M1 Service Manual

PREFACE
The HAVAL M1 is equipped with a GW4G13 gasoline engine. The GW4G13 engine incorporates
the latest VVT technology which meets the Euro IV emission standards. The HAVAL M1 front suspen-
sion is a McPherson independent suspension, the rear suspension is a single trailing arm independent
suspension, and the vehicle body is an ultra-light body made from structural steel. With the high-intensity
front and rear fender impact beams as well as a collision impact absorption system, it is able to maintain
the cab's integrity and safety to a greater extent. We created this maintenance manual in order to meet the
demands of the Great Wall after-sales service technicians. This manual mainly introduces the areas of
importance in regard to maintenance and care and removal and installation of each system's assembly and
maintenance technical parameters, but not include all the items for vehicle repair and maintenance.
This manual is provided by the Great Wall Motor Co., Ltd. and is written for a technician's use. If
non-professional or unqualified personnel repair or maintain the vehicle, it may injure the operator and
other persons in and around the vehicle and damage the vehicle if the operator only refers to this manual
or doesn't have the appropriate equipment or tools.
To prevent dangerous operational situations and avoid damaging the vehicle, read and follow the in-
structions carefully:
Read this manual carefully. Have a full understanding of all the contents in the sections entitled "Ar-
eas of Importance" in the "Preface."
Any maintenance method introduced in this manual is effective for the maintenance and repair of
the vehicle. While following the procedures in this manual to complete repairs, please use specified or
recommended tools. If the user doesn't use specified or recommended tools, please guarantee the safety
of the maintenance personnel before operating and make sure that it won't cause bodily damage or ve-
hicle damage.
If any vehicle part change is necessary, please use a part with the same part number or same quality
and same specification. Never use unqualified parts.
To effectively avoid bodily and vehicle damage or an unsafe environment due to misoperation dur-
ing maintenance or repair, please follow the sections entitled "Caution," "Hints," and "Warnings" in this
manual. In addition, the contents of the "Caution," "Hints," and "Warnings" sections in this manual are
not exaggerated, and actions contrary to these notes may cause dangerous results.
Please read carefully the section "Areas of Importance" before carrying out any maintenance or re-
pair on the airbag system's components or its surrounding electrical components. Actions contrary to any
of the "Areas of Importance" may lead to unexpected deployment the airbag, which may cause serious
accidents. If the airbag system and other systems require maintenance, it is recommended to repair the
airbag system first and then repair other systems to avoid unexpected deployment of the airbag and caus-
ing serious accidents.
All of the information in this manual is based on the latest product information when the manual is
published. The maintenance specifications and procedures are subject to change without prior notice.
Although we have tried our best to write this manual well, we do not guarantee that the entire con-
tents of this manual is absolutely correct. Users may not make any legal claim against the Great Wall
Motor Co., Ltd. in regards to this manual. Any loss caused by failure in following this manual is not our
responsibility. Because of the writer's limited experience, we welcome any user comments, suggestions,
and corrections.
Great Wall Motor Co., Ltd. reserves the final right of explanation.
Editor
April 2009
Contents
Chapter I........................................................................................... Overview
How to Use This Manual........................................................................1-2
Maintenance Instructions........................................................................1-5
How to Troubleshoot ECU Control Systems.........................................1-18
Terms....................................................................................................1-28
Chapter II.....................................................................................Maintenance
Maintenance and Inspection...................................................................2-2
Overall Parameters.................................................................................2-8
Vehicle Body's Basic Calibration Measurements ................................ 2-21
Chapter III.........................................................................Engine Accessories
Exhaust System......................................................................................3-2
Cooling System......................................................................................3-5
Engine Suspension...............................................................................3-12
Fuel Supply System..............................................................................3-14
Chanper IV.................................................................................Drive System
Propeller Shaft........................................................................................4-3
Rear Axle Assembly..............................................................................4-20
Rear Main Reducer Assembly.............................................................. 4-23
Front Axle Hub Subassembly LH.......................................................... 4-38
Rear Axle Hub Subassembly LH.......................................................... 4-45
Clutch...................................................................................................4-49
Chapter V...................................................................................Transmission
Transmission's Introduction and External Schematics........................... 5-3
Transmission Assembly Inspection......................................................... 5-9
Differential Assembly............................................................................5-17
Transfer Case Assembly.......................................................................5-21

Adjusting Method of Gear Surface Contact..........................................5-33
Input Shaft Assembly............................................................................5-35
Output Shaft Assembly.........................................................................5-40
Maintenance of the Housing Assembly................................................ 5-46
Maintenance of Other Common Easily-Damaged Parts....................... 5-52
Chapter VI.................................................................................... Suspension
Front Suspension System...................................................................... 6-2
Rear Suspension System.....................................................................6-17
Tires and Wheels . ...............................................................................6-30
Chapter VII.........................................................................................Steering
Steering System.....................................................................................7-2
Power Steering System..........................................................................7-8
Chapter VIII..........................................................................................Brakes
Brake System.........................................................................................8-2
ABS Brake System...............................................................................8-25
Chapter IX.....................................................Supplemental Restraint System
Seat Belts...............................................................................................9-2
Airbags...................................................................................................9-7
Chapter X...................................................................................... AC System
System Introduction..............................................................................10-2
Technical Specifications.......................................................................10-3
Malfunction Indicator Table................................................................... 10-4
Areas of Importance.............................................................................10-5
Routine Inspections..............................................................................10-6
AC System Components....................................................................10-10
Refrigerant.......................................................................................... 10-11
Compressor Assembly........................................................................10-19
AC Controller Assembly Replacement............................................... 10-21
AC Assembly......................................................................................10-22
Maintenance and Replacement of the AC Filter Screen..................... 10-25
Subcooling Condenser Assembly....................................................... 10-26
Chapter XI.................................................................................. Vehicle Body
Engine Hood......................................................................................... 11-2
Engine Hood Lock Cable Assembly..................................................... 11-4
Trunk Power-Assisted Strut Bar........................................................... 11-5
Retainer................................................................................................ 11-5
Door Hinges.......................................................................................... 11-6
Bumper................................................................................................. 11-7
Door Cable of Fuel Tank Filler............................................................ 11-13
Chapter XII............................................................................Audio and Video
Audio and Video System......................................................................12-2
Chapter XIII..........................................................................................Interior
Combination Meter...............................................................................13-2
Door Lock System..............................................................................13-22
Immobilizer System............................................................................13-33
Top Interior Cover...............................................................................13-36
Seats..................................................................................................13-39
Chapter XIV.........................................................................................Exterior
Lighting System....................................................................................14-3
Windshield/Door Window Glass/Rearview Mirror............................... 14-13
Exterior Rearview Mirror.....................................................................14-25
Wipers and Washer System...............................................................14-30

Horn System.......................................................................................14-42
Reverse Sensor..................................................................................14-45
Chapter XV.........................................................................................Circuitry
Basic Information about the Electrical System.....................................15-2
Electrical System Schematics Instructions...........................................15-5
Areas of Importance in Circuit Maintenance.........................................15-7
Circuit Inspection Steps........................................................................15-7
Ground Points .....................................................................................15-8
Key Electrical Components Module.................................................... 15-10
Wiring Diagram . ................................................................................15-12
Fuse Box............................................................................................15-17
Connector...........................................................................................15-21
Connector List....................................................................................15-30
General Circuitry Diagram .................................................................15-37

Overview 1-1
Overview
How to Use This Manual..................................................................1-2

Identification Information...............................................................1-4
Maintenance Instructions.................................................................1-5
Areas of Importance......................................................................1-5
Vehicle Hoisting and Supporting Position...................................1-16
How to Troubleshoot ECU Control Systems..................................1-18
General Information....................................................................1-18
Usage Methods for Scanners.....................................................1-18
Circuit Check Procedure.............................................................1-23
Terms..............................................................................................1-28
1-2 HAVAL M1 Maintenance Manual
How to Use This Manual

1. Overview.
(a) Maintenance operation includes 3 main steps:
(1) Diagnosis.
(2) Removal/installation, replacement, disassembly/reassembly, inspection, and adjustment.
(3) Final inspection.
(b) This manual describes "diagnosis" and "removal/installation, replacement, disassembly/reassembly, inspec-
tion, and adjustment." "Final inspection" is omitted.
(c) This manual does not include the following basic operations. However, these operations must be performed
in actual situations.
(1) Operating with a jack or lift.
(2) Clean the removed parts if necessary.
(3) Visual inspection.
2. Preparations.
Special service tools (SST) may be required according with the maintenance circumstances. If necessary, be sure
to use SST and strictly follow the correct maintenance procedures.
3. Maintenance procedures.
(a) Components schematics are provided under the related subject if necessary.
(b) Disposable parts, grease application position, pre-coated parts, and tightening torques are specified in the
component schematics.
30±5
Brake cylinder subassembly
◆Rectangular sealing ring

Bleed screw
10±2
Inner brake pad assembly
Bleed screw cap
Outer brake pad assembly
Piston
◆Piston dust cover

Brake block clamp Guide pin dust cover
spring plate
Inner muffler plate subassembly
Alarm plate
Outer muffler plate subassembly
Guide pin
Brack cylinder Brake block clamp spring plate

mounting bracket
Rubber grease
N·m : Specified torque
◆ Disposable parts MLA001G

Overview 1-3
(c) This procedure mainly describes the tightening torque, grease application position, and disposable parts.
Caution: In some cases, this kind of information can only be explained by illustrations. At this time, all
information, including torque and engine oil, will be explained by illustrations.
(d) The installation sequence is reserve to the removal sequence. However, only the installation procedures con-
taining additional information are included.
(e) The text of the manual only introduces important items. How to operate and other details are indicated in the
illustration beside the text. Both the text and the illustration are accompanied by standard values and notices.
(f) Sometimes, illustrations of similar vehicles may be used. In this case, the details may be different from the
actual vehicle.
(g) The operation procedure is introduced step by step:
(1) The illustration displays how and where to operate.
(2) The task subject tells how to operate.
(3) The instruction text tells how to perform the task. In addition, it also tells maintenance specifications,
warnings, and similar information.
For example:
Work subject: How to operate
4. Inspect the front disc brake thickness.

Standard thickness: 22.0 mm Specifications
Minimum thickness: 20.0 mm
The brake disc must be changed when it reaches the minimum
level of thickness.
Detailed Instruction: How to do it

MLA002G
Correct vehicle maintenance and repair is very important to

the safety of the maintenance person and the vehicle. If any
Illustration: How and where to operate vehicle part change is necessary, please use a part with the
same part number or part number specified by the Great Wall
Motor Co., Ltd. Never use a part that has not been authorized
by the Great Wall Motor Co., Ltd.
Hint: This form provides experienced technicians with the information necessary for a fast follow up. The task
subject is easy to understand and the text under the task subject provides the details. Important maintenance spec-
ifications are highlighted in bold.
5. Maintenance specifications.
The specifications are highlighted in bold where required in this manual. In addition, you can also refer to the
"Maintenance Specifications" chapter for the them as well.
6. Terms and definitions.
Warning Indicates the possibility of causing injury to yourself or to others.
Caution Indicates the possiblity of causing damage to the component under maintenance.
Hint Provides additional information to help improve maintenance efficiency effectively.
7. SI UNIT.
The units used in this manual comply with the SI UNIT (international system of units) standard.
For example: Torque: 30 N·m
Identification Information
Vehicle identification number and serial number
A
1. Vehicle Identification Number.
As shown in the figure, the vehicle identification number (VIN)
is printed on the vehicle identification number plate and the
nameplate.
A: Vehicle Identification Number plate (VIN)
MLA003G B: Nameplate
MLA004G
2. Engine model number.

The engine model number is printed on the engine cylinder
block, as shown in the figure GW4G13.
Engine serial number

printing position MLA005G
Overview 1-5
Maintenance Instructions
Areas of Importance
1. Basic maintenance hints.
(a) Operational hints
5
3
6
4
MLA006G
Make sure to wear proper working clothes.

1 Clothing
Make sure to wear a cap and safety shoes.
Before operation, prepare the radiator grille, fender protective cover, seat cover, and
2 Vehicle protection
floor cover.
If two or more people are working together, make sure to check the safety conditions
mutually.
When working under the condition that the engine is operating, make sure that the
workshop is equipped with ventilation devices.
3 Safe operation When carrying out maintenance of high temperature, rotating, moving or vibrating
parts, take care not to burn or hurt yourself.
When jacking up the vehicle, make sure to use a safety stand to support the specified
position.
When hoisting the vehicle, please use safety equipment.
Prepare tools and mea- Before operation, prepare the tool stand, SST, meter, engine oil, cotton rags, and re-
4
suring instruments placement parts.
After a full understanding of the problem, carry out the diagnosis and the correct re-
pair.
Removal and in-
Before removing the parts, check the overall status of the assembly to see if deforma-
stallation, disas-
5 tion or damage exists.
sembly, and reas-
When reassembling complicated parts, make records or installation marks to prevent
sembly procedures
mistakes.
If necessary, clean the removed parts and reassemble them after thorough inspection.
Place the removed parts in the proper order to avoid confusion or contamination.
For disposable parts such as gaskets, O-rings, and lock washers, replace them with
6 Removed parts
new parts according to the instructions in this manual.
If necessary, collect and keep the replaced parts so that the customer can check them.
(b) Jack up and support the vehicle
Be careful when jacking up and supporting the vehicle. Make
sure to jack up and support the vehicle in the correct locations
(See page 1-16).
(c) Pre-coated parts
(1) Pre-coated parts refer to the parts coated with sealant
in the factory, such as bolts and nuts.
(2) If the pre-coated part is re-tightened, loosened or
moved in any way, it must be coated with prescrip-
tive sealant again.
Sealant (3) When the pre-coated part is reused, the original seal-
ant should be cleaned and dried using compressed
ALA007G
air. Then, apply the corresponding new sealant to the
bolt or nut.
Caution: Tighten with the lower limit of torque tolerance.
(4) If sealant is used, it may be necessary to leave the
sealant stationary for a specified time until it has so-
lidified.
(d) Gaskets
When necessary, apply sealant to gaskets to avoid leakage.
(e) Bolts, nuts, and screws
All maintenance specifications regarding tightening torque
must be strictly followed. Make sure to use a torque wrench.
(f) Fuses
Medium current fuse and high current fuse
with equally-rated amperage Before changing a fuse, make sure that the rated amperage of
30A 30A the new fuse is correct. It is prohibited to use fuses higher or
lower than the rated amperage.
ALA008G
Illustration Symbol Part name Abbreviation
Fuse FUSE
BE5594 IN0365
Medium current fuse M-FUSE

BE5595 IN0366
High current fuse H-FUSE

D27353 IN0367
Overview 1-7
(g) Clips
Methods for removal and installation of the vehicle's body
typical part clips are shown in the table below.
Hint: If the clip is damaged during operation, it must be re-
placed with a new one.
Shape (Example) Removal/Installation
Clip
Pliers
Clip remover
Protective adhesive tape
Screwdriver
Protective adhesive tape
Scraper
ALA010G
Shape (example) Removal/Installation

Removal Installation
ALA011G
Overview 1-9
(h) Vacuum hose removal and installation

(1) To disconnect the vacuum hose, pull the end of the
hose and not the center.
Incorrect Correct
ALA012G
(2) When disconnecting the vacuum hose, label the sec-

tions to be reconnected.
(3) After performing this task, check carefully to make
sure the vacuum hose is connected correctly.
(4) When using a vacuum gauge, do not use force to
connect the hose to an oversized connector. Make
adjustments by using a reducer.
If the hose is stretched, it may lead to air leakage.
ALA013G
(i) Torque in case the combination of wrench and extended

tool is used
L1 L2 (1) In case the SST or the combination of extended
tool and torque wrench is used to extend the overall
length, when the reading of the torque wrench reach-
es the specified torque, the actual torque is too big.
(2) This manual only describes the specified torque.
When the SST or extended tool is used, calculate the
ALA014G
reading of the torque wrench according to the fol-
lowing formula:
(3) Formula T'=T × L2/(L1+L2)

T' Reading of torque wrench (N·m)
T Torque (N·m)
L1 L2
L1 Length of SST or extended tool (cm)
L2 Length of torque wrench (cm)
ALA015G
2. For vehicles equipped with a SRS (Supplemental Restraint System) and seat belt pretensioner.
Hint: This vehicle is equipped with a Supplemental Restraint System (SRS) and seat belt pretensioner.
If the maintenance operation is not carrried out in the correct order, the SRS airbag may be deployed accidentally
during maintenance and thus lead to serious accidents.
In addition, if errors occur during the maintenance of the SRS, the SRS may be unable to operate properly.
Before carrying out maintenance (including the removal or installation, inspection, or replacement of parts), read
the following areas of importance carefully. Then, carry out maintenance according to the correct procedure intro-
duced in this manual.
(a) General Areas of Importance
(1) Because the problem of the SRS is difficult to be confirmed, the Diagnostic Trouble Code (DTC) be-
comes the most important information source for troubleshooting. During the troubleshooting of the
SRS, check the DTC before disconnecting the battery (See page 9-15).
(2) To avoid serious injury, start the maintenance of SRS 90 seconds after the following conditions have
been satisfied:
• The ignition switch is moved to the LOCK position.
• The battery's negative (-) terminal cable is disconnected.
Hint: The SRS is equipped with a backup power supply. Therefore, the SRS may be deployed if the maintenance
work is started within 90 seconds after the battery's negative (-) terminal cable has been disconnected. Discon-
necting the negative (-) terminal cable will clear the clock memory and the settings for the stereo system. Before
disconnecting the cable, if necessary, record the data as required. To avoid clearing the setting of the memory, use
a backup power supply.
(3) If a minor collision occurs without SRS deployment, before continuing to use the vehicle, check the
driver side airbag assembly, front passenger side airbag assembly, and seat belt pretensioner.
(4) Never use SRS parts from other vehicles. When replacing the SRS parts, please replace them with new ones.
(5) If the airbag ECU assembly might be hit during maintenance, it should be removed before carrying out
maintenance.
(6) Never disassemble and repair the airbag ECU assembly, driver side airbag assembly, front passenger
side airbag assembly, or seal belt pretensioner.
(7) Replace the airbag ECU assembly, driver side airbag assembly, or front passenger side airbag assembly
in the following cases: 1) damage occurs due to dropping, 2) breaks, dents, or other flaws appear in the
case, bracket, or connector.
(8) It is strictly prohibited to expose the airbag ECU assembly, driver side airbag assembly, front passenger
side airbag assembly, or seat belt pretensioner directly to hot air or flame.
(9) It is strictly prohibited to use a multimeter to measure the driver side airbag assembly or front passenger
side airbag assembly. Otherwise, the airbag may be deployed and thus lead to injury.
(10) The SRS components have information labels. Follow the instructions in the directions.
(11) After maintenance of the SRS, check the SRS warning lamp.
Mark (b) Clock spring (combination switch)

(1) The steering wheel must be installed correctly on
the steering column, so that the clock spring is in the
middle position. Otherwise, cable disconnection or
other problems may occur.
ALA016G
Overview 1-11
(c) Driver side airbag assembly (with airbag)

(1) When removing the driver side airbag assembly or handling a new horn button, the top surface of the
decorative cap should face upwards. Refer to the diagram below.
If the surface of the decorative cap faces downwards, serious accidents may occur once the airbag is de-
ployed accidentally. Furthermore, do not place anything on the top of the horn button.
(2) Never measure the resistance of the airbag ignition tube. Otherwise, the airbag may be inflated and thus
lead to serious injury.
(3) It is strictly prohibited to apply any type of grease or detergent to the steering wheel decorative cap.
(4) Store the driver side airbag assembly in a place far from radio noise interference, where the ambient
temperature is lower than 93oC and the humidity is not high.
(5) Before using electric welding in any part of the vehicle, disconnect the airbag ECU connectors.
These connectors contain short circuit springs. They can reduce the possibility that the airbag or pre-
loaded seat belt is deployed due to the electric current flowing into the wire of the ignition tube.
(6) Before discarding the vehicle or the driver side airbag assembly, inflate the airbag using the SST (See
page 9-35). Please perform this operation in a safe place far from radio noise interference.
For example:
Correct Incorrect
ALA017G
For example:
ALA018G
(d) Front passenger side airbag assembly

(1) Make sure to place the detached or new front passenger side airbag assembly with the airbag deploy-
ment side facing upwards. If the airbag asseembly is placed with the airbag deployment side facing
downwards, serious accidents may occur once the airbag is inflated.
(2) Never measure the resistance of the airbag ignition tube. Otherwise, the airbag may be deployed and
thus lead to serious injury.
(3) It is strictly prohibited to apply any type of grease or detergent to the front passenger side airbag assem-
bly.
(4) Store the airbag assembly in a place far from radio noise interference, where the ambient temperature is
lower than 93oC and the humidity is not high.
(5) Before using electric welding in any part of the vehicle, disconnect the airbag ECU connectors (4 yellow
pins).
(6) Before discarding the vehicle or the airbag assembly, deploy the airbag using the SST (See page 9-35).
Carry out activation in a safe place far from radio noise interference.
For example:
ALA019G
(e) Seat belt pretensioner

(1) Never measure the resistance of the seat belt pretensioner. This may activate the seat belt pretensioner
and thus lead to serious personal injury.
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seal belt pretensioner on other vehicles.
(4) Store the seat belt pretensioner in a place far from radio noise interference, where the ambient tempera-
ture is lower than 80oC and the humidity is not high.
(5) Before using electric welding in any part of the vehicle, disconnect the airbag ECU connectors.
(6) As a safety measure, make sure to activate the seat belt pretensioner before discarding. Activate the pre-
tensioner in a safe place far from radio noise interference. (The seat belt pretensioner will warm up after
being activated. Let it cool down before discarding. Never use water to cool the seat belt pretensioner)
(7) It is strictly prohibited to place oil or water on the front seat belt or use any type of detergent to clean the
front seat belt.
For example:
ALA020G
Overview 1-13
(f) Airbag ECU assembly

(1) If the SRS has been deployed in a collision, never reuse the airbag ECU assembly.
(2) When connecting or disconnecting the connectors of the airbag ECU assembly, place the ECU on the
floor. If the connectors are connected or disconnected when the airbag ECU assembly is not placed on
the floor, the SRS may be deployed accidentally.
(3) To avoid serious injury, start the maintenance of the SRS 90 seconds after the following conditions have
been satisfied:
• The ignition switch is moved to the LOCK position.
• The battery's negative (-) terminal cable is disconnected.
(g) Wire harness and connectors
Airbag harness and instrument panel harness is separate, and all airbag harness external protective covers
and connectors are yellow. If the SRS wire harness is disconnected or the connector is broken, it should be
repaired or replaced.
3. Electronic controls.
(a) Battery terminal removal and installation
(1) Before carrying out electrical work, disconnect the
battery's negative (-) terminal cable to prevent short
circuiting or blowing.
(2) When disconnecting and installing the terminal
cable, turn off the ignition switch and lighting switch
and loosen the terminal nut completely. When carry-
ing out these operation, do not twist or pry the termi-
nal.
(3) When the battery terminal cable is removed, all the
data stored (clock, CD player, DTC, etc.) will be
cleared. Before removing the cable, record the set-
ting of each memory system.
(4) When the battery's negative (-) terminal cable is
disconnected, the storage of each system will be
cleared. Refer to the pre-examination of each system
to determine whether the system needs to be initial-
ized after the battery's negative (-) terminal cable has
been disconnected. Initialize the system if necessary.
(b) Handling electronic parts
(1) Unless absolutely necessary, do not open the ECU
cover or case.
(Hitting the integrated circuit terminal may develop
faults in the integrated circuit due to static electric-
ity).
(2) When disconnecting the electronic connector, pull
Incorrect out the connector itself instead of the wire harness.
ALA022G
(3) Be careful not to drop electronic components, such
as sensors and relays. If they have been dropped onto
a hard floor, replace them at once and never use them
again.
(4) When cleaning the engine with steam, prevent water

from entering the electronic components, air filters,
and components related to emission.
(5) It is prohibited to use an impact wrench to remove or
install temperature switches or temperature sensors.
(6) When checking if the wire harness connector is con-
ducting, insert the scanner probe carefully in order to
prevent the terminal from being bent.
4. Fuel control parts removal and installation.
(a) Place of removal and installation of fuel system parts
(1) Operate in a well-ventilated place where there are no
welders, grinders, drilling machines, motors, or fur-
naces.
(2) Never operate in or near tunnels, because fuel vapor
may concentrate in such places.
(b) Fuel system part removal and installation
(1) Before starting operation, please have a fire extin-
guisher on hand.
(2) To avoid static electricity, a ground wire should be
installed on the oil changer, vehicle and fuel tank and
it is strictly prohibited to spray water in this area.
The operating surface may become slippery. It is
strictly prohibited to clean the spilled gasoline with
water, because this may lead to the diffusion of gaso-
line and thus cause a fire hazard.
(3) Never use electrical equipments\similar to motors
or work lamps because they may produce sparks or
high temperatures.
(4) Never use hammers because they may produce
sparks.
(5) Use a fireproof container to clean the cotton rags
stained with the fuel separately.
5. Engine air intake parts removal and installation.

(a) Any metal particles entering the intake passage may
damage the engine.
(b) When removing and installing the air intake system
parts, seal up the openings of the removed parts and the
engine opening. Use cotton rag, adhesive tape, or other
suitable materials.
(c) Before installing the air intake system parts, check to
ALA023G
make sure that no metal particles have entered the engine
or the parts to be installed.
Overview 1-15
6. Handling hose clips.

Spring clip
(a) Before removing the hose, check the position of the clip
so that it can be put back in the same position.
(b) Replace the deformed or depressed clip with a new one.
(c) When the hose is reused, attach the clip in the impression
left by the clip.
(d) Spring clips can be tightened by pulling the clips gently
Impression left by the clip in the directions indicated by the arrows after installation.
ALA024G
7. For vehicles equipped with a catalytic converter.

Hint: A large amount of unburned gasoline or gasoline vapor
that has entered the catalytic converter may lead to overheat-
ing and thus cause a fire hazard. To prevent this from happen-
ing, please follow the following areas of importance.
(a) Only use unleaded gasoline.
(b) Avoid operating the engine at an idle speed for a long time.
(c) Avoid a spark jump test.
(1) Carry out a spark jump test only when it is absolutely
necessary. Complete the test as quickly as possible.
(2) Never operate the engine at a high speed during the
test.
(d) Avoid measuring the compression pressure of the engine
for a long period of time.
The measurement of the compression pressure of the en-
gine must be completed as quickly as possible.
Vehicle Hoisting and Supporting Position

1. Areas of importance of vehicle conditions when jacking up the vehicle.
(a) Before jacking up the vehicle, the vehicle must be unloaded. Never jack up/hoist an overloaded vehicle.
(b) When disassembling heavy equipment, such as the engine and transmission, the vehicle's center of gravity
may transfer. To stabilize the vehicle, put a balance weight in a position where it will not roll or move, or fix
the hoisting bracket with the transmission jack.
2. Areas of importance in using a 4-column lift.
(a) Operate according to the safety procedures described in the instruction book.
(b) Take precautionary measures to prevent the free wheel cross member from damaging the tires or wheels.
(c) Please use wheel chocks to stabilize the vehicle.
3. Areas of importance in using a jack and safety stand.
(a) When operating on a flat surface, please make sure to use wheel chocks.
Rubber attachment (b) As shown in the figure, please use a safety stand with a
rubber attachment.
(c) Place the jack and rigid bracket accurately on the speci-
fied position of the vehicle.
(d) When jacking up the front wheel, release the park-
ing brake and simply put wheel chocks behind the rear
wheels. When jacking up the rear wheel, simply put
wheel chocks in front of the front wheels.
MLA007G
(e) It is strictly prohibited to use jacks in the absence of a
rigid bracket.
(f) When only jacking up the front wheel or rear wheel, please put wheel chocks on both sides of the wheel in
contact with the ground.
(g) When using a jack to lower a vehicle of which the front wheel is jacked up, release the parking brake and
simply put wheel chocks in front of the rear wheels. When using jack to lower a vehicle of which the rear
wheel is jacked up, simply put wheel chocks behind the front wheels.
˖Jacking up position
˖Supporting position, position of

diamond-stand jack
˖Vehicle's center of gravity

(no load)
MLA008G
Overview 1-17
4. Areas of importance in using a rocker lift.

(a) Operate according to the safety procedures described in the instruction book.
(b) As shown in the figure, please use a bracket with rubber attachment.
(c) When using a lift, put its center as close to the vehicle's center of gravity as possible.
(d) Place the vehicle on the bracket as horizontally as possible. Then, match the bracket slot to the rigid bracket
supporting position. Do not hoist the vehicle excessively, because this may cause the vehicle to become un-
stable.
(e) Please make sure to lock the rocker during operation.
(f) Hoist the vehicle off the ground and shake it to make sure that the vehicle is stable.
5. Areas of importance in using plate lift.
(a) Operate according to the safety procedure described in the instruction book.
(b) Use the plate lift attachment.
(c) Refer to the table below to determine how to set the vehicle correctly.
Left and right fixing po-
Place the vehicle in the middle of the lift.
sitions
Front and rear fixing po- Align the rubber cushion end of the plate with the lower end of the attachment (A and C).
sitions Align the upper end of the attachment (B) with the groove at the front end of the sill flange.
(d) Hoist the vehicle off the ground and shake it to make sure that the vehicle is stable.
Lift center
Rocker lift
Vehicle's center of gravity (no load)

Rubber attachment
Plate lift
Dimensions of attachment
85 mm
70 mm
B
A C 100 mm
200 mm
Attachment
MLA009G
How to Troubleshoot ECU Control Systems

General Information
This vehicle uses a large number of ECU control systems. It is generally considered that ECU control systems are
so complicated that their troubleshooting requires high-level technical knowledge. However, most fault detection pro-
cedures only check the circuits of the ECU control system one by one.
A good understanding of the system and a mastery of basic electricity knowledge are sufficient for carrying out effec-
tive troubleshooting, accurate diagnosis, and the necessary maintenance. The main details and troubleshooting proce-
dures related to the ECU control systems of this vehicle are stated as follows:
System Page (s)
ABS system with EBD 8-25
Supplemental Restraint System 9-1
Combination meter 13-2
Power door lock control system and remote door lock control system 13-22
Usage Methods for Scanners

·· Before using a diagnostic tool or scanner, read through the diagnostic tool instruction book or the scanner op-
eration manual.
·· If the diagnostic tool or scanner is unable to communicate with the ECU control system, the vehicle or scan-
ner has a malfunction.
(1) If the communication is normal when the scanner is connected to another vehicle, check the diagnostic data
link (bus⊕circuit) or ECU power supply circuit of the vehicle.
(2) If the communication is still abnormal when the scanner is connected to another vehicle, it is likely that the
scanner itself has a malfunction. Therefore, perform the self-detection procedure described in the scanner
operation manual.
How to carry out troubleshooting

Hint: Carry out troubleshooting according to the following procedure. Only the basic procedure is indicated. The
details in the diagnosis chapter indicates the most effective method for each circuit. Before carrying out trouble-
shooting, confirm the troubleshooting procedure for the related circuit.
1 Send the vehicle to the repair workshop
2 Customer problem analysis

Ask the customer about the condition and environment under which the problem occurred.
3 Symptom confirmation and DTC (and freeze frame data) check

(a) Check the battery positive voltage.
Voltage: 11-14 V (the engine stops)
(b) Visually inspect if the wire harness, connector, or fuse is open or short circuited.
(c) Warm up the engine to the normal working temperature.
(d) Confirm the problem and conditions and check the DTC according to the related diagrams.
Normal Go to Step 5
Overview 1-19
Abnormal
4 DTC table
Check the results obtained in Step 3 and then confirm the system and part check procedure according to the DTC table.
Go to Step 6
5 Malfunction indicator table

Check the results obtained in Step 3. Then confirm the system and part check procedure according to the malfunc-
tion indicator table.
6 Circuit check or part check

Check the system circuits or parts according to the malfunction indicator table or the results obtained in Step 4.
7 Maintenance
Repair the faulty system or part according to the instructions given in Step 6.
8 Confirmation test
After maintenance, confirm that the problem has been resolved. (If no problem occurs, carry out a confirmation
test under the same conditions and environment as the first occurence of the problem)
End
Customer problem analysis

Hint: During troubleshooting, the malfunction symptom must be confirmed accurately. Forget the first impres-
sions to make a correct judgment. To find out the malfunction symptom, it is important to ask the customer about
the condition and environment under which the fault occurred.
Collect as much information as possible. Even the problems that seem to be irrelevant may be helpful. The diag-
nosis chapter provides a customer problem analysis sheet for each system.
The following 5 items are the key points of problem analysis:
Key points of customer problem analysis
What ––––– Vehicle, system name
When ––––– Date, time, incidence
Where ––––– Road condition
Under what condition? ––––– Operating conditions, driving conditions, weather conditions
How did it happen?––––– Malfunction symptom
(Sample) Checklist of the supplemental restraint system
Customer problem analysis and detection

Check list of the supplemental restraint system Inspector name
Vehicle identi-
fication code
Date of manu-
Customer name facture / /
License plate
number
Vehicle purchase date / / Odometer reading Kilometer/mile
Date of first malfunction
Weather □Sunny □Cloudy □Rainy □Snowy □Other
Temperature Approximately
Vehicle working □Starting □Idle running

condition □Driving □Running at constant speed □Accelerating □Decelerating □Other
Symptom confirmation and diagnostic trouble code

Hint: The diagnostic system in this vehicle has all kinds of functions.
The first function is the Diagnostic Trouble Code (DTC) check. Using the DTC check, the technician is able to
check the DTCs of previous problems during troubleshooting (DTC is the code stored in the ECU memory when
a fault occurs in the signal circuit to the ECU).
Another function is the input signal check, which checks whether the signal coming from each switch has been
sent to the ECU correctly.
Using these check functions will reduce the faulty section and enable more effective troubleshooting.
In this vehicle, the diagnostic function is associated with the following systems:
Diagnostic trouble Input signal check Diagnostic test
System
code check (Sensor check) mode (Active test)
ABS system with EBD
Supplemental Re-
straint System
Combination meter
During the DTC check, it is necessary to determine whether the problem represented by this DTC: 1) still ex-
ists or 2) has occurred before, but returned to normal later. In addition, compare the DTC with the malfunction
symptom in order to determine whether they are related to each other. Therefore, check the DTC before and after
confirming the malfunction symptom (for example, whether the malfunction symptom exists) to determine the
current status, as shown in the table below.
Never skip the DTC check. Simply relying on the fault condition without carrying out DTC check may lead to
unnecessary troubleshooting of systems in normal operation and maintenance operations not related to problems.
Overview 1-21
Carry out troubleshooting in compliance with the procedures listed above in the correct order.
The flow chart below shows how to use the DTC check to carry out troubleshooting. The flow chart indicates
how to carry out DTC troubleshooting or how to carry out troubleshooting of the malfunction indicator table.
1 DTC check
2 Record the DTC displayed and then clear the memory
3 Symptom confirmation
A Symptom exists
B No symptom exists
A Go to step 5
4 Carry out simulation test by the symptom simulation method
5 DTC check
A DTC display
B No DTC display
If the DTC has been displayed in the first DTC check, it indi-
cates that problems may have occurred in the wire harnesses
or connectors of this circuit.
Therefore, check the wire harnesses and connectors (See page
1-24).
A The system is normal
Carry out troubleshooting of each malfunction symptom

The fault still exists, but not in the diagnostic circuit (The DTC displayed first is a previous or minor fault).
Symptom simulation
Hint:
During troubleshooting, the most difficult situation is that no symptom occurs. In this case, a comprehensive cus-
tomer fault analysis is required. Simulate exactly or approximately the condition and environment under which
the fault occured in the customer vehicle. No matter how skillful or experienced the technician is, if the malfunc-
tion symptom is not confirmed during troubleshooting, important maintenance may be ignored and thus lead to
errors or a delay.
For example:
If symptom inspection is only carried out when the engine is warm or when the vehicle is stationary, it will be
impossible to find the problems that may only occur when the engine is cold or when the vehicle is driving on un-
even road surfaces. It is difficult to attach importance to problems caused by vibration, high temperature, or water
seepage (moisture). The following symptom simulation test is very effective in this case and can be applied to
stationary vehicles.
Key points in the symptom simulation test:
In the malfunction symptom simulation test, the malfunction symptom and the problem section or faulty part
must be confirmed. First, reduce the possible range of the faulty circuit according to the symptom. Then, connect
the scanner and carry out symptom simulation test and judge whether the circuit being tested is faulty or normal.
At the same time, confirm the malfunction symptom. Please refer to the malfunction indicator table of each sys-
tem to reduce the range of possible causes.
Vibrate gently 1. Vibration method: Use this method if vibration is possibly

the main cause.
(a) Parts and sensors
Vibrating gently with fingers may cause problems in the sen-
sor parts. Check if problems occur.
Shake gently
Hint: Vibrating a relay violently may lead to disconnection of
the relay.
(b) Connectors
Vibrate gently ALA029G
Shake the connector gently in a vertical and a horizontal direc-
tions.
(c) Wire harnesses
Shake the wire harness gently in a vertical and a horizontal di-
rections.
Connector joints and fulcrums of the vibration method are the
main parts to be inspected thoroughly.
2. Heating method: Use this method if problems seem to

occur when the suspected area is heated.
Problem
(a) Heat the suspected components with an electric dryer or
similar devices. Check to see if problems occur.
Caution:
· · Do not heat to over 60 o C (140 oF) (the component
may be damaged when this temperature is exceed-
ed).
ALA030G
· · Do not heat the parts in the ECU directly.
Overview 1-23
3. Water spray method: Use this method if problems seem

to occur on rainy days or under damp conditions.
Spray water over the vehicle and check to see if problems occur.
Caution:
· · Never spray water directly over the engine compart-
ment. Change the temperature and humidity indirect-
ly by spraying water over the front part of the radia-
tor.
MLA010G
· · Never spray water directly over the electronic com-
ponents.
Hint: If a leakage exists or has occurred in the vehicle, the
ECU or connecting parts may have been damaged by leakage.
Look for evidence of corrosion or a short circuit. Be careful
when carrying out tests.
4. Others: Use this method if the problems may be caused
by an electrical overload.
Turn on all electrical loads, such as heater blower, front com-
ON
bination lamp, and rear window defogger and check to see if
problems occur.
MLA011G
Circuit Check Procedure

1. Basic check.
(a) Resistance measuring condition for electronic components
Unless otherwise stated, all measurements of resistance should be carried out at the ambient temperature of
20oC. At high temperatures, for example, when the vehicle has just been started, the resistance measured may not
comply with the regulations. All measurements should be carried out after the engine has cooled down completely.
(b) Handling connectors
(1) When disconnecting the connector, first unlock it by
pressing the two halves together and then press down
the lock pawl to release the connector.
Incorrect
(2) When disconnecting the connector, it is strictly pro-
hibited to pull the wire harness forcibly. Grasp the
connector directly and release it.
Correct (3) Before connecting the connector, check if the termi-
ALA033G
nal is deformed, damaged, loose, or lost.
(4) When connecting the connector, press forcibly until
a click of the lock is heard.
(5) If an electronic scanner is used to check the connec-
tor, use a small test lead to check the connector from
the rear side (wire harness side).
Caution:
· · Because it is impossible to check a waterproof con-
nector from the rear side, it should be checked by

connecting a sub wire harness.
Loosening of · · Do not move the inserted scanner probe in order not
compression joint
to damage the terminal.
(c) Connector check points
Core wire (1) Carry out inspection when the connector is connect-
ed: press the connector to see if it has been inserted
Terminal
Deformation and locked completely.
(2) Carry out inspection after the connector has been
Pull gently disconnected: pull the wire harness gently from the
ALA034G
rear side of the connector. Check if the terminal is
loose or lost, if the compression joint is loose, and if
the wire is broken.
Caution: When testing a gold-plated negative
terminal, make sure to use a gold-plated posi-
tive terminal.
(3) Check the contact pressure of the terminal: Prepare
a spare positive terminal. Insert it into a negative
terminal and check if the tension is sufficient during
insertion and after lapping.
Terminal same as the positive terminal

ALA035G
(d) Maintenance method for connector terminals

(1) If there are foreign matters on the terminal, clean the
contact point with an air gun or cotton rag. It is strictly
prohibited to rub the contact point with sandpaper, as
this will cause the coating to peel off.
(2) In case of abnormal contact pressure, replace the
negative terminal.
Correct Incorrect
If the positive terminal is gold-plated (golden yel-
ALA036G
low), use a gold-plated negative terminal. If the posi-
tive terminal is silver-plated (silvery white), use a
silver-plated negative terminal.
(3) Replace the terminal if it is damaged, deformed, or cor-
roded. If the terminal cannot be locked in the case, the
case may need to be replaced.
Overview 1-25
(e) Handling wire harnesses

Incorrect (1) To remove a wire harness, first check the wires and
clamps to faciliate their reinstallation.
(2) Never over-twist, pull, or loosen the wire harness.
(3) Never bring the wire harness into contact with high
- temperature, rotating, moving, vibrating, or sharp
parts. Avoid panel edges, screw points, and similar
sharp objects.
ALA037G
(4) When installing the parts, never press the wire har-
ness.
(5) It is strictly prohibited to scratch or damage the skin
of the wire harness.
If the skin is scratched or broken, replace the wire
harness or repair it with a vinyl tape.
2. Check for an open circuit.
Diagram 1
ECU (a) For the open circuit of the wire harness shown in dia-
C
Open
circuit B A gram 1, perform a resistance check (Step b) or voltage
Sensor
1 1 1 1 check (Step c).
2 2 2 2
ALA038G
Diagram 2 (b) Check the resistance.

(1) Disconnect connectors A and C and measure the re-
sistance between them.
ECU Resistance: 1 Ω or less
Sensor
1 1 1
Hint: Measure the resistance when shaking the wire
2 2 2 harness gently in vertical and horizontal directions.
C B A Diagram 2:
Between Terminal 1 of Connector A and Terminal 1
ALA039G
of Connector C → 10 kΩ or more
Between Terminal 2 of Connector A and Terminal 2
of Connector C → less than 1 Ω
At this time, there is an open circuit between Terminal
1 of Connector B2 and Terminal 1 of Connector C.
(2) Disconnect Connector B and measure the resistance

Diagram 3
between connectors.
ECU Diagram 3:
Sensor Between Terminal 1 of Connector A and Terminal 1
of Connector B1 → less than 1 Ω
1 1 1 1 Between Terminal 1 of Connector B2 and Terminal 1
2 2 2 2 of Connector C → 10 kΩ or more
C B2 B1 A
At this time, there is an open circuit between Terminal
ALA040G
1 of Connector B2 and Terminal 1 of Connector C.
(c) Check the voltage.

Diagram 4
(1) In the circuit which applies voltage to the ECU con-
nector terminals, check for an open circuit through a
5V voltage check.
Sensor 0V Diagram 4:
1 14 V 1 1
2 2 2 When the connectors are still connected, measure the
C B A voltages between the body ground and Terminal 1 of
connector A, Terminal 1 of Connector B and Termi-
ALA041G
nal 1 of Connector C at the ECU's 5V output termi-
nal in sequence.
(2) Example of result:
5V: Between Terminal 1 of Connector A and the
body ground
5V: Between Terminal 1 of Connector B and the
body ground
0V: Between Terminal 1 of Connector C and the
body ground
If the result complies with the above example, there
is an open circuit between Terminal 1 of Connector
B and Terminal 1 of Connector C.
Diagram 5
3. Check for a short circuit.
C Short circuit B A (a) If the wire harness is short circuited to the ground (Dia-
1 1 1 gram 5), perform a resistance check on the body ground
2 2 2 to locate the short circuited part (see below).
ALA042G
(b) Check the resistance to the body ground.

Diagram 6
(1) Disconnect Connectors A and C and measure the re-
sistances between Terminals 1 and 2 of Connector A
ECU and the body ground.
Sensor Resistance: 10 kΩ or more
1 1 1 Hint: Measure the resistance when shaking the wire
2 2 2
C A harness gently in vertical and horizontal directions.
B
In Diagram 6:
ALA043G Between Terminal 1 of Connector A and the body
ground → less than 1 Ω
Between Terminal 2 of Connector A and the body
ground → 10 kΩ or more
At this time, there is a short circuit between Terminal
1 of Connector A and Terminal 1 of Connector C.
Overview 1-27
Diagram 7 (2) Disconnect connector B and measure the resistance

between Terminal 1 of Connector A and the body
ground and the resistance between Terminal 1 of
ECU Connector B2 and the body ground.
Sensor Diagram 7:
1 1 1 1
2 2 2 2 Between Terminal 1 of Connector A and the body
C B2 B1 A ground → 10 kΩ or more
Between Terminal 1 of Connector B2 and the body
ALA044G
ground → less than 1 Ω
At this time, there is a short circuit between Terminal
1 of Connector A and Terminal 1 of Connector C.
4. Check and replace the ECU.
Caution:
· · When the connector is connected to the ECU, carry
out inspection from the rear side of the wire harness
side connector.
· · If the measuring condition is not specified, stop the
engine and turn the ignition switch to the ON position
and then carry out inspection.
· · Check if the connector is in its position. Check if the
wire is loose, corroded, or broken.
First check the ECU ground circuit. If there is any malfunc-
tion, maintenance should be carried out.
If it is normal, the ECU may have a malfunction. Replace the
original ECU with a normal one and then check if the symp-
tom still appears.
For example:
(a) Measure the resistance between the ECU ground termi-
nal and the body ground.
Resistance: 1 Ω or less
Ground
ALA045G
ECU side (b) Disconnect the ECU connector. Check if the ground
terminal (ECU side and wire harness side) is bended,
corroded or is contaminated. Finally, check the contact
Ground pressure of the negative terminal.
Wire harness side
Ground
ALA046G
Terms
Abbreviations used in this manual
Abbreviation Meaning
ABS Anti-lock Brake System
A/C Air Conditioner
CD CD
CPU Central Processing Unit
DTC Diagnostic Trouble Code
EBD Electronic Brake Distribution
ECU Electronic Control Unit
GAS Gasoline
GND Ground
HI High
LH Left-hand side
LO Low
MAX. Maximum value
MIN. Minimum value
N Neutral position
RH Right-hand side
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
T/M Transmission
VIN Vehicle Identification Number
VVT-i Variable Valve Timing-Intelligent
W/H Wire Harness
1st 1st gear
2nd 2nd gear
2WD Two-Wheel Drive vehicle (4 × 2)
3rd 3rd gear
4th 4th gear
5th 5th gear
Maintenance 2-1
Maintenance
Maintenance and Inspection............................................................2-2

General Exterior Maintenance......................................................2-2
General Interior Maintenance.......................................................2-2
General Maintenance under the Engine Hood.............................2-4
Vehicle Chassis Inspection...........................................................2-6
Vehicle Body Inspection................................................................2-6
Inspection of Power Supply System.............................................2-7
Overall Parameters..........................................................................2-8
Basic Parameters of the Overall Vehicle.......................................2-8
Engine Technical Parameters.......................................................2-9
Transmission Technical Parameters.............................................2-9
Wheels and Tires........................................................................2-10
Vehicle Body...............................................................................2-10
Electrical System........................................................................ 2-11
Air Conditioning System..............................................................2-12
Grade Specification of
Each Individual Functioning Component's Working Agent.........2-12
Other Information........................................................................2-13
Tightening Torques for the Important Fastening Pieces.............2-14
Maintenance Data.......................................................................2-19
Vehicle Body's Basic Calibration Measurements ..........................2-21
Engine Compartment..................................................................2-22
Chassis.......................................................................................2-23
Chassis (Continued)...................................................................2-24
Trunk Door Frame.......................................................................2-25
Subframe....................................................................................2-26
Right side Panel..........................................................................2-27
Left side Panel............................................................................2-27
Maintenance and Inspection

General Exterior Maintenance
The owner is responsible for the maintenance and inspection of his/her own vehicle. The owner may maintain the
vehicle by himself/herself or send the vehicle to an automotive maintenance center.
Carry out daily inspection on the following vehicle parts. In most cases, SST are not required.
The general maintenance procedure is as follows:
1. General areas of importance
(a) The maintenance requirements vary from country to country.
(b) Check the Maintenance Schedule in the Owner's Manual Supplement.
(c) This Maintenance Schedule must be followed.
(d) Determine the proper vehicle maintenance time according to the travelled distance or elapsed time (months),
whichever is earlier.
(e) Unless otherwise stated, try to carry out maintenance periodically.
(f) Failure to check the vehicle parts may lead to poor engine performance and increased exhaust emission.
2. Tires
(a) Check the tire pressure with an air pressure gauge. Make adjustments if necessary.
(b) Check if the tire surface is cracked, damaged, or excessively worn.
3. Wheel nuts
(a) Check if the nuts are loose or missing. Tighten the nuts if necessary.
4. Tire rotation
(a) Check the Maintenance Schedule in the Owner's Manual Supplement.
5. Windshield wiper blades
(a) If the blade is unable to clean the windshield, check if it is worn or broken. Replace it if necessary.
6. Fluid leakage
(a) Check whether there fuel, oil, water or other liquids leaking from under the vehicle.
(b) If there is a smell of gasoline or any leakage, find out the cause and make the necessary corrections.
7. Door and engine hood
(a) All of the doors and the trunk door can be operated smoothly and all the locks can be latched securely.
(b) When the main lock is released, check if the engine hood auxiliary lock can prevent the engine hood from
being opened.
General Interior Maintenance

The owner is responsible for the maintenance and inspection of his/her own vehicle. The owner may maintain the
vehicle by himself/herself or send the vehicle to an automotive maintenance center.
Carry out daily inspection on the following vehicle parts. In most cases, SST are not required.
The general maintenance procedure is as follows:
(a) The maintenance requirements vary from country to country.
(b) Check the Maintenance Schedule in the Owner's Manual Supplement.
(c) This Maintenance Schedule must be followed.
(d) Determine the proper vehicle maintenance time according to the travelled distance or elapsed time (months),
whichever is earlier.
(e) Unless otherwise stated, try to carry out maintenance periodically.
(f) Failure to check the vehicle parts may lead to poor engine performance and increased exhaust emission.
2. Lamps
Maintenance 2-3
(a) Check whether the front combination lamps, brake lamps, rear combination lamps, turn signal lamps, and
other lamps light up or flash. In addition, check whether the brightness of the lamps is sufficient.
(b) Check whether the focusing of the headlights is accurate.
3. Warning lamps and buzzers
(a) Check to make sure that all warning lamps and buzzers work.
4. Horn
(a) Check to make sure that the horn works.
5. Windshield
(a) Check to see if it is scratched, misshapen, cracked, or worn.
6. Windshield wipers and washer fluid
(a) Check whether the windshield washer fluid is working within the proper range. In addition, check whether
the washing fluid sprays directly over the center of the operating range of each wiper on the windshield.
(b) Check whether the wipers leave stripe on the glass.
7. Windshield defroster
(a) When the heater or air conditioner is set to defrost, check whether the defroster outlet is blowing out air.
8. Rearview mirror
(a) Check to make sure that the rearview mirror is installed securely.
9. Sun visors
(a) Check to make sure that the sun visors are installed securely and can be moved freely.
10. Steering wheel
(a) Check to make sure that the steering wheel has the proper amount of free play. In addition, check whether
the steering wheel is difficult to be turned or makes unusual noises.
11. Seats
(a) Check the front-and-back regulator of front seat, backrest an-
gle adjuster, and other front seat controllers are operating smoothly.
(b) Check to make sure that all locks in the latched position can lock securely.
(c) Check to make sure that the headrest can be moved up and down smoothly and that all locks in latched posi-
tion can lock securely.
(d) When the rear seat backrest is folded, check whether its latch can locked securely.
12. Seat belts
(a) Check to make sure that the seat belt system (including the lock button, retractor, and lock) can be operated
smoothly.
(b) Check to make sure that the seat belt hanger is not cut, worn, or damaged.
13. Accelerator pedal
(a) Check whether the pedal can operate smoothly, whether the pedal force is uniform, and whether the pedal is
blocked.
14. Clutch pedal
(a) Check whether the pedal can operate smoothly.
15. Brake pedal
(a) Check whether the pedal can operate smoothly.
(b) Start the engine and check the function of the vacuum booster.
16. Brakes
(a) In a safe location, check to make sure that the vehicle slows down or stops when the brake is applied.
17. Parking brake
(a) Check to make sure that the tie rod can be moved within a proper range.
(b) On a slight incline, check whether the parking brake itself can stop the vehicle completely.
General Maintenance under the Engine Hood

(a) The maintenance items may vary from country to country. Check the Maintenance Schedule indicated in the
Owner's Manual Supplement.
(b) All the maintenance items listed in the Periodic Maintenance Schedule must be performed.
(c) Periodic maintenance must be performed according to the odometer reading (in kilometers) or the time in-
terval (in months) given in the Periodic Maintenance Schedule, whichever is earlier.
(d) Unless otherwise stated, maintenance should be performed at the same time interval after the last maintenance.
(e) The omission of even one item may lead to poor engine operation and increased exhaust emission.
2. Windshield washing fluid
(a) Check to make sure that there is sufficient washer fluid in the reservior.
3. Engine coolant level
(a) Check to make sure that the coolant level is between the scale marks "F" and "L" of the transparent reser-
voir.
4. Radiator and hose
(a) Check to make sure that the front part of the radiator is clean and not blocked by leaves, dust, or insects.
(b) Check to see whether the hose is cracked, twisted, corroded, or loose.
5. Brake fluid level
(a) Check to make sure that the brake fluid level is near the upper scale mark of the transparent reservoir.
6. Engine drive belt
(a) Check whether the drive belt is worn, broken, or greasy.
7. Engine oil level
(a) When the engine has stopped, check the oil level with the oil dipstick.
8. Power steering fluid level
(a) Check the liquid level with the oil dipstick.
(b) Depending on the temperature of the power steering fluid, the fluid level should be within the range of
"HOT" or "COLD."
9. Manual transmission fluid level
(a) Park the vehicle on a flat surface.
(b) When the engine is operating at an idle speed, set the shift lever to the neutral position and pull the parking
brake.
(c) Loosen the transmission fluid filler plug with a wrench.
(d) Check to make sure that the fluid level is 10-15 mm below the lower edge of the fluid filler. If it is lower
than this level, add transmission fluid. Otherwise, discharge the fluid.
10. Exhaust system
(a) If any changes in the exhaust sound or smell have been noticed, carry out an alignment procedure and cor-
rect the cause.
Maintenance 2-5
Vehicle engine inspection

Hint:
Check these items when the engine has cooled.
1. Check the drive belt (See page 2-4)
2. Replace the spark plug
3. Check the air filter
(a) Remove the air filter.
(b) Visually inspect to make sure that the air filter is free
Outside
from damage, contamination, or oil stains. Replace the
air filter element, if necessary.
(c) Clean the filter element with compressed air.
Inside Purge the filter element from the inside to the outside.
(d) Reinstall the air filter element.
ALB001G
4. Replace the air filter element
(a) Replace the air filter element with a new one.
5. Replace the engine oil and the oil filter
6. Replace the engine coolant (See page 3-8)
7. Check the fuel tank cap gasket
8. Check the fuel pipeline and its connections, the hoses of the fuel tank steam ventilation system, and the
fuel tank
(a) Visually inspect if the fuel pipeline is broken or leaking, if the connector is loose or deformed, or if the fuel
tank bolt is loose.
9. Check the exhaust pipe and installation parts
(a) Visually inspect if the pipeline, hanger, or connector is seriously corroded, leaking, or damaged.
Vehicle brake inspection

1. Check brake pipeline
Hint:
Work in a well-lighted area. Before inspection, turn the front
wheel to the rightmost or leftmost position.
(a) Check all the brake lines and hoses for:
• damage
• wear and tear
• deformation
ALB002G
• breaks
• corrosion
• leakage
• bending
• twisting
(b) Check whether all the clips are fastened and whether
leakage exists in the connections.
(c) Check to make sure that the hoses and lines are far from
sharp objects, moving parts, and the exhaust system.
(d) Check to make sure that the line is installed via the cen-
ter of the gasket.
2. Check the front brake pad and brake disc

3. Check rear brake shoe and brake disc
4. Check or replace the brake fluid (See page 8-5)
Brake fluid: DOT4 synthetic brake fluid
Vehicle Chassis Inspection

1. Check the steering gear.
(a) Check the steering wheel free play (See page 7-5).
(b) Check whether the steering gear is loose or damaged.
(1) Check to make sure that the clearance at the tie rod end is not too large.
(2) Check to make sure that the dust sealing ring and dust cover are not damaged.
(3) Check to make sure that the dust cover clip is not loose.
2. Check the steering gear housing oil.
(a) Check the leakage of steering gear housing oil.
If oil leakage is found, find out the cause and carry out maintenance.
3. Check the ball joint and dust cover.
(a) Check whether the ball joint is too loose.
(1) Jack up the front part of the vehicle and put a 180 to 200 mm high wood block under the front tire.
(2) Lower the vehicle until the front coil spring reaches one half of its normal load. For the sake of safety,
place a scaffold under the vehicle.
(3) Check to make sure that the front wheels of the vehicle are pointing straight ahead. Use chock blocks.
(4) Pry up the end of the lower arm with a crowbar. Check the clearance.
Maximum vertical clearance of the ball joint: 0 mm
If there is clearance, replace the ball joint.
(b) Check whether the dust cover is damaged.
4. Check the propeller shaft dust cover.
(a) Check the propeller shaft dust cover for loose clips, grease leakage, twisting, or damage.
5. Check the drive axle oil (liquid).
(a) Visually inspect if the drive axle leaks oil (liquid).
If oil leakage is found, find out the cause and carry out maintenance.
6. Tire rotation (See page 6-34)
Vehicle Body Inspection
1. Tighten the nuts and bolts on the chassis and vehicle body.
(a) Tighten the nuts and bolts of the following chassis parts, if necessary:
• Front axle and suspension
• Drive system
• Rear axle and suspension
• Brake system
• Engine support
• Other chassis parts
(b) Tighten the nuts and bolts of the following body parts, if necessary:
• Seat belt system
• Seats
Maintenance 2-7
• Door and engine hood

• Body support
• Fuel tank
• Exhaust pipe system
• Other body parts
2. Replace the air conditioner filter.
(a) Remove the glove box assembly.
(b) Remove the filter housing from the filter outlet.
(c) Remove the filter element from the filter housing.
(d) Replace the filter element with a new one.
(e) The installation sequence is reserve to the removal sequence.
Inspection of Power Supply System

1. Generator
(a) Check the heat dispersion of the generator.
(b) Check the tension of the generator belt and the installation of the pulley.
(c) Check the brush pressure and the commutator surface.
(d) Check the connection of the battery circuit.
(e) Check whether the connector is damaged.
(f) Check whether there is a scale deposit on the rectifier.
(g) Check the degree of wear of the bearing.
2. Battery
(a) Check whether the battery container is cracked, broken, or damaged.
(b) Check the battery's ground wire.
(c) Check the electric charge of the battery according to the working condition of the headlights.
3. Charge indicator
(a) Check the charge indicator circuit.
(b) Check whether the filament is burned.
(c) Check whether the generator generates electricity.
Overall Parameters
Basic Parameters of the Overall Vehicle
CC7131MMA23 CC7131MMA03
Model number of the overall vehicle
CC7131MMA25 CC7131MMA05
Drive type 4×4 4×2
Length (mm) 3645 3645
External
Width (mm) 1625 1625
dimensions 1620 1630
Height (no load) (mm)
Wheelbase (mm) 2296 2296
Front (mm) 1370 1370
Tread
Rear (mm) 1355 1355
Front suspension (mm) 819 819
Rear suspension (mm) 530 530
Curb weight (kg) 1095,1130 1035,1065
Gross vehicle weight (kg) 1505 1440
Quality
Full load front axle load (kg) 762 737
Parameters 743 703
Full load rear axle load (kg)
Load capacity (kg) 375 375
Front Kingpin Left 2°30′±30′ 2°30′±30′
axle caster Right 2°30′±30′ 2°30′±30′
Difference between left and right ±30′ ±30′
Kingpin Left 9°±30′ 9°±30′
angle Right 9°±30′ 9°±30′
Wheel Left -1°±30′ -1°±30′
Wheel Right -1°±30′ -1°±30′
camber
positional Difference between left and right ±30′ ±30′
parameters Wheel toe-in Left 6′±3′ 6′±3′
(no load) Right 6′±3′ 6′±3′
Summation 12′±6′ 12′±6′
Rear Wheel Left -30′±30′ -30′±30′
axle camber Right -30′±30′ -30′±30′
Wheel toe-in Left 9′±15′ 9′±15′
Right 9′±15′ 9′±15′
Summation 18′±30′ 18′±30′
Maximum steering Inside wheel 34.5°— 41.5° 34.5°— 41.5°
angle of front wheel Outer wheel 29.5°— 36.5° 29.5°— 36.5°
Rated capacity (persons) 5 5
Maximum speed (km/h) ≥160 ≥160
Minimum stable speed of the direct gear (km/h) ≤25 ≤25
Acceleration time (0-100 km/h) (s) 15.5 15.3
Direct drive 30 km/h-100 km/h acceleration time (s) ≤32 ≤32
Maximum climbing capacity (%) ≥40 ≥40
Under the urban and suburban driving cycle simulation (L/100 km) ≤6.5 ≤6.65
≤19 (no load), ≤19 (no load),
Service braking distance (m) of 50 km/h initial braking speed
≤20 (full load) ≤20 (full load)
Parking brake (at a gradient of 20%) Not less than 5 min Not less than 5 min
Fuel consumption of 90 km/h speed with constant velocity (L/100 km) ≤6 ≤5.6
Fuel consumption of 120 km/h speed with constant velocity (L/100 km) ≤8 ≤7.6
Outer acceleration noise dB (A) ≤74 ≤74
60 km/h constant velocity interior noise dB (A) ≤79 ---
Maintenance 2-9
50km/h constant velocity interior noise dB (A) --- ≤79

Driver operating noise dB (A) ≤75 ≤75
CO (g/km) ≤1 ≤1
HC (g/km) ≤0.1 ≤0.1
NOX (g/km) ≤0.08 ≤0.08
Emission index (Ⅳ) Pollutant emission at low idle speed 800±50 CO≤0.5%, CO≤0.5%,
r/min HC≤100 ppm HC≤100 ppm
Pollutant emission at high idle speed 2000±50 CO≤0.3%, CO≤0.3%,
r/min HC≤100 ppm HC≤100 ppm
OBD Standard Standard
Approach angle (no load/full load) (°) 20 20
Departure angle (no load/full load) (°) 40 40
Data
Minimum ground clearance (full load) (mm) ≥130 ≥136
Minimum turning diameter (m ) ≤9.8 ≤9.8
Having good starting performance at
Engine starting performance
above -30oC
Engine Technical Parameters

Item Structural parameters
Engine model number GW4G13
4-stroke, water cooling, inline, electric starting, pentroof
combustion chamber, multipoint, electronic fuel injection,
Engine type
16-valve, dual overhead camshaft, chain drive, variable
valve timing, combined force-feed, and splash lubrication
Discharge capacity (L) 1.298
Cylinder bore × Stroke (mm) 75 × 73.5
Rated power/rotation speed (kW/rpm) 68/6000
Max. torque/rotation speed (N·m/rpm) 118/4200
Lowest rate of fuel consumption of the engine (g/kW·h) ≤265
Compression ratio 10.5: 1
External dimensions
600 × 524 × 613 (without transmission)
(Length × Width × Heigth) (mm)
Engine configuration Transverse, three-point mount
Transmission Technical Parameters

Type Mechanical, 5-forward gear Mechanical, 5-forward gear
Transmission model number 001T1B-03 0011D
Max. input torque (N·m) 160 160
Center distance (mm) 70 70
1st gear 3.545 3.545
2nd gear 1.905 1.905
3rd gear 1.310 1.310
Speed ratio
4th gear 0.970 0.970
5th gear 0.816 0.816
R gear 3.250 3.250
Main deceleration ratio of the transmission 4.3125 4.3125
Transfer case speed ratio 18/41 ---
Main deceleration ratio of the rear axle 41/18 ---
Odometer sensor speed ratio 31/35 31/35
Wheels and Tires

Tire type Tubeless radial tire Tubeless radial tire (spare)
Tire specification 185/65 R14 86H T125/70 R16 96M
Tire pressure 220 kPa±10 kPa 420 kPa±10 kPa
Vehicle Body
System assembly Structural parameters
Bearing body, two-box 4-door 5-seat (domestic)/4-door 4-seat (ex-
Body type
ported)
Natural frequency of white
Not less than 30 Hz
body
Vehicle Body
Integral type, four-door sliding open, catch plate type door lock,
Door assembly
hinge joint, with side impact beam, retainer, central door lock
Engine hood Open backwards, fixed-axis rotation hinge

Trunk door Overturn arm hinge, gas spring support
Front and rear bumper Injection molded main body
Softened design, taking into consideration ergonomic and comfort
Interior trim
requirements
Dashboard Injection molded, integral dashboard with concealed airbag
A, B, C-pillar trim panel and Injection molded, the front and rear door decoration boards are
door decoration board equipped with glove boxes
Car roof handle Injection molded, with coat and hat hook
Hyperboloidal laminated glass windshield
Hyperboloidal toughened glass rear window with defroster (op-
Window glass tional )
Toughened glass front and rear door windows and rear corner win-
Interior and dow
exterior trim Outside rearview mirror: Electric outside rearview mirror with side
turn signal lamp, electric defroster, manual outside rearview mir-
Rearview mirrors
ror, with side turn signal lamp
Interior rearview mirror: manual mechanical type
Driver seat: independent seat the cushion height, front and back
positions, and backrest angle are manually adjustable
Front passenger seat: independent seat-, the front and back posi-
Seats tions, and backrest angle are manually adjustable
Rear seat: With rear seat headrest, the backrest can be folded for-
wards
Distance between the front seat R point and the ground ≤675 mm
Door handles Pull-out door handle
The front wiper is a four-bar type. The rear wiper is standard (or
Wiper system
Body ac- optional for two-wheel drive vehicles)
cessories Left and right sun visors both have cosmetic mirrors and ticket
Sun visor
holders
Maintenance 2-11
Electrical System
System assembly Structural parameters
Circuit Single wire system, negative ground, with a voltage of DC 12 V
Generator 14 V/90 A
Electromagnetically-operated type (supplied with the engine), with a volt-
Power, start Starter
age of 12 V and a power of 1.2 kW
up, and charg-
Electronic fan
ing system Two-stage speed regulation fan
of the engine
Maintenance-free lead battery
Battery
Using single wire negative ground system
Fuel gauge, speedometer, engine tachometer, engine water thermometer,
Combination meter
warning and signal lamps, LCD odometer
Dashboard
Fuel level sensor, speed sensor, brake fluid level sensor, water temperature
system Sensors and
sensor, manual brake switch, four-door switch, oil pressure switch, lamp
switches
switch, defroster switch
Windshield Using a combination switch lever control, the wiper motor and rod are ar-
wiper system ranged at the cowl panel
Stereo equipment Single disc CD, radio, USB interface
Cigarette lighter Equipped with 1 cigarette lighter, which is a mature product
Rear window
Using heated glass and switch control
defroster
The four doors have central door locks and a remote control function. The
Central door locks
Auxiliary elec- trunk door has a remote control and electronic unlocking function
trical Power window Two operation methods for the front power window regulator: manually
system regulator and electrically. The method for the rear power window regulator is manual
Power sunroof Optional
It locks the engine and fulfills the function of an immobilizer through the
Immobilizer device communication between the theft deterrent ECU and the electrojet ECU.
Engine immobilizer is optional
ABS+EBD Standard (or optional for two-wheel drive vehicles)
Electronic driver side airbag is standard (or optional for two-wheel drive
Airbags
vehicles). Front passenger side airbag is optional
Including high and low beams, with a power of 60 W/55 W
Front combina- Front turn signal lamps, with a power of 21 W
tion lamps Front parking lamps, with a power of 5 W, with electric vertical adjustment
reserved
Front fog lamps With a power of 55 W, 2 pieces, switch control
2 pieces, including parking lamp, with a power of 21 W/5 W
Lighting and Rear combination
Turn signal lamp, with a power of 21 W
signal system lamps
Back-up lamp, with a power of 21 W
Rear fog lamps With a power of 21 W, 2 pieces, switch control
The high mounted brake lamp has a power of 25 W and 5 bulbs
The reading lamp has a power of 10 W
Other lamps
The trunk lamp has a power of 10 W
The rear license plate lamp has a power of 5 W
Horn Horn 1 high-pitched horn, disc type
Air Conditioning System

Structure type Vapor compression refrigeration, water warmer, and water heater
Controls Manual
Refrigerant Model number R134a
Refrigerating capacity ≥2.1 kW/1000 rpm
Compressor discharge The discharge capacity is 96 ml/r
capacity
Air cleaning system Dust filter
HVAC Integral structure, layered evaporator, layered heater, H-shaped expansion valve, cen-
trifugal blower
Condenser Parallel flow structure
Dehydrator Subcooling aluminium structure
Air ducts The dashboard's central air duct is blow molded. The defroster air duct is injection mold-
ed and welded together with the dashboard
Air vents The four air vents are symmetrical and of a willow-leaf structure. The air direction is ad-
justable. The air vents can be closed completely
Refrigeration line A compound structure using a rubber cooling pipe and an aluminum pipe
Water pipe Molded rubber pipe
Sensor Evaporator temperature sensor
Pressure switch Three position combination type
Maintenance 2-13
Grade Specification of Each Individual Functioning Component's Working Agent

Number Functioning component Quantity Specifications
#93 and above high quality unleaded gasoline for
1 Engine fuel (RON) 35 L
vehicle use
3.2L(without oil filter) SJ grade 10W-40 (Winter)
2 Engine lubricant SJ grade, 15W-40 (Summer)
3.5L(with oil filter) SL grade 5W-30 (Alpine)
Domestic model for China:
Ethylene-Glycol-35oC antifreeze fluid
3 Coolant 5.0L±0.15L
For alpine region model:
Ethylene-Glycol-45oC antifreeze fluid
GL-4 80W/90 (domestic model for China), GL-5
140 (for exported high-temperature region mod-
4 Transmission 1.9±0.15 L
el), GL-4 75W-90 (for exported alpine region
model)
5 Transfer case 0.83±0.15 L 140 (for exported high-temperature region model),
GL-5 75W/90 (for exported alpine region model)
Main decelerator of the
6 0.6±0.15 L 140 (for exported high-temperature region model),
rear axle
GL-5 75W/90 (for exported alpine region model)
7 Power steering fluid 600mL±10 ml ATF DEXR0NⅢ Mobil fluid
465±10 ml (routine brake)
8 Brake fluid DOT4 synthetic brake fluid
480±10 ml (ABS brake)
9 Window washing liquid 2.0±0.1 L -35oC window washing liquid
Air conditioner refriger-
10 500 g±50 R134a
ant
Other kinematic friction No.3 general purpose lithium base grease for au-
11 ---
pairs tomobile
Other Information
Clutch:
Single chip dry type diaphragm spring clutch, mechanical cable control. The clutch pedal's working stroke is 110
mm.
Steering system:
Rack and pinion steering gear (hydraulic assisted), separation type rear steering trapezium organization, energy
absorbing steering column, slipping intermediate propeller shaft, and the steering wheel diameter is 370±1 mm.
The steering system speed ratio is 41.728. The steering wheel rotation number is 3.212.
Tightening Torques for the Important Fastening Pieces

No. Fastening piece name Fastening piece position Tightening torque Quantity Surface coating
(N·m)
Vehicle Body
1 Hexagon bolt for Front and rear side door 25±2 16
flange face hinge installation
2 Hexagon bolt for Front and rear side door 25±2 8
flange face hinge installation
3 Hexagon socket head Front side door re- 20±2 2
cap screw and flat tainer installation
washer subassembly
4 Hexagon socket head Front side door re- 10±1 4
washer subassembly
5 Hexagon socket head Rear side door re- 20±2 2
washer subassembly
6 Hexagon socket head Rear side door re- 10±1 4
washer subassembly
7 Hexagon nut and conical Trunk door hinge installation 10±2 4
spring washer subassembly
8 Hexagon bolt for Trunk door hinge installation 25±3 2
flange face-oversize
9 Hexagon bolt for Trunk door power-assisted 10±1 4
flange face brace gas spring installation
10 Door power-assisted Trunk door power-assisted 16±2 2
brace gas spring's back- brace gas spring installation
door ball head bolt
11 Front seat belt mount- Seat belt upper and 45±5 6
ing bolt (7/16") lower mounting points,
retractor mounting
12 Hexagon head bolt and Front impact beam 45±5 4
spring washer subassembly installation
13 Hexagon nut for flange face Front impact beam 45±5 2
installation
14 Left/right rear seat Rear seat belt upper and 45±5 4
belt assembly lower mounting points
Interior and exterior trim
15 Hexagon head bolt and Driver's seat installation 38±5 4
flat washer subassembly
16 Hexagon head bolt and Front passenger 38±5 4
flat washer subassembly seat installation
17 Hexagon socket head Rear backrest rotating 38±5 1
cap bolt and flat wash- shaft pressing plate fixing
er subassembly
18 Hexagon head bolt and Rear seat cushion 38±5 6
flat washer subassembly mounting bolt
Maintenance 2-15
(N·m)
19 Hexagon head bolt and Rear seat left and right 38±5 4
flat washer subassembly backrest mounting bolts
Air conditioner
20 Hexagon bolt for Compressor & engine 22±3 4
flange face
21 Joint connection Condenser discharge 13.5±1.5
pipe with pressure switch
front section assembly
and condenser discharge
pipe with pressure switch
rear section assembly
22 Joint connection Compressor suction pipe 32.5±2.5
front section assembly &
compressor suction pipe
rear section assembly
23 Hexagon bolt for Joint between refrig- 10±2 1
flange face eration pipeline and
expansion valve
24 Hexagon head bolt, Battery negative wire har- 22±3
spring washer, and flat ness assembly ground bolt
washer subassembly
25 Hexagon bolt for Air conditioner hose, 10±2 4
flange face compressor, and con-
denser coupling bolt
Chassis
26 Hexagon bolt for Left mount & left 56±6 4
flange face side member
27 Hexagon bolt for Right mount & body bracket 56±6 2
flange face
28 Hexagon bolt for Right mount & transmission 46±5 3
flange face
29 Hexagon bolt for Right mount & engine 78±5 2
flange face
30 Chip-removal hexagon Left mount & left 78±5 1
bolt for flange face mounting bracket
31 Chip-removal hexagon Rear mount & 95±10 1
bolt for flange face front subframe
32 Non-metal insert hexagon Right mount & body bracket 56±6 1
lock nut for flange face
33 Non-metal insert hexagon Right mount & engine 78±5 1
lock nut for flange face
34 Hexagon bolt for Exhaust bolt 60±6 6
flange face
35 Hexagon bolt for Start & transmission 46±5 2
flange face
(N·m)
36 Hexagon head bolt, Fuel tank and beam 26±3 4
spring washer and flat
washer subassembly
37 Hexagon nut for Accelerator pedal and cowl 10±1 3
flange face
38 Hexagon nut for Filter and floor 23±2 2
flange face
39 Non-metal insert hexagon Connection between clutch, 23±3 6
lock nut for flange face brake pedal assembly,
cowl, and booster pump
40 Hexagon head bolt and Connection between 46±5 7
spring washer subassembly transmission and engine
41 Oil filler/drain plug Transmission oil drain 33±3 1
42 Oil filler/drain plug Transmission oil filler 33±3 1
43 Oil filler plug II Transfer case oil filler 33±3 1
44 Oil filler/drain plug Transfer case oil drain 33±3 1
45 Hexagon bolt for Connection between trans- 46±5 4
flange face fer case bracket, trans-
fer case, and engine
46 Hexagon nut for Connection between trans- 20±2 3
flange face mission control mechanism
assembly and dashboard
brace reinforcement
47 Hexagon bolt for flange Connection between trans- 23±2 1
face - oversize mission control mechanism
assembly and dashboard
brace reinforcement
48 Hexagon head bolt and Connection between 26±3 4
spring washer subassembly propeller shaft and rear
main decelerator
49 Propeller shaft nut Connection between propel- 50±5 4
ler shaft and transfer case
50 Hexagon bolt for Connection between 26±3 2 Surface coating
flange face propeller shaft interme-
diate support and sup-
port bracket plate
51 Front drive shaft nut Connection between 225±20 4
drive shaft and brake
52 Oil filler plug Rear main decel- 12±3 1
erator oil filler
53 Oil drain plug Rear main decel- 12±3 1
erator oil drain
54 Bolt subassembly I Front subframe & 120±10 2 Thread fasten-
vehicle body ing sealant
55 Bolt subassembly II Front subframe & 180±15 2 Thread fasten-
vehicle body ing sealant
Maintenance 2-17
(N·m)
56 Bolt subassembly Rear subframe & ve- 120±10 2 Thread fasten-
hicle body ing sealant
57 Bolt subassembly Rear subframe & ve- 80±10 6 Thread fasten-
hicle body ing sealant
58 Hexagon head bolt and Lower swing arm 210±10 4 Thread fasten-
flat washer subassembly & subframe ing sealant
59 Slotted nut Lower swing arm & 70-90 2
steering knuckle
60 Type 1 non-metal in- Front shock absorber 40±5 2
sert lock nut & vehicle body
61 Bolt Front shock absorber 80±10 4 Thread fasten-
& steering knuckle ing sealant
62 Hexagon bolt for Front stabilizer bar 25±3 4 Thread fasten-
flange face-oversize & front frame ing sealant
63 Hexagon nut for Stabilizer bar & con- 63±5 2 Thread fasten-
flange face necting rod ing sealant
64 Trailing arm mount- Trailing arm & rear frame 120±10 2
ing bolt assembly
65 Hexagon head bolt, Trailing arm & rear frame 120±10 2
spring washer and flat
washer subassembly
66 Bolt subassembly Rear shock absorber 63±5 2 Thread fasten-
& vehicle body ing sealant
67 Bolt subassembly Rear shock absorber 120±10 2 Thread fasten-
& trailing arm ing sealant
68 Hexagon bolt for Rear stabilizer bar 25±3 4
flange face & rear frame
69 Hexagon nut for Stabilizer bar & con- 63±5 2 Thread fasten-
flange face necting rod ing sealant
70 Wheel nut Wheel & brake 110±10 16
71 Hexagon nut for Steering column assembly 35±5 1
flange face & steering wheel assembly
72 Hexagon bolt for Steering column assem- 25±3 1
flange face bly & dashboard brace
reinforcement assembly
73 Hexagon bolt for Steering column as- 25±3 1
flange face sembly & power steer-
ing gear assembly
74 Hexagon bolt for Steering column assem- 25±3 2
flange face bly & dashboard brace
reinforcement assembly
75 Hexagon nut for Power steering fuel filler 12-17 2
flange face and return pipe bundle &
front subframe assembly
76 Hexagon bolt for Power steering fuel 10±2 1
flange face filler and return pipe
bundle & floor assembly
(N·m)
77 Hollow bolt Power steering fuel 30±4 1
filler and return pipe
bundle & power steer-
ing pump assembly
78 Power steering fuel Power steering fuel 12±3 2
filler and return pipe filler and return pipe
bundle coupling bolt bundle & power steer-
ing gear assembly
79 Hexagon bolt for Tension regulator bracket 40±4 1
flange face & engine assembly
80 Hexagon bolt for Power steering pump 40±4 1
flange face bracket II & tension
regulator bracket
81 Hexagon bolt for Power steering pump 30±3 1
flange face bracket, bracket II, and
engine assembly
82 Hexagon head bolt and Power steering pump as- 25±3 1
spring washer subassembly sembly & power steer-
ing pump bracket
ing pump bracket II
ing pump bracket
85 Hexagon bolt for Vehicle body & steer- 10±2 3
flange face ing fluid reservior
mounting bracket
86 Type 1 non-metal in- Tie rod ball assembly, steer- 50±5 2
sert lock nut ing knuckle, and brake
87 Hexagon head bolt and Power steering gear assem- 75±5 2 Thread fasten-
flat washer subassembly bly, mounting gasket, and ing sealant
front subframe assembly
88 I-type hexagon nut Power steering gear assem- 37±5 2
bly & tie rod ball assembly
89 Front brake hose Connection with front brake 40±4 2
line connector
90 All of the brake line 16±2
connectors M10
91 All of the brake line 16±2
connectors M12
92 Rear brake hose assem- Connection with rear brake 16±2 2
bly II line connector
Maintenance 2-19
Maintenance Data
Fuel
Fuel pump
Resistance at 20°C (68°F) 0.2-3.0 Ω
Cooling system
Thermostat
Valve opening temperature 80-84 oC
Valve lift at 95°C (205°F) 8mm or more
Radiator filler cap subassembly
Standard opening pressure 107.8±10.8 kPa
Minimum opening pressure 97 kPa
Cooling fan High speed current 7.0±1 A
Low speed current 5.7±1 A
Cooling fan resistor
Resistance at 20°C (68°F) 0.31-0.38 Ω
Clutch
Pedal height above cowl panel 140-150 mm
Distance between the clutch separation point
35 mm or more
and the pedal stroke end position
Clutch driven disc rivet head depth Minimum value 1.3 mm
Clutch drive disc assembly radial runout Minimum value 1.0 mm
Wear and tear of diaphragm Maximum depth 0.5 mm
spring finger Maximum width 6.0 mm
Flywheel subassembly radial
Maximum value 0.1 mm
runout
Diaphragm spring end deviation Maximum depth 0.5 mm
Tires and wheels

185/65R14 86H Front 220±10 kPa
Cool tire inflation
185/65R14 86H Rear 220±10 kPa
pressure
T125/70R16 96M Spare tire 420±10 kPa
Tire radial runout 1.4 mm or less
Adjusted degree of unbalance 5.0 g or less
Steering System
Steering wheel free play Steering angle ≤10°
Maximum steering angle of front wheel Inside wheel 34.5° –41.5°

Outer wheel 29.5° –36.5°
Power steering system
Fluid level rise Maximum value 5 mm
Steering torque at idle speed (reference value) 3.9±0.5 N·m
Steering tie rod ball assembly Starting torque 3.0 N·m (MAX)
Sway torque 0.5-2 N·m
Brake System
Clearance between the vacuum booster's push rod and the piston (with SST) 1.5 mm
Front wheel brake pad thickness Standard value 10.5 mm
Minimum value 2.0 mm
Front wheel disc brake thickness Standard value 22.0 mm
Front wheel disc brake radial runout Maximum value 0.11 mm
Rear wheel brake pad thickness Standard value 9 mm
Rear wheel disc brake thickness Standard value 11 mm
Minimum value 9 mm
Rear wheel disc brake radial runout Maximum value 0.11 mm
Parking brake system
Parking brake lever stroke at 196 N: 6-8 clicks
Maintenance 2-21
Vehicle Body's Basic Calibration Measurements

This section shows the basic parameters of the overall vehicle. Please refer to this section when servicing or re-
pairing.
All figures used to express measurements are actual figures.
Measuring points are taken from the center of the mounting holes.
When using the gauge, adjust the two measuring needles until they reach an equal length, then check the measur-
ing needle and the gauge itself to ensure there are no gaps.
When using measuring tape, make sure not to stretch, twist, or bend it.
The asterisk (*) symbol after a numerical measurement value indicates that the other side's symmetrical position
is of equal value.
Coordinates of the measuring points refer to the distances measured between the point and "X," "Y," and "Z"
standard lines.
The left and right symmetry points of a measuring point's coordinate represent a coordinate point on the left side,
and that the right and left side are symmetrical.
Z(+)
Vehicle center line
Imaginary reference
Y(+) X(+) line
Y(-)
(0) X(-) Front wheel center line
"Z" represents the imaginary ref-
(0) erence line (below reference line
("OZ" line of the design diagram)
300 mm)
MLB001G
Engine Compartment
124
1.0
105
2.0
1269.4*
899
.7
113
7.5
901
.1
53
7205.0
870 .2
.2
Unit: mm
MLB002G
Mark Axis (X, Y, Z) Diameter (mm) Mark Axis (X, Y, Z) Diameter (mm)
A (102.3, 620.5, 636.1) 12 × 8 a (102.3, -620.5, 636.1) 12 × 8
B (21.0, 526.0, 564.3) 61 × 44 b (21.0, -526.0, 564.3) 61 × 44
C (-334.5, 568.6, 566.6) Φ8 c (-334.5, -568.6, 566.6) Φ8
D (-584.1, 360.1, 472.6) Φ7 d (-584.1, -360.1, 472.6) Φ7
E (-222.6, 532.6, 361.1) Φ10.5 h (-247.7, -435.7, 236.3) Φ13
F (-146.2, 459.9, 318.4) Φ12 i (-169.7, -435.7, 237.5) Φ13
G (-303.2, 459.9, 318.4) Φ12
Maintenance 2-23
Chassis
859.8
Front
1052.0
882.0
Right
354.4*
393.0*
665.7*
33.5*
742.0
921.6*
1099.8
1099.8
15
93
.7
*
331.0*
234.3
1111.8
4*
1162. *
.8
1196 *
377.1*
593.9*
672.7*
.2
1103
1144.0
1012.9
1141.6*
962.4*
1137.4
711.5
844.0
881.6
880.7
1110.5
O o
Unit: mm
MLB003G
Chassis (Continued)
465 Mark Axis (X, Y, Z) Diameter (mm)

A (-251.7, 429.9, 465.0) 30 × 20
B (21.0, 526.0, 864.3) 61 × 44
864 C (59.6, 441.0, 239.4) Φ15
D (380.4, 371.0, 246.7) Φ17
239
E (414.0, 549.9, 230.5) Φ25
F (564.0, 549.9, 230.5) Φ12
G (1561.5, 555.9, 230.1) Φ25
H (1795.8, 572.0, 387.2) Φ17
231
I (1815.1, 506.4, 385.7) Φ17
J (1938.6, 568.7, 391.1) Φ17
231 K (2155.4, 355.8, 494.9) Φ11
L (2234.2, 422.0, 373.4) Φ7.5
M (2523.9, 440.4, 476.5) 28 × 28
N (2703.2, 55.3, 386.2) 10.5 × 10.5
O (2451.3, 440.8, 175.0) Φ17
Mark Axis (X, Y, Z) Diameter (mm)
a (-251.7, -429.9, 465.0) 30 × 20
b (21.0, -526.0, 864.3) 61 × 44
c (59.6, -441.0, 239.4) Φ15
d (380.4, -371.0, 246.7) Φ17
e (414.0, -549.9, 230.5) Φ25
f (564.0, -549.9, 230.5) Φ12
g (1561.5, -555.9, 230.1) Φ25
h (1795.8, -572.0, 387.2) Φ17
230 i (1815.1, -506.4, 385.7) Φ17
j (1938.6, -568.7, 391.1) Φ17
k (2155.4, -355.8, 494.9) Φ11
387 l (2234.2, -422.0, 373.4) Φ7.5
m (2523.9, -440.4, 476.5) 28 × 28
390
n (2703.2, -55.3, 386.2) 10.5 × 10.5
o (2451.3, -440.8, 175.0) Φ17
495
373
477
386
Upper Lower
Unit: mm Rear
MLB004G
Maintenance 2-25
Trunk Door Frame
984.2
*
1034.6
1049.7
*
4 .3
120
739.1*
11
11 97
19 .1 *
.0 *
1117.4
1021.3 *
18
9.
8
*
Unit: mm MLB005G
A (2473.6, 492.1, 1094.2) Φ9 C (2589.0, 558.7, 517.4) Φ9
B (2511.5, 524.8, 907.9) Φ9 D (2666.5, 450.6, 382.0) Φ9
Subframe
Unit: mm
MLB006G
Maintenance 2-27
Right side Panel
104
4.5 8
999.
Unit: mm
MLB007G
A (375.0, 699, 514.7) Φ14 C (1334.9, 712.8, 235.5) Φ14
B (375.0, 708.2, 185.3) Φ14 D (1348.4, 709.7,563.9) Φ14
Left side Panel
999. 4.5
8 104
Unit: mm
MLB008G
A (375.0, -699, 514.7) Φ14 C (1334.9, -712.8, 235.5) Φ14
B (375.0, -708.2, 185.3) Φ14 D (1348.4, -709.7, 563.9) Φ14
Engine Accessories 3-1
Engine Accessories
Exhaust System...............................................................................3-2
Components..................................................................................3-2
Replacement.................................................................................3-3
Cooling System................................................................................3-5
Vehicle Inspection.........................................................................3-5
Cooling Fan System......................................................................3-6
Engine Coolant.............................................................................3-8
Radiator Assembly........................................................................3-9
Engine Suspension........................................................................3-12
Components................................................................................3-12
Removal......................................................................................3-12
Fuel Supply System.......................................................................3-14
Components................................................................................3-14
Removal......................................................................................3-15
Exhaust System
Components
Hanger
Muffler heat shield
Three-hole
Muffler assembly rubber block
Exhaust pipe sealing gasket

Rear catalytic converter heat shield
Hanger
60±6
Rear catalytic converter assembly

Hanger
60±6
60±6
Exhaust pipe front joint assembly

MLC001G
Replacement
Hint:
The installation sequence is the reverse of the removal se-
quence. Nevertheless, only installation procedures of addi-
tional information is included.
Note: Wait at least 30 minutes between the engine being
turned off and the actual removal of any component of
the exhaust system, so as to avoid personnel injury due
to hot components.
The exhaust pipe gasket is mainly used for sealing.
When it has been installed for the first time, there will be
probably a distortion and the sealing effect will be poor. It
is recommended that such gaskets not be used repeat-
edly and even if necessary, it will be permitted that they
could be used repeatedly only once at the most.
1. Remove the muffler.

(a) First, remove the coupling bolt between the muffler as-
sembly and the rear catalytic converter assembly with
a No.13 open-end wrench or a No.13 socketed ratchet
wrench. Then take out the exhaust pipe sealing gasket
between the flanges.
MLC002G
Hanger (b) Remove the hanger and three-hole rubber block from the
rear of the muffler.
Three-hole
rubber block
MLC003G
(c) Remove the hangers from the front of muffler, then the
muffler can be removed.
Caution: While performing this kind of operation, another
person should be present to support the exhaust tail
pipe assembly to avoid injury in the event that the muf-
fler falls.
Hanger
MLC004G
2. Remove the rear catalytic converter assembly.

(a) Remove the coupling bolt between the rear catalytic con-
verter assembly and the exhaust pipe front joint assem-
bly with a No.13 open-end wrench or a No.13 socketed
ratchet wrench, then take out the exhaust pipe sealing
gasket between the flanges.
MLC005G
(b) Rear catalytic converter assembly Vehicle Body Hanger.

Remove the rear catalytic converter assembly.
Caution: While performing this kind of operation, another
person should be present to support the exhaust tail
pipe assembly to avoid injury in the event that the muf-
fler falls.
MLC006G
3. Remove the exhaust pipe front assembly.

(a) Remove the coupling bolt connecting the exhaust pipe
front joint assembly and the engine exhaust manifold
with a No.13 sleeve, ratchet, and extension bar. Then,
take out the sealing gasket between flanges.
(b) Remove the exhaust pipe front joint assembly.
MLC007G
Cooling System
Vehicle Inspection
1. Check the leakage of the cooling system.
Caution:
Do not remove the radiator filler cap while the engine
and radiator are still very hot to prevent burns. Heat ex-
pansion may lead to the spilling of hot engine coolant
and vapor out of the radiator.
(a) Fill the coolant into the radiator and connect the radiator
filler cap scanner.
MLC008G
(b) Warm up the engine.
(c) Adjust the pump pressure to 120 kPa, then check and
confirm that the pressure does not drop down.
In case that the pressure cannot be maintained, check the leak-
age of the pipes, radiator, or pump. If there does not exist any
sign of external liquid leakage, then check the heater core, cyl-
inder body, and the cylinder cover.
2. Check the coolant level in the storage tank.
(a) After the engine has cooled down, the coolant level needs
to be maintained between the "L" line and the "F" line.
If the level is excessively low, check for leakage and add Gly-
col antifreeze fluid (-35oC) to the "F" line.
3. Check the quality of the coolant.
(a) Remove the radiator filler cap.
Caution: Do not remove the radiator filler cap when
the engine and radiator are still very hot as you may get
burned from the steam. Heat expansion may lead to a spill-
age of hot engine coolant and vapor out of the radiator.
(b) Check that whether there is any rust and/or dirt on the
radiator filler cap and the radiator filler. No grease in the
coolant is a must. If the coolant is too dirty, then have it
replaced.
(c) Reinstall the radiator filler cap.
4. Check whether the cooling fin is blocked.
(a) If it is blocked, clean with water or a steam cleaner and
dry it with compressed air.
Caution:
If the steam cleaner is too close to the radiator core, the
cooling fin might become damaged. Therefore, the fol-
lowing spray distances must be maintained:
Spray pressure (kPa) Spray distance (mm)
ALC008G
2,942 to 4,903 300
4,903 to 7,845 500
If the cooling fin is bent, repair with a screwdriver or pliers.
Do not immerse the electronic parts into the water.
Inspection
1. Check the radiator filler cap subassembly.
Caution: If the radiator filler cap is dirty, flush and clean
with water.
Moisten the relief valve and vacuum valve with engine
coolant or water before the usage of a radiator filler cap
scanner.
When performing the steps (a) and (b), keep the scanner
above 30° of the horizontal axle.
(a) Use the radiator filler cap scanner and pump the scanner
Radiator filler cap scanner slowly. Confirm that the air has been released through
the vacuum valve.
Pump speed: pull out once every 3 seconds or longer
30°or above Caution: The pumping speed needs to be constant.
If there is no air has been released through the vacuum
Radiator filler cap valve, replace the radiator filler cap.
(b) Pump the scanner and measure the relief valve opening
ALC009G
pressure.
Pump speed: once per second
Caution:
The pump speeds above are only suitable for the first
pumping pressure (so as to switch off the vacuum valve).
The pump speed might be dropped lower after the first
pumping.
Standard opening pressure:
107.8±10.8 kPa
Minimum opening pressure:
97 kPa
If the opening pressure is less than the minimum value,
replace the radiator filler cap.
Hint:
Set the scanner maximum reading as the opening pressure.
Cooling Fan System

Vehicle Inspection
1. Check the cooling fan working condition when it operates at a low temperature (below 96oC)
(a) Set the ignition switch to the ON position.
(b) Confirm that the cooling fan has stopped working.
If the operation is not stopped, check the cooling fan relay and engine coolant temperature sensor. Check whether
they are disconnected or a short circuit exists.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Confirm that the cooling fan begins to operate.
If not, check the fuse, cooling fan relay, ECM, and cooling fan. Check to see if there is a short circuit between the
cooling fan relay and the engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. Check the cooling fan working condition when operating at a high temperature (below 99oC).
(a) Start the engine and get the coolant temperature raised to above 99oC.
Hint:
The coolant temperature of the engine coolant temperature sensor should be checked at the outlet.
(b) Confirm that the cooling fan begins to operate.
If not, replace the engine coolant temperature sensor.
Note: The working condition of cooling fan
Direction of rotation Low rotational speed High rotational speed
(looking from the radiator) (r/min) (r/min)
Counterclockwise 1,850±250 2,250±250
3. Check the cooling fan.
(a) Disconnect the cooling fan connector.
(b) Connect the battery and ampere meter to the cooling fan.
(c) Confirm the cooling fan opertates smoothly. In the meantime, check the readings on the ampere meter.
Standard ampere readings: (5.7±1) A (low speed)
(7.0±1) A (high speed)
(d) Reconnect the cooling fan connector.
Inspection
1. Check the cooling fan relay (high speed).
(a) Inspect the conducting condition
Check if the terminals are conducting with an ohmmeter.
2
5 3 Specified condition:
3 5 Terminal No. Specified condition
1 2
1-2 Conducting
1
Not conducting
Conducting
MLC009G 3-5
(Apply the battery voltage onto terminals 1
and 2)
2. Check the cooling fan relay (low speed).

(a) Inspect the conducting condition
3 Check if the terminals are conducting with an ohmmeter.
3 5 5 Specified condition:
2 1 Terminal No. Specified condition
1 2 1-2 Conducting
Not conducting
Conducting
MLC010G 3-5
(Apply the battery voltage onto terminals 1
and 2)
3. Check the cooling fan resistor.
(a) Measure the resistance between terminals with an ohmmeter.
Resistance: 0.31-0.38 Ω at 20oC
Engine Coolant
Replacement
1. Drain the engine coolant.
Caution: Do not remove the radiator filler cap when the
engine and radiator are still very hot to prevent burns
from occurring. Heat expansion may lead to the spillage
of hot engine coolant and vapor out of the radiator.
(a) Remove the radiator filler cap.
(b) Release the radiator drainage switch and drain the engine
coolant.
Drainage switch subassembly
Radiator filler cap subassembly
Radiator drainage switch subassembly

ALC012G
2. Fill the engine coolant.

(a) Tighten the radiator drainage switch and fill with coolant
into the radiator until it overflows.
Capacity: 5.0±0.15L
Hint:
Press the radiator inlet and outlet pipe several times manually.
If the coolant level drops, add more coolant.
(b) Tighten the radiator filler cap.
(c) Fill the engine coolant into the reservoir until it reaches
the FULL line.
(d) Warm up the engine until thermostat valve opens.
Hint: Press the radiator inlet and outlet pipe several times
manually when warming up the engine.
(e) Stop the engine until the coolant cools down.
(f) Remove the radiator filler cap and check the coolant
level.
(g) If the level drops down, perform the procedures from (a)
to (f) again.
(h) If the level does not drop down, add the engine coolant
to adjust the coolant level in the reservoir.
3. Check the engine coolant leakage.
(a) Pour coolant into the radiator and connect the radiator
filler cap scanner.
(b) Adjust the pump pressure to 137 kPa and check whether
any leakage exists.
Radiator Assembly
Radiator filler cap connecting rubber tube
Radiator cap assembly

Radiator assembly
Radiator filler assembly Radiator upper

mount rubber block
Radiator upper rubber tube
Q1460616
Radiator lower
mount rubber block
Radiator lower rubber tube
Electronic fan with overflow tank assembly

MLC011G
Removal
1. Disconncet the battery negative terminal.
2. Drain the engine coolant (See page 3-8).
3. Disconnect the radiator inlet and outlet pipe.
Caution: Avoid impurities entering the pipes.
4. Remove the front bumper.
5. Remove the front impact beam.
6. Remove the radiator upper cross member.

(a) Remove 2 bolts and separate the condensator from the
radiator upper cross member.
(b) Remove the 6 bolts and the radiator upper cross member.
MLC012G
7. Remove the radiator assembly.

(a) Disconnect the cooling fan motor connector and then
remove the radiator assembly from the engine compart-
ment.
(b) Remove the 2 radiator upper mounts and lower mounts.
MLC013G
(c) Remove the 3 bolts and separate the electric fan with
overflow tank assembly.
MLC014G
(d) Remove the 2 bolts and the filler cap.
MLC015G
Installation
1. Install the radiator assembly.
(a) Install the filler cap with 2 bolts.
MLC016G
(b) Install the electronic fan with the overflow tank assembly
with 3 bolts.
Torque: 10 N·m
MLC017G
(c) Install the 2 radiator upper mounts and lower mounts on

the radiator.
(d) Install the radiator assembly and attach the connector to
the cooling fan motor.
MLC018G
2. Install the radiator upper cross member.

(a) Install the radiator upper cross member with 4 bolts.
(b) Install the condenser on the radiator upper cross member
with 2 bolts.
MLC019G
3. Adjust the engine hood.

4. Install the front impact beam.
5. Install the front bumper.
6. Fill the engine coolant.
7. Check the engine coolant leakage.
8. Connect the battery negative terminal.
Engine Suspension
Components
56±6 56±6 46±5
95±10
Engine right suspension assembly
Engine rear suspension assembly
78±6
78±6
56±6
78±6
Engine left suspension bracket
Engine left suspension assembly

MLC020G
Removal
Hint:
quence.
1. Disconnect the engine from the suspension.
(a) Hang the engine with a crane.
(b) Remove the nut connecting the rear suspension and the
subframe with a socket wrench.
MLC021G
(c) Remove the nut connecting the engine left suspension

and the left suspension bracket with a socket wrench.
MLC022G
(d) Remove the nut and two bolts connecting the engine
right suspension and the engine with a socket wrench.
MLC023G
2. Remove the engine left suspension.

(a) Remove the engine left suspension's 4 mounting bolts
and the engine left suspension assembly with a No.13
wrench, ratchet, and extension bar.
MLC024G
3. Remove the engine right suspension.

(a) Remove the engine right suspension's 2 mounting bolts
and one mounting nut, then remove the engine right sus-
pension assembly with a No.13 socket wrench, No.15
socket wrench, ratchet, and extension bar.
MLC025G
Fuel Supply System

Components
Evaporation pipe assembly

Evaporation hose
Fuel tank return pipe

Fuel tank lock
Evaporation hose
Fuel tank
outlet pipe
Fuel filler pipe

assembly
Electronic fuel pump
Engine inlet pipe

Charcoal canister
inlet pipe
Fuel tank assembly
Fuel filter bracket
Solenoid valve outlet pipe

Fuel filter Charcoal canister outlet pipe
Rotary valve
Solenoid valve
mounting bracket
Canister solenoid valve
Solenoid valve mounting rubber cover

Charcoal canister
Electronic accelerator pedal
MLC026G
Removal
1. Fuel tank removal
Caution: When maintenance of the fuel supply system
requires removal of the fuel line, the pressure of the
fuel system should first be released, so as to avoid the
spraying of high-pressure fuel.
(a) Remove the rear seat and lift the carpet.
(b) Pull out the electrical connector of the fuel pump on the
top of the fuel tank.
(c) Pull out the fuel tank inlet and outlet pipe quick connec-
tors and disconnect the evaporation hose from tank. Af-
terwards, use a cotton cloth to block the opening to avoid
the spraying of high-pressure fuel.
MLC027G
(d) Raise the vehicle.

(e) Remove the fuel filler pipe connecting hose and air re-
turn hose (two attachment clips) at the rear of the fuel
tank.
MLC028G
(f) Remove the 4 bolts holding the fuel tank.

(g) Remove the fuel tank slowly and block the opening with
cotton cloth.
2. Fuel tank installation
Hint: The installation sequence is the reverse of the removal
sequence. Nevertheless, only the installation procedures of ad-
ditional information is included.
Tightening torque of the bolts fixing the fuel tank: 26±3
N·m.
MLC029G
3. Fuel pump and charcoal canister removal.

(a) Remove the rear seat.
(b) Clean any accumulated dirt from the flange of the fuel
pump.
(c) Pull out the electrical connector of the fuel pump on the
top of the fuel tank.
(d) Pull out the fuel tank inlet and outlet pipe quick connec-
tors and disconnect the evaporation hose from the tank.
MLC027G
Afterwards, use a cotton cloth to block the opening to
avoid the spraying of high-pressure fuel.
(e) Starting diagonally, use a wrench to successively remove
the small bolts on the install panel of the fuel pump in
the diagnostic mode.
(f) Pay careful attention not to damage the fuel level sensor
when removing the assembly from the fuel tank.
(g) Disconnect the pipeline connected to the fuel pump.
MLC030G
4. Fuel pump and charcoal canister installation.

(a) Carefully install the fuel pump and charcoal canister as-
sembly as well as the oil level sensor, ensuring they will
not be damaged.
(b) Ensure that the port of the pipeline between the fuel
pump and charcoal canister is correct.
(c) Replace the weatherstripping and install the fuel pump
pressure plate.
Bolt torque: 3-4 N·m
(d) Connect the electrical connector of the fuel pump onto
the top of the fuel tank.
(e) Connect the fuel tank inlet and outlet pipe quick connec-
tors and then connect the evaporation hose and tank.
5. Fuel filter removal

(a) Raise the vehicle.
(b) Pull out the two quick connectors which connect to the
fuel filter.
(c) Loosen the bolts on the fuel filter mount in order to take
out the filter and have it replaced as a whole.
MLC031G
6. Fuel filter installation

sequence. Nevertheless, only the installation procedures of ad-
ditional information is included.
When installing the filter, pay attention to the direction of the
arrow which should be consistent with the fuel flow.
MLC032G
7. Fuel filler pipe assembly removal.

(a) Remove the filler cap.
(b) Remove the fixed bolts connecting the fuel filler pipe as-
sembly bracket and the vehicle body.
MLC033G
(c) Remove the fuel filler pipe connecting hose and the air
return hose attachment clip.
(d) Block the fuel tank port with a piece of cotton cloth, then
remove the fuel filler pipe assembly.
8. Fuel filler pipe assembly installation.
sequence.
MLC028G
9. Electronic accelerator pedal removal.

(a) Pull out the electronic wire harness connector.
(b) Unscrew the three mounting nuts.
MLC034G
Solenoid valve outlet pipe
Canister solenoid valve
Solenoid valve mounting bracket
Canister solenoid valve installation rubber cover

Attachment clip
Charcoal can-
ister outlet pipe
assembly Charcoal canister
Charcoal
canister
inlet pipe
MLC035G
10. Fuel evaporation control system removal.

(a) Remove the charcoal canister.
(1) With pliers, remove the attachment clips connecting
the two rubber pipes and pull out the charcoal canis-
ter outlet and inlet pipe.
(2) Remove the charcoal canister from the dovetailed
groove upward.
(b) Remove the charcoal canister solenoid valve.
(1) Detach the connector.
(2) With pliers, remove the attachment clips connecting
the charcoal canister solenoid valve and pull out the
solenoid valve outlet and charcoal canister outlet pipe.
(3) Take off the charcoal canister solenoid valve rubber
cover from the bracket. Afterwards, remove the sole-
noid valve from its rubber sleeve.
Drive System 4-1
Drive System
Propeller Shaft..................................................................................4-3
Malfunction Indicator Table...........................................................4-3
Front Axle Drive Shaft Components..............................................4-4
Front Axle Drive Shaft Structural Diagram....................................4-5
Front Axle Drive Shaft Overhaul...................................................4-6
Propeller Shaft Components.......................................................4-15
Malfunction Indicator Table.........................................................4-15
Propeller Shaft Removal.............................................................4-15
Rear Drive Shaft Components....................................................4-17
Rear Drive Shaft Overhaul..........................................................4-17
Rear Axle Assembly.......................................................................4-20
Components................................................................................4-20
Trailing Arm Assembly Removal.................................................4-21
Rear Main Reducer Assembly Removal ....................................4-21
Rear Main Reducer Assembly Installation..................................4-22
Trailing Arm Assembly Installation..............................................4-22
Rear Main Reducer Assembly........................................................4-23
Areas of Importance....................................................................4-23
Components................................................................................4-26
Preparations Before Removal.....................................................4-27
Rear Main Reducer Assembly Removal.....................................4-27
Rear Main Reducer Assembly Installation..................................4-31
Front Axle Hub Subassembly LH...................................................4-38
Components................................................................................4-38
Vehicle Inspection.......................................................................4-39
Replacement...............................................................................4-39
Front Hub Bolt LH Replacement.................................................4-44
Rear Axle Hub Subassembly LH....................................................4-45
Components................................................................................4-45
Vehicle Inspection.......................................................................4-46
Overhauling.................................................................................4-46
Rear Axle Hub Bolt LH Replacement..........................................4-48
Clutch.............................................................................................4-49
Clutch Pedal Subassembly Components....................................4-50
Clutch Pedal Replacement.........................................................4-50
Clutch Assembly Components....................................................4-54
Clutch Assembly Overhaul..........................................................4-55
Drive System 4-3
Propeller Shaft
Malfunction Indicator Table
The following table places suspected parts in numerical sequence to confirm the reasons for the problem. Inspect, re-
pair, or replace parts in the procedures listed in the following pages if necessary.
Problem Location in Question Reference Page(s)
1. Wheel 6-32
2. Front wheel alignment 6-4
3. Rear wheel alignment 6-17
4. Front hub bearing (worn) 4-3
5. Rear hub bearing (worn) ---
Deviation in driving
6. Front shock absorber with coil spring as-
sembly 6-7
7. Steering propeller mechanism (loose or
worn) ---
8. Stabilizer bar ---
1. Wheel balance
6-38
2. Hub bearing (worn)
Front wheel shimmy 4-3
3. Front shock absorber with coil spring as-
6-7
sembly
1. Outer joint (worn) 4-9
Noise (Propeller shaft)
2. Inner joint (worn) 4-7
Front Axle Drive Shaft Components
Front axle right propel- Front axle left propeller shaft assembly
ler shaft assembly
Front stabilizer bar
63±5
Brake hose
Left steering tie rod ball assembly
80±10
50±5
◆Cotter pin ◆Cotter pin
Drive shaft nut
Front suspension lower swing arm LH
◆ Disposable parts
MLD001G
Drive System 4-5
Front Axle Drive Shaft Structural Diagram
Outer joint shaft assembly of front axle left propeller shaft
◆Large clip of dust cover for outer joint
◆Dust cover for outer joint
◆Small clip of dust cover for

outer joint
◆Small clip of dust cover for inner joint
Three-ball stud joint assembly

Inner joint assembly of front axle
left propeller shaft
◆Oil seal of front axle
◆Dust cover for inner joint left propeller shaft
◆Large clip of dust cover for inner joint
◆Inner clasp of front axle left propeller shaft
MLD002G
Front Axle Drive Shaft Overhaul

Hint:
Repair the right side in the maintenance procedure for the left.
1. Drain propeller axle oil.
2. Remove the front wheel.
3. Remove the front axle drive axle nut LH.

(a) Pry out the protruding parts of the front axle drive shaft
nut LH with the SST and hammer.
Caution: Loosen the locked parts of the nut completely
or the thread of the propeller shaft will be damaged.
(b) When applying brake, remove the front drive shaft nut
LH.
SST
MLD003G
4. Separate the wheel speed sensor.

(a) Remove the brake hose wire clamp, remove the brake
hose from the front shock absorber assembly LH, and
remove the front wheel speed sensor assembly LH.
MLD004G
(b) Remove the bolt and separate the wheel speed sensor
from the steering knuckle.
Caution:
· · Do not damage the wheel speed sensor.
· · Avoid any contamination to the wheel speed sensor.
MLD005G
5. Remove the front stabilizer bar.

(a) Remove the retaining bolt of the front stabilizer bar from
the front shock absorber bracket.
(b) Remove the coupling nut between front stabilizer bar and
stabilizer bar.
MLD006G
Drive System 4-7
6. Remove the steering tie rod ball assembly LH.

(a) Remove the cotter pin and nut.
(b) Use the SST to remove the steering tie rod ball assembly
LH from the steering knuckle.
MLD007G
7. Remove the front suspension lower swing arm LH.

(a) Remove the lock pin and nut.
(b) Use the SST to separate the front suspension lower swing
arm LH from the steering knuckle.
8. Seperate the front axle hub assembly LH.
(a) Use a plastic hammer to seperate the front axle drive
shaft assembly LH from the front axle hub assembly LH.
Caution: Do not damage the dust cover and wheel speed
MLD008G
sensor.
9. Remove the front axle left drive shaft assembly.

(a) Use the SST or pry bar to pry off the connection of the
SST differential and drive shaft to make the drive shaft obvi-
ously slide outside and remove the front axle left propel-
ler shaft assembly (To remove the four wheel-drive front
drive shaft RH, eject the snap ring from the transfer case,
remove the mounting bolt with washer raising the drive
SST shaft bearing from the transfer case and then pry the
ALE013G
drive shaft).
Caution
· · Do not damage the oil seal and dust cover.
· · Do not drop the propeller shaft assembly.
10. Check the front axle left drive shaft assembly.

Place the propeller shaft assembly in horizontal during
checking.
(a) Check and confirm whether the outer joint has obvious
clearance in radial direction.
(b) Check and confirm whether the inner joint slides smooth-
ly in an axial direction.
ALE016G
(c) Check and confirm whether the inner joint has obvious
clearance in radial direction.
(d) Check whether the dust cover is damaged.
11. Remove the large clip of dust cover for inner joint of front
axle LH.
(a) As shown in the figure, use needle nose pliers to remove
the large clip of dust cover for inner joint of front axle
LH.
MLD009G
12. Remove the small clip of the dust cover for the inner joint
of the front axle LH.
(a) As shown in the figure, use needle nose pliers to remove
the small clip of the dust cover for the inner joint of the
front axle LH.
13. Separate the dust cover for the inner joint of the front
axle.
(a) Separate the dust cover for the inner joint from the front
MLD010G
axle inner joint assembly LH.
14. Remove the front axle inner joint assembly LH.

Installation mark
(a) Remove the grease from the front axle inner joint assem-
bly LH.
(b) Make an installation mark on the front axle inner joint
assembly LH and outer joint shaft assembly.
Hint:
Do not use a punch to mark the component.
(c) Remove the front axle inner joint assembly LH from the
ALE019G
outer joint shaft assembly.
(d) Use a clasp expander to remove the inner clasp of left

propeller shaft.
ALE020G
(e) Make installation mark on the outer joint shaft assembly

Brass rod
Installation mark
and three-ball stud joint assembly.
Hint:
Do not use a punch to mark the component.
(f) Use a brass rod and hammer to remove the three-ball
stud joint assembly from the outer joint shaft assembly.
Caution: Do not tap or strike the roller.
ALE021G
Drive System 4-9
15. Remove the large clip of dust cover for the outer joint of
the front axle LH.
(a) Use a screwdriver to remove the large clip of the dust
cover for left outer joint.
ALE023G
16. Remove the small clip of the dust cover for the outer
joint of the front axle LH.
(a) Use a screwdriver to remove the clip of the dust cover
for the front axle inner joint LH.
17. Remove the dust cover for the outer joint of front axle.
(a) Remove the dust cover for the outer joint from the outer
joint shaft assembly.
(b) Remove the grease from the outer joint.
ALE024G
18. Remove the clasp of the front axle left propeller shaft.
(a) Use a screwdriver to remove the clasp of the left propel-
ler shaft.
ALE025G
19. Remove the oil seal of the front axle left propeller shaft.
SST (a) Use the SST and press to remove the oil seal of the left
propeller shaft.
Caution:
Do not drop the inner joint assembly.
ALE026G
SST 20. Install the oil seal of the front axle left propeller shaft.
(a) Use the SST and press to install the oil seal of the left
propeller shaft.
Caution:
· · Do not damage the oil seal.
· · The oil seal must be mounted in position.
21. Install the clasp of the front axle left propeller shaft.
(a) Install a new clasp for the front axle left propeller shaft.
ALE027G
22. Install the dust cover for the outer joint of the front axle.
(a) Use PVC insulating tape to wrap the spline of outer joint
shaft to avoid damaging the dust cover.
(b) Install the new part on the inner joint shaft assembly in
the following sequence:
(1) Large clip of the dust cover for the outer joint of the
front axle LH
(2) Dust cover for the outer joint
(3) Small clip of the dust cover for the outer joint of the
front axle LH
(c) Use grease to seal the outer joint assembly of front axle LH.
Grease capacity: 155 to 170 g
(d) Install the dust cover of the outer joint onto the outer
joint shaft assembly.
23. Install the large clip of the dust cover for the outer joint of
Attach
the front axle LH.
SST Rotate (a) Install the large clip of the dust cover for the outer joint of
the front axle LH onto the dust cover of the outer joint.
(b) Place the SST on the large clip of the dust cover for the
outer joint of the front axle LH.
(c) Fasten the SST to tighten the large clip of the dust cover
for the outer joint of front axle LH.
ALE028G
Caution: Do not over tighten the SST.
(d) Use the SST to measure the clearance of the large clip of
SST the dust cover for the outer joint of the front axle LH.
Clearance: 0.8 mm or smaller
Caution: If the measured value exceeds the specified
value, retighten the large clip.
ALE029G
Drive System 4-11
Fix 24. Install the small clip of the dust cover for outer joint of
front axle LH.
SST
(a) Clip the propeller shaft in the vice.
(b) Install the dust cover for the outer joint of the front axle
LH onto the dust cover of the outer joint.
(c) Place the SST on the small clip of the dust cover for the
outer joint of the front axle LH.
(d) Fasten the SST to tighten the clip of the dust cover for
ALE030G
the outer joint of front axle LH.
Caution: Do not over tighten the SST.
(e) Use the SST to measure the clearance of the small clip of
the dust cover for the outer joint of front axle LH.
Clearance: 0.8 mm or smaller
Caution: If the measured value exceeds the speci-
fied value, retighten the small clip.
SST
ALE031G
25. Install the inner joint assembly of the front axle left pro-
peller shaft.
Hint:
Before installing the dust cover, use PVC insulating tape to wrap
the spline of the propeller shaft to avoid damaging the dust cover.
(a) Install the new part on the outer joint shaft assembly in
the following sequence:
(1) Small clip of the inner joint of the front axle LH
(2) Dust cover for the inner joint
(3) Large clip of the inner joint of the front axle LH
(b) Align the installation marks and install the three-ball stud
joint assembly onto the outer joint assembly.
(c) Use a brass rod and hammer to install the three-ball stud
joint assembly.
Caution:
· · Do not strike the roller.
· · Make sure that the three-ball stud joint is mounted in
Installation marks the correct direction.
ALE033G
(d) Use a clasp expander to install a new inner clasp of the

left propeller shaft.
(e) Coat the grease on the front axle inner joint assembly
LH.
Grease capacity: 125 to 135 g
ALE020G
(f) Align the installation marks and install the front axle in-
Installation marks
ner joint assembly LH onto the outer joint shaft assem-
bly.
ALE019G
26. Install the dust cover for the inner joint of the front axle.
(a) Install the dust cover of the inner joint onto the inner
joint assembly and outer joint shaft assembly.
27. Install the large clip of the dust cover for the inner joint of
the front axle LH.
(a) As shown in the figure, use needle nose pliers to install
the large clip of the dust cover for the inner joint of the
front axle LH.
MLD009G
28. Install the small clip of the dust cover for the inner joint
of front axle LH.
(a) As shown in the figure, use needle nose pliers to install
the small clip of the dust cover for the inner joint of the
front axle LH.
MLD010G
Drive System 4-13
29. Check the front axle drive shaft.

Hint: Place the propeller shaft assembly horizontally during
checking.
(a) Check whether the outer joint has an obvious clearance.
ly in an axial direction.
(c) Check and confirm whether the inner joint has an obvi-
ous clearance in a radial direction.
ALE016G
30. Install the front axle left propeller shaft assembly.

(a) Apply the gear oil on the spline of the inner joint shaft
assembly.
(b) Align the spline of the shaft and install the front axle left
drive shaft assembly with brass rod and hammer. When
a clear and sharp clicking sound is heard (to install the
four-drive front drive shaft RH, install the snap ring into
the transfer case, install the fastening bolt with a washer
ALE036G
raising the drive shaft bearing onto the transfer case and
tighten it to finish the assembly). The drive shaft and
transmission should have a clearance of 1 mm.
Caution:
· · Install the clasp with the engaging part downwards.
· · Do not damage the dust cover and oil seal.
31. Install the front axle hub assembly LH.
(a) Install the left propeller shaft assembly onto the front
axle hub assembly LH.
Caution:
· · Do not damage the dust cover of the outer joint.
· · Do not damage the rotor of the wheel speed sensor.
· · Do not over push the front axle assembly LH.
32. Install the steering tie rod ball assembly LH.
(a) Use a nut to install the steering tie rod ball assembly LH
onto the steering knuckle.
Torque: 50 N·m
(b) Install a new cotter pin.
Caution:
If the hole for mounting the cotter pin isn't aligned, rotate
the nut for 60°.
33. Install the front suspension lower swing arm LH.
(a) Use a nut to install the front suspension lower swing arm
LH onto the steering knuckle.
Torque: 98 N·m
(b) Install a new lock pin.
Caution:
If the hole for mounting lock pin isn't aligned, rotate the
nut for 60°.
34. Install the front stabilizer bar.

(a) As shown in the figure, install the fastening nut of the
front stabilizer bar and the shock absorber bracket.
(b) As shown in the figure, install the fastening nut of the
front stabilizer bar and stabilizer bar.
Torque: 63±5 N·m
MLD006G
35. Install the wheel speed sensor.

(a) Use the brake hose wire clamp to install the brake hose
onto the front shock absorber LH to directly attach the
wheel speed sensor on the bracket of the shock absorber.
MLD005G
(b) Install the wheel speed sensor on the steering knuckle

with bolts.
Caution:
· · Do not damage the wheel speed sensor.
· · Keep the wheel speed sensor clean.
· · When installing the sensor, do not twist the sensor
wire harness.
MLD004G
36. Install the front axle drive shaft nut LH.

(a) Install a new left wheel drive shaft nut.
Torque: 225±20 N·m
(b) Use a punch and hammer to lock the left hub nut.
37. Install the left bottom cover of the engine.
38. Install the front wheel.
SST
39. Add propeller axle oil.
MLD011G
40. Check and adjust the propeller axle oil.
41. Check and adjust the front wheel alignment.
42. Check the signal of the ABS speed sensor.
Drive System 4-15
Propeller Shaft Components
Transfer case assembly
Middle support assembly
Transmission assembly
50±5 Propeller shaft assembly
Rear axle main reducer assembly
26±3
26±3
MLD012G

Problem Location in Question Operation
1. One or more joints are worn or damaged 1. Replace the entire propeller shaft
2. One or more joints lack lubricant 2. Replace the entire propeller shaft
3. Spider bearing is worn or seized 3. Replace the spider bearing
4. Bolt at the propeller shaft and coupling 4. Tighten the bolts according to the
looses specifications
Propeller shaft has
5. Fixed fork or drive bevel gear fork loosened 5. Tighten the bolts according to the
an abnormal noise
6. The countersink of the differential axle shaft specifications
gear hub is too large because of wear 6. Replace the differential case
7. Drive bevel gear flange protector or mid- 7. Correct the interference according to
dle bearing is frictionizing the conditions
8. Middle bearing in worn 8. Replace the middle bearing
1. Correct the angle of transmission sys-
1. The angle of the joint for the transmission
tem
system is too big or the setting is improper
2. Replace the entire propeller shaft
Vibration 2. One or more joints are worn or damaged
3. Tighten the bolts according to the spec-
3. The bolt of the rubber coupling loosened
ifications
4. The spline of joint fork is seized
4. Replace the joint fork
Propeller Shaft Removal

Removal
1. Remove the propeller shaft nuts.
(a) Use a No.16 open-end wrench to remove the propeller
nut (2201012-K00) that connects the transmission and
rear axle propeller shaft and remove the spring washer
(Q40310).
MLD013G
2. Remove the middle support bolts.

(a) Use a No.10 sleeve, extension bar, and ratchet to remove
the hexagon bolt for the flange face (Q1840820, me-
chanical performace level 10.9) that connects the middle
support bracket and rear axle propeller shaft and remove
the large washer (Q40208).
MLD014G
3. Remove the support bolts of rear axle propeller shaft.

(a) Use a No.10 open-end wrench to remove the hexagon
head bolt and spring washer subassembly (Q1420825)
that connect the rear axle main reducer assembly and rear
axle propeller shaft.
MLD015G
Installation
1. Install the rear axle propeller shaft bolts.
(a) Use a No.13 open-end wrench to install the hexagon
head bolt and spring washer subassembly (Q1420825)
that connect the rear axle main reducer assembly and rear
axle propeller shaft.
Tightening torque: 26±3 N·m
MLD015G
2. Install the middle support bolts.

(a) Use a No.10 sleeve, extension bar, and ratchet to install
the hexagon bolt for the flange face (Q1840820, me-
chanical performace level 10.9) that connects the middle
support bracket and rear axle propeller shaft (with thread
glue), and also install the large washer (Q40208).
MLD014G
3. Install the propeller shaft nuts.

(a) Use a No.16 open-end wrench to install the propeller nut
(2201012-K00) that connects the transmission and rear
axle propeller shaft and also install the spring washer
(Q40310).
MLD013G
Drive System 4-17
Rear Drive Shaft Components
Rear trailing arm assembly LH
50±5
Rear hub brake

assembly LH
Rear drive
shaft nut LH
Rear drive shaft assembly RH
Rear differential assembly
Rear drive shaft assembly LH

MLD016G
Rear Drive Shaft Overhaul

Hint:
Repair the right side in the maintenance procedure on the left.
1. Drain the propeller axle oil.
3. Remove the rear axle drive axle nut LH.

(a) Pry off the protruding parts of the rear axle drive shaft
nut LH with the SST and a hammer.
Caution:
Loosen the locked parts of the nut completely or the
thread of the propeller shaft will be damaged.
(b) When applying the parking brake, remove the rear drive
shaft nut LH.
MLD017G
4. Remove the rear axle left drive shaft.

(a) Remove the bolts of the stabilizer bar and trailing arm
assembly.
(b) Use a No.18 socket wrench to remove the bolt of the rear
shock absorber lower end and trailing arm assembly.
(c) Separate the left drive shaft and hub.
Caution:
· · Use a tool to support the trailing arm assembly.
MLD018G
· · Do not damage the dust cover and wheel speed
sensor.
(d) Use a pry bar to forcefully pry the connection between

the differential and the drive shaft until the drive shaft
obviously moves towards the outside. Do not damage the
dust cover of drive shaft.
MLD019G
5. Check the rear axle left propeller shaft assembly.

Hint:
Place the propeller shaft assembly in horizontal during check-
ing.
(a) Check and confirm whether the outer joint has obvious
clearance in a radial direction.
ly in the axial direction.
ALE016G (c) Check and confirm whether the inner joint has an obvi-
ous clearance in the radial direction.
6. Remove of the rear axle drive shaft assembly.
Hint:
The removal of the rear axle drive shaft assembly is the same
as the front drive shaft (See page DT-7)
Drive System 4-19
7. Install the rear axle propeller shaft assembly LH.

(a) Apply the gear oil on the spline of the inner joint shaft
assembly.
(b) Align the spline of the shaft and install the front axle pro-
peller shaft assembly LH with a brass rod and hammer.
Caution:
· · Install the clasp with the engaging part downwards.
· · Do not damage the dust cover and oil seal.
MLD020G
Hint:
Judge whether the inner joint shaft comes into contact with the
small gear shaft through the sound and feeling when pulling it
inside.
(c) Install the left propeller shaft assembly onto the rear axle
hub assembly LH.
Caution:
· · Do not damage the dust cover of the outer joint.
· · Do not damage the rotor of the wheel speed sensor.
· · Do not excessively push the front axle assembly LH.
(d) Use a socket wrench to install the bolt of the rear shock
absorber lower end and trailing arm assembly.
(e) Install the coupling bolts of the stabilizer bar and trailing
arm assembly.
8. Install the rear axle drive shaft nut LH.
(a) Install a new rear axle drive shaft nut LH.
(b) Use a punch and hammer to lock the left hub nut.
9. Install the rear wheel.
10. Add the propeller axle oil.
11. Check and adjust the propeller axle oil.
MLD021G
Rear Axle Assembly

Components
Rear subframe assembly
Rear drive shaft RH
Rear main reducer

assembly
120±10
78±10 Type I non-metal insert lock
nut M12 × 1.25
All-metal hexagon flange

Rear drive shaft LH lock nut M12×1.25 120±10 Rear hub brake
Partial gasket II
assembly
120±10
Type I non-metal insert 120±10
lock nut M12 × 1.25
Partial gasket II
Rear hub brake assembly
MLD021G
Drive System 4-21
Trailing Arm Assembly Removal

Remove the rear axle assembly from the vehicle body.
1. Remove the trailing arm assembly.
(a) Before removing the trailing arm assembly, mark on the
partial gasket II with paint pen as shown in the figure.
MLD022G
2. Remove the trailing arm mounting bolt assembly.

(a) Use a No.18 socket wrench to remove the Type I non-
metal insert lock nut M12 × 1.25 and remove the trailing
arm mounting bolt assembly and partial gasket II.
MLD023G
3. Remove the hexagon head bolt washer subassembly.

(a) Use a No.17 socket wrench to remove the hexagon head
bolt, spring washer, and flat washer subassembly (M12 ×
1.25 × 105), nut - fasten lower swing arm ball stud seat.
(b) Separate the trailing arm assembly and drive shaft.
(c) Remove the trailing arm assembly.
MLD024G
Rear Main Reducer Assembly Removal

After removing the trailing arm assembly, tap the drive shaft
lightly and remove it, and then remove the rear main reducer
assembly.
1. Remove the hexagon bolt for the flange face.
(a) Use a No.17 socket wrench to remove nut - fasten lower
swing arm ball stud seat and the hexagon bolt for flange
MLD025G face (M12 × 1.25 × 100).
2. Remove the hexagon head bolt and flat washer subas-

sembly.
(a) Use a No.16 socket wrench to remove the four hexagon
head bolts and flat washer subassembly M10 × 1.25 × 65.
(b) Remove the rear main reducer assembly.
MLD026G
Rear Main Reducer Assembly Installation

1. Install the hexagon bolt for the flange face.
(a) Place the rear main reducer assembly into the installation
position of the rear subframe.
(b) Install the hexagon bolt for the flange face M12 × 1.25
× 100 and nut, coat thread fastening sealant for three to
four screw distances along the bolt axles, and tighten to
the specified torque.
MLD027G
2. Install the hexagon head bolt and flat washer subassem-
bly M10 × 1.25 × 65.
(a) Coat thread fastening sealant for three to four screw dis-
tances on the four hexagon head bolts and tighten to the
specified torque.
MLD028G
Trailing Arm Assembly Installation

After installing the rear main reducer assembly, tap the drive
shaft lightly and install it to real main reducer and hub unit,
and then install the trailing arm assembly.
1. Install the trailing arm bolt assembly.
(a) Place the trailing arm assembly into the installation posi-
tion of the rear subframe.
(b) Install the trailing arm bolt assembly, partial gasket II
MLD029G
and Type I non-metal insert lock nut M12 × 1.25.
2. Install the hexagon head bolt, spring washer, and flat
washer subassembly.
(a) Install the hexagon head bolt, spring washer, and flat
washer subassembly M12 × 1.25 × 105, nut - fasten the
lower swing arm ball stud seat.
3. Tighten the tightening nut and lower swing arm ball stud
seat.
(a) Use a No.19 socket wrench to tighten the Type I non-
MLD030G
metal insert lock nut M12 × 1.25 and nut - fasten the
lower swing arm ball stud seat respectively.
Drive System 4-23
Rear Main Reducer Assembly

Areas of Importance
During removal, all components of the rear main reducer assembly should be gently handled to avoid knocking,
especially the joint surface. All components should be placed in order to avoid losing or taking the wrong parts.
In addition to the notice above, please pay attention to the items below:
1. Clean all components (except rubber parts) before installing.
2. Do not use the oil seal, gasket, and elastic pins repeatedly.
3. The rubbing surfaces should be coated with lubricant, and the openings of all oil seals should be coated with
lithium grease.
4. Make sure not to tilt when installing the oil seal.
5. Coat thread fastening sealant onto the thread connector and pre-tighten in specified torque.
6. When the rear main reducer is operating normally, there should be no lubricant leakage from any of the parts.

Problem Location in Question Troubleshooting
Engagement clearance of the drive and driven
Use a dial indicator to check the clearance of
bevel gears is too big: Long-term usage causes
the drive and driven bevel gears, replace the
gear wear or damage, improper installation,
adjusting gasket, and compensate the clearance
too big of a gear clearance and the gear sur-
between gears.
faces collide.
Engagement clearance of the drive and driven Use a dial indicator to check the clearance of
bevel gears is too small: Engagement clear- the drive and driven bevel gears, replace the
ance of the gears too small, improper engage- adjusting gasket, compensate the clearance be-
ment or ineffective lubrication. tween gears, and replace the gear lubricant.
Engagement clearance of the drive and driven
bevel gears is uneven: The driven bevel Replace the drive and driven bevel gears.
gear surface rises, the nut-fastening driven There is no impurity on the surface of the part
bevel gear loosens, the joint surface deforms, before installing and coat with 1271 thread fas-
knocks, or has impurities, causing the driven tening sealant on the bolts.
bevel gear to lean or shift during operation.
The engaging position of the drive and driven
bevel gear is improper: When the vehicle ac-
The rear main
celerates (or upgrades), the engaging position
reducer assem- Replace the insert - differential bearing and ad-
tends to the dedendum (engagement too deep).
bly produces just the engaging position of the gears.
When the vehicle decelerates (or downgrades),
irregular noises.
the engaging position tends to shift toward the
Drive and
gear end (engagement is too low).
driven bevel
Abnormal sounds from the bearing: Bearing
gears are not en-
clearance is too big, causing the bearing to tilt, Replace the adjusting gasket and measure the
gaged properly.
maintain resistance while rotating and gear en- torque with a high-precision torque wrench.
Gears are worn
gagement shifts.
and broken gear.
Abnormal sounds from the bearing: Bearing is
Replace the bearing, adjust the bearing clear-
worn and loose, bearing clearance is improper,
ance through the gasket and spacer, and mea-
bearing flakes off, bearing bracket is damaged,
sure the starting torque and rotating torque
the interference between the bearing and case
with a dial indicator.
is small.
When driving on a straight road, the differen- Replace the planetary gear gasket and measure
tial assembly has an abnormal sound because the adjusted gear clearance, making sure the
the clearance of planetary gear is too small. adjusted clearance is in the specified range.
The differential assembly has abnormal sounds
when the vehicle turns and no abnormal
Clear the scuffs on the component surface.
sounds when driving on a straight road: The
Check the clearance between the thrust washer
planetary gear and planetary gear shaft do not
and the differential case. Check whether the
fit properly. The planetary gear is seized by the
planetary gear has damage or broken gearteeth
planetary gear shaft. The planetary gear has
on the surface. The planetary and axle shaft
damage and broken gearteeth on the surface.
gears can rotate flexibly after installation.
The planetary gear does not match the axle
shaft gear and the gear motion has resistance.
Drive System 4-25
Problem Location in Question Troubleshooting

After replacing the adjusting gasket, use a
torque wrench to inspect the starting torque of
Matching clearance between bearings is small. the rear main reducer assembly and rotation
torque of the drive and driven bevel gears until
Rear main the specified torque is reached.
reducer as-
Engaging clearance of gears is too small. Replace the adjusting gasket.
sembly emits
abnormal heat Check whether the oil drain plug has a mag-
The lubricant capacity is not sufficient or the
net. Replace lubricant, inject hypoid gear oil,
model and specification are improper, the gear
whose number is GB13895 85W/90 (API GL-5
surface has corrosive pitting, bonding, and
85W/90). Also, replace the drive and driven
wear.
bevel gears.
The oil seal of the drive bevel gear is dam- Replace the oil seal and measure the depth of
aged. oil seal pressed into the case.
Adjust the length of rubber pipe, making sure
The vent hole of the main reducer assembly is
the pipe does not interfere with other compo-
blocked and the pressure in the case raises.
nents.
The preload of the drive bevel gear shaft is
Replace adjusting gasket - spacer to adjust the
too high. The temperature is too high when
clearance between large bearings of the main
Rear main the bearing is operating and the pressure in the
gear.
reducer assem- case raises, causing oil leakage.
bly leaks oil Axle shaft oil seal is tilted or damaged during Replace the oil seal and measure the depth of
press fitting. the oil seal pressed into the case.
Replace the rear cover of the main reducer and
Joint surface of the rear cover of the main re-
coat glue on the contact of the rear cover of the
ducer is not flat or has a knocking sound.
main reducer and case.
Coat pre-coated dry film thread sealant on
Oil drain plug is loose. the thread surface and tighten to the specified
torque.
Components
All-metal hexagon lock nut for the flange surface
Hexagon head bolt and conical spring

Clamped clutch
washer subassembly M12 × 32
◆Oil seal of drive
bevel gear
◆Axle shaft oil seal LH Lock nut of main gear
Small bearing of main gear
Spacer
Left mount
Adjust insert - front assembly - rear Adjusting gasket - spacer
differential bearing main reducer Large bearing of main gear
Differential bearing Adjusting gasket - large bear-
ing of main gear
Drive bevel gear
Bolt - fastening
driven bevel gear Rear main reducer case
Driven bevel gear
Right mount assembly - rear
Oil drain plug
main reducer
Oil filler plug Hexagon head bolt and conical spring
Air valve assembly washer subassembly M12 × 32
Steel band elastic hoop
Rubber pipe - air valve ◆Axle shaft oil seal RH
of main reducer Planetary gear
Rubber pipe connector
Planetary gear shaft
Rear cover of main reducer
Rear mount shaft Elastic cylindrical pin
sleeve assembly - Axle shaft gear
rear main reducer Bearing gland Axle shaft gear gasket
Hexagon bolt for
flange face Planetary gear gasket
Gland bolt

MLD031G
Drive System 4-27
Preparations Before Removal

1. Open the oil drain plug before removal to drain the gear oil.
2. Use a steam cleaner or cleaning solvents to clean the
exterior of the main reducer before removal, avoid mix-
ing impurities on the main reducer into the rear main
reducer during removal, ensuring no impurity in the case
and extending the service life of the main reducer.
3. Use a cleaning solvent to clean the removed rear main
reducer assembly components (except the bearing and
oil seal) and use compressed air to dry.
4. Use a clean container to hold the removed components
to avoid losing any part or mixing with other parts. Also,
check whether any part has not been installed during the
installation.
Rear Main Reducer Assembly Removal

1. Remove the clutch.
Use the SST to fix the differential assembly, loosen the all-
metal hexagon head lock nut for the flange face M16, and take
out the clutch.
MLD032G
2. Remove the left and right mount assembly of the rear

main reducer.
Use a wrench to loosen the hexagon head bolt and conical
spring washer subassembly M12 × 32. Remove the left and
right mount assembly - rear main reducer and put them in the
container together with the bolts.
MLD033G
3. Remove the rear cover of rear main reducer.

Use a wrench to loosen the hexagon bolt for flange face M8 ×
25 and remove the rear cover of the main reducer.
MLD034G
4. Use a torque wrench to remove the rubber pipe connec-

tor.
5. Remove the air valve assembly.
Use pliers to remove the steel band elastic hoop as well as the
rubber pipe connector, rubber pipe - main reducer air valve,
and air valve assembly.
MLD035G
6. Remove the rear mount shaft sleeve assembly.

Use the SST to press out the rear mount shaft sleeve assembly
- the rear main reducer and place in specified container.
MLD036G
7. Remove the lock nut of the main gear.

Use the SST to fix the differential assembly and remove the
main gear lock nut M30 × 1.5.
MLD037G
8. Use the SST to remove the main gear oil seal and left
and right axle shaft oil seal.
SST
MLD038G
9. Use a wrench to remove the two bearing glands.

Caution: Distinguish the left and right when removing the
bearing gland to avoid mixing.
10. Remove the differential assembly.
Use a rubber hammer to tap the rear main reducer case to
make the differential assembly fall off from the case and put
the differential assembly in specified container.
11. Remove the outer ring of the differential bearing and
MLD039G mark to distinguish the left and right parts.
Drive System 4-29
Right 12. Remove and mark the left and right gaskets.
Left
MLD040G
SST 13. Use the SST to remove the differential bearing, distin-
guish the left and right parts, and place separately.
Rubber gasket
MLD041G
14. Use a wrench to remove the bolt - fastening driven bevel

gear and take out the driven bevel gear.
Installation mark
Rubber gasket
MLD042G
SST 15. Use a hammer and SST to tap out the elastic cylindrical
pin.
MLD043G
16. Tap the planetary gear shaft out of the differential case.
17. Rotate the axle shaft gear and remove the planetary
gear and gasket.
Caution: Distinguish the left and right when removing
the planetary gear gasket and axle shaft gear gasket to
avoid mixing.
MLD044G
18. Remove the drive bevel gear, spacer, adjusting gasket,

large and small bearings of the drive bevel gear from the
reducer case.
MLD045G
19. Use the SST to take out the large bearing of the drive
bevel gear and remove the adjusting gasket.
SST
MLD046G
20. Use a copper bar and hammer to knock out the big bear-
ing lightly.
MLD047G
21. Use a copper bar and hammer to knock out the outer
ring of the small bearing of the drive bevel gear.
MLD048G
Drive System 4-31
Rear Main Reducer Assembly Installation

Areas of importance before installing the rear main reducer assembly:
(a) Receive the components before installing. Check the integrity of the components, which shouldn't have
damage or scuffing.
(b) Check whether the necessary tools for the installation are in place. For precision instruments, inspect the in-
struments to reduce installation error caused by tools.
(c) Test the leakage of the main reducer case and make sure the product is qualified.
(d) Clean the components and prepare to install.
1. Install the axle shaft gear and gasket and put them into
the differential case.
The specifications of the axle shaft gear gasket are as follows
(Unit: mm):
Group No. A±0.02
1 0.85
2 0.90
3 0.95
MLD049G 4 1.00
5 1.05
Caution: The left and the right gaskets must be of the
same depth
2. Install the planetary gear.

(a) Roll the planetary gear and gasket to install into the dif-
ferential case, insert the planetary gear shaft, and the two
planetary gears are distributed in symmetrical locations.
MLD044G
3. Inspect the clearance between the axle shaft gear gasket

and the differential case.
(a) Inspect the clearance between the axle shaft gear gas-
ket and differential case, and the clearance in theory
shouldn't exceed 0.35 mm. If the clearance isn't in the
specified range, replace appropriate axle shaft gear gas-
ket according to specific conditions.
Caution: Make sure that the axle shaft gear and planetary
MLD050G
gear rotate flexibly and there is no appearance of clamping.
4. Use the SST to tap the elastic cylindrical pin into the pin
hole until it reaches the specified position.
MLD051G
5. Clean the surface of the differential case and install the

driven bevel gear on the differential case with a copper
bar.
6. Tighten the bolt - fasten the driven bevel gear and use
a torque wrench to gradually tighten the bolts symmetri-
cally.
Caution: Coat about 0.076 ml 1271 thread lock sealant
MLD052G
for the 3-4 buckles at the thread connecting position.
7. Use the SST to install the differential bearing on the dif-

ferential case.
MLD053G
SST 8. Use the SST to install the outer ring of the large bearing
of the main gear on the inner case of the rear main re-
ducer.
Outer ring of the
large bearing of
the main gear
MLD054G
9. Use the SST to install the outer ring of the small bearing
SST of the main gear on the inner case of the rear main re-
ducer and place the small bearing on the outer ring.
Small bear-
ing of the
main gear
MLD055G
Drive System 4-33
10. Install the oil seal on the inner case of the main reducer
SST with SST.
Oil seal of the
drive bevel gear
MLD056G
11. Install the drive bevel gear.

Drive bevel gear (a) Use a press and SST to install the selected adjusting gas-
ket and large bearing on the drive bevel gear.
(b) Adjusting gasket selection.
SST Group No. A±0.01 Group No. A±0.01
1 0.93 8 1.14
Adjusting gasket - 2 0.96 9 1.17
large bearing of the main 3 0.99 10 1.20
gear MLD057G
4 1.02 11 1.23
5 1.05 12 1.26
6 1.08 13 1.29
7 1.11 14 1.32
(c) Place the spacer and selected adjusting gasket on the in-
stalled drive bevel gear and put them into the rear main
reducer case.
12. Install the drive bevel gear.

(a) Use a special torque wrench to tighten the main gear lock
nut.
Tightening torque: 200±10 N·m.
for 3-4 buckles at the thread connecting position.
List of adjusting gasket - spacer depth specification:
Group No. A±0.01 Group No. A±0.01
MLD058G
1 1.29 9 1.53
2 1.32 10 1.56
3 1.35 11 1.59
4 1.38 12 1.62
5 1.41 13 1.65
6 1.44 14 1.68
7 1.47 15 1.71
8 1.51 16 1.74
13. Install the differential assembly.

(a) Select the adjusting gasket and put the differential assem-
bly and gasket into the rear main reducer case.
(b) Press the bearing cover.
(c) Tighten the cover bolt with a torque wrench. Tightening
torque: 46±5 N·m.
for 3-4 buckles at the thread connecting position.
MLD059G
List of insert-front differential bearing depth specification:
Group A±0.01 Group A±0.01 Group A±0.01
No. No. No.
1 2.00 10 2.45 19 2.90
2 2.05 11 2.50 20 2.95
3 2.10 12 2.55 21 3.00
4 2.15 13 2.60 22 3.05
5 2.20 14 2.65 23 3.10
6 2.25 15 2.70 24 3.15
7 2.30 16 2.75 25 3.20
8 2.35 17 2.80
9 2.40 18 2.85
(d) Use the SST to install the left and right axle shaft oil
SST seals and the depth is 3.5±1 mm.
MLD060G
14. Check the engaging mark on the drive and driven bevel
gears.
(a) Use a dial indicator to measure the engaging clearance
between the drive and driven bevel gears. Measure at least
three points and the error should be within 0.10-0.18 mm.
MLD061G
(b) Use red lead powder to check the requirement of the

mark. The position that the gear touches the mark should
be in the smaller end of the gear width, the mark length
is 40-60% of the gear width, and the mark is higher than
50% of the gear height.
MLD062G
Drive System 4-35
(c) The standard of the engaging mark is as shown in the

Mark height H ≥ 4 Mark height H ≥ 4
Distance from smaller end 2 ≤ A ≤ 5 Distance from smaller end 3 ≤ A ≤ 5 figure.
Mark length 10 ≤ L ≤ 15
Distance from gear top C ≥ 1
Distance from gear bottom C ≥ 1

Protruding surface of the driven bevel gear Concave of the driven bevel gear
MLD063G
(d) Measure the starting torque of the main reducer assembly

and measure the starting torque of the main reducer as-
sembly with an indication-type torque wrench.
Starting torque: 1.8-2.4 N·m.
MLD064G
15. Install the rear mount shaft sleeve assembly.

SST (a) Use press and SST to install the shaft sleeve into the rear
cover of the main reducer, and the depth is 35.3 mm.
MLD065G
(b) Install the air pipe assembly and with a torque wrench
install the air pipe on the rear cover of the main reducer.
Caution: Coat about 0.042 ml thread lock sealant for 3-4
buckles at the thread connecting position.
MLD066G
(c) Coat about 5 g of silicon rubber plane sealant on the con-

tact surface of the reducer case and rear cover. The diam-
eter of the rubber line is 3 mm and the coating length is
about 600 mm. No sealant break is allowed.
MLD067G
(d) Tighten the bolt in the rear cover of the main reducer
with a torque wrench.
MLD068G
16. Install the mount assembly.

(a) Use a press and SST to install the left/right bracket as-
sembly into the left/right mount shaft sleeve assembly.
Caution:
The distance from the mounting surface of the right
bracket to the central line of the mount bracket shaft
sleeve assembly is 34±0.5 mm.
The distance from the mounting surface of the left brack-
MLD069G
et to the central line of the mount bracket shaft sleeve
assembly is 45.7±0.5 mm.
17. Install the left/right mount assembly.

(a) Attach the left and right mount assemblies on the main
reducer case with bolts and then use a wrench at a fixed
torque to tighten the bolts.
(b) Distance between the left and right mount assemblies:
MLD070G
254±1 mm.
18. Install the clamped clutch assembly.

(a) Use a torque wrench and nut to install the clamped clutch
on the main reducer.
MLD071G
Drive System 4-37
19. Install the main reducer assembly.

(a) Connect the main reducer assembly and the rear sub-
frame with bolts. Use a torque wrench to tighten the bolts
in the rear subframe (Coat about 0.13 ml thread lock
sealant for 3-4 buckles at the thread connecting position).
(b) The bolts that connect the rear cover of main reducer and
rear subframe (Coat about 0.23 ml thread lock sealant for
MLD072G
3-4 buckles at the thread connecting position).
(c) Fill gear oil into the main reducer.
Caution: Oil filling specifications for the rear main re-
ducer: GL-5 80W/90 (domestic oil) and GL-5 140 (for the
exported high-temperature region), GL-5 75W/90 (for the
exported alpine region).
When filling with oil, if the oil flows out of the oil filler, it
indicates that it is full.
Front Axle Hub Subassembly LH

Components
Assembly of left front shock absorber with helical spring
Front stabilizer bar
Front axle left drive shaft assembly 63±5
Left front wheel speed

sensor assembly
Steering knuckle bolt
Left steering tie rod ball assembly

Brake hose
40±4 80±10
Left front axle hub assembly
Front brake disc
◆Front axle drive

100±5 80±10 shaft nut LH
50±5
Front wheel brake caliper assembly LH
◆Lock pin
◆Split pin
Left lower control arm assembly
◆Front axle hub

clasp LH
◆Front axle hub bearing LH

Wheel bolt
Front axle hub subassembly LH
Left steering knuckle
Front brake disc cover LH

9±2
MLD073G
Drive System 4-39
Vehicle Inspection
1. Hoist the vehicle and remove the wheels.
2. Loosen the riveted areas of the front drive shaft nut and
remove the nut.
3. Inspect the front disc brake plate surface runout.
When measuring, tighten the two wheel nuts in symmetrical
positions. The runout of the brake surfaces on both sides of
the front disc brake is no more than 0.11 mm. If the measured
MLD074G
value is extremely poor, please repair or replace.
4. Inspect the front brake disc thickness.
Standard thickness: 22.0 mm
The disc brake must be changed when it reaches the minimum
level of thickness.
MLD075G
Replacement
1. Remove the front wheel LH (See page 6-38).
2. Remove the front axle hub nut LH (See page 4-6).
3. Separate the front speed sensor LH (See page 4-6).
4. Remove the front brake caliper.
Unscrew the fastened front brake caliper's bolt to remove the
brake caliper.
Caution: Remove the front brake caliper and attach the
brake caliper with steel wire (Avoid excessive twisting,
bending, or pulling of the brake pipeline).
MLD076G
5. Remove the front brake disc.

After driving the vehicle for some time, it may be hard to re-
move the brake discs. In this case, screw two M8 bolts into the
removed disc brake's threaded holes (refer to the left figure for
locations), and use a wrench to alternately turn the two bolts,
thereby ejecting the brake disc.
6. Inspect the front brake disc.
Inspect the weariness of the front brake disc. If it has obvious
MLD077G
scuffing, the plate surface runout is oversized, or its thickness
is smaller than the minimum thickness, the brake disc should
be replaced.
7. Remove the front brake disc cover.

Remove the fastened brake disc cover bolts with a wrench and
remove the front disc brake cover.
MLD078G
8. Remove the steering knuckle's front hub bearing and

front hub flange assembly.
Caution: The steering knuckle's front hub bearing and
front hub flange assembly, under normal circumstances,
should not undergo disassembly. Replace entirely if any
problem is inspected.
MLD079G
9. Inspect the steering knuckle's front hub bearing and

front hub flange assembly.
(a) Use dye penetrant to inspect the steering knuckle for
cracks, deformities, and damage, which should be re-
placed if found.
MLD080G
(b) Rotate the front hub flange and examine the bearing
for flexible rotation and whether there is appearance of
clamping.
(c) Measure the front hub flange plate surface runout.
The runout should not exceed 0.03 mm.
MLD081G
(d) Measure the front hub bearing's starting torque.

SST Put the SST on the wheel bolts, which are at the symmetrical
locations. Put a dial torque wrench on the SST to slowly rotate
the flange assembly (45°/4s), which requires a starting torque
range of 0.1-0.3 N·m.
If the bearing rotation is not flexible, the front hub flange plate
surface movement inaccurate or the front hub bearing starting
torque is too much, the assembly must be replaced.
MLD082G
Drive System 4-41
10. Remove and inspect the front hub flange assembly.

Bearing inner ring
(a) Use the SST like a hand-held travel hammer to repeat-
edly hammer off the front hub flange assembly from the
steering knuckle and front hub bearing.
MLD083G
(b) Remove the bearing inner ring on the front hub.
SST
MLD084G
Use the SST to remove the bearing inner ring.

(c) Use dye penetrant to inspect the front hub flange for
cracks, which should be replaced if found.
(d) If one would like to continue using the front hub flange
assembly, first inspect the dimensions for the mounting
area of the bearing for inaccurate dimensions. If over-
sized, replace.
Dimensions: Φ38 +0, 025
+0, 009 mm
MLD085G
11. Remove the steering knuckle's front hub bearing (Refer

to the front mount assembly).
12. Remove the snap ring for hole 72.
Use a bent nose retaining ring caliper for holes to remove the
snap ring for hole 72.
MLD086G
13. Replace the removed bearing inner ring back to the

bearing's original position.
MLD087G
14. Press out the front hub bearing from the inside of the
steering knuckle.
On the press, withstand the bearing inner ring that was put on
SST with the SST and press out the entire front hub bearing.
Removal of the steering knuckle and hub brake assembly are
complete.
Caution: The front hub bearing assembly is a disposable
SST part, which needs to be replaced with a new one.
MLD088G
15. If the steering knuckle has no cracks and one would like
to continue to use it, first inspect the bearing's mounting
location dimensions of the steering knuckle's inner hole.
If the measurements are oversized, replace the steering
knuckle.
Dimensions: Φ71 -0, 032
-0, 062 mm
MLD089G
16. Press the front hub bearing assembly into the steering
knuckle hole bearing mounting position.
SST
On the press, press the front hub bearing assembly into the
steering knuckle hole bearing mounting position with the
SST.
MLD090G
17. Press the front hub flange assembly.

On the press, press the front hub flange into the front hub bear-
ing mounting position with the SST.
SST
MLD091G
18. Examine the front hub flange plate surface runout.

Examining methods are the same as the methods used during
disassembly. Plate surface runout should not exceed 0.03 mm.
MLD081G
Drive System 4-43
19. Examine the front hub bearing assembly's starting

torque.
Examining methods are the same as the methods used during
disassembly. Put the SST on the wheel bolts, which are at the
symmetrical locations. Put a dial torque wrench on the SST to
slowly rotate the flange's flange assembly (45°/4s), which re-
quires a starting torque range of 0.4-1.5 N·m.
MLD082G
20. Install the snap ring for hole 72.

Use a bent nose retaining ring caliper for holes to install the
snap ring for hole 72 at the steering knuckle's retaining ring
mounting position.
MLD092G
21. Refer to front mount assembly for installing the steering

knuckle's front hub bearing and front hub flange assem-
bly.
22. Install the front brake disc cover.
Install the front brake disc cover on the steering knuckle and
tighten the bolt to the set torque.
MLD093G
23. Install the front brake disc.
MLD094G
24. Examine the front brake disc plate surface runout.

When measuring, tighten the two wheel nut's symmetrical lo-
cations. The front brake disc's brake linings runout on the two
sides should be no more than 0.11 mm.
MLD074G
25. Install the front wheel brake caliper assembly LH.

(a) Use 2 bolts to install the brake caliper assembly on the
steering knuckle.
Torque: 100±5 N·m
26. Check whether front axle swings and has clearance (See
page 4-3).
27. Install the front speed sensor LH (See page 4-14).
MLD095G
28. Install the front axle drive shaft nut LH.

(a) Install a new left wheel drive shaft nut.
30. Check and adjust the front wheel alignment (See page
SST 6-4).
MLD011G
Front Hub Bolt LH Replacement

Hint:
Components: See page 4-38
2. Remove the front wheel brake caliper assembly LH.
3. Remove the front brake disc.
4. Remove the front hub bolt LH.
(a) Use the SST and screwdriver or similar tools to attach
the front axle hub subassembly LH and remove the
wheel bolts.
SST
MLD096G
5. Install the front hub bolt LH.

Washer (a) As shown in the figure, install the washer and nut on the
Nut new wheel hub bolt.
(b) Use a screwdriver or similar tools to attach the front axle
hub subassembly LH and tighten the nuts to install the
wheel bolts.
6. Install the front brake disc.
7. Install the front wheel brake caliper assembly LH.
MLD097G
Drive System 4-45
Rear Axle Hub Subassembly LH

Components
Rear trailing arm assembly LH

Rear drive shaft assembly LH
Rear hub brake assembly LH
Rear speed sensor
◆Rear hub nut LH

85±5
Rear hub bearing seat ◆Rear hub bearing assembly
Rear brake disc cover 100±10

Rear brake disc
Rear hub flange
Flattened steel retainer for hole
70-75
Wheel bolt
◆Hexagon head bolt and spring washer subassembly
Rear brake caliper LH

MLD098G
Vehicle Inspection
1. Examine the rear brake disc plate surface runout.
(a) Remove the rear wheels.
(b) Remove the rear brake caliper assembly.
Tighten the two wheel nut's symmetrical locations. The rear
brake disc's brake linings runout on the two sides should be no
more than 0.11 mm measured with dial indicator.
MLD099G
(e) Examine the rear hub flange plate surface runout.

(1) Measuring with a dial indicator, the plate surface
runout should be no more than 0.03 mm.
If the swing exceeds the maximum value, replace the rear axle
hub and bearing assembly.
(f) Install the rear brake disc.
(g) Install the rear brake caliper.
(h) Install the rear wheel.
MLD100G
Overhauling
Hint:
Repair the right side in the maintenance procedure as the left.
1. Remove the rear wheel LH.
2. Remove the rear axle hub nut LH.
3. Remove the rear shock absorber LH (See page 6-18).
4. Remove the rear drive shaft LH (See page 4-17).
MLD017G
5. Remove the rear brake caliper LH.

(a) Remove 2 bolts and the front wheel brake caliper assem-
bly LH from the rear hub bearing seat.
Caution: Use a cord or other tools to avoid the brake
caliper suspending.
MLD101G
Drive System 4-47
6. Remove the rear axle hub LH and bearing assembly.

(a) Remove 4 bolts and gaskets.
(b) Remove the rear axle hub and bearing assembly.
MLD102G
7. Install the rear axle hub LH and bearing assembly.

(a) Use 4 bolts and gaskets to install the rear axle hub and
bearing assembly.
Torque: 85±5 N·m
MLD102G
8. Install the rear brake caliper LH.

(a) Remove 2 bolts and the front wheel brake caliper assem-
bly LH from the rear hub bearing seat.
9. Install the rear drive shaft LH.
10. Install the rear shock absorber LH.
11. Install the rear axle hub nut LH.
12. Check whether the rear axle swings and has clearance
(See page 4-46).
MLD101G
Rear Axle Hub Bolt LH Replacement

Hint:
Component: See page 4-45
1. Remove the rear wheel.
2. Remove the rear wheel brake caliper.
3. Remove the rear wheel brake disc.
4. Remove the rear axle hub bolt LH.
(a) Use the SST and screwdriver or similar tools to remove
the left hub bolt.
MLD103G
5. Install the rear axle hub bolt LH.

(a) As shown in the figure, install the washer and nut on the
new rear hub bolt LH.
(b) Use a screwdriver or similar tools to attach the hub and
bearing assembly and tighten the nuts to install the rear
hub bolt LH.
6. Install the rear wheel brake disc.
7. Install the rear wheel brake caliper.
Washer Nut MLD104G
Drive System 4-49
Clutch
The following table places the suspected parts in numerical sequence to confirm the reasons for the problems. In-
spect, repair, or replace parts in the procedures listed in the following pages, if necessary.
Problem Location in Question Reference Page (s)

1. Engine mount (loose) -
2. Clutch driven disc assembly (excessive runout) 4-55
3. Clutch driven disc assembly (oil build-up) -
Clutch vibration 4. Clutch driven disc assembly (worn) 4-55
5. Clutch driven plate torsion damper (damaged) -
6. Clutch driven disc assembly (polished) 4-55
7. Diaphragm spring (the top end is not aligned) 4-57
Clutch pedal cannot return to the 1. Clutch pedal spring is broken Replace
original position 2. Clutch pedal spring's fixed end comes off Check, fix
1. Clutch release bearing subassembly (worn and

torn, dirty, or damaged) -
2. Clutch driven plate torsion damper (damaged) -
Clutch makes abnormal noises
3. Bushing or connecting pin is seriously worn out Replace
4. Clutch pedal spring is broken Replace
5. Clutch pedal spring's fixed end comes off Check, re-fix
2. Clutch driven disc assembly (worn) 4-55
Clutch slips 3. Diaphragm spring (damaged) -
4. Pressure plate (deformed) -
5. Flywheel subassembly (deformed) 4-56
1. Clutch driven disc assembly (installed incorrectly) 4-56

2. Clutch driven disc assembly (excessive runout) -
3. Clutch driven disc assembly (ruptured) -
Insufficient clutch separation 4. Clutch driven disc assembly (dirty or burnt) -
6. Clutch driven disc assembly (lack of grease on the
spline) -
Clutch Pedal Subassembly Components
Cowl assembly
Clutch switch
assembly
16±2
Clutch cable assembly
5±1
Clutch pedal assembly
Transmission assembly

MLD105G
Clutch Pedal Replacement

1. Remove the clutch and brake pedal assembly.
(a) Disconnect the connector between clutch start switch and
brake switch assembly.
(b) Use a No.13 socket, lever, and quick wrenches to remove
the six lock nuts that fasten the pedal.
(c) Remove the clutch cable connector from the clutch pedal
arm.
MLD106G
Drive System 4-51
2. Remove the clutch cable assembly.

(a) Use a No.14 socket to release the adjusting nut at the end
of the cable, take out the screw rod, remove the cylindri-
cal pin, spring and gasket, and take out the cable from
the cable bracket hole.
(b) Open the fixing clamp and remove the cable.
(c) Use a No.10 wrench to remove the cable lock nut from
the front cowl panel and take out the clutch cable.
MLD107G
3. Remove the clutch start switch assembly.

(a) Remove 2 nuts and clutch start switch assembly from the
bracket.
MLD108G
4. Remove the clamp from the clutch pedal shaft.

(a) Remove the clutch pedal shaft and nut.
(b) Remove the clutch spring.
(c) Remove the clutch pedal from the clutch pedal bracket.
MLD109G
5. Remove the clutch pedal shaft.
MLD110G
6. Remove the clutch pedal bushing.

(a) Remove the clutch pedal arm from the clutch pedal
bracket.
(b) Remove the clutch spring.
(c) Remove 2 bushings from the clutch pedal.
MLD111G
7. Remove the U-clamp on the clutch pedal arm.

(a) Use needle nose pliers to remove the U-clamp bushing
from the clutch pedal.
MLD112G
8. Install the U-clamp on the clutch pedal arm.

(a) Coat common grease in the exterior of the new U-clamp.
(b) Install the U-clamp on the clutch pedal.
MLD113G
9. Install the clutch pedal bushing.

(a) Coat common grease on both sides of the 2 new bush-
ings.
(b) Install 2 bushings onto the clutch pedal.
MLD114G
10. Install the clutch pedal shaft.

(a) Install spring on the clutch pedal arm and place it on the
clutch pedal bracket.
(b) Install the clutch pedal connection shaft.
MLD110G
11. Install the clutch pedal shaft clamp.

Caution:
The clamp should be clipped into the slot of the clutch
pedal shaft.
MLD109G
Drive System 4-53
12. Install the clutch switch.

(a) Install the lock nut and adjusting nut of the clutch switch.
MLD108G
13. Install the clutch cable assembly.

(a) Use a No.10 wrench to fasten the cable lock nut on the
front cowl panel.
Torque: 5±1 N·m
(b) Fix the clutch cable with a fixing clamp.
(c) The clutch cable passes through the bracket hole. Install
a cylindrical pin, spring, gasket, and lever. Use a No.14
socket to fasten the adjusting nut at the end of the cable.
MLD107G
14. Install the clutch and brake pedal assembly.

(a) Install the clutch cable connector on the clutch pedal
arm.
(b) Use a No.13 socket, lever, and quick wrenches to install
the six lock nuts on the clutch and brake pedal assembly.
Torque: 23±3 N·m
(c) Connect the connector between clutch start switch and
brake switch assembly.
MLD106G
Clutch Assembly Components
Flywheel subassembly
Clutch driven disc assembly

Clutch cover assembly
Release rocker
limiting clasp
Release rocker
assembly
Bushing I Clutch housing
Release fork
assembly
Bushing II
Release bearing assembly
MLD115G
Drive System 4-55
Clutch Assembly Overhaul

1. Remove the propeller axle assembly.
2. Remove the clutch release fork subassembly.
(a) Remove the clutch release fork from the propeller axle
assembly.
3. Remove the clutch release fork dust cover.
4. Remove the clutch release bearing assembly.
(a) Remove the clutch release bearing assembly from the
clutch release fork.
5. Release the release bearing hub clamp spring.
MLD116G
6. Remove the release fork bracket.
(a) Remove bracket and release the fork from the propeller
axle.
7. Remove the clutch cover assembly.
(a) Align the installation mark on the clutch cover assembly
to the corresponding installation mark on the flywheel
subassembly.
(b) Release every fixing bolt one circle every time until the
spring tension is released totally.
(c) Remove the fixing bolt and clutch cover assembly.
Caution: Do not let the clutch-driven disc fall off.
Installation mark ALE081G
8. Remove the clutch-driven disc assembly.
9. Check the clutch-driven disc assembly.

(a) Use a vernier caliper to measure the depth of the rivet
head.
Minimum rivet depth: 1.3 mm
Replace the clutch-driven disc assembly if necessary.
(b) Install the clutch-driven disc assembly onto the propeller
axle assembly.
Caution: Do not install the clutch-driven disc assembly in
ALE082G
the wrong direction.
(c) Use a dial indicator to examine the runout of the clutch-
driven disc assembly.
Minimum runout: 1.0 mm
Replace the clutch-driven disc assembly if necessary.
Propeller axle side
ALE083G
10. Check the clutch cover assembly.

B (a) Use a vernier caliper to measure the wearing depth and
A width of diaphragm spring.
Maximum value:
A (depth): 0.5 mm
B (width): 6.0 mm
Replace the clutch cover assembly if necessary.
ALE084G
11. Check the flywheel subassembly.

(a) Use a dial indicator to check whether the flywheel subas-
sembly has runout.
Maximum runout: 0.1 mm
Replace the flywheel subassembly if necessary.
ALE085G
12. Check the clutch release bearing assembly.

(a) When applying forces in an axial direction, rotate the re-
lease bearing with hands.
Hint:
This bearing is permanently lubricating. No cleaning or lubri-
cating is needed.
Replace the release bearing assembly if necessary.
ALE086G
13. Install the clutch-driven disc assembly.

(a) Insert the SST into the clutch-driven disc assembly and
SST
then insert them into the flywheel subassembly.
Caution:
Flywheel Do not install the clutch-driven disc assembly in the
side
wrong direction.
ALE087G
Drive System 4-57
14. Install the clutch cover assembly.

5
SST 1 (Temporary) (a) Align the installation mark on the clutch cover assembly
3 to the corresponding installation mark on the flywheel
subassembly.
6 (b) As shown in the figure, tighten the six bolts from the one
4 near the top restrict pin.
Torque: 19 N·m
2 Hint:
Installation mark ALE088G
Tighten the bolts gradually in the sequence shown in the figure.
After examining and confirming that the driven disc is in the
center, move the SST lightly to tighten the bolts.
15. Check and adjust the clutch cover assembly.
(a) Use a dial indicator with a roller to measure the top
height gap of diaphragm spring.
Maximum gap: 0.5 mm
ALE089G
(b) If the gap is not in the specified range, adjust with the
SST.
16. Install the release fork bracket.
(a) Install the release fork bracket onto the propeller axle as-
sembly.
Torque: 37 N·m
17. Install the clutch release fork dust cover.
SST 18. Install the release bearing hub clamp spring.
ALE090G
19. Install the clutch release fork subassembly.

(a) Coat release hub grease onto the contact surface of the
release fork and release the bearing assembly, contact
surface of release fork and push rod, and release fork
point.
(b) Install the release fork onto the release bearing assembly.
20. Install the clutch release bearing assembly.
Release hub grease (a) Coat clutch spline grease onto the input shaft slpine.
MLD117G
(b) Install the bearing on the release fork and then install
them onto the propeller axle assembly.
Caution:
After the installation, move the release fork back and
forth to examine and confirm whether the clutch release
bearing slides smoothly.
21. Install the propeller axle assembly.
Transmission 5-1
Transmission
Transmission's Introduction and External Schematics.....................5-3

Main technical parameters............................................................5-4
Thread fastening piece tightening torque table.............................5-5
Transmission assembly propeller section.....................................5-6
Troubleshooting............................................................................5-7
Maintenance areas of importance.................................................5-8
Transmission Assembly Inspection..................................................5-9
Transmission removal...................................................................5-9
Transmission cleaning................................................................5-12
Transmission inspection.............................................................5-12
Transmission installation.............................................................5-12
Bearing gaskets selection...........................................................5-16
Differential Assembly......................................................................5-17
Components................................................................................5-17
Differential Assembly Removal...................................................5-17
Differential Assembly Installation................................................5-19
Transfer Case Assembly................................................................5-21
Components................................................................................5-21
Transfer Case Removal..............................................................5-23
Transfer Case Installation...........................................................5-27
Adjusting Method of Gear Surface Contact....................................5-33
Input Shaft Assembly......................................................................5-35
Components................................................................................5-35
Input Shaft Assembly Removal...................................................5-36
Measurement of the axial and
radial clearances of the gears and synchronizer allowance.......5-36
Input shaft assembly installation explanation..............................5-37
Output Shaft Assembly...................................................................5-40
Components................................................................................5-40
Output Shaft Assembly Removal................................................5-41
Measurement of the axial and
radial clearances of gears and synchronizer ring allowance......5-42
Output Shaft Assembly Installation.............................................5-43
Maintenance of the Housing Assembly..........................................5-46

Maintenance of the Clutch Housing Assembly............................5-46
Maintenance of the Transmission Case Assembly.....................5-49
Maintenance of Other Common Easily-Damaged Parts................5-52
Maintenance of the shift forks and shift fork shafts.....................5-52
Manipulation Lid Assembly Maintenance....................................5-53
Maintenance of the back-up lamp switch....................................5-55
Transmission 5-3
Transmission's Introduction and External Schematics

The 35001T1B-03 transmission is a step mechanical transmission with differential, two-shaft front wheel drive
application. The forward gear has adopted the inertia synchronizer gear-shifting mechanism, which offers smooth
and easy gear shifting, reduces noise dramatically, and improves the service life of the gear - important in achiev-
ing the overall economical efficiency. Regarding its control mechanism, the set steel ball and spring allow for
gear shifting to be quick and accurate with solid handling. The 5th gear transmission is equipped with an inter-
locking mechanism to prevent accidentally switching to reverse and to improve driving comfort and reliability. A
four-drive transfer case is added to make the passing ability of the vehicle better and the power more abundant.
MLE001G
The model and information of the transmission reflect on the transmission assembly number (transmission case).
When undergoing maintenance, confirm the model of the transmission according to the transmission assembly
number and then replace the components for the transmission according to corresponding assembly list.
Main technical parameters

Basic parameters of the 35001T1B-03 transmission
Max. input torque 138 N·m/4400
Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ R
Speed ratio for each gear
3.545 1.905 1.310 0.970 0.816 3.250
Main deceleration ratio 4.313
Transmission ratio of transfer case 18/41
Odometer speed ratio 31/35
Center distance (mm) 70
Lubricant capacity (L) 1.9±0.15 (transmission) 0.83±0.15 (transfer case)
Transmission GL-4 80W/90 (Domestic oil),
GL-5 140 (High-temperature region model for export),
Lubricant type
GL-4 75W-90 (Alpine region model for export)
Transfer case SAE75W-90 GL-5
Net weight (kg) 36.2+14.3=50.5
Match engine GW4G13
MLE002G
Inspect the axial play (δ) between the synchronizer ring and the gear shaft
Shift position Ⅰ(δ1) Ⅱ(δ2) Ⅲ(δ3) Ⅳ(δ4) Ⅴ(δ5)
Standard clear-
0.8-1.6 0.8-1.6 0.8-1.6 0.8-1.6 0.8-1.6
ance (mm)
Check the axial play (δ) between each gear
Shift position Ⅰ(δ1) Ⅱ(δ2) Ⅲ(δ3) Ⅳ(δ4) Ⅴ(δ5)
Axial play (mm) 0.1-0.3 0.205-0.455 0.125-0.275 0.175-0.425 0.175-0.445
Transmission 5-5
Thread fastening piece tightening torque table

Tightening Specifications
Parts Used Bolt code Quantity (pcs)
torque (N·m)
Clutch housing × Cable bracket 1706124-001 3 11.3±3.4 M8 × 1.25
Clutch housing × Release fork support nail 1601013-001 1 36.8±7.4 M10 × 1.25
Clutch housing × Guide plate 1701027-001 1 11.3±3.4 M8 × 1.25
Clutch housing × Output shaft's roller bearing M8 × 1.25
Q1420812 1 11.3±3.4
plate
Transmission case × Lock plug 1702583-001 2 24.5±3.4 M12 × 1.25
Shift fork shaft × Shift fork 1702115-001 4 15.7±3.1 M6 × 0.75
Clutch housing × Lock plug 1702583-001 1 24.5±3.4 M12 × 1.25
Clutch housing × Reverse gear arm bracket M8 × 1.25
1702435-001 2 17.2±3.4
subassembly
Transmission case × Neutral position locating M18 × 1.5
1702550-001 1 29.4±5.9
seat
Transmission case × Reverse gear lock plug 1702574-001 1 12.7±3.4 M10 × 1.25
Transmission case × Input (output) shaft guide M8 × 1.25
1701021-001 2 17.2±3.4
plate
Transmission case × Reverse gear locating M14 × 1.5
1702560-001 1 39.2±11.7
seat subassembly
Transmission case × Back-up lamp switch 1701014-001 1 40.2±12 M18 × 1.5
Transmission case × Oil filling/drain plug 1701013-001 2 39.2±11.7 M18 × 1.5
Transmission case × Clutch housing 1701022-001 13 29.4±5.9 M8 × 1.25
Transmission case × Clutch housing Q1840845 3 29.4±5.9 M8 × 1.25
Transmission case × Rear housing Q1420820 9 18.1±3.4 M8 × 1.25
Transmission case × Gear shifting arm bracket Q1841025TF2 2 24.5±3.4 M10 × 1.25
Transmission case × Manipulation lid subas- M10 × 1.25
Q1421025-1.25 2 19.6±3.4
sembly
Transmission case × Manipulation lid subas- M10 × 1.25
Q1421030-1.25 2 19.6±3.4
sembly
Transmission case × Bearing plate 1701030-001 5 27.4±5.9 M8 × 1.25
Transmission case × Reverse gear idler shaft 1701493-001 1 29.4±8.8 M8 × 1.25
Output shaft × Output shaft lock nut 1701253-001 1 118 ±7.4 M18 × 1.5
Gear shifting arm bracket × Gear shifting arm M8 × 1.25
1703113-001 1 11.8±2.4
subassembly
Differential case × Differential gear ring 2303110-001 8 77.4±7.4 M11 × 1
Clutch housing × Release cylinder assembly 1609021-001 2 11.8±2.4 M8 × 1.25
Transmission assembly propeller section
MLE003G
Transmission 5-7
Troubleshooting
Common problems Possible causes Troubleshooting
Not applying clutch Use proper driving method
Insufficient clutch separation Check and adjust
Difficult gear engagement
Serious abrasion of the synchronizer ring Replace components
Self-locking spring is too hard Replace components
Oil level is too low Fill oil to specified level
Lubricant is of poor quality Replace specified oil
Untimely oil changes Replace oil and damaged parts
Noise is too loud or abnormal Improper gear axial position and clear-
Check and adjust
ance
Damaged bearing Replace components
Gear has a burr or has been knocked Repair or replace the gear
Too much oil is added, oil level too high Make the oil level to specified level
Reinstall, tighten according to require-
Bolt loose or missing
Oil leakage ment
Breather plug fails Replace
Damaged seal Replace
Excessive gear shifting force Replace
Not applying clutch Use proper driving method
Synchronizer is damaged
Synchronizer's spring expansion ring is
Replace
damaged
Control mechanism malfunction Check and adjust
Spring or steel ball missing Install
Self-locking spring malfunction Replace
Gear disengagement
Fork groove of the gear sleeve is worn
Replace
out
Shifting fork is worn out Replace
Oil level is too low Replace parts and fill oil
Lubricant is of poor quality Replace parts and lubricant
Untimely oil replacement causes the oil
Bearing and gear are burned Replace parts and lubricant
to be too dirty
Mixed use of different oils or use of ad-
Replace parts and lubricant
ditives
Synchronizer spring malfunction Replace
The internal groove of the synchronizer
Replace
ring is worn out
The synchronizer ring is seized into the
Difficulty shifting gears Replace
conical surface
Deformed shifting fork or shifting fork
Replace
shaft
Shifting fork is worn out Replace
Maintenance areas of importance

Removal
1. Open the oil drain plug before removal to drain the oil.
2. Use cleaning solvents to clean the exterior of the transmission before removal. Avoid mixing impurities
on the transmission or into the transmission during removing.
3. Use a clean container to hold the removed components to avoid losing any part or mixing with other
parts. Aso check whether any part has not been installed during the installation.
4. Check whether every component works normally during removal and whether it is damaged, deformed,
or has any other problem.
Installation
1. Clean all parts before installation (except rubber pieces and bearings). Use proper methods to clean
the components carefully and thoroughly.
2. When using compressed air to dry parts, the air may raise dust and other particles and cause eyes to
become irritated.
3. All oil seals, shaft retainers, elastic pins, and clasps should not be reused.
4. Tighten all bolts to the specified torque.
5. All rubbing surfaces should be coated with lubricant, and the openings of all oil seals should be coated
with grease. Use SST to press the oil seal into the transmission case and maintain the proper installa-
tion. Be careful while installing to avoid scratching the oil seal and causing oil leakage.
6. During installation of the bearings, do not use any kind of rolling element to transmit pressure, and
make sure not to tilt it.
7. During the installation of the synchronizer components, the two sides of the spring piston's openings
should alternate.
8. Pay special attention to the parts that have requirement a regarding installation direction.
9. Coat with the specified sealant at the specified position. Clear the sealant on the contact surface before
coating and install parts within 10 minutes after coating.
Transmission 5-9
7 Transmission Assembly Inspection

6
5 Transmission removal
4 1. Place the transmission that has had the oil drained on
8 the work bench.
Remove all peripheral components with tools, remove the
3 transfer case assembly, remove the release shifting fork mech-
anism assembly and release bearing, and finally remove the
back-up lamp switch and neutral position locating seat.
9 2
10 1
1. Transfer case assembly 2. Release bearing

3. Release fork assembly 4. Back-up lamp switch
5. Neutral position locating seat
6. Engine left mount bracket assembly
7. Mount bolt/gear shifting bracket bolt
8. Gear shifting arm assembly
9. Gear shifting cable bracket
10. Shift cable bracket MLE004G
2. Remove the manipulation lid bolt and manipulation lid

assembly.
2 1
1.��
Manipulation
��
lid bolt and spring washer subas-
sembly
2. Manipulation lid assembly MLE005G
3. Use tools to remove the rear cover and corresponding

1 inner parts.
3
4
5
6
1. Rear cover bolt and spring wahser subassembly

2. Rear body subassembly
3. 5th gear hub shaft retainer
4. 5th gear synchronizer assembly
5. 5th gear shift fork
6. Shift fork mounting bolt
MLE006G
2 3 4. Use tools to remove the parts as shown in the figure.

4
1
5
6
1. Shift fork shaft limiting clasp

2. 5th driven gear
3. Output shaft lock nut
4. 5th gear subassembly
5. 5th gear needle bearing
6. 5th gear needle bearing spacer MLE007G
5. Remove the reverse gear idler shaft mounting bolt and

flat washer.
1
1. Reverse gear idler shaft mounting bolt

and flat washer MLE008G
1 6. Remove the lock ball plug, lock ball spring seat, lock ball
2 spring, lock ball, reverse gear locating seat, shift fork
3 7
shaft limiting clasp, plate bolt and flat washer subas-
4
5 sembly, bearing plate, input shaft, output shaft rear ball
bearing stopper ring, and the 13 hexagon bolts for flange
face.
6
4
1. Plate bolt and flat washer subassembly
2. Bearing plate
3. Output shaft rear ball bearing stopper ring
4. Lock ball plug, lock ball spring seat, lock ball spring, lock ball
5. Hexagon bolt for flange face
6. Reverse gear locating seat
7. Input shaft rear ball bearing stopper ring MLE009G
7. Rotate the case 90 degrees to remove the other three

1 hexagon bolts on the flange face.
1. Bolt
MLE010G
Transmission 5-11
8. Remove the transmission case assembly.
1. Transmission case assembly MLE011G
9. Use tools to remove the reverse gear arm bracket mount-

ing bolt, reverse gear idler shaft, reverse gear idler subas-
sembly, and reverse gear arm bracket subassembly.
1
2
3
4
1. Reverse gear idler shaft

2. Reverse gear idler subassembly
3. Reverse gear arm bracket mounting bolt
4. Reverse gear arm bracket assembly MLE012G
3 10. Vertically pull out the input shaft assembly, output shaft
4
assembly, 1st/2nd gear fork shaft assembly, 3rd/4th gear
fork shaft assembly, 5th reverse gear fork shaft assem-
5
bly, and finally remove the differential assembly.
2
1. Clutch housing assembly 2. Differential assembly

3. Output shaft assembly 4. Input shaft assembly
5. Shift fork shaft assembly of each gear MLE013G
Transmission cleaning
After disassembling the transmission, use solvent to clean the
input shaft assembly, output shaft assembly, manipulation lid
assembly, reverse gear idler assembly, clutch housing assem-
bly, transmission case assembly, shift fork assemblies, and the
magnet. Dry with compressed air after cleaning.
Transmission inspection
1. Check whether any gear has cracks, abnormal wear,
or damage. Replace the gear if it has any of the above
problems.
2. Check whether the front and rear bearings and inner ring
of the input and output shafts are damaged, whether
the self-sealing of the bearing is damaged, and whether
there is abnormal sound when rotating the bearing. Re-
place the bearing if it has any of the above problems.
3. Check whether the 1st/2nd gear shift fork, 3rd/4th gear
shift fork, and 5th reverse gear shift fork have abnormal
wear. Replace the fork if any show abnormalities.
4. Check whether the ring on each fork has abnormal wear,
cracks, or deformation. Replace the part if it has any of
the above problems.
Transmission installation
1. After installing the 1st/2nd gear shift fork shaft assembly
and 3rd/4th, 5th reverse gear shift fork shaft assembly,
put them on corresponding synchronizer gear sleeve re-
1 2
spectively.
Caution: Do not miss the two interlocking steel balls.
3
1. Output shaft assembly

2. 1st/2nd shift fork shaft assembly
3. Input shaft assembly
4. 3rd/4th, 5th reverse gear shift fork shaft assembly
MLE014G
Transmission 5-13
3 2. Keep the release bearing surface of the clutch housing

4
assembly downwards, put in the differential assembly,
and then put in the input shaft assembly, output shaft as-
5
sembly, 1st/2nd gear fork shaft assembly, 3rd/4th, and
2 5th reverse gear fork shaft assembly.
1. Clutch housing assembly

2. Differential assembly
3. Output shaft assembly
4. Input shaft assembly
5. Shift fork shaft assembly of each gear MLE013G
3. Put in the reverse gear arm bracket assembly. Use

17.2 N·m to tighten the mounting bolt of the reverse gear
arm bracket. Put in the reverse gear idler subassembly,
1
2 reverse gear idler thrust washer, and reverse gear idler
3 shaft.
4
5
1. Reverse gear idler shaft

2. Reverse gear idler thrust washer
3. Reverse gear idler subassembly
4. Reverse gear arm bracket mounting bolt
5. Reverse gear arm bracket assembly
MLE015G
Caution: The mark line on the reverse gear idler shaft aligns
with the bolt hole A in clutch.
MLE016G
4. Coat sealant on the surface of the transmission case as-

Gluing position sembly as shown in the figure.
MLE017G
5. Put the transmission case assembly and clutch housing

assembly closing box in 13 box closing bolts.
1 Transmission case assembly
MLE011G
6. Install the reverse gear idler shaft mounting bolt and

4 flat washer, lock ball plug, lock ball spring seat, lock ball
6
3 spring, lock ball, reverse gear locating seat, shift fork
5
shaft limiting clasp, input shaft, output shaft rear ball
bearing stopper ring, bearing plate, plate bolt and flat
2 washer subassembly in sequence. Tighten in the speci-
7
6 1
fied torque.
1 Reverse gear idler shaft mounting bolt and flat washer (glue)
2 Hexagon bolt for flange face
3 Input shaft, output shaft rear ball bearing stopper ring
4 Plate bolt and flat washer assembly, bearing plate
6. Lock ball plug, lock ball spring seat, lock ball spring, lock ball
7. Reverse gear locating seat
MLE018G
2 3 7. Install the 5th gear and other components.

4
1
5
6

2. 5th driven gear
3. Output shaft lock nut
4. 5th gear gear assembly
5. 5th gear needle bearing
6. 5th gear needle bearing spacer MLE007G
Transmission 5-15
8. Install the rear cover, 5th gear synchronizer, and other

components.
1
3
4
5
6
1 Rear cover bolt and srping wahser subassembly

2 Rear body subassembly
3 5th gear hub shaft retainer
4 5th gear synchronizer assembly
5 5th gear shift fork
6. Shift fork mounting bolt MLE019G
9. Rotate the transmission 90°, screw in 3 bolts in clutch

1 housing, and tighten in the specified torque.
1. bolt
MLE020G
10. Install the manipulation lid assembly.

Caution: Coat glue on the two manipulation lid mounting
bolts at the bottom.
2 1
1. Manipulation lid bolt and spring washer assembly

2. Manipulation lid assembly MLE021G
11. Install the release bearing subassembly, release shift

fork subassembly, air filter bracket assembly, engine
mount, neutral position locating seat, back-up lamp
switch, gear shifting arm assembly, steering bracket and
other gear shift mechanism subassembly, manipulation
lid bolt, and transfer case assembly. Tighten in the speci-
fied torque to finish the entire installation.
MLE022G Bearing gaskets selection

If the input shaft, output shaft or gear, hub, or bearing on the
shaft is replaced during maintenance, measure the axial play
during installation, and select the proper gasket and shaft re-
tainer to satisfy the requirement of axial play. If the transmis-
sion case, clutch housing, differential case, or front/rear bear-
ing of differential is replaced, measure the differential rotation
starting torque when installing.
Standard start torque:
New bearing: 0.78-1.57 N·m
Worn in bearing: 0.49-0.98 N·m
Transmission 5-17
Differential Assembly
Components
Differential inner oil seal (2)

Front tapered roller bearing
Oil seal retaining ring

Odometer drive gear
Bolt for flange face (8)
Cylindrical pin
Axle shaft gear adjusting gasket (2)

Differential case
Axle shaft gear (2)
Differential ring gear

Planetary gear (2)
Planetary gear shaft
Planetary gear spherical

gasket (2)
Rear tapered
roller bearing
MLE023G
For the removal and installation of the differential assembly, this manual only provides the common installation
and removal procedures. However, during actual maintenance, the odometer drive gear, differential ring gear, and
front/rear tapered roller bearing can be removed and installed separately.
Differential Assembly Removal

1. Use the SST to remove the front/rear tapered roller bear-
ing of the differential and remove the odometer drive
gear.
MLE024G
2. Remove 8 bolts on the flange face and remove the dif-

ferential ring gear.
MLE025G
3. Use the SST to remove the cylindrical pin that attaches

Tool removal hole
the planetary gear shaft.
MLE026G
4. Remove the planetary gear shaft.
MLE027G
5. Remove the planetary gear and axle shaft gear.
MLE028G
6. Use the SST to remove the two inner oil seals of the dif-
ferential and one oil seal retaining ring.
MLE029G
Transmission 5-19
Areas of importance before installing

1. Replace with a new component after removing the front/
rear bearing of the differential.
2. Clean all parts except the bearing before installing and
check whether any component has abnormal wear and
tear or is damaged.
3. Make sure no component (especially) is bumped during
removing.
Differential Assembly Installation

1. Install the axle shaft gear.
Install two axle shaft gear adjusting gaskets on the axle shaft
gear and then put then into the differential case.
MLE030G
2. Install the planetary gear.

Put the spherical gasket on the planetary gear and insert be-
tween two axle shaft gears, and then rotate the two planetary
gears simultaneously to align the holes to the two holes install-
ing planetary gear shaft in the differential case.
MLE031G
3. Install the planetary gear shaft.

Put the planetary gear shaft through the two planetary gears
and align the pin hole in the shaft to the pin hole in the differ-
ential case.
MLE032G
4. Pound into the cylindrical pin with SST.

Install the rear-riveted differential case to avoid the cylindrical
pin falling off.
MLE033G
5. Install the differential ring gear and 8 bolts for the flange
face.
Put the differential ring gear on the differential case, align the
holes, and install. Then use a 77.4 N·m tightening torque to
tighten the bolts for the flange face.
MLE034G
6. Use the SST to press fit the front/rear tapered roller

bearing. Put in the odometer drive gear before press fit-
ting the front tapered roller bearing.
MLE035G
7. Use the SST to press and fit two inner oil seals of the
differential and one oil seal retaining ring. Refer to the
figure on the right after installing.
MLE036G
8. Finish the installation of the differential.
MLE037G
Transmission 5-21
Transfer Case Assembly

Components
Hexagon bolt for flange face Hexagon bolt for flange face
Oil filling plug II
Oil drain plug with magnetic transfer case
Mounting bolts with washer

Rubber plug
Right oil seal of the transfer case

Axle shaft bearing bushing
Oil filling/drain plug
Transfer case
Restrict pin of front cover

Right retainer of the input shaft
Right bearing adjusting
gasket of the input shaft
Mounting bolt for bearing seat
Right bearing of the input shaft
Right bearing seat of the input shaft
Left bearing of input shaft
Left bearing adjusting

gasket of the input shaft
Restrict pin of front cover
Left oil seal of the transfer case
MLE038G
Output shaft O-ring
Output shaft lock nut
Transfer case driven bevel gear

Output shaft adjusting gasket
Double-line angle contact

ball bearing assembly
Rear oil seal of the transfer case

Knurled thumb bolt
Transfer case output shaft
Output shaft dust cover
Knurled thumb bolt
Right bearing of the input shaft Bevel gear mounting bolt
Transfer case input shaft
Transfer case input drive bevel gear

Left bearing of input shaft
Bevel gear mounting bolt
Transfer case front cover

Breather plug
Double-head bolt
Restrict pin
Front cover connection hexagon bolt for flange face

Front cover connection hexagon bolt for flange face II
MLE039G
Transmission 5-23
Transfer Case Removal

1. Remove the double-head bolt and restrict pin.
Place the transfer case that has been drained of oil on the work
bench and remove the four double-head studs and two restrict
pins.
2
1
1. Double-head bolt 2. Restrict pin
MLE040G
To remove the double-head stud, tighten the two nuts reversely

1
and then screw on the first nut. For installation, screw on the
second nut.
1. Hexagon nut for flange face

2. Hexagon nut for flange face MLE041G
2. Remove the oil drain plug of the magnetic transfer case,

oil filling plug II, and oil filling/drain plug.
Use a No.24 socket wrench to remove the oil drain plug of
1 2
the magnetic transfer case and turn the oil filling/drain plug
counterclockwise. Then use a No.10 inner hexagon wrench to
3
remove the oil filling/drain plug counterclockwise.
1. Oil drain plug with magnetic transfer case

2. Oil filling plug II
3. Oil filling/drain plug
MLE042G
3. Use a No.14 socket wrench to remove the hexagon bolt

1 for the flange face counterclockwise.
2
1. Hexagon bolt for flange face

MLE043G
4. Remove the output shaft assembly.
MLE044G
1 2 5. Remove the front cover connection hexagon bolt for the

2 1 flange face.
Use a No.14 socket wrench to remove the front cover connec-
tion hexagon bolt for the flange face and front cover connec-
tion hexagon bolt for flange face 2 counterclockwise.
1 1 1 MLE045G
6. Tap lightly to remove the transfer case front cover and

then remove the front cover restrict pin.
MLE046G
3
7. Remove the rubber plug and right bearing seat of the in-
put shaft.
4 Use a No.14 socket wrench to remove the mounting bolt with
a washer and mounting bolt of the bearing seat counterclock-
wise. Remove the rubber plug and right bearing seat of input
2 shaft.
1
1. Mounting bolts with washer
2. Rubber plug
3. Mounting bolt for bearing seat
4. Right bearing seat of the input shaft MLE047G
2
8. Remove the input shaft assembly.
1 Use a screwdriver to tap the right retainer of the input shaft at
the right hole and remove the right bearing adjusting gasket of
the input shaft and input shaft assembly.
1. Right retainer of the input shaft

2. Right bearing adjusting gasket of the input shaft
MLE048G
Transmission 5-25
1
9. Use a screwdriver to remove the right oil seal of the
transfer case.
1. Right oil seal of

the transfer case
MLE049G
10. Tap out the left oil seal of the transfer case lightly from
the left hole.
1. Left oil seal of the transfer case

MLE050G
11. Use screwdriver to tap the left bearing adjusting gasket

1 of the input shaft lightly at the three notches.
1. Left bearing adjusting gasket of the input shaft

MLE051G
12. Remove the transfer case input drive bevel gear.

Attach the input shaft assembly first. Use a No.15 socket
wrench to loosen the bevel gear mounting bolt counterclock-
wise, and then remove the transfer case input drive bevel gear.
MLE052G
13. Use the SST to remove the left bearing and right bearing
2 of the input shaft respectively.
1
1. Left bearing of input shaft

2. Right bearing of input shaft MLE053G
14. Remove the output shaft O-ring.
MLE054G
15. Use the SST to fix the groove in the lock nut of the out-
put shaft to make the removal easier.
MLE055G
16. Use a No.30 socket wrench to remove the lock nut of the
output shaft counterclockwise.
MLE056G
17. Remove the transfer case output shaft.

1
Use the SST to lock the connection of the transfer case driven
2
bevel gear and double-line angle contact ball bearing assembly
and then tap on the transfer case output shaft.
1. Transfer case driven bevel gear

2. Double-line angle contact ball bearing assembly
MLE057G
18. Remove the transfer case driven bevel gear.

Use the SST to lock the connection of the transfer case driven
bevel gear and double-line angle contact ball bearing assem-
bly. Then tap on the transfer case driven bevel gear.
MLE058G
Transmission 5-27
19. Remove the output shaft dust cover with SST.

1
1. Transfer case output shaft

2. Output shaft dust cover MLE059G
Transfer Case Installation

1 1. Install transfer case driven bevel gear.
Put the selected transfer case output shaft adjusting gasket on
2
the transfer case driven bevel gear, and then use the SST to
3 press the top surface of transfer case driven bevel gear until it
reaches the bottom.
1. Transfer case driven bevel gear Caution: When pressing, apply force only to the inner
2. Transfer case output shaft adjusting gasket
3. Double-line angle contact ball bearing assembly ring of the double-line angle contact ball bearing assem-
MLE060G
bly.
2. Output shaft dust cover.
Place the transfer case output shaft on the work bench and
then use the SST to press fit the output shaft dust cover until it
1 reaches the bottom.
1. Output shaft dust cover

2. Transfer case output shaft MLE061G
3. Press the installed driven bevel gear and double-line

angle contact ball bearing assembly on the transfer case
output shaft until it reaches the bottom.
MLE062G
4. Tighten the output shaft lock nut.

Insert two pins into the opposite holes below the output shaft
and then attach to the vise and tighten output shaft lock nut
with specified torque.
Output shaft lock nut: 118±7.4 N·m
MLE063G
5. Use a punch to punch the edge of the output shaft lock

nut to the slot of the output shaft.
MLE064G
6. Install the knurled thumb bolt.

Install two knurled thumb bolts on the output shafts and then
use a tool to support them. Tap the rear side of the output shaft
until the knurled thumb bolts reach the bottom.
MLE065G
7. Put the output shaft O-ring on the double-line angle con-

tact ball bearing.
1. Output shaft O-ring

MLE066G
8. Press fit the right bearing inner ring of the input shaft.
Place the transfer case input shaft on the SST and then use the
SST to press fit the right bearing inner ring of the input shaft
to the bottom.
MLE067G
9. Press fit the left bearing inner ring of the input shaft.
Place transfer case input shaft on the SST inversely and then
use the SST to press fit the left bearing inner ring of the input
shaft to the bottom.
MLE068G
Transmission 5-29
10. Press fit the transfer case input drive bevel gear.
Use the SST to press the transfer case input drive bevel gear
into the transfer case input shaft.
Caution: Align the thread holes when pressing.
MLE069G
11. Fasten the drive bevel gear mounting bolt.

Use the SST to attach the transfer case input shaft. Tighten the
bevel gear fixing blot clockwise with No.15 socket wrench
and use a torque wrench to conduct torque calibration.
MLE052G
12. Install the input shaft left bearing adjusting gasket and
outer ring.
Place the selected input shaft left bearing adjusting gasket
into the left bearing hole of the transfer case and use the SST
to press fit the left bearing outer ring of the input shaft until it
2
reaches the bottom.
1
Caution: Align the outer ring of the bearing and the holes
1. Left bearing adjusting gasket of the input shaft before installing, otherwise it may damage the case.
2. Left bearing outer ring of input shaft MLE070G
13. Insert the installed input shaft assembly into the transfer
case.
MLE071G
14. Install the right bearing adjusting gasket and outer ring
2 of input shaft.
1
Put in the right retainer of the input shaft first and then press
the selected right adjusting gasket of the input shaft to the bot-
tom.
1. Right retainer of the shaft

2. Right bearing adjusting gasket of the input shaft
MLE072G
15. Refer to the figure after press fitting.
MLE073G
16. Install the right bearing seat of the input shaft.

Tighten the bearing seat mounting bolt clockwise with No.14
socket wrench and use a torque wrench to conduct torque cali-
bration.
Bearing seat mounting bolt: 39.2±5.9 N·m
MLE074G
17. Adjust the start torque of the bearing.

Place the transfer case as shown in the figure. Use SST to con-
duct calibration of the start torque of the bearing. If the start
torque is in the specified range, do not adjust the gasket. If the
start torque is too big, reduce the thickness of the gasket. If the
start torque is too small, increase the thickness of the gasket,
until the torque reaches the specified range.
MLE075G
18. Install the front cover restrict pin and coat dye on the
bevel gear.
The reveled height of the restrict pin is half of the total length.
Coat dye on the transfer case input drive bevel gear evenly.
MLE076G
19. Use a small brush to coat the dye evenly on the transfer
case driven bevel gear surface of the output shaft as-
sembly.
MLE077G
Transmission 5-31
20. Put on the front cover of the transfer case and then in-
stall the transfer case output shaft assembly.
MLE078G
21. Check the contact of the gear and gear surface.

Install two hexagon bolts for the flange face (not adjacent) in
the input shaft of the transfer case. Use SST to lock the input
shaft and forcibly twist the output shaft assembly in both di-
rections simultaneously. Then, open the front covers respec-
tively and remove the output shaft assembly to observe the
contact of the hyperboloidal gear and gear surface.
Refer to the section entitled "Adjusting Method of Gear
MLE079G
Surface Contact."
22. Use the SST to examine whether the clearance between
the drive gear and driven gear is in the specified range.
MLE080G
23. Install the transfer case front cover.

After adjusting the contact point and clearance, glue on the trans-
fer case front cover, tighten all the bolts of front cover and output
shaft, and use a torque wrench to conduct the calibration of torque.
Hexagon bolt for flange face: 29.4±5.9 N·m
Front cover connection hexagon bolt for flange face:
29.4±5.9 N·m
Front cover connection hexagon bolt for flange face II:
MLE081G 29.4±5.9 N·m
24. Use the SST to press fit the right oil seal of the transfer
case into position.
1. Right oil seal of the transfer case

MLE082G
25. Press fit the axle shaft bearing bushing.

Caution: Align axle shaft bearing bushing hole to the
thread hole in the case before press fitting.
MLE083G
26. Install the oil drain plug of the magnetic transfer case, oil
filling plug II, and oil filling/drain plug.
1 2 Use a No.24 socket wrench to tighten the oil drain plug of the
magnetic transfer case and oil filling/drain plug clockwise.
Use a No.10 inner hexagon wrench to tighten oil filling plug II
3 clockwise and use a torque wrench to conduct the calibration
of torque.
Oil drain plug of magnetic transfer case: 39.2±11.7 N·m
Oil filling plug II: 39.2±11.7 N·m
1. Oil drain plug with magnetic transfer case Oil filling/drain plug: 39.2±11.7 N·m
2. Oil filling plug II
3. Oil filling/drain plug
MLE042G
27. Use the SST to press fit the left oil seal of the transfer
case into position.
1. Right oil seal of the transfer case

MLE084G
28. Install the double-headed bolt and restrict pin.

Tighten the glued side of the double-headed stud to the bot-
tom. Press in the restrict pin to half of its length.
1
1. Double-headed bolt
2. Restrict pin
MLE085G
Transmission 5-33
29. Install the breather plug with SST.
1. Breather plug
MLE086G
Adjusting Method of Gear

A
Surface Contact
1. Contact style of standard gear surface.
A. Smaller end of the gear
B. Working gear surface (the bearing surface when forward
B C D driving)
C. Bigger end of the gear
MLE087G
D. Non-operating gear surface (the bearing surface when
driving in reverse)
2. Contact style of gear surface when the installation dis-

A tance of the drive gear is too big.
Reason: The drive gear is too close to the driven gear.
B C D
MLE088G
Correction method: Replace the thin right adjusting gasket of

A the input shaft.
B D
C
MLE089G
3. Contact style of gear surface when the installation dis-

A tance of the drive gear is too small.
Reason: The drive gear is too far from the driven gear.
B D
C
MLE090G
Correction method: Replace the thick right adjusting gasket of

A the input shaft.
B C D
MLE091G
4. If no satisfying gear surface contact point is achieved in

the above method, coordinate the left and right adjusting
gaskets of the input shaft and the adjusting gasket of the
output shaft simultaneously.
MLE092G
Transmission 5-35
Input Shaft Assembly

Components
9
8
7
6
5
1. Input shaft 2. 3rd gear gear subassembly 3. 3rd gear needle bearing
4. 3rd/4th gear synchronizer assembly 5. 3rd/4th gear hub shaft retainer 6. 4th gear needle bearing
7. 4th gear gear subassembly 8. Rear ball bearing of input shaft 9. Rear ball bearing shaft retainer of input shaft
MLE093G
1 Input Shaft Assembly Removal

2
1. Remove the rear ball bearing shaft retainer of the input
3
shaft. Use the SST to press down the 4th gear gear sub-
assembly and rear ball bearing of the input shaft simulta-
neously and remove 4th gear needle bearing.
4
1. Rear ball bearing shaft retainer of input shaft

2. Rear ball bearing of input shaft
3. 4th gear gear subassembly
4. 4th gear needle bearing MLE094G
1 2. Remove the 3rd/4th hub shaft retainer and take out the
2
3 4th gear synchronizer ring. Use the SST to press out the
4 3rd gear gear subassembly and 3rd/4th gear synchroniz-
er assembly and take out the 3rd gear needle bearing.
1. 3rd/4th gear hub shaft retainer

2 4th gear synchronizer ring
3. 3rd/4th gear synchronizer assembly
4 3rd gear gear subassembly
5. 3rd gear needle bearing MLE095G
Measurement of the axial and radial clearances

of the gears and synchronizer allowance
1. Axial clearance control of gears.
Item Data (mm)
Synchronizer ring gear allowance 0.8-1.6
Axial clearance of 3rd gear 0.125-0.275
Axial clearance of 4th gear 0.175-0.425
Caution: Measure the gears and shafts only after wash-
ing and drying to ensure the accuracy and validity of the
MLE096G
dimensions.
2. Radial clearance control of gears.
Measure the radial clearance of the gears after washing and
drying the parts. Compare the results with the table below and
replace with a new input shaft gear and needle bearing if the
Transmission 5-37
results exceed the specified range.

Item Data (mm)
Radial clearance of 3rd gear 0.015-0.058
Radial clearance of 4th gear 0.015-0.058
3. Examine 3rd/4th gear synchronizer ring allowance.
Synchro- Use your hands to press the synchronizer rings onto the gears
nizer ring
flatly and use a feeler gauge to measure the allowance between
Allowance
the gear and synchronizer ring.
If the allowance is smaller than 0.8 mm or bigger than 1.6 mm,
replace the synchronizer ring and measure again. If the allow-
ance of the new synchronizer ring is still smaller than 0.8 mm
Gear subassembly
or bigger than 1.6 mm, replace with a new gear.
MLE097G
4. Areas of importance before installing.

(a) During removal, place the gears, needle bearings, and
synchronizer rings separately, e.g. put the 3rd gear main
gear, 3rd gear synchronizer ring and 3rd gear needle
bearing together, same for 4th gear and 5th gear. Do not
mix when installing.
(b) After washing, check whether the conical surface of any
gear is damaged or has cracks. Replace the gear if the it is.
(c) After washing, check the wear of synchronizer gear
sleeves and lock angles of gears. Replace the synchro-
nizer and gear if they are seriously worn.
(d) If the synchronizer disperses during removal (slider and
spring come out or gear sleeve detaches), please refer to
the section entitled "Maintenance of Synchronizers of
Different Gears."
(e) When installing, we suggest replacing all used clasps and
install claps of the appropriate thickness.
(f) When installing the synchronizer, do not crush the con-
vex plate of the synchronizer ring. Also pay attention to
the installation directions of the gear hub and gear sleeve.
(g) The synchronizer ring gear of the 3rd gear is different
from the one for the 4th gear (has number mark) and they
can't be interchanged.
(h) The removed parts must be washed before installing.
Input shaft assembly installation explanation

1 1. Install the 3rd gear needle bearing.
1. Input shaft
2. 3rd gear needle bearing
MLE098G
2. Install the 3rd gear drive gear subassembly.

Caution: Coat oil on the 3rd gear needle bearing before
1
installing.
2
Oil coating position
1. Input shaft
2. 3rd gear drive gear subassembly
MLE099G
3. Install the 3rd gear synchronizer ring (marked with num-

ber "3").
1 Caution: Coat oil on the conical surface of the 3rd gear
subassembly before installing.
2
1. Input shaft
2. 3rd gear synchronizer ring
MLE100G
4. Install the 3rd/4th gear synchronizer assembly.

Press to press in the synchronizer with tools and press.
1 2 Caution: Align the synchronizer ring groove to the slider
of the synchronizer when installing. Keep the surface of
the gear sleeve outer ring marked with a notch down-
wards (3rd gear direction).
3
Notch mark
1. 3rd/4th gear synchronizer assembly

2. 3rd/4th gear synchronizer press fitting tool
3. Input shaft seat tool MLE101G
5. Use a clasp caliper to install the 3rd/4th gear hub shaft

retainer and put in the 4th gear needle bearing spacer.
1 Install 4th gear synchronizer ring (marked with a number
3 2 "4") and the 4th gear needle bearing.
4 The thickness of the shaft retainer has six specifications and
the installation clearance should be smaller than 0.1 mm.
1. 4th gear needle bearing 3. 3rd/4th gear hub shaft retainer

2. 4th gear needle bearing 4. 4th gear synchronizer ring
MLE102G
Transmission 5-39
6. Install the 4th gear gear subassembly.

Caution: Coat oil on the conical surface of the 4th gear
1
subassembly and needle bearing before installing.
1. 4th gear gear subassembly MLE103G
7. Install the rear ball bearing shaft retainer of the input

shaft and rear ball shaft of the input shaft.
Use the SST to press fit the rear ball bearing of the input shaft
1
and install rear ball bearing shaft retainer of the input shaft.
2
The thickness of the shaft retainer has six specifications and
the installation clearance should be smaller than 0.1 mm.
1. Rear ball bearing shaft retainer of input shaft

2. Rear ball bearing of input shaft
MLE104G
8. Finish the installation of the input shaft.

Caution: After installing input shaft assembly, place the
synchronizer gear sleeve of different gears in the neutral
position. Then, use your hands to check whether the 3rd
gear drive gear and 4th gear driven gear work normally.
Check and reinstall if the gears can't rotate.
MLE105G
Output Shaft Assembly

Components
2
3
4
5
6
7
9
10
11
12
13
14
15
16
1. Output shaft 2. Rear ball bearing of output shaft 3. 4th driven gear
4. 3rd/4th gear spacer 5. 3rd driven gear 6. 2nd gear gear subassembly
7. 2nd gear needle bearing 8. 2nd gear needle bearing spacer 9. 1st/2nd gear hub shaft retainer
10. 2nd gear synchronizer ring gear 11. 1st/2nd gear synchronizer assembly 12. 1st gear synchronizer ring gear
13. 1st gear needle bearing 14. 1st gear gear subassembly 15. 1st gear thrust washer
16. Steel ball Sφ 4.7625
MLE106G
Transmission 5-41
1 Output Shaft Assembly Removal

2 1. Use SST and press to press out the 4th gear driven gear
and rear ball bearing of the output shaft.
Remark: Press out the two parts together.
1. Rear ball bearing of

output shaft
2. 4th gear driven gear
MLE107G
2. Take out the 3rd/4th gear spacer and use the SST and
1
press to press out the 2nd gear subassembly and 3rd
2 gear driven gear.
Remark: Press out the two parts together.
3
1. 3rd/4th gear spacer

2. 3rd gear driven gear
3. 2nd gear gear subassembly
MLE108G
3. Take out the 2nd needle bearing, 2nd gear needle bear-
ing spacer, 2nd gear synchronizer ring gear, and use a
1
clasp caliper to remove the 1st/2nd gear hub shaft re-
2 tainer.
3
4
1. 2nd gear needle bearing

2. 2nd gear needle bearing spacer
3. 2nd gear synchronizer ring gear
4. 1st/2nd gear hub shaft retainer
MLE109G
4. Use the SST and press to press out the 1st gear subas-
sembly, 1st synchronizer ring gear, and 1st/2nd synchro-
nizer assembly.
1
Remark: Press out the three parts together.
1. 1st/2nd gear synchronizer assembly

2. 1st gear synchronizer ring gear
3. 1st gear subassembly
MLE110G
5. Take out the 1st gear needle bearing, 1st gear thrust
washer, and steel ball Sφ 4.7625.
2
3
1. 1st gear needle bearing

2.1st gear thrust washer
3. Steel ball Sφ 4.7625 MLE111G
Measurement of the axial and radial clearanc-

es of gears and synchronizer ring allowance
1. Axial clearance control of gears.
Shift position Ⅰ Ⅱ
Synchronizer ring gear 0.8-1.6 0.8-1.6
allowance (mm)
Axial play of gears (mm) 0.1-0.3 0.205-0.455
MLE112G
2. Radial clearance control of 1st/2nd gears.
Measure the radial clearance of gears after washing and drying
the parts. Compare the results with the table below and replace
new input shaft gear and needle bearings if the results exceed
the specified range.
Item Radial clear- Radial clearance
ance of 1st gear of 2nd gear
Data (mm) 0.015-0.056 0.015-0.056
3. Examine the 1st/2nd gear synchronizer allowance.

Use your hands to press the synchronizer rings on the gears
Synchro-
flatly and use a feeler gauge to measure the allowance between
nizer ring
Allow- the gear and synchronizer ring.
ance If the allowance is smaller than 0.8 mm or bigger than 1.6
Gear sub-
assembly mm, replace the synchronizer ring and measure again. If the
allowance of the new synchronizer ring is still smaller than 0.8
mm or bigger than 1.6 mm, replace with a new gear.
MLE113G
4. Areas of importance before installing
(a) During removal, place the gears, needle bearings, and syn-
chronizer rings separately, e.g. put the 1st gear subassem-
bly, 1st gear synchronizer ring, and 1st gear needle bearing
together - same for 2nd gear. Do not mix when installing.
(b) After washing, check whether the conical surface of any
gear is damaged or has cracks. Replace the gear if it has
them.
(c) After washing, check the wear of the synchronizer gear
Transmission 5-43
sleeves and lock angles of the gears. Replace the syn-

chronizer and gear if they are seriously worn.
(d) If the synchronizer disperses during removal, please refer
to the section entitled "Maintenance of Synchronizers" in
Chapter VII.
(e) When installing, we suggest the replacement of all used
clasps and install claps of an appropriate thickness.
(f) When installing the synchronizer, do not crush the con-
vex plate of the synchronizer ring. Also, pay attention to
the installation directions of the gear hub and gear sleeve.
(g) The synchronizer ring gear of the 1st gear is different
from that of 2nd gear (has number marked) and they
can't be interchanged.
(h) The removed parts must be washed before installing.
Output Shaft Assembly Installation

1
1. Install the steel ball Sφ 4.7625 and the 1st gear thrust
washer.
2
1. Steel ball Sφ 4.7625 2. 1st gear thrust washer

MLE114G
2. Install the 1st gear needle bearing and 1st gear subas-
sembly.
Caution: Coat oil on the 1st gear needle bearing before
installing the 1st gear subassembly.
1
2
1. 1st gear subassembly
2. 1st gear needle bearing
MLE115G
3. Install the 1st gear synchronizer ring and use a press and
the SST to press in the 1st/2nd synchronizer assembly.
Caution: Coat oil on the conical surface and spline be-
fore installing. Pay attention to the direction of the syn-
1 chronizer and align the slider to the synchronizer ring
groove during press fitting.
2
1. 1st/2nd gear synchronizer assembly

2. 1st gear synchronizer ring gear MLE116G
4. Use a clasp caliper to install the 1st/2nd gear hub shaft re-
tainer and install the 2nd gear needle bearing spacer. The
thickness of the shaft retainer has six specifications and the
installation clearance should be smaller than 0.1 mm.
1
1. 2nd gear needle bearing gasket

2. 1st/2nd gear hub shaft retainer
MLE117G
5. Install the 2nd gear synchronizer ring and 2nd gear nee-
dle bearing.
1. 2nd gear needle bearing

2. 2nd gear synchronizer ring
MLE118G
6. Install the 2nd gear subassembly. The slider should be

blocked in the slot of the synchronizer ring.
Caution: Coat oil on the conical surface of gear and nee-
dle bearing before installing.
1
1. 2nd gear subassembly

MLE119G
7. Use the SST to press fit the 3rd gear-driven gear.

Caution: Coat oil on the spline before installing.
1. 3rd gear-driven gear

MLE120G
Transmission 5-45
8. Install the 3rd/4th gear spacer and use the SST to press
1 fit the 4th gear-driven gear.
Caution: Coat oil on the spline before installing.
1. 4th gear-driven gear

2. 3rd/4th gear spacer
MLE121G
9. Finish the installation of output shaft assembly.

Caution: After installing the output shaft assembly, place
the 1st/2nd gear synchronizer assembly in the neutral
position. Then, use your hands to check whether the 1st
gear subassembly and 2nd gear subassembly work nor-
mally. Check and reinstall if the gear can't rotate.
MLE122G
1 Maintenance of the Housing Assembly

2 Maintenance of the Clutch Housing Assem-
3 bly
4 Clutch housing assembly removal
5 1. Remove the clutch release shift fork mechanism assem-
bly and release bearing.
1. Release shift fork limiting clasp

2. Release rocker assembly
3. Bushing I
4. Release fork assembly
5. Release bearing
6. Bushing II MLE123G
2. Use the SST to remove the cylindrical roller bearing of

1
2 the input shaft and input shaft oil seal.
Caution: Replace the new bearing and oil seal.
1. Cylindrical roller bearing of input shaft

2. Input shaft oil seal MLE124G
1 3. Use the SST to remove the bearing plate, plate bolt and
2 flat washer subassembly, cylindrical roller bearing of
3 output shaft, and remove the guide nozzle of the output
shaft.
1. Bearing plate, plate bolt and flat washer assembly

2. Cylindrical roller bearing of output shaft
3. Output shaft guide nozzle MLE125G
4. Use the SST to remove the front oil seal of the differential
1
Caution: Replace with the new oil seal.
1. Front oil seal of differential MLE126G

Transmission 5-47
5. Remove the outer ring of the front-tapered roller bearing

1 of the differential and front gasket of the differential.
2
1. Outer ring of the front-tapered roller bearing

2. Front gasket of differential MLE127G
1 6. Take out and clean the magnet, remove the guide plate,
bolt, and spring washer subassembly.
2
1. Guide plate, bolt, and spring washer subassembly

2. Magnet
MLE128G
1 Clutch housing assembly installation

2
1. Use the SST to press fit the input shaft oil seal and ta-
pered roller bearing of the input shaft into position .
Caution: Do not tilt during press fitting.
1. Cylindrical roller bearing of input shaft

2. Input shaft oil seal MLE124G
2. Install the guide nozzle. Use the SST to press fit the
1
tapered roller bearing of the output shaft into position,
2 install bearing plate, plate bolt, and flat washer subas-
3
sembly, and then install the guide plate, bolt, and spring
4 washer subassembly.
1. Bearing plate, plate bolt and flat washer subassem-

bly
2. Cylindrical roller bearing of output shaft
3. Guide plate, bolt and spring washer subassembly
4. Guide nozzle MLE129G
3. Install the front gasket of the differential and use the SST
1 to press fit the outer ring of front tapered roller bearing of
2 the differential into position.
1. Outer ring of front tapered roller bearing

2. Front gasket of differential MLE127G
4. Use the SST to press fit the differential front oil seal into
1 position.
1. Front oil seal of differential MLE126G
5. Tap in the four locating pins and install the clutch release
1
shift fork mechanism assembly and release the bearing.
2
4
5
1. Release shift fork limiting clasp

2. Release rocker assembly
3. Bushing I 4. Release fork assembly
5. Release bearing 6. Bushing II MLE123G
Transmission 5-49
Maintenance of the Transmission Case As-

sembly
Transmission case assembly removal
1. Remove the oil filling plug, oil drain plug, and flat washer.
1 2
1. Oil filling plug 2. Oil drain plug

MLE130G
2. Use the SST to remove the rear oil seal of the differential.
1. Rear oil seal of differential MLE131G
3. Remove the outer ring of the rear tapered roller bearing

1
of the differential and rear adjusting gasket of the differ-
2 ential.
1. Outer ring of rear tapered roller bearing

2. Rear adjusting gasket of differential
MLE132G
4. Use the SST to remove the rear straight bearing.
1. Rear straight bearing

MLE133G
5. Remove the reverse gear lock mechanism subassembly.

1
1. Reverse gear lock mechanism subassembly

MLE134G
Transmission case assembly installation

1
1. Install the reverse gear lock mechanism subassembly,
2 tap in the elastic pin, and tighten the reverse gear lock
plug with the specified torque.
3
1. Reverse gear lock mechanism subassembly
2. Elastic pin
3. Reverse gear plug
MLE135G
2. Use the SST to press in the rear straight bearing.

1
1. Rear straight bearing

MLE133G
3. Install the rear-adjusting gasket of the differential and

1
use the SST to press in the outer ring of the rear tapered
2 roller bearing of the differential.
Caution: Select the correct adjusting gasket first.
1. Outer ring of the rear tapered roller bearing

2. Rear adjusting gasket of the differential MLE132G
Transmission 5-51
4. Use the SST to press in the rear oil seal of the differen-
tial.
1
1. Rear oil seal of the differential

MLE131G
5. Tighten the oil filling plug, oil drain plug, and flat washer
with the specified torque.
1 2
1. Oil filling plug 2. Oil drain plug

MLE130G
Maintenance of Other Common Easily-Damaged Parts

Maintenance of the shift forks and shift fork shafts
1. Shift fork and shift fork shaft of each gear removal.
The maintenance of the shift fork and shift fork shaft of each gear is simple: remove the shift fork shaft limiting
clasp with a clasp caliper, remove the mounting bolt, and then remove the shift fork.
Caution: The removed clasps can't be reused. Protect the working surfaces of the shift fork and keep
the shift fork shaft from damage during removal.
2. Shift fork and shift fork shaft of each gear installation.
The maintenance installation of the shift fork and shift fork shaft of each gear is simple: Place every part in the
correct position, tighten the shift fork mounting bolt, and install the shift fork shaft limiting clasp. Do not miss the
two interlocking steel balls when installing the reverse gear shift lever.
Caution:
· · Protect the working surfaces of the shift fork and shift fork shaft from damage during installation.
· · Coat thread-fastening glue on the shift fork mounting bolt before installing.
· · Check if any interlocking steel ball and other parts miss after installing.
5th gear shaft fork

Shift fork mounting bolt
3rd/4th gear shift fork Reverse gear spring

Reverse gear pin
3rd/4th gear shift block Elastic pin
5th reverse gear shift fork shaft
Interlocking steel ball Sφ 6.35
3rd/4th gear shift fork shaft
1st/2nd gear shift fork shaft
1st/2nd gear shift fork
Reverse gear shift lever
MLE136G
Transmission 5-53
1
Manipulation Lid Assembly Maintenance
2
Manipulation lid assembly removal
1. Remove the gear shift arm mounting bolt and take out
the gear shift mechanism subassembly.
1. Bolt and spring subassembly

2. Counterweight MLE137G
1 2 3 2. Use the SST to remove the three elastic pins. Remove

the shaft spring retainer, 5th reverse gear return spring
seat, and 5th reverse gear return spring.
4
1. Shaft spring retainer
2. 5th reverse gear return spring seat
3. 5th reverse gear return spring
4. Elastic spring MLE138G
3. Remove the interlocking shift block, gear shift block and

gear shift interlocking block, reverse gear sensing block,
1st/2nd gear return spring seat, 1st/2nd gear return
spring, and the 1st/2nd gear return spring seat clasp.
4
3
5 6 2
7
5 1
1. Interlocking shift block
2. Gear shift interlocking block
3. Gear shift block
4. Reverse gear sensing block
5. 1st/2nd gear return spring seat clasp
6. 1st/2nd gear return spring seat
7. 1st/2nd gear return spring MLE139G
4. Take out the gear shift shaft and dust cover.

3
2
1. Gear shift shaft assembly

2. Manipulation lid subassembly
3. Gear shift shaft dust cover MLE140G
1 5. Remove the front straight bearing and manipulation lid

2
oil seal from the manipulation lid subassembly with tool.
1. Front straight bearing

2. Manipulation lid oil seal MLE141G
Manipulation lid assembly installation

Install the manipulation lid assembly: Install the gear shift as-
sembly, gear shift interlocking plate, and other components in
the reverse sequence of removal.
Caution: Protect the openings of the oil seals during in-
stallation and clean the shaft.
Maintenance of the synchronizer of each gear
The transmission has three synchronizer assemblies: 1st/2nd
gear synchronizer assembly, 3rd/4th gear synchronizer assem-
bly, and 5th gear synchronizer assembly. Each synchronizer
consists of a gear sleeve, gear hub, slider, and spring expan-
sion ring.
Caution:
· · The openings of the spring expansion rings should
alternate.
· · When installing the 1st/2nd gear synchronizer, keep
the gear hub with the conical surface upwards (2nd
gear direction) and keep the gear sleeve with gear
upwards (2nd gear direction).
· · When installing 3rd/4th gear synchronizer, keep the
gear sleeve with the notch mark downwards (3rd
gear direction).
· · When installing the 5th gear synchronizer, keep the
bigger end of the gear hub inner ring downwards (5th
gear direction) and keep the gear sleeve with the
notch mark downwards (5th gear direction). Keep the
bevel surface of the slider upwards.
Transmission 5-55
Installation explanation:
The installation processes for the three synchronizers are simi-
1 lar. This manual only provides the installation process of the
5th gear synchronizer.
1. Installation process of the synchronizer.
2
As shown in the figure: put the slider in the slider slot of the
3 gear hub. Put on the gear sleeve and then install the spring ex-
pansiom ring.
4
Caution:
· · Align the notch position of the gear sleeve to the
1. Gear sleeve three slots of the gear hub.
2. Spring expansion ring · · The openings of spring expansion rings should alter-
3. Slider
4. Gear hub MLE142G
nate for 120°.
2. Installation characteristics of the 5th gear synchronizer.

Caution: When installing, keep the bigger end of the
gear hub inner ring downwards (5th gear direction) and
keep the gear sleeve with the notch mark downwards
(5th gear direction). Keep the bevel surface of the slider
upwards.
MLE143G
3. Installation characteristics of the 3rd/4th gear synchro-

nizer.
Caution: When installing the 3rd/4th gear synchronizer,
keep the gear sleeve with the notch mark downwards
(3rd gear direction).
MLE144G
4. Installation characteristics of the 1st/2nd gear synchro-

nizer.
Caution: When installing the 1st/2nd gear synchronizer,
keep the gear hub with the conical surface upwards (2nd
gear direction) and keep the gear sleeve with the gear
upwards (2nd gear direction).
MLE145G
Maintenance of the back-up lamp switch
The back-up lamp switch is in its entirety. The maintenance
is just to remove the back-up lamp switch with a wrench and
replace it with a new one. The new back-up lamp switch only
needs to be tightened to the specified torque.
Suspension 6-1
Suspension
Front Suspension System................................................................6-2

Components..................................................................................6-3
Front Wheel Alignment..................................................................6-4
Front Shock Absorber with Coil Spring Assembly.........................6-7
Steering Knuckle.........................................................................6-10
Front Suspension Lower Swing Arm LH ....................................6-12
Subframe....................................................................................6-15
Rear Suspension System...............................................................6-17
Rear Wheel Alignment................................................................6-17
Components................................................................................6-18
Rear Coil Spring LH....................................................................6-21
Rear Stabilizer Bar......................................................................6-22
Left Trailing Arm Assembly..........................................................6-23
Tires and Wheels . .........................................................................6-30
Tires............................................................................................6-30
Wheel..........................................................................................6-35
Front Suspension System

1. Tires (worn or improper inflation) 6-31
2. Wheel alignment (incorrect) 6-4
3. Steering propeller mechanism (loose or worn) -
Deviation
4. Hub bearing (worn) 4-3
5. Steering (out of alignment or damaged) -
6. Suspension parts (worn) -
1. Vehicle (overload) -
Drooping 2. Spring (fatigue) -
3. Shock absorber (worn) -
2. Stabilizer bar (bent or broken) -
Tilting
3. Spring (fatigue) -
2. Wheels (out of balance) 6-35
Front wheel shimmy
5. Ball stud (worn) -
7. Steering propeller mechanism (loose or worn) -
8. Steering (out of alignment or damaged) -
Tire's abnormal wear
Suspension 6-3
Components
Q32812
Upper support (M12 × 1.25)
cover component
Nut
Fixed plate assembly

Needle bearing
Front spring
upper support
Upper spring washer
Bumper
Front coil spring
Dust cover
Front shock absorber assembly
Front shock absorber with

coil spring assembly LH
80±10
Bolt
Right steering
Front subframe assembly knuckle and hub
brake assembly
210±10
Cotter pin
210±10
Lower swing arm assembly

MLF001G
Front Wheel Alignment

Adjustment
1. Inspect the tires (See page 6-30).
2. Measure the vehicle height.
Vehicle height
B A
Measuring point:
A: Front wheel central ground clearance
B: Front suspension lower swing arm front bolt central
ground clearance
C: Rear twist beam mounting bolt central ground clearance
C D MLF002G
D: Rear wheel central ground clearance
Caution: Adjust the vehicle height to the recommended
value before inspecting the vehicle location.
Hint:
Bounce the corners of the vehicle up and down to steady sus-
pension and inspect the height of the vehicle.
3. Inspect toe-in.
A D B Toe-in:
Front Toe-in (total) 12' ± 6'
If the toe-in is not in the specified range, adjust it at the joint
of the steering tie rod.
4. Adjust toe-in.
C Caution: Adjust the camber before inspecting the toe-in.
(a) Remove the dust cover of the gear rack to fasten the
MLF003G
clamp.
(b) Loosen the lock nut at the joint of the tie rod.
(c) Turn the joint of the left and right gear racks in equal
amounts to adjust the toe-in.
Hint:
Adjust the toe-in to intermediate value within the specified
range.
MLF004G
(d) Make sure the length of the joints of the left and right
gear racks is the same.
Length difference of the joint of the gear rack: 1.5 mm or
less
(e) Fasten the lock nut at the joint of the tie rod.
Torque: 37 N·m
(f) Place the dust cover on the base and install the clamp.
Hint:
MLF005G
Make sure the dust cover is not twisted.
Suspension 6-5
A-B A B
5. Inspect the wheel angle.
(a) Turn the steering wheel to the end and measure the angle.
Wheel angle
Front
Inner side of the wheel Outer side of the wheel:
37±2.5° 33±2.5°
A: Inner side If the angle of the inner sides of the left and right wheels is not
B: Outer side in conformity with the specified value, inspect the length of
the joints of the left and right gear racks.
MLF006G
6. Inspect the front wheel camber, front wheel kingpin cast-

er, and front wheel kingpin angle.
Meter
Front wheel camber, front wheel kingpin caster, and front
wheel kingpin angle:
Front wheel camber – 1°±30′
Location scanner Left - right error 30′ or lower
Front wheel kingpin caster 2°30′±30′
Front wheel kingpin angle 9°30′±30′
MLF007G If the front wheel kingpin caster and the front wheel kingpin
angle are not in the scope of the specified value, adjust the
camber first and then inspect again whether the suspension
parts are damaged and/or worn.
7. Adjust the camber.

(a) Remove the front wheel.
(b) Remove the 2 nuts under the stock absorber.
(c) Clean the mounting surface and steering knuckle of the
shock absorber.
MLF008G
(d) Temporarily install 2 nuts.

(-) (+) (e) Push/pull the underside of the shock absorber to adjust
1 the camber along the direction it requires.
2 (f) Fasten the nuts.
Torque: 80±10 N·m
(g) Install the front wheel.
Torque: 110 N·m
: using adjusting bolts (h) Inspect the camber.
MLF009G
Hint:
Adjust the camber to the middle of the specified value.
The range to adjust the mounting bolt is form 6' to 30' (0.1° to
0.5°). If the camber is not in the scope of the specified value,
evaluate the value needs to be adjusted, and select the camber
adjusting bolts using the following table.
Caution:
Fasten the adjusting bolts using washers and new nuts.
Front Shock Absorber with Coil Spring Assembly

Overhaul
Hint:
1. Remove the front wheel and remove the front stabilizer
bar assembly connecting bar from the front shock ab-
sorber support.
Front shock absorber support and front stabilizer bar as-
sembly connecting torque: 63±5 N·m
MLF010G
2. Disconnect the brake hose.

(a) Take out the brake hose from the shock absorber bracket.
Remove wheel speed sensor from steering knuckle.
MLF011G
3. Remove the front shock absorber with coil spring assem-

bly.
(a) Remove the front shock absorber with coil spring assem-
bly and the steering knuckle coupling bolt.
The tightening torque of the front shock absorber sup-
port and the steering knuckle bolt is 80±10 N·m
MLF012G

bly lock nut and upper support cover component.
Do not use an impact wrench. It may damage the SST.
bly.
MLF013G
Suspension 6-7
6. As shown in the figure, use the SST to grasp the spring,

separated by adhesive tape, at the contact area. Alter-
nately rotate the bolts on the SST until there is no ten-
sion on the spring seat from the spring.
MLF014G
7. Use an open-end wrench along with a No.6 inner hexa-

gon wrench to remove the nut on the upper side and the
coil spring.
Inner hexa- 8. Remove the front bumper installation base.
Open-end gon wrench
wrench 9. Remove the front bumper and the dust cover.
10. Remove the front shock absorber assembly LH.
MLF015G
11. Inspect the front shock absorber assembly LH.

(a) Contract and expand the shock absorber bar. Inspect and
make sure there are no abnormal resistance or noise dur-
ing the operation.
If anything is abnormal, use a new shock absorber instead.
Caution:
When discarding the shock absorber, see the "Disposal"
section on page 6-9.
ALF020G
12. Install the front coil spring LH.

(a) Use the SST to compact the spring until the total length
of the spring is about 300 mm.
Caution:
Do not use an impact wrench. It may damage the SST.
(b) Install the coil spring on the shock absorber.
Hint:
Install the lower end of the coil spring to the clearance of the
MLF016G
lower seat of the spring.
13. Install the dust cover, bumper, and front bumper installa-
tion base to the strut piston rod. For order of installation,
refer to the disassembly diagram of the front shock ab-
sorber with coil spring assembly.
14. Pull up the strut piston rod as hard as possible and make
sure not to let it draw back into the strut.
The location of the mark 15. Observe the "▽" of the upper tray of the spring, the
on the spring's upper tray
location hole of the lower tray of the spring, the shock
SST absorber and the steering knuckle mounting surface and
make sure their central lines are in the same line.
The front coil

spring's upper seat
MLF017G
16. Install the bearing, the strut's fixed plate assembly, and
the nut in order one at a time. Refer the direction of the
strut nut's fixed plate assembly to the position of the
Inner hexagon components dismantled by the front shock absorber with
Open-end wrench
wrench coil spring assembly.
The torque for fastening the upper end nut of the plate:
30-40 N·M
17. Install the brake hose.
MLF018G
(a) Use the brake hose wire clamp to fasten the brake hose
onto the shock absorber bracket and directly fasten the
wheel speed sensor on the shock absorber bracket.
Torque: 110 N·m
Disposal
Hint:
Disposal on the right side is the same as it is on the left side.
1. Discard the front shock absorber assembly LH.
(a) Fully expand the shock absorber bar.
A B
(b) As shown in the figure, drill a hole between A and B on
the cylinder with the drill to drain the gas in the cylinder.
Caution:
Be careful when drilling as the metal fragments may
spray, so make sure to use proper safety equipment.
The gas is free of color, odor, or toxicity.
ALF025G
Suspension 6-9
Steering Knuckle
Removal
Hint: the procedure for removal on the right side is the same
with the left side.
1. Remove the front wheel LH.
2. Remove the front axle hub nut LH.
(a) Pry off the protruding parts of the front axle hub nut LH
with the SST and a hammer.
Caution:
Loosen the locked parts of the nut completely or the
thread of the propeller shaft will be damaged.
SST
(b) When using brake, remove the front axle hub nut LH.
ALF026G
3. Separate the wheel speed sensor and the brake hose.

(a) Remove the bolt and separate the wheel speed sensor of
the front wheel LH from the steering knuckle.
Caution:
Do not damage the wheel speed sensor.
Avoid adhering any contamination to the wheel speed
sensor.
MLF019G
4. Remove the front brake caliper assembly LH.

(a) Remove 2 bolts and remove the front brake caliper as-
sembly LH from the steering knuckle.
(b) Fasten with a rope to avoid damaging the brake hose.
MLF020G
5. Release the front stabilizer bar.

(a) Use a No.10 wrench to fasten the bolt and remove the
nut.
(b) Remove 2 washers, 2 bushings, and release the front sta-
bilizer bar.
MLF021G
6. Release the front suspension lower swing arm LH.

(a) Remove the lock pin and the nut.
(b) Use the SST to separate the front suspension lower swing
arm from the steering knuckle.
MLF022G
7. Release the steering tie rod ball assembly LH.

(a) Remove the lock pin and the nut.
(b) Use the SST to remove the steering tie rod ball assembly
LH from the steering knuckle.
MLF023G
8. Release the front shock absorber assembly LH.

(a) Remove 2 bolts and 2 nuts and release the front shock
absorber assembly LH from the steering knuckle assem-
bly.
9. Remove the front axle left propeller shaft assembly.
(a) Use a plastic hammer to remove the front axle drive shaft
assembly LH from the front axle hub assembly LH.
Caution:
MLF023G
Do not damage the dust cover.
Do not damage the rotor of the wheel speed sensor.
10. Remove the front axle hub hole clasp LH.
(a) Use the clasp pliers to remove the front axle hub hole
clasp LH.
11. Remove the front axle hub assembly LH.
12. Remove the left steering knuckle.

(a) Remove 3 bolts and the left steering knuckle.
Left steering
knuckle
ALF034G
Installing
Hint:
The installation sequence is the reverse of the removal sequence.
Suspension 6-11
Front Suspension Lower Swing Arm LH

Replacement
Hint:
Remove the front suspension lower swing arm RH in the same
steps as removing the LH.
2. Release the front suspension lower swing arm LH (See
page 6-11).
3. Release the front stabilizer bar (See page 6-10).
4. Remove the front suspension lower swing arm LH.
(a) Remove 2 bolts, the nuts, and the front suspension lower
swing arm.
Warning: Do not rotate the nut.
MLF024G
5. Check the front suspension lower swing arm LH.

(a) As shown in the figure, move the ball stud back and forth
5 times in front of the mounting nut.
(b) Use a torque wrench to continuously rotate the nut at a
speed of 2 to 4 seconds per round and read the torque
reading during the fifth round.
Torque: 5.0 N·m or less
(c) Check to see if the ball stud is damaged.
ALF036G
(d) Check to see if the ball stud dust cover is damaged and
replace it if necessary.
Caution:
Do not take apart the lower swing arm weld assembly
and the lower swing arm ball stud. If the rotation is not
flexible and the ball stud is damaged, you must replace
the entire lower swing arm with ball stud assembly.
6. Replace the ball stud dust cover.
(a) Rotate it with the SST and remove the clasp of the dust
cover of the ball stud.
SST (b) Replace the dust cover of the ball stud and the same SST
can be used to install the clasp.
ALF037G
7. Inspect the lower swing arm's large and small shaft

sleeve.
(a) Clean the large and small shaft sleeve of the lower swing
arm with water and inspect for damage, wear, cracks, and
similar flaws and replace it if necessary.
ALF038G
8. Replace the lower swing arm's large shaft sleeve.

(a) Before removing, mark two lines on the lower swing arm
according to the shaft sleeve location, so as to refer to the
proper location during installation.
ALF039G
(b) On the press, press out the lower swing arm's large shaft
SST
sleeve with the SST and replace it with a new one.
(c) Check that the lower swing arm's large shaft sleeve's
mounting hole dimensions are φ55-0.2
-0.3 . If the result of the
measurement is not in conformity with the recommended

value, replace the lower swing arm's weld assembly.
SSTALF040G
(d) Align to the marks before installing

Mark the same position on the new lower swing arm's large
shaft sleeve, so as to correspond to the mark on the lower
swing arm, and thus ensure proper angle alignment.
ALF041G
(e) On the press, use the SST to install the new lower swing
arm's large shaft sleeve into the correct position.
SST
SST
ALF042G
Suspension 6-13
9. Replace the lower swing arm's small shaft sleeve.

Sanding (a) Use a sander to smooth level the rubber flange on the
spots
lower swing arm's small shaft sleeve.
Caution: When using the sander, be very careful not to
Sanding
damage the lower swing arm.
spots
ALF043G
(b) On the press, press out the lower swing arm's small shaft
SST sleeve with the SST and replace it with a new one.
(c) Check that the lower swing arm's small shaft sleeve's
mounting hole dimensions are φ360-0.1. If the result of the
measurement is not in conformity with the recommended
SST
value, replace the lower swing arm's weld assembly.
ALF044G
(d) On the press, use the SST to install the new lower swing
SST arm's small shaft sleeve into the correct position.
SST
ALF045G
10. Temporarily fasten the front suspension lower swing arm

LH.
(a) Use 2 bolts and nuts to temporarily fasten the front sus-
pension lower swing arm LH.
11. Connect the front suspension lower swing arm LH (See
page 6-11).
12. Connect the front stabilizer bar (See page 6-10).
MLF024G
Torque: 110 N·m
14. Fully fasten the front suspension lower swing arm LH.
(a) Use 2 bolts to install the suspension lower arm.
Torque:
Bolt A: 210±10 N·m
A Bolt B: 210±10 N·m
Warning: Do not rotate the nut.
15. Inspect and adjust front wheel alignment (See page 6-4).
B
MLF024G
Subframe
Removal
Hoist the vehicle with a jack, then remove the left and right
front wheels.
1. Remove the front stabilizer bar and connecting bar as-
sembly.
MLF025G
2. Remove the steering pipeline.

Firstly, remove the hexagon nut for flange face as shown in
the figure with a No.10 wrench, then remove the conneting nut
between the steering pipeline and the steering gear high and
low pressure oil port with a No.17 wrench.
MLF026G
3. Remove the power steering gear assembly.

Use the SST to remove the power steering gear.
MLF027G 4. Loosen the riveted areas of the drive shaft nut and re-
move the nut.
5. Remove the steering knuckle and hub brake assembly.
Refer to removal and installation of the lower swing arm
assembly.
6. Remove the mounting bolts at the engine's rear suspen-
sion. Refer to removal and installation of the engine's
rear suspension.
Caution: When removing the mounting bolts at the en-
gine's rear suspension, support the transmission to avoid
the engine from leaning back and pressing the vehicle
body to damage some parts.
7. Remove the connecting nut between the steering ball
stud and the steering knuckle.
MLF023G
Suspension 6-15
8. Remove the connecting nut between the stabilizer bar

and the connecting bar.
9. Remove the subframe assembly.
Remove the subframe assembly from the vehicle body. Hold
up the subframe assembly with your hands when removing the
four mounting bolts of the subframe
The tightening torque of the subframe's front mounting
bolt subassembly: 120±10 N·m
The tightening torque of the subframe's rear mounting
MLF028G
bolt subassembly: 180±10 N·m
10. Remove the front stabilizer bar.
(a) Remove 4 bolts, the mounting brackets at the right and
The front stabilizer bar support left side of the front stabilizer bar, and 2 bushings.
The front stabilizer bar's (b) Remove the front stabilizer bar.
rubber bushing
11. Inspection of the front stabilizer bar.
(a) The front stabilizer bar assembly.
The connecting bar should always be straight and be replaced
in case of deformity. The angle between the two ball stud seats
MLF029G
should be 180°, which can be simplely tested and should be
replaced in case of deformity.
(b) Front stabilizer bar rubber bushing.
Inspect for damage, wear, cracks, and similar flaws. Replace it
if found.
(c) The front stabilizer bar and connecting bar assembly.
There will be an abnormal noise if it is loosened, and in
such case it should be replaced.
(d) The stabilizer bar ball.
Check whether the rotation of the stabilizer bar's connecting
bar is flexible.
Check whether the stabilizer bar's connecting bar ball is dam-
aged.
Check whether the ball stud's rubber cover is damaged.
MLF030G
12. Remove the lower swing arm from the subframe.

The coupling bolt torque for the lower swing arm and
subframe assembly is: 210±10 N·m
13. Inspection of the subframe assembly.
Inspect whether it is cracked, deformed, or damaged.
The limit of the deformation: ±0.5 mm
MLF031G
Rear Suspension System

The following table places suspicious parts in the sequence of the number to confirm the reasons for the problems.
Inspect, repair, or replace parts in the procedures listed in the following pages if necessary.
Deviation
1. Vehicle (overload) -
Drooping 2. Spring (fatigue) -
Tilting
2. Wheel (out of balance) 6-35
Rear wheel shimmy
Tire's abnormal wear
Rear Wheel Alignment

Inspection
1. Inspect the tires (See page 6-30).
2. Measure the vehicle height.
Caution: adjust the vehicle height to specified value be-
fore inspecting vehicle location.
3. Inspect the rear wheel toe-in.
A D B Rear wheel toe-in:
Front Toe-in (total) 12' ± 18'
If the toe-in is not in the scope of the recommended value, in-
spect it and replace the suspension parts when necessary.
4. Inspect the camber.
C (a) Install the front wheel alignment scanner or place the ve-
hicle on the wheel alignment scanner.
MLF032G
(b) Inspect the camber.
Camber:
Camber -30′
Left/right error 30′ or less
If the result of the measurement is not in the specified range,
inspect whether the suspension parts are damaged and/or worn.
As the camber is not adjustable, replace the part if necessary.
Suspension 6-17
Components
Bolt subassembly
Rear shock ab-

sorber assembly Rear coil spring's rubber cushion
Rear suspension's limiting stopper
Bolt subassembly Full-metal hexa- Trailing arm

gon lock nut for mounting bolt
Rear coil spring flange face subassembly
Left trailing arm

assembly
Bolt subassembly
Trailing arm mount-
Bolt subassembly ing bolt assembly
Partial gasket
Hexagon bolt for Non-metal insert
flange face hexagon lock nut
Rear stabilizer
bar assembly
Rear stabilizer bar bushing Right trailing arm assembly

Rear stabilizer bar mounting bracket
Rear stabilizer bar and Hexagon nut for
connecting bar assembly flange face
MLF033G
Rear shock absorber replacement

Hoist the vehicle with a jack.
Unscrew the 4 nuts with a No.21 socket wrench. Firstly, loos-
en by opposite angles and then unscrew the nuts one by one to
remove the wheel.
MLF034G
2. Remove the rear shock absorber assembly.

(a) Unscrew the connecting bolt subassembly between the
upper end of the rear shock absorber and the vehicle
body. Use a No.16 socket wrench.
MLF035G
(b) Unscrew the connecting bolt subassembly at the lower

end of the rear shock absorber.
(c) Hold up the trailing arm assembly with a tool and then
remove the two rear shock absorbers.
MLF036G
3. Inspect the rear shock absorber assembly LH.

(a) Contract and expand shock absorber and inspect and
make sure there is no abnormal resistance or noise dur-
ing the operation.
If anything is abnormal, use a new shock absorber instead.
Caution:
When discarding the shock absorber, see the "Disposal"
section on page 6-20.
MLF037G
4. Install the rear shock absorber assembly LH.

(a) Install the connecting bolt subassembly between the up-
per end of the rear shock absorber and the vehicle body.
Use a No.16 socket wrench.
MLF035G
(b) Use the nut to install the shock absorber on the trailing
arm assembly.
Torque: 120 N·m

Torque: 110 N·m
6. Inspect the rear wheel positioning (See page 6-17).
MLF036G
Suspension 6-19
Disposal
1. Discard the rear shock absorber assembly LH.
(a) Fully expand the shock absorber bar.
(b) Drill a hole on the cylinder with a drill to drain the gas in
the cylinder.
Caution:
Be careful when drilling for the metal fragments may
spray, so make sure to use proper safety equipment.
The gas is free of color, odor, or toxicity.
Rear Coil Spring LH

Replacement
Hint:
2. Release the wheel speed sensor wire harness.
(a) Disconnect the wheel speed sensor's connector.
(b) Remove the bolt and release the wheel speed sensor wire
harness from the rear trailing arm assembly.
Hint:
The procedures to release on the right side are the same as the
left side.
MLF038G
3. Release the rear wheel's brake pipeline.

(a) Release the rear wheel's brake pipeline with a No.10
open-end (crescent) wrench.
(b) Remove the clasp.
Hint:
The procedures to release on the right side are the same as the
left side.
Caution:
MLF039G
The clasp cannot be reused.
4. Release the left parking brake cable assembly.
(a) Remove the parking brake cable from the brake caliper.
5. Release the right parking brake cable assembly.
Hint:
The procedures for releasing the right parking brake cable as-
sembly are the same with the left.
MLF040G
6. Release the rear shock absorber LH.

(a) Raise the left and right sides of the rear trailing arm with
a jack.
(b) Remove the nut and washer and release the rear shock
absorber assembly LH.
7. Release the rear shock absorber RH.
Hint:
The procedures for removing at the right side are the same
MLF041G
with the left side.
Suspension 6-21
8. Remove the rear coil spring assembly LH.

Remove the left coil spring, the spring's rubber cushion and
the limiting stopper by slowly lowering the jack.
9. Inspect the rear coil spring.
Inspect whether the spring is damaged, deformed, or its elas-
ticity is standard, replace with the same mark if found.
10. Install the rear coil spring assembly.
Installation follows the reverse steps.
Caution: the rear wheel's torque is 110 N·m
11. Inspect after installation.
(a) Rear wheel alignment (See page 6-17).
(b) Check the signal of ABS speed sensor.
Rear Stabilizer Bar

Removal
1. Remove the rear stabilizer bar and connecting bar as-
sembly.
The tightening torque of the connecting nut between the
rear stabilizer bar assembly and the stabilizer bar and
connecting bar assembly is: 63±5 N·m
MLF044G
2. Remove the rear stabilizer bar's mounting bracket.

Stabilizer
bar bushing Tightening torque: 25±3 N·m
3. Remove the rear stabilizer bar's support and the rear
stabilizer bar's rubber bushing.
Stabilizer bar bracket
MLF045G
4. Inspection of the rear stabilizer bar.

(a) Rear stabilizer bar assembly
The connecting bar should always be straight and be replaced
in case of deformity. The angle between the two ball stud seats
should be 0°, which can be simply tested and should be re-
placed in case of deformity.
(b) Rear stabilizer bar rubber bushing
Inspect for damage, wear, cracks, and similar flaws. Replace it
MLF046G
if found.
(c) Rear stabilizer bar and connecting bar assembly. There
will be an abnormal noise if it is loosened, and in such
case the stabilizer bar's ball stud should be replaced
Left Trailing Arm Assembly
Rear brake disc
Rear hub flange
Wheel's bolt
Rear brake disc cover LH

Rear hub bearing seat
◆Hexagon head bolt and
spring washer subassembly 70-75 ◆Rear brake mounting bolt 100±10
Flattened steel retainer for hole

Rear brake caliper
assembly LH Trailing arm spindle sleeve
Trailing arm spindle

◆Rear hub bearing sleeve's outer tube
assembly
Left trailing arm

welding assembly
Trailing arm spindle

sleeve's outer tube
Trailing arm spindle sleeve
MLF047G
Inspection and removal

1. Inspection and maintenance of the rear disc brake.
(a) Hold up the vehicle with a jack.
(b) Remove the wheel by removing the the wheel's bolts in
opposite angles.
(c) Inspect the rear disc brake surface runout.
When measuring, tighten the 2 wheel's nuts at the symmetric
locations, and measure within a range of φ148 mm - φ235
MLF048G
mm around the rear brake disc, with the surface runout no
more than 0.11 mm. Replace it if the measurement is inaccu-
rate.
Suspension 6-23
(d) Inspect the rear disc brake thickness.

Measure the rear disc brake thickness with a micrometer.
Minimum thickness: 9 mm
Maximum thickness: 11 mm
The disc brake should be replaced when its thickness is
smaller than the minimum level.
MLF049G
2. Remove the rear brake caliper assembly.

(a) Remove the rear cable connector and the brake pipeline,
use open-end wrench to unscrew the 2 fastened rear
brake caliper's bolts, and then remove the rear brake cali-
per assembly.
Caution: Remove the rear brake caliper and fix the brake
caliper with steel wire to avoid excessive twisting, bend-
ing, or pulling off the brake pipeline.
MLF050G
(b) If the noise of rubbing against the steel plates is heard

Vernier caliper during braking, the friction plate must be replaced. When
Friction
plate the friction material thickness is smaller than or equal to
2 mm, the friction plate should be replaced. (If the mea-
suring method as shown on the left is adopted, the steel
plate thickness of 5 mm should be added.)
MLF051G
3. Remove the rear disc brake.

After driving the vehicle for some time, it may be hard to re-
move the discs brakes. In this case, screw two No.8 bolts into
the removed disc brake's threaded holes, and use a wrench to
alternately turns the two bolts, thereby ejecting the brake disc.
Caution: inspect the wear of the rear disc brake. (See
page 6-23).
MLF052G
4. Inspection of the rear hub flange.

(a) Under the torque of 160 N·m, the wheel's bolt should not
loosen or rotate.
(b) Measure the rear hub flange plate surface runout.
The runout should be less than 0.05 mm.
MLF053G
(c) Measure the rear hub bearing's starting torque.

SST Put the SST on the wheel bolts, which are at the symmetrical
locations, and put a dial torque wrench on the SST to slowly
rotate the flange's flange assembly (45°/4S).
Starting torque range: 0.4 N ·m-1.5 N ·m
If the rear hub flange plate surface runout is inaccurate
or the rear hub bearing's starting torque is inaccurate,
the assembly should be replaced.
MLF054G
Bearing
Removal of the rear hub flange assembly and the
inner ring
rear hub bearing seat assembly
SST
1. Removal and inspection of the rear hub flange assembly.
(a) Use the SST like a handheld travel hammer to repeatedly
hammer off the rear hub flange assembly from the rear
hub bearing.
Caution: the removed rear hub flange is with the bear-
MLF055G ing's inner ring.
(b) Remove the bearing's inner ring on the rear hub flange.
Use the SST to remove the bearing's inner ring.
SST
MLF056G
(c) Use dye penetrant to inspect the front hub flange for
cracks, which should be replaced if found.
(d) If one would like to continue using the rear hub flange
assembly, first inspect the dimensions for the mounting
area of the bearing for inaccurate dimensions. If over-
sized, replace.
φ35m6(+0.009 )
+0.025
Dimensions: φ35.025 mm - φ35.009 mm
MLF057G
2. Remove the rear hub bearing seat assembly.

The rear hub bearing is connected with the rear brake cover
through the rivet and is usually not removed.
Caution: the rear hub bearing assembly should not be
removed under normal circumstances. If determined to
have a problem, it should be replaced in its entirety.
MLF058G
Suspension 6-25
3. Remove the spring snap ring for hole 72.

Retaining ring Remove the spring snap ring for hole 72 with a screwdriver.
MLF059G
4. Press out the rear hub bearing in the rear hub bearing
seat.
(a) Place the removed bearing's inner ring back to the bear-
ing's original position.
MLF060G
(b) On the press, withstand the bearing inner ring that was
put on with the SST, and press out the entire rear hub
SST bearing.
SST
MLF061G
5. Removal of the wheel bolt.

On the press, press out the wheel bolt.
Caution: The rear hub flange assembly is a disposable
part, which needs to be replaced with a new one.
SST
MLF062G
6. If the rear hub bearing seat has no cracks and one

would like to continue to use it, first inspect the mounting
location dimensions of the rear hub bearing seat. If over-
sized, the bearing seat must be replaced.
Dimensions: φ66 -0.032
-0.062 mm.
Caution: the rear hub flange assembly and the rear hub
bearing seat assembly should not be removed under
normal circumstances. If determined to have a problem,
MLF063G they should be replaced in their entirety.
Inspection and removal of the trailing arm spindle

sleeve.
First remove the rear shock absorber and the coil spring and
then remove the spring cushion's limiting stopper.
1. Remove the trailing arm assembly.
Unscrew the 2 mounting bolts connecting the trailing arm as-
sembly and the rear subframe with a No.18 socket wrench.
MLF064G
2. Remove the trailing arm spindle sleeve.

Remove the trailing arm spindle sleeve on both the left and
Trail- right and use a press to press out when necessary.
ing arm Trailing Caution: When performing the pressing out process, be
spindle arm spindle certain to ensure the trailing arm spindle sleeve is verti-
sleeve sleeve
cally forced out.
3. Inspect the trailing arm spindle sleeve.
(a) Inspect the trailing arm spindle sleeve for deformities, shift-
ing, partial or serious cracks, or the gaskets for loosening.
MLF065G
(b) If any existing damage of the trailing arm spindle sleeve is
not clearly seen, take the following steps: wash the trailing
arm spindle sleeve's rubber areas with clean water, at the same
time rub it clean with cotton, and check and make sure the
rubber surface has none of the previously mentioned flaws.
Caution: if the above flaws exist, replace with a the new
trailing arm spindle sleeve.
Installation of the trailing arm assembly

1. Install the rear disc brake cover.
Use the bolt to fasten the rear disc brake cover on the rear hub
bearing seat.
2. Press the rear hub bearing assembly into the rear hub
bearing seat's bearing mounting position.
Install the rear hub bearing assembly into the rear hub bearing
SST
seat's bear mounting position.
MLF067G
3. Install the snap ring for hole 72.

Retaining ring Use the press plate with slot to install the snap ring 72 at the
rear hub bearing seat's mounting position.
MLF068G
Suspension 6-27
4. Press the rear hub flange assembly.

(a) On the press, press the wheel bolt into the rear hub
flange's mounting position.
MLF069G
(b) On the press, press the rear hub flange assembly into the
rear hub bearing mounting position using the SST.
SST
MLF070G
5. Examine the front hub flange plate surface runout.

Measure the rear hub flange plate surface runout.
The runout should be less than 0.05 mm.
MLF071G
6. Examine the front hub bearing assembly's starting

SST torque.
The examining methods are the same as the methods used dur-
ing disassembly. Put the SST on the wheel bolts, which are at
the symmetrical locations, and put a dial torque wrench on the
SST to slowly rotate the flange's flange assembly (45°/4S).
Required starting torque range: 0.4 N ·m-1.5 N ·m.
MLF072G
7. Install the rear disc brake.
MLF073G
8. Inspect the rear disc brake surface runout.

When measuring, tighten the two wheel nut's symmetrical lo-
cations and measure within a range of φ148 mm-φ235 mm
around the rear disc brake, with the surface runout no more
than 0.11 mm.
MLF074G
9. Install the brake caliper assembly.

Use an M10 torque wrench to tighten the 2 fastened rear brake
caliper's bolts.
Tightening torque: 70-75 N ·m.
MLF075G
10. Install the trailing arm spindle sleeve.

SST
Platform On the press, install the trailing arm spindle sleeve into
the trailing arm spindle sleeve's outer tube.
Caution: When performing the installation, be certain to
SST ensure the trailing arm spindle sleeve is vertically forced
in.
MLF076G
11. Install the rear brake assembly.

Use an M14 torque wrench to install the rear brake assembly
on the trailing arm assembly.
Tightening torque: 100±10 N ·m
MLF077G
Suspension 6-29
Tires and Wheels

Tires
Explanation
This vehicle uses tubeless tires. The optimal design condition is met when the inflation pressure is at the recom-
mended value, and the tires are under full load. Maintaining suitable tire pressure and proper driving habits great-
ly influence the tire's life. It not only achieves the vehicle's riding comfort, stability, and handling quality, but also
reduces tread wear, damage to the tire, and extends tire life. Overloading, speeding, and unnecessary emergency
braking will all add to the tire's wear.
The tire pressure is too high and the tire The tire pressure is too low and the
surface is worn and torn in the middle The tire pressure is normal tire shoulder is worn
ALF074G
Tire pressure measurements should be taken under normal temperature conditions. If the tire pressure rises due
to motion-generated heat when driving, cooling it will return it to the normal temperature. Therefore, do not de-
flate the tire when the air pressure has risen to this point. The tire's air pressure will naturally and slowly decrease
when used under normal conditions. Hence, please inspect the air pressure regularly (suggested once a month).
The spare tire should be kept in a useable condition at all times. The suggested inflation pressure of this vehicle is
evaluated through careful calculation. The tire pressure should be inspected when the tire is cool. Adjust the tire
pressure to the recommended level. It is suggested to inspect the tire pressure monthly or before a long drive, in-
cluding the spare tire.
Tire inflation
During a new tire's initial stage of use, warming due to motion
will cause the tire to swell, and thus reduce the correspond-
ing air pressure. Therefore, after 24 hours or a 2000-3000 km
drive, change the air pressure.
(a) Inspect whether the tire inflation pressure is normal.
Inflation pressure of a cool tire:
Tire size Front, rear KPa
185/65 R14 86H 220 kPa±10 kPa
(b) Use the dial indicator to inspect the tire's radial hop.
Tire's radial hop: 1.4 mm or less
ALF075G
Areas of importance for tire inflation:

1. Inflate safely. Watch the pressure meter until reaching the
recommended value to avoid over-inflating and causing a rup-
tured tire.
2. After driving, inflate the tire only when it becomes cool, for the tem-
perature will rise during driving and influence the air pressure.
3. Inspect the inflation nozzle and the nozzle core. If the inflation
nozzle and the nozzle core are unsmooth and have other flaws,
it will be difficult to inflate or to measure the air pressure.
4. Keep clean when inflating. The inflated air should not mix with
water or oil to avoid damaging the rubber sealing.
5. Do not wait until the specified air pressure is exceeded to bleed the
air. Neither should one inflate air excessively after no inflation due
to a long absence. If the specified value is greatly exceeded, the tire
cord will over-expanded, causing the decrease of its intensity and
shortening the life of the tire.
6. Clean away the dust on the inflation nozzle before inflating and
do not loosen the nozzle core. After inflating, apply some soapy
water on the nozzle to check whether it is leaking (small air bub-
bles will be generated if leaking), and then fasten the nozzle cover
to avoid dust entering the nozzle.
7. Regularly calibrate the pressure meter equipped on the vehicle
and used in the workshop to make sure the air pressure will be
accurately gauged.
Possible problems caused by tire pressure:

Exceeding the recommended Below the recommended air pressure Same vehicle
air pressure axle, different
air pressure
Possible 1. Bumpy ride 1. Noisy turns 1. Uneven braking
problems it 2. The tear or rupturing of the 2. Uneasy turns 2. Over-steering
can create tire 3. Tread edge wear is accelerated and uneven 3. Steering failure
3. Rapid wear of the tire tread's 4. The tire's rim is damaged or ruptured 4. Deviation while
center 5. The steel belt ruptures accelerating
6. High tire temperature
7. Steering failure
Tire and wheel (steel wheel) installation instructions

When installing the tire and wheel, the tire's radial hardware
components, also called the high spot, should be at the same
level of the wheel's minimum radius, or so-called low spot. The
high spot of the tire is initially marked by the paint spot on the
side of the tire's surface. This paint will eventually be washed
away. The low spot of the wheel is initially marked by a paint
spot on the wheel flange. If no paint spot is found on the tire,
draw a line on the tire and the wheel before they are removed, in
order to make sure that the tire and the wheel will be re-assem-
bled at the same place. Whenever the tire is installed, the tire and
wheel need re-balancing to make sure the vehicle runs smoothly.
Generally when installing a tire, pay attention to the items below:
1. The specification of the tire should match the specification of
the rim, which should have no deformation, rust, cracks, or
break, otherwise it may cause damage to the tire.
2. Keep it clean when installing the rim on the tire. Grit, scraps,
Suspension 6-31
or other grainy hard items, if mixed in the tire, will cause par-
tial heating of the tire.
3. Tires with different specifications or patterns should not be
installed on the same vehicle, otherwise it can cause uneven
wear.
4. Protect the inflation nozzle and keep the nozzle core complete
and clean when removing the tire.
5. Timely clean away the chips, hard items, or other sharp items on
the surface of the tire to reduce damage to the tire.
6. Cracks and breaks on the tire head, shoulder, and side should
be renovated and repaired. If not repaired in time, the damage
will get worse.
Using tires that are different in dimension or type will influ-
ence the vehicle's riding comfort, handling, speedometer and
odometer calibration, vehicle ground clearance, and the clear-
ance between the tire or the tire's skidproof chain, and the ve-
hicle body or chassis. It is suggested to use a new pair of tires
on the same axle. If only one tire needs to be replaced, make
sure to use a tire with a tread most similar to the original, so as
to keep the brake power and traction balanced.
Caution: Do not mix radial tires, bias belted tires, etc.,
which are of different structures on the same vehicle un-
less it is an emergency. Mixing different tires would seri-
ously influence the vehicle's handling and stability, and
even possibly lead to losing control of the vehicle.
A Tire's abnormal wear

The tire's abnormal wear and tear includes uneven and excessive
wear of the tire. There are many causes for this. For example,
improper tire pressure, tire rotation has not been timely main-
tained, bad driving habits, abnormal front wheel location, etc.
B
Change the tires in the following situations
1. When the extent of wear and tear of the front and rear tires
are different.
2. When any of the tire's tread has uneven wear and tear.
ALF076G
3. When the extent of the wear and tear of the left and right
front tires are different.
4. When the extent of wear and tear of the left and right rear
wheels are different.
5. When the tire tread wear appears abnormal and the tire's
contact area starts to flatten.
Inspect the front wheel alignment when the following
situations occur:
1. When the extent of the wear and tear of the left and right
front tires are different.
2. When any of the tire's tread has uneven wear and tear.
3. When the tread pattern strip or pattern block of a front
tire's single side is badly worn.
A: Steering problems, air pressure not sufficient, or tire rota-
tion has not been maintained in a timely manner.
B: Abnormal front wheel alignment. Tire or wheel structure
is not the same.
Wear marks
There are several tread wear marks (refer to A in the figure
shown on the left) on the inside of the tire's pattern groove.
These marks indicate that the tire has been worn to the point of
A
replacing. The tire's usage limit refers to when the remaining
pattern's depth reaches 1.6 mm (and its main pattern groove
bottom protrudes to the same level). For your safety, please re-
ALF077G
place the tire before this happens. When serious wear leads to
the partial protrusion of the steel belt, or outside objects dam-
age the tire to a depth that reaches the cord fabric level or steel
band level, stop using the tire.
Radial tire sway

Here, the sway means the vehicle's front or rear part shakes
from side to side, together or individually. Tire sway is caused
by the tire bead not being straight. It is the most obvious when
the vehicle runs at the speed of 8 - 48 km/h. Road tests can
help finding malfunctioning tires. If the malfunction is with
the rear tires, then left and right shaking or swaying would
take place at the back of the vehicle. Here the driver of the
MLF078G
vehicle would feel as if someone were pushing from one side
of the vehicle to the other. If the malfunction is with the front
tires, swaying would be even more obvious.
Vehicle road test methods

1. Drive the vehicle and find out if the swaying is coming from the
front tires or the back tires. Then, replace the identified prob-
lem tire with a standard tire (one that has been tested on the
same model of vehicle).
2. If unable to determine the problem tire, replace the rear
wheels. Continue the road test and if the driving condition ob-
viously changes, replace the original tires, and only switch one
at a time until the problem tire is identified.
3. If no obvious improvement, replace all four tires with standard
tires, and then replace the original tires one by one following
the steps mentioned above.
Front
Tire rotation
To ensure the even wear and tear of the tires, the tires should
be regularly switched as stipulated. The swapping principle is
shown on the left. Radial tires should be regularly switched.
Add pressure according to the regulations.
Caution: Due to structural reasons, radial tires usually
quickly receive most of its wear on the shoulders, espe-
ALF079G
cially the front tires. Do a tire rotation every 8000-12000
km, and the tire life can increase by 20%. This makes
regular tire rotation especially useful.
Suspension 6-33
Adjust the tire pressure to

the recommended level
Test by driving back and forth

on a straight and level road
After swapping the right and left front

tires, perform the above test again
Tends to lean in After solving, if working, switch the tires again Tends to lean in
the same direction the other direction
Return the tires to their Replace one of the front

initial positions and inspect side tires with a "good tire"
the front wheel alignment
After solving, switch If the problem is not yet

the tires again solved, replace with a "good
tire" at the other side in front
If the problem is not yet

After solving, switch solved, it means the "good
the tires again tire" is in fact not good
Deviation causes
Incorrect tire and front wheel alignment.
Braking force is not even.
Tire structure problems.
Tire production and manufacturing methods can also lead to
vehicle deviation. For example, the arrangement of the tires'
inner steel belt. A steel belt, which is inside the radial tire, de-
viating from the tires centerline can create lateral force when
the tires are rolling in a straight line. If one of the tire's di-
ameter is larger than the other, the tire will tend to roll to that
side. This also creates lateral force (a tapering effect), leading
to vehicle deviation.
When the front wheel alignment is found to be correct and in
proper order, the above process is also applicable in judging
tire deviation. Rear tires cannot cause deviation.
Tire installation and removal
Install or remove tires with a tire changer. When operating
machinery, make sure to comply to the machine manufactur-
er's operation manual. Please do not change tires merely with
manual hand tools or tire installation crowbars.
Use a wire brush or coarse steel wool to clean off grease and
old rubber, as well as light rust or corrosion from the rim tire
bead's tire chafer seat. Before tire installation or removal, first
use the indicated tire lubricant to thoroughly lube the tire cha-
fer portions one at a time.
After installing the tire, inflate it to the specified pressure and
make sure the tire bead is properly seated.
Caution: Do not over-inflate the tire. If the tire bead sev-
erally expands and exceeds the safety limit, it may burst
and cause serious personal injury. Do not exceed the
specified pressure when inflating. If the specified pres-
sure does not allow the tire bead to sit properly, deflate
the tire, re-lubricate, and then re-inflate.
Spare tire usage

Spare tire standard inflation pressure is 420 kPa.
Spare tire pressure measurements should be taken under nor-
mal temperature conditions.
After inflating, check if the air nozzle core is leaking air with
soapy water, then lock on the cap.
The spare tire should be kept in a useable condition at all
times. Check the air pressure at least once a month.
ALF081G
The spare tire's usage limit refers to when the remaining pat-
tern's depth reaches 1.6 mm (and its main pattern groove bot-
tom protrudes to the same level). For your safety, please stop
using the spare tire.
Caution:
The △ symbol on the tire bead of the spare tire indicates
the set position of the wear index (as shown in the figure).
The spare tire's maximum driven speed is 80 km/h, and
maximum distance is 200 km per trip.
Each vehicle is allowed to use only one spare tire.
The spare tire is only used as a temporary backup.
Please go to a professional service station immediately
ALF082G
to get the initial tire repaired or replaced.
Wheel
General balancing procedures
Clean out the accumulated dirt and debris from the inside of
the rim.
Caution:
The gravel on the tread must be eliminated to avoid
flying out and injuring the operator when undergoing
rotational balancing. This is also a good way to acquire
better balance. First thoroughly inspect the tire's dam-
aged condition, then according to the balancing device
manufacture's recommendations, carry out the balancing
operation.
Suspension 6-35
Off-vehicle balancing
Most off-vehicle balancers are more accurate and convenient
than on-vehicle rotational balancers. They are also able to
perform dynamic (two-sided) balancing. Although it does not
correct drum brake and disc brake imbalance like on-vehicle
balancing, it achieves the same effect based on its accuracy.
On-vehicle balancing
On-vehicle balancing is different based on the equipment and
tool manufacturer. Therefore, when performing balancing op-
erations, be sure to comply with each manufacturer's operating
instructions.
Caution: Control the wheel rotation speed to make sure
the speedometer stays within 55 km/h. This restriction is
necessary because when a driven wheel slides while the
other one stays still, the speedometer will display only
half of the actual wheel speed. When a wheel is sliding,
be extremely careful, because sliding wheels can reach
very high speeds. This may lead to the tire rubber peel-
ing or differential damage, which may cause serious per-
sonal injury, or damage to the vehicle.
Dynamic balance and static balance

[A] [B] 2 There are two types of wheel balance: static and dynamic.
Diagram 1 shows static balance, and diagram 2 shows dynam-
ic balance. Static balance means that the weight distribution
around the wheel is equal. If the wheel is static and unbal-
3 anced, violent vibrations may be created, called jump vibra-
1 tion. This kind of situation can ultimately lead to the uneven
Diagram 1
wear and tear of the tires, as shown in diagram 1.
ALF083G
1. Wheel hop important points [A]: Counterweight not yet
added
2. Locations to add [B]: Counterweight added
counterweight
3. Axis
Dynamic balance means that the weight distribution on the

[C] [D] 2 two sides of the medium plane of the wheel is equal, so during
the rotation process, the tire assembly cannot create a tendency
for the medium plane of the wheel to shift from one side to the
other. If the wheel is dynamic and unbalanced, it can create a
shimmying effect, as shown in diagram 2.
3 1. Wheel shimmy important [C]: Counterweight not yet
1 points added
Diagram 2
ALF084G
2. Locations to add counter- [D]: Counterweight added
weight
3. Axis
The methods to test the wheel's dynamic balance

are as follows:
1. Clean the wheel to be tested and remove dirt, sand-
stone, and the old counterweight.
2. Inflate the tire to the specified value.
3. Install the wheel on the dynamic balancer and lock it up.
4. Switch on the power and check whether the indicator
ALF085G works properly.
5. Enter the diameter and width of the rim, measure the
distance between the rim and the cabinet, and enter it.
6. Release the protective cover and press the Start button
to start measuring.
7. When the wheel stops rotating, read the quality and po-
sition of the inner and outer imbalance of the wheel from
the indicator.
8. Rotate the wheel slowly by hand and stop when the indi-
cator signals.
9. Place the quality of the dynamic imbalance displayed by
the dynamic balancer on the edge of the rim and lock it
up.
10. Restart the dynamic balancer and make dynamic bal-
ance test, until the dynamic imbalance is less than 5 g
and the balancer shows pass.
11. Remove the wheel and switch off the power and the test
is finished. Operations are different for dynamic balanc-
ers of different models and brands, so make sure to
carefully read the user's manual before using.
Suspension 6-37
Wheel maintenance
Do not use welding, heating, or hammering to repair the
wheels. All damaged wheels must be replaced. If the vehicle's
wheel is twisted or deformed, sunken or depressed, having
too much horizontal or radial hop, leaking air from the welded
parts, stretched out at the bolt holes, having a flimsy nut bolt
lock, or severely rusty, the wheel must be replaced. When the
wheel is hopping too much, it will lead to undesirable vibra-
tions. When replacing the tire, be sure that the load capacity,
diameter, rim width, offset distance, and the installation struc-
ture of it are equal to the settings of the original wheel. If the
wheel dimensions are not appropriate, this will influence the
wheel and bearing's life, brake cooling effect, speedometer
and odometer calibration, vehicle ground clearance, as well
as the clearance between the tire and the vehicle body, and the
tire and vehicle chassis.
Wheel (steel wheel) removal

1. Remove the wheelhouse and loosen the nuts, 1-2 turns is
enough.
2. Hoist the vehicle.
3. Unscrew the nuts and remove the wheel.
Nut tightening torque: 110±10 N·m
Caution: Heating methods absolutely must not be used
to loosen tightened wheels. Otherwise the heat will re-
ALF086G duce its service life and damage the hub bearing.
Wheel (steel wheel) installation

B A Installation according to the reversed instructions used for re-
moval and pay attention to the following requirements:
Wheel nuts must be tightened in the proper order and accord-
ing to the specified torque, so as to avoid wheel or brake disc
deformity. When installing the wheel house, be sure to line up
C D the wheel housing notch locations with the inflation nozzle.
Tightening sequence: A-C-B-D
ALF087G
Caution: Before installing the wheel, first clean off the
corrosion on the wheel's mounting surface and drum
brake or brake disc's installation surface with a wire
brush in order to make the wheel installation easier by
making the space between its metal firmly connect to the
mounting surface. Otherwise, it may lead to the wheel
nuts loosening to the extent that the vehicle's wheel may
come off while driving.
Steering 7-1
Steering
Steering System...............................................................................7-2
Leakage Test for the Power Steering System...............................7-5
Vehicle Maintenance.....................................................................7-5
Vehicle Inspection.........................................................................7-6
Power Steering System....................................................................7-8
Components..................................................................................7-8
Structure Introduction....................................................................7-9
Steering Column...........................................................................7-9
Power Ateering Fluid Reservior Assembly.................................. 7-11
Steering Pump............................................................................7-12
Power Steering Gear Assembly..................................................7-14
Steering System
Areas of Importance
1. Operation notice of steering system
Be careful when replacing components. Incorrect replacement may influence the steering system's performance
and cause danger during drivng. Check the fluid level when the engine is off so as to avoid personal injury caused
by moving parts. If the engine is already in operation, the power steering fluid, engine components, and exhaust
sytem may be very hot. Do not start the engine in case any hose is loose or disconnected. Do not bring the hose
into contact with hot exhaust manifold or catalytic converter.
2. Special Note
If the air is not released from the steering system after the maintenance of the power steering system, the fluid
level reading will be inaccurate. The air in the fluid will produce a cavitation noise in the fluid pump and even
damage the fluid pump after long term operation.
Problem Causes Troubleshooting
1. Too much clearance between the steering 1. Have the clearance adjusted by professionals,
gear and gear rack. and if it cannot be adjusted, replace the steering
gear.
2. The inner and outer ball stud of the steering 2. After inspection, replace the ball stud if neces-
tie rod ball is worn out. sary.
Excessive 3. Steering joint is worn out. 3. Replace the lower section of the steering col-
steering wheel umn.
play/abnor- 4. Steering propeller shaft and steering gear 4. Fasten the connection bolts in accordance with
mal noise connection is loose. the specified torque.
5. Steering wheel and steering column connec- 5. Fasten the lock nut of the steering wheel. When
tor is loose. the spline is damaged, make sure to replace the
steering wheel or steering column.
6. Steering gear mounting bolt is loose. 6. Fasten the mounting bolts of the steering gear.
7. The sliding spline of the lower propeller shaft 7. Replace the lower section of the steering col-
is worn and loose. umn.
1. Insufficient tire pressure. 1. Inflate according to the specified pressure.
2. Front wheel alignment angle incorrect. 2. Check and adjust the front wheel alignment
angle.
3. Clearance between the steering gear presses 3. Replace the steering gear or have professionals
too small. adjust the clearance between the presses.
4. Steering column's spider bearing broken. 4. Replace the lower section of steering column.
5. Steering tie rod ball stud lacks oil or is dam- 5. Replace the steering tie rod ball.
aged.
6. Front shock absorber's support bearing bro- 6. Replace the connecting components of the
ken. front shock absorber (refer to the front suspen-
sion maintenance section).
Difficulty 7. Damaged lower swing arm ball end. 7. Replace the lower swing arm (refer to the front
steering suspension maintenance section).
8. Damaged steering pump leads to insufficient 8. Replace the power steering pump.
output volume and output pressure.
9. Power steering pump belt slides. 9. Adjust the belt's tension.
10. Power steering gear internal leakage is too much. 10. Replace the power steering gear.
11. Power steering contains air bubbles and pro- 11. In place, repeatedly turn, release the air bub-
duces irregular noises. bles, then after leaving it stationary for one
hour, refill the power steering according to the
12. Power steering is insufficient. specific model number.
12. Fill the power steering receptacle (with the
specific model number) until it reaches the PS
fluid reservoir's specified scale mark.
Steering 7-3

1. Tire pressure insufficient. 1. Inflate according to the specified pressure.
2. Wheel counterweight falls off or other factors 2. Recalibrate the wheel's dynamic balance.
cause extremely poor wheel balance.
3. Lower swing arm's rubber bushing is too old, 3. Replace the lower swing arm.
big difference between the left and right's
rigidity.
4. The front shock absorber's support bearing 4. Fill with grease of the specified model number.
Poor steering and lower swing arm ball lacks sufficient
lubrication.
return, straight
5. The four wheels' positional parameters are 5. Re-measure and adjust the four wheels' posi-
movement
incorrect. tional parameters.
stability poor 6. Steering gear's gear rack meshing condition 6. Replace the steering gear.
worsens and causes intense reverse resis-
tance.
7. Steering column bearing and spider bearing 7. Replace the steering column assembly.
are damaged.
8. Power steering pump's oil supply insufficient. 8. Replace the power steering pump.
9. Inner portion of the steering gear's control 9. Replace the power steering gear.
valve performance degradation.
1. Check if the power steering hose comes into 1. Ensure that the power steering hose is installed
contact with the vehicle body. correctly.
2. Check if the power steering gear lacks suf- 2. Lubricate the steering gear.
Power steering
ficient lubrication.
gear makes a
3. Check if the power steering gear base is in- 3. Fasten the power steering gear's mounting rack
gurgling noise
stalled improperly. bolts.
4. Check if the outer steering tie rod is installed 4. Fasten the outer steering tie rod ball joint.
improperly. Replace the outer steering tie rod.
1. Check if the steering wheel comes into con- 1. Adjust the combination switch case.
tact with the combination switch case.
2. Check if the intermediate shaft connector is 2. Replace the intermediate shaft.
clamped or loose.
3. Check if the power steering pump's flow con- 3. Replace the power steering pump.
Steering wheel trol valve is clamped or displaced.
does not return 4. Check the wheel alignment. 4. Align the wheel.
to the middle 5. Check if the wheel bearing is worn out or 5. Replace the wheel bearing.
position damaged.
6. Check if the steering tie rod and ball joint are 6. Fasten the steering tie rod and ball joint. Re-
clamped or loose. place the steering tie rod and ball joint.
7. Check power steering gear adjustment. 7. Perform straight movement inspection.
8. Check if the steering column's shaft seal rubs 8. Replace cowl panel seal.
against the shaft.
1. Check whether leakage exists in the power 1. Replace the power steering pump.
Feels sud- steering pump.
2. Check if the hose is damaged or blocking the 2. Replace the power steering hose and/or tube.
denly laborious
flow of fluid.
when turning
3. Check the power steering fluid level. 3. Fill the power steering fluid reservoir with
the steering
steering fluid.
wheel rapidly. 4. Check if the power steering pump's flow con- 4. Replace the power steering pump.
trol valve is clamped or operated improperly.

Steering flut- 1. Check if the power steering pump's pressure 1. Replace the power steering pump.
ters when is insufficient.
turning during 2. Check if the power steering pump's flow con- 2. Replace the power steering pump.
the operation trol valve is clamped or operated improperly.
of the engine 3. Check if the power steering pump belt slips. 3. Tension the power steering pump belt.
4. Check whether air pollution exists in the power 4. Release the air from the power steering system.
steering system.
Steering vibra- 1. Check whether air pollution exists in the power
1. Release the air from the power steering system.
tion during steering system.
low speed or 2. Check if the power steering pump belt is 2. Tension the power steering pump belt.
static steering loose.
1. Check whether air pollution exists in the power 1. Release the air from the power steering system.
steering system.
2. Check if the wheel bearing is worn out or 2. Replace the wheel bearing.
damaged.
Steering wheel
3. Check if the power steering gear base is in- 3. Fasten the power steering gear's mounting
kickback is too
stalled improperly. bolts.
big or loose
4. Check if the intermediate shaft connector is 4. Adjust the connector between the power steering
installed improperly. gear and the steering column.
5. Check if the outer steering tie rod and ball 5. Fasten the steering tie rod and ball joint.
joint are loose. Replace the steering tie rod and ball joint.
1. Check the intermediate shaft and connecting 1. Adjust the connecting flange between the
flange between the power steering gear and power steering gear and the steering column.
the steering column. Replace the flange if necessary.
2. Check if the power steering pump's flow con- 2. Replace the power steering pump.
Difficult steer- trol valve is clamped or installed improperly.
ing or poor 3. Check if the power steering pump's pressure 3. Replace the power steering pump.
boost (espe- is insufficient.
cially when 4. Check whether leakage exists in the power 4. Replace the power steering pump.
parking) steering pump.
5. Check if the intermediate shaft is loose or 5. Fasten the intermediate shaft. Replace the in-
worn out. termediate shaft if necessary.
6. Check the power steering pump belt's ten- 6. Tighten the power steering pump belt.
sion.
Steering 7-5
Leakage Test for the Power Steering System

General process, check the following:
• Whether the reservior is overfilled.
• Whether the fluid contains air or overflow.
• Check whether the hose connector is loose.
• Check whether the torque rod, stub axle, and adjuster seals leak oil.
• Check whether the components' sealing faces are damaged.
Areas of importance: Find out the exact leak point. The oil dropping point is not necessarily the true
leak point. If maintenance is required, clean the surface containing the leak after removal, replace the
leaking oil seal, check whether the components' sealing faces are damaged, and, if necessary, fasten
the bolts to the specified torque.
External leakage inspection
The purpose of this procedure is to determine the position of the leak point. In some cases, it is easy to find leak-
age but difficult to determine seepage. Look for seepage by the following methods:
1. After the engine has been turned off, clean the entire power steering system.
2. Check the power steering fluid level in the pump reservior. Adjust the fluid level if necessary. See also
"Check and Add Fluid" in this section.
Special Note: Do not hold the steering wheel when it has been turned to the limiting position. Other-
wise, the power steering pump will be damaged.
3. Start the engine. Turn the steering wheel from lock position to lock position several times.
4. Find out the exact leak point and carry out repair work.
Vehicle Maintenance
Release the air from the power steering system
After maintenance of the power steering hydraulic system, the air must be released from the system in order to
obtain an accurate fluid level reading. Release the air from the system using the following steps:
1. Turn the steering wheel to the left limiting position, add power steering fluid to the MIN (minimum) fluid level mark.
Special Note: When adding or replacing the fluid, make sure to use ATF DEXR0N III power steering
fluid. Otherwise, it may lead to damage of the hose and seal or leakage of fluid.
2. Start the engine. Allow the engine to operate at a fast idle speed, recheck the fluid level. If necessary,
add fluid to the MIN (minimum) mark.
3. Turn the steering wheel from one side to the other without reaching the limiting positions in order to
release the air from the system. Maintain the fluid level at the MIN (minimum) mark. To obtain normal
steering performance, the air in the fluid must be released.
4. Allow the steering wheel to return to the middle position. Allow the engine to continue to operate for 2-3 minutes.
5. Carry out a vehicle road test and make sure that the steering function is normal and no noise is produced.
6. Recheck the fluid level using Steps 1 and 2. Make sure that the fluid level reaches the MAX (maximum)
mark after the system has stabilized at the normal working temperature. Add fluid if necessary.
Check and add fluid
Special Note: When adding or replacing the fluid, make sure to use ATF DEXR0N III power steering
fluid. The use of improper fluid may lead to damage of the hose and seal or leakage of fluid.
1. Power steering fluid level is indicated by the marks on the transparent reservior.
2. If the fluid temperature reaches 66oC (150oF), the fluid level should be between the MAX (maximum)
and MIN (minimum). Add fluid if necessary.
3. If the fluid temperature is low, 21oC (70oF), the fluid level should be at the MIN (minimum) mark. Add
fluid if necessary.
Vehicle Inspection
Maximum free play 1. Check the steering wheel free play.
(a) Stop the vehicle, with the wheels pointed straight ahead.
(b) Check the steering wheel free play by turning the steel
≤10°
wheel in the clockwise and counterclockwise directions
until the resistance increases.
Maximum free play: ≤10°
MLG001G
2. Check the steering pump belt.

Visually inspect to see if the steering pump belt is excessively
worn and if the cord is broken. If any of these flaws are found,
replace the steering pump belt.
Hint: Cracks on the edge side of the steering pump belt are
acceptable. However, in case of any loss of the edge, the belt
should be replaced.
ALH018G
Maintenance
Steering wheel
Adhesive tape Steering eccentricity maintenance procedure
Combination 1. Check the mannerisms of the steering wheel.
switch's upper (a) Apply adhesive tape to the center of the upper part of the
protective cover
steering wheel and the combination switch's upper pro-
tective cover.
(b) Drive straight ahead for 100 meters at a constant speed of
56 km/h and grip the steering wheel to keep on the road.
ALH002G
Combination switch's (c) As shown in the figure, draw a line on the adhesive tape.
upper protective cover
Mark line
Steering wheel
Adhesive tape
ALH003G
Combination switch's (d) Turn the steering wheel to the middle position.
upper protective cover
Hint: For the middle position, please refer to the steering
Mark line
Steering wheel wheel's top surface, the steering wheel's radial and SRS airbag
line.
(e) As shown in the figure, draw a new line on the adhesive
tape on the steering wheel.
(f) Measure the distance between the two lines on the adhe-
sive tape on the steering wheel.
ALH004G
Steering 7-7
(g) Convert the measured distance into the steering angle.

Measured distance of 1 mm = Steering angle of about 1
degree.
Hint: Record the steering angle.
2. Adjust the steering angle.

Tie rod Rack end 3. Perform the following steps respectively on the left and
right sides.
(a) Mark the tie rod and rack end in prominent positions.
(b) Use a gauge to measure the distance between the tie rod
and the rack end thread.
Mark line
ALH005G
(c) Remove the left and right dust cover clips from the rack
dust cover.
(d) Loosen the left and right lock nuts.
(e) Rotate the left and right rack ends in the same angle (dif-
ferent directions). The 360° rotation (1.5 mm horizontal
movement) of the rack end - steering angle of 9′.
(f) Tighten the left and right lock nuts.
Torque: 37 N·m
ALH006G
Caution: Make sure that the length difference between
the left and right tie rod ends and the rack end thread is
within 1.5 mm.
(g) Install the left and right dust cover clips.
Power Steering System

Components
Airbag module
Combination switch's upper cover Steering wheel
Lock nut of steering wheel

Combination
switch's lower cover
Power steering fluid reservior assembly Clock spring
Power steering
Power steering fluid reservior column assembly
mounting bracket assembly
8-12
Power steering fuel filler

hose assembly
Power steering fuel filler
Power steering pump assembly and return pipe bundle
45-55
22-28
45-55
45-55
Tension regulator bracket
22-28
Power steering pump bracket
Power steering pump bracket II
Dust cover
Dust cover assembly
Left tie rod ball assembly Power steering Right tie rod ball assembly
gear assembly
Steering gear
mounting gasket
70-80

MLG002G
Steering 7-9
Structure Introduction
To increase the ease of steering, this vehicle is equipped with a power steering sytem. The steering column's up-
per section adopts a steel deformation and energy absorbing crumple structure, which ensures collision protection
for the driver. The lower section uses a high precision sliding spline structure, which can effectively eliminate
structural interference caused by body deformation. The steering column angle is adjustable, which can more eas-
ily adapt to the driver. The steering gear is a rack and pinion power steering gear, of which the boost characteristic
is a low speed high degree of boost and a high speed low degree of boost. The steering pump, the power source of
the booster system, also has an output characteristic of a low speed high flow rate and a high speed low flow rate
so as to ensure easy of control of the vehicle during low speed driving or backing up and, at the same time, to en-
sure good operation stability and effective intensity of the vehicle during high speed driving.
Steering Column
Steering column removal
1. Disconnect the battery negative terminal.
2. Keep the front wheel pointed straight ahead.
3. Remove the driver side airbag (See page 9-30).
Remove 2 bolts and the driver's side airbag.
Bolt
ALH008G
Lock nut 4. Remove the steering wheel.

(a) Remove the lock nut of the steering wheel with a No.18
socket wrench in a counterclockwise direction.
(b) Grip the entire steering wheel and shake it several times,
and then pull the steering wheel upwards to release.
ALH009G
5. Remove the upper and lower trim cover of the combina-

tion switch. For the operating procedures, refer to the
maintenance instructions of the accessories section.
MLG003G
6. Pull out the wire harness on the left and right combina-
tion switch and the ignition lock.
7. Remove the left and right combination switch and the ig-
nition lock.
8. Separate the steering column and the power steering

gear.
(a) Make installation marks on the steering propeller shaft
Installation marks
joint and steering propeller connection shaft.
(b) Unscrew the bolt (as shown in the figure) with a No.10
socket wrench in a counterclockwise direction and pull
out the lower section of the steering column.
MLG004G
9. Remove the steering column assembly.

Unscrew the three bolts connecting the steering column's up-
per section and the dashboard brace reinforcement with a
No.10 socket wrench, and then pull out the steering column
assembly along the steering column's upper axis.
MLG005G
10. Separate the upper and lower sections of the steering

column.
Unscrew the hexagon head bolt with a No.13 socket wrench
and pull out the lower section of the steering column.
Caution: Since the two joint forks on the lower section of
Do not pull out these steering column have an accurate phase relation, do not
two parts completely pull them out of the sliding spline completely. The lower
section of steering column is already the minimum main-
MLG006G
tenance unit. The bolts here are supplied with the lower
section of the steering column. New bolts must be used
during reassembly.
Steering column installation

Install the steering column by reversing the removal process.
Operate from Step 10 to Step 3. Pay attention to the items be-
low:
(a) The bolt should align with the circular groove of the
power steering pinion shaft when inserted into the
threaded hole.
(b) When installing the steering wheel, make sure that the
front tires are in a straight line, turn the vehicle logo on
the top of the steering wheel to where it faces straight
ahead, and make sure that the inner steering spine and
steering shaft spline are aligned.
(c) Fasten the bolts and nuts according to the specified tight-
ening torque.
Steering 7-11
Power Ateering Fluid Reservior Assembly

Removal
1. Remove the fuel filler hose and fuel return hose.
Open the two steel band hoops on the fuel filler hose and fuel
return hose with locking pliers and move them backward re-
spectively to the position shown on the left. Remove the fuel
filler hose and fuel return hose in the direction shown in the
MLG007G figure and collect the power steering fluid in a container.
Push the spring clip 2. Remove the steering fluid reservior.

downwards along here Push the spring clip with a slotted screwdriver until it has
with a screwdriver
been removed from the locking position, and then push out the
steering fluid reservior upwards with the other hand.
MLG008G
3. Remove the steering fluid reservior bracket.

Unscrew the three bolts with a No.8 wrench and complete the
removal of the steering fluid reservior bracket.
MLG009G
Installation
Install the power steering fluid reservior by reversing the re-
moval process.
Steering Pump
Removal
1. Remove the oil pipe connected to the steering pump.
(a) Open the steel band hoop on the fuel filler hose with
locking pliers and move it backward to the position
shown on the left, and then pull out the fuel filler hose
upwards by hand.
MLG010G (b) After disconnecting the fuel filler hose from the power
steering pump, collect the power steering fluid flowing
out of the fuel filler hose with a container.
(c) Disconnect the hollow bolt which connects the high pres-
sure oil pipe and the power steering pump with a No.22
socket wrench.
2. Remove the generator belt.

Loosen the generator adjusting arm bolts and remove the gen-
erator belt.
MLG011G
3. Remove the steering pump belt.

2 Remove Bolt 1 and loosen Bolt 2 with a No.13 open-end
wrench. Push the steering pump in the direction shown in the
figure and remove the steering pump belt.
1
MLG012G
4. Remove the steering pump.

Unscrew the bolt, remove the pump, and complete the removal
of the steering pump.
MLG013G
Steering 7-13
Installation
1. Install the steering pump.
Install the steering pump on the vehicle. Then, install the steer-
ing pump mounting bolts and adjusting arm bolts.
MLG014G
2. Install the steering pump belt.

Install the steering pump belt, push the steering pump by hand
in the direciton shown in the figure, tighten the adjusting arm
bolts, and fasten the steering pump bolts according to the
specified torque.
Caution: Adjust the steering pump belt's tension to 450±
50 N. Use an exertion force of 98 N in the middle of the
belt. The belt deflection should 4-6 mm.
MLG015G
3. Install the engine belt.

98 N Place the belt into the damper pulley's external groove, the air
conditioner compressor pulley, and the generator pulley. The
6-8 mm winding direction of the generator belt is shown in the figure.
Caution: Do not install the belt in the wrong groove.
4. Adjust the position of the generator assembly, check if
the belt deflection meets the requirement, and fasten the
bolts.
MLG016G
Check the belt deflection: As shown in the figure, use an
exertion force of 98 N in the middle of the belt. The belt
deflection should be 6-8 mm.
The tightening torque used to fasten the generator ad-
justing arm bolts: 24±2 N·m
The tightening torque used to fasten the hexagon bolts
for flange face of the generator: 60±2 N·m
5. Install the oil pipe that is connected to the steering pump.

Remark: When installing, each of the two seal gaskets should
be positioned at either side of the high pressure oil ring.
6. Fill the power steering fluid.
7. Bleed air from the power steering system.
8. Check for leakage of fluid.
MLG010G
Power Steering Gear Assembly

Removal
Installation marks 1. Separate the steering column and the power steering
gear.
(a) Make installation marks on the steering propeller shaft
joint and steering propeller connection shaft.
(b) Unscrew the bolt shown in the figure with a No.10 sock-
MLG004G et wrench in a counterclockwise direction and pull out
the lower section of the steering column.
2. Remove the steering dust cover.
Pry off the steering dust cover with a slotted screwdriver.
Remark: To ensure that the via holes in the vehicle body are
sealed completely, use a new steering dust cover once the
steering gear has been removed.
MLG017G
3. Remove the steering tie rod ball.

(a) Loosen the Type I non-metal insert hexagon head lock
nut with a No.16 socket wrench.
Caution: Type I non-metal insert hexagon head lock nut
can be used only once. Otherwise, the fastening effect
of the nut will be decreased. Use only new parts during
reassembly.
MLG018G
(b) Pound the circumference of the steering knuckle arm

with a hammer along the direction of the taper bore di-
ameter until the tie rod ball and steering knuckle arm's
taper fittings loosen, and then pull out the tie rod ball in
an upward motion.
MLG019G
4. Remove the connection between the power steering

pipeline and the steering pump and steering fluid reser-
vior.
Caution: When disconnecting the pipeline, collect the
power steering fluid with a container.
5. Remove the connection between the low pressure oil
pipe and the front floor.
Remove the bolt at the connection between the low pressure
MLG020G oil pipe and the front floor with a No.8 wrench.
Steering 7-15
6. Remove the subframe assembly from the vehicle body.

Remove the power steering gear and the steering pipeline to-
gether with the subframe from the entire vehicle.
7. Remove the steering pipeline.

First, remove the hexagon nuts for the flange face in the two
positions shown in the figure with a No.10 wrench. Then, re-
move the coupling nut of steering pipeline and steering gear's
high-low pressure oil port with a No.17 open-end wrench and
complete the removal of the steering pipeline.
Two bolts
MLG021G
8. Remove the power steering gear assembly.

Unscrew the two hexagon bolt gasket groups installed on the
subframe with a No.18 socket wrench and complete the re-
moval of the power steering gear.
MLG022G
Replacement
1. Remove and replace the steering tie rod ball assembly.
Lock nut
(a) Loosen the hexagon lock nuts on the steering tie rod
with two No.18 open-end wrenches, and then remove the
steering tie rod ball assembly from the steering gear with
No.12 and No.18 open-end wrenches.
MLG021G
(b) If ball pair loosening or dust cover damage exists in the

steering tie rod ball assembly, the entire steering tie rod
ball assembly should be replaced. Please note that the as-
sembly is divided into left and right parts, the left part is
L
marked with an "L," and the right part is marked with an

"R."
Left tie rod Right tie rod
ball assembly ball assembly
MLG022G
(c) When installing the steering tie rod ball assembly, after
making adjustments according to the dimensions shown
in the figure, tighten the hexagon nut slightly with a
23
No.18 open-end wrench. After installing the overall ve-
hicle and adjusting the toe-in, tighten this nut.
Tightening torque: 32-42 N·m
MLG023G
2. Remove and replace the dust cover.

(a) Open the clamps at both ends of the dust cover with pli-
ers, rotate, and push outward to remove the dust cover.
(b) When installing the dust cover, apply vaseline to the
position shown in the figure. When fastening the clamp,
take care not to pull or twist the dust cover. After instal-
lation, rotate the steering gear's input shaft to the left and
Apply vaseline uniformly to this surface
right limiting positions. The dust cover should not be
MLG024G
shrunken or expanded.
3. Remove and replace the steering tie rod.

The tightening torque here is 70-90 N·m Clip the steering gear to a vise, clamp the rack with an adjust-
able wrench, clamp the steering tie rod with another adjustable
wrench, and then remove the steering tie rod.
When installing the steering tie rod, the tightening torque
is: 70-90 N·m.
MLG025G
Installation
1. Install the power steering gear.
Place the entire power steering gear assembly on the subframe
and tighten the two hexagon bolt gasket groups with a No.18
socket wrench.
MLG022G
2. Install the steering pipeline.

Keep the steering pipeline in place. First, tighten the coupling
nut of steering pipeline and steering gear's high-low pressure oil
port with a No.17 open-end wrench. Then, tighten the hexagon
nuts for the flange face with a No.10 wrench in the two positions
shown in the figure and complete the installation of the steering
Two bolts
pipeline.
MLG021G
Steering 7-17
3. Install the assembled subframe assembly on the vehicle

body.
See also the suspension and vehicle axle section
4. Fasten the connection between the low pressure oil pipe
and the front floor.
Tighten the bolt at the connection between the low pressure oil
pipe and the front floor with a No.8 wrench.
5. Connect the connection between the power steering pipe-
MLG020G
line and the steering pump and steering fluid reservior..
6. Install the steering tie rod ball.

Tighten the Type I non-metal insert hexagon head lock nut
with a No.16 socket wrench.
Caution: A Type I non-metal insert hexagon head lock
nut can be used only once. Otherwise, the loosening
effect of the nut will be decreased. Use only new parts
during installation.
MLG018G
7. Install the steering dust cover.

After installing the steering dust cover together with the steer-
ing gear on the vehicle body, push the steering dust cover
downwards against the carpet and heat insulation pad from the
inside of the cab.
Caution: To ensure that the via holes in the vehicle body
are sealed completely, use a new steering dust cover
once the steering gear has been removed.
MLG017G
8. Connect the steering column and the power steering

gear.
(a) Align the installation marks on the steering propeller
Installation marks
shaft joint and steering propeller connection shaft.
(b) Fasten the bolt with a No.10 socket wrench.
MLG004G
9. Adjust the power steering gear.

After installing steering tie rod and dust cover on the me-
chanical steering gear, keep the steering gear assembly in the
middle position. The adjusting method is as follows: rotate the
steering gear's input shaft to the limiting position in any direc-
tion, then rotate backwards for 1.61 revolutions. At this time,
the steering gear is in the middle position.
Brakes 8-1
Brakes
Brake System...................................................................................8-2
Components..................................................................................8-2
Checks and Adjustments..............................................................8-4
Brake Fluid Air Bleeding................................................................8-5
Brake Pedal..................................................................................8-9
Vacuum Booster with Brake Cylinder Assembly.........................8-13
Brakes.........................................................................................8-19
ABS Brake System.........................................................................8-25
ABS Brake System Description (with EBD)................................8-25
System Diagram.........................................................................8-25
ABS Working Process.................................................................8-25
EBD Working Process................................................................8-26
Position Schematics....................................................................8-27
ABS General Problem Maintenance and Areas of Importance...8-30
ABS Hydraulic Pressure Control Unit Assembly ........................8-33
Parking Brake Control Device.....................................................8-34
Brake System
Components
Left steering
knuckle and
hub brake Right steering
assembly knuckle and
hub brake
Front wheel speed assembly
sensor assembly LH Front wheel speed
sensor assembly RH
Front brake
hose assembly Clutch and brake pedal assembly
ABS hydraulic pres-

sure control unit Front brake hose assembly
Vacuum booster with Brake line

brake cylinder assembly
Acceleration sensor
Remarks: two-wheel-drive
model is not equipped with
acceleration sensor.
Parking brake control

mechanism assembly
Rear wheel speed

sensor assembly
Left parking brake

Rear brake hose Right parking brake
cable assembly
assembly cable assembly
Rear hub brake Rear hub brake

assembly LH assembly RH
Rear brake hose
assembly 2
MLH001G
Brakes 8-3
Areas of Importance
1. Pay careful attention to replace each part correctly as using incorrect parts will influence the perfor-
mance of the brake system and become dangerous to drive the vehicle. Replace with parts having the
same part number or the equivalent product.
2. While maintaining the brake system, it is very important to keep the parts and maintenance area clean.
3. If the vehicle is equipped with a mobile communication system, please refer to the "Areas of Impor-
tance" section in the "Overview" part.

Hint: Refer to following tables to find the cause of the malfunction. The numbers indicate the possibility of the
cause of the malfunction. Check each part in order. Replace these parts if necessary.

1. Brake fluid in the brake system leaks -
2. Air exists in the brake system 8-5
3. Piston seals (worn or damaged) 8-21
Pedal is positioned too low or feels
4. Brake reservoir does not have enough fluid -
spongy
5. Brake master cylinder (failure) -
6. Booster's push rod (out of alignment) -
7. Brake pedal has too much free play -
1. Free play of brake pedal (too little) -
2. Parking brake lever's stroke (out of alignment) -
3. Parking brake cable (broken) -
4. Brake linings (broken or deformed) -
Brakes drag
5. Disc brake piston (clamping) -
7. Vacuum in booster system leaks -
8. Brake master cylinder (failure) -
1. Disc brake piston (clamping) -
2. Brake linings (oil build-up) -
Brakes deviate 3. Front wheel alignment is loss of position 6-4
4. Brake disc (scratched) -
1. Brake fluid in brake system leaks -
2. Air exists in the brake system 8-5
3. Brake linings (worn) -
Poor braking efficiency 5. Brake linings (oil build-up) -
6. Brake linings (polished) -
9. Vacuum in booster system leaks

2. Mounting bolt (loose) -
4. Brake linings' clip reed (loose) -
Brake noises
5. Brake guide pin (worn) -
6. Brake linings (dirty) -
7. Brake linings (polished) -
8. Muffler gasket (damaged) 8-23
Checks and Adjustments

Check and replacement of brake fluid
Brake fluid directly influences brake performance, the operating conditions, and service life of the brake system
components. Brake fluid has very strong hygroscopic properties, and thus absorbs water easily, which will then
deteriorate the metal and rubber pieces. Polluted and deteriorated brake fluid or its mixture will cause the brake
fluid to boil and vaporize, hence reducing braking efficiency. Therefore, pay attention to the items below when
filling or replacing the brake fluid:
1. Containers used to hold brake fluid must be tightly closed and sealed.
2. Brake fluid is poisonous and damaging to the paint, therefore if it gets on the vehicle surface, rub it off im-
mediately.
3. If water or other contaminates are found in the brake fluid and the brake master cylinder's piston seal has
been broken, then the brake fluid and all rubber pieces inside the brake system, including the brake hose, must be
replaced.
4. The correct brake fluid level in the reservoir must be between the MAX and MIN level lines.
Caution: After the vehicle has been driven for over 1,000 km, check the brake fluid level in the reser-
voir. If the brake fluid level is not as spelified , more brake fluid should be added to the reservoir until it
reaches the MAX level.
Hydraulic component inspection and system flushing
1. If the oil-based solvent gets into the hydraulic system, flush the entire system and change all of the rub-
ber pieces.
2. Clean your hands before installing new rubber pieces or other components.
3. Do not use regular solvents (kerosene, gas, etc.) when inspecting or cleaning hydraulic components,
instead use absorbing alcohol or brake fluid.
4. After inspecting the components, drain the brake fluid from the system. Use new brake fluid to flush the
system. Afterwards, add new brake fluid to perform hydraulic system exhaust.
5. Flushing completion sign: When the brake fluid flowing out of the dump valve is clear of any contami-
nates.
Brakes 8-5
Brake Fluid Air Bleeding

Caution: If the brake system is maintained or air in the
brake lines is suspected, then perform air bleeding on
the brake system.
Warning: Immediately clean if the brake fluid is splashed
on any surface of the paint.
1. Fill the brake fluid to reservoir.

Hint: The brake fluid level in the reservoir needs to be be-
tween the MIN and MAX levels.
MLH002G
2. Master cylinder air bleeding.

Hint: Perform air bleeding on the master cylinder if the master
cylinder is removed or the reservoir is empty.
When performing air bleeding on the master cylinder, it will
need to be carried out by two people.
(a) Disconnect the brake line from the master cylinder.
(b) Slowly press the brake pedal.
MLH003G
(c) Plug the hole with your fingers and loosen the brake
pedal.
(d) Repeat steps (b) and (c) for 3 or 4 times.
(e) Connect the brake line to the master cylinder.
Torque: 16 N·m
MLH004G
3. Brake line air bleeding

(a) Connect the plastic pipe to the bleed screw.
(b) Press the brake pedal several times and then loosen the
bleed screw in the process.
(c) When the brake fluid stops flowing, tighten the bleed
screw and then loosen the brake pedal.
Torque: 11 N·m
(d) Repeat steps (b) and (c) until all the air in the brake fluid
MLH005G
is released.
(e) Repeat the above procedures to release the air in the
brake line of each wheel.
4. ABS hydraulic pressure control unit air bleeding.

Warning: After performing air bleeding on the brake
system, if the correct height or contact feel of the brake
pedal is not acquired, then use a hand-held detector to
perform air bleeding on the ABS controller assembly.
(a) With the engine off, press the brake pedal more than 20
times.
(b) Connect the hand-held detector to the DLC3 and then
switch the ignition switch to the ON position.
Caution: Do not start the engine.
Hand-held detector (c) Select "AIR BLEEDING" on the hand-held detector.

Hint: For detailed information, please refer to the Operation
Manual of the Hand-held Detector.
(d) When the "Step 1: Increase" is displayed on the hand-
held detector, exhaust the air from the brake line.
Warning:
· · Release the air according to the procedures dis-
DLC3 played on the hand-held detector.
MLH006G
· · Be sure not to empty the brake fluid in the master
cylinder reservoir.
(1) Connect the plastic pipe to the bleed screw.

(2) Press the brake pedal several times and then loosen
the bleed screw at the same time.
(3) When the brake fluid stops flowing, tighten the bleed
Torque: 11 N·m
(4) Repeat steps (2) and (3) until all the air in the brake
fluid is released.
MLH005G
(5) Repeat the above procedures to release the air in the
(e) When "Step 2: Inhalation" is displayed on the hand-held
detector, release the air from the suction line.
Warning:
played on the hand-held detector.
cylinder reservoir.
(1) Connect the plastic pipe to the bleed unscrew the
front right wheel or rear front wheel.
(2) Operate the ABS controller assembly with a hand-held
detector to release the air.
Warning:
· · The operation will automatically stop within 4 seconds.
· · Make sure to loosen the brake pedal at that time.
(3) Check and confirm if the image operation performed
Brakes 8-7
by hand-held detector stops.

fluid is released.
Torque: 11 N·m
(5) Perform air bleeding according to the same proce-
dure for the other wheels.
(f) When "Step 3: Decrease" is displayed on the hand-held
detector, release the air from the pressure reduction line.
Warning:
cylinder reservoir.
(1) Connect the plastic pipe to any of bleed screw.

(2) Loosen the bleed screw.
(3) Operate the ABS controller assembly with a hand-held
detector and keep pressing on the brake pedal fully.
Warning:
· · The operation will automatically stop within 4 sec-
onds. At least a 20 second time interval is needed when
performing the procedure continuously.
· · After performing the operation, the brake pedal will
drop slightly, and it is normal if the solenoid valve is on
at that time.
· · While performing the procedure, the pedal will be
heavy, but it will still need to be pressed fully to drain the
brake fluid from the bleed screw.
· · Make sure to press the brake pedal and please do
not press and release the pedal repeatedly.
(4) Tighten the bleed screw and then loosen the brake
pedal.
Torque: 11 N·m
(5) Repeat steps (2) to (4) until all the air in the brake fluid
is released.
(g) When "Step 4 Increase" is displayed on the hand-held
detector, release the air from the brake line again.
Warning:
· · Exhaust the air according to the procedures dis-
cylinder reservoir.
(1) Connect the plastic pipe to any of bleed screw.
(2) Press the brake pedal several times and then loosen
the bleed unscrew any wheel.
(3) When no brake fluid is flowing out, tighten the bleed
Torque: 11 N·m
fluid is released.
MLH005G
5. Check the fluid level in the reservoir.

(a) Check the fluid level and add to it if necessary.
Caution: Check the brake fluid level in the reservoir dur-
ing air bleeding and immediately add to it if level is too
low.
The tightening torque of the bleed screw: 11 N·m
MLH002G
Brakes 8-9
Brake Pedal
Sleeve 3
Sleeve 2
Sleeve 1
Main bracket Conversion bracket

Cover Sleeve
U-clamp
Buffer pad
Clutch pedal lever
Spring
Bushing
Connecting pin Clamp
Pedal pad
Brake pedal lever
MLH007G
Areas of Importance
During removal of the clutch and brake pedal, all components should be gently handled to avoid knocking, espe-
cially the junction surface. All components should be placed in order to avoid losing or taking the wrong parts.
During assembly, pay attention to the following items except for the ones above:
1. The bushing, connecting pin, clamps, and pedal pad should not be reused after removal.
2. Keep all parts clean and free of dust, chips, rust corrosion, oil build-up, or any other contaminants.
3. All rubbing surfaces must be coated with lubricant.
4. Connecting pins should be vertically forced in.
5. The spring collar should be flexible in rotation after clipping.
6. While installing the clutch return spring, be careful to avoid operator injury from it bouncing back.
Troubleshooting
Problem Possible causes Troubleshooting

Clutch pedal cannot return to the original Spring is broken Replace spring
position. Spring's fixed end comes off Check, secure in place
There is an impact sound or a hard stop Buffer pad is worn out or comes
Replace the buffer pad
feeling when pressing the clutch pedal. off
Feels slippery when stepping on the pedal. Pedal pad is worn out/comes off Replace/Reinstall
Bushing or connecting pin is seri-
Replace
Stepping on the pedal produces abnormal ously worn out
noises Spring is broken Replace
Spring's fixed end comes off Check, re-fix
Brake Pedal Lever Removal

1. Remove the clamps with needle nose pliers.
MLH008G
2. Remove the connecting pin with needle nose pliers and

take out the brake pedal lever.
MLH009G
3. Take out two bushings of the brake pedal lever.
MLH010G
Brake Pedal Installation

1. Install the pedal of the clutch pedal lever .
Hint: For the removal and installation of the clutch pedal le-
ver, please refer to the clutch information.
MLH011G
2. Install the pedal pad of the brake pedal lever.

3. Install the bushing on the brake pedal lever and fill with
lubricant. A worn out bushing is not allowed.
MLH012G
Brakes 8-11
4. Put the brake pedal arm subassembly in the main brack-

et and install the clamps.
Caution: The worn out connecting pin is not allowed, and
the clamps should be clipped into the groove of the con-
necting pin.
MLH013G
5. Coat grease on the U-joint of the clutch pedal lever and

the brake pedal cover.
Coat
grease
MLH014G
Replacement of Assembly
1. Remove the battery.
2. Remove the dashboard body.
3. Release the push rod of the brake master cylinder.
(a) Disconnect the brake lamp switch connector.
(b) Release the conversion bracket from the pedal lever with
a slotted screwdriver, loosen the lock nuts, and then re-
lease the master cylinder from the groove of the conver-
sion bracket.
MLH015G
4. Remove the clutch and brake pedal assembly.

(a) Disconnect the clutch's starting switch connector.
(b) Use a No.13 sleeve, extension bar, and quick-wrench to
remove 6 lock nuts tightening the pedal.
(c) Remove the clutch cable ends from the clutch pedal lever.
MLH016G
5. Remove the brake lamp switch assembly.
Remove the brake lamp switch assembly from the brake pedal
lever.
6. Install the brake lamp switch assembly.
(a) Install the nuts on the brake lamp switch assembly.
7. Install the clutch and brake pedal assembly.
(b) Install the clutch cable ends on the clutch pedal arm.
(a) Use a No.13 sleeve, extension bar, and quick-wrench to in-
stall the 6 lock nuts on the clutch and brake pedal assembly.
Torque: 23±3 N·m
(c) Connect the clutch's starting switch and brake switch as-
sembly connector.
MLH016G
8. Install the push rod of the brake master cylinder.

Vertically force the push rod of the brake master cylinder in
the connection bracket of brake pedal.
MLH017G
Brakes 8-13
Vacuum Booster with Brake Cylinder Assembly
Clutch and brake pedal assembly
Non-metal insert lock nuts

with hexagon flange head
Vacuum booster with brake cylinder assembly

MLH018G
The vacuum booster with the brake cylinder assembly is provided by two suppliers, each component is
not interchangeable.
· · The vacuum booster is tightly connected with the pedal bracket on the cowl panel using four lock
nuts and insert into the pedal lever directly. Therefore, prior to removing the vacuum booster, first re-
lease the conversion bracket from the brake lever with a slotted screwdriver and loosen the lock nut
and then operate the booster assembly.
· · If there is vacuum inside of the booster, before removal, fully press the brake pedal 3 - 5 times, so
as to release the vacuum.
· · To avoid a large amount of brake fluid flowing out when removing the brake master cylinder, it's
suggested to siphon the brake fluid from the reservoir into another container using a hose, or loosen
the drain connector and collect the fluid in the container, then drain the brake fluid inside of the pump
by pressing the brake pedal.
Vehicle Check
Good Poorly
1. Check the vacuum booster
(a) Check the air pressure.
(1) Start the engine and stop it after 1 or 2 minutes.
Slowly press the pedal several times.
Third times Hint: If you press the brake pedal towards the floor for the
Second times
First time first, releasing gradually the second or third time, it indicates
ALG024G the booster has a good vacuum seal.
(2) Press the brake pedal when the engine is running and
then stop the engine while keeping the pedal pressed.
Hint: After pressing the pedal for 30 seconds without any
change on the pedal stroke allowance, it indicates the booster
has a good vacuum seal.
(b) Operation Check

AC
C ON
AC
C ON (1) When the ignition switch is off, press the brake pedal
L O CK
START
L O CK
START
several times, check and confirm if the pedal stroke

allowance has changed.
(2) Press the brake pedal and start the engine.
Hint: If the pedal is moved down slightly, it means that the
system is operating normally.
ALG025G
Ventilation No ventilation 2. Check the vacuum check valve

(a) Slide the retaining clip and disconnect the vacuum boost-
er rubber pipe.
(b) Remove the vacuum check valve.
(c) Check and confirm if ventilation from the booster to the
engine is available or whether from the engine to the
booster is not available.
(d) If a problem is found, replace the vacuum check valve.
ALG026G
Brakes 8-15
Brake Master Cylinder Replacement

1. Drain the brake fluid.
Warning: Immediately clean if brake fluid is splashed on
any painted surface.
2. Remove the battery assembly.
3. Remove the brake master cylinder.

(a) Disconnect the switch connector of the fluid level warn-
ing switch.
(b) Disconnect the 2 brake lines from the brake master cylin-
der with an M10 open-end wrench.
Hint: If there is vacuum inside of the booster, fully press the
brake pedal 3-5 times, so as to discharge the vacuum.
MLH019G
(c) Remove 2 nuts and pull out the brake master cylinder.
MLH020G
4. Remove the reservoir assembly.

Split the reservoir fixture with your hands to release it from
the anchor pins of reservoir, and when the fixtures on both
sides are released from the anchor pin, pull out the reserior as-
sembly in an upward motion and pay careful attention not to
use too much force so as to break the fixture.
Anchor pin Reservoir fixture
MLH021G
5. Install the brake reservoir assembly.

Sealing ring (a) As shown in the figure, coat the grease onto the 2 gaskets
and install them to the brake master cylinder without the
reservoir.
Braek master cylinder

Grease MLH022G
(b) Press the reservoir, split the reservoir down and fixtures
on both sides to connect with the anchor pins.
Anchor pin Reservoir fixture
MLH023G
6. Install the brake master cylinder.

(a) Install the brake master cylinder to the booster with 2
nuts.
MLH020G
(b) Connect the 2 brake lines to the master cylinder with ap-
propriate tools.
Torque: 16 N·m
(c) Connect the switch connector of the fluid level warning
switch.
7. Fill the brake fluid into the reservoir.
8. Perform air bleeding on the master cylinder.
MLH019G
10. Check for leaking brake fluid.
Brakes 8-17
Vacuum booster with the brake cylinder replacement

on any painted surface.
2. Remove the battery.
3. Remove the vacuum booster with the brake cylinder as-
sembly.
(a) Disconnect the fluid level warning component.
(b) Disconnect the vacuum hose from the Vacuum booster
rubber hose assembly by sliding the elastic hoop.
Vacuum booster rub-

Hoop
ber hose MLH024G
(c) Release the conversion bracket from the pedal lever with
a slotted screwdriver.
MLH015G
(d) Loosen the lock nuts on the vacuum booster and remove
the vacuum booster with the brake cylinder assembly.
ALG013G
4. Install the vacuum booster with the brake cylinder as-

sembly.
(a) Insert the push rod ball of the vacuum booster into the
conversion bracket groove of the brake pedal and forc-
ibly press down by aligning with the clips.
MLH017G
(b) Install 4 lock nuts.
ALG013G
(e) Connect the vacuum booster rubber pipe to the check

valve of the vacuum booster with the brake cylinder as-
sembly and clamp the steel band elastic hoop tightly.
Hoop Vacuum hose

MLH024G
5. Install the battery.

6. Fill the brake fluid into the reservoir.
8. Perform air bleeding on the brake line.
11. Use a hand-held detector to check the ABS hydraulic
pressure control unit.
Brakes 8-19
Brakes
Front disc brake

guide pin
◆ Guide pin dust cover

Front disc brake cylinder fixed
88
mount LH
◆ Guide pin dust cover

No.2 muffler gasket Brake linings
88
No.1 muffler gasket
Front disc brake No.2 muffler gasket

Brake hose
guide pin
Front disc brake
bleed screw
Joint bolt 8.3 No.1 muffler gasket
30
34
Front disc brake cylin-
der subassembly LH
◆ Piston seal
◆ Copper washer
◆ Piston dust cover
Brake lining clip reed
Bleed screw cap
34
High temperature resistant grease ◆ Location ring

Rubber grease
Front disc brake piston

MLH025G
Overhauling
Hint: The overhauling sequence on the right side is the same
as the left.
on any painted surface.
3. Remove the brake cylinder subassembly of front disc

brake.
(a) Remove the joint bolt and copper washer from the brake
cylinder of front disc brake and then disconnect the brake
hose.
ALG031G
(b) Secure the front disc brake guide pin and remove 2 bolts.
4. Remove the front brake lining subassembly (only linings)
(a) Remove the brake linings with a muffler gasket.
5. Remove the front muffler gasket subassembly.
(a) Remove No.1 and No.2 muffler gasket from each lining.
6. Remove the front brake lining clip reed.
(a) Remove 2 front brake lining clip reeds from the fixed
mount of the brake cylinder of the front disc brake.
ALG032G
Front disc brake guide pin 7. Remove the front disc brake guide pin.
(a) Remove 2 front disc brake guide pins from the fixed
mount of the brake cylinder of front disc brake.
ALG033G
Fixed mount of the brake cyl-

8. Remove the guide pin dust cover.
inder of the front disc brake (a) Remove 2 guide pin dust covers from the fixed mount of
the brake cylinder of the front disc brake.
Guide pin dust cover

ALG034G
Brakes 8-21
9. Remove the fixed mount of the brake cylinder of the front

disc brake.
(a) Remove 2 bolts and the fixed mount of the brake cylin-
der of the front disc brake.
ALG035G
10. Remove the piston dust cover.

(a) Remove the location ring and piston dust cover with a
screwdriver.
ALG036G
11. Remove the front disc brake piston.

(a) Place cotton rags between the front disc brake piston and
(b) Remove the front disc brake piston from the brake cylin-
der subassembly of the front disc brake with compressed
air.
Caution: When using compressed air, be sure not to
Cotton rags
place your fingers in front of the piston.
ALG037G
Warning: Be sure not to spill the brake fluid.
12. Remove the piston seals.

(a) Remove the piston seals from the brake cylinder of front
disc brake with a screwdriver.
Warning: Be sure not to damage the inside cylinder and
the brake cylinder groove.
13. Remove the front disc brake bleed screw.
(a) Remove the bleed screw cap and the front disc brake
bleed screw from the brake cylinder subassembly of the
ALG038G
front disc brake.
14. Check the brake cylinder and piston.
(a) Check the brake cylinder bore and front disc brake piston
for rust and scratches.
15. Check the lining thickness.

(a) Measure the lining thickness with a ruler.
16. Check the front brake lining clip reed.
(a) Check the 2 front brake lining clip reeds. Make sure they
have sufficient rebound and are free of deformation,
breakage or are worn out, and all rusts, dirt, and contami-
ALG039G
nates are cleaned out.
17. Inspect the disc brake thickness.

(a) Use a micrometer caliper to measure the disc brake
thickness.
ALG040G
18. Remove the front disc brake.

Installation mark
(a) Make installation mark on the disc brake and axle hub.
(b) Remove the disc brake.
19. Install the front disc brake.
(a) Install the front disc brake by aligning the installation
mark.
Hint: When replacing with a new disc brake, select the mini-
mum axial runout positon of front disc brake for installation.
ALG041G
20. Check the axial runout of disc brake.

(a) Temporarily tighten the disc brake with hub nuts.
Torque: 110 N·m
(b) Use a dial indicator to measure the disc brake axial run-
out at 10 mm away from the outer edge of the brake.
Maximum axial runout of disc brake: 0.1 mm
(c) If the axial runout of the disc brake is larger or equal to
the maximum value, check the bearing axial clearance
ALG042G
and the radial runout of the axle hub.
If the bearing clearance and the radial runout of the axle
hub is normal, then adjust the axial runout of the brake
disc or grind it on the brake turning machine.
21. Temporarily tighten the front disc brake bleed screw.
(a) Install the front disc brake bleed screw onto the brake
cylinder of the front disc brake.
(b) Install the bleed screw cap on the bleed screw.
22. Install the piston seal.
(a) Coat grease to the new piston seal.
Brakes 8-23
(b) Install the piston seal onto the brake cylinder of the front
disc brake.
23. Install the front disc brake piston.
Piston dust cover
(a) Coat grease onto the front disc brake piston and the new
piston dust cover.
(b) Install the piston dust cover on the front disc brake pis-
ton.
(c) Install the piston on the brake cylinder inside the front
Piston disc brake.
Warning: Make sure not to use force to install the piston
ALG043G
on the brake cylinder inside the disc brake.
24. Install the piston dust cover.
Piston dust cover
Front disc
(a) Install the new piston dust cover on the brake cylinder
brake piston
subassembly of front disc brake.
Warning: Install the dust cover onto the groove of the
brake cylinder and piston.
(b) Install the location ring with a screwdriver.
Location ring Warning: Do not damage the piston dust cover.
ALG044G
25. Install the fixed mount of the brake cylinder of front disc
brake.
(a) Install the fixed mount of the brake cylinder of front disc
brake with 2 bolts.
Torque: 100 N·m
ALG035G
26. Install the guide pin dust cover.

Fixed mount of the brake
cylinder of front disc brake (a) Coat grease onto the surface of the 2 new dust cover
seals.
(b) Install the 2 guide pin dust covers on the fixed mount of
the brake cylinder of front disc brake.
Guide pin dust cover
Rubber grease ALG045G

Front disc brake guide pin 27. Install the front disc brake guide pin.
(a) Coat grease to the sliding part and sealing surface of the
2 disc brake guide pins.
(b) Install the 2 front disc guide pins on the fixed mount of
28. Install the front brake lining clip reeds.
(a) Install the front brake lining clip reeds on the fixed
mount of the brake cylinder of front disc brake.
Rubber grease ALG046G
29. Install the front muffler gasket subassembly.

No.1 muffler gasket
(a) Coat the disc brake grease on both sides of the No.1 and
No.2 muffler gasket.
(b) Install the muffler gasket on each lining.
30. Install the front brake lining subassembly (only linings)
When replacing the brake linings, replace the muffler gasket
No.2 muffler gasket
subassembly if necessary.
(a) Install the brake lining subassembly on the fixed mount of
High temperature resistant grease ALG047G
the brake cylinder of front disc brake.
Caution: The rubbing surfaces of the linings and brake
discs should be free of oil build-up and grease.
31. Install the brake cylinder subassembly of the front disc

brake.
(a) Install the brake cylinder subassembly of the front disc
brake with 2 bolts.
Torque: 34 N·m
ALG048G
(b) Install the new copper washer and brake hose with joint
bolt.
Torque: 30 N·m
Hint: Install the brake hose lock onto the brake cylinder
subassembly lock hole of the brake disc.
32. Fill the reservoir with brake fluid.
34. Perform air bleeding on the brake line.
ALG031G
Torque: 110 N·m
Brakes 8-25
ABS Brake System

ABS Brake System Description (with EBD)
The ABS brake system detects the wheel's speed via speed sensor detection. After signal processing, the wheel
speed will be transferred to the ECU, which controls the solenoid valve's operating condition and the pressure in-
side the brake wheel cylinder to avoid wheel locking based on the signal of the wheel speed.
The Electronic Brake Distribution (EBD) is used to adjust the vehicle's rear wheel brake pressure by using the
ABS components when the ABS does not respond to vehicle braking. It is also used to balance the vehicle’s front
and rear wheel brake pressure, maximizing the vehicle's braking efficiency.
System Diagram
ABS control unit (ECU)
Vaccum booster and

brake master cylinder
Wheel speed signal Work instruction
Speed sensor
Hydraulic adjuster
Brake cylinder of the rear wheel brake
ALG072G
ABS Working Process

(a) Pressure rising phase: While servicing the brake system, oil pressure output from the pump passes the inlet
solenoid valve and enters the brake wheel cylinder. The brake generates braking force and the wheel speed
sharply declines until the ABS control unit detects that the wheel is starting to lock via the wheel speed sen-
sor detection.
(b) Pressure maintaining phase: When the ABS control unit detects that the wheel is starting to lock via the
wheel speed sensor signal, the inlet solenoid valve closes. With the outlet solenoid valve shut as usual, the
pressure maintaining phrase begins.
(c) Pressure dropping phrase: During the pressure maintaining phase, the wheels tend to lock further. This
brings the ABS into the pressure dropping phrase. With the inlet valve closed and the outlet valve open, the
hydraulic pump starts working, and brake fluid returns to the brake pump from the wheel cylinder by pass-
ing through the low pressure accumulator. The brake pressure reduces and the brake pedal bounces back.
(d) Pressure maintaining phase: When the degree of wheel locking decreases and the wheel speed begins to in-
crease, the pressure maintaining phrase begins.

(e) Next cycle's pressure rising phase: When the wheels reach a certain speed, the ABS enters the pressure ris-
ing phase and starts the next cycle.
Note: The ABS's pressure adjusting frequency is generally 2 to 4 cycles per second.
Vehicle speed
Wheel slippage
Wheel speed
Master cylin-
der pressure
Wheel cylinder
brake pressure
MLH026G
EBD Working Process

The EBD comes into effect when the wheel brakes are lightly applied. The wheel speed sensor detects the speed
of the wheels, and the ECU calculates the speed. If the rear wheel's slip ratio increases, adjust the brake pressure
to maintain or reduce the rear wheel's braking force. The EBD guarantees the rear wheel's lateral force and even
brake force distribution. If the ABS fails to respond, the electronic brake distribution system can still adjust the
rear wheel's braking force to guarantee the rear wheels do not lock before the front wheels, in order to ensure ve-
hicle safety.
The EBD's working process for lifting and holding pressure is completely the same as that of the ABS working
process. However, the process for lowering the pressure is quite different. When the rear wheel has a tendency
to lock up, the normally open valve of the rear wheel closes, the normally closed valve opens, and the rear wheel
pressure reduces. The difference with the ABS is that the hydraulic pump does not operate at this time, and the
brake fluid released during depressurization is temporarily stored in the low pressure accumulator. After braking,
the brake pedal is loosened, and the brake pressure inside the pump drops to zero. Open the normally closed valve
one more time at this point. The brake fluid inside the low pressure accumulator returns to the pump by passing
through the normally closed valve and normally open valve. Empty the low pressure accumulator to prepare for
the next braking event.
Brakes 8-27
Position Schematics
Wheel housing of the vehicle body

Vacuum booster with brake cylinder assembly
ABS hydraulic pressure control unit
MLH027G
ABS Hydraulic Pressure Control Unit Replacement

1. Removal
(a) Disconnect the brake line and drain the brake fluid.
(b) Disconnect the wire harness connectors.
(c) Remove 2 bolts which attach the hydraulic pressure con-
trol unit mounting bracket.
(d) Pull the mount pin out of the shock pad and pull the an-
Hydraulic pressure control chor pin of the hydraulic unit out of the bracket.
unit mounting bracket
2. Installation
ABS hydraulic pres- ABS hydraulic pressure pump shock pad
sure control unit MLH028G (a) Fix the hydraulic pressure control unit mounting bracket to
the wheel house of the vehicle body with hexagon bolts for
the flange face.
(b) Fix the shock pad of the ABS hydraulic pump onto the
mounting holes of the wheel house of the vehicle body.
(c) Insert the mount pin of the ABS hydraulic pressure con-
trol unit into the shock pad holes by simply inserting the
two anchor pins into the bracket.
Wheel speed sensor assembly

1. Remove the front wheel speed sensor.
(a) Remove the front wheel.
(b) Disconnect the wheel speed sensor connector.
(c) Remove 4 fixed clamps from the wheel house.
(d) Remove the front wheel speed sensor from the wheel
speed sensor mounting bracket and shock absorber.
Front wheel speed
sensor assembly (e) Remove the sensor from the steering knuckle mounting
MLH029G
hole by removing the mounting bolts.
2. Install the front wheel speed sensor.
(a) Use the hexagon head bolts, spring washers, and flat
washer subassembly to connect the sensor and the steer-
ing knuckle.
(b) Fix the front wheel speed sensor to the mounting holes of
the shock absorber bracket, sensor mounting bracket, and
vehicle body (secured with clamps).
(c) Plug the wheel speed sensor connector to the electronics
MLH030G wire harness.
Caution:
· · Foreign matters on the sensor ends should be
avoided.
· · The wheel speed sensor is provided by two suppli-
ers and are not interchangeable. The front and rear sen-
sor from the same manufacturer must be installed on the
same vehicle.
3. Remove the rear wheel speed sensor.

(a) Remove the rear wheel.
(b) Disconnect the wheel speed sensor connector.
(c) Remove the fixed clamps on the rear subframe and rear
trailing arm and disconnect the rear wheel speed sensor.
(d) Remove the sensor from the mounting hole of rear hub
unit by removing the mounting bolt.
Rear wheel speed
sensor assembly 4. Install the rear wheel speed sensor.
MLH031G
(a) Use the hexagon head bolts, spring washers, and flat
washer subassembly to connect the sensor and the rear
hub unit.
Brakes 8-29
(b) Fix the rear wheel speed sensor to the wire harness
mounting hole of the rear trailing arm, rear subframe (se-
cured with clamps), and the vehicle body.
(c) Plug the wheel speed sensor connector to the electronics
wire harness.
Caution:
· · Foreign matters on the sensor ends should be avoid-
ed.
MLH032G
· · The wheel speed sensor is provided by two suppli-
ers and are not interchangeable. The front and rear sen-
sor from the same manufacturer must be installed on the
same vehicle.
5. Install the acceleration sensor assembly.

Install the acceleration sensor to the vehicle floor (under the
left driver's seat) with hexagon bolts for the flange face and
connect the electronics wire harness.
Caution: The acceleration sensor assembly is a Bosch
BS5 and installation direction is required. Install the HA-
VAL M1 reversely and avoid installing it in wrong direc-
tion.
MLH033G
ABS General Problem Maintenance and Areas of Importance

1. When braking, the ABS hydraulic pressure adjuster noise is extremely loud.
(a) When the ABS is working, the motor inside the hydraulic pressure adjuster is constantly rotating. At this
time, the driver can feel the brake pedal bouncing back. However, this bounce back feeling will be entirely
different depending on the speed and road conditions.
(b) When performing an actuator movement test, the sound of the running motor may also be sensed. When the
vehicle is being driven and the brake is off, the sound of the motor running can still occasionally be heard.
This is the ABS undergoing a component inspection, not a malfunction.
(c) If the ABS hydraulic pressure adjuster noise is irregular, a movement test can be initiated. Compare the
noise to that of normal vehicles to determine if the ABS hydraulic pressure adjuster noise is abnormal.
2. Inlet and outlet solenoid valve malfunction
Once the ignition switch is ON, the ABS control unit automatically initiates a self-check. If an inlet and outlet
solenoid valve short circuit or open circuit is found, it will record the failure, light up the problem lamp, and abort
the operation. If using a scanner to adjust the problem code, make sure to use the movement test to confirm that
the solenoid valve has a problem and then immediately replace the hydraulic pressure adjuster assembly.
X431 data flow: While the ABS is functioning, the inlet and outlet solenoid valves rapidly change operating con-
ditions.
EVFL - Front inlet valve LH Off/On

AVFL - Front outlet valve LH Off/On
EVFR - Front inlet valve RH Off/On
AVFR - Front outlet valve RH Off/On
EVRL - Rear inlet valve LH Off/On
AVRL - Rear outlet valve LH Off/On
EVRR - Rear inlet valve RH Off/On
AVRR - Rear outlet valve RH Off/On
3. Inlet and outlet solenoid valve malfunction

With the engine running, measure the voltage between the sensor's signal line and the ground with an oscillo-
scope.
(a) The output signal when the wheel is stationary is as

V shown on the left.
Hint: The two states in the diagram are both normal.
0
t
State 1
0
t
State 2
MLH034G
Brakes 8-31
(b) Output signal when the wheels are rotating: the signal
type is 0.44 V and 1.26 V square wave signal, duty cycle:
V 50:50.
0
t
MLH035G
(c) The X431 scanner possesses a function showing the data flow in waveform. The wheel speed signal error
(wheel speed sensor failure) only appears when intermittent problems occur, such as high speed, and when
in use, some signal errors may occasionally appear. Continue observing the waveform to make sure there is
nothing abnormal. When driving the vehicle on a flat and straight road, all four wheels' speed sensor wave-
forms are extremely similar. One can compare the two front wheels' with the two rear wheels' signal wave at
the same time.
Mechanical causes: Signal gear distortion, loosened hub bearings, smudges on the sensor surface, etc., all may
lead to wheel speed signal intermittency and inaccuracy. Failure examples are is as follows:
V (km/h)
60
30
Signal interruption
t
ALG075G
As shown above, once the intermittent failures with the wheel's speed sensor signal are detected, the ABS control
unit records the sensor problems and illuminates the warning lamp.
4. Wheel speed sensor velocity malfunction
If the ECU detects an excessive difference between the two wheels' speed sensor signals, the possible causes are
the gear's wheel speed sensor gap is excessively large, or the wheel speed sensor signal is experiencing interfer-
ence. For this, first determine which sensor is emitting the signal and then use failure table to perform trouble-
shooting.
Areas of Importance
1. Sometimes, in order to determine whether there is a common brake system problem or an ABS prob-
lem, the ABS must be terminated by pulling out its ABS ECU connector or fuse. At this time, the ABS/
EBD loses function as well. On muddy, icy, or snowy roads, the vehicle may fishtail or slide, in which
case one must be extremely careful to avoid hard braking.
2. The ABS malfunction rate is extremely low, when the brake system shows any problem (before the
warning lamp goes on), first eliminate the normal brake system problems, then consider the ABS mal-
functions.
3. When raining or on gravel, this adjusting process is longer than the standard process, because this
kind of road's unstable adhesion coefficient will lead to a difference between the sliding measurement
and calculation procedures, thus it is necessary to remind drivers to be especially careful when driving
under the circumstances mentioned above.
4. ABS ECU Areas of Importance
(a) The ABS ECU is easily damaged from impact or collisions, thus pay attention to ensure the ECU avoids
such incidents.
(b) High temperature environments can also easily damage the ECU, so when the vehicle undergoes hot paint
work, make sure to first take the ECU out of the vehicle.
(c) When the power switch is ON, do not disassemble the system's electrical elements and wire harness plugs
in order to avoid damage to the ECU. If removal or installation must be carried out, be sure first to discon-
nect the ignition switch. When welding components or circuits to the system, the connector should also be
removed from the ECU.
(d) Do not let oil contaminate the ECU. Be especially careful of the ECU terminals. Otherwise, it might obstruct
the connection among terminals of the connector.
ABS Trouble Code List:

Trouble code Problem description
Front wheel speed sensor LH circuit failure, velocity fail-
C0035
ure
Front wheel speed sensor RH circuit failure, velocity fail-
C0040
ure
Rear wheel speed sensor LH circuit failure, velocity fail-
C0045
ure
Rear wheel speed sensor RH circuit failure, velocity fail-
C0050
ure
C0060 Front ABS outlet solenoid valve LH failure
C0065 Front ABS inlet solenoid valve LH failure
C0070 Front ABS outlet solenoid valve RH failure
C0075 Front ABS inlet solenoid valve RH failure
C0080 Rear ABS outlet solenoid valve LH failure
C0085 Rear ABS inlet solenoid valve LH failure
C0090 Rear ABS outlet solenoid valve RH failure
C0095 Rear ABS inlet solenoid valve RH failure
C0110 Pump motor circuit failure, operational error
C0121 Solenoid valve relay circuit failure
Brakes 8-33
C0161 Brake switch circuit failure

Wheel speed sensor frequency error, wheel speed sensor
C0245
signal failure
C0287 Acceleration sensor failure
C0550 ECU failure
C0800 Voltage fault, voltage too high or too low
Warning lamp positive short circuit, warning lamp
C0232
ground short circuit
ABS Hydraulic Pressure Control Unit Assembly

Vehicle Check
Hand-held detector 1. Connect the hand-held detector.

(a) Connect the hand-held detector to the DLC3.
(b) Start up and run the engine at an idle speed.
(c) Select the ACTIVE TEST mode on the hand-held detec-
tor.
Hint: For detailed information, please refer to the Operation
Manual of the Hand-held Detector.
DLC3 2. Check the operation conditions of the actuator motor.
MLH006G
(a) Check the operation sound of the actuator motor when
the motor relay is connected.
(b) Disconnect the motor relay.
3. Check the operation conditions of the front right wheel.
(a) Press the brake pedal and hold it for 15 seconds. Confirm
that further pressing the brake pedal is not possible.
(b) Confirm the pedal vibration when the motor relay is con-
nected.
Warning: The continuous connection time of the motor
relay must not exceed 5 seconds. When it is in continu-
ous operation, an interval of over 20 seconds should be
set.
(c) Disconnect the motor relay and loosen the brake pedal.
Warning: The following procedures to be obeyed when
connecting the solenoid valve:
(d) When pressing the brake pedal, perform following opera-
tion.
(e) Connect the EVFR and AVFR solenoid valve simultane-
ously and confirm that further pressing the pedal is not
possible.
Warning: The connection time of the solenoid valve must
not exceed 5 seconds. When it is in continuous opera-
tion, an interval of over 20 seconds should be set.
(f) Disconnect the EVFR and AVFR solenoid valve simulta-
neously and confirm that further pressing the pedal is not
possible.
(g) Connect with the motor relay and confirm the pedal re-
turns to the original position.
Warning: The connection time of motor relay must not
exceed 5 seconds. When it is in continuous operation,
an interval of over 20 seconds should be set.
(h) Disconnect the motor relay and loosen the brake pedal.
4. Check the operation conditions of the other wheels.
(a) Check the solenoid valve of the other wheels with the
same procedure.
Warning: Do not press the brake pedal if only the pres-
sure reducing solenoid valve is connected.
Hint:
Left Front wheel: EVFL, AVFL
Right rear wheel: EVRR, AVRR
Left rear wheel: EVRR, AVRR
Parking Brake Control Device
Right brake cable bracket
Parking brake control

mechanism assembly Mushroom head break mandrel blind rivets
Right parking brake cable assembly
Left parking brake cable assembly
Mushroom head break mandrel blind rivets
Left brake cable bracket
Hexagon socket cap screws

MLH036G
Parking brake control mechanism assembly Parking Brake Control Mechanism Assembly
1. Removal
(a) Remove the auxiliary facia console and pull the parking
brake lever to the lowest position. Disconnect the park-
Floor ing brake lamp switch connector.
(b) Remove two hexagon socket cap screws used to stablize
the parking brake control mechanism assembly onto the
MLH037G
vehicle floor.
(c) Loosen the parking brake cable's adjusting nuts (nut with
Brakes 8-35
an abnormal shape) with a wrench and take the cable out

from the adjusting clamp.
Abnormally-shaped nut 2. Assembly

Complete the parking brake control mechanism's installation
by reversing its removal sequence.
Cable
Hexagon
clamp Areas of Importance in assembly
socket cap
screw · · The open end of the parking brake control mecha-
nism assembly's cable clamp should face down.
Hexagon socket · · While installing the parking brake control mechanism
cap screw
assembly, it must be properly adjusted, which is usually
Parking indicator switch MLH038G
6 to 8 gears.

1. Parking brake lever's stroke (out of alignment) -
2. Parking brake cable (broken) -
Parking brake functions poorly 3. Parking brake caliper's clearance (out of alignment) -
5. Brake caliper (damaged) -
Supplemental Restraint System
Seat Belts.........................................................................................9-2
Overview.......................................................................................9-2
Seat Belt Inspection Items............................................................9-2
Test Drive......................................................................................9-3
Maintenance Guide.......................................................................9-3
Components..................................................................................9-3
Airbags.............................................................................................9-7
Overview.......................................................................................9-7
SRS Airbag System Diagnosis....................................................9-12
Basic Processes of the Malfunction Diagnostic..........................9-13
Troubleshooting..........................................................................9-18
Vehicle Collision Diagnostics......................................................9-25
Components................................................................................9-28
Individual Components Removal................................................9-29
Airbag Disposal...........................................................................9-35
Seat Belts
Overview
When leaning 12° or less in any direction at the specified mounting position, the retractor should not be locked.
When leaning more than 27° in any direction at the specified mounting position, the retractor must be locked.
Areas of Importance
1. Only people that have received training are allowed to inspect, install, and repair the seat belt.
2. Any parts of the seat belt are not allowed to be removed or repaired. You can only replace them with
new ones in principle to avoid the risk of injury.
3. A seat belt that has been stricken hard or fallen on the ground is not allowed to be installed in the vehicle.
4. Replace the seat belt that has physical damage (protruded, sunken, or cracked).
5. Do not bleach or dye on the seat belt. Wash it with a neutral liquid soap and soft brush or cloth only.
6. Prevent sharp and harmful substances from touching the seat belt, and avoid winding or breaking any
parts of the seat belt lock button or lock plate.
7. Only use correct seat belt mounting bolts and screws.
(a) Tighten the bolts and screws to the required torque value.
(b) When installing the seat belt with mounting bolts, starting tightening by your hand to make sure the thread
is aligned.
8. Some seat belts and retractors must be repaired as a whole. Do not repair or replace them separately.
9. Make sure the replaced part's number is applicable to the specific seat of the vehicle. Do not replace
with the seat belt of a different seat.
Seat Belt Inspection Items

Carefully inspect the seat belt system after every accident. If damage is determined according to the inspection
items, the seat belt must be replaced. The inspection items mainly include:
Items Damages Contents

The belt body is cut or cracked Replacement of seat belt
Inspect the body The fabric on the edge is torn and lock button
The belt is burned by a cigarette, etc. Seat belt replacement
Inspect the retractor (for lock- Pull out the belt body hard and quickly. It is not locked.
ing) The vehicle body is not locked during braking
Lock button visual inspection Cracked or broken
Insert the lock tongue into the lock button and pull the
belt body hard, the lock system is not engaged
Lock button function inspec- (at least inspect for 5 times) Replacement of seat belt
tion Press the lock button with your finger, the belt body loos- and lock button
ens, and the lock tongue ejected from the lock button
(inspect for at least 5 times)
Inspect the guiding board and The deformation, cracks or breaks of plastic pieces
lock tongue Grooves or damages appear
The lock tongue is deformed (stretched)
Inspect the fastening pieces
Fastening point (seat, pillar, floor) is deformed or its
and fastening points Replace the fastening point
thread is damaged
Test Drive
1. Fasten the front seat belt.
2. Drive the vehicle at the speed of 16 km/h and step on the brake pedal forcibly. Inspect and make sure
the seat belt locks and is not stretchable.
Hint: Test in a safe area. If the seat belt does not lock, remove the seat belt assembly and inspect it. In addition,
whenever installing a new seat belt assembly, make sure it works properly before installing.
Maintenance Guide
The maintenance and inspection required after an impact: the protection system will be damaged upon impact. In
order to avoid personal injury and make sure all required parts are replaced: replace all seat belt systems used in
the impact that can activate the auto protection devices (such as the airbag and the seat belt pretensioner). Replace
all seat belt systems that have cracked, worn, or broken parts. If the above mentioned impact occurs, do not only
replace a single seat belt system part, but replace the entire seat belt system (including the lock latch and belt) with
the lock button, guide plate, and retractor assembly. If a light impact occurs and the auto protection devices are not
activated, you don't need to replace the seat belt system unless some parts are cracked, worn, or broken.
Components
Right B-pillar upper guard plate Seat belt retractor
45±5
Rear seat belt assembly
Guide bracket
Rear seat mortise lock assembly
45±5
45±5
Decorative cap
Seat belt Front passenger seat belt assembly
retractor
Right B-pillar lower guard plate

45±5
45±5
Front passenger seat mortise lock assembly

MLI001G
Removal
1. Remove the front passenger seat belt.
Hint:
quence. However, only the installation procedures containing
additional information are included.
The procedures on the right side are the same as the left side.
(a) Remove the front passenger seat assembly.
(b) Remove the front threshold protector RH.
(c) Remove the rear threshold protector RH.
(d) Unscrew the bolt at the seat belt's lower fastening point
and remove the seat belt fastening piece 2.
B-pillar lower
guard plate
Fastening piece 2
MLI002G
(e) After removing the B-pillar lower guard plate, unscrew

Woven band the bolt of the seat belt's guide bracket to remove it.
Guide bracket
Guide bracket nut
MLI003G
(f) Open the guide ring's decorative cap, unscrew the bolt,
and remove the guide ring.
B-pillar upper
Guide ring guard plate
Bolt
MLI004G
(g) Unscrew the retractor's mounting bolt to remove the re-

Retractor
tractor.
Retractor's
mounting bolt
MLI005G
2. Install the front passenger seat belt.

3. Inspection after installation.
(a) After installing, swiftly pull out the seat belt, inspect it
and make sure it locks. If it doesn't work properly, re-
place the outer seat belt assembly.
(b) Inspect and make sure that after fully pulling out, the seat
belt cannot be pulled out any more but can be retracted.
(c) Inspect to make sure that the seat belt can be pulled out
and retracted after fully retracting.
If it doesn't work properly, replace the seat belt assembly.
4. Remove the rear seat belts.

sequence. However, only the installation procedures contain-
ing additional information are included.
(a) Remove the rear door weatherstripping RH.
(b) Remove the rear seat.
(c) Unscrew the bolt at the lower fastening point to remove
the fastening piece.
Rear threshold protector
Fastening piece
MLI006G
(d) Remove the seat belt's guide plate and take out the wo-
ven band from the guide plate.
Seat belt guide plate
MLI007G
(e) As shown on right, after removing the C-pillar guard

plate assembly, unscrew the retractor's mounting bolt to
remove the retractor.
5. Install the rear seat belt.
6. Inspection after installation.
(a) After installing, swiftly pull out the seat belt, inspect it
and make sure it locks. If it doesn't work properly, re-
MLI008G
place the seat belt assembly.
(b) Inspect and make sure that after fully pulling out, the seat
belt cannot be pulled out any more but can be retracted.
(c) Inspect and make sure that the seat belt can be pulled out
and retracted after fully retracting.
If it doesn't work properly, replace the seat belt assembly.
Airbags
Overview
Airbag usage
The safety measures on the vehicle can be divided into active safety measures and passive safety measures. The
former can be used to prevent accidents from happening, and the later can be used to reduce the severity of the
accident.
An airbag is a passive safety measure. When the vehicle bumps and the speed changes sharply, the airbag swiftly
expands and forms an air cushion between the driver, passenger, and the structure of the vehicle, so that the head
and chest of the driver and passenger will hit on the cushion instead of the hard components inside the vehicle to
reduce the severity of personal injury.
Airbag's components and functions
The airbag mainly consists of an impact sensor, airbag control component (SRS ECU), airbag components, and
the airbag system indicator (SRS).
Impact sensor: its function is to find out the impact or deceleration value of the vehicle during the impact and then
send the signal to the electronic control system to determine whether the airbag should be deployed.
ECU: its function is to receive the signals from the impact sensor and other sensors to determine whether to fire
the airbag and to diagnose the system failure.
The airbag mainly consists of the airbag, coil spring, air generator, and igniter. The air generator acts according to
the signal received to ignite the solid fuel and generate air to inflate the airbag with a volume of or more or less.
SRS indicator: it is used to indicate the work status of the airbag. When an abnormal condition occurs, the indica-
tor is on and an alarm sounds.
The basic principle of the airbag
The basic principle of the airbag is that, when an impact occurs, the controller recognizes and determines the in-
tensity of the impact according to the impact speed (deceleration) signal, and when the impact intensity reaches
the preset condition, the sensor immediately activate the igniter to ignite the solid nitrogen particles and form a
swiftly expanding airbag, to reduce the impact intensity received by the driver.
Areas of Importance
Caution:
· · The vehicle is equipped with an SRS, which contains the driver side airbag, the front passenger
side airbag, and seat belt. Incorrect maintenance procedures may result in SRS airbag accidental de-
ployment and causing serious accidents. In addition, if an error occurs during maintenance of the SRS,
it may not work properly in the future. Before maintenance (including the installation, inspection, or re-
placement of the parts), make sure to carefully read the following items and then follow the procedures
specified in the maintenance manual.
· · Set the ignition switch to the LOCK position, disconnect the battery's negative (-) cable, and wait
at least 90 seconds. (SRS has a backup power supply, so if you do not wait at least 90 seconds before
continuing, the SRS may deploy)
· · Do not directly expose the driver side airbag assembly, the front passenger side airbag assembly,
and the airbag ECU assembly to dry and hot air or flame.
Warning:
· · Since it is hard to determine the SRS malfunction symptom, the DTC is a very important informa-
tion source when clearing the malfunction. When clearing the SRS malfunction, the DTC must be in-
spected before disconnecting the battery.
· · In case of impact, even if the SRS is not deployed, you must also inspect the driver side airbag as-
sembly, the front passenger side airbag assembly, and the airbag ECU assembly.
· · If the airbag ECU might cause an electrical shock during maintenance, remove it before performing
maintenance.
· · Never use any SRS parts from other vehicles. You must replace with the components.
· · Never remove or maintain the driver side airbag assembly, the front passenger side airbag assem-
bly, and airbag ECU assembly with the purpose of reusing them.
· · If the driver side airbag assembly, the front passenger side airbag assembly, or the airbag ECU
assembly has been dropped or there are cracks, indentations or other flaws on their shell, bracket, or
connector, just replace them with new ones.
· · Use an X—431 scanner to troubleshoot the circuit malfunction.
· · Information labels can be found on the outside of the SRS components. Follow the instructions in
the notice.
· · After completing the work on the SRS, inspect the SRS warning lamp.
· · When the batter's negative (-) cable is disconnected, the clock and stereo system memory will be
cancelled. Therefore, before working, record the contents in the stereo storage system and when the
work is completed, reset the stereo system to the original status and adjust the clock. To avoid clearing
the storage, use an external backup power supply.
· · If the vehicle is equipped with a mobile communication system, refer to the "Areas of Importance"
in the Preface.
1. SRS connector
1
Front passenger
seat outer belt as-
sembly (Squib)
2
3
Front passenger
side airbag as-
sembly (Squib)
4
Airbag ECU
5 7
Clock spring Driver side airbag
subassembly assembly (Squib)
6 8
9
Driver seat outer belt
assembly (Squib)
10
MLI009G
Gasket Hint: All connectors in the SRS are yellow in order to distin-
guish them from other connectors. To ensure high reliability,
Shell all of these connectors use wearable plated terminals.
(a) Terminal dual-lock mechanism
Each connector has a double-element part, which consists of a
shell and gasket. This kind of design allows the terminal to be
Negative firmly locked by two lock-up devices (a retainer and contact
Positive flat) to prevent the terminal from sliding out.
ALK002G
(b) Explosion-proof mechanism
Each connector contains a short connected spring. When the
connector is disconnected, the short connected spring will au-
tomatically connect to ignition pipe's positive (+) and negative
(–) terminals.
When the connector is connected When the connector is disconnected
Short connected spring
Short connected spring

Shell
Contact positive terminal
Shell
Short connected spring conducting
Terminal
Short con- Squib

Connector Closed circuit
nected spring Squib
ALK003G
(c) Half connection prevention mechanism

If the connector is not fully connected, it will be disconnected due to the retractibility of the spring so the conduc-
tion is broken.
Slider Stopper
Lock arm Spring
Lock up piece Rebound via slider
Stopper (Spring)
ALK004G
(d) Connector lock-up mechanism

Lock the connector's lock-up button to firmly attach to the connector.
Lock-up button
Claw
Slot
ALK005G
(e) Connector position determination mechanism:

The CAP (yellow part) will slide only when the case lock (white part) is fully jointed, so as to complete the joint
of the connector.
Case lock
(white part)
Case lock
(white part)
CPA (yellow part) CPA (yellow part)

ALK006G
Figure 1
In case the vehicle has suffered from a front impact in the
shaded area (as shown in the Figure 1) and the impact is
greater than expected, the SRS will activate automatically. The
Figure 2 Power supply deceleration for conducting the security sensor is smaller than
the deceleration for conducting the airbag sensor. As shown in
Security sensor Squib Figure 2, when the security sensor and the deceleration sensor
are conducted at the same time, the current flows to the squib
Deceleration sensor ALK007G
and the squib ignites. When the deceleration force takes effect
on the sensor, the two squibs on the driver side and front pas-
senger side airbags will generate gas and the airbags will de-
ploy. When the gas is released through the exhaust hole behind
or beside the airbag, the airbag is deflated.
2. Disconnect the driver side airbag assembly connector.

Hint: Please have the screwdriver tip wrapped with adhesive tape before using the screwdriver.
(a) Loosen the lock-up button (yellow part) of the connector with a screwdriver.
(b) Insert the head of the screwdriver into the middle of the connector and the base, and then lift up the connector.
Lock-up button (yellow)

(a) Lock-up button (yellow) (b)
Mark
ALK008G
3. Connect the driver side airbag assembly connector.

(a) Attach the connector
(b) Fully press the connector's lock-up button (yellow part).
Lock-up button (yellow)
ALK009G
SRS Airbag System Diagnosis

1. For the sake of safety, carefully read the following maintenance notices before operation.
(a) While performing maintenance on the airbag, make sure to work in accordance with this chapter's steps and
notes.
(b) Be sure to use the specified test apparatus and SST which are mentioned in this chapter.
(c) While performing maintenance on the following mentioned components, if there is any problem with a com-
ponent, be sure to replace it with a new one.
(1) Airbag ECU
(2) Clock spring assembly (5) Driver seat belt pretensioner
(3) Driver side airbag assembly (6) Front passenger seat belt pretensioner
(4) Front passenger side airbag assembly (7) Airbag wire harness
(d) Wait 90 seconds after disconnecting the negative terminal to avoid deployment of the airbag.
2. Airbag ECU terminal
25 19 18 17 16 14 13 11 10 9 7 6 5 1
50
MLI010G
Terminal No. Name Description Terminal No. Name Description

5 IGN Battery voltage 13 D PBT HI Driver seat belt pretensioner,
high end
14 D PBT LO Driver seat belt pretensioner,
low end
7 WL Airbag warning lamp 16 P PBT HI Front passenger seat belt
pretensioner, high end
9 K Serial data I/O (K wire) di- 17 P PBT LO Front passenger seat belt
agnosis pretensioner, low end
10 DAB HI Driver side front airbag, high 18 PAB HI Passenger side front airbag,
end high end
11 DAB LO Driver side front airbag, low 19 PAB LO Passenger side front airbag,
end low end
3. Diagnostic Scanner
Instrument Name Application
X-431 diagnostic scan- Check the system malfunction of the SRS airbag
ner system and clear the ECU trouble code.
Basic Processes of the Malfunction Diagnostic

After installing a new SRS airbag system electronic control unit, the airbag system warning lamp will remain on
for 6 seconds when the ignition switch is set to the ON position. This indicates that the SRS airbag is operating
properly. At this point, the system does not need to be inspected and repaired. Aside from this case however, the
system should be diagnosed and repaired.
If the airbag system warning lamp is not on when the ignition switch is ON, inspect the corresponding circuit of
the warning lamp and use it again to ensure operation.
Warning lamp Connect the scanner and K Trouble- Clear the

Detected problem
is always on wire to scan the ECU shooting trouble code
SRS airbag warning lamp inspection

(a) When the ignition switch is set to the ON position, check
whether the SRS warning lamp is on.
(b) When on and off for six times, check whether the warn-
ing lamp is off permanently.
(c) Except for the items listed above, diagnostic inspection
is still needed.
Airbag warning lamp MLI011G
System diagnosis
The HAE2 will initiate a series of diagnostic test cycles to check if the airbag system functions are ready for
use. This diagnostic test can guard against the restraint system's faulty execution and at the same time guarantee
prompt execution in a collision. If a malfunction appears, the HAE2 will store the appropriate trouble code and
light up the warning lamp to point out the malfunction, so as to make maintenance more convenient.
Malfunction judgment
1. Malfunction record (trouble code storage).
After the ECU performs the diagnostic test cycle in order to verify a malfunction, the HAE2 will store the rele-
vant code, the initial detection time, the final detection time, and the number of times it occurred in the EEPROM.
The HAE2 can at most store 6 faults, low voltage faults, and two impact records (front and side).
Trouble code recognized by the HAE2:
No. Malfunction introduction Troubleshooting

1 Ignition circuit 1 (driver side front airbag), resistance is too high or open Available
circuit
2 Ignition circuit 1 (driver side front airbag), resistance is too low or short Available
circuit
3 Ignition circuit 1 (driver side front airbag), grounded Available
4 Ignition circuit 1 (driver side front airbag), connected to the power Available
5 Ignition circuit 1 (driver side seat belt pretensioner), resistance is too high Available
or open circuit
6 Ignition circuit 1 (driver side seat belt pretensioner), resistance is too low Available
or short circuit
7 Ignition circuit 1 (driver side seat belt pretensioner), grounded Available
8 Ignition circuit 1 (driver side seat belt pretensioner), connected to the Available
power
9 Ignition circuit 2 (passenger side front airbag), resistance is too high or Available
open circuit
10 Ignition circuit 2 (passenger side front airbag), resistance is too low or Available
short circuit
11 Ignition circuit 2 (passenger side front airbag), grounded Available
12 Ignition circuit 2 (passenger side front airbag), connected to the power Available
13 Ignition circuit 2 (passenger side seat belt pretensioner), resistance is too Available
high or open circuit
14 Ignition circuit 2 (passenger side seat belt pretensioner), resistance is too Available
low or short circuit
15 Ignition circuit 2 (passenger side seat belt pretensioner), grounded Available
16 Ignition circuit 2 (passenger side seat belt pretensioner), connected to the Available
power
17 Supply voltage is too high Available
18 Supply voltagee is too low Available
19 Warning lamp fault - connected to the power or bulb is short circuited Available
20 Warning lamp fault - grounded or open circuit in filament Available
21 Algorithm parameter shortage/error Unavailable (replace HAE2)
22 Front impact is recorded Unavailable (replace HAE2)
23 Communication malfunction Available
24 Internal malfunction (see the following table) Unavailable (replace HAE2)

2. DTC.
No. Malfunction Trouble code Flash code
1 Error not stored $12
2 Driver side front airbag, resistance is too high $9,021 $21
3 Driver side front airbag, resistance is too low $9,022 $22
4 Driver side front airbag, GND short circuit $9,024 $24
5 Driver side front airbag, VBATT short circuit $9,025 $25
6 Driver side seat belt pretensioner, resistance too high $9,015 $15
7 Driver side seat belt pretensioner, resistance too low $9,016 $16
8 Driver side seat belt pretensioner, GND short circuit $9,018 $18
9 Driver side seat belt pretensioner, VBATT short circuit $9,019 $19
10 Passenger side front airbag, resistance too high $9,041 $41
11 Passenger side front airbag, resistance too low $9,042 $42
12 Passenger side front airbag, GND short circuit $9,043 $43
13 Passenger side front airbag, VBATT short circuit $9,044 $44
14 Passenger side seat belt pretensioner, resistance too high $9,045 $45
15 Passenger side seat belt pretensioner, resistance too low $9,046 $46
16 Passenger side seat belt pretensioner, GND short circuit $9,047 $47
17 Passenger side seat belt pretensioner, VBATT short circuit $9,048 $48
18 Battery voltage is too high $9,031 $31
19 Battery voltage is too low $9,032 $32
20 Warning lamp failure $9,061 $61
21 Internal malfunction (replace SDM) $9,071 $71
22 Front impact record $9,051 $51
23 Driver side impact record $9,056 $56
24 Passenger side impact record $9,057 $57
25 Seat belt pretensioner impact $9,058 $58
26 Exceed allowed reuse time limit $9,054 $54
3. Internal malfunction
(a) The microcontroller can detect the following items not only when starting up detection, but also during the
diagnostic detection cycle.
(1) The ignition circuit triggers the transistor: the high-end transistor will be detected not only when starting
up detection but also during the diagnostic detection cycle. However, if a short circuit on the power sup-
ply causes a malfunction and the low-end transistor is opened while malfunctioned, the low-end transis-
tor can only be detected when starting up detection, as to avoid faulty execution.
(2) Ignition voltage is provided by a pressure increase converter.
(3) Acceleration sensor performs self-detection when starting up detection.
(4) Allowed offset range of the acceleration sensor during a diagnostic cycle.
(5) Microcontroller includes AD converter, ROM, RAM, etc.
(6) Security sensor status.
Caution: There is a short-circuiting bar inside the squib circuit connector. When the connector is not
connected, the short circuit happens between the squib circuit's terminal (+) and terminal (-), so as to
avoid faulty deployment caused by static electricity. When the connector is bad and the short-circuiting
bar is connected, the fault symptom may not be eliminated.
Hint: An external Watchdog can inspect the running state of the microcontroller. If microcontrol fails, activate the
Watchdog, which will reset the microcontroller and turn on the warning lamp.
(b) Internal malfunction confirmed by HAE2

No. Malfunction list Malfunction description
1 Microcontroller AD converter or EEPROM error (if RAM and ROM error, the
microcontroller will reset and the warning lamp is on)
2 Driver side front airbag ignition cir- Activate malfunction
cuit Measure the circuit malfunction
3 Passenger side front airbag ignition Activate malfunction
circuit (if possible) Measure the circuit malfunction
4 Seat belt pretensioner ignition circuit Activate malfunction
(if possible) Measure the circuit malfunction
5 Passenger side seat belt pretensioner Activate malfunction
ignition circuit (if possible) Measure the circuit malfunction
6 Driver side airbag ignition circuit (if Activate malfunction
possible) Measure the circuit malfunction
7 Passenger side airbag ignition circuit Activate malfunction
(if possible) Measure the circuit malfunction
8 Ignition voltage Too low
9 Watchdog/reset Malfunction
10 Maximum count of seat belt preten- Reaches the maximum value 6
sioner's ignition
11 ECU energy saving time (self-sup- Too short
port time)
12 Acceleration meter Offset range
The sensor is not in permanent stable mode
Sensor malfunction self-inspection
13 Ignition circuit measurement is dis- Do not perform diagnostic test cycles (repeat arithmetic calcu-
carded continuously lation)
14 Security sensor Close for 2 seconds and exceed 2 seconds
When calculating malfunction through arithmetic, the security
sensor is open-circuited
15 Ignition current When the front airbag is deployed, all the ignition currents are
normal
16 Side airbag ignition is not confirmed Even if HAE2 has received ignition information for 5 times
during HSIS's ignition circle, due to the side security function,
the side ignition cannot pass HAE2 confirmation.
(c) Clear the trouble code.
When the X-431 diagnostic scanner receives the "Clear the Trouble Code" order sent through the serial interface,
the trouble code inside the ECU will be cleared. However, if an internal trouble code is recorded or has a collision
record, it will not carry out this order.
4. Malfunction status display (warning lamp is always on)

(a) Bulb inspection.
When the working voltage is supplied to the HAE2 through a battery, the HAE2 will light the warning lamp to
inspect the bulbs. During the initialization, the warning lamp will flash in 1 Hz for 6 seconds and then off. In or-
der to inform the driver that the system has a malfunction, the warning lamp will continue to remain on after the
operating voltage is supplied. If the history trouble's quantity is less than 5, the warning lamp will remain lit for 6
seconds after turning the ignition on and then turn off automatically. During the initialization, HAE2 will not in-
tend to detect impact or prevent deployment until the HAE2 wire is stable.
Therefore, after turning the ignition on, the display method of the warning lamp will be one of the following pro-
grams listed during the initialization:
Plan 1: When impact exists or if the history record of the malfunction reaches or exceeds 5 times, the warning
lamp will remain on. Meanwhile, if the ignition malfunction exists, the warning lamp will also remain on.
ON
lgnition ON MLI012G
Plan 2: Historical malfunction reaches or exceeds 1 and is less than 5 times ("Battery voltage is too low" is not
calculated as a malfunction).
6 sec
ON
OFF
lgnition ON MLI013G
Plan 3: Works normally (no ignition failure or history failure).
6 sec
ON
OFF
1 sec(=1Hz)
lgnition ON MLI014G
(b) Malfunction indication

Once there is a malfunction, the warning lamp will indicate it. If the external malfunction is historical, the indica-
tion will be cancelled. When historical malfunction happens for or more than 5 times, even if there is no malfunc-
tion, the warning lamp will remain on. "Battery low" is not calculated as a malfunction.
A displayed or history malfunction can only be reset by service personnel. A HAE2 internal malfunction or mal-
function’s collision record cannot be reset. In this situation, the HAE2 must be replaced.
(c) Microcontroller - independent warning lamp is lit.
The microprocessor that has specific malfunctions will not function, thus it cannot control the warning lamp. In
such case, the warning lamp with light through appropriate circuit regardless of the microprocessor, as shown be-
low:
(1) Battery supplying power to HAE2 fails: The warning lamp remains on through the self-signed lamps
driving function.
(2) Lose internal operating voltage: The warning lamp remains on.
(3) Reset due to failure of ignition of the Watchdog: The warning lamp flashes.
(4) The microprocessor does not operate: The warning lamp remains on.
(5) The HAE2 connector is not fully inserted: The warning lamp remains on through the short-circuiting bar.
Troubleshooting
Hint: If the airbag warning lamp is always on, even if it is finally off, inspect it according to the following steps.
Firstly, detect the malfunction’s position with a scanner. If the scanning result is an internal malfunction or having
to do with airbag execution, the SRS-ECU can be directly replaced.
Malfunction 1: Airbag system warning lamp does not light up.
Airbag system warning lamp does not light up

Inspection status Airbag system circuit malfunction warning
Possible causes Voltage disappears (fuse open circuit)
Combination meter malfunction
Wire harness malfunction between the instrument cluster and ECU unit
Diagnostic procedures
While performing the first malfunction detection, it is suggested to wiggle the wire harness and plugs to check for
intermittent or poor contact. If there is, please check whether the plugs, terminals, and the wire harness are con-
nected properly and undamaged. If the above mentioned problems do not exist, please take the following steps:
Step Detection Operation

1 Locate the other wire harness and instrument clus- Yes Set the ignition switch to the LOCK position and
ter indicator lamps then proceed to the next step.
• Set the ignition switch to the ON position No Detect the instrument cluster's power supply sys-
• Other warning and indicator lamps are on tem and the grounded system (fuse) and then go
to step 5.
2 Inspect the bulbs Yes Go to the next step
Warning:
Incorrect airbag system component operation will
cause the airbag and preloaded seat belt to open ac-
cidentally, which may cause serious injuries. Please
No Replace the warning lamp bulb.
read the airbag system services warning before
working on the airbag components.
• Set the ignition switch to the LOCK position.
• Disconnect the battery's negative cable and main-
tain for at least 60 seconds.
• Remove the combination meter.
• Check whether the two corresponding pins of the
airbag warning lamp are conducting.
3 Detect the wire harness connection between the Yes Go to the next step.
ECU unit and the instrument cluster
• Set the ignition switch to the LOCK position.
• Disconnect the battery's negative cable No Replace the wire harness and then go to step 5.
• Disconnect the instrument cluster connectors
• Check whether the warning lamp's corresponding
circuits are conducting
Malfunction 2: Airbag system warning lamp is always on
Airbag system warning lamp is always on

Inspection status Airbag system warning lamp is always on
Possible causes • Battery power supply is insufficient
• ECU internal malfunction
• Combination meter airbag warning lamp malfunction
• ECU connector is improperly connected
• Combination meter plug poorly contacted
• ECU power supply fuse circuit broken or poorly contacted
• Poor ECU plug terminal connection
• Poor wire harness contact between the ECU plug terminal and the ground
• Driver side or front passenger side airbag circuit malfunction
Diagnostic procedures
Before the inspection, please diagnose the communication and determine the causes of malfunction with the spe-
cial diagnostic scanner and ECU. If communication fails, please perform the following inspections:

1 Examine the battery Yes Go to the next step
• Measure the battery voltage No Battery power supply is insufficient.
• Is the voltage higher than 9 V? Examine the charging/discharging sys-
tem, and then go to the next step
2 Examine the conducting state of the wire harness between Yes Go the next step
the ECU unit and combination meter No Check the circuit and then go to step 5
• Set the ignition switch to the LOCK position after troubleshooting has occurred
• Disconnect the battery's negative terminal
• Open the central channel protector
• Disconnect the instrument cluster connectors
• Connect the battery's negative terminal
• Set the ignition switch to the ON position
• Check whether the corresponding connector terminal's
voltage is 12 V (power supply and meter connection)
3 • Set the ignition switch to the LOCK position Yes Go to the next step
• Check if the meter connector's corresponding terminal
No Repair or replace the wire harness. Then
and diagnostic interface's corresponding terminal are con-
go to step 5
ducting (diagnose the K wire's two ends)
4 Disconnect the battery's negative cable and maintain for at Yes Go to the next step
least 1 minute
• Disconnect the ECU connector No Replace the wire harness and then go to
• Disconnect the instrument cluster connectors step 5
• Are the ECU connector terminals 5, 7, 9, and the instru-
ment cluster's connectors conducting?
5 Remove the ECU to check whether the terminal is in good Yes Replace the ECU
condition and whether the short-circuiting bar is broken No Reconnect the ECU connector and then
go to step 5

6 Check and make sure the malfunction symptom does not Yes The malfunction is removed and explain
appear again after it is repaired the maintenance procedure to the client
• Set the ignition switch to the LOCK position
• Disconnect the battery's negative cable and maintain for No Recheck the malfunction symptom. If
at least 1 minute the malfunction happens again, repeat
• Connect all of the ECU connectors the repairing procedures starting from
• Connect the airbag subassembly plugs on the driver side the first step
• Connect the airbag subassembly plugs on the passenger
side
• Connect the driver and passenger side seat belt preten-
sioner plugs (equipped with seat belt pretensioner)
• Connect the clock spring plugs
• Connect the battery's negative cable
• Set the ignition switch to the ON position
• Does the airbag warning lamp work properly?
Malfunction 3: Internal malfunction
Trouble code $9071 SRS airbag system unit internal malfunction

Detecting conditions Warning
• This malfunction's diagnosis requires a trouble code not to be shown prior to inspec-
tion. Use a DTC to perform inspection. Performing this malfunction detection might
cause operator injury or system damage due to incorrect operation. Therefore, before
inspection, please properly prepare.
• SRS airbag system electronic control unit circuit internal malfunction
Possible causes SRS airbag system unit internal malfunction
Operation Replace the SRS airbag system unit. Refer to airbag system and SRS airbag system unit
removal and installation
Malfunction 4: Power supply malfunction

Trouble code $9032 The SRS airbag system electronic control unit's power supply voltage is too
low
• This malfunction's diagnosis requires a trouble code not to be shown prior to inspec-
tion. Use a DTC to perform inspection. Performing this malfunction detection might
cause operator injury or system damage due to incorrect operation. Therefore, before
inspection, please properly prepare.
• Voltage of the SRS airbag system unit's 5 and 6 connector pins is lower than 9 V
Possible causes Battery voltage is too low
The wire harness between the battery and SRS airbag system electronic control unit
has a malfunction
Troubleshooting steps

1 Examine the battery Yes Go to the next step
• Check the battery voltage No Battery's voltage too low. Inspect the
• Is the voltage higher than 9 V? charging/discharging system
2 Inspect the wire harness between the battery and the fuse Yes Go to the next step
box No Inspect and repair the wire harness
Set to the ON position
Check whether the fuse box's two corresponding terminal
stub voltage is higher than 9 V
3 Inspect the wire harness between the fuse box and SRS air- Yes Go to the next step
bag system unit connectors No Replace the wire harness
If it's not handled properly, the airbag module and stretch
tension type seat belt may open or lock up, causing serious
operator injury.
Therefore, before performing maintenance, please read the
maintenance warnings carefully.
See also Airbag System Maintenance Warning
Set the ignition switch to the LOCK position
Loosen the battery's negative cable and wait for at least 1
minute
Take out the steering column housing
Loosen the clock spring connector
Take out the glove box (with the front passenger side airbag
module)
Loosen the front passenger side airbag module connectors
Take out the left side inner decoration board
Loosen all the SRS airbag system unit connectors
Install the battery's negative cable and set the ignition
switch to the ON position. Is the airbag system unit's 5 and
6 (ground) connector pin voltage higher than 9 V?
4 Set the ignition switch to the LOCK position Yes Complete the diagnosis of power supply
Loosen the battery's negative cable and wait for at least 1
min No Replace the wire harness
Disconnect the SRS airbag system unit switching connec-
tors
Install the battery's negative cable, and set the ignition
switch to the ON position. Is the voltage of the switching
connector's corresponding pin and ground higher than 9 V?
Malfunction 5: Driver side malfunction

Trouble code Driver side airbag malfunction (resistance too low or too high, short circuit, grounded,
$9021, $9022, etc.)
$9024, $9025
• If it's not handled properly, the airbag module and stretch tension type seat belt may
open or tense up, causing serious operator injury. Therefore, before maintenance,
please read the maintenance warnings carefully.
See also airbag system maintenance warning
If driver side airbag exists
• The resistance between the terminal stubs of the SRS airbag system unit connector is
out of the specified range
• Wire harness related SRS driver side airbag is short- or open-circuited
Possible causes • Driver side airbag module malfunction
• Clock spring internal malfunction
• Connector malfunction between the clock spring and SRS electronic control unit
• The wire harness between the clock spring and the SRS electronic control unit circuit
is broken or short-circuited
• SRS driver side airbag generator connectors are improperly connected

1 Check the clock spring Normal Go to the next step
Warning
If not handled properly, the airbag module may deploy and Abnormal Replace the clock spring
cause serious operator injury. Therefore, before performing See also airbag system and
maintenance, please read the maintenance warnings carefully. clock spring removal/installa-
See also airbag system maintenance warning tion
Are the components relating to the clock spring working
normally (the relationship between each pin is normal, no un-
necessary short or open circuit, etc.)? If possible, use a good
clock spring to replace the current one.
2 Check whether the malfunction is on the driver side airbag Yes Replace the driver side airbag
module or other components module
Replace with a good DAB module or connect a 2 ohm resistor See also airbag system and
Install the battery's negative cable driver side airbag module re-
Set the ignition switch to the ON position moval/installation
Is a trouble code displayed? Or can it be cleared?
No Go to the next step
3 Inspect the clock spring's wire harness connectors Yes Go to the next step
Loosen the battery's negative cable and wait for at least 1 minute No Replace the wire harness
Loosen the clock spring connector
Is the clock spring working normally?

4 Check the wire harness between the clock spring and SRS Yes Fault diagnosis complete and
electronic control unit install all components
Loosen the battery's negative cable and then wait for at least 1
minute No Replace the wire harness
Take the glove box off (with the front passenger side airbag)
Loosen the passenger side airbag module connectors
Check the wire harness of the connectors' terminal studs be-
tween the SRS electronic control unit and the clock spring to
see whether they have the following problems.
• Grounded
• Short connected with the power
• Open-circuited
Is the related wire harness normal?
Malfunction 6: Passenger side malfunction
Trouble code Passenger side airbag module (resistance too low or too high, short-circuit or grounded)
$9015, $9016,
$9018, $9019
• If it's not handled properly, the airbag module and stretch tension type seat belt may open
or lock up, causing serious operator injury. Therefore, before maintenance, please read the
maintenance warnings carefully.
If passenger side airbag exists
• The resistance between the SRS airbag system unit connector's 18 and 19 pin is out of the
specified range.
• The wire harness between the SRS airbag system unit connector’s 18 and 19 pins has
short-circuited.
• The SRS airbag system unit connector's 18 and 19 pins are open-circuited, if there is no
front passenger side airbag.
Possible causes • Passenger side airbag module malfunction
• Connector between the passenger side airbag module and the SRS airbag system electronic
control unit malfunction
• Connectors between the SRS airbag system unit and the grounded point malfunction
• Circuit between the passenger side airbag module and the SRS airbag system electronic
control unit is broken or short-circuited
• Circuit between the SRS airbag system unit and the grounded point is broken or short-circuited
• SRS airbag system unit malfunction

1 Is the vehicle equipped with a passenger side airbag module? Yes Go to the next step
No Go to step 5
2 Check the passenger side airbag module connector warning Yes Go to the next step
If it's not handled properly, the airbag module and stretch tension
type seat belt may open, causing serious operator injury. No Replace the wire harness
Therefore, before performing maintenance, please read the mainte- and restore the system
nance warnings carefully.
Loosen the battery's negative cable and wait for at least 1 minute
Take out the glove box
Loosen the passenger side airbag module connectors
Is the passenger side airbag module connector normal?
3 Check whether the malfunction is on the passenger side airbag mod- Yes Go to the next step
ule or other components
Connect a good module or a 2 ohm resistor with the passenger side
airbag module connector's A and B terminal studs No Replace the passenger side
Connect the battery's negative cable airbag module
Set the ignition switch to the ON position See also airbag system and
Is a trouble code displayed? passenger side airbag mod-
ule removal/installation
4 Inspect the wire harness between passenger side airbag module and Yes After the troubleshooting.
SRS airbag system electronic control unit install all of the compo-
Set the ignition switch to the LOCK position nents and clear all existing
Loosen the battery's negative cable and then wait for at least 1 minute trouble codes.
Loosen the clock spring connector No Replace the wire harness
Loosen the driver side and passenger side airbag module connectors
Inspect the circuit between the connector terminal stubs of SRS air-
bag system electronic control unit and passenger side airbag module,
and check if it has the following problems:
• Grounded
• Short connected with the power
• Open-circuited
Is the related wire harness normal?
5 The inspection completes. Restore the system and check whether it Yes
works properly
No Repeat the above steps

Vehicle Collision Diagnostics

Whether the airbag is deployed or not, vehicle collision diagnostics and maintenance must be conducted accord-
ing to the following procedures.
1. Check the SRS-ECU diagnostic signal.
(a) Connect the diagnostic connector (X-431 diagnostic scanner).
(b) Read the diagnostic result with the (X-431 diagnostic scanner).
Caution: Due to impact, and when the battery's power supply is insufficient, the scanner will be unable
to communicate with the SRS-ECU. At this time, use an external power supply or make sure to perform
inspection and maintenance on the dashboard's wire harness.
2. Maintenance sequence
(a) When the airbag is deployed, the following components should be replaced.
• Passenger side airbag module
• SRS-ECU
• Driver side airbag module
(b) Inspect the following components, if anything is abnormal, replace with a new one.
• Clock spring
• Steering wheel, steering column, and lower shaft components.
(c) Installation status of the driver side airbag module regarding the steering wheel.
• Inspect whether the steering wheel's noise is abnormal, for improper movement, or abnormal clearance.
• Inspect whether the wire harness connectors are broken and whether the terminals are deformed.
3. SRS-ECU
(a) Inspect whether the SRS-ECU housing and bracket are
sunken or depressed, cracked, deformed, etc.
(b) Inspect for broken connectors as well as deformed termi-
nals.
(c) Inspect the SRS-ECU bracket's installation status.
• Inspect whether the cover is sunken or depressed,
cracked, deformed, etc.
MLI015G
• Inspect for broken connectors as well as deformed terminals
and biting wire harnesses.
• Check whether the gas generator's housing is sunken or
depressed, cracked, deformed, etc.
• Inspect whether the arrow's direction is pointed towards
the front of the vehicle.
(d) Inspect the airbag module's installation status.
4. Driver side airbag module.

Generator
MLI016G
5. Front passenger side airbag module.
MLI030G
6. Clock spring
Connected horn Connected driver (a) Inspect for broken connectors and protective tube and
side module
deformed terminals.
(b) Inspect for deformed housing.
MLI017G
7. Steering wheel, steering column, and lower shaft components

(a) Inspect the driver side airbag module's installation status.
(b) Inspect the steering wheel for abnormal noise and whether the clearance is normal.
8. Inspect the wire harness connectors (dashboard wire harness).
9. Inspect whether the wire harnesses are firm and check for damaged connectors and deformed termi-
nals.
10. While maintaining and using the airbag, please work in accordance with the label. Furthermore, when a
label becomes damaged or dirty, please replace it with a new one.
Components
Driver side airbag
Screw
Screw
Combination switch's upper protective cover
Clock spring assembly Nut
Combination switch lower protective cover
Driver side airbag assembly
ALK026G
Individual Components Removal

Airbag electronic control unit
Caution:
· · After disconnecting the battery's negative (-) terminal, wait for 60 seconds before operating. Wrap
the removed negative (-) terminal in tape to insulate it.
· · The SRS-ECU can not be dismantled or repaired. If there is any malfunction, please replace it with
a new one.
· · Do not let the SRS-ECU vibrate or collide with anything. If sunken or depressed, cracked, de-
formed, etc., please replace with a new SRS-ECU.
· · Every time the airbag is deployed, please replace with a new SRS-ECU.
· · Do not bump the SRS-ECU while removing or performing maintenance on the SRS-ECU's sur-
rounding components.
1. Operation before removal.

a. Set the ignition switch to the OFF position.
b. After disconnecting the battery's negative (-) terminal, put them in a proper place or wrap them in tape.
2. Removal sequence
(a) Cover the plate of one side of the central channel (or re-
move the auxiliary facia console).
(b) Remove the connectors connected with the airbag ECU.
(c) Remove the SRS-ECU.
3. Installation sequence
(a) SRS-ECU.
(b) Install the connectors connected with the airbag ECU.
(c) Cover the plate of one side of the central channel (or re-
SRS-ECU
move the auxiliary facia console).
(d) Connected ground cable.
MLI019G 4. Installation points
(a) Install the SRS-ECU.
(b) Inspect after installation.
· · Set the ignition switch to the ON position.
· · The SRS warning lamp lights in 6 seconds and then re-
mains off.
(c) If it is not off, inspect and remove the malfunction.
5. Inspect
(a) Whether the SRS-ECU cover has sunken or depressed,
cracked, deformed, etc.
(b) Whether the connectors are damaged or deformed.
Caution:
· · If SRS-ECU isn't installed correctly, the SRS airbag
will not operate properly.
· · Please replace with a new SRS-ECU, if there is any
sunkeness or depression, cracking, deformity, etc.
Except for the areas described above, to perform SRS-ECU in-
spections, please refer to the related troubleshooting contents.
Airbag module, clock spring

Caution:
· · Disconnect the battery's negative (-) terminal, and wait for 60 seconds before operating. Wrap the
removed negative (-) terminal in tape to insulate it.
· · The airbag module and clock spring must not be dismantled or repaired. If there is any malfunction,
replace them.
· · Pay attention to the usage of the airbag module and clock spring. Do not drop it or immerse it in
water or oil. Furthermore, if there is any sinking or depression, cracking, deformity, etc., please replace
it with a new one.
· · Make sure the extended surface is faced upwards when the airbag module is to be deployed. Put it
on a flat surface and do not place anything on top of it.
· · Do not put the airbag module in a place where the temperature is over 85 oC.
· · After the airbag module is deployed, replace it with a new one. At the same time, inspect the clock
spring, and if there is anything abnormal, replace it with a new one.
· · Use gloves and protective glasses while operating on a deployed airbag.
· · While scraping an undeployed airbag, make sure to discard it after it has been deployed first.
Hint: During removal, to avoid experiencing static electricity interference leading to faulty execution, make sure
to remove the other wire harness connectors after the DAB and PAB module wire harness connectors have been
removed. Installation is done in reverse order.
1. Operation before removal

(a) When the steering wheel and front tires are pointing straight ahead, take out the ignition switch.
(b) Disconnect the battery's negative (-) terminal.
2. Driver side airbag module (DAB) removal sequence

(a) Align the front wheel ahead.
(b) Loosen the screws on both sides.
MLI020G
(c) Pull out the driver side airbag from the steering wheel as-
sembly and support the airbag with your hand, as shown
in the figure.
Caution: When removing driver side airbag assembly, do
not pull the airbag wire harness.
(d) Disconnect the driver side airbag assembly connector
with a screwdriver.
(e) Disconnect the airbag connector.
ALK028G
(f) Remove the driver side airbag assembly.
(g) Remove the steering wheel.
Cautions while removing:
· · Due to the overly-tight occlusion of the spline and
column, the steering wheel and steering column may be

hard to separate, in which case make sure not to use
force to remove the steering wheel. The correct method
is to rotate the screw on the steering pipe for several
times, and then pull up the steering wheel (because the
steering wheel bottom is connected to the clock spring, if
force is used to remove it, it may damage it).
· · Diagnose the airbag module's circuit with an electri-
cal measuring instruments but do not dismantle it.
· · Face the bottom of the removed passenger side air-
bag upwards and store it in a clean and dry place.
3. Clock spring removal sequence

(a) Remove the 4 screws and the combination switch's pro-
tective cover.
(b) Disconnect the airbag connector and the clock spring as-
sembly connector.
Airbag connector (c) As shown in the figure, separate the 3 claws and remove
the clock spring subassembly.
: Claw
ALK047G
4. Inspect the clock spring subassembly.

(a) If the following conditions are confirmed, replace with
new clock spring subassembly.
Conditions:
· · There are scratches or cracks on the connector
· · There are cracks, indentations, or gaps on the clock
spring subassembly.
Caution: Store the removed clock spring in a clean and
dry place.
5. Front passenger side airbag module (PAB) removal se-
quence
(a) Remove all hoods and glove boxes of the dashboard and
separate the PAB module's airbag wire harness connector
and the airbag harness's PAB side connector.
(b) Remove the M8 bolt and separate the PAB module and
the dashborad reinforcement.
(c) Remove the dashboard.
6. Front passenger side airbag module (PAB) installation
MLI029G sequence
(a) Lightly pick up the PAB module and install it on the
dashboard.
(b) Install the dashboard on the vehicle body.
(c) Use two M8 bolts to fasten the PAB module on the cross
member of the vehicle.
(d) Securely connect the PAB module's airbag wire harness

connector and the airbag harness's PAB side connector,
and then the installation of PAB module is complete.
(e) Connect the battery's negative (-) terminal.
(f) Inspection after installation.
7. Clock spring installation sequence
(a) Set the steering lamp switch to the central position.
Caution: Since the steering lamp's switch pin may break,
make sure the switch is in the central position.
(b) Engage the 3 claws and install the clock spring subas-
sembly.
Caution: When replacing with a new clock spring subas-
sembly, remove the lock pin before installing the steering
wheel assembly.
(c) Connect the airbag connector and the clock spring as-
sembly connector.
(d) Install the combination switch's protective cover with 4
screws.
8. Adjust the clock spring subassembly.
(a) Check and make sure the ignition switch is off.
(b) Check and make sure the battery's negative terminal is
disconnected.
Caution: Do not continue within 90 seconds after the ter-
minal is disconnected.
(c) Slowly rotate the clock spring subassembly clockwise
with your hand until you feel it is fastened.
ALK048G
Marks
(d) Then rotate the clock spring assembly counterclockwise
for about 3.5 rounds to become level with the mark.
Hint: Rotate the clock spring from the center to left and right
for about 3.5 rounds.
Caution: If the clock spring is not in the involution cen-
tral, the steering wheel will be unable to rotate midway
or cause clock spring circuit failure, which will obstruct
the normal operation of the airbag.
ALK049G
9. Install the steering wheel assembly.

10. Check the central point of the steering wheel.
11. Install the driver side airbag assembly.
Inspection before installation
(a) Connect the battery's negative (-) terminal.
(b) Connect the K-431 scanner to diagnostic interface (16
plugs).
Caution: When connecting or disconnecting the K-431
scanner, set the ignition switch to the OFF position first.
(c) The ignition switch is set to the ON position.
(d) Read diagnosis line and check whether the airbag mod-
ule is in a normal state.
(e) The ignition switch is set to the OFF position.
(f) Disconnect the battery's negative (-) terminal and wrap it
in tape to insulate it.
12. Inspection after installation
(a) Lightly turn the steering wheel left and right to check
whether there is anything abnormal or if any strange
noises are heard. (driver side airbag module, clock
spring, etc.)
(b) Set the ignition switch to the ON position.
(c) The SRS warning lamp lights in 6 seconds and then goes
off.
(d) If it goes off after 6 seconds and then remains on (or nev-
er goes off but always on), perform the troubleshooting.
Inspection
1. Driver side airbag module inspection
Inspect each of the following items. If any faults are found, replace with a new corresponding airbag module part.
Discard the old components after they have been deployed in the proper order.
Caution: The specified measuring instrument cannot measure the airbag module (tube rupture) circuit
resistance. This is because when testing the resistance with a testing instrument, there is an electric
current in the tube rupture which may lead to accidental deployment due to static electricity and may
cause serious accidents.
(a) Whether the cover sunken or depressed, cracked, or deformed.
(b) Whether the wire harness has broken connectors and deformed terminals.
(c) Whether the gas generator's housing is sunken or depressed, cracked, or deformed.
(d) The airbag module's installation status.
Caution: Please replace with a new airbag module, if there is any sunken part or depression, cracking,
deformity, etc. Used components must be discarded after they have been deployed.
2. Clock spring inspection
Inspect each of the following items. If any fault is found, replace with a new clock spring.
(a) Whether there are broken connectors or protective pipes and deformed terminals.
(b) Whether the housing is damaged.
(c) Inspect whether the clock spring's upper connector terminal and lower corresponding connector terminal is
conducting.
(d) Insert a thin probe behind the #3 joint of the clock spring.
Caution: Do not insert the probe directly under the joint.
Airbag Disposal
Caution:
· · Deploy the airbag before discarding the SRS airbag.
· · Deploy the airbag outside the vehicle when replac-
ing the airbag module.
· · There may be some smoke when deploying the air-
bag, so make sure to operate near a smoke detector.
· · When deploying the airbag, the sound will be very
loud. Please ask nearby people to plug their ears and try
not to operate near residential areas.
· · Remove the battery's positive and negative termi-
nals and wait for 60 seconds before operating.
1. Deploy in the vehicle
(a) Remove the positive and negative terminals of the bat-
tery to take the battery off the vehicle.
(b) Remove the combination switch hood.
(c) Remove the #2 joint of the clock spring and the dash-
3 board wire harness joint (yellow).
2 Hint: When the clock spring joint is removed from the dash-
board wire harness, the joint will be open-circuited automati-
cally to avoid deployment of the driver side airbag module due
to static electricity, which may cause serious accidents.
(d) Connect 2 wire harnesses longer than 6 m for deploy-
ment to the airbag connecting wire harness and wrap the
Case joint in tape for insulation. Connect the other ends of the
2 wire harnesses (short circuited) to avoid accidental de-
ployment due to static electricity.
MLI021G
(e) At the #2 joint of the clock spring, use the wire harness
Short circuit position for deployment to lead the SRS airbag's connecting wire
Wire harness for deployment harness out of the vehicle.
SRS connecting
wire harness Longer than 6 m
MLI022G
(f) Cut off the connection of the driver side airbag module's
Vehicle cover- wire harness, which is used for deployment, at a place
ing piece as far away from the vehicle as possible and connect it
to the two terminals removed from the vehicle battery,
causing it to deploy.
Wire harness for deployment Caution:
· · To restrain the noise, close all windows and doors
and cover the vehicle house.
MLI023G
· · The glass is easy to break when there is crack in it,
so make sure to cover the vehicle housing.
· · Make sure there are no people in or near the vehicle
before operating.
· · After the deployment of driver side airbag, the gas
generator will be extremely hot, so leave it stationary for
at least 30 minutes and use it only when it is cool.
2. Deployment outside the vehicle

Caution:
· · When deploying the airbag, make sure to maintain
a distance of at least 6 m away from objects or people,
and perform the deployment on a flat surface.
· · While deploying the airbag module outdoors, avoid
strong winds, and ignite it against the wind.
(a) Remove the driver side airbag module from the vehicle.
Caution: When the joint of the driver side airbag module
is not connecting, the both ends of the terminal will be
short-circuited automatically, so as to avoid the acci-
dental deployment due to static electricity. If accidental
deployment happens anyway, make sure the extended
surface is facing upwards. Put it on a flat surface and do
not place anything on top of it.
(b) Prepare 2 wire harnesses longer than 6 m for deployment
Wire harness for deployment and connect one of their ends together (to short-circuit)
Short circuit position
to avoid faulty deployment caused by static electricity.
Warning: Touch the vehicle with your hand to clear all
static electricity and to avoid accidental deployment of
the airbag.
Longer than 6 m
MLI024G
(c) Cut the wire harness of the driver side airbag harness and
Front passenger side Wire harness for deployment
connect it with two wire harnesses for deployment. The
airbag module
joint must be wrapped in take for insulation.
Short-
circuit
position
Insulating tape
MLI025G
Driver side airbag module (d) Install the unused bolts on the driver side airbag module's
inside bolts and bind the wheel rim with a thick metal
wire, so as to set the wheel rim in place.
Wire harness (e) Connect the wire harness used for deployment which is
for deployment
connected with the driver side airbag module with the
lower part of the old tire that is used for installing the
wheel rim. Upwardly attach the driver side airbag mod-
ule with the metal wire which is connected to the bolt.
MLI026G
(f) Place 3 old tires with no hub on the tires which are used
to fix in place the driver side airbag module.
Old tire without hub
Wire harness for deployment
MLI027G
(g) Cut off the connection of the driver side airbag module's
wire harness which is used for deployment at a place
Wire harness for deployment as far away from the vehicle as possible and connect it
to the two terminals removed from the vehicle battery,
causing it to deploy.
Caution:
· · Make sure there are no people near the airbag be-
fore operating.
· · After the deployment of driver side airbag, the gas
generator will be extremely hot, so leave it stationary for
MLI028G
at least 30 minutes and use it only when it is cool.
AC System 10-1
AC System
System Introduction....................................................................10-2
Technical Specifications..............................................................10-3
Routine Inspections....................................................................10-6
AC System Components...........................................................10-10
Refrigerant................................................................................ 10-11
Compressor Assembly..............................................................10-19
AC Controller Assembly Replacement......................................10-21
AC Assembly.............................................................................10-22
Maintenance and Replacement of the AC Filter Screen...........10-25
Subcooling Condenser Assembly.............................................10-26
System Introduction
The AC system consists of an independent system and a monolithic construction and can be controlled manually
or automatically, with steam compression as its cooling method. It uses two kinds of compressors - a rotary vane
compressor and a swash-plate compressor. The compressor is driven directly by the engine. High temperature and
high pressure refrigerant vapor released from the compressor will pass through the high pressure pipe into the
condenser, dissipate the heat via temperature differences, and then forms a high pressure liquid. The high pressure
liquid passes through the condenser discharge pipe with a pressure switch assembly into the expansion valve, and
after passing through the throttle valve, it becomes a low temperature and low pressure liquid. Heat exchange via
the evaporator will cool down the room’s air, and then the refrigerant inside the system will reach a low tempera-
ture and low pressure vapor, which is then sucked into the compressor and compressed into high temperature and
high pressure air again. Thus, a cooling cycle is formed. The circulation continues, which maintains a comfortable
temperature inside the vehicle.
Condenser discharge pipe with pressure switch assembly

Condenser electronic fan
Condenser assembly
Exhaust pipe assembly of

compressor
Radiator assembly
with electronic fan
Compressor assembly
Suction hose assembly of

compressor
Blower H-shaped expansion valve
Filter screen
Evaporator
MLJ001G
AC System 10-3
Technical Specifications
Structure Type Vapor compression refrigeration, water heating
Controls Manually, Automatically
Refrigerant R134a
Refigerating effect 2.1 kw/1000 rpm
Compressor Type JSS09T401002, SEBX11
Specification and Type of AC System
Air Purification Sys- Powder dust filter

tem
HVAC Monolithic construction, layered evaporator and heater, H-shaped expansion
valve, centrifugal blower
Condenser Advective and subcooling structure
Air duct The middle air duct of the dashboard uses blow molding and is installed on the
dashboard with screws
Air outlet Four air outlets are symmetrical with a willow leaf structure and adjustable wind
direction, the air outlet can be completely closed
Refrigeration line A compound structure using a rubber cooling pipe and an aluminum pipe
Water heating pipe Molded rubber pipe
Sensors Evaporator temperature sensor, interior and exterior temperature sensor (auto-
matic)
Pressure switch Three-position combination

The table below lists the location in question by the numerical order to confirm the causes of a malfunction.
Check, repair, or replace the parts according to the procedures listed in the following pages, if necessary.
Reference
Problem Location in Question
Page(s)
1. Heater fuse -
AC system does not work. 2. AC controller assembly 10-21
3. Wire harness or connector -
1. Heater fuse -
2. Speed adjustive resistance of blower -
3. Blower relay -
Blower does not work or works poorly.
4. Blower assembly 10-8
5. AC controller assembly 10-21
1. Blower assembly 10-8
2. Speed adjustive resistance of blower
Insufficient air vent function.
1. Refrigerant amount 10-11
2. Tension of drive belt -
3. Refrigerant pressure 10-11
4. Compressor assembly -
Temperature control: no cold air is emitted.
5. Pressure switch -
6. Condenser fan -
1. Engine coolant amount -
Temperature control: no warm air is emitted.
3. AC assembly 10-22
Temperature control: air vent temperature is
higher or lower than the setting or has a slow
2. Temperature threshold cable -
response.
Temperature control: no temperature control.
2. Temperature threshold cable -
1. AC control knob assembly -
No air intake control.
No air outake control.
2. Position damper cable -
1. A/C Switch -
Engine cannot run at an idle speed or runs 2. Compressor assembly -
continuously at an idle speed. 3. AC controller assembly 10-21
AC System 10-5
Areas of Importance
1. Do not handle the refrigerant in an enclosed area or
close to an exposed flame.
2. Make sure to wear goggles.
MLJ001G
3. Pay close attention not to get liquid refrigerant in the

eyes or on the skin.
(a) If the liquid refrigerant splashed into the eyes or on
the skin, rinse the eyes or skin immediately with large
amounts of cool water.
Caution:
Do not rub the eyes or skin.
(b) Apply petroleum jelly to the skin.
ALJ002G
(c) Go to the hospital to recive professional treatment imme-
diately.
4. Never heat the refrigerant tank or keep close to an open
flame.
5. The refrigerant tank must not be dropped and must be
handled with care.
6. Do not operate the compressor in the event that there is

Incorrect Correct
not enough refrigerant in the refrigeration system.
LO HI LO HI
If there is not enough refrigerant in the refrigeration system,
the engine oil may lack sufficient lubrication and the compres-
sor may burn out. Please pay special attention so that this does
not occur.
7. Never open the high pressure manifold valve during the
operation of the compressor.
MLJ003G If the high pressure valve is opened, the refrigerant will flow
in the opposite direction and might break the charging cylin-
der. Therefore, only the low pressure valve is allowed to be
opened and closed.
8. Make sure not to put too much refrigerant into the system.
If filling with too much refrigerant, then insufficient cooling,
poor fuel economy, and overheating of the engine might occur.
Routine Inspections
1. Evaporator thermistor.
1
(a) Check whether the evaporator thermistor is conducting.
2
(1) As shown in the figure, measure the resistance be-
tween Terminal 1 and Terminal 2 when the evapora-
tor thermistor is at varying temperatures.
ALJ011G
KC222H339F - Type NTC Thermistor R-T Characteristic Table
Temperature (oC) Lower limit value (ΚΩ) Nominal value (ΚΩ) Upper limit value (ΚΩ) Remarks
-30 24.285 25.16 26.056

-25 18.803 19.43 20.07
-20 14.678 15.13 15.589
-15 11.553 11.88 12.211
-10 9.155 9.392 9.631
-5 7.309 7.481 7.654
0 5.875 6 6.125
2 5.393 5.503 5.613
4 4.948 5.053 5.158
5 4.741 4.844 4.947
10 3.843 3.935 4.027
15 3.136 3.217 3.299
20 2.572 2.644 2.717
25 2.123 2.186 2.25
30 1.761 1.817 1.874
35 1.469 1.518 1.568
40 1.23 1.274 1.319
45 1.036 1.075 1.115
50 0.872 0.906 0.941
55 0.745 0.7749 0.806
60 0.635 0.6622 0.69
65 0.544 0.5683 0.593
70 0.468 0.4895 0.512
75 0.404 0.4233 0.443
80 0.35 0.3673 0.385
85 0.305 0.3199 0.336
90 0.266 0.2796 0.294
95 0.233 0.2451 0.258
100 0.205 0.2156 0.227
If the measured resistance value is not up to regulation, replace the evaporator thermistor.
AC System 10-7
2. Manual controller connector.
A1 A2 A3 A4 A5 A6 A7 A8
A9 A10 A11 A12 A13 A14 A15 A16
Controller connector (A) MLJ004G
No. Function pin Direction Voltage range Current Remarks

A1 Backlight ground (ILL-) ≤600 mA
A2 Power supply ground ≤1100 mA
A3 Potentiometer ground ≤20 mA
A4
A5
A6
A7 A/C output request signal Output 12V/0V ≤50 mA High level effective
A8 Backlight power supply (ILL+) 12V ≤600 mA
Inner/outer circula-
A9 Output 12V/0V ≤500 mA High level effective
tion motor signal #2
Inner/outer circula-
A10 Output 12V/0V ≤500 mA High level effective
tion motor signal #1
Circulation motor po-
A11 Input 0V-12V ≤20 mA
sition feedback
Opening signal of sup-
A12 Input 12V/0V ≤50 mA Low level effective
ply blower motor
A13
A14 Positive power of potentiometer ≤20 mA
A15 BATT+ ≤1100 mA
A16 IGN2 ≤1100 mA
B1 B2 B3
B4 B5 B6
Controller connector (B) MLJ005G
No. Function pin

B1 Air speed: medium, Speed 1
B2 A/C switch controls
B3 Common terminal of air speed switch (ground input terminal)
B4 Air speed: high
B5 Air speed: medium, Speed 2
B6 Air speed: low
3. Electric controller unit (ECU).
Front view of ECU connector

MLJ006G
ECU interface signal meaning

Interface Interface
Pin Description Remarks Pin Description Remarks
signal signal
Power sup- Temperature damper
A-1 GND B-1 TEMP-
ply ground motor drive –
Temperature damper
A-2 IG2 Power supply B-2 TEMP F/B
motor feedback
Mode damper mo-
A-3 NC B-3 MODE-
tor drive –
Cycle damper mo-
A-4 NC B-4 INTAKE-
tor drive –
Battery's pow-
A-5 BATT B-5 LIGHT Backlight control High level
er supply
Rear window
A-6 RR_SW Low level B-6 NC
defrost control
A-7 A/C Compressor signal High level B-7 NC
A-8 HS Blower high speed Low level B-8 NC
AC System 10-9
Interface Interface
Pin Description Remarks Pin Description Remarks
signal signal
Power sup-
A-9 GND B-9 NC
ply ground
Damper motor
A-10 IG2 Power supply B-10 GND feedback power
supply ground
Temperature damper
A-11 NC B-11 TEMP+
motor drive +
Mode damper mo-
A-12 NC B-12 MODE F/B
tor feedback
Battery's pow- Mode damper mo-
A-13 BATT B-13 MODE+
er supply tor drive +
Cycle damper mo-
A-14 NC B-14 INTAKE+
tor drive +
INTAKE Cycle damper mo-
A-15 TB Air volume control B-15
F/B tor feedback
Air volume Damper motor feed-
A-16 TC B-16 VDD +5 V
feedback back power supply
B-17 NC
Vehicle exterior
B-18 AMB
temperature sensor
Vehicle interior tem-
B-19 INCAR
perature sensor
B-20 GND Sensor ground
4. Blower speed adjustive resistance.

(a) Check whether the speed adjustive resistance of the
blower is conducting.
Measure the resistance according to the value in the following
table:
Blower Testing instru- Specified resis-
speed ment connection tance value
1 HI-LO 2.95 ± 10% Ω
MLJ007G 2 HI-ML 0.39 ± 10% Ω
3 HI-MH 1.27 ± 10% Ω
If the measured value is not up to regulations, replace the
speed adjustive resistance of the blower.
AC System Components
Dashboard middle air duct assembly Condenser assembly
Electric AC Condenser
controller Manual AC discharge
pipe with
controller
Compressor exhaust pressure
pipe assembly switch as-
sembly
Evaporator assembly Compressor assembly
Compressor suction hose assembly
Lower air outlet assembly LH
Lower air outlet assembly RH
MLJ008G
AC System 10-11
Refrigerant
Vehicle inspection
1. Check the amount of refrigerant.
Observation port (a) Check the observation port on the condenser discharge pipe.
Test conditions:
• Operate the engine with a speed of 1,500 rpm.
• Set the blower speed control switch at the RH side.
• Set the AC switch to the "ON" postion.
• Set the temperature regulation knob to the "coldest" po-
sition.
MLJ009G • Open the door completely.
Items Problem Amount of refrigerant Corrective measures

1. Check whether there is air leakage,
repair if necessary
1 Bubbles are present Insufficient*
2. Charge refrigerant until bubbles dis-
appear
Empty, insufficient, or
2 No bubbles Refer to 3 and 4
too much
1. Check whether air leakage exists with

There is no temperature difference
an air leakage tester, repair if necessary
3 between the inlet port and outlet Empty or not enough
2. Charge refrigerant until bubbles dis-
port of the compressor
appear
The temperature difference is too
Appropriate amount, or
4 much between the inlet and outlet Refer to 5 and 6
too much
port of the compressor
1. Recycle the refrigerant
The refrigerant is clear immediately
5 Too much 2. Bleed air and charge the appropriate
after switching off the AC
amount of pure refrigerant
After switching off the AC, the re-
6 frigerant bubbles immediately and Appropriate amount -
becomes clear later
*: ��
If cooling is enough and the environmental temperature is higher than normal, then the bubbles inside the ob-
servation port will be considered normal.
2. Check the refrigerant pressure with a manifold pressure
gauge subassembly.
Read the pressure on the manifold pressure gauge after these
conditions are met.
Test conditions:
• When the switch is set at the inner circulation position, the
temperature at the inlet port is 30oC to 35oC.
• Operate the engine with a speed of 1,500 rpm.
• Set the blower speed control switch to the RH side.
• Set the temperature regulation knob to the "coldest" position.
• Set the AC switch to the "ON" postion.
• Open the door completely.
04
(a) Refrigeration system under normal operation.
15 2
Instrument Reading:
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
01
1
{cmHg kgf/cm2}
7
07
05
5
{cmHg kgf/cm2}
30
Low pressure side:
0 8 3
0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2)

-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
High pressure side:

R134a 1.37 to 1.57 MPa (14 to 16 kgf/cm2)
ALJ018G
(b) Humidity appears in the refrigeration system.
Condition: cyclic cooling and finally fails to produce cold air.
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
8 3
0
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
ALJ019G
Problem Possible cause Diagnosis Corrective measures

The dryer is in a su- 1. Replace the dryer.
The humidity in the re-
persaturation state. 2. Wipe off the humid-
frigeration system is
During operation, the pres- The humidity in the re- ity in the circulation
frozen at the throttle hole
sure on the low pressure frigeration system is area by releasing
of the expansion valve,
side is switching between frozen at the throttle hole air repeatedly.
which suspends the cir-
normal and vacuum status. of the expansion valve, 3. Charge the appro-
culation while returning
which stops the circula- priate amount of
to normal in melting.
tion of the refrigerant. new refrigerant.
(c) There is insufficient refrigeration.
Condition: refrigeration system does not work effectively.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01 35
MPa MPa
ALJ020G
AC System 10-13

1. Check whether there
is air leakage, re-
pair if necessary.
2. Charge the appro-
High and low pressure
priate amount of
side's pressure is low.
new refrigerant.
Bubbles can be con-
Air leakage occurs in the Insufficient refrigerant 3. When connecting
stantly seen from the
refrigeration system. The refrigerant leaks. with the instrument,
observation ports.
the indicating pres-
Refrigeration perfor-
sure values are close
mance is insufficient.
to zero. The vacuum
is available after
checking and repair-
ing the leaked area.
(d) Poor circulation of refrigerant.
Condition: refrigeration system does not work effectively.
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
ALJ021G

High and low pressure
side's pressure is low. The refrigerant flow
The pipeline from con- is blocked by dust in- The reservoir is blocked. Replace the reservoir.
denser to refrigerating side the reservoir.
device frosts over.
(e) Refrigerant does not circulate.
Condition: refrigeration system does not work or only works some of the time.
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
ALJ021G

1. Check the expan-
sion valve.
Low pressure side indi- 2. Remove the dust
The refrigerant flow is
cates vacuum, the high inside the expansion
blocked by the humd-
pressure side indicates valve by air-blowing.
ity or dust in the re- Refrigerant can-
that it is too low. 3. Replace condenser.
frigeration system. not circulate.
Frosting or condensation 4. Release and charge
The leakage of the ex-
appears on the pipeline at appropriate amount
pansion valve blocks
both sides of the reservoir/ of new refrigerant.
the refrigerant flow.
dryer or expansion valve. 5. Gas leakage occurs in-
side the expansion valve,
replace expansion valve.
(f) Too much refrigerant charged or the condenser cools poorly.
Condition: refrigeration system does not work.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
ALJ022G

1. Clean the condenser.
Too much refrigerant in
2. Check the cooling
Low and high pressure Over-use of the refrig- circulating → Too much
fan when the cooling
side's pressure is too high eration system prohib- refrigerant charged.
fan motor operates.
The engine speed drops its full performance. The condenser cools
3. If 1 and 2 are normal,
and no bubbles can be seen The condenser poorly → The condenser
check the refrigerant
from the observation ports. cools poorly. cooling fin of cool-
amount and provide the
ing fan is blocked.
appropriate refrigerant.
(g) Air exists in the refrigeration system.
Condition: refrigeration system does not work.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0 Remark: Open the refrigera-
0 08 -76 35
-76
-01
085 0
-01
tion system and charge the
15 35
MPa MPa refrigerant without vacuum
pumping.
The gauge will show the
indication as shown in the
figure.
ALJ023G
AC System 10-15

Low and high pressure
side's pressure is too high 1. Check whether the
The low pressure pipe- There is air in the re- compressor oil is
line cannot be reached There is air in the system. frigeration system and dirty or insufficient.
due to overheating, and poor purification. 2. Vacuum and charge
bubbles can be seen from new refrigerant.
the observation ports.
(h) Expansion valve failure.
Condition: Insufficient cooling.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01
35
MPa MPa
ALJ023G

Low and high pressure There is too much re-
side's pressure is too high. frigerant in the low
Expansion Check the expan-
There is frost or a buildup pressure pipeline.
valve failure. sion valve.
of condensation in the low Expansion valve open-
pressure side's pipeline. ing is too big.
(i) Compressor functions poorly.
Condition: Insufficient cooling.

04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07 30
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 - 01 35
MPa MPa
ALJ024G

Low and high pressure Compressor failure.
side's pressure is too high. Internal leakage of Leakage has occured in Maintain or repair
High pressure side's pres- the compressor. the damaged valve or the compressor.
sure is too low. broken sliding parts.
Charging and replacement of refrigerant

1. Charge refrigerant.
(a) Vacuum the system.
Close (1) Connect the low pressure pipe (blue) on the manifold
Close
gauge to the low pressure charging valve of the AC
system, the high pressure pipe (red) to the high pres-
Vacuum pump
sure charging valve of the AV system, and the middle
yellow pipe to the vacuum pump.
Connect to AC high
pressure charging valve
Connect to AC low
MLJ033G
(2) Open the high and low pressure valve, connect to

the power supply of the vacuum pump, and open the
vacuum pump for vacuuming. The vacuuming time
should last for 15-30 min. with a vacuum pump flow
Open
Open of 2.5 litre/min.
Vacuum pump
MLJ034G
(b) Maintaining pressure for leak testing.

After the vacuuming time is over, close the high and low pres-
sure valve as well as compressor's power supply. Observe the
indicator of the low pressure gauge and make sure not return
within 30 minutes.
Close Close
MLJ035G
(c) Charge the refrigerant.

(1) Remove the middle yellow pipe from the vacuum
Screwdriver pump and connect it to the refrigerant tank switch.
Next, open the valve core on the manifold gauge
Close Close
with a screwdriver to empty the air.
Open
Connect to AC high
Refriger- pressure charging valve
ant tank Connect to AC low
MLJ036G
AC System 10-17
(2) Turn the refrigerant tank upside-down (as seen in

figure), open the high pressure valve until the charge
quantity of refrigerant moves up to 300-400 grams,
and then close the high pressure valve.
Open Open
Charge 300-400 gram
Open Open
MLJ037G
(3) Flip the refrigerant tank back to its original position,

open the low pressure valve, and start the engine.
Switch on and set the AC system to the coldest set-
ting, set the fan to maximum speed, and then step on
Open Close
the throttle pedal and run the engine with a constant
Charge to the
specified quantity speed of about 2,000 rpm.
Close (4) When charging the refrigerant up to the specified
quantity, close the low pressure valve. Now the re-
Connect to AC frigerant charge is completed.
high pressure
charging valve
Connect to AC low
MLJ038G
2. The recycling and emptying of the refrigerant.

Areas of Importance:
1) The recycle area shall be well-ventilated and make sure not to expose the drained refrigerant to flame so as
to prevent poisonous gas from escaping.
2) The drainage of the refrigerant doesn't mean that of frozen lubricant, therefore, be sure to measure the
drained lubricant capacity for filling in order to fill.
Traditional emptying method:
1) Connect the manifold pressure gauge subassembly to the high and low pressure inspection valve in the sys-
tem.
2) Start up and run the engine with a speed of 1000-1200 r/min for 10-15 min.
3) Opearate the fan with high speed, set all the control switches to the coldest position for maintaining the sys-
tem in a steady state.
4) Adjust the engine speed to normal idle state.
5) Switch off the AC's control switch and stop the engine.
6) Fully open the low pressure manual valve on the manifold pressure gauge subassembly,let the refrigerant
flow into the recycle device via middle hose. When the pressure drops to 350 kPa, open the high pressure
manual valve slowly to prevent refrigeration oil from being taking out.
7) When the high and low pressure gauge indicator of the manifold pressure gauge subassembly is zero, it
means the refrigerant in the system is empty.
Recycle emptying method:
1) Recycle the refrigerant in the AC refrigeration system to the reservoir with the gauge valve system, in which
the high pressure valve is connected to the compressor exhaust pipe, the low pressure valve is connected to
the compressor suction hose, and the middle interface of the gauge valve is connected to a steel cylinder of
Φ60 mm × 100 mm. A stop valve is available at the bottom of the steel cylinder for draining the refrigera-
tion oil together with refrigerate. When the pressure begins to drop, first slowly unscrew the high pressure
manual valve to let refrigerant flow gradually without refrigeration oil together with it. When the pressure
drops to 350 kPa, open the low pressure manual valve slowly. The refrigerant is recompressed, condensed,
in a fluid form, and put into the reservoir after being subjected to depressurization, acid removal, drying, and
filtering.
2) During the process, the neutralization method or film treatment method is always used to clear away the
generated acidoid and automatically separates the acidoid. The moisture mixing with the refrigerant is al-
ways adsorbed with a molecular sieve, so as to reduce the water content of refrigerant needed to meet the
reused standard (water content of 0.001%��
)��
. The AC filter can be used for elimination of such insoluble im-
purities such as iron chips, oily dirt and dust, etc.
Refrigerant pipeline
Plastic bracket
Condenser discharge pipe
Compressor suction hose assembly
Compressor exhaust
pipe assembly Heater inlet pipe
Compressor assembly
Heater outlet pipe
Condenser discharge pipe with

pressure switch assembly
MLJ010G
AC System 10-19
Compressor Assembly
Replacement
1. Recycle the refrigerant in the refrigeration system.
2. Raise the vehicle, loosen the fixing bolt of the generator
and remove the drive belt of the engine.
3. Disconnect the compressor exhaust pipe assembly.
(a) Remove the bolt and disconnect the exhaust pipe assem-
bly from the compressor assembly.
(b) Remove the o-ring from the compressor exhaust pipe as-
sembly.
Caution:
Disconnect the part's opening with PVC empire tape seal to pre-
vent humdity and foreign matters from entering the equipment.
MLJ011G
4. Disconnect the compressor suction hose assembly.

(a) Remove the bolt and disconnect the suction hose assem-
bly from the compressor assembly.
(b) Remove the o-ring from the compressor suction hose as-
sembly.
Caution:
MLJ012G
5. Remove the compressor assembly.

(a) Disconnect the connector of the electromagnetic clutch.
(b) Remove the 4 bolts and the compressor assembly.
6. Check the compressor oil.
(a) When replacing with a new compressor, first release the
gaseous refrigerant from the maintenance valve gradu-
ally and then drain the following oil amount from the
new compresson assembly before installing.
MLJ013G
Standard:
The oil amount in the new compressor - residual oil amount in the
removed compressor = drained oil amount in the replacement
Hint: The oil amount in the new compressor:
200ml for JIANSHE compressor
150ml for SANDEN compressor
Caution:
When checking the oil level of compressor, comply with the Ar-
eas of Importance during the removal/installation of compressor.
Because residual compressor oil is still available in the vehicle's
pipeline, and if you are installing a new compressor without
draining the residual oil, then the oil amount will be too much and
the heat exchange during refrigeration circulation will be blocked
causing refrigerant failure.
Check whether oil leakage exists if there is not enough residu-

al compressor oil in the removed compressor.
Be sure to use compressor oil RFL-100X or SP10 (PAG46).
7. Install the compressor assembly.

(a) Install the compressor assembly with 4 bolts.
Torque: 22 N·m
Caution:
Tighten the bolts as shown in the figure to install the compres-
sor assembly.
(b) Connect the connector of the electromagnetic clutch.
MLJ013G
8. Install the compressor suction hose assembly.

(a) Remove the PVC empire tape wound around the hose.
(b) Fully apply the compressor oil on the new o-ring and as-
sembly surface of the compressor assembly.
Compressor oil:
JIANSHE compressor: RFL-100X
SANDEN compressor: SP10 (PAG46)
(c) Install a new o-ring on the compressor suction hose as-
MLJ012G
sembly.
(d) Install the compressor suction hose assembly to the com-
pressor assembly with bolts.
Torque: 10 N·m
9. Install the compressor exhaust pipe assembly.
(a) Remove the PVC empire tape wound around the hose.
(b) Fully apply the compressor oil to the new o-ring and as-
sembly surface of the compressor assembly.
Compressor oil:
JIANSHE compressor : RFL-100X
(c) Install the o-ring on the compressor exhaust pipe assem-
MLJ011G
bly and then install them on the compressor assembly
with bolts.
Torque: 10 N·m
10. Install the drive belt and tension then belt of engine and
then tighten the locking bolt of generator.
11. Charging Refrigerant.
Specified quantity: 500±50 g
12. Warm up the engine and switch on the AC system.
13. Check for leaking refrigerant.
AC System 10-21
AC Controller Assembly Replacement
1. Remove the central control panel (manually).

Hint: There are 12 claws.
2. Remove the switch block (See page 13-11).
MLJ014G
3. Remove the AC controller (manually).

(a) Remove the 4 screws from the dashboard and take out
the AC controller.
(b) Detach the connector.
(c) Disconnect the temperature control and fan knob cable.
MLJ015G
4. Remove the central panel (electric).

5. Remove the switch block (See page 13-11).
MLJ016G
6. Remove the AC controller (electric).

(a) Detach the connector.
(b) Remove the 4 screws from the AC control panel and take
out the AC controller.
7. Install the AC controller.
(a) Connect the temperature control and fan cable (manu-
ally).
(b) Connect the connectors (manually)
MLJ017G
(c) Install the controller (manually) on the dashboard.
(d) Connect the wire harnesses terminals (electric).
(e) Install the controller (electric) on the control panel.
(f) Tighten the 4 mounting screws.
8. Install the central panel.
AC Assembly
Components
Q2214816
Q2214816
Q2204816
7
6
5
21 8
4
9
3
24
2 10
Q2734216
1
11
23
12
13
20 14
22
19
18 15
17
16
1. Heater core cover 13. Combination control panel

2. Blower 14. Evaporator core body
3. HVAC left housing 15. Thermistor
4. HVAV right housing 16. HVAC lower housing
5. Speed adjustive resistance 17. H-shaped expansion valve
6. Inner/outer circulation air duct 18. Lower air outlet LH
7. Wire harness mounting bracket 19. Bottom air duct
8. Inner/outer circulation damper crank 20. Heating core body
9. Filter screen protector 21. Dashboard middle air duct assembly
10. Filter screen 22. Left side bracket of dashboard lower protector
11. Lower air outlet RH 23. Right side bracket of dashboard lower protector
12. Temperature change throttle 24. Inner/outer circulation actuator
MLJ018G
AC System 10-23
Overhaul
Hint:
The installation sequence is the opposite of the removal se-
quence. However, it only includes the installation sequence
with additional information.
2. Unscrew the mounting bolts of the expansion valve and

the engine compartment's AC pipeline and separate the
engine compartment's AC pipeline from the expansion
valve.
3. Remove the AC gasket.
MLJ019G
4. Disconnect the heater's water inlet and outlet hose.

(a) Joint the clip dog with pliers, slide the clip, and discon-
nect the heater's water inlet and outlet hose.
5. Remove the center console panel (See page 10-21).
6. Remove the AC controller assembly (See page 10-21).
7. Remove the dashboard (See page 13-10).
ALJ044G
8. Remove the central air duct.

Q2214816
(a) Remove the 6 mounting screws of the central air duct
and take out the central air duct.
Q2214816
Q2204816
MLJ020G
Mounting nut 9. Remove the combination of the dashboard brace rein-

Mounting nut
forcement and the AC unit, as shown on the left after
removal.
10. Separate the dashboard brace reinforcement and the AC
unit.
Mounting bolt (a) Unscrew the 4 nuts and 1 mounting bolt at the 5 mount
points to separate the dashboard brace reinforcement and
air conditioner
Mounting nut Mounting nut MLJ021G
Mounting screw 11. Remove the air conditoner.

(a) Remove the inner/outer circulation air duct: Unscrew the
mounting unscrew the inner/outer circulation air duct
and then unscrew the air conditioner by rotating the in-
ner/outer circulation air duct clockwise.
MLJ022G
(b) Remove the speed adjustive resistance of blower.

(1) Disconnect the connector.
(2) Remove the 2 screws and the speed adjustive resis-
tance of blower.
MLJ023G
(c) Remove the blower: Unscrew that 2 mounting screws of

Mounting the blower to remove the blower.
screw
MLJ024G
Screw (d) Remove the heater core.

(1) Unscrew the mounting screw on the heater core cov-
er to remove the heater core cover.
(2) Remove the heater core.
Screw Screw MLJ025G
Screw (e) Remove the evaporator:

(1) Unscrew the HVAC lower housing screw to take
out the HVAC lower housing, and then take out the
evaporator.
Screw
Screw MLJ026G
AC System 10-25
(2) Remove the evaporator thermistor.
Rear part of the

discharge pipe
Thermistor
MLJ027G
(f) Remove the filter screen: Unscrew the mounting unscrew

the filter screen protector, and then take out the filter
screen by taking out the filter screen protector.
Screw 12. For the installation sequence, simply reverse the removal
steps.
MLJ028G
Maintenance and Replacement of the AC Filter Screen

The AC filter screen is the filter for the AC air inlet. The longer cleaning or replacement is not done, the more
dust is absorbed onto it, and then blown into a relatively enclosed space by the AC fan. The degree to which the
air inlet is purified or clean directly relates to the health and safe driving of the passenger. Therefore, it is suggest-
ed that cleaning and removing the dust from the filter screen shall be done at approximately every 6,000 km. The
cleaning method: Knock the AC filtering element on a flat surface or something hard, and then blow off the dust
from the dust accumulation side of the filtering element with compressed air at a pressure of 0.6 MPa, or wipe off
with a small brush. Afterwards, take out the filter element and clean every 3000 km (or 2 months). It is suggested
to replace the filter component after every 15,000 km because the filtering material in the component is degraded
and the filtering effect becomes poor.
Areas of Importance:
If the purchased vehicle is always driven in a sand-dust environment, the cleaning and replacement pe-
riod for the filter component needs to be sooner due to the circumstances.
Remove the AC filter screen from the vehicle:
1. Remove the package tray assembly at the bottom of the auxiliary facia console.
2. Remove the filter screen protector screw with a screwdriver.
3. Extract the filter screen for maintenance or replacement.
The installation method of the AC filter screen is the opposite of the removal method.
Subcooling Condenser Assembly

Vehicle check
1. Check the subcooling condenser assembly.
(a) If the cooling fin of the subcooling condenser assembly is
dirty, it should be cleaned and dried using compressed air.
Caution:
Be sure not to damage the cooling fin of the subcooling con-
denser assembly.
(b) If the cooling fin of the subcooling condenser assembly
is bent, it will need to be straightened with a screwdriver
or pliers.
2. Check whether refrigerant leakage exists in the con-
denser.
(a) Use the refrigerant leak tester to check whether air leak-
age exists at the pipe connector.
(b) If air leakage is detected at the pipe connector, check the
torque of the connector.
Components
Subcooling condenser assembly

Condenser upper mount assembly
Condenser fan assembly
Compressor exhaust pipe

assembly
Condenser discharge pipe
Condenser lower mount assembly
MLJ029G
AC System 10-27
Overhaul
2. Remove the front bumper and front impact beam (See
page 11-8).
3. Disconnect the compressor exhaust pipe assembly.

(a) Remove the bolts and disconnect the compressor exhaust
pipe assembly from the subcooling condenser assembly.
(b) Remove the o-ring from the compressor exhaust pipe as-
sembly.
Caution:
Disconnect the part's opening with PVC empire tape seal to
prevent humdity and foreign matters from entering the equip-
MLJ030G
ment.
4. Disconnect the condenser discharge pipe.

(a) Remove the condenser discharge pipe from the subcool-
ing condenser assembly.
(b) Remove the o-ring from the condenser discharge pipe.
Caution:
(c) Disconnect the discharge pipe from the condenser dis-
MLJ031G
charge pipe bracket.
5. Remove the subcooling condenser assembly.

(a) Remove the 2 bolts and the subcooling condenser assem-
bly.
MLJ032G
6. Install the the subcooling condenser assembly.

(a) Install the subcooling condenser assembly with 2 bolts.
Torque: 9.8 N·m
MLJ032G
7. Install the condenser discharge pipe.

(a) Remove the PVC empire tape wound around the con-
denser discharge pipe and the subcooling condenser as-
sembly.
(b) Fully apply the compressor oil to the new o-ring and
hose connector.
Compressor oil:
JIANSHE compressor: RFL-100X
MLJ031G
(c) Install the o-ring on the condenser discharge pipe.
(d) Fix the condenser discharge pipe on the bracket.
(e) Install the condenser discharge pipe on the subcooling con-
denser assembly with bolts.
Torque: 10 N·m
8. Install the compressor exhaust pipe assembly (See page

10-20).
(a) Remove the PVC empire tape wound around the com-
pressor discharge pipe and the subcooling condenser as-
sembly.
(b) Fully apply the compressor oil to the new o-ring and
hose connector.
(c) Install the o-ring on the condenser discharge pipe.
MLJ030G
(d) Install the compressor exhaust pipe on the subcooling
condenser assembly with bolts.
Torque: 10 N·m
9. Charging refrigerant.
Specified quantity: 500±50 g.
10. Check for leaking refrigerant.
11. Install the front bumper and front impact beam (See
page 11-8).
Vehicle Body 11-1
Vehicle Body
Engine Hood................................................................................... 11-2

Engine Hood Lock Cable Assembly............................................... 11-4
Trunk Power-Assisted Strut Bar..................................................... 11-5
Retainer.......................................................................................... 11-5
Door Hinges................................................................................... 11-6
Bumper........................................................................................... 11-7
Front Bumper.............................................................................. 11-7
Rear Bumper............................................................................. 11-10
Door Cable of Fuel Tank Filler...................................................... 11-13
Engine Hood
Adjustment
Hint: The centering bolt is used for the installation of engine
hood hinge. When installing the centering bolt, the engine
hood can not be adjusted. During the adjustment, replace the
centering bolt with a standard bolt (with a washer).
Centering bolt Standard bolt
ALN001G
1. Check the engine hood subassembly.

(a) Check and confirm if the clearance is within the standard range.
MLK001G
Standard:
Position Measured value
A 4.0 mm
B 0 mm
2. Adjust the engine hood subassembly.

(a) Adjust the engine hood horizontally and vertically.
(1) Loosen the 2 hinge bolts at the side of the engine
hood.
ALN003G
Vehicle Body 11-3
(2) Adjust the clearance by moving the engine hood to

set it within the standard range.
Standard range (A): 4.0 mm
(3) After adjustment, tighten the hinge bolt at the side of
engine hood.
Torque: 20 N·m
MLK002G
(b) Adjust the front height of the engine hood with the adust-
ing block.
(1) Rotate the adjusting block to align the engine hood
with the fender.
Hint: Move the adjusting block up and down by rotating.
MLK003G
(c) Adjust the engine hood lock.

(1) Remove the clip and grille.
(2) Adjust the position of engine hood lock to let the
lock catch into it smoothly.
(3) After adjustment, tighten the engine hood lock bolt.
Torque: 7.0 N·m
MLK004G
Engine Hood Lock Cable Assembly

Replacement
1. Remove the engine hood lock cable assembly.
(a) Open the engine hood.
(b) As shown in figure, remove the engine hood lock cable
assembly from the dashboard.
MLK005G
(c) Remove the cable from the cable handle assembly of en-
gine hood lock
(d) As shown in figure, remove the bolt and engine hood
lock assembly.
MLK006G
(e) Remove the cable from the engine hood lock assembly.
2. Install the cable assembly of the engine hood lock.
Hint: Different metals making direct contact will acceler-
ate corrosion. Make sure to use the correct fastening piece to
avoid premature corrosion.
(a) Install the cable assembly onto the engine hood lock as-
sembly.
(b) Install the engine hood lock assembly with the bolts.
(c) Install the cable assembly onto the cable handle assem-
bly of engine hood lock assembly.
(d) Install the engine hood lock cable assembly onto the
dashboard.
(e) Close the engine hood.
Vehicle Body 11-5
Trunk Power-Assisted Strut Bar

Replacement
Hint: Installation sequence is the reverse of the removal se-
A quence. However, it only includes the installation sequence
The operation sequence at the right side is the same as the left
one.
1. Remove the trunk power-assisted strut bar assembly.
B
MLK007G (a) Remove bolt A from the trunk door.
Hint: Stop the trunk door with your hands when removing the
trunk door air spring.
(b) Remove the 2 bolts B and air spring from the vehicle
body panels.
2. Install the left power-assisted brace gas spring of the
trunk door.
(a) Install the air spring with bolts.
Tightening torque: Bolt A: 22 N·m
Bolt B: 8 N·m
Disposal
Hint: The operation sequence at the right side is the same as
the left one.
1. Dispose the trunk door left side air spring assembly.
(a) Extract the piston rod and fix the air spring onto the
bench clamp horizontally.
b (b) Wear the safety glasses, cut the part between A and B
a
A B (As shown in the figure) with a metalworking saw, and
release the gas gradually.
MLK008G
a 80 mm
b 20 mm
Warning: Cover the cut position carefully due to the
metal chips might be blown out of it by air. (The gas is
colourless, odourless, and innocuous)
Retainer
Replacement
1. Remove the front door retainer LH.
Remove 1 bolt A, 2 bolts B, and the retainer.
Hint: Remove the retainer via inspection hole.
B A
MLK009G
2. Install the front door retainer LH.

(a) Apply the general grease to the sliding region of the re-
tainer.
(b) Install the retainer onto the vehicle's door sheet with 2 bolts.
Torque: 10 N·m
(c) Apply adhesive to the thread of the bolt.
(d) Install the retainer onto the vehicle's door sheet with bolts.
Torque: 20 N·m
3. Remove the rear door retainer LH.
(a) Remove 1 bolt A, 2 bolts B, and the retainer.
Hint: Remove the retainer via inspection hole.
B
MLK010G
4. Install the rear door retainer LH.

(a) Apply general grease to the sliding region of the retainer.
(b) Install the retainer onto the vehicle's door sheet with 2
B
bolts.
Torque: 10 N·m
(c) Apply adhesive to the thread of the bolt.
A
(d) Install the retainer onto the vehicle's door sheet with
bolts.
MLK010G
Torque: 20 N·m
Door Hinges
Removal
1. Remove the front door hinge LH.
Open the door by 60° and remove the mounting bolt of the
hinge axis with a sleeve, then lift the door upward and remove
it.
quence.
MLK011G
2. Remove the rear door hinge LH.

Open the door by 60° and remove the mounting bolt of hinge
axis with a sleeve, then lift the door upward and remove it.
quence.
MLK011G
Vehicle Body 11-7
Bumper
Front Bumper
Front bumper body
Front bumper upper grating

Horn decorative cap
Energy-absorbing foam
Front bumper left

connection bracket
Front bumper right
connection bracket
Front bumper
trim panel LH
Front bumper Front fog

trim panel RH lamp decora-
tive cap LH
Front fog lamp

decorative cap RH
Front bumper draw-

bar close lid
Front bumper lower grating
Front bumper chromatic panel
MLK012G
Removal
quence.
1. Unscrew the cross recess head self-tapping screw con-
necting the front bumper and splash pad as well as two
screws at the bottom and side of the flat washer subas-
sembly (A total of four, two on the left and two on the
right).
MLK013G
2. Remove the expansion button connecting the front bum-

per and bumper connection bracket (A total of two, one
on the left and one on the right).
MLK014G
3. Unscrew the hexagon head bolt and flat washer subas-

sembly for the installation of front bumper bottom (A total
of four).
MLK015G
4. Unscrew the mounting bolts of front bumper for the in-

stallation of the top front bumper (A total of four).
MLK016G
Vehicle Body 11-9
5. Pull the front bumper out of the clamping structure along

the bumper connection bracket, front bumper, and head-
light.
MLK017G
6. Disconnect the connector assembly of the front fog

lamp.
MLK018G
7. Unscrew the cross slot and concave hexagon head self-

tapping screw and washer subassembly connecting the
left and right connection bracket of the front bumper and
remove the left and right connection bracket of the front
bumper.
MLK019G
8. Remove the front impact beam assembly.

(1) Remove 1 nut and 2 bolts from the left and right bracket
assembly of the front impact beam.
(2) Remove 1 nut and 2 bolts from the right bracket assem-
bly of the front impact beam.
(3) Remove the front impact beam assembly from the left
and right side bracket .
MLK020G
Rear Bumper
Rear bumper body
Rear bumper body
Rear bumper trim panel RH
Right reverse sensor

hole blank cover
Rear bumper drawbar close lid
Rear bumper trim panel
Rear bumper trim panel LH

Left reverse sensor hole blank cover
MLK021G
Vehicle Body 11-11
Removal
quence.
1. Unscrew the screw connecting the rear wheel mudguard
and rear bumper (A total of four, two on the left and two
on the right).
MLK022G
2. Loosen the clamp connecting the rear wheel mudguard

and rear bumper.
MLK023G
3. Unscrew three cross slot and concave hexagon head

self-tapping screws and washer subassemblies for the
installation of the rear bumper bottom.
MLK024G
4. Unscrew two (one on the left and one on the right) hexagon
flange head tapping screws for the connection of rear bum-
per and side wall.
5. Unscrew two hexagon head bolts and large washer sub-

assemblies (one on the left and one on the right) for the
connection of rear bumper and side wall.
MLK025G
6. Unscrew the four hexagon head bolts and larger washer

subassemblies for the installation of the top rear bumper.
MLK026G
7. Pull out the mounting clips connecting the rear bumper

and side wall.
MLK027G
8. Disconnect the connector assembly of the rear fog lamp

and reverse sensor.
MLK028G
9. Remove the rear impact beam assembly.

(1) Remove 2 nuts from the left bracket assembly of the rear
impact beam.
(2) Remove 3 nuts from the right bracket assembly of the
rear impact beam.
(3) Remove the rear impact beam assembly from the left and
right side bracket.
MLK029G
Vehicle Body 11-13
Door Cable of Fuel Tank Filler

Removal
1. Open the trunk door.
2. Remove the trim panel under the tail lamp.
3. Then remove the larger rubber plug (arrow).
4. Put in the hand from the round hole to rotate A throttle
lock along the arrow direction and then pull out the throt-
A Throttle lock
tle lock at an approporiate position.
MLK030G
5. Remove the C-pillar interior and pull out the cable via the
through hole B.
6. Remove the driver seat.
B Cable
through hole
MLK031G
7. Remove the left side carpet.

8. Remove the attachment clip C on the cable from the pro-
jection welding stud bolt.
C Fixing clip
MLK032G
9. Remove the attachment nut D on the attachment handle.

10. Remove the cable ends from the handle and detach the
handle and cable.
11. Take out the cable handle.
12. Pull out the cable together with the rubble plug E from
D Fixing nut
E Rubber plug the hole, and take out the whole door cable of fuel tank
filler.
MLK033G
Installation
1. Fix the cable together with the rubber plug E to the
round hole at first.
2. Then connect the cable ends and the handle.
3. Tighten the handle with the attachment nut D.
D Fixing nut
E Rubber plug
MLK033G
4. Fix the attachment clip C on the cable to the projection

welding stud bolt.
5. Then put the cable through the hole B.
C Fixing clip
MLK032G
6. Put the left side carpet into its original position.

7. Install the driver seat.
8. Install the C-pillar interior.
B Cable through hole
MLK031G
9. Put in the hand from the round hole along the arrow di-
rection to hold the throttle lock A and then insert it into
the long, square hole till being stuck by rotating, and cog
out of it is impossible even pulling by force.
A Throttle lock
10. Install the larger rubber plug on the round hole (arrow).
11. Install the trim panel under the tail lamp.
12. Close the trunk door.
MLK030G
Audio and Video 12-1
Audio/Video
Audio and Video System................................................................12-2

Components ..............................................................................12-2
Inspection....................................................................................12-3
CD Player Assembly...................................................................12-3
Front Door Speaker Assembly RH..............................................12-4
Antenna Wire Harness Assembly...............................................12-5
Audio and Video System

Components
Radio with
bracket assembly
CD player with
bracket assembly
Center console
panel body
Antenna assembly
Front door speaker

assembly LH
Rear door speaker assembly LH
Note: The right speaker is not displayed.
MLL001G

In the following table, the suspected areas are listed according to the order of the number, in order to determine the
cause of the problem. When necessary, inspect, repair, and replace the parts with the steps listed in the following pages.
Hint:
The causes and the suspected areas of other speakers are the same with the following table.
Problem Location in Question Reference
Page (s)
Only sound of the front door speaker RH is not 1. Front door speaker assembly RH -
hearable. 2. Wire harness -
Inspection
Hint:
Inspection methods for other speakers are the same with the
front door speaker RH.
1. Front door speaker assembly RH.
1 2
(a) Inspect whether the front door speaker RH is conducting.
(1) Inspect and confirm the terminals are conducting
MLL002G with each other.
Scanner connection Condition Specification

1-2 Always 4Ω
CD Player Assembly
Replacement
2. Remove the center console panel body.
3. Remove the CD player with the bracket assembly.

(a) Remove the 4 bolts.
(b) Disconnect the connector.
(c) Remove the CD player with bracket assembly.
MLL003G
4. Remove the CD player's right bracket.

(a) Remove the 4 bolts and the CD player's right bracket.
MLL004G
5. Remove the CD player's left bracket.

(a) Remove 4 bolts and the CD player's left bracket.
6. Replace the CD player assembly.
7. Install the CD player assembly by reversing the removal
steps.
MLL005G
Front Door Speaker Assembly RH

Replacement
Hint:
The replacement of the front door speaker LH is the same as
with the front door speaker RH.
1. Remove the front door triangular trim panel RH.
2. Remove the front door protector RH.
3. Remove the front door speaker assembly RH.

(a) Disconnect the speaker connector.
(b) Remove the 3 bolts.
(c) Remove the speaker.
(d) Remove the 3 plastic buckles.
MLL006G
4. Install the front door speaker assembly RH.

(a) Install the 3 plastic buckles.
(b) Install the speaker.
(b) Install the 3 bolts.
(c) Connect the speaker connector.
MLL006G
Antenna Wire Harness Assembly

Replacement
1. Remove the roof assembly.
2. Remove the C-pillar inner guard plate.
3. Remove the rear threshold RH.
4. Remove the right B-pillar lower guard plate.
5. Remove the right A-pillar lower guard plate.
6. Remove the front threshold RH.
7. Remove the dashboard.
8. Disconnect the connector.
9. Remove the antenna's lock nut.
10. Remove the antenna wire harness (As the antenna wire harness and the floor wire harness are
wrapped together, it is suggested not to remove it, but test whether the antenna wire harness is con-
ducting with meter).
11. When installing, use the tape to wrap the replaced antenna with the floor wire harness and (or) the
dashboard wire harness. For others installations, please reverse the removal steps.
MLL007G
Interior 13-1
Interior
Combination Meter.........................................................................13-2
Pin Definition...............................................................................13-2
Technical Specifications..............................................................13-4
Dashboard/Meter........................................................................13-7
Dashboard................................................................................13-10
Cigarette Lighter Assembly.......................................................13-15
Power Socket............................................................................13-16
Ignition Switch...........................................................................13-18
Combination Switch..................................................................13-19
Switch Block Assembly.............................................................13-20
Window Regulator Switch.........................................................13-21
Door Lock System........................................................................13-22
Electric Door Locks Overview ..................................................13-22
Technical Specifications............................................................13-23
Areas of Importance..................................................................13-25
Door Locks................................................................................13-26
Transmitter Battery...................................................................13-30
Immobilizer System......................................................................13-33
Overview...................................................................................13-33
Position Diagram.......................................................................13-34
Theft Deterrent ECU Terminal Definition...................................13-34
Top Interior Cover.........................................................................13-36
Components..............................................................................13-36
Seats............................................................................................13-39
Components..............................................................................13-39
Overview...................................................................................13-40
Removal....................................................................................13-40
Combination Meter
Pin Definition
17
9
18-pin outlet 1 32 32-pin outlet
10
18
16 1
MLM001G
32-pin outlet pin definition

Pin No. Function Pin No. Function Pin No. Function
1 Ignition 12 23 Outside temperature (+)
2 Battery 13 Central door lock output 24 Water temperature gauge
3 Meter ground 14 AT oil temperature indi- 25 Fuel gauge
cator
4 Main relay 15 Wheel chain maintenance 26 3rd gear
5 16 Anti-theft 27 2nd gear
6 Malfunction indicator 17 Meter interior communi- 28 1st gear
cation
7 Charging indication 18 P position 29 Outside temperature (-)
8 Oil pressure 19 R position 30 Neutral position
9 4WD (ESP) 20 N position 31 Speedometer
10 Seat belt 21 D position 32 Tachometer
11 ABS 22 Interior lighting (+)
18-pin outlet pin definition

Pin No. Function Pin No. Function Pin No. Function
1 Pre-heating 7 Front passenger side air- 13 Left turn signal lamp
bag lock
2 Oil-Water Separation (-) 8 Parking brake 14 Interior lighting (-)
3 Oil-Water Separation (+) 9 WINTER 15 Right turn signal lamp
4 Door open warning 10 POWER 16 Rear defroster
5 Rear fog lamp 11 High beam 17 Airbag fault
6 Front fog lamp 12 Master lighting switch 18 Braking system fault
Interior 13-3

Indicator lamps:
Reference page
(s)
2. Front fog lamp switch -
Front fog lamp indicator doesn't illuminate.
3. Combination meter assembly -
4. No.1 fuse box 15-17
2. Rear fog lamp switch -
Rear fog lamp indicator doesn't illuminate.
2. Left combination switch lighting handle as-
High beam indicator doesn't illuminate. sembly 13-19
4. Ignition lock -
2. Turn signal and hazard warning system -
Turn signal lamps don't illuminate.
2. Courtesy lamp switch -
Door open warning lamp doesn't illuminate.
Charging indicator doesn't illuminate. 2. Generator -
Parking brake lamp doesn't illuminate. 2. Parking brake switch -
Airbag warning lamp doesn't illuminate. 2. Airbag ECU assembly -
Seat belt unfastened indicator lamp doesn't il-
2. Seat belt switch -
luminate.
Brake system failure indicator doesn't illumi- -
2. Brake fluid level warning switch
nate. -
3. Combination meter assembly
ABS failure indicator doesn't illuminate. 2. Combination meter assembly -
3. ABS ECU -
Oil pressure warning lamp doesn't illuminate. 2. Oil pressure switch -
Reference page
(s)
Fuel warning lamp doesn't illuminate. 2. Fuel gauge sensor -
Engine system failure indicator doesn't illumi-
2. ECM -
nate.
2. ECM -
Vehicle service indicator doesn't illuminate. 3. Sensors of various kinds connected to the en-
gine -
EBD indicator doesn't illuminate. 2. ABS ECU
Light main switch indicator doesn't illuminate. 2. Combination switch lighting handle assembly -
2. Rear defroster switch -
Rear fog lamp indicator doesn't illuminate.
120 km warning lamp doesn't illuminate. 2. Speed sensor -
Front passenger side airbag lock indicator doesn't 2. Airbag ECU assembly -
illuminate 3. Combination meter assembly -
4. Front passenger side airbag lock -
1. Check the speedometer
(a) Check the working condition.
(1) Check the speedometer's permitted indication error with a speedometer detector and the working condi-
tion of the odometer.
Standard value (km/h) Allowable range (km/h)
20 (7 to 23
40 36 to 40
60 55 to 60
80 75 to 80
100 95 to 100
120 114 to 120
140 133 to 140
160 152 to 160
180 171 to 180
Interior 13-5
Caution: Tire wear and excessive tire inflation or under-inflation will increase the indication errors.
2. Check the speedometer
(a) Check the working condition.
(1) Connect the scanner and start the engine.
Caution:
· · If the tachometer were reversely connected, the internal transistor and diode would be damaged.
· · When removing or installing the tachometer, take care that it should not be dropped or subjected to
strong impacts.
(2) Make a comparison between the reading on the scanner and that of the tachometer. The reading on the
tachometer will usually display as follows:
Standard value (r/min) Allowable error (r/min)
1,000 ± 100
3,000 ± 150
6,000 ± 240
3. Check the fuel gauge circuit

Test the accuracy of the readings on the fuel gauge with slide rheostat. Have one end of the slide rheostat con-
nected to the Pin 25 on the 32-pin outlet of the meter while the other end is grounded. Then, adjust the slide rheo-
state as prescribed in the following table. If the measurement results are consistent with the table below, it will be
accurate. If not, it will be problematic.
Calibration points Input resistance (Ω) Indication angle (°)

E 240 ±3
Alarm point 215
1/2 140 ±3
F 40 ±3
Caution:
Low fuel warning: When the fuel sensor's resistance is more than 215 Ω (alarm point), the warning in-
dicator must come on. When the the fuel sensor's resistance is less than 205 Ω (alarm trip point), the
warning must be relieved. When the needle is between the fuel alarm point and the alarm trip point, the
warning indicator will maintain the former state. Then, there will be two possibilities:
(a) If the needle runs upward from the alarm point and lies between the alarm point and the alarm trip
point, the warning indicator will be continue to illuminate.
(b) If the needle runs downward from the alarm trip point and lies between the alarm point and the
alarm trip point, the warning indicator will be continue to go out.
4. Water temperature gauge inspection

Test the indication on the water temperature gauge with a slide rheostat. Have one end of the slide rheostat con-
nected to the Pin 24 on the 32-pin outlet of the meter while the other end is grounded. Then make adjustments to
the slide rheostate as prescribed in the following table. If the measurement results are consistent with the table
below, they will be accurate. If not, they will be problematic.
Calibration points Input resistance (Ω) Permitted error (°)
C (50oC) 228 ±5
o o
90 C-105 C 53.7-33.3 ±3
Alarm point 115oC 26.9 ±3
Caution: When the resistance is between 53.7 Ω and 33.3 Ω, it is equal to 90-105 oC if the needle on the
water temperature gauge stays immovable in a middle position. However, the water temperature will be
higher than 105 oC if the needle surpasses the middle position. Then, it will be necessary for the driver
to take care. The water temperature will be lower than 90 oC if the needle on the water temperature
gauge lies below the middle position.
5. Check the seat belt unfastened indicator lamp (driver's seat)
Check the working condition.
(1) Set the ignition switch to the "ON" position, check and confirm that the indicator illuminates.
(2) Fasten the safety belt to the socket, check and confirm that the indicator goes out.
(3) Disconnect the connector of the buckle switch while the terminal of the connector on the side of wire har-
ness is grounded.
6. Check the oil pressure warning lamp
Check the circuit.
(1) Disconnect the low oil pressure switch connector.
(2) Set the ignition switch to the "ON" position.
(3) Connect the connector's terminal on the side of the wire harness and have it grounded. Then check and con-
firm that the low oil pressure warning lamp illuminates.
7. Check the parking brake lamp
Check the parking brake lamp.
(1) Disconnect the connector of the parking brake switch while having the terminal of the connector on the side
of wire harness grounded.
8. Check the brake fluid level warning lamp
(1) Disconnect the connector of the brake fluid level warning switch while having the terminal of the connector
on the side of wire harness grounded.
9. Malfunction indicator remains illuminated
Disconnect the engine ECU connector and set a low electric level for the Pin 6 on the 32-pin meter outlet. It will
be correct if the indicator lamp illuminates, but the indicator lamp going out indicates that the meter is problem-
atic.
10. Vehicle service indicator remains illuminated
Disconnect the engine ECU connector and set a low electric level for the Pin 15 on the 32-pin meter outlet. It will
be correct if the indicator lamp illuminates, but the indicator lamp going out indicates that the meter is problem-
atic.
Interior 13-7
Dashboard/Meter
Components
Dashboard main duct
Dashboard middle duct assembly
Right defroster vent
Dashboard lower reforcing panel LH
Left defroster vent AC right vent assembly
Combination meter decorating cover

Cartridge
Combination meter
AC left vent assembly
Dashboard lower protective panel LH
MLM002G
CD player
Air conditioner
controller assembly
Combination switch
wiper arm assembly
Combination switch
lighting handle assembly
Switch block assembly

Combination switch upper cover
Center control panel
Combination switch lower cover
Key
Ignition switch
MLM003G
Interior 13-9
AC central lower vent

protective panel LH
Window regulator switch
Gear shift dust cover

Dashboard central lower
protective panel Gear shift cover plate
MLM004G
Dashboard
Hint: Disconnect the battery negative terminal before removal.
Removal
1. Remove the driver side airbag.
2. Remove the steering wheel.
3. Combination switch upper and lower covers.

Remove 2 screws on the upper part of the cover and 2 screws
on the lower part of the cover.
MLK005G
4. Remove the combination meter cover.

Remove 4 screws and the combination meter cover.
MLM006G
5. Remove the combination meter.

(a) Remove 3 screws and pull out the combination meter.
(b) Release the connector.
MLM007G
6. Remove the dashboard lower protective panel LH

Hint: Pay attention to these 2 claws.
: Claw MLM008G
Interior 13-11
7. Remove the center control cover.

: Claw MLM009G
8. Remove the switch block.

(a) Release the connector.
(b) Separate the switch block from the center control panel.
: Claw MLM010G
9. Remove the AC controller (manually).

(a) Remove 4 screws and pull out the AC controller.
MLM011G
10. Remove the CD player.

(a) Remove 4 screws and pull out the CD player.
MLK003G
11. Remove the gear shift dust cover.

(a) Release 8 claws as shown in the figure.
: Claw
MLM012G
(b) Remove the inner hexagon bolt, then remove the gear
shift dust cover.
MLM062G
12. Remove the gear shift cover plate.

13. Remove the two window regulator switches.
(a) Separate the window regulator switches and the gear
shift cover plate.
: Claw MLM013G
14. Remove the AC central lower vent protective panel.
MLM014G
15. Remove the dashboard central lower protective panel.

(a) Remove 2 bolts on the top.
MLM015G
(b) Remove 2 bolts on the bottom.

(c) Remove the dashboard central lower protective panel.
: Claw MLM016G
Interior 13-13
16. Remove the exterior rearview mirror switch.

Cigarette Cigarette lighter
lighter (a) Pry the cigarette lighter cover off with a screwdriver.
cover
Hint: Please have the screwdriver tip wrapped with adhesive
Exterior rearview
mirror switch tape before using the screwdriver.
(b) Disconnect the connector between the cigarette lighter
and the exterior rearview mirror switch.
(c) Remove the exterior rearview mirror switch.
MLM017G
17. Remove the auxiliary facia console.

Cup cushion
(a) Remove 2 cup cushions in the front.
(b) Pry off 2 decorative caps.
Decorative cap
Decorative cap
MLM018G
(c) Remove 2 nuts in the front and 2 fixing nuts in the mid-
dle and rear with a socket spanner.
MLM019G
(d) Remove the auxiliary facia console.
MLM020G
18. Remove the glove box assembly.

Remove 4 screws and 1 bolt, take off the glove box assembly.
MLM021G
MLM022G
19. Remove the dashboard body with duct assembly.

(a) Remove the left and right defroster vents.
(b) Remove 6 bolts.
(c) Disconnect the connector.
(d) Pull out the dashboard body with duct assembly and re-
move it.
Interior 13-15
Cigarette Lighter Assembly

Removal

2. Pry off the cigarette lighter cover with a screwdriver.
(a) Separate 2 claws and remove the cigarette lighter cover.
tape before using the screwdriver.
: Claw MLM023G
3. Remove the cigarette lighter assembly.

(a) Remove the cigarette lighter assembly.
(b) Separate the claws between the cigarette lighter seat as-
sembly and the cigarette lighter clear aperture assembly.
Then rotate the cigarette lighter seat assembly in the di-
rection as shown in the figure and pull it out.
ALI013G
(c) Align the cigarette lighter seat assembly with the slot on
the cigaretter lighter clear aperture assembly and remove
the cigarette lighter assembly.
MLM024G
4. Install the cigarette lighter assembly.

(a) Align the cigarette lighter seat assembly with the slot on
the cigarette lighter clear aperture assembly and push the
cigarette lighter assembly in as far as possible.
(b) Install the cigarette lighter head assembly.
Ignition Switch
Removal
sequence.
3. Remove the combination switch lower and upper covers
(See page 13-10).
4. Remove the ignition switch assembly.
(a) Disconnect the ignition switch connector and the key de-
tector switch connector.
(b) Remove the anti-theft coil or the ignition switch photo-
mask assembly.
(c) Remove 2 pressure plate fixing bolts and the ignition
switch assembly.
MLM026G
Inspection
ACC ON Inspect respective resistances of gears on the ignition switch.
START Standard:
Switch condition Scanner Resistance under the
connection normal condition
ACC 2-4 Below 1 Ω
ON 2-4
5-6
1-6
START 1-6
3-6
5-6
If the result is not as specified, replace the ignition switch as-
sembly.
MLM027G
Interior 13-17
Combination Switch
Removal
sequence.
3. Remove the combination switch lower and upper covers
(See page 13-10).
4. Remove the combination switch lighting handle assem-
bly.
(a) Disconnect the conncetor and remove the combination
switch lighting handle assembly.
5. Remove the combination switch wiper arm assembly.
(a) Disconnect the conncetor and remove the combination
switch wiper arm assembly.
Inspection
Combination switch lighting handle assembly
Standard
Switch gear Scanner connection Specified
condition
OFF All of the pins are off 10KΩ
Parking lamp 4-7 Below 1 Ω
Low beam lamp 7-9 Below 1 Ω
High beam lamp 7-8 Below 1 Ω
Left turn signal lamp 10-11 Below 1 Ω
Right turn signal lamp 12-11 Below 1 Ω
MLM028G
Combination switch wiper arm assembly

Standard
Switch gear Scanner Specified
connection condition
Front wiper MIST 8-9 Below 1 Ω
LO 8-9 Below 1 Ω
HI 9-10 Below 1 Ω
Front washer switch 4-5 Below 1 Ω
Rear wiper INT 1-5 Below 1 Ω
ON 2-5 Below 1 Ω
Rear washer switch 3-5 Below 1 Ω
MLM029G
Switch Block Assembly

Removal
sequence.
For removal, please see page 13-11.
Inspection
condition
Hazard warning switch 1-4 Below 1 Ω
Front fog lamp switch 1-5 Below 1 Ω
Rear fog lamp switch 1-8 Below 1 Ω
Rear defroster switch 1-3 Below 1 Ω
MLM030G
Interior 13-19
Window Regulator Switch

Removal
sequence.
1. Remove the gear lever cover plate.
2. Disconnect the window regulator switch connector.
3. Separate the window regulator switch and the gear lever
cover plate.
: Claw MLM031G
Inspection
condition
UP 4-2 Below 1 Ω
DOWN 3-2 Below 1 Ω
MLM032G
Door Lock System

Electric Door Locks Overview
1. Remote-control locking
Press the LOCK button once after getting out and shutting the doors. Then, the lamps will flash once (while the
alarm indicator will not flash) with the remote-control locking (with all four doors locked). If the controller de-
tects that any door is not completely shut, the lamps will flash four times and the doors will not be locked.
2. Remote-control unlocking
When the vehicle doors are locked, press the UNLOCK button on the remote controller once and then, the re-
mote-controlled lock will be unlocked (the four doors will be unlocked while the rear doors will not, and it not
function even if the back door unlocking switch is locked).
3. Trunk
Press the trunk door unlocking button, and the trunk door unlocking motor will run (to unlock the trunk door)
within one minute when the trunk door switch is switched off and the trunk door unlocking switch is switched on.
Then, it will be possible to unlock the trunk door. Even if the trunk door unlocking switch is always switched on,
the trunk door unlocking motor will not repeat this function.
When the back door switch is switched on, the trunk door unlocking motor will not run any longer, even if the
trunk door unlocking switch is switched on.
Hint: The trunk door switch is equal to the trunk door lamp switch and it is placed on the trunk lock.
The trunk door lamp switch is placed in the license plate lamp.
4. Vehicle pager function
At night or in a large parking lot, press the LOCK button once when the doors are locked and the lamps will flash
quickly ten times so as to make it convenient to the location of the parked car. It is possible to stop the vehicle
pager function so long as the UNLOCK button on the remote controller is pressed.
5. Auto-defense function
When the doors are locked, if the vehicle owner presses the UNLOCK button on the remote controller uninten-
tionally and get the remote-controlled lock unlocked, the doors will automatically lock in 30 seconds on the con-
dition that the vehicle owner fails to open any door.
6. Remote controller function suspension
When the vehicle key is inserted into the ignition lock, the remote controller function will be suspended.
7. Manual unlocking and locking
It is possible to unlock and lock by use of the left front door lock state switch. When the remote-controlled switch
is switched on, it will not be locked if any door is not completely shut. When locked, any other door will not open
if the doors other than the left front door is unlocked.
8. SRS collision detection unlocking
The SRS-ECU connected and automatic unlocking will be conducted when receiving a trigger at a low electric
balance. The remote-controlled lock must begin to unlock twice, and the unlocking will be repeated twice more
three seconds later.
9. Safety and protection
(a) Door lock priority
The remote-controlled door lock will not work simultaneously with the electric window closing mechanism.
When they are both in use simultaneously, the remote-controlled door lock will have the priority while the win-
dow closing mechanism will suspend its running. When the remote-controlled door lock has stopped, the window
closing mechanism will continue to its former working condition.
(b) Protection
If the remote-controlled door lock will be consecutively unlocked/locked for more than three times within 10
Interior 13-21
seconds, then the remote-controlled locking will be restricted from running for 15 seconds so as to protect the
remote-controlled door lock.
(c) Repeated running protection
Actions having the same result as the current state of the door lock will not be performed.
10. Remote controller battery test
If the remote control indictor always flashes when the unlocking button, the locking button or the trunk button is
pressed down, then it is necessary to get the remote controller charged.
11. Clearing and registering remote control
If the remote control is lost, the remote control information can be eliminated from host computer to avoid illegal
operation, or you can also add no more than 2 remote controls based on the original function. (All these remote
controls should learn at the same time)
Learning method for remote control:
(a) Switch key from OFF to ON position thrice within 7s and finally keep the key at OFF position; the lamp
shall flicker thrice and the lamp shall keep flickering in 2s after flicking stopped.
(b) When the lamp is flickering, switch key from OFF to ON and then OFF position once within 4s, the lamp
shall stop flickering and the learning mode is accessed; if no operation on key is performed within 4s, it
shall return to normal mode.
(c) After accessing the learning mode, press any key on remote control for a long time (equal to or more than 2s
is a must), the No. 1 fuse box begins to receive key signals, the lamp shall flicker once when the first valid
key is received and the vehicle learns the first key; by similar method, the lamp shall flicker twice while re-
ceiving the second key signal; the vehicle can learn two keys in total. If the key is at OFF position or there is
no signal input for 10s, exit the learning mode immediately. The lamp shall flicker twice while quitting the
learning mode.
Checking the working condition of the electric door locks
1. Lock the front doors with the key
(a) Turn the key counterclockwise when locking the front doors. When unlocking, turn the key clockwise.
(b) Lock or unlock all other vehicle doors simultaneously when locking or unlocking the front doors.
2. Lock the doors without a key
(a) Front door.
The left front door cannot be locked if the key is in the vehicle and having no key. This is to prevent the vehicle
doors from becoming unintentionally locked when the key is inside the vehicle.
Caution: If the left front door is locked while the door handle is lifted, the vehicle doors will become
locked.
(b) Other doors
When locking without a key outside of the vehicle, press the internal locking mechanism to the locked position
and then shut the vehicle doors.
3. Automatic door locking
Operate the left front door locking switch, and it is possible to have all door locks locked or unlocked.
4. Rear door "Child Protection" lock
The "Child Protection" lock can prevent unintentional door unlocking, especially when there is a child in any of
the the rear seats. There is also a lock rod on each back door.
(a) If the lock rod is set into the "Lock" position, the doors cannot be unlocked with the internal door handles.
If it is necessary to get the door unlocked when the "Child Protection" lock is in use, please use the external
door handle.
(b) If the lock rod is placed in the "unlocked" position, the "Child Protection" mechanism will not work.
5. Trunk
(a) Opening the trunk
Take out the key from the ignition switch, press the unlock button for the trunk and pull the trunk handle upward.
(b) Closing the trunk
Pull the trunk handle downward and release the trunk handle before it is completely shut. Press down the trunk
lightly from the outside to get it completely shut.
Inspect the lighting

1. Checking the door unlocking lighting system.
Hint: "All vehicle doors" refers to the left and right front doors as well as the left and right rear doors.
(a) When all vehicle doors are completely shut, press the LOCK button on the remote controller once. Then, the
vehicle lamps will flash once and all vehicle doors will lock.
(b) When locking, press the UNLOCK button once on the remote controller and all vehicle doors will be un-
locked except for the trunk door.
2. Checking the onboard lighting system
Hint: "All vehicle doors" refers to theleft and right front doors as well as the left and right rear doors. "Any ve-
hicle door" refers to any of the vehicle doors mentioned above.
(a) Move the dome lamp switch to the DOOR position.
(b) When any door is unlocked, the dome lamp will illuminate and then go out after a time delay of one minute.
During the time delay of the dome lamp, the dome lamp will go out after a time delay of 15 seconds after all
vehicle doors have been shut.
(c) When the key has been removed from the ignition switch, the dome lamp will come on and go out after a
time delay of one minute.
(d) The dome lamp will come on after remote-controlled unlocking. It will go out if no door is opened within 15
seconds.
(e) When all vehicle doors have been shut and the dome lamp illuminates, the dome lamp will go out so long as
doors are locked or the key is inserted into the ignition switch.
3. Trunk door independent opening function
Press the trunk door unlocking button, and the trunk door unlocking motor will run (to unlock the trunk door)
within one minute when the trunk door switch is switched off and the trunk door unlocking switch is switched on.
Then, it will be possible to unlock the trunk door, even if the trunk door unlocking switch is always switched on,
the trunk door unlocking motor will not repeat its running.
When the back door switch is switched on, the trunk door unlocking motor will not run any longer even if the
trunk door unlocking switch is switched on.
Hint: The trunk door switch is equal to the trunk door lamp switch and it is placed in the trunk lock.
The trunk door lamp switch is placed in the license plate lamp.
Areas of Importance
1. Areas of importance when checking the remote control functions
(a) Electric door locking/unlocking function
Unless the following three conditions are satisfied, the remote control function will not work:
(1) There is no key inserted into the ignition switch.
(2) All vehicle doors are shut.
Interior 13-23
(3) The electric locking system works normally.

Hint: When a certain door is unlocked, the unlocking function can still work.
(b) Remote control function
The remote controller will only work when the key is not inserted into the ignition switch.
(c) Under various conditions, the working scope of the remote-controlled locking control will vary.
(1) The working scope will vary according to the differences in terms of users and the pattern of holding the
device.
(2) In a certain areas, the remote control function can only work in parts of its working scope and its work-
ing scope will diminish due to the impact from the shape of the vehicle body and the surrounding envi-
ronment.
(3) As the device makes use of weak radio waves, strong radio waves or noise disturbances within the fre-
quency used will make the working scope weak and the remote controlling function is unlikely to work.
(4) If the battery has no sufficient power, the working scope will diminish or the remote controlling func-
tions is unlikely to work.
Hint: If the door control device is placed in direct sunlight (for example, on the dashborad), the battery electricity
capacity will be weakened or other problems may occur.
Door Locks
Components
Left front door 6 5

7
13 12 11 10 8
14
4
Left rear door

7
6 5
13 12 11 10 8
1 MLM033G
1 Buckle 5 Door lock inside 8 External handle frame 11 External handle front gasket
handle assembly
2 Lock body assembly 6 Buckle 9 Fixed expansion buckle 12 Front door outside handle
3 Fastener 7 External handle 10 External handle 13 Decorative handle cover
assembly rear gasket
4 Door lock drawing buckle 14 Lock cylinder
Interior 13-25
Inspection
Locking
Unlocking
1. Check the front door lock fastener assembly LH.
(a) Apply the battery voltage onto the fastener terminal and
check the working condition of the lock motor.
Standard:
Measurement conditions Specified condition
Battery positive polar (+)→ Terminal 2
Locking
Battery negative polar (-)→ Terminal 1
Unlocking
If the result is not as specified, have the door lock assembly
replaced.
(b) Check the resistances among the respective actuators.
Standard:
MLM034G
Scanner connection Switch state Specified condition
1-2 Off Less than 1 Ω
Hint: The test methods for the respective actuators are same.
replaced.
2. Check the front door lock fastener assembly RH.
Locking
Unlocking (a) Apply the battery voltage onto the fastener terminal and
check the working condition of the lock motor.
Standard:
Measurement conditions Specified condition
Locking
Unlocking
replaced.
MLM035G
Installation
Hint: The installation sequence is the reverse of the removal sequence.
Left front door
Decorative handle cover
External handle External handle rear gasket
External handle
front gasket
External handle frame
Lock cylinder
Expansion
button
Screw
MLM036G
1. Install the external handle assembly.

(a) Attach the external handle frame onto the door plate.
(b) Tighten the expansion button tapping screw.
(c) Attach the front and rear cushion gaskets onto the exte-
rior door plate.
(d) Install the external door handle.
(e) Attach the lock cylinder decorative cover onto the lock
cylinder.
(f) Install the decorative cover and the cylinder onto the ex-
ternal handle frame and tighten them with fixing bolts.
Interior 13-27
2. Install the front door lock.

External handle frame
(a) After positioning the lock body, tighten the 3 fixing
bolts.
(b) Install the external opening rod and the locking rod.
External
opening rod (c) Attach the connector.
Locking rod
Fastener
Lock body assembly
MLM037G
Internal buckle seat plate 3. Install the inside handle.

(a) Engage the buckle on the inside buckle seat plate.
(b) When the front end of internal buckle has been inserted
into the slot, slide it forward. Then, have the third fixing
point attached to the internal plate.
MLM038G
4. Install the front door guard plate.

(a) Secure 8 buckles as shown in the figure.
(b) Install 4 screws as shown in the figure.
(c) Install the inside buckle decorative cover.
: Clip
MLM039G
Transmitter Battery
Inspection
1. Check the door control transmitter.
(a) Check the transmitter working condition.
(1) Remove the battery (lithium cell) from the transmit-
ter.
(2) Install a new or normally working battery (lithium
cell).
(3) Align the radiator's key plate with the vehicle in a
position about 1 m to the left front door external
handle. Then, check the transmitter working condi-
tion by pressing the switch on the transmitter shell.
Standard: It may be possible to operate the door lock
with the remote controller.
Hint: The minimum operating distance varies according to
various operators, various modes for holding the device, and
various positions. As the transmitter uses weak electrical
waves, the operating distance is likely to diminish if there ex-
ists a noise or strong electrical wave in the area where the fre-
quency is used.
(4) Install the transmitter battery (lithium cell).
(b) Check the battery's electric quantity.
Hint:
The battery's charge cannot be confirmed until the battery has
been installed into the transmitter. If lithium cells are to be
used on the transmitter, then the voltage indicated on the de-
tector will be above 2.5 V unless the battery's electric quantity
has been used up or there is no battery installed. Therefore, it
is necessary to measure the voltage on the condition that bat-
teries have been installed into the transmitter (and the resis-
tance exerted onto the battery shall be 1.2 kW) when checking
the battery's remaining charge.
If the transmitter is faulty, then it is possible that the battery's
remaining charge cannot be correctly checked.
(2) Have the lead wire connected to the transmitter nega-
tive polar (-) terminal and install the battery.
(3) Have the detector's positive pole (+) probe connected
Lead wire
to the battery's positive pole (+) while having the de-
tector's negative pole (-) connected to the lead wire.
(4) Press any radiating switch on the transmitter for
about one second.
(5) Press the transmitter radiation switch once again to
MLM040G check the voltage.
Standard: 2.2 V or even higher
Interior 13-29
Hint:
When the battery's temperature is excessively low, the check-
up will not be accurate.
When the tesing result is lower than 2.2 V, place the battery in
a location with a temperature of 18 oC for over 30 minutes and
then conduct the testing once again.
When having pressed the switch for 0.8 seconds, the auto-
matic power off function can lead to a battery voltage of 2.5 V
or even higher (the voltage when there is no resistance exerted
onto the battery). Therefore, be sure to read the voltage after
pressing the switch.
As the battery may display a high voltage once or twice when
having resumed the designated temperature, a checkup should
be conducted when the switch has been pressed for at least
three times and has shown the voltage.
(6) Disconnect the lead wire.
Replacement
1. Remove the transmitter battery.
Caution: As various parts and components are all preci-
sion electronic parts and components, special care shall
be taken during operation.
(a) Remove the bolt and take out the transmitter housing.
MLM041G
Pry here
b) Take out the remote controller, then pry the remote con-
troller's shell from the position (as shown in the figure)
and take out the circuit board.
MLM042G
(c) Remove the battery from the position as shown in the

figure and take out the used batteries (two pieces). Re-
place them with new batteries while taking care to place
the batteries with the positive polars pointed upward.
Caution:
· · Be sure the transmitter battery's positive polar is cor-
rectly matched to the negative polar.
· · When inserting the batteries, take care not to bend
MLM043G
the electrodes of the transmitter's batteries.
· · Take care not to get the transmitter's housing tainted
with dust or oil.
2. Install the transmitter housing.
Interior 13-31
Immobilizer System
Overview
The immobilizer system consists of a theft deterrent ECU, theft deterrent coil, and converter.
Installing an immobilizer system onto a vehicle can effectively reduce the risk of vehicle theft and make it impos-
sible for people having entered the vehicle illegally to start the engine, and protecting the interests of the vehicle's
owner.
Functional description:
The figure below is the diagram for the layout of the immobilizer system components and the fixed standard
parts.
Theft deterrent
ECU
Bolt and flat washer

subassembly
Theft deterrent converter assembly
Theft deterrent coil assembly
MLM044G
Inside each key, there is a theft deterrent converter. When inserting the key into the lock cylinder and turning the
key to the ON position, the theft deterrent ECU assembly and the converter in the key will communicate by ra-
diofrequency identification. If the key is confirmed to be correct, the theft deterrent ECU assembly and the engine
ECU assembly will conduct password authentification. If having passed the authentification, the electronic theft
deterrent system will permit the engine to start. If any of the two kinds of password authentification fails, the en-
gine will not start.
Position Diagram
Except for the theft deterrent converter assembly in the key, all other parts and components of the theft deterrent
system are installed onto the finished automobile. They communicate via the wire harness. The figure below il-
lustrates the positions of the various parts and components in the finished automobile.
Theft deterrent
converter assembly
(inside the key)
Theft deterrent coil assembly
Ignition switch
Theft deterrent ECU

MLM045G
Theft Deterrent ECU Terminal Definition

The theft deterrent ECU has two connectors: Connector A has eight pins and Connector B has three pins. The
front view of connector is as follows:
Theft deterrent ECU connector A Theft deterrent ECU connector B
MLM046G
Interior 13-33
Terminal definition:
Pin Pin definition Rated working voltage Working current
A1 to B+ 12 V <200 mA
A2 Ground 0V <200 mA
A3 to LED 12 V <50 mA
A4 to ON end 12 V <200 mA
A5 to R-LINE 12 V <200 mA
A6 --- --- ---
A7 to K-LINE 12 V <200 mA
A8 to W-LINE 12 V <200 mA
B1 Coil terminal A --- ---
B2 Coil terminal B --- ---
B3 GND --- ---
Top Interior Cover

Components
MLM047G
Removal
sequence.
1. Remove the left A column upper guard plate assembly.
Clip (a) Separate 3 buckles with a screwdriver and remove the
left A column upper guard plate assembly.
MLM048G
2. Remove the right A column upper guard plate assembly.
Hint: The operation sequence on the right side is the same as
the left one.
3. Remove the front door weatherstrip RH.
4. Remove the front door weatherstrip LH.
5. Remove the rear door weatherstrip RH.
6. Remove the rear door weatherstrip LH.
Interior 13-35
7. Remove the right B column lower guard plate.

Clip
(a) Remove the front threshold pressure plate RH.
(b) Remove the rear threshold pressure plate RH.
(c) Separate 2 buckles connecting the B column lower guard
plate and upper guard plate.
(d) Remove the left B column lower guard plate.
8. Remove the left B column lower guard plate.
MLM049G
the left one.
9. Remove the right B column upper guard plate assembly.

(a) Remove the seat belt guide ring.
Claw (b) Remove the seat belt bolt.
(c) Remove the mounting bolt.
(d) Separate the claws and remove the B column upper
guard plate assembly.
10. Remove the left B column upper guard plate assembly.
MLM050G
the left one.
11. Remove the trunk door weatherstrip.

Claw 12. Remove the right C column upper guard plate assembly.
Clip
(a) Remove the seat belt guide plate and seat belt.
(b) Remove 3 bolts attaching the C column.
(c) Separate 1 claw and 3 clips with the screwdriver and re-
move the left C column guard plate assembly.
MLM051G
13. Remove the left C column upper guard plate assembly.
the left one.
14. Remove the front passenger side sun visor assembly.

(a) Remove a bolt with the screwdriver and remove the sun
visor.
15. Remove the driver side sun visor assembly.
the left one.
MLM052G
16. Remove the front passenger side sun visor support.

(a) Remove the bolt.
(b) Separate a claw with weatherstrip remover and remove
the support.
17. Remove the driver side sun visor support.
the left one.
ALL122G
18. Remove the reading lamp assembly.

(a) Separate 4 claws with a screwdriver and remove the mir-
ror cover as shown in the figure.
(b) Remove 2 screws.
(c) Disconnect the connector and remove the reading lamp
assembly.
: Claw MLN023G
19. Remove the roof handle assembly.

(a) Separate 2 claws and remove the roof handle assembly
with a screwdriver.
(b) Remove 2 bolts and the roof handle.
Hint: There are 3 roof handles and their procedures are same.
MLM054G
20. Remove the top internal cover.

Clip
Separate 4 claws with a screwdriver and remove the top inte-
rior cover.
: Clip
MLM055G
Interior 13-37
Seats
Components
Seat headrest
assembly
Seat headrest bracket
Seat headrest bracket
Backrest regulating lever
Regulator adjusting lever Seat belt lock assembly
Right side panel Backrest regulating lever
Right side panel
Seat belt lock assembly
Left side panel Left side panel

Front passenger seat assembly Driver seat assembly
Rear seat headrest assembly
Rear seat backrest loop RH
Rear seat head-

Seat headrest rest assembly
bracket
Rear seat backrest assembly RH
Rear seat backrest rotating Seat headrest

shaft pressure plate bracket
Rear seat backrest rotating shaft sleeve Rear seat back-
rest loop LH
Rear seat central mounting bracket
Seat belt lock assembly
Rear seat cushion

assembly
Rear seat backrest assembly LH
Rear seat assembly

MLM056G
Overview
All seat frames adopt a one-piece stamped part and the foam is cold cured. This is a pattern pretty much adopted
in medium and high-end cars.
The driver's seat can be manually adjusted in six directions, and the headset can be manually adjusted in two di-
rections. The cushion height can be adjusted upward or downward with a course of 55 mm. The seat position can
be adjusted forward or backward with a course of 110 mm (forward) or 80 mm (backward). The included angle
between the backrest and the cushion has an adjustment scope of 38-145°. However, the front passenger's seat
cushion cannot be elevated or dropped down, but its backrest adjustments and the forward and backward adjust-
ments are the same as those of the driver's seat.
The rear row seats adopt a structure of separating the seat from the backrest. The seat cushion is a one-piece com-
ponent, but the backrest adopts a 30% to 50% structure. The cushions are fixed onto the vehicle body and they
cannot be turned over. However, it is possible to get the backrest flipped forward.
When dismantling and installing the seats, care shall be taken not to get the lateral cover plate scratched and at-
tention shall be paid to the tightening torqure of the installation bolts.
Removal
Hint:
quence. Nevertheless, only installation procedures of addi-
tional information is included.
The driver's seat has the same sequence as that of the front
passenger's seat.
Caution: It is necessary to get the ignition switch turned
to the LOCK position, and it can only begin to work at
least 90 seconds after the cable connected to the nega-
tive (-) terminal has been disconnected from the battery
for at least 90 seconds (The SRS is equipped with a
back-up power supply. If the work starts within 90 sec-
onds after the cable at the negative (-) terminal is discon-
nected from the battery, then the SRS can be presented.
1. Remove the driver's seat assembly.
(a) Remove 4 bolts at the rear of the driver's seat.
(b) Disconnect the connector.
MLM057G
Interior 13-39
(c) Make it possible for barb at the internal guide rail to re-
Internal
treat slowly.
guide rail
(d) Remove the seat.
barb
MLM058G
2. Remove the rear seat assembly.

(a) Remove 4 bolts attaching the rear seat.
MLM059G
(b) Put down the seat backrest, remove the bolts on the in-
stallation support in the middle of the rear seats, take
down the rear seat backrest rotating shaft pressure plate,
and then remove the rear seat backrest.
MLM060G
(c) Remove 5 bolts attaching the rear seat and remove the
seat cushion.
MLM061G
Exterior 14-1
Exterior
Lighting System..............................................................................14-3
Problem Diagnosis......................................................................14-3
Lighting Components..................................................................14-5
Rear Combination Lamp Assembly LH.......................................14-9
High-mounted Brake Lamp.......................................................14-10
License Plate Lamp..................................................................14-10
Front Fog Lamp LH................................................................... 14-11
Rear Fog Lamp LH................................................................... 14-11
Reading Lamp...........................................................................14-12
Windshield/Door Window Glass/Rearview Mirror.........................14-13
Windshield................................................................................14-13
Right Side Window Glass.........................................................14-18
Trunk Door Glass......................................................................14-22
Exterior Rearview Mirror...............................................................14-25
Layout.......................................................................................14-25
Right Exterior Rearview Mirror Components............................14-26
Exterior Rearview Mirror and Its Regulation Switch..............................14-27
Right Door Exterior Rearview Mirror Assembly.........................14-29
Wipers and Washer System.........................................................14-30
Front Wiper Components..........................................................14-30
Problem Diagnosis....................................................................14-31
Washer Spraying Motor............................................................14-32
Windshield Wiper Motor Assembly...........................................14-33
Rear Wiper Motor Assembly.....................................................14-36
Left Wiper Rubber Strip............................................................14-37
Rear Wiper Rubber Strip...........................................................14-38
Washer Nozzle..........................................................................14-40
Horn System.................................................................................14-42
Components..............................................................................14-42
Horn .........................................................................................14-43
Reverse Sensor............................................................................14-45
System Overview......................................................................14-45
Technical Specifications............................................................14-47
Areas of Importance..................................................................14-49
Layout.......................................................................................14-49
Exterior 14-3
Lighting System
Problem Diagnosis
Hint: The table below lists the suspected parts in numerical order for the determination of the cause for failure
of a component. If necessary, check, repair, or replace the parts according to procedures listed in the following
pages.
1. Headlights and rear parking lamps.
1. Bulb -
Low beam lamp is not on (one side).
2. Wire harness -
1. Low beam fuse -
2. Low beam relay -
Low beam lamps are not on (both). 3. Left combination switch assembly 13-19
4. Bulb -
5. Wire harness -
1. Bulb -
High beam lamps is not on (one side).
2. Wire harness -
1. High beam fuse -
2. High beam relay -
High beam lamps are not on (both). 3. Left combination switch assembly 13-19
4. Bulb -
5. Wire harness -
1. Fuse -
2. Left combination switch assembly 13-19
Flashers are not on (both).
3. Wire harness -
1. Bulb -
The lighting from headlight is dim.
2. Wire harness -
1. Bulb -
Only one rear parking lamp comes on.
2. Wire harness -
Both of the two rear parking lamps are not on 1. Bulb -
(the front parking lamp is normal). 2. Wire harness -
1. Parking lamp fuse -
2. Parking lamp relay -
Both of the two rear parking lamps are not on
3. Left combination switch assembly 13-19
(the front parking lamp is not on).
4. Bulb -
5. Wire harness -
2. Fog lamp.
1. Wire harness, fuse, relay, and connector -
2. Front fog lamp switch, low and high
The rear fog lamp does not work. beam switches, or rear fog lamp switch -
3. No.1 fuse box assembly with clip 15-17
4. Bulb -

2. Lamplet switch and front lamp switch -
The front fog lamp does not work.
3. No.1 fuse box assembly with clip 15-17
4. Bulb -
3. Turn signal lamp.

2. Turn signal lamp switch -
Turn signal lamp does not work.
4. Bulb -
4. Brake lamp system.

1. Brake lamp fuse -
Both of the brake lamps are not on. 2. Brake lamp switch assembly -
3. Wire harness -
1. Brake lamp switch assembly -
The brake lamp remains on.
2. Wire harness -
1. Bulb -
The brake lamp is not on (one side).
2. Wire harness -
5. Reverse lamp system.

1. Bulb -
2. Fuse -
The reverse lamp is not on.
3. Reverse lamp switch assembly -
4. Wire harness -
1. Reverse lamp switch assembly -
The reverse lamp remains on.
2. Wire harness -
6. Dome lamp system

1. Bulb -
2. Fuse -
The reading lamp is not on.
3. Wire harness -
4. Reading lamp switch -
Areas of Importance
1. Areas of importance in replacing a headlight bulb.
(a) If the halogen bulb (headlight) is coated with oil, its life will be shortened due to the heat produced during usage.
(b) The internal pressure of the halogen bulb (headlight) is very high, so please handle carefully. Dropping the
bulb may lead to personal injury.
(c) When replacing the bulb, do not try to touch the reflector with your fingers, as this may lead to bulb con-
tamination or scratching. Before installation, be sure to prepare a new bulb.
(d) The new bulb should have the same wattage as the old one.
(e) No moisture or water should exist in the lamp housing.
(f) After replacing the bulb, reinstall the lamp holder securely.
Exterior 14-5
Lighting Components
Reading lamp
Right turn signal Front combination lamp assembly LH

lamp
Front
combination
lamp as-
sembly RH
Left turn signal lamp
Front fog lamp assembly RH

Front fog lamp assembly LH
High-mounted brake lamp assembly License plate lamp

assembly
Rear combination
lamp assembly RH
Rear combination
lamp assembly LH
Trunk
lamp
Rear fog lamp assembly RH

Rear fog lamp assembly LH
MLN001G
Removal
1. Remove the front combination lamp assembly LH.
Hint: The removal sequence of the front combination lamp as-
sembly LH is the same as the front combination lamp assem-
bly RH.
(a) Remove the front bumper body.
(b) Remove the front combination lamp assembly LH.
(1) Remove the three screws.
(2) Disconnect the wire harness connector.
(3) Remove the front combination lamp assembly LH.
MLN002G
2. Disassemble the front combination lamp assembly LH.

(a) Pull out from the position indicated by the arrow and re-
move the low and high beam lamp seat.
MLN003G
(b) As shown in the figure, remove the high and low beam
bulbs of the front combination lamp.
MLN004G
(c) As shown in the figure, rotate the turn signal lamp holder
in a counterclockwise direction to remove the turn signal
lamp bulb.
MLN005G
Exterior 14-7
(d) As shown in the figure, rotate the parking lamp holder in

a counterclockwise direction to remove the parking lamp
bulb.
3. Install the headlight assembly.
sequence.
MLN006G
Adjustment
Only for the focusing of headlight high beams
Hint: Perform the focusing adjustment using the headlight
high beams.
Adjust the low beams by the same method.
1. Prepare the vehicle according to the following conditions:
• Check to make sure that the vehicle body around the
headlight is not damaged or deformed.
• The fuel tank is full.
• The tire pressure is within the specified range. (See page
6-31)
• The vehicle is parked on a flat road surface.
• A person of moderate weight (68 kg) is sitting in the driv-
er seat.
• Bounce the vehicle up and down to stabilize the suspen-
sion in the normal position.
2. Prepare a thick piece of white paper (draw a base line).
Left V-line V-line Right V-line Hint: Stand the paper vertically against the wall.
Different base-lines are used in the "low beam inspec-
tion" and "high beam inspection."
H-line
(a) V-line (vehicle center position)
Draw a vertical line in the center of the paper to align with the
vehicle's center.
Ground
(b) H-line (headlight height)
ALL018G
Draw a horizontal line on the paper at the same height above
the ground as the high beam's center mark.
(c) Left V-line, right V-line (at the center mark positions of
the left and right headlights)
Draw left and right vertical lines in the same positions as the
high beam's center marks.
Hint: Perform the same procedure for the adjustment of the
low beams.
3. Check the focusing of the headlight high beams.

(a) Align the paper with the vehicle.
Keep a distance of 3 m between the headlight and the paper.
Place the paper on a wall with the H-line at the same height as
the center mark.
Align the vehicle's center with the V-line center of the paper,
ensuring that the paper is at an angle of 90 degrees to the V
-line.
MLN007G
(b) Start the engine.
(c) Turn on the headlights and check to make sure that the
Low beam: Left V-line
Right V-line focusing is within the specified values shown in the fig-
ure.
Caution: The headlight lens is fragile because it is made
of a synthetic resin.
Hint: When checking the high beam focusing, turn off the low
beams or disconnect the low beam headlight connector.
MLN008G
High beam: Left V-line

Right V-line
MLN009G
4. Adjust the focusing in the vertical direction.

Turn focusing screw A to adjust the focusing of the headlight
low beams to the specified range.
Caution: Turn the screw in the tightening direction to ad-
just the focusing of the headlight low beams. If the nut is
overtightened, loosen and retighten it to adjust the focus-
A
ing of the headlight low beams.
Hint: When the screw is turned in a clockwise direction, the
MLN010G
focusing axis moves downwards. When the screw is turned
in a counterclockwise direction, the focusing axis moves up-
wards.
Exterior 14-9
5. Adjust the focusing in the horizontal direction.

Turn focusing screw B to adjust the focusing of the headlight
low beams to the specified range.
Caution: Turn the nut in the tightening direction to adjust
the focusing of the headlight low beams. If the screw is
overtightened, loosen and retighten it to adjust the focus-
ing of the headlight low beams.
Hint: When the screw is turned in a clockwise direction, the
MLN011G
light beam is adjusted towards the outside of the vehicle body.
When the screw is turned in a counterclockwise direction, the
light beam is adjusted towards the inside of the vehicle body.
Rear Combination Lamp Assembly LH

Removal
1. Remove the rear combination lamp assembly LH.
(a) Remove the three mounting bolts.
(b) Disconnect the two restrict pins.
(c) Disconnect the connector and remove the rear combina-
tion lamp assembly.
MLN012G
2. Remove the rear turn signal lamp bulb.

(a) As shown in the figure, turn in a counterclockwise direc-
tion to remove the turn signal lamp holder and bulb.
MLN013G
3. Remove the parking lamp bulb.

tion to remove the parking lamp holder and bulb.
MLN014G
4. Remove the rear back-up lamp bulb.

tion to remove the back-up lamp holder and bulb.
MLN015G
5. Install the rear combination lamp assembly LH.

sequence.
High-mounted Brake Lamp

Removal
sequence.
1. As shown in the figure, remove the two screws.
2. Disconnect the wire harness connector and remove the
high-mounted brake lamp assembly.
MLN016G
3. As shown in the figure, remove the two screws and re-

move the LED lamp.
MLN017G
License Plate Lamp

Removal
sequence.
1. Remove the trunk door protector.
2. Remove the license plate lamp assembly.
(a) As shown in the diagram, remove the 4 nuts.
(b) Disconnect the wire harness connector and remove the
MLN018G
license plate lamp assembly.
3. Remove the license plate lamp bulb.
Exterior 14-11
Front Fog Lamp LH

Removal
Hint: The removal sequence of the front fog lamp assembly
LH is the same as the right side.
1. Remove the front bumper body.
2. Remove the front fog lamp assembly LH.
(a) As shown in the figure, remove the 3 screws
(c) Disconnect the wire harness connector and remove the
front fog lamp assembly from the bumper.
MLN019G
3. As shown in the figure, rotate the front fog lamp holder in

a counterclockwise direction and remove the bulb.
4. Install the front fog lamp assembly LH.
quence.
MLN020G
Rear Fog Lamp LH

Removal
Hint: The removal sequence of the rear fog lamp assembly LH
is the same as the right side.
1. Remove the rear bumper body.
2. Remove the rear fog lamp assembly LH.
(a) As shown in the figure, remove the 3 screws.
(g) Disconnect the wire harness connector and remove the
rear fog lamp assembly LH from the bumper.
MLN021G
3. As shown in the figure, rotate the rear fog lamp holder in

a counterclockwise direction and remove the bulb.
4. Install the rear fog lamp assembly LH.
The installation sequence is the reserve of the removal se-
quence.
MLN022G
Reading Lamp
Removal
1. As shown in the figure, detach the 4 clips with a screw-
driver and remove the lens cover.
Hint: Before using a screwdriver, please wrap its tip in adhe-
sive tape.
2. Remove the 2 screws.
: Clip 3. Disconnect the connector and remove the lamp.
MLN023G
Inspection
1. As shown in the figure, check whether the reading lamp
assembly is conducting properly.
Standard:
Switch operation Scanner connection Specified condition
Ω ON 1-2 Below 1Ω
- + DOOR 1-2 Below 1Ω
OFF 1-2 10 KΩ or above
MLN024G 2. Check the delay control (the reading lamp switch in the
vehicle is in the DOOR position).
When any door is opened, the reading lamp lights up. It will
go out after a delay of 1 minute. During the delay, the reading
lamp will go out 15 seconds after all of the doors have been
closed. When the key is removed from the ignition switch, the
reading lamp lights up. It will go out after a delay of 1 minute.
When all the doors are closed and the reading lamp is lit, the
reading lamp will go out upon locking or as soon as the key
is inserted into the ignition switch. After remote unlocking,
the reading lamp lights up. It will go out if no door is opened
within 15 seconds.
Exterior 14-13
Windshield/Door Window Glass/Rearview Mirror

Windshield
Components
Roof board handle

Front passenger side sun visor body Dome lamp assembly
Right A-pillar protective panel assembly Dome lamp

lens cover
Driver's side sun visor body
Front passenger side
sun visor bracket
Front door weath-
◆Windshield outer
erstripping RH
protective strip
Driver's side sun

visor bracket
Left A-pillar protective

panel assembly
Windshield
Vent panel body
Front right Vent panel front

wiper arm weatherstripping
Right wiper arm

bolt cover
Front left wiper arm
Left wiper arm bolt cover
Front door weatherstrip ping LH
MLN025G
Removal
Hint:
The installation sequence is the reverse of the removal sequence. However, only the installation sequence contain-
ing additional information is included.
1. Remove the roof inner facing.
(a) Remove the front door weatherstrip ping LH and front door weatherstrip ping RH.
(b) Remove the left and right A-pillar protective panel assemblies.
(c) Remove the driver's side sun visor body and front passenger side sun visor body.
(d) Remove the roof board handle assembly.
(e) Remove the driver's side sun visor bracket and front passenger side sun visor bracket.
(f) Remove the dome lamp lens cover.
(g) Remove the dome lamp.
(h) Remove a part of the roof inner facing to facilitate the removal of the windshield.
2. Remove the vent panel body.
(a) Remove the left and right wiper arm nut decorative caps.
(b) Remove the left and right front wiper arms.
(c) Remove the vent panel front weatherstripping.
(d) Detach the connection between the washer pipe and the nozzle.
(e) Remove the vent panel body.
3. Remove the windshield.

(a) As shown in the figure, insert a steel wire between the
vehicle body and the glass from the inside.
(b) Tie an object which can act as a lever (such as a wood
Locating block
block) to both ends of the steel wire.
Steel wire
MLN026G
Hint:
Plastic plate
To prevent the external surface of the vehicle body from being
scratched, apply a protective adhesive tape to its external surface.
Caution:
· · When detaching the glass from the vehicle, take
care not to damage the body paint or the interior and ex-
terior trimmings.
Protective adhesive tape · · When removing the glass, to prevent the dashboard
ALM039G
from being scratched, place a plastic plate between the
steel wire and the dashboard.
(c) Pull the steel wire around the glass to cut the glass.
(d) Detach the locating block.
(e) Remove the glass with a suction disc.
Exterior 14-15
4. Clean the windshield.

(a) Remove the damaged stop block, weatherstripping, and
the binding agent adhering to the glass with a scraper.
(b) Clean the periphery of the glass with white gasoline.
Caution:
· · After cleaning, do not touch the glass surface.
· · Be careful not to damage the glass.
· · Clean the glass with white gasoline even if new
ALM040G
glass is used.
5. Install the 2 locating blocks.
A 6. Install the door window glass weatherstripping.

A
A A
Weatherstripping
A-A
MLN027G
7. Install the windshield.

Binding agent (a) Clean and trim the vehicle body contact surface.
(1) Remove the residual or unwanted binding agent on
Binding agent the contact surface with a knife.
(2) Clean the vehicle body contact surface with a rag
dampened with detergent.
Hint:
Continue to clean the vehicle body even if the binding agent
ALM042G
has been removed completely.
(b) Locate the glass.
(1) Place the glass in the correct position with a suction
disc.
Mark
(2) Check to make sure that the entire contact surface at
the edge of the glass is smooth enough.
(3) Make a reference mark between the glass and the ve-
hicle body.
Caution:
MLN028G
Check to make sure that the locating block is bonded to
the vehicle body correctly.
Hint:
When the glass is reused, check and correct the position of the
reference mark.
(4) Remove the glass.
(c) Apply the primer to the contact surface at the side of the
Correct
Primer vehicle body with a brush.
Caution:
Incorrect
Primer · · The primer should be air-dried for at least 3 minutes.
Binding agent · · Do not apply the primer onto the binding agent.
· · Discard the residual primer.
Primer
˖ ALM044G
Rear side: (d) As shown in the figure, apply the primer to the edge of
A
the glass and the contact surface with a brush or sponge.
A
Specifications:
A A
A B Position Specified condition
A B a 16±1 mm
a
A-A
b 48.0 mm
Hint:
B-B b
If the primer has been applied to other parts of the vehicle ac-
cidentally, wipe it off with a clean rag before it dries.
Primer MLN029G Caution:
· · The primer should be air-dried for at least 3 minutes.
· · Do not apply the primer onto the binding agent.
(e) Apply the binding agent.
Rear side: A
(1) As shown in the figure, cut off the end of the nozzle
A
of the binding agent barrel.
A A
A B Hint:
A a After cutting off the end, use all of the binding agent within
A-A the time listed in the table below.
b
b a Service life
B-B a
Temperature Service life
b o
35 C 15 minutes
o
20 C 1 hour 40 minutes
MLN030G
o
5C 8 hours
(2) Install the binding agent barrel onto a glue gun.
(3) Apply the binding agent to the glass as shown in the
figure.
Specifications:
a 9±2 mm
b 12±2 mm
Exterior 14-17
(f) Install the glass.

(1) Set the glass with a suction disc to align with the ref-
erence mark. Press gently along the edges.
Caution:
· · Check to make sure that the stop block is bonded to
the vehicle body correctly.
· · Check the clearance between the vehicle body and
ALM047G
the glass.
(2) Press the front surface of the glass gently to make
sure that it fits snugly and securely.
(3) Clear all excessive or protruding binding agent with
a scraper.
Hint:
Apply the binding agent to the edge of the glass.
Caution:
Do not drive the vehicle within the time stated in the
Binding agent
table below.
Minimum time:
ALM048G
Temperature Minimum time before driving
o
o
20 C 5 hours
o
5C 24 hours
8. Check for seepage and carry out maintenance.
(a) A seepage test should be carried out after the binding
agent has hardened completely.
(b) Seal the seepage position with a vehicle glass sealant.
Right Side Window Glass

Components
Right side window glass

Right C-pillar protector
Restrict pin
Side window trim strip

Rear right seat belt
guide plate
Restrict pin
Rear door weath-

erstripping RH
Rear right side window

trim strip
Rear door sill protector RH
Rear carpet assembly
Basic hand tool carrier
MLN031G
Exterior 14-19
Removal
Hint:
1. The installation sequence is the reverse of the removal sequence. However, it only includes the installation
sequence with additional information.
2. The sequence of the right side is the same the left side.
1. Remove the rear seat right backrest (See page 13-41).
2. Remove the rear seat left backrest (See page 13-41).
3. Remove the rear seat cushion subassembly (See page 13-41).
4. Remove the rear right seat backrest hinge subassembly.
5. Remove the right C-pillar protector assembly.
(a) Remove the rear door sill pressing plate RH.
(b) Remove the rear door weatherstripping RH.
(c) Remove the right C-pillar protector assembly.
6. Remove the right side window assembly.

Cut Side window (a) As shown in the figure, cut off the trim strip with a knife.
Caution: Do not damage the vehicle body with the knife.
(b) Remove the remaining trim strip.
Hint: Cut open the protective strip partially. Then, pull up and
remove it by hand.
Trim strip
MLN032G
(c) As shown in the figure, insert a steel wire between the

Restrict pin
(d) Tie an object which can act as a lever (such as a wood
Steel wire Restrict pin

MLN033G
Protective adhesive tape Hint: To prevent the external surface of the vehicle body from
being scratched, apply a protective adhesive tape to its exterior
surface.
Caution: When detaching the glass from the vehicle,
take care not to damage the body paint or the interior
and exterior trimmings.
(e) Pull the steel wire around the glass to cut the glass.
(f) Remove the glass.
MLN034G
Installation
1. Clean the right side window glass.
(a) Clean the periphery of the glass with white gasoline.
Caution:
ALM054G
2. Apply the primer.

A
(a) Apply the primer to the edge of the glass and the contact
A surface with a brush or sponge.
Caution:
B B A A · · The primer should be air-dried for at least 3 minutes.
A
· · Do not apply too much primer.
A
A-A B-B Specifications:
a b a 8 mm
MLN035G b 12 mm
3. Install the right side window assembly.

(1) Remove the residual or unwanted binding agent on
Binding agent the contact surface with a knife.
Hint: Keep on cleaning the vehicle body even if the binding
agent has been removed completely.
ALM042G
(b) Apply the primer to the vehicle body contact surface

Correct with a brush.
Primer
Caution:
· · Do not apply the primer on the binding agent.
Primer
Incorrect · · Discard the residual primer.
Binding
agent Hint: If the primer has been applied to other parts of the ve-
：Primer hicle accidentally, wipe it off with a clean rag before it dries.
MLN036G
Exterior 14-21
(c) Apply the binding agent.

Hint: After cutting off the end, use all of the binding agent
B B A A within the time listed in the table below.
Service life:
Temperature Service life
o
A-A 35 C 15 minutes
a o
20 C 100 minutes
o
5C 8 hours
b (2) Install the binding agent barrel onto a glue gun.
c
B-B (3) As shown in the figure, apply the binding agent to the
b a
a glass along the inside of the sponge strip.
b Specifications:
f
a 6±1 mm
b 11±1 mm
MLN037G (d) Install the glass on the vehicle body.
(1) Fix the corner window glass assembly securely with
protective adhesive tape or similar products until the
binding agent has hardened.
Caution:
· · Check to make sure that the restrict pin is installed
on the vehicle body correctly.
the glass.
(3) As shown in the figure, clear all excess or protruding
binding agent with a scraper.
Hint: Apply binding agent to the outer edge of the glass.
Caution: Do not drive the vehicle within the time stated
in the table below.
Minimum time:
Binding agent Temperature Minimum time before driving
o
o
ALM048G 20 C 5 hours
o
5C 24 hours
4. Water seepage inspection and maintenance
Trunk Door Glass

Removal
sequence. However, it only includes the installation sequence
1. Remove the trunk door glass.
(a) Remove the rear wiper assembly.
(b) As shown in the figure, insert a steel wire between the
Steel wire
(c) Tie an object which can act as a lever (such as a wood
Clip
MLN038G
Protective adhesive tape Hint: To prevent the external surface of the vehicle body from
being scratched, apply a protective adhesive tape to its exterior
surface.
Caution: When detaching the glass from the vehicle,
take care not to damage the body paint or the interior
and exterior trimmings.
(d) Pull the steel wire around the glass to cut the glass.
Caution: To reuse the trunk door glass, be careful not to
MLN039G
damage the clip installed on the glass when removing
the binding agent.
(e) Remove the glass with a suction disc.
Installation
1. Clean the trunk door glass.
(a) Clean the periphery of the glass with white gasoline.
Caution:
ALM054G
Exterior 14-23
2. Install the trunk door glass clip.

(a) Apply the primer to the edge of the glass and the contact
surface with a brush or sponge.
R L
(b) Install a new clip.
Hint: If the primer has been applied to other parts of the ve-
hicle accidentally, wipe it off with a clean rag before it dries.
Caution:
MLN040G
· · Do not apply too much primer.
3. Install the trunk door glass.
(1) Cut off the uneven binding agent on the vehicle body
Binding agent contact surface with a knife to ensure a good surface
shape.
Hint: Keep on cleaning the vehicle body even if the binding
ALM042G
agent has been removed completely.
Correct
(b) Apply the primer to the exposed part of the vehicle body
Primer
with a brush.
Incorrect
Caution:
Primer · · The primer should be air-dried for at least 3 minutes.
Binding agent
· · Do not apply the primer on the binding agent.
Primer
˖ MLN041G
(c) Apply the binding agent.

A
A
Hint: After cutting off the end, use all of the binding agent
B B within the time listed in the table below.
Service life:
A-A Temperature Service life
a o
35 C 15 minute
b 20 C o
1 hour and 40 minutes
B-B
a 5C o
8 hours
b a b (2) Install the binding agent barrel onto a glue gun.
(3) As shown in the figure, apply the binding agent to
MLN042G
the glass along the inside of the sponge strip.
Specifications:
a 9±2 mm
b 12±2 mm
(d) Install the glass on the vehicle body.

(1) Fix the trunk door window glass to the vehicle body
securely with protective adhesive tape or similar
products until the binding agent has hardened.
Caution:
· · Check to make sure that the clip is installed on the
vehicle body correctly.
the glass.
(3) Clear all the excessive or protruding binding agent
with a scraper.
Hint: Apply binding agent to the outer edge of the glass.
Caution: Do not drive the vehicle within the time stated
in the table below.
Minimum time:
Binding agent Temperature Minimum time before driving
o
35 C 1 hour and 30 minutes
o
ALM048G
20 C 5 hours
o
5C 24 hours
4. Check for seepage and carry out maintenance.
Exterior 14-25
Exterior Rearview Mirror

Layout
Electrical
Door exterior Right door exterior rearview mirror assembly

rearview mirror
regulation switch
Left door exterior rear-

view mirror assembly
MLN043G
Right Exterior Rearview Mirror Components
Front door
triangular
protector
Exterior rearview mirror
Exterior rearview mir- Front door RH

ror base mounting nut
MLN044G
Diagnosis

1. Door exterior rearview mirror regula- 14-27
tion switch
The rearview mirror does not work
2. Door exterior rearview mirror assembly 14-28
3. Wire harness -
1. Door exterior rearview mirror regulate 14-27
switch
The rearview mirror works abnormally
2. Door exterior rearview mirror assembly 14-28
3. Wire harness -
Overview
The exterior rearview mirrors are divided into two types, manual and power (with an electric defroster) rearview
mirrors. Both the left and right mirrors are convex deflectors with a curvature radius of 1400 mm. When installing
the exterior rearview mirror, pay attention to its fitting relationship with the door's window weatherstrip whether
the exterior rearview mirror is cracked or broken, and whether the electric heating mechanism has failed and the
mirror cover is worn or broken.
Exterior 14-27
Exterior Rearview Mirror and Its Regulation Switch

Removal
For the removal method, please see page 13-12.
Inspection
UP
LEFT OFF RIGHT Rearview mirror 1. Check the door exterior rearview mirror regulate switch.
DOWN
regulation switch (a) Left/right selector switch L side: Check the resistance of
the rearview mirror switch.
Standard (left side):
Terminal State of switch Specified condition
connection
7-1
UP
6-5
7-6
LEFT RIGHT
DOWN
Left/right selector switch 1-5
Less than 1 Ω
7-3
LEFT
6-5
7-6
RIGHT
3-5
If the results do not comply with the regulations, change the
switch assembly.
(b) Left/right selector switch R side: Check the resistance of
the rearview mirror switch.
Standard (right side):
Rearview mirror
regulation switch Terminal State of switch Specified condition
MLN045G
connection
7-2
UP
6-5
7-6
DOWN
2-5
Less than 1 Ω
7-4
LEFT
6-5
7-6
RIGHT
4-5
switch assembly.
2. Check the left door exterior rearview mirror assembly.

(A)
(a) Disconnect the rearview mirror connector.
(C) (D)
(b) As shown in the table and figure, apply the battery volt-
(B) age to the rearview mirror terminal and check the work-
ing condition of the rearview mirror.
Standard:
Measuring condition Rearview mirror working
3 2 1 condition
Battery positive (+) → 5
UP (A)
6 5 4 Battery negative (-) → 4
DOWN (B)
MLN046G
Battery negative (-) → 5
LEFT (C)
RIGHT (D)
rearview mirror assembly.
3. Check the right door exterior rearview mirror assembly.

(a) Disconnect the rearview mirror connector.
(A)
(C) (D)
(b) As shown in the table and figure, apply the battery volt-
(B) age to the rearview mirror terminal, and check the work-
ing condition of the rearview mirror.
Standard:
Measuring condition Rearview mirror working
3 2 1 condition
UP (A)
6 5 4 Battery negative (-) → 4
DOWN (B)
MLN047G Battery negative (-) → 5
LEFT (C)
RIGHT (D)
rearview mirror assembly.
Exterior 14-29
Right Door Exterior Rearview Mirror Assembly

Removal
Hint:
quence. However, it only includes the installation sequence
The sequence of the right side is the same the left side.
1. Remove the front door triangular protector RH.
MLN048G
2. Remove the right door rearview mirror.

(a) Disconnect the connector.
(b) Remove the exterior rearview mirror base mounting nut
(turn in a counterclockwise direction).
(c) Remove the right door rearview mirror.
MLN049G
Installation
quence.
Wipers and Washer System

Front Wiper Components
Front right wiper arm and blade assembly
Front left wiper arm and blade assembly
Washer nozzle
Decorative cap
Nut
Washer nozzle
Decorative cap
Nut
Vent panel
Wiper rod
Wiper motor
: Clip
MLN050G
Exterior 14-31
Problem Diagnosis
Hint: The table below lists the suspected parts in numerical order for the determination of the cause for failure of a
component. If necessary, check, repair, or replace the parts according to procedures listed in the following pages.
1. Wiper fuse -
2. Right combination switch assembly 13-19
The front wiper does not work.
3. Windshield wiper motor assembly 14-32
4. Wire harness -
The front wiper does not work in the LO or HI
position.
3. Wire harness -
The front wiper does not work in the INT posi-
tion.
3. Wire harness -
1. Cleaner fuse, relay, connector -
The washer fluid cleaner motor does not work. 3. Right combination switch assembly 13-19
4. Washer fluid cleaner motor -
5. Wire harness -
The front wiper stops working when the washer
fluid cleaner switch is set to the ON position.
5. Wire harness -
The rear wiper and washer fluid cleaner do not 2. No.1 fuse box 15-17
work. 3. Right combination switch assembly 13-19
4. Wire harness -
1. Wiper fuse, relay, connector -
The rear wiper stops working when the washer
fluid cleaner switch is set to the ON position.
4. Wiper motor -
5. Wire harness -
The washer fluid does not flow. 1. Cleaner hose and nozzles -
The wiper blades cannot retract or retract to the 1. Windshield wiper motor assembly (wip-
wrong place, when the wiper switches set to the er arm and blade position) 14-31
OFF position
The wiper blades make contact with the vehicle
body.
Washer Spraying Motor

Inspection
1. Operation inspection
(a) Pour water into the washer reservoir.
(b) As shown in the figure, connect the battery positive cable
to the positive terminal of the windshield washer spray-
ing motor, connect the battery negative cable to the nega-
tive temrinal of the windshield washer spraying motor,
and then check to make sure that the fluid flows out of
the washer reservoir.
MLN051G
(c) As shown in the figure, connect the battery positive cable

to the negative terminal of the windshield washer spray-
ing motor, connect the battery negative cable to the posi-
tive temrinal of the windshield washer spraying motor,
and then check to make sure that the water flows out of
the washer reservoir.
2. Check the combination switch's wiper lever (See page
13-19).
MLN052G
3. Check the windshield wiper motor assembly.

(a) LO (low speed) operation inspection
Connect the battery positive cable to terminal 5 of the connec-
tor, connect the battery negative cable to terminal 3, and then
5 4 3 2 1
check to make sure that the motor operates at low speed (LO).
(b) HI (high speed) operation inspection
Connect the battery positive cable to terminal 4, connect the
battery negative cable to terminal 3, and then check to make
MLN053G
sure that the motor operates at high speed (HI).
(c) Autostop operation inspection
(1) Connect the battery positive cable to terminal 5 of
the connector and connect the battery negative cable
to terminal 3. When the motor is operating at low
speed (LO), disconnect terminal 5 to stop the wiper
motor in any position other than the autostop posi-
tion.
7°~20°
(2) Use wires to connect terminal 5 to terminal 1 and
MLN054G connect the battery positive cable to terminal 2. The
Exterior 14-33
motor starts to operate at a low speed again.

(3) Check the autostop position.
Standard: as shown in the figure.
4. Check the rear wiper motor assembly.

(a) Operation inspection
2 1
Connect the battery positive cable to terminal 1 of the connec-
4 3 tor, connect the battery negative cable to terminal 2 of the con-
nector, and then check to make sure that the rear wiper motor
works.
(b) Autostop position operation inspection
(1) Connect the battery positive cable to terminal 1 of
MLN055G
the connector and connect the battery negative cable
to terminal 2 of the connector.
(2) When the motor is operating, disconnect terminal 1
to stop the motor in any position other than the auto-
stop position.
(3) Use wires to connect terminal 1 to terminal 4 and
connect the battery positive cable to terminal 3.
Check to make sure that the motor starts to operate
again and returns to the initial position.
Windshield Wiper Motor Assembly

Removal
1. Remove the vent panel of the cowl.
(a) Remove the windshield wiper arm nut decorative cap.
(b) Remove the wiper tightening nut.
(c) Remove the front left wiper arm and blade assembly.
(d) Remove the front right wiper arm and blade assembly.
(e) As shown in the figure, remove the vent panel of the
cowl.
Remove the 3 screws, detach the 12 clips and remove the vent
panel on the cowl panel.
(f) Detach the connection between the washer pipe and the
nozzle.
: Clip
MLN056G
2. Remove the wiper motor assembly.

(a) Disconnect the connector.
(b) Remove the 2 bolts and remove the windshield wiper rod
motor assembly.
MLN057G
(c) Disconnect the 2 rods on the crank arm pivot of the wip-
er motor with a screwdriver.
Caution: Before using a screwdriver, please wrap its tip
in adhesive tape.
ALM014G
ALM015G
(d) Remove the 3 bolts and the wiper motor assembly.
ALM016G
Installation
1. Install the wiper motor assembly.
(a) Install the wiper motor assembly with 3 bolts.
(b) Apply all-purpose grease to the crank arm pivot of the
wiper motor assembly.
(c) Install the two rods on the wiper motor assembly.
2. Install the wiper rod motor assembly.
(a) Install the windshield rod motor assembly with 2 bolts.
ALM016G
(b) Attach the connector.
3. Install the vent panel of the cowl.
(a) Connect the washer pipe and the nozzle.
(b) Engage 10 clips to install the vent panel.
(c) Install 3 screws.
: Clip
MLN056G
Exterior 14-35
4. Install the front left wiper arm and blade assembly.

Triangular spline
(a) Operate the wiper and stop the windshield wiper motor
assembly in the autostop position.
(b) Clear the impurities in the triangular spline with a three-
Wiper pivot tooth face square needle file or steel saw blade.
Wire brush
(c) Clean the wiper pivot tooth face with a wire brush.
MLN058G
(d) Install the front left wiper arm and blade assembly with a
nut in the position shown in the figure.
Installation position mark: 25 to 40 mm
Installation Hint: Hold the wiper arm to tighten the nut.
position mark (e) Operate the wiper while spraying water or wiper fluid
over the door window. Check the wiping effect and make
25 to 40 mm
sure that the wiper does not touch the body of the vehicle.
MLN059G
Triangular spline 5. Install the front right wiper arm and blade assembly.
(a) Remove the impurities in the triangular spline with a
three-square needle file or steel saw blade.
(b) Clean the wiper pivot tooth face with a wire brush.
Wiper pivot tooth face
Wire brush
MLN058G
(c) Install the front right wiper arm and blade assembly with
a nut in the position shown in the figure.
Installation position mark: 29 to 44 mm
Installation Hint: Hold the arm hinge with hand to tighten the nut.
position mark 6. Install the windshield wiper arm nut decorative cap.
29 to 44 mm
MLN060G
Rear Wiper Motor Assembly

Removal
1. Remove the rear wiper arm and blade assembly.
Open the rear wiper arm cover, remove the rear wiper arm nut,
and then remove the rear wiper arm and blade assembly
2. Remove the trunk door protector.
3. Remove the rear wiper motor assembly.
(c) Detach the connector.
(d) Remove the 3 bolts and the rear wiper motor assembly.
4. Remove the rear wiper motor gasket.
MLN061G
Installation
1. Install the rear wiper motor gasket.
Installation position mark As shown in the figure, install the rear wiper motor gasket.
MLN062G
2. Install the rear wiper motor assembly.

(a) As shown in the figure, install the rear wiper motor as-
sembly with 3 bolts.
(b) Link the connector.
(c) Install the trunk door protector.
MLN061G
Triangular spline 3. Install the rear wiper arm and blade assembly.
(a) Operate the wiper and stop the windshield wiper motor
assembly in the autostop position.
(b) As shown in the figure, remove the impurities in the tri-
Wiper pivot tooth face angular spline with a three-square needle file or steel saw
Wire brush
blade.
(c) Clean the wiper pivot tooth face with a wire brush.
MLN058G
Exterior 14-37
(d) Install the rear wiper arm and blade assembly with a nut
Blade position mark in the position shown in the figure.
Caution: Hold the wiper arm with hand to tighten the nut.
(e) Operate the wiper while spraying water or wiper fluid
over the door window. Check the wiping effect and make
sure that the rear wiper does not touch the body of the
vehicle.
MLN063G
Left Wiper Rubber Strip

Removal
1. Remove the front wiper blade LH.
Remove the front wiper blade LH from the front wiper arm
LH.
Caution: When removing the front wiper blade from the
front wiper arm, do not bend the front wiper arm down-
wards.
2. Remove the left wiper rubber strip LH.
Bend (a) Remove the wiper rubber strip from the front wiper blade
LH.
(b) Remove the 2 wiper rubber strip back boards from the
left wiper rubber strip.
ALM022G
Installation
Bend
1. Install the left wiper rubber strip.
(a) Install the two wiper rubber strip back boards on the left
wiper rubber strip.
Caution: Make sure to install the wiper rubber strip back
boards in the correct direction.
ALM022G
(b) Install the left wiper rubber strip such that the head (the
longer side) of the wiper rubber strip is directed towards
the arm's spindle side.
Caution:
· · Push the wiper blade into the wiper rubber strip
groove so that they lock completely.
· · Before replacing the driver side wiper arm, replace
the front passenger side wiper arm.
ALM023G
Rear Wiper Rubber Strip

Removal
(1)
1. Remove the rear wiper rubber strip.
(2)
(a) Raise the rear wiper blade to the position shown in the
figure, so that the clip is disengaged and produce a click
sound.
Caution: Do not damage the clip.
ALM024G (b) Pull the rear wiper blade from the wiper arm directly to
the left side of the vehicle.
Caution: If there is no wiper blade, do not fold in the rear
wiper arm.
(c) As shown in the figure, pull out the protruding rubber
strip end from the blade stop block.
Push Caution: Do not pull out the wiper rubber strip forcibly.
Otherwise, the back board will be deformed or the blade
Pull clip will be damaged.
Hint: Press the position near the middle of the blade to raise
the rubber strip. In this way, it will be easier to pull out the
rubber strip.
Stop block
ALM025G
Installation
Bend
1. Install the rear wiper rubber strip.
(a) Install the 2 wiper rubber strip back boards on the rear
wiper rubber strip.
Caution: Make sure to install the wiper rubber strip back
boards in the correct direction.
ALM022G
(b) Insert the rear wiper rubber strip from the clip side in the
middle of the end of the rear wiper blade.
ALM026G
Exterior 14-39
(c) Let the rear wiper rubber strip extend out through the
rear side clip and go through the front side clip.
ALM027G
Washer Nozzle
Adjustment
1. Check the washer nozzle.
When the engine is operating, turn on the washer nozzle switch and check to make sure that the washer fluid
sprays across the windshield in the position shown in the figure and over the rear door window in the position
shown in the figure.
Front:
Spray range of washer nozzle

ALM029G
Rear:
Spray range of washer nozzle
ALM030G
Exterior 14-41
2. Adjust the washer nozzle.

Adjust the direction of the washer nozzle with a pin.
Caution: Adjust the direction of the washer nozzle with a
smooth-ended pin.
ALM031G
Horn System
Components
Horn button switch
Front engine
compartment
fuse box
Horn assembly
MLN064G
Exterior 14-43
Horn
Diagnosis
1. Horn button switch -
2. Horn assembly 14-41
The horn does not work. 3. Horn fuse -
4. Horn relay assembly 14-41
5. Wire harness -
Inspection
1. Check the horn assembly.
(a) Apply battery voltage to the horn and check its working
condition.
Standard:
Measuring condition Specified condition
Battery positive (+) → Terminal 1
The horn sounds
Battery negative (-) → Terminal 2
MLN065G
horn assembly.
2. Check the horn relay assembly.
3 (a) Remove the horn relay from the front engine compart-
ment fuse box.
3 5 (b) Check the resistance of the horn relay.
5 Standard:
2 1 Testing instrument connection Specified condition
10 KΩ or more
2
1 Less than 1 Ω
MLN066G 3-5 (when the battery
voltage is applied to
terminals 1 and 2)
relay assembly.
Removal
1. Pry open the horn decorative cap above the bumper with
a screwdriver.
Hint: Before using a screwdriver, please wrap its tip in adhe-
sive tape.
2. Remove the connector.
MLN067G
3. Remove the horn.
MLN068G
Installation
1. Install the horn.
Engage the horn brace with the horn mounting bracket and
then tighten the bolt.
Caution: The tightening torque should enable the bolt to
flatten the spring washer.
2. Attach the connector and fasten the decorative cap.
MLN069G
Exterior 14-45
Reverse Sensor
System Overview
MLN070G
Composition and principle

The components of the reverse sensor system include: 1 ECU (with alarm buzzer) and 2 sensors.
The reverse sensor system emits an ultrasonic wave produced by the ultrasonic sensor behind the vehicle. When
the wave touches an object within a certain range, a reflected wave will return to the emission source (the surface
of the ultrasonic sensor). The ECU will then measure the distance using the delay time between the transmitted
wave and the reflected wave and the acoustic wave velocity and thus enable the buzzer to give different alarm
sounds.
Function
1. Basic detection parameters
(a) Detection distance: 20 cm-150 cm, accuracy of detection distance: ±5 cm.
(b) Sound: >75 dB (30 cm)
2. Automatic inspection function
When the power switch is set to ON and the gear is shifted to R, the system will start the automatic inspection
after a delay of 0.3 seconds. If all sensors operate normally, the buzzer will not sound. If any sensor has a failure,
the buzzer will sound twice.
3. Normal use function
(a) When the power switch is in the ON position and the gear is shifted to R, the system will enter the opera-
tional mode. When the gear is shifted to other positions, the system will stop operating.
(b) During normal operation

(1) When the reflected wave received by the ultrasonic sensor is within the detection range, the system will
emit an alarm signal.
(2) For the detection distance of the sensor and the alarm frequency of the buzzer, please refer to the table
below.
Obstacle distance Buzzer response frequency
100 cm to 150 cm 2 Hz
40 cm to 100 cm 4 Hz
Below 40 cm Continuous beeps
(3) Depending on the distance between the sensor installed on the rear bumper and the obstacle, three kinds
of alarm sounds will be given. When the obstacle is beyond the sensing range of the sensor, no alarm
sound will be given.
Sounds Obstacle distance Signs indicated as follows
Slow and intermittent beeps 100 cm to 150 cm
Fast and intermittent beeps 40 cm to 100 cm
Continuous beeps Below 40 cm
<40 cm
40-100 cm
100-150 cm
The data indicated above are not accurate detection data. They are
only used to distinguish the detection range of the sensor.
MLN071G
Exterior 14-47
Circuitry diagram
Left sensor
Power
Reverse Sensor ECU supply
(with buzzer)
Reverse lamp switch
Right sensor
MLN072G
ECU
Standard voltage DC 12 V
Working voltage DC 9.6 - 16 V
Working temperature -40oC - +80oC
Storage temperature -40oC - +85oC
Sensor
Standard voltage DC 12 V
Working voltage DC 9.6 - 16 V
Working frequency 58 ± 1.5 KHZ
150 cm ± 5 cm
Maximum detection distance
(tested with a 30 cm wide, 1 m high flat plywood)
Alarm buzzer
Alarm sound pressure 75 dB /30 cm
Operating mode Built-in buzzer
Connector terminal definitions

1. ECU connector terminal definitions
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
MLN073G
Terminal Definition Terminal Definition

1 ECU power supply 9 NC
2 NC 10 NC
3 NC 11 NC
4 Right sensor 12 NC
5 NC 13 NC
6 NC 14 NC
7 NC 15 NC
8 Left sensor 16 Ground
2. Sensor connector terminal definitions
Terminal number Color of lead wire Terminal definition

2 Black Ground
Green yellow (left) Signal terminal
1
Green white (right) (connected to ECU)
MLN074G
Exterior 14-49
Areas of Importance
The narrower the detection range, no operation or misoperation may be caused by the physical property, the posi-
tion, angle, size, and material of the object or a complicated background. However, this does not mean that the
system is not functioning correctly.
1. The detection may be impossible or difficult in the following cases:
(a) Fine objects such as wire mesh or ropes.
(b) Driving on grassy or uneven road surface.
(c) Cotton or materials of which the surface tends to obsorb sound waves.
(d) Impurities attached to the surface of the sensor.
(e) Ultrasonic noises, metal sounds, and high pressure gas emission sounds of the same frequency.
(f) The obstacle is a sharp-edged reflector or conical object.
Layout
Reverse sensor
ECU
Left sensor
Right sensor
MLN075G
Removal
sequence.
1. Remove the sensor.
(a) Disconnect the battery negative.
(b) Disconnect the connector of the sensor.
(c) As shown in the figure, press the spring clip from the in-
side of the rear bumper to remove the sensor.
Hint: There are 4 spring clips on the sensor.
: Clip
MLN076G
2. Remove the anti-collision radar ECU.

(a) Remove the right C-pillar protector (See page 13-37).
(b) Disconnect the connector and, as shown in the figure, re-
move the 2 bolts of the anti-collision radar ECU from the
right C-pillar with a screwdriver.
(c) Remove the anticollision radar ECU.
MLN077G
Circuitry 15-1
Circuitry
Basic Information about the Electrical System............................15-2

Electrical System Schematics Instructions.................................15-5
Areas of Importance in Circuit Maintenance...............................15-7
Circuit Inspection Steps..............................................................15-7
Ground Points ............................................................................15-8
Key Electrical Components Module..........................................15-10
Wiring Diagram ........................................................................15-12
Fuse Box...................................................................................15-17
Connector.................................................................................15-21
Connector List...........................................................................15-30
General Circuitry Diagram .......................................................15-37
Basic Information about the Electrical System

Terminology and Symbol Table
Symbols used in the Great Wall vehicle's circuitry diagram are as follows:
Battery Ground
Stores chemical energy and This indicates the point con-
converts it into electric en- necting the power supply neg-
ergy. Provides DC for each ative pole and vehicle body,
circuit of the vehicle. and thus a loop is provided
for the circuit. If the ground is
not available, then the cur-
rent can not form a loop.
Capacitor Engine speed sensor
This is a small-size storage de- Inspects the speed of the
vice for temporary electricity. crankshaft and provides it to
the ECU to serve as a refer-
ence signal confirming ignition
timing and working sequences.
Cigarette lighter Knock sensor
This is an electrical resis- This is installed on the engine
tance heating element. block for detecting when an en-
gine begins knocking, and then
provides it to the ECU for the
adjustment of the ignition ad-
vance angle based on this signal.
Circuit breaker Horn
The circuit breaker is a switch This is an electronic com-
which can be used repeatedly. ponent emitting an HF
If too much current flows audio frequency signal.
through it, the circuit breaker
will heat and disconnect.
After cooling, some break-
ers will automatically reset
and conduct electricity, while
others must be reset manually.
Diode Ignition coil
This is a semiconduc- This converts low-voltage DC
tor only allowing current to high-voltage ignition cur-
to flow unidirectionally. rent that ignites the spark plug.
Zener diode Lamp

With a specified voltage, the The current flowing through
diode only allows the currrent the filament will heat up
to flow unidirectionally and and light the filament.
blocks it from flowing in re-
verse. If the specified voltage
is exceeded, it will divert the
residual voltage. It can simply
serve as a voltage regulator.
Photosensitive diode LED ( Light Emitting Diode)
A photosensitive diode is These diodes are different
a semiconductor which from common lamp. They
controls the current on the are based on the current and
basis of light intensity. glow without heat generation.
Circuitry 15-3
Pump Analogue meter

This is a device sucking or The current will start a sole-
discharging gas or liquids. noid coil in order to move the
probe. Then a corresponding
display relative to backgroud
scale will be provided.
Fuse Digital meter
This is a thin metal sheet. The current starts one or
If over-rated current flows several LED, LCD, or
through it, it will melt and the FUEL fluorescent displays. Then
circuit will be protected from a relative or digital dis-
damage by breaking the current. play will be provided.
(Medium current fuse)
Safety fuse Motor
This is a heavy gage wire for This is a power device con-
the strong current circuitry. verting electrical energy to
If an over-rated current flows M mechanical energy, especially
through it, it will melt and the for the rotation movement.
circuit will be protected. The
(Strong current fuse number indicates the cross-
or safety fuse) section area of the wire.
Relay Woofer
Basically, #1 is normally This is an electrical de-
1. Normally closed or the electromag- vice generating soundwave
closed netic operation switch of on the basis of current.
#2 is normally opened.
2. Normally The current flowing through Manual switch
open the small coil will produce an Opens or closes the cir-
electromagnetic field to open cuit to stop or circulate
or close the affiliated switch. 1. Normally open the current in #1 or #2.
Double-throw relay
This is a relay in which
the current flows through 2. Normally closed
one group contact or
that of another group.
Resistor Double-throw switch
This is an electronic ele- This is a switch in which
ment having fixed resistance, the current constantly flows
which is installed on the through one group contact
circuit to drop the volt- or that of another group.
age to a specified value.
Tapped resistor Ignition switch
This is a resistor having This is a key switch, which
two or many different non- have many positions to
adjustable resistance values. make each circuit oper-
able, especially for the
Sliding resistor or vari- primary ignition circuit.
able resistor
This is a control resistor whose
resistance ratio is adjustable.
Sometimes it is also called a
potentiometer or rheostat.
Sensor (Thermistor) Wiper stop switch

This resistor can change When the wiper switch is off,
its resistance according to this switch will return to the
variable temperatures. stopped position via the wiper.
Speed sensor Transistor

The flux of induction coils This is a typical solid-state
1 2 will change along with circuit device being used
the concave and convex as an electronic relay. It
configuration of the tooth breaks or conducts the cur-
profile accordingly and rent according to the voltage
will induce the AC signal provided by the "base."
on the induction coils.
Short circuit pin Wiring
This is used to provide In the circuit diagram, the
an uninterrupted connec- wiring is usually shown
tion in the junction box. (1) Not connected in a straight line.
There is no joint for the cross
wiring #1 without a black
Solenoid valve
round point at the intersec-
This is a solenoid coil, and one
tion. There is a joint for the
magnetic field will form when
(2) Connected cross wiring #2 with a black
the current flows through it.
round point or octagonal mark
at the intersection.
Circuitry 15-5
Electrical System Schematics Instructions

1. Configuration introduction
The HAVAL M1 comes in three configurations: comfort, luxury, and elite. All of them are applicable to this manual
except for some of the wire harness connectors that might be deleted according to a different configuration.
2. Fuse box and power supply introduction
Key
Take out the key

Position Insert the key
Key detection
Lead Switch
-out State
Terminal
Red green
White
Black
blue
White green
MLN001G
The fuse box located inside the left side of the dashboard is the No.1 fuse box. The other one inside the left side
of the engine compartment is the No.2 fuse box.
· · 30 represents a power cord for normal power, which is from the battery positive.
· · 30a represents a power cord for normal power, which is from the battery positive fuse box — 60 A.
· · 30b represents a power cord for normal power, which is from the battery positive fuse box — 30 A.
· · 30c represents a power cord for normal power, which is from the battery positive fuse box — 30 A.
· · 15a represents a power cord for small-capacity electronics. When the ignition switch is in the ON
position, power is supplied by IG1.
· · 15b represents a power cord for small-capacity electronics. When the ignition switch is in the ON
position, power is supplied by ignition switch IG2.
· · X represents a power cord for small-capacity electronics. When the ignition switch is in the ACC
position, power is supplied by the ACC relay.
3. Connector Terminal
(a) Negative connector pin number - Arranged from upper
left to lower right.
(b) Positive connector pin number - Arranged from upper
right to lower left.
ALO002G
(c) Differences between the positive and negative connec-

tors.
The differences lie mainly in the different types of interior pins.
(1) Every connector is indicated by its engaging part and
locked on top.
(2) Please remove the connector instead of its wires.
Caution: Before removing the connector, please check
its type first.
ALO003G
4. Disconnection of the connector

To disconnect the connector, remove the connector instead of the wire harness.
Hint: Before disconnection, please check its type first.
ALO004G
5. Wire's color and sectional area (mm2)

B— Black W— White R— Red Bl— Blue Br— Brown Y— Yellow
G— Green P— Pink Or— Orange V— Violet Lg— Light green Gr— Gray
In addition: Double-colored wires are marked in two-colored letters, for instance, 0.5BlR means the primary color
of wire is Blue, the secondary color is Red, and sectional area is 0.5 mm2.
Circuitry 15-7
Areas of Importance in Circuit Maintenance

1. Before operating any electronic devices, and when tools or maintenance devices may easily make
contact with an uncovered electronic terminal, please make sure to turn the ignition switch to the LOCK
position and then disconnect the battery's negative cable to avoid injury or vehicle damage. When the
ignition switch is in the ON position, please do not disconnect the battery's connecting wire or take out
the power's fuse, regardless if the engine is running or not. Otherwise, it would seriously damage the
ECU and related micro-electronic devices such as sensors.
2. When replacing the fuse, please make sure that the new fuse has the proper current rating and is not
above or below this rating.
3. When repairing the wire harnesses of the airbag and pretensioner, only specified contact points, plugs,
and wires are allowed to be used.
4. Before repairing the wire harness, make sure to eliminate any factors that might cause damage. For
example, the edge of a vehicle body part is too sharp or the used electronics are damaged or corroded.
5. Shielded wire should not be repaired. It must be replaced entirely once it is damaged.
6. Unless it is specified during the test, please do not use an analog multimeter to test the ECU and sen-
sor, instead use a high-impedance digital multimeter (the internal resistance should be ≥10 kΩ) or a
vehicle multimeter for inspection.
7. When inspecting the connector with a digital multimeter, take the waterproof rubber cover off the con-
nector and insert the test pen snugly along the connecting terminal. Don't use too much force, as to
avoid cracking the connector.
Circuit Inspection Steps
The principle of troubleshooting is to confirm the "Location in Question." Once the possible cause is confirmed,
the components that need to be inspected are limited to the components that are related to the possible cause. The
confirmed possible cause should be based on theory and be supported by facts, but not just by intuition. If one
tries to solve the problem but does not adopt the proper troubleshooting steps, it may make the problem worse.
At that point, the possible cause not only can't be confirmed, but also maintenance can't be performed properly.
Troubleshooting should adhere to the four steps below:
1. Observe the symptoms carefully, inspect if there is anything else abnormal, and record it.
2. While confirming the Location in Question, study the circuitry diagram carefully, and regard it as a
whole system in order to understand the circuit. Thorough knowledge of switches, relays, and other
electronic components is obligatory for proper analysis.
3. Inspect and eliminate the problems one by one until the cause is found.
4. After the malfunction is fixed, make sure to check if the inspected system is working properly, and also
check if maintenance may have caused any new problems.
Ground Points
The body ground point is a place connecting the ground cable and the vehicle body. The ground cable is attached to the
vehicle body's steel plate by putting the bolt through the hole at ground cable terminal and the nut on the body's steel plate.
The ground point positions are shown below:
MLO002G
Circuitry 15-9
MLO003G
No. Ground cable number Ground position Remarks

1 906 Top of front roof drip channel under the Engine compartment's wire har-
windshield ness assembly
2 905 Front wheel housing side LH Engine compartment's wire har-
ness assembly
3 904 Front wheel housing side LH Engine compartment's wire har-
ness assembly
4 901 902 Battery bracket side Engine wire harness assembly
5 900 903 Inner decoration board front side of the front Engine compartment's wire har-
side member LH ness assembly
Battery's negative cable assembly
6 907 Cowl panel inside Engine compartment's wire har-
ness assembly
7 908 Cowl panel right side Dashboard wire harness assembly
Engine compartment floor wire
harness assembly
8 909 Central channel top Airbag wire harnesses assembly
9 910 Inner side decoration board of the rear wheel Engine compartment floor wire
housing LH harness assembly
Key Electrical Components Module

Key Electrical Components Module Schematics
Key electrical components module includes the No.1 fuse box, No.2 fuse box, the engine ECU, airbag ECU, theft
deterrent ECU, and the reverse sensor ECU.
The position of key electrical components module is as shown in the figure:
No.2 fuse box

ABS ECU
Engine ECU
MLO004G
Reverse sensor ECU
MLO005G
Circuitry 15-11
No.1 fuse box

Theft deterrent ECU
Airbag ECU
MLO006G
Wiring Diagram
The wiring diagram refers to the circuit diagram drafted on the basis of the wire harness arranged on the vehicle and in-
cludes detailed connection of each branch wire terminal. The wiring diagram is mainly used to indicate the connection
position between the wire harness and each of the electronics as well as the shape and position of the connectors.
Dashboard Wire Harness Assembly
7 8 9 10 11
12
13
20 19 18 14
15
16
17
No. Terminal connection definition No. Terminal connection definition

1 Front door wire harness assembly LH B 11 CD player signal wire
2 Front door wire harness assembly LH A 12 Engine compartment floor wire harness assembly C
3 No.1 fuse box assembly A 13 Front door wire harness assembly RH A
4 No.1 fuse box assembly G 14 Front door wire harness assembly RH B
5 Diagnostic port 15 Engine compartment floor wire harness assembly B
6 Airbag wire harnesses assembly 16 Engine compartment wire harness assembly
7 Combination meter B 17 Ground
8 Combination meter A 18 Engine compartment floor wire harness A
9 Switch block 19 Front window regulator switch RH
10 CD player 20 Front window regulator switch LH
MLO007G
Circuitry 15-13
Engine compartment wire harness assembly

No. Terminal connection definition No. Terminal connection definition No. Terminal connection definition No. Terminal connection definition
1 Tristate pressure switch 13 ABS acceleration sensor 25 ABS-FL sensor 37 Ground
2 Condenser fan 14 Headlight vertical switch 26 Front combination lamp LH 38 Air conditioner wire harness assembly
3 Washer 15 No.1 fuse box D 27 Left headlight adjustment motor 39 Brake switch
4 Front fog lamp RH 16 No.1 fuse box C 28 Rediator fan 40 Clutch switch
5 ABS-FR sensor 17 No.1 fuse box F 29 Ground 41 Theft deterrent controller
6 Right headlight adjustment motor 18 No.1 fuse box E 30 Horn 42 Ignition switch B
7 Front position lamp RH 19 Floor wire harness assembly 31 Front fog lamp LH 43 Ignition switch A
8 Front turn signal lamp RH 20 Ground 32 Engine wire harness assembly B 44 Wiper switch
9 Front combination lamp RH 21 Battery positive 33 Engine wire harness assembly C 45 Light switch
10 Dashboard wire harness assembly 22 ABS ECU 34 Engine wire harness assembly A
11 ABS-RR sensor 23 Front turn signal lamp LH 35 Brake fluid level
12 ABS-RL sensor 24 Front position lamp LH 36 Wiper motor
MLO008G
Engine compartment floor wire harness assembly
1 2
3
4
32
5
31
33 15 14
6
8
9 10 11 12 13
30
7
16
17
18
19
29 28 27 26 25 24 23 22 21 20
No. Terminal connection definition No. Terminal connection definition No. Terminal connection definition No. Terminal connection definition
1 High mount brake lamp 10 Rear door wire harness assembly 19 Dashboard wire harness assembly A 28 Rear door lamp switch RH
LH
2 Antenna 11 Electronic rearview mirror 20 Ground 29 Rear door wire harness assembly
RH
3 Antenna power supply 12 Seat belt detected switch 21 Dashboard wire harness assembly C 30 Rear bumper wire harness assembly
4 Rear combination lamp LH 13 Front door lamp switch LH 22 Dashboard wire harness assembly B 31 Reverse sensor controller
5 Trunk lamp 14 Dome lamp 23 Front door lamp switch RH 32 Rear combination lamp RH
6 Ground 15 Sunroof 24 Cigarette lighter 33 Trunk door wire harness assembly
7 Backup power supply 16 Engine compartment wire har- 25 Parking brake switch
ness assembly
8 Driver's seat belt pretensioner 17 No.1 fuse box assembly H 26 Fuel pump sensor
9 Rear door lamp switch LH 18 No.1 fuse box assembly B 27 Front passenger seat belt pretensioner
MLO009G
Circuitry 15-15
Front and rear door wire harness assembly
Window regulator
Outer electric rearview mirror
Speaker
Fastener
Dashboard wire
harness assembly
Fastener Speaker Engine compartment floor wire

harness assembly
MLO010G
Trunk door wire harness assembly
Left defroster
Right defroster Rear wiper Trunk door lock Trunk door License plate lamp Engine compart-
actuator lock switch ment floor wire
harness assembly
MLO011G
Circuitry 15-17
Fuse Box
Cab fuse box (No.1 fuse box)
Front view
15A
20A
15A
10A
15A
15A
15A
10A
10A
15A
15A
10A
20A
15A
15A
5A
5A
Left door win-
dow regulator
Airbag
Combination
meter
Sunroof
Front wiper
motor
Backup
Rearview
mirror
Radio
Rear wiper
motor
Backup
Cigarette
lighter
Backup nor-
mal power
Dome lamp
Rear fog lamp
Rear defroster
Flasher
Lock /unlock
motor
C14
5 1 1 7
15A
Rear wiper relay

15A
Left window Rear defroster relay

raising relay
Right door window regulator CD player

10 6
C07 C12
Left window C06

lowering relay
3 1 Rear fog lamp relay
Flasher relay RH
6 4 6 14
Right window Right window Left flasher relay Unlock relay Lock relay Trunk door unlock
raising relay lowering relay relay
Back view
C11 C13 C05
C08
MLO012G
Connector pin definition

Connector C05
Pin Function
1 Ground
Connector C06
Pin Function
1 Power supply
Connector C07
Pin Function Pin Function Pin Function
1 Front wiper motor 3 Backup 15 A 5 Ground
2 IG1 4 ACC 6 IG2
Connector C08
1 Front and rear washer fluid output (+) 6 Front and rear washer fluid output (-) 11 Rear washer fluid switch
2 Front and rear washer fluid output (+) 7 Rear wiper INT 12 High beam lamp
3 Right turn signal lamp control 8 Rear wiper low speed ON 13 Low beam lamp
4 Left turn signal lamp control 9 Front washer switch 14 Front fog lamp output
5 Front and rear washer fluid output (-) 10 Key detection
Connector C11
1 Dome lamp control 7 Front right door switch 13 ---
2 Dome lamp control 8 Front left door switch 14 ---
3 Trunk door unlock switch 9 ANT antenna (backup) 15 ---
4 Trunk door switch 10 Horn (backup) 16 Impact switch
5 Rear door lamp switch RH 11 ---
6 Rear door lamp switch LH 12 ---
Connector C12
1 Cigarette lighter 6 Sunroof 11 Rear fog lamp
2 --- 7 Rearview mirror 12 Trunk door unlock motor
3 Rear wiper motor (power sup- 8 Backup 15 A normal power 13 Left turn signal lamp
ply)
4 Rear wiper motor (reset) 9 Dome lamp 14 Right turn signal lamp
5 Rear wiper motor (low speed) 10 Rear defroster
Connector C13
1 Door condition 8 Backup input 1 15 Rear fog lamp switch
2 Backup output 2 9 Front door window RH lower- 16 Rear defroster switch
ing
3 Backup output 1 10 Front door window RH raising 17 Alarm lamp control
4 Central door lock locking 11 Automatic unlocking detection 18 Position lamp input
5 Central door lock unlocking 12 Automatic locking detection 19 Front door window LH
raising
6 Seat belt detection 13 Alarm lamp switch 20 Front door window LH
lowering
7 Backup input 2 14 Front fog lamp switch
Circuitry 15-19
Connector C14
1 Radio 5 Left power window actuator (+) 9 Right power win-
dow actuator (+)
2 Combination meter 6 Lock (-) 10 Left power win-
dow actuator (-)
3 Airbag 7 Unlock (+)
4 CD player 8 Right power window actuator (-)
Engine compartment fuse box (No.2 fuse box)
$
$ 5 $
5
Blower $ $
< Low speed relay
%
'
$ 5*U
$ & $
$ 5 5 :%O
<5
$
:*U
Electronic fan

Blower relay
' $
5*U :%
$
% :3
5%O $ $
<5

% $
No.1 fuse box
5 :5 %
<

$
5* $ '
5*U Compressor relay

Ignition switch
High speed fan relay
$ $ $ $
$ $
2U% 5%
$ % $ '
2U < 5 5*U
(
$
5< 5 & $ & $ & $ $
%5 %O5 %%O %O< %U %U% % :%O

Fuel pump relay Main relay
$ $ $ $
% % $ %: %< %U: 5<
: : <

% % %
$ $ $ $ 5%U
%5 %%O %U
$ $ $ $
5< <: 5: %O*
High beam relay Low beam relay Horn relay Relay ON
Electrojet IG Air conditioner IG ABSIG Back-up lamp
Main relay $ &
ECU Normal power Fuel pump Electronics Brake Compressor High beam Low beam Front fog lamp Position lamp Electric horn Air conditioner *: *
$ $ $ $ $ $ $ $ $ $ % $
$ %
$ 5%O 5 < 5 5: < %5 %%O %O5 * %U 5 %O5 %O: *: *
$ $
$ $ $ $ $ $ $ $ $ $ $ %O% *%
$%6

Front fog lamp relay Position lamp relay
MLO013G
ABS-FL Sensor Outdoor temperature sensor (Auto AC)
Front fog lamp LH
Tristate pressure switch
Front turn signal lamp LH
Left headlight adjustment motor Front fog lamp RH

Front combination
lamp LH
Condenser fan
Front position lamp LH
Rediator fan Back-up switch

Starter Oil pressure switch Starter control Air conditioner clutch
Horn
Ground Charging fuse box
Generator
Washer
Body ground Ground Engine wire harness assembly
Knocking sensor Generator control Connected VVT valve
1 2
Ground
ABS-FR
Sensor
Right headlight adjustment motor

Ignition coil 4 Nozzle 4 Ignition coil 3 Nozzle 3 Ignition coil 2 Nozzle 2 Ignition coil 1 Nozzle 1
Battery negative Battery Canister control valve Phase sensor
Battery positive
No.2 Fuse Box Front Crankshaft Water Speed
oxygen position tempera- sensor
sensor Sensor ture sensor
Ground Front position lamp RH
Inlet pressure & Electronic
Power steering pump temp. sensor
throttle
Front turn signal lamp RH
Rear oxygen sensor
Brake fluid level

Front combination lamp RH
Ground Rubber cover

Ground
Wiper motor Compartment wire harness assembly
Clutch switch
Brake lamp switch Blower ground
Acceleration pedal
Air conditioner ECU A Air conditioner ECU B
Rubber cover Ignition
switch A Air conditioner controller A Blower
Theft deterrent
controller Ignition 8
Rubber cover
1
switch B 9 16
Thermistor Blower regulate Blower regulate module

1 3
resistance
ABS-RL sensor
4 6
Indoor temperature sensor Blower high Thermistor
Air conditioner controller B Inner/outer circu- speed relay
Wiper switch lation mode motor
Lamp switch 1 6 ABS-RR sensor
Air conditioner wire harness Blower
Combination meter A Combination meter B
assembly (Manual)
Inner/outer circulation actuator
CD player B CD player A Temperature
No.1 Fuse Box change actuator
Air conditioner wire harness
Connected scanner
assembly (Auto)
Dashboard's wire
harness assembly
Circuitry
Connector
Panel switch cluster
assembly LH
Ground
Ground
Front regulator switch LH
assembly RH
Front regulator switch RH

Rubber cover
Front door wire harness
Front door wire harness

Rubber cover
view mirror
Airbag ground
Outer power
PAB Generator
rearview mirror
(Yellow)
Dome lamp
Sunroof
Outer power rear-

Clock spring B Airbag switch
Wire harness connector & Connector numbered diagram
Clock spring A
Airbag wire harness assembly
Speaker
Speaker Regulator
Regulator
Airbag ECU (Yellow)
Airbag ground
Fastener
Fastener
Floor wire harness assembly

Front door lamp switch RH
Acceleration sensor
Front door lamp switch LH
Driver seat belt pretensioner

switch
Parking brake switch
Cigarette lighter lamp
Power rearview mirror switch
Seat belt detection

Cigarette lighter
Ground
Fuel pump sensor
Rear door lamp switch RH
Rubber cover
Rubber cover
Rubber cover
Backup power supply
Rear door lamp switch LH
Luggage compartment lamp

Speaker
Speaker
Reverse Sensor
Left tail lamp

Right tail lamp
High mount
Rear wiper
harness assembly LH
Fastener
Fastener
brake lamp Left defroster

Rear door wire harness assembly RH
Rear fog lamp LH

Connected rear door wire
Antenna power supply
Left probe
Right defroster Right probe
Trunk door wire harness assembly Rear fog lamp LH
License plate lamp Trunk door Trunk door lock actuator

15-21
lock switch
Circuitry 15-23
Function Diagram of the Wire Harness Connector Terminal
C01
Euro Ⅳ Euro Ⅲ
Connected engine wire harness assembly A Connected engine compartment wire harness assembly A
C02
402 402
RGr RGr
3.0 3.0
Connected engine wire assembly B Connected engine compartment wire harness B

C03
Connected engine wire harness assembly C Connected engine compartment wire harness assembly C
C04
Connected air conditioner wire harness(手动)

assembly (manual) Connected engine compartment wire(手动)
harness assembly (manual)
Connected air conditioner wire harness(自动)

assembly (automatic) Connected engine compartment wire harness
(自动)assembly (automatic)
C05
Connected No.1 fuse box F Connected engine compartment wire harness F

Circuitry 15-25
C06
Connected No.1 fuse box D Connected engine compartment wire harness D
C07
Connected No.1 fuse box C Connected engine compartment wire harness C

C08
Connected No.1 fuse box E Connected engine compartment wire harness E

C09
Connected engine compartment wire harness assembly Connected floor wire harness assembly
C10
Connected engine compartment wire harness assembly Connected meter wire harness assembly
C11
Connected No.1 fuse box assembly H Connected engine compartment floor wire harness assembly H
C12
Connected No.1 fuse box assembly B Connected engine compartment floor wire harness assembly B
C13
Connected No.1 fuse box assembly G Connected dashboard wire harness assembly G
C14
Connected No.1 fuse box assembly A Connected dashboard wire harness assembly A
Circuitry 15-27
C15
Connected dashboard inside wire harness assembly A Connected front door wire harness assembly LH A
C16
Connected dashboard inside wire harness assembly B Connected front door wire harness assembly LH B
C17
Connected dashboard inside wire harness assembly A Connected engine compartment floor wire harness assembly A
C18
Connected engine compartment floor wire harness assembly B Connected dashboard inside wire harness assembly B
C19
Connected front door wire harness assembly RH A Connected dashboard inside wire harness assembly A
C20
Connected front door wire harness assembly RH B Connected dashboard inside wire harness assembly B
C21
Connected rear door wire harness assembly LH Connected engine compartment floor wire harness assembly
C22
Connected rear door wire harness assembly RH Connected engine compartment floor wire harness assembly
C23
Connected trunk door wire harness assembly Connected engine compartment floor wire harness assembly
Circuitry 15-29
C24
Connected rear bumper wire harness assembly Connected engine compartment floor wire harness assembly
C25
Connected engine compartment floor wire harness assembly Connected airbag wire harness assembly
C26
Connected airbag wire harness assembly Connected dashboard wire harness assembly
C27
Connected front passenger side airbag assembly (Yellow) Connected airbag wire harness assembly (Yellow)
C28
Connected dashboard wire harness assembly Connected air conditioner wire harness assembly
Connector List
Power Supply and Start-up System
Generator
发电机控制 Control Ignition
点火开关A switch A
Electrojet System
Electronic control ECU

电控ECU
(Without（不带防盗）
immobilizer system)
(With immobilizer
（带防盗） system)
Electronic
电子节气门 throttle Brake switch
制动灯开关 Accelerator
加速踏板 pedal
Circuitry 15-31
Front oxygen sensor Inlet pressure temperature sensor Speed sensor
Rear oxygen sensor Water temperature sensor Knocking sensor Phase sensor
Ignition coil 1 Ignition coil 2 Nozzle 1 Nozzle 2
Ignition coil 3 Ignition coil 4 Nozzle 3 Nozzle 4
Connected VVT valve Radiator fan Tristate pressure switch
1 2
Fuel pump sensor Clutch switch Theft deterrent controller
Crankshaft position sensor Condenser fan Canister control valve

ABS, airbag system
ABS-ECU
Four-Wheel
四驱
Drive
Two-Wheel
两驱
Drive
ABS-FL Sensor ABS-FR Sensor ABS-RR Sensor ABS-RL Sensor
Airbag ECU (Yellow)
2 2
1 1
Driver seat belt pretensioner Front passenger seat belt pretensioner PAB generator
Connected scanner Airbag switch

Circuitry 15-33
No.1 Fuse box, window regulator system
Connected No.1 fuse box E Connected No.1 fuse box C Connected No.1 fuse box D
Connected No.1 fuse box assembly A Connected No.1 fuse box assembly G
Connected No.1 fuse box assembly H Connected No.1 fuse box assembly B
Fastener Regulator Trunk door lock switch Trunk door lock actuator
Fastener Ignition switch B

Power rearview mirror, CD player
Electric rearview mirror switch Exterior electric rearview mirror Exterior electric rearview mirror
CD player B CD player A
7 1 7 1
8 2 8 2
Speaker Speaker Speaker Speaker
Lighting, signal alarm system
Front fog Front fog Front combina- Front combina- Front position Front position
lamp LH lamp RH tion lamp LH tion lamp RH lamp LH lamp RH
Horn Rear fog lamp LH Rear fog lamp RH License plate lamp Dome lamp
Left tail lamp Right tail lamp
Front turn signal Front turn signal

lamp LH lamp RH
Circuitry 15-35
Combination meter system

Combination meter A
Combination meter B Brake fluid level Seat belt detection switch
Front door lamp Rear door lamp Front door lamp Rear door lamp
switch RH switch RH switch LH switch LH
Air conditioner (manual), defroster system
Panel switch group AC controller A
1 8
9 16
Thermistor Blower Blower speed adjustive AC controller B Inner/outer circulation

resistance mode motor
1 3
205
YGr
1.5
4 6
Wiper, washer system
Wiper switch Washer Wiper motor Rear wiper

Electric AC control system

Air conditioner ECU A Air conditioner ECU B Thermistor
Blower high speed relay Blower regulator module Interior temperature sensor
Temperature change actuator Inner/outer circulation actuator Blower

Circuitry 15-37
General Circuitry Diagram

Power Supply and Start-up System
Connected No.1
Ignition switch
Key
Insert the key
Take out the key

Position
Lead-out
fuse box
Switch
State
Terminal
E10
Red green
Black
White
blue
Charging indicator
White
green
C10 13/22
C02 10/15
Red
Starter relay
White
white
black
Red
Red yel-
yellow
White
Battery
low
Generator
C02 7/15
Starter
Immobilizer system
Connected
Connected
engine
engine
C01 8/16
C10 11/22
C10 5/22
brown
Blue
Theft deterrent ECU
Diagnostic input
Connected
airbag
Coil
Yellow
Yellow
white
C10 2/22
Connected
engine
Diagnostic port
C26 8/10
Blue red
Connected di-
Driver side airbag

Blue yellow agnostic port
C26 7/10
Clock spring
Connected di-
agnostic port
C26 2/10
White red
White blue
Blue
C26 5/10
Green red
side airbag lock side airbag

Circuitry
Front passenger Front passenger

Green
Green yellow Auxillary airbag
Airbag system
lock warning
Airbag ECU
C26 3/10
Red blue
Pink White red
black Airbag warning lamp
Yellow blue
C26 6/10
Red green
Collision Connected No.1
output
Yellow green fuse box
loaded seat belt preloaded seat belt

Driver side pre- Front passenger side
15-39
ABS/EBD electronic control system
Press brake switch

Installed on Four-Wheel Drive,
uninstalled on Two-Wheel Drive
Connected diagnostic
White
Red blue
Blue red
red
Acceleration sensor
Warning lamp
Warning
port 7 pin
lamp
Brown
Green brown
Brown red
black
Red white
Brown
black
Pink
black
C10 2/22
C10 21/22 C10 22/22
Four-Wheel Drive
High-mounted brake lamp

Two-Wheel Drive
Right brake lamp

Left brake lamp
Two-Wheel Drive
Four-Wheel Drive
Oil pump motor
Green black
Green brown
Yellow black
Yellow blue
Yellow red
Yellow brown
Green blue
Green red
Control solenoid valve
Integrated ABS control module assembly
Front LH Front RH Rear LH Rear RH

Brown black
Door lamp indicator
C10 4/22
Green white
Meter lamp
tion lamp relay

Blue black
Brake fluid level Brake warning lamp
switch Red
C17 12/22
White green
White
C17 15/22
Seat belt switch Seat belt indicator lamp
Central controller Connected posi- Central controller
green
White
C02 5/15
Parking brake lamp
C10 15/22
Parking brake
switch blue
Yellow
Oil pressure switch black Oil pressure indicator
White White
red
Circuitry
Exterior temperature White

brown Temperature gauge
C17 5/22
Combination meter
sensor
Fuel sensor Yellow Fuel gauge

white
Combination meter system
Fuel warning
lamp
Water temperature
gauge
Brown white
Odometer
Brown green
Connected water temperature sensor
Speed sensor
Tachometer
C10 3/22
Brown blue
C01 14/16
Connected engine
15-41
Connected engine
Warning switch
15-42
Rear fog lamp switch
Rear defroster switch
Orange
Front fog lamp switch
Amber
Left rearview mirror
defroster
Central switch cluster assembly
Warning lamp
Lamp (orange)
Right rearview mirror
defroster
No.1 fuse box assembly
C23 10/12
Rear window defroster
C17 11/22
Defroster indicator
Orange
white Red blue
Defroster relay
C04 2/8
Yellow
Yellow black Yellow
Red
red Red
Blower
Blower relay
Blue yellow
Yellow green
HAVAL M1 Maintenance Manual
resistance
Green yellow
Yellow gray
Blue black
Speed adjustive
C04 8/8
Yellow
Air conditioner (manual), defroster system
Blue green
Red Red
Green black
Inner/outer circulation motor

Yellow red
C04 5/8
Connected engine
Output request signal Black

Pink
AC controller assembly Tristate pressure switch

C04 6/8
Yellow white White

C04 3/8
Backlight
relay
Green white
Connected
position lamp
Shift position
Wire No.
Gray blue
Rear wiper switch

Gray black
Yellow gray
Front washer output
Yellow white
washer motor
Front and rear
Rear washer output
Yellow blue
Front Washer Front wiper switch
Built-in front wiper intermittent circuit
Gray
Yellow
Front wiper motor

Circuitry
Gray
yellow
Wiper, washer system
Gray red
Central controller assembly

White
Front washer switch input
Rear wiper control

Rear wiper relay
Gray white
C23 5/12
C23 4/12
Gray
Gray red
Red blue
C23 11/12
Rear wiper motor

15-43
White
AC (automatic) system
Connected engine
Red blue
White
White Red
Yellow brown
Red
Pink white
Yellow white
Tristate pressure switch

Connected position lamp relay Red
C04 8/8
Yellow
Yellow white
Black Pink
Green white
Black Yellow red
Orange
C04 2/8
Defroster relay
No.1 fuse box C04 6/8 C04 3/8 Blower

assembly C28 3/4
C04 5/8
Orange white Yellow black

Speed regulation
C23 10/12 C17 11/22 module
Left rearview mirror defroster
Defroster indicator
Right rearview mirror
Rear window defroster
Yellow green
Yellow gray
Black
defroster
Automatic AC controller assembly
Yellow white
Orange black Red
Green black
White black
Green yellow
Blue yellow
Orange
Blue
Blue black
White
Green
Pink
White yellow
C28 1/4
Exterior temperature sensor
Interior temperature sensor
C28 2/4
Mode actuator Inner/outer circulation Temperature actuator

actuator
Circuitry 15-45
Engine electronic control system
Connected meter A32 Tristate pressure switch Connected meter A24

Connected brake lamp
Connected speed sensor
Connected theft deterrent C09 5/8 C10 8/22 C10 20/22
C01 13/16
Connected theft
Red White deterrent Pink Yellow
Brown and white

Brown and blue
Brown and green

and and and brown
blue white
switch
Central pressure
Red and grey
C02 2/15
‑

C10 9/22
Yellow
Engine speed signal output
Speed signal
Fuel pump relay
Charcoal canister cleaning control solenoid valve

C02 9/15
Red C02 3/15
and C04 7/8
Red white
Yellow
Low speed fan relay
Evaporator temperature sensor

Compressor relay
Warning lamp
Maintenance indicator
High speed fan relay

Main relay
Red and
Brake lamp switch

yellow
Coolant temperature sensor

C09 8/8 C10 5/22
Igniter 1 Igniter 2 Igniter 3 Igniter 4 C10 12/22

Fuel pump
red
White and
blue
White and
grey
White and
Red and White Yellow and red C01 6/16
Injector 1 Injector 2 Injector 3 Injector 4 C10 14/22
Orange and black Red and Red and grey Red and Red and yellow and C02 4/15
black Red and Red and Red and Red and yellow blue black C01 5/16
yellow
Blue and
C01 7/16
blue black white green
Electromagnetic Clutch
Condenser fan
C02 11/15
Black
White and pink

Compressor
Cooling fan
C01 3/16
black
Blue and
Pink and green
Pink and blue

C02 6/15
C02 15/15 C04 4/8
C01 1/16
Blue and green

C02 1/15
C01 4/16 Yellow and white Yellow and green Yellow and orange Yellow and Violet and C01 2/16
blue green
C02 14/15 C01 12/16
C01 11/16
C02 13/15
Grey Grey and yellow Grey Grey and Grey and red C03 3/8 C03 8/8
and green White C03 4/8 Blue and white
brown Red and black
White Brown and Green Violet Brown and Brown Orange Violet and Green and brown Green and Violet and Blue and black Brown and yellow Blue Blue and white
Green and Green and red C01 9/16
Booster pump switch
Clutch switch
and green green and red white yellow blue white Green Green and yellow
black and white
C03 2/8 C03 1/8 C03 7/8
Connected diagnostic interface 7th

pin (without theft deterrent)
Connected theft deterrent control-
ler A8 (with theft deterrent)
Black Black
Rear oxygen sensor Front oxygen sensor Variable cam timing Phase sensor Electronic throttle Accelerator pedal module Inlet manifold pressure temperature sensor Knock sensor Engine speed sensor
Central door locks, power window system
30b
15a
15b
X
Left turn Right turn

Meter signal signal
B#4 lamp relay lamp relay
Connected Connected seat

Connected ignition belt detect Connected position )
airbagECU switch k1 switch lamp relay
) $
$
Red and
blue
Brown and
Unlock relay

Lock relay
white ) )
$ $
Yellow Blue White and Green and
green white D D Brown
and
6 black
6
Blue

Central door lock switch
Green Yellow White Blue

and and
Front door switch LH
Front door switch RH
Rear door switch LH
Rear door switch RH
Trunk door switch
Trunk door unlock switch white red
Right window lowering relay

Left window lowering relay
Right window lifting relay
& &
Left window lifting relay

ON OFF

Trunk door unlock relay

D D D D 0

6
Dome lamp
Front door fastener LH
6
Keyhole light
6 6 6 %OXH
Grey and Grey Red and Blue
Front power window RH detect input

Front power window LH detector input
& Front window regulator Front window regulator &
red and yellow and
switch LH switch RH blue yellow 0
Door status indication control

Front door fastener RH
Dome lamp delay control
Right window lowering control

& &
Automatic unlock input
Key detect input
Seat belt detector
& & &

Left window lowering control
Right window lifting control

Left window lifting control
Trunk door unlock motor

Trunk door unlock control
0
Brown and green

&
83 ': 83 ': 0
Main power supply

&
Black 0 0 Rear door fastener LH

Left turn control
Right turn control

Unlock control
Lock control
Front door motor LH Front door motor RH
Blue and Blue and Brown Brown Brown
ACC IG1 IG2 yellow green and and and Orange and Orange Pink and Green %ODFN 0
yellow red Brown white and white and
white Rear door fastener RH
green yellow
BAT
& & & ) * * + + + + * ( * * * * * ' 6 6 + 6 6 6 6 6 6 6 * 6 6

Circuitry 15-47
Rearview mirror, player, cigarette lighter, sunroof system
Red and blue

Yellow
Connected position lamp relay
Red and blue

Violet
Green Blue and white
Green and white
Front speaker LH
Front speaker RH
Pink
Red
Sunroof switch
Red and blue
Middle
Violet Black and Black and Violet and Open

and yellow white white
yellow Close
Middle
Left
C16 6/10
C16 5/10
C20 5/10
C20 6/10
Steering wheel stereo switch
Right
Black
Upper
Rearview power mirror switch
Pink
Lower
Middle
Radio CD integrated Blue
Close Left
Right
Sunroof ECU assembly
Upper
Lower
Cigarette lighter
Backup power supply
Middle Violet Black White Black Violet

Left and blue and and and green
blue green
Right
Upper
Lower C17 3/22
C17 14/22
Signal feed line
C21 1/8
C22 2/8
Pink Pink Pink Pink Pink C17 4/22
and and and and and C21 2/8
blue white black yellow green Sunroof assembly Sunroof sensor
C17 14/22
C17 18/22 C22 1/8
C17 6/22 C19 7/8
Rear speaker LH
Rear speaker RH
C15 8/8 C15 7/8
C15 6/8 C17 19/22
C17 8/22 C19 6/8
C17 7/22
C19 8/8
Overhead antenna
Vertical Horizontal Vertical Horizontal
Left back-up mirror Right back-up mirror

Light, Signal Alarm System
C03 5/8
Blue and
green
Back-up lamp switch
Red
Blue and
white Black and red Black and blue
Check the resistance Brown
Central switch block assembly Green
relay
High beam
relay
Low beam
C03 6/8
Front fog lamp relay

Blue
Rear fog lamp relay
Position lamp relay

and red
Left turn relay
Right turn relay

Alarm switch
Rear fog lamp switch
Rear defroster switch
Front fog lamp switch
Horn relay
Blue and yellow
Lamp (orange)
Blue and
red
Green and white
Back-up radar controller Black and

Green and red Green
white
Green and blue

Amber
and Brown Brown
Warning lamp Blue and black and and
Blue and white

Light main switch indicator C09 1/8 yellow
Green and brown
Green and Green and C17 10/22 black white

black white C10 18/22
C09 2/8
Green and Green and Green Green and Green Front posi- C16 1/10 C26 1/10
Left headlight
Right headlight
black and blue Front turn signal lamp LH C17 9/22
Horn switch
yellow white tion lamp
Horn
C17 2/22 LH C20 1/10
C24 2/4
C24 3/4
C24 1/4 Left turn signal lamp C19 6/8
C10 1/22 Front position lamp RH
High beam indicator

High beam Low beam Low beamHigh beam Rear turn signal lamp LH
Black Black
Rear fog indicator lamp
C10 6/22
Rear fog lamp LH
Rear fog lamp RH
Front fog lamp LH
Front fog lamp RH
Front fog lamp indicator

Rear position lamp LH Left turn signal lamp
Overtak-
ing Close
Black Black Turn switch
Low Clearance
Rear position lamp RH Front turn signal lamp RH
Left back-up lamp
Right back-up lamp
beam Lamp Line number

High
Headlight
Black beam
Dimmer switch Lamp switch Left license plate lamp Right turn signal lamp C19 6/8 Left
Ignition switch
Key Insert the key
Take out the key

Location Right
Right license plate lamp Rear turn signal lamp RH Shift position
Leading-out
Switch
Terminal
Status Blue
Right turn signal lamp
Green and blue

C17 19/22
Green and white

Black
Left sensor Right sensor Black
Black Black Black Black
Left turn control
Right turn control
Flasher detection input

Warning lamp control
lamp input
Position
supply
Main power
control
Rear fog lamp
lamp control
Front fog
High beam
Low beam
Left turn
Right turn

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PREFACE

How to Use This Manual........................................................................1-2

How to Troubleshoot ECU Control Systems.........................................1-18

Maintenance and Inspection...................................................................2-2

Vehicle Body's Basic Calibration Measurements ................................ 2-21

Chapter III.........................................................................Engine Accessories

Fuel Supply System..............................................................................3-14

Chanper IV.................................................................................Drive System

Rear Axle Assembly..............................................................................4-20

Rear Main Reducer Assembly.............................................................. 4-23

Front Axle Hub Subassembly LH.......................................................... 4-38

Rear Axle Hub Subassembly LH.......................................................... 4-45

Transmission's Introduction and External Schematics........................... 5-3

Transmission Assembly Inspection......................................................... 5-9

Transfer Case Assembly.......................................................................5-21

Input Shaft Assembly............................................................................5-35

Output Shaft Assembly.........................................................................5-40

Maintenance of the Housing Assembly................................................ 5-46

Maintenance of Other Common Easily-Damaged Parts....................... 5-52

Chapter VI.................................................................................... Suspension

Front Suspension System...................................................................... 6-2

Rear Suspension System.....................................................................6-17

Tires and Wheels . ...............................................................................6-30

Power Steering System..........................................................................7-8

ABS Brake System...............................................................................8-25

Chapter IX.....................................................Supplemental Restraint System

Chapter X...................................................................................... AC System

Malfunction Indicator Table................................................................... 10-4

AC Controller Assembly Replacement............................................... 10-21

Maintenance and Replacement of the AC Filter Screen..................... 10-25

Subcooling Condenser Assembly....................................................... 10-26

Chapter XI.................................................................................. Vehicle Body

Engine Hood......................................................................................... 11-2

Engine Hood Lock Cable Assembly..................................................... 11-4

Trunk Power-Assisted Strut Bar........................................................... 11-5

Door Hinges.......................................................................................... 11-6

Door Cable of Fuel Tank Filler............................................................ 11-13

Chapter XII............................................................................Audio and Video

Audio and Video System......................................................................12-2

Door Lock System..............................................................................13-22

Top Interior Cover...............................................................................13-36

Windshield/Door Window Glass/Rearview Mirror............................... 14-13

Exterior Rearview Mirror.....................................................................14-25

Wipers and Washer System...............................................................14-30

Basic Information about the Electrical System.....................................15-2

Electrical System Schematics Instructions...........................................15-5

Areas of Importance in Circuit Maintenance.........................................15-7

Circuit Inspection Steps........................................................................15-7

Ground Points .....................................................................................15-8

Key Electrical Components Module.................................................... 15-10

Wiring Diagram . ................................................................................15-12

General Circuitry Diagram .................................................................15-37

How to Use This Manual..................................................................1-2

How to Use This Manual

Brake cylinder subassembly

◆Rectangular sealing ring

◆Piston dust cover

Outer muffler plate subassembly

Brack cylinder Brake block clamp spring plate

N·m : Specified torque

Vehicle's center of gravity (no load)