismantle the rear window glass. Refer to the “Replacement of Rear Window Glass”.
⑤ Dismantle the glass frame riser of rear window. Refer to the “Replacement of Glass Frame Riser of
Rear Window”.
⑥ Dismantle the decorative cap on the outer handle of the rear door.
Fig. 2.1.106
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⑦ Dismantle the clamping screw for outer handle and take the handle off.
Fig. 2.1.107
⑩ Cut off the inner handle pull rod and the pull Fig. 2.1.109
rod of locking button.
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⑫ Take out the rear door lock and cut off the electrical connector for the lock.
Fig. 2.1.110
2) Installation steps:
① Put the door lock in and connect the electrical connector of it.
② Mount the clamping screw for rear door lock. Tightening torque: 7.5N•m.
③ Connect the inner handle pull rod and the pull rod of locking button.
⑥ Mount the clamping screw for outer handle and mount the outer handle.
⑦ Mount the decorative cap on the outer handle of the rear door.
⑧ Mount the glass frame riser of rear window. Refer to the “Replacement of Glass Frame Riser of
Rear Window”.
⑨ Mount the weather seal on rear window glass. Refer to the “Replacement of Weather Seal on the
Rear Window Glass”.
⑩ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”
⑪ Mount the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
Attention:
The replacements for the components of left and right rear door are the same.
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V. Boot Cover
Precautions:
■ Two workers are needed for the handling of boot cover because of its heavy weight.
1- Torsion bar of boot 2- Boot cover 3- Lock core of boot cover 4- Boot cover lock 5- Adjusting pad
of boot cover
6- Weather seal of boot 7- Boot cover Latch
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2) Dismantlement steps:
Fig. 2.1.111
③ Cut off the wire harness connector of the boot Fig. 2.1.113
cover lock.
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④ Dismantle the clamping screws on the boot cover with the help of the assistant.
Fig. 2.1.114
⑤ Lift the boot cover assembly down with the help of an assistant.
3) Installation steps:
② Mount the clamping screws on the boot cover with the help of the assistant. Tightening torque:
25N•m.
④ Mount the boot top trimming plate. Refer to the “Replacement of Top Trimming Plate of the Trunk”.
1) Dismantlement steps:
Fig. 2.1.115
Precautions:
■ Knock the weather seal moderately with the rubber hammer during the installation, to protect the
seal from being damaged.
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2) Installation steps:
① Mark the original mounting position of the weather seal and mount it according to that position.
② Fix manually the guide slot on the seal to the vehicle body.
③ Knock the weather seal into the required position with rubber hammer.
1) Check if there exists surface difference between the upper surface and the side walls of the boot
cover. If there exists, the surface difference can be eliminated by adjusting the height of buffer
stopper of boot cover.
Fig. 2.1.116
2) Check for uniform gap between the boot cover and side wall exterior panel.
Precautions:
■ If the gap is not uniform but just with little deviation, knock the boot cover latch with a little hammer
and close the cover to re-check the uniformity of the gap.
■ If the gap offtracks a lot, loosen the cover hinges and 4 clamping screws, and then move the cover
upward/downward or leftward/rightward to make the gap uniform; then pre-tighten the four screws
and tighten them until the boot cover has been adjusted to proper position.
■ Check for the flexibility of the opening/closing of the boot cover. If it is not flexible, adjust the latch
frontward/rearward or leftward/rightward to achieve the flexibility after loosening the clamping
screws of the latch.
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1) Dismantlement steps:
Fig. 2.1.117
② Lift the spare tire cover plate and tow out two Fig. 2.1.118
right-angled grabs.
2) Installation steps:
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② Press the two right-angled grabs on the spare tire cover plate into the corresponding holes on the
boot door sill fender.
1) Dismantlement steps:
① Dismantle the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
Fig. 2.1.120
2) Installation steps:
① Place the spare tire into the carriage without damaging other components.
③ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
6. Replacement of Coatrack
1) Dismantlement steps:
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2) Installation steps:
① Connect the electrical connector for the high position brake lamp.
③ Mount and tighten the clamping screws on the coatrack. Tightening torque: 2N•m,
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1) Dismantlement steps:
Fig. 2.1.125
1) Dismantlement steps:
① Dismantle the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
Fig. 2.1.126
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Fig. 2.1.127
2) Installation steps:
① Align to the mounting hole for snaps-in on the back of the door sill fender and mount the fender.
③ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
1) Dismantlement steps:
① Dismantle the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
② Dismantle the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
Fig. 2.1.128
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Fig. 2.1.129
2) Installation steps:
① Put the boot protecting plate into the carriage and mount the fixed snaps-in on the plate by
sequence.
② Mount and tighten the clamping screws on the protecting plate by sequence. Tightening torque:
2N•m.
④ Mount the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
⑤ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
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1) Dismantlement steps:
Fig. 2.1.131
2) Installation steps:
Place the plate properly; press the snaps-in of the trimming plate into the mounting hole and clamp
tightly.
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1) Dismantlement steps:
Fig. 2.1.133
③ Dismantle the clamping screws for the oil filler Fig. 2.1.135
door.
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2) Installation steps:
② Mount the door to the side shroud with screws. Tightening torque: 0.6-1.0N•m.
③ Connect the wire between the oil filler cap and the oil filler door.
Fig. 2.1.137
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2) Installation steps:
② Mount the connection between the cap and the oil filler door.
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1) Dismantlement steps:
Fig. 2.1.142
④ Cut off the lock body connecting wire and take Fig. 2.1.143
off the lock body of engine hood.
2) Installation steps:
① Connect the lock body connecting wire and mount the lock body of engine hood.
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② Mount and tighten the clamping screws for the lock body. Tightening torque: 5N•m.
1) Dismantlement steps:
① Dismantle the bottom part of the instrument panel at the driver’s side.
Fig. 2.1.144
Fig. 2.1.145
③ Cut off the wiredrawing for the engine hood Fig. 2.1.146
handle.
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Fig. 2.1.147
2) Installation steps:
② Mount and tighten the clamping screws for switch handle of engine hood. Tightening torque: 2N•m.
③ Mount the bottom part of the instrument panel at the driver’s side.
1) Dismantlement steps:
Fig. 2.1.148
② Dismantle the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
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2) Installation steps:
② Mount and tighten the clamping screws of actuator with cross screwdriver.
④ Mount the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
Precautions:
■ Open the after-closed boot lock body check function after finishing the assembly
■ If the engagement between lock body and latch offtracks, loosen 2 fixed bolts of latch, and tighten
the bolts after adjusting the latch to the proper position.
1) Dismantlement steps:
Fig. 2.1.152
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2) Installation steps:
1) Dismantlement steps:
Fig. 2.1.154
Fig. 2.1.055
③ Pull out the latch and cut off the pull rod of boot cover lock latch.
2) Installation steps:
② Pull out the latch and its pull rod of boot cover lock.
③ Mount and fasten the bolts for the boot cover latch.
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1) Dismantlement steps:
① Dismantle the inner trimming plate of boot cover. Refer to the “Replacement of Inner Trimming Plate
of Boot Cover”.
② Cut off the electrical connector between the wire harness of rear body and the wire harness of boot
cover.
Fig. 2.1.156
③ Cut off the fastening band for wire harness of boot cover.
⑤ Pull out the wire harness of boot cover from the vehicle body.
2) Installation steps:
① Lay wire for the wire harness of rear boot from the door of the boot cover.
③ Fix the wire harness of boot cover with fastening band as per required.
④ Connect the electrical connector between the wire harness of rear body and the wire harness of
boot cover.
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■ During dismantlement and installation of elements, use a cloth to protect the spare parts to be
dismounted from damage.
■ When dismounting the metal clip from trimmings, use a cloth to cover the blade of slotted screw
driver.
■ When installing body trimmings, make sure the clip is firmly installed in the stamping hole of body
and then carefully press them in.
■ When it is impossible to dismantle and install some elements by one person, two people shall work
together to prevent the elements from falling.
■ When dismantling and installing some trimmings, please don’t press too hard as it may result in
distortion of spare parts.
Attention:
■ The trimming plate of bumper is made from resin material. Please don’t apply great force on it and
keep it away from oil.
■ When dismantling the trimming plate of bumper, it is necessary to operate by two people to prevent
it from falling.
■ For the convenience of dismantlement and installation, put the vehicle on lifter to lift the vehicle at
any time.
1. Lift the vehicle to an appropriate height and dismount the clamping screw of front bumper base
board.
Fig. 2.2.001
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2. Take off the snap fasteners at the two sides connecting the front bumper and mudguard.
Fig.2.2.002
3. Dismount the clamping screw connecting the rear end of front bumper and mudguard.
Fig. 2.2.003
4. Dismount the screw at the two sides connecting the front bumper and fender.
Fig. 2.2.004
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6. Remove the front bumper and cut off the connectors of front fog lamp.
Fig. 2.2.005
7. Take off the front bumper and take out the percussion absorption pad.
Fig. 2.2.006
Fig. 2.2.007
Attention:
■ After installation, check if it is installed properly and if the fitting clearance between other
components is right.
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Fig. 2.2.008
Fig. 2.2.009
Attention:
■ For the upper frame, fix the upper frame of front bumper to the body with 8 nuts. The tightening
torque is 12~15 N.m.
■ For the lower frame, take the projection welding nut in the center of body as locating hole. Use 5
nuts to fix the lower frame of front bumper to the body. The tightening torque is 5~6 N.m.
■ Finally, take the circular hole in the center of the upper frame of front bumper as datum hole. Align
the datum hole and set the front bumper percussion absorption pad to the upper frame of front
bumper.
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1-Datum hole for assembling percussion absorption pad 2-Upper frame 3-Lower frame
4-Percussion absorption pad 5-Datum hole for assembling lower frame
For the convenience of dismantlement, lift the vehicle up to dismount the tire.
Fig. 2.2.010
2) Dismount the fixed snap-in and clamping screw of front wheel cover.
4) Take off the front wheel cover and check it for crack. If any, replace it.
Attention:
■ Before installation, check if there is defects such as crack of front wheel cover and omission of fixed
snap-in of wheel cover.
■ After installation, make sure the wheel cover is fitting properly with the fender and front bumper.
Align the hole and tighten the screw.
2. Replacement of Right Rear Wheel Cover
1) Dismount the 3 snap fasteners fixing the rear wheel cover in turn.
Fig. 2.2.011
Fig. 2.2.012
Fig. 2.2.013
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Attention:
■ Before installation, check if there is defects such as crack of rear wheel cover and omission of fixed
snap-in of wheel cover.
■ After installation, make sure the wheel cover is fitting properly with the body and rear bumper. Align
the hole and tighten the screw.
1. Dismantlement Steps
1) Pry out the ceiling stripe at the welding part of car roof with plastic flat-edge tools.
2) Dismount the ceiling stripe from the guide slot of car roof.
Attention:
■ Don’t damage the clip on the ceiling stripe. Otherwise, it is required to replace it.
Fig. 2.2.014
2. Installation Steps
1) Align the front end of the stripe with the fixed snap-in at the front end of guide slot.
3) Use the rear end of stripe to cover the weather seal of rear window.
Fig. 2.2.015
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Attention:
■ The trimming plate of bumper is made from resin material. Please don’t apply great force on it and
keep it away from oil.
■ When dismantling the trimming plate of bumper, it is necessary to operate by two people to prevent
it from falling.
1. Dismount the rear wheel cover. Refer to “Replacement of Rear Wheel Cover”.
Fig. 2.2.016
2. Put the vehicle on the lifter and lift it to an appropriate height. Dismount the clamping screws at the
lower part of rear bumper in turn.
3. Dismount the screw, at the left and right sides, connecting the rear bumper and fender.
Fig. 2.2.017
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4. Dismount the clamping screw at the upper part of rear bumper in turn.
Fig. 2.2.018
Fig. 2.2.019
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2. Pry out the wiring clip fixing the wire harness on the rear bumper frame.
Fig. 2.2.020
3. Dismount the nuts fixing the lower frame and body in turn.
■ Tightening torque: 34 N.m
Fig. 2.2.021
Diagram for Left and Right Connection Supports at the Lower Part
Fig. 2.2.022
3. Dismount the screw on the hook of sun visor with cross screw driver.
Fig. 2.2.023
Note: The replacement steps for left and right sun visors are the same.
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1. Pry out the fixed snap-in of A-pillar trim board with slotted screw driver.
Attention:
Fig. 2.2.024
Fig. 2.2.025
3. During installation, align the snap-in of trim board with hole, press it in with force and make it seized.
1. Use a slotted screw driver to pry out the metal fixed snap-in of front door.
Attention:
Fig. 2.2.026
■ Don’t scratch the pedal.
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3. During installation, align the snap-in of pedal with hole, press it in with force and make it seized.
1. Dismantlement Steps
1) Dismount the front door pedal at first. Refer to “Replacement of Front Door Pedal”.
Fig. 2.2.027
2) Hold the A-pillar lower trim board and pull it out, disconnect the snap-in and dismount the lower trim
board.
Fig. 2.2.028
3) Install in the reverse order with dismantlement. During installation, align the snap-in of trim board
with hole, press it in with force and make it seized.
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Fig. 2.2.029
2. Use slotted screw driver to pry out the rear door pedal.
Attention:
Fig. 2.2.030
3. During installation, align the snap-in of pedal with hole, press it in with force and make it seized.
Then tighten the clamping screw.
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1. Dismantlement Steps
Fig. 2.2.031
2) Dismount the front door pedal. Refer to “Replacement of Front Door Pedal”.
Fig. 2.2.032
3) Dismount and replace the rear door pedal. Refer to “Replacement of Rear Door Pedal”.
Fig. 2.2.033
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Fig. 2.2.040
2. Installation Steps
1) Install the B-pillar upper trim board and tighten its clamping screw.
4) Align the installation hole and fix the B-pillar lower trim board properly.
7) Install the rear door pedal. Refer to “Replacement of Rear Door Pedal”.
8) Install the front door pedal. Refer to “Replacement of Front Door Pedal”.
Attention:
■ Align the snap-in of trim board with hole, press it in with force and make it seized.
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1. Dismantlement Steps
Fig. 2.2.041
4) Screw off the fixed bolt at the rear end of safety belt of rear seat.
Fig. 2.2.042
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Fig. 2.2.044
10) Pry out the fixed snap-in of C-pillar lower trim board.
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Attention:
■ Align the snap-in of trim board with hole, press it in with force and make it seized.
1. Use slotted screw driver to pry out the screw decorative cap of auxiliary handle.
Fig. 2.2.047
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1. Dismantlement Steps:
Fig. 2.2.050
4) Dismantle the A-pillar trim board. Refer to “Replacement of A-pillar Trim Board”.
5) Dismantle the B-pillar trim board. Refer to "Replacement of B-pillar Trim Board".
6) Dismantle the C-pillar trim board. Refer to "Replacement of C-pillar Trim Board".
7) For the convenience of removing ceiling, rotate the right front seat backrest to horizontal position.
8) Dismantle the fixed snap-in at the back of ceiling interior trimming with special tools.
Fig. 2.2.051
9) Dismantle the ceiling interior trimming from the weather seal of door.
10) Remove the ceiling interior trimming from right front door.
2. Installation Steps:
2) Install the ceiling interior trimming from the weather seal of door.
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5) Install the C-pillar trim board. Refer to "Replacement of C-pillar Trim Board".
6) Install the B-pillar trim board. Refer to "Replacement of B-pillar Trim Board".
7) Install the A-pillar trim board. Refer to "Replacement of A-pillar Trim Board".
Attention:
■ During installation, don’t bend the ceiling interior trimming too much.
■ When installing ceiling interior trimming, align the holes of sun visor on the ceiling interior trimming
and the two holes at the back of ceiling interior trimming with the correspondent holes on the body.
1. Dismantlement Steps
Attention:
■ The carpet is a single layer of molded carpet covering the front/rear floor. Replace the carpet
according to the following steps:
4) Screw off the fixed bolt of front seat safety belt retractor.
6) Dismantle the A-pillar trim board. Refer to “Replacement of A-pillar Trim Board”.
8) Dismantle the auxiliary facia console assembly. Refer to “Replacement of Auxiliary Facia Console”.
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2. Installation Steps
6) Install the auxiliary facia console assembly. Refer to “Replacement of Auxiliary Facia Console”.
7) Install the A-pillar lower trim board. Refer to "Replacement of A-pillar Lower Trim Board”.
11) Install the rear seat backrest. Refer to “Replacement of Rear Seat”.
12) Install the rear seat cushion. Refer to “Replacement of Rear Seat”.
Fig. 2.2.052
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Fig. 2.2.053
Attention:
■ Before installation, check if there is any defect affecting appearance, such as scratch, shrinkage,
uneven gloss, etc.
■ Check if the 5 plastic snap-ins are firmly set to the outer panel of rear boot cover and if there is any
omission.
■ After installation, make sure the protecting plate of rear boot cover is fitting well with the edge of
outer panel.
■ During installation, don’t scratch the outside surface of protecting plate of rear boot cover.
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1. Dismantlement Steps
1) Adjust the seat to an appropriate position to dismantle the clamping screw at the front end of seat.
Fig. 2.2.054
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Attention:
■ When moving the seat, pay attention to prevent the paint from scratch.
Fig. 2.2.058
2. Installation Steps
1) Adjust the seat backrest to an appropriate position to put the seat in.
3) Install the clamping screw at the rear end of seat. Tightening torque: 35~55 N•m.
4) Adjust the seat to an appropriate position again to install the clamping screw at the front end of seat.
5) Install the clamping screw at the front end of seat. Tightening torque: 35~55 N•m.
Fig. 2.2.059
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Fig. 2.2.060
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Attention:
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1. Dismantlement Steps
Fig. 2.2.066
Fig. 2.2.067
Fig. 2.2.068
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3) Use plastic flat-edge tool to pry out or dismantle the name plate from the surface of panel.
Fig. 2.2.069
Fig. 2.2.070
Attention
2. Installation Steps
1) Clean the area on which the name plate is about to be installed and make the area completely dry.
2) Mark the tape with the dimension when the nameplate is located correctly.
4) Stick the adhesive foam tape to the back side of name plate and press the name plate to the correct
position.
Attention:
■ Try to stick the name plate in an environment without dust. Dust or other foreign substances may
lead to improper stickup.
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1. Dismantlement Steps
2) Cover the surrounding area of front windshield to protect the paint and the interior ceiling lining.
3) Dismantle the wiper arm and wiper blade of front windshield. Refer to “Replacement of Wiper Arm”
in “Wiper and Wiper Cleaner System”.
4) Dismantle the air inlet grid. Refer to “Replacement of Front Wiper Driving Components”.
5) Dismantle the inside rear-view mirror. Refer to “Replacement of Inside Rear-view Mirror”.
6) Dismantle the A-pillar trim board. Refer to “Replacement of A-pillar Trim Board”.
① Hold the lower corner of stripe ornament of windshield and slowly pull it out.
② If the stripe ornament of windshield is too tight, cut it along the windshield with multi-purpose knife to
dismantle it.
Attention:
8) Use tools for dismantling glass sealing layer or static window glass to dismantle the windshield.
9) Dismantle the front windshield from the vehicle with the help of assistant.
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10) Check the following components which may lead to breakage of windshield:
③ Windshield.
12) Clear all broken glass from the front cover plate, seat, floor and the duct of defroster.
13) Moisten a lint-free cloth with solution mixed by isopropyl alcohol and water (the volume ratio is 50/50)
to clean the edge of windshield’s inner surface.
2. Installation Steps
After treating the windshield frame according to the requirement, conduct the following operations:
2) Use new coating tools to coat the surface of binding part (1) with hold-down welding primer.
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3) Wait for the primer to be dry for around 10 min. Make sure all the scratch and rubbing marks are
covered.
5) Install stripe ornament of window at the edge of windshield. If the original stripe ornament of window
is damaged, replace it.
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6) With the help of an assistant, fit the windshield and frame to confirm the correct way to locate the
front windshield in the frame.
9) With the help of an assistant, dismantle the windshield from frame with suction cup.
10) Put the windshield on a clean and safe surface, making the inside face upwards.
11) For using the original windshield repeatedly, get rid of all carbamate adhesive from the surface of
windshield with multi-purpose knife or shaver blade. However, leave a layer of film there.
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12) Moisten a lint-free cloth with solution mixed by isopropyl alcohol and water (the volume ratio is 50/50)
to clean the edge of windshield’s inner surface.
Attention:
■ Don’t get rid of all marks of adhesive. Just get rid of all accumulated or scattered chips of carbamate
adhesive.
13) For long-term usage, get rig of all adhesive at the flanging of hold-down welding. However, leave
about 2 mm of adhesive there.
15) Use new coating tools to coat the surface of the flanging of hold-down welding with primer.
Attention:
■ Please take care when adding glass protective agent (transparent) to windshield. This primer may
become dry immediately. If coating unevenly, the visible area on windshield may be polluted.
17) Use new coating tools to coat along the edge of inside surface of window with 10~16 mm of glass
protective agent.
18) Coat the same position on the glass with a second layer of glass protective agent.
19) Use a clean lint-free cloth to wipe the position, coated with primer, clean immediately.
21) Use new coating tools to coat the glass primer on the same place coated with glass protective agent.
The glass primer may be used in 8 hours after coating. The surface of glass for primer coating must
be clean.
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24) Use barrel-type caulking gun to coat the flanging of glass glue evenly and continuously.
26) With the help of an assistant, install the windshield in the frame with suction cup.
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27) Align the windshield with the tape line (1) on the body.
29) Use tape to stick the windshield to the body to reduce moving until the glass glue is solidified.
Attention:
■ Don’t directly spray high pressure water on the glass glue which is just coated.
33) If there is leakage, use plastic scraper to coat more glass glue at the leaking position.
34) When the glass glue is solidified, check for leakage of windshield again.
Caution:
■ It takes 24 h for the maintenance material to be solidified completely. Don’t interfere with the
maintenance part before it is completely solidified. Otherwise, the passenger without any protective
measures will fall out from the vehicle and get hurt.
35) Dismount the protective tape and covering from windshield area.
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I. Precautions
Strictly comply with the precautions for operation of SRS, or else, damage to vehicle and people
may be caused.
Dismount the negative pole of storage battery and wait for at least 1 min before dismounting the
connector of electrical appliance, or else, vehicle damage will be caused.
■ Use cloth to protect the dismounted spare parts from being damaged and scratched during
dismantling and installing the elements.
■ Wrap the right-angled screwdriver blade with cloth, when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly mounted into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
1. Dismantlement steps
Fig. 2. 3.001
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3) Dismantle the clamping screw of airbag module. Rotate the steering wheel along its central position
so as to take off the second screw.
Fig. 2. 3.002
4) Move away the driver airbag module and cut off the connector of airbag module at the driver’s side.
Fig. 2. 3.003
5) Cut off the connector of horn button and dismantle the clamping screw of horn switch.
Fig. 2. 3.004
7) Mark out a location mark on the steering wheel hub and align this mark with the notch on steering
shaft.
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Fig. 2. 3.005
9) Use special tools to dismount the steering wheel from steering shaft.
Fig. 2. 3.006
11) Remove the wiring of airbag module connector from the steering wheel.
2. Installation steps
2) Align the mark on steering wheel with the notch on steering shaft.
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5) Install the clamping screw of horn switch and connect the connector of horn switch.
Fig. 2. 3.007
6) Place the driver airbag module on steering wheel, connect the connector of driver airbag module
and ensure that the circuit is correctly and firmly installed during installation.
Fig. 2. 3.008
■ Horn
■ Steering wheel
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Fig. 2. 3.009
Fig. 2. 3.010
Fig. 2. 3.011
5. Install with the reverse order. Notice that the steering column should be placed at central position
and install the clamping screw of left lower protective cover of console.
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1. Dismount the bottom cover of lower protective cover of console at driver’s side.
Fig. 2. 3.012
Fig. 2. 3.013
3. Cut off every connector seat connected with the lower protective cover of console at driver’s side.
Fig. 2. 3.014
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Fig. 2. 3.015
2. Dismantle the driver airbag module. Refer to “Replacement of Driver Airbag Module”.
4. Dismantle the upper/lower protective cover. Refer to “Replacement of Trimming Cover of Steering
Column”.
5. Dismantle the clock spring of airbag. Refer to “Replacement of Clock Spring of Airbag”.
6. Dismantle the lower protective cover of console at driver’s side. Refer to “Replacement of Lower
Protective Cover of Console at Driver’s Side”.
Fig. 2. 3.016
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Fig. 2. 3.018
10. Dismantle the ignition switch and key alarm switch assembly from ignition lock module assembly.
11. Install in reverse order with dismantlement; ensure that the circuit is correctly and firmly installed
during installation.
Fig. 2. 3.019
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Fig. 2. 3.020
1. Dismantlement steps
1) Dismantle the lower protective cover of console at driver’s side. Refer to “Replacement of Lower
Protective Cover of Console at Driver’s Side”.
3) Dismantle the clamping screw of left/right trimming plate of auxiliary fascia console and slightly pull
out the trimming plate outward.
Fig. 2. 3.021
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Fig. 2. 3.023
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12) Dismantle the front/rear fastening bolt of rear part assembly of auxiliary fascia console and then
slightly pull out the rear part assembly of auxiliary fascia console forward.
2. Installation steps
1) Install the rear part assembly of auxiliary fascia console to the vehicle and fasten the front/rear
fastening bolt of auxiliary fascia console.
5) Install the middle fastening bolt of front part assembly of auxiliary fascia console.
Fig. 2. 3.027
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Fig. 2. 3.028
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3. Dismount the trimming cover of steering column. Refer to “Replacement of Trimming Cover of
Steering Column”.
4. Dismantle the clock spring of Airbag. Refer to “Replacement of Clock Spring of Airbag”.
5. Dismantle the lower protective cover of console at driver’s side. Refer to “Replacement of Lower
Protective Cover of Console at Driver’s Side”.
8. Dismount the fastening bolt connected with intermediate steering shaft and steering gear.
Fig. 2. 3.032
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Fig. 2. 3.035
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5. Cut off the connector of combined device and dismount the combined device.
Fig. 2. 3.038
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Fig. 2. 3.041
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Fig. 2. 3.044
3. Dismount the trimming cover of steering column. Refer to “Replacement of Trimming Cover of
Steering Column”.
4. Dismantle the clock spring of Airbag. Refer to “Replacement of Clock Spring of Safety Airbag”.
5. Dismantle the lower protective cover of console at driver’s side. Refer to “Replacement of Lower
Protective cover of Console at Driver’s Side”.
9. Dismantle the lamp of glove box. Refer to “Replacement of Glove Box Lamp”.
Fig. 2. 3.045
13. Dismantle the auxiliary fascia console assembly. Refer to “Replacement of Auxiliary Fascia
Console”.
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14. Dismantle the combined device assembly. Refer to “Replacement of Combined Device”.
Fig. 2. 3.046
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30. Take down the console with the aid of the assistant.
Fig. 2. 3.058
Fig. 2. 3.059
6. Take down the console support with the aid of the assistant.
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