A19 PDF

CHERY A19 CAUTION:
This manual is only for specialized

technicians. If non-specialized or uncertified
Service Manual individuals perform repairs or maintenance
privately only referring to this manual or
2014 without proper equipment and tools, it may

cause damage to the customer's vehicle
and injury to you and other persons nearby.
01
In order to prevent dangerous operation and

FOREWORD damage to the vehicle, be sure to follow the
instructions shown below:
This manual contains on-vehicle diagnosis
and service procedures for Chery A19. - The contents in this manual must be read
thoroughly. Have a good understanding of
It is very important to read and be familiar all the contents written in the
with this manual thoroughly for proper repair PRECAUTION of "INTRODUCTION"
and maintenance. This manual should be section.
kept in a handy place for quick and easy
reference. - Before performing the repair procedures,
be sure to put on protective tools properly
The contents in this manual, including all to avoid personal injury.
illustrations and specifications, are current at
the time of printing. As modifications affecting - When performing the repair procedures,
repair and maintenance occur, relevant be sure to use specified and
information supplementary to this volume will recommended tools to prevent damage to
be made available at Chery dealers. the customer's vehicle. Be sure to confirm
the safety of the technicians before
Chery Automobile Co., Ltd. reserves all operating to avoid personal injury.
rights. Specifications and contents in this
manual are subject to change without - If a part needs to be replaced, use Chery
notification, and the Chery Automobile Co., genuine part with the same part number.
Ltd. takes no legal obligations and Do not use any inferior quality part.
responsibilities. - Observe the "WARNING" and
All rights reserved. Any unit or individual "CAUTION" in this manual carefully in
shall not reproduce or copy this manual in order to reduce the risk of personal injury
any form or by any means, or transmit it on and vehicle damage due to improper
the network by any form for any purpose operation during service and
without written permission of Chery maintenance.
Automobile Co., Ltd.
This manual only applies to the model listed
below:
A19 1.5 L MT
All Rights Reserved © 2014

Chery Automobile Co., Ltd.
FOREWORD 01
INTRODUCTION 02
PREPARATION 03
SERVICE SPECIFICATIONS 04
MAINTENANCE 05
SQR477F ENGINE MANAGEMENT SYSTEM 06
SQR477F ENGINE MECHANICAL 07
SQR477F FUEL SUPPLY SYSTEM 08
SQR477F EMISSION CONTROL SYSTEM 09
SQR477F INTAKE SYSTEM 10
SQR477F EXHAUST SYSTEM 11
SQR477F COOLING SYSTEM 12
SQR477F LUBRICATION SYSTEM 13
SQR477F IGNITION SYSTEM 14
SQR477F STARTING SYSTEM 15
SQR477F CHARGING SYSTEM 16
QR515MHA TRANSMISSION 17
CLUTCH 18
DRIVE SHAFT 19
DIFFERENTIAL 20
AXLE 21
SUSPENSION 22
TIRE AND WHEEL 23
BRAKE CONTROL SYSTEM 24
BRAKE 25
PARKING BRAKE 26
STEERING COLUMN 27
HYDRAULIC ASSIST STEERING 28
AIR CONDITIONING 29
SUPPLEMENTAL RESTRAINT SYSTEM 30
SEAT BELT 31
ENGINE IMMOBILIZER 32
LIGHTING SYSTEM 33
WIPER AND WASHER 34
DOOR LOCK 35
INSTRUMENT CLUSTER 36
AUDIO SYSTEM 37
REVERSING RADAR SYSTEM 38
HORN 39
OTHER SYSTEM 40
WINDSHIELD/WINDOW GLASS 41
REAR VIEW MIRROR 42
INSTRUMENT PANEL 43
SEAT 44
ENGINE HOOD/DOOR 45
EXTERIOR 46
INTERIOR 47
BODY DIMENSIONS 48
WIRE HARNESS 49
INTRODUCTION
SERVICE INFORMATION 02-3 Diagnosis and Troubleshooting 02-14
How to Use This Manual 02-3 Circuit Simulation Test 02-15
Preparation 02-4 Precautions for Control Module and 
Service Operation 02-7 Electrical Components Inspection 02-18
VEHICLE INFORMATION 02-10

How to Check Connector 02-19 02
Vehicle Identification Information 02-10 CIRCUIT INFORMATION 02-21
Symbols 02-13 How to Read Circuit Diagram 02-21
Circuit Diagram Index 02-24
CIRCUIT DIAGNOSIS 
INFORMATION 02-14 ABBREVIATION TABLE 02-26
How to Use Tester 02-14 Abbreviation Table 02-26
ECM Control System 
Troubleshooting 02-14
Chery Automobile Co., Ltd. 02–1

02
02–2 Chery Automobile Co., Ltd.

02 - INTRODUCTION
SERVICE INFORMATION
INTRODUCTION
How to Use This Manual

1. General information
This manual includes all the necessary procedures for service operations.
These procedures can be divided into three categories:
 Diagnosis 02
 Removal and installation, replacement, disassembly and assembly, inspection and adjustment
 Inspection
The following procedures are omitted from this manual. However, they must be performed.
 Use a transmission carrier or lifter to perform the operations.
 Clean all the removed parts.
 Perform a visual check.
This manual includes the following prompt information:
WARNING This indicates that injuries to you or other people may happen.
This indicates that damage to the repairing components may
CAUTION
happen.
ENVIRONMENTAL PROTECTION Dispose of the waste materials according to local regulations.
Provide additional information to help you with the service
HINT
operations.
2. Service procedure
Illustrations attached with the service procedure are used to identify components, show the assembling
relevance of parts, and explain the visual check for parts. Removal and installation procedures are
explained in words.
Service procedures include:
 Detailed removal and installation instruction
 Illustration
 Torque specifications
 Specifications
Sometimes, the illustrations of similar models are used. In this case, minor details may be different from
the actual vehicle.
3. Diagnosis procedure
Diagnosis procedures are divided as below:
 Diagnostic Trouble Code (DTC)
DTC is an important hint when troubleshooting is difficult to simulate. The malfunction can be
diagnosed quickly and accurately by performing the specified DTC diagnosis and check.
 Problem symptoms table
The malfunction locations can be determined quickly by troubleshooting in accordance with the
symptom type.
4. Specifications
This manual categorizes specifications as below:
 Torque specifications
 Clearance specifications
 Capacity specifications

02 - INTRODUCTION
Preparation
1. Preparation for vehicle service
02
6 3
RA19020010

02 - INTRODUCTION
 Always wear a clean uniform.

1 Attire
 A hat and safety shoes must be worn.
Before starting work, prepare a radiator grille cover, fender cover, seat
2 Vehicle Protection
cover and floor mat.
 When working with two or more persons, be sure to check the safety
each other.
 When working with the engine running, make sure to provide 02
ventilation for exhaust gas in the workshop.
 If working on high temperature, high pressure, rotating, moving, or
3 Safety Operation
vibrating parts, be sure to wear appropriate safety equipment and take
extra care not to injure yourself or others.
 When jacking up the vehicle, be sure to support the specified locations
with safety stands.
 When lifting up the vehicle, use appropriate safety equipment.
Preparation for Tools and Before starting work, prepare a tool stand, special tools, gauge, oil and
4
Measuring Gauge parts for replacement.
 Diagnose after thoroughly understanding the proper service
procedures and reported problem.
 Before removing the parts, inspect the general condition of the
assembly to check for any deformation or damage.
Removal and Installation,  Take notes for the complicated assembly. For example, note the total
5 Disassembly and number of electrical connections, bolts, or hoses that are removed.
Assembly Operations  Add matchmarks to ensure that each component is assembled to its
original position. Temporarily mark the hoses and their joints as
necessary.
 Clean and wash the removed parts if necessary and assemble them
after a thorough inspection.
 Place the removed parts in a separate box to avoid mixing them up
with the new parts or contaminating the new parts.
6 Removed Parts  For non-reusable parts such as gaskets, O-rings, and self-locking
nuts, replace them with new ones as instructed in this manual.
 Retain the removed parts for customer inspection, if requested.

02 - INTRODUCTION
2. Jacking up and supporting vehicle

Care must be taken when jacking up and supporting the vehicle. Be sure to jack up and support the vehicle
at proper locations.
a. Precautions for using a swing arm type lifter
 Follow the safety procedures described in the operation manual.
 Keep the vehicle stable when using a lifter to prevent the vehicle from tilting during operation.
Stabilize the vehicle by adjusting the length of lifter arm and vehicle position.
02
Lifter Center
Front
RA19020020

02 - INTRODUCTION
b. Precautions for using a plate type lifter

 Follow the safety procedures described in the operation manual.
 Use plate type lifter attachments (rubber lifting blocks) on the plate surface.
02
Attachment
RA19020030
Service Operation
1. How to use fasteners
WARNING
 Using incorrect fasteners may cause damage to the components. Injury and death may occur without
observing the instructions below.
 The reference values of fasteners and torque specifications in this service manual use metric unit.
 Recycling all the fasteners (nuts and bolts, etc.) during maintenance and service operation is important
for assembly.
If it's impossible to recycle fasteners, be sure to use other fasteners with the same specifications.

02 - INTRODUCTION
2. Remove parts
When repairing the malfunction, try to determine the
cause. Before starting work, parts or sub-assemblies that
have to be removed and replaced should be confirmed
first. After removing the parts, block all the holes and
ports to prevent foreign objects from entering.
02
RA19020040
3. Disassemble components
If the disassembly procedures are complicated and multiple parts need to be disassembled, make sure
that the disassembly methods won't affect the performance or appearance of parts. Identify each part for
assembly.
4. Check parts
After removal, check each part for deformation, damage or other problems.
5. Arrange parts
Carefully arrange all the disassembled parts to make the assembly easier.
Always separately arrange the replaced parts and reusable parts, and make marks on them.
6. Clean parts
Make a thorough and careful cleaning for reusable parts.
WARNING
 Blowing out the dirt or other particles with compressed air may hurt your eyes, and be sure to wear
goggles during operation.
7. Assemble components
When assembling the parts, always strictly use the standard values (tightening torque and clearance
value, etc.).
If the following parts need to be replaced, replace them
with new ones.
Oil Seal Cotter Pin
- Oil seal
- Gasket
- O-ring Gasket Nylon Nut
- Lock washer
- Cotter Pin
O-ring Lock Washer
- Nylon nut
RA19020050
8. Lubrication and seal

Use seal gum and gasket based on the position.
If seal gum is applied, install the components before the seal gum dries to prevent leakage.
Apply lubricant to movable area and friction area of the components.
During assembly, apply permitted lubricant or grease to the specified area (such as oil seal).
9. Adjustment
Use proper meter and tester for adjustment.

02 - INTRODUCTION
10.Pre-coated parts
Pre-coated parts are bolts and nuts that are coated with
seal lock adhesive in the factory.
If a pre-coated part is retightened, loosened, or moved in
any way, be sure to reapply the specified adhesive.
Seal Lock Adhesive 02

RA19020060
11. Rubber parts and rubber hoses

Avoid gasoline or oil dripping on the rubber parts or rubber hoses.
12.Hose clamp
Before removing a hose, observe the position of the Elastic Clamp
clamp so as to reinstall it to the same position.
Replace the deformed or dented clamps with new ones.
When reusing a hose, fix the clamp on the clamp track
portion of hose.
For elastic clamp, push tabs in the direction of arrow as
shown in the illustration after installation to widen the tabs
slightly. Clamp Track
RA19020070
13.Vise
When using vise, install protective plates on the jaws of
vise to prevent the parts from being damaged.
RA19020080
14.Dynamometer
When testing vehicle on the dynamometer, pay attention to the following:
- Place a fan in front of the vehicle. It's best to use a fan of which the power changes in proportion to the
vehicle speed.
- Connect an exhaust gas ventilator.
WARNING
 Exhaust gas may cause injury and death. There is odorless, colorless Carbon Oxide (CO) in the exhaust
gas. People will faint and get poisoned after inhaling it.
- Cool the exhaust pipe with a fan.

- Keep the area around vehicle clean and tidy.
- Monitor the engine coolant thermometer.

02 - INTRODUCTION
VEHICLE INFORMATION
Vehicle Identification Information
1. Vehicle Identification Number (VIN)
* *
VIN is located on the front left part of instrument panel. XXXXXXXXXXXXXXXXX
02
RA19020090
The code can also be found on the body bottom board

under the front right seat.
* *
XXXXXXXXXXXXXXXXX
RA19020100
Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) consists of World Manufacturer Identifier (WMI), Vehicle
Descriptor Section (VDS) and Vehicle Indicator Section (VIS), with a total of 17-digit characters. The
specifications are as follows:
WMI VDS VIS
ƶƶƶ ƶƶƶƶƶƶ ƶƶƻƻƻƻƻƻ
1 2 3 4 5 6
RA19020110
□: represents a letter or a number (letters I, O and Q cannot be used); ○: represents a number.

02 - INTRODUCTION
No. Definition
1 World Manufacturer Identifier
2 Vehicle Features
3 Accuracy Check Digit
4 Model Year
5 Production Plant 02
6 Sequential Number
 The first three digits of VIN represent world manufacturer identifier.
No. WMI Code Vehicle Category

1 LVV Category M1 (for vehicle type number started with 7)
 The fourth digit of VIN represents vehicle type.

- Letter "D" means all vehicles in the category M1.
 The fifth digit of VIN represents vehicle body type and drive type.
- Letter "C" means 4-door sedan 4 × 2 type.
 The sixth digit of VIN represents transmission type.
- "1" means manual transmission.
 The seventh digit of VIN represents dynamic characteristics.
- "1" means the gasoline engine that is 1.5 L - 2.0 L (2.0 L excluded).
 The eighth digit of VIN represents restraints system.
- "B" means seat belt and airbag.
 The ninth digit of VIN represents check digit.
- It is used to check the accuracy of VIN record, and made out through computation after confirming
the other sixteen digits of the VIN.
 The tenth digit of VIN represents model year:
- "E" represents 2014.
 The eleventh digit of VIN represents assembly plant code.
- "D" represents "Chery Automobile Co., Ltd.".
 The last six digits of VIN represent production sequence number.
- The number means the real production serial number of this model.
2. Vehicle data plate
The vehicle data plate is located on the upper part of right Chassis NO:
* *
Engine NO:
shock absorber seat in the engine compartment, and it is *
MADE IN CHINA
*
marked with chassis number and engine number.
RA19020120

02 - INTRODUCTION
3. Engine number
The engine number is located between the engine
exhaust manifold and generator.
* * *
SQR477F XXXXXXXXX
02
RA19020130
4. Transmission number
The transmission number is stamped on the transmission
case near the transmission shift mechanism.
QR515MHA
XXXXXXXXX
RA19020140

02 - INTRODUCTION
Symbols
The symbols below are instrument cluster display symbols and some international standard symbols.
1 2 3 4 5 6
02
7 8 9 10 11 12
+ -
13 14 15 16 17 18
OFF
19 20 21 22 23 24
EPC WIN
25 26 27 28 29 30
SRS
31 32 33 34 35 36
1 - Seat Belt Reminder Light 2 - ABS Warning Light

3 - Door Open Warning Light 4 - Brake System Warning Light
5 - High Coolant Temperature Warning Light 6 - Turn Signal Indicator
7 - Low Fuel Level Warning Light 8 - SRS Warning Light (if equipped)
9 - Low Beam Indicator 10 - Position Light Indicator
11 - Rear Fog Indicator 12 - Engine Malfunction Warning Light
13 - Low Engine Oil Pressure Warning Light 14 - Charging System Warning Light
15 - Maintenance Indicator 16 - Daytime Running Light Indicator
17 - High Beam Indicator 18 - Automatic Cruise
19 - Front Fog Indicator 20 - Transmission Malfunction Warning Light
21 - Courtesy Dome Light 22 - Electronic Steering Assist Warning Light
23 - ESP Warning Light 24 - ESP OFF Indicator
25 - EPC Warning Light 26 - Parking Brake Warning Light
27 - Front Seat Belt Reminder Light 28 - Immobilizer System Warning Light
29 - Snow Mode Indicator 30 - Hazard Flasher Warning light
31 - Horn 32 - Cigarette Lighter
33 - Hood Open 34 - Rear Windshield Heater Indicator
35 - Airbag 36 - Windshield Washer

02 - INTRODUCTION
CIRCUIT DIAGNOSIS INFORMATION

How to Use Tester
Connect the tester cable to DLC, turn the ignition switch to
ON and try to use the tester. If communication malfunction
appears on the display, it indicates that the vehicle or tester
is defective.
02
ཽ⪔⊳䖜
 If the communication is normal when the tester is
connected to another vehicle, inspect the DLC on the
original vehicle.
 If the communication is still not possible when the tester
is connected to another vehicle, the tester itself is
probably defective. RA19020150
ECM Control System Troubleshooting

This model uses the ECM control system. Most malfunction inspection procedures only involve in checking
the circuits of ECM control system one by one. An adequate understanding of the system and a basic
knowledge of electricity are enough to perform effective troubleshooting, accurate diagnosis and necessary
repairs.
Diagnosis and Troubleshooting

1. Diagnosis basis and troubleshooting methods
Procedure Types Details Troubleshooting Methods

Use eliminating methods to
determine malfunctioning parts in
accordance with DTC detection
Diagnosis procedure is based on conditions.
Diagnosis based on DTC
stored DTC.
Inspect relevant parts with the
tester and eliminate possible
malfunctions one by one.
Use eliminating methods to
determine malfunctioning parts in
Diagnosis based on symptoms (no Diagnosis procedure is based on accordance with symptoms.
DTCs stored) problem symptoms. Inspect relevant parts with the
tester and eliminate possible
malfunctions one by one.
2. Detailed troubleshooting steps
Step Description
1 Obtain detailed information when electrical malfunction occurs.
Operate affected system, and perform a road test as necessary.
2 Confirm malfunction parameter.
If it is impossible to duplicate malfunction, refer to "Electrical Malfunction Simulation Test".

02 - INTRODUCTION
Step Description
Collect proper diagnosis materials, which includes:
 Circuit Diagram
 System Schematic Diagram
3  Relevant Chapter in the Service Manual
 Service Bulletin
Perform diagnosis according to the mastered system operation knowledge and customer's 02
feedback.
Check if there is any bonding, loose connector or damaged wire harness in the system.
4 Determine related circuits and components, and diagnose according to the circuit diagram and
wire harness layout diagram.
5 Repair circuit and replace component as necessary.
Operate system in all modes. Confirm that the system can operate normally in all conditions.
6 Confirm that you have not inadvertently created new malfunctions during your diagnosis or
repair steps.
Circuit Simulation Test

The non-regular malfunctions and other malfunctions that cannot be detected through a road test can be
detected by circuit simulation test. The possible vehicle malfunction can be determined efficiently by
simulating the condition/environment when the malfunction occurs.
Simulation test can be classified into the following 7 types:
 Vehicle vibration test
 Thermosensitive test
 Freezing test
 Leakage test
 Load test
 Cold/hot start test
 Voltage drop test
HINT:
It is extremely important to listen carefully to customer's description about the malfunction for simulating the
conditions when the symptoms occur.
1. Vehicle vibration test
When the vehicle is running on an uneven road or the engine is vibrating (A/C is on and engine is idling),
malfunctions may occur. In this case, check the conditions related to the vibration. Check the following
areas on the vehicle:
a. Connector and wire harness
Slightly Vibrate
Determine the connectors and wire harnesses that
may affect the electrical system being inspected.
When monitoring whether the system has
malfunctions that are being simulated, vibrate or
wiggle each connector and wire harness slightly. This
test may show loose or poor electrical connections.
Slightly Vibrate
Slightly Wiggle
RA19020160

02 - INTRODUCTION
HINT:
When the connector is exposed to humid environment, a layer of corrosive film may be formed on its
terminals. With the connector connected, this condition may not be found by visual check. If an
intermittent malfunction occurs, it may be caused by corrosion. It is recommended that the terminals of
the relevant connectors in the system should be checked and cleaned after disconnecting the
connectors.
b. Sensors and relays
Vibrate the sensors and relays in the system being checked slightly. The sensors or relays that are
02 loose or poorly installed may be found through this test.
c. Engine compartment
 There are many reasons for the electrical malfunction that occurred due to vehicle vibration, and it is
necessary to check the following conditions:
- Connectors are not installed correctly.
- Wire harness is not long enough, so it is extended when the engine is vibrating or shaking.
- Wire harness hangs over the bracket or movable components.
- Ground wire is loose, dirty or corrosive.
- Wire harness is too close to the high temperature components.
 To inspect the components under the engine hood, first confirm that the ground connection is in
perfect condition (refer to the grounding inspection described below). First confirm that the system is
correctly grounded. Then slightly vibrate the wire harness or components as previously instructed to
check if the connection is loose. Refer to the circuit diagram to check the continuity of wire harness.
d. Backside of instrument panel
 Improper wire clamping will cause the wire harnesses to twist together when installing the
accessories. The vibration of vehicle will cause the wire harnesses near the bracket or mounting
screw to wind excessively.
 When the vehicle vibrates, unclamped or loose wire harness will be stuck in the seat components
(such as slide guide). If the wire harness passes through the underside of the mounting area, check
if the wire harness is damaged or stuck.
2. Thermosensitive test
In hot weather or after the vehicle is parked for a short time, the user may worry about the vehicle
condition. At this time, it is necessary to perform thermosensitive test.
Perform the test by heating the components with a heat gun or equivalent.
CAUTION
 DO NOT heat the components to a temperature higher than 60°C (140°F).

 If malfunction occurs when performing heating test on the components, replace or properly insulate the
components as necessary.
3. Freezing test
If the malfunction disappears after warming up the vehicle in winter, it may be caused by freezing of some
parts in the wire harness/electrical system. Use the following two methods to check this condition:
Method 1: Put the vehicle outdoors overnight. Make sure that the temperature is low enough to duplicate
the malfunction. Perform a quick and thorough diagnosis on the component that may be affected in the
morning.
Method 2: Put the suspected part in the refrigerating room and wait until it is frozen. Reinstall the
component to the vehicle and check if the malfunction reoccurs. If the malfunction occurs, repair or replace
the component.

02 - INTRODUCTION
4. Leakage test
The malfunction may occur only during high humidity or
in rainy or snowy weather. In this case, the malfunction
may occur due to water entering the electrical parts. The
leakage can be checked by spraying water to the vehicle
(similar to car wash).
02
RA19020170
5. Load test
The malfunction occurs only when the electrical device is
turned on. Turn on the electrical equipment (including A/
C, rear window defogger, radio and fog light, etc.) one by
one and determine the relationship between electrical
equipment and malfunction. Confirm the malfunction by a
load test.
STORAGE BOX
RA19020180
6. Cold/hot start test

Some malfunctions occur in cold start and disappear when the engine warms up. In this case, park the
vehicle without operation for a whole night and restart it the next day, perform the test and determine the
cause quickly.
7. Voltage drop test
Generally the voltage drop test is used to find out the possible causes that affect the normal function of the
electrical components or circuits.
Check the circuit with a digital multimeter.
If the resistance of single wire harness measured by a digital multimeter is very low (0 Ω or close to 0 Ω),
the wire harness or circuit is normal.
The unnecessary resistance in the circuit may be caused by poor, loose grounding, corrosive switch
contact and loose wire connector or adapter.

02 - INTRODUCTION
Precautions for Control Module and Electrical Components Inspection

 Before performing electrical operations, turn the ignition
switch to LOCK and disconnect the negative battery
cable, then wait for 2 minutes until the backup power
supply of the airbag module is depleted (w/ airbag
system).
02
RA19020190
 Disconnecting the battery cable will delete the clock, audio and DTC records. Therefore, it is necessary to
confirm these records before disconnecting the cable.
 Never connect the electrodes of the battery terminals reversely.
 Only install components that meet the vehicle specifications.
1. Inspect input and output conditions of components and their functions before replacing control module
 When disconnecting the components:
- Do not use excessive force when disconnecting the connector.
- If the connector is installed by tightening the bolt, loosen the mounting bolt and then disconnect the
connector by hand.
 When connecting the components:
- Before installing the connector, make sure that the terminals are not bent or damaged, and then
connect it correctly.
- When installing the connector by tightening the bolt, tighten the mounting bolt until the painted area
of the connector is flush with the surface.
 Never drop or hit the control module to prevent excessive impact.
 Note that the condensation is not formed on the control module due to extreme change of temperature
and keep it free from water drop or rain. If water is found on the control module, dry it thoroughly and
then install it to the vehicle.
 Be careful not to allow the fluid to adhere to the control module connector.
 Avoid cleaning the control module with volatile fluid.
 When using the digital multimeter, be careful not to
get the testing probes to contact with each other to
result in a short circuit. Avoid damaging the battery
due to short circuit in the power transistor inside the
control module.
RA19020200
 Use the specified test adapter to check the input and output signals of the control module.

02 - INTRODUCTION
2. Check fuse
 Check that the fuse wire is connected.
Good Blown
02
RA19020210
 If the fuse wire is blown, confirm that there is no short in the circuit.
 A fuse with the same rated amperage must be used for replacing.
How to Check Connector

Many electrical malfunctions are caused by electrical
Crimping Looseness
connections or wire malfunctions, and also may be caused
by the bonding of components or relays. Before determining Cord Wire
if the malfunction is caused by components or wire harness
assembly, check if the connection of the connectors is good.
Terminal
Deformation
Slightly Pull
RA19020220
1. Check connector with a digital multimeter

 Damaged connectors and poor connections are caused by incorrect connector detection during the
circuit inspection.
 The probe of digital multimeter may be connected incorrectly with the socket of connector. To detect the
connector correctly, use a "T" shaped needle and follow the procedures below. To obtain the optimal
connection, clamp the "T" shaped needle with a spring clamp.
a. Detect from wire harness side
- If there is a back cover for the connector, remove the back cover before detecting the terminal.
- Do not detect the water-proof connector from the wire harness side. Failure to do this may
damage the seal between wire harness and connector.
b. Detect from terminal side
- Female terminal
Do not insert any object that is bigger than the male terminal into the female connector.
- Male terminal
Carefully detect the contact surfaces of each terminal with a "T" shaped needle. Do not bend the
terminal.
2. Check for proper tension of terminal contact spring
 The contact spring on the terminal may produce intermittent signals in the circuit.
 If intermittent open circuit occurs, follow the procedures below to check the open wire harness and
contact spring on the female terminal.
- Use a male terminal matched with the female terminal.
- Disconnect the suspected defective connector and secure the terminal side upward.

02 - INTRODUCTION
- When securing the wire harness of male terminal, try to insert the male terminal into the female
terminal.
- Move the connector and check if the male terminal can be inserted easily.
HINT:
If the male terminal can be inserted into the female terminal easily, replace the female terminal.
02

02 - INTRODUCTION
CIRCUIT INFORMATION
How to Read Circuit Diagram
1. Connector symbols
 Most of connector symbols in circuit diagrams indicate
the terminal side.
Terminal Side
02
Harness Side
RA19020230
 The terminal side view in the circuit diagram is shown

at the bottom of the circuit diagram.
Female
Connector Symbol Connector

RA19020240
2. Option splices
MANUAL TRANSMISSION AUTO TRANSMISSION

CONTROL CONTROL
UNIT UNIT
E-106 E-106
E-106 E-106
16 15 8 4
E-106 E-106
SENSOR SENSOR
E-106 E-106
RA19020250
Option splice is indicated by diamonds (solid line), and marked with pin number inside.

02 - INTRODUCTION
3. Circuit diagram example
EXAMPLE
[1] BATTERY
IGNITION SWITCH
ON OR START [13]
B+ ENGINE
02 [2] SB5
COMPARTMENT
FUSE AND RELAY BOX [14]
E-014
30A
E-049
D3
[3] A
A11 A13
2 3
INSTRUMENT
[4] MAIN
RELAY EF14 PANEL FUSE [15]
AND RELAY BOX
10A
1 5 I-004
EF19
15A
A4 A3 A1 [12]
VR
SENSOR
I-003
RW
1 2
BW
G
[5]
B
I-013
[6] 2 3 E-010
[8] [16]
10 13 3 4
1 CONTROL
MODULE
I-001
MOTOR 5 7
[7] M E-011
GR
O
TO BACKLIGHT [17]
V
POWER
I-006
2 6 1 6
B-008 SWITCH
[9]
B
I-009
5 [19]
[18]
[10] LIGHT
E-014 [11]
B-003 3 5
4
B-002 I-006
D1 D2 D3 D4 D5
1 2 3 4 5 6 7 8 9 10 11 12 13 A16 A15 A14 A9 A8 A7
14 15 16 17 18 19 20 21 22 23 24 25 26
A6 A5 A4
A13 A12 A11 A10
A3 A2 A1
[20] D6 D7 D8 D9 D10 D11 D12
E-049
I-001 I-004 [21] W
W W
2 1
1 2 3 4 5 6 7 8 4 5 6 1 2 B+
8 7 6 5 4 3 2 1 1 2 1 2 3 6 5 4 3
9 10 11 12 13 14 15 16
16 15 14 13 12 11 10 9
E-014
I-009 I-003
B-008 I-013 B-003
E-011 W W
W W W
Gr
EA19490000
The connector pin layout is shown at the bottom of the circuit diagram.

02 - INTRODUCTION
The following is a list of symbols defined in the circuit diagram.
No. Definition Description

It indicates the power supply from battery positive to electrical
1 Battery
equipment.
This symbol indicates a fuse; "SB5" indicates the fuse number; "30A"
2 Fuse
indicates the rated amperage of fuse.
3 Splice Point The solid circle indicates that each intersecting wire is interconnected. 02
This symbol indicates a relay; "MAIN RELAY" indicates the relay
4 Relay
name; "1, 2, 3 and 5" indicate the terminal numbers of relay.
It indicates the color of this wire. The color codes are as follows:
B = Black;
W = White;
R = Red;
G = Green;
L = Blue;
Y = Yellow;
5 Color Br = Brown;
O = Orange;
Gr = Gray;
P = Pink;
V = Violet;
Lg = Light Green.
For example: "BrR" indicates that the main color is brown in the wire
color, and the second color is red.
It indicates the plug-in connector. "Λ" is the female connector, and 
"I-013" is the applicable number; "◊" is the male connector, and "E-010"
6 Connector is the applicable number. The number "2" inside the male connector
symbol indicates the terminal number. "----" indicates different terminals
come from the same junction connectors.
7 Motor This symbol indicates a motor.
8 Component Name It indicates the name of component.
E-011 indicates the connector number of this component. Letter "E"
indicates the wire harness code in which the connector is located.
Connector codes are as follows:
E = Engine Wire Harness, Engine Compartment Wire Harness;
I = Instrument Panel Wire Harness;
B = Body Wire Harness;
F = Front Left Door Wire Harness;
9 Connector No. H = Front Right Door Wire Harness;
L = Rear Left Door Wire Harness;
R = Rear Right Door Wire Harness;
T = Rear Bumper Wire Harness;
K = A/C Wire Harness;
P = Battery Positive, Negative Wire Harness;
C = Roof Wire Harness.
10 Ground Point It indicates the ground connection.

02 - INTRODUCTION

11 Bulb This symbol indicates a bulb.
12 Terminal No. It indicates the terminal number in the connector of this component.
It indicates the power supply from ignition switch to electrical
13 Ignition Switch
equipment.
It indicates that the wire harness is connected to the circuit diagram
02 14 Connected to… on next page. Letter "A" is connected with "A" in the circuit diagram on
the next page.
15 Fuse and Relay Box Name It indicates the name of fuse and relay box.
16 Twisted-pair It indicates that the two wires are twisted.
It indicates the illumination power supply output from the fuse of front
17 Backlight Power Supply
position light.
It is used for indicators, warning lights or illuminations in the switches
18 LED
or instrument cluster.
19 Switch This symbol indicates a switch.
It indicates the cross section of connector and description of the
20 Connector View
terminal number.
Letter "W" indicates the color of connector. The color codes are the
21 Connector Color
same as above.
Circuit Diagram Index

Use the table below to find the location of components or vehicle systems in the circuit diagram. It is easy to
find the circuit diagrams throughout the service manual based on components or vehicle systems.
It has been marked under "If There Is Any Circuit Diagram" column to tell you that if there is any circuit
diagram in the components or vehicle systems.
Service Manual Chapter If There Is Any Circuit Diagram

Foreword -
Introduction -
Preparation -
Service Specifications -
Maintenance -
SQR477F Engine Management System Yes
SQR477F Engine Mechanical -
SQR477F Fuel Supply System Yes
SQR477F Emission Control System Yes
SQR477F Intake System Yes
SQR477F Exhaust System -
SQR477F Cooling System Yes
SQR477F Lubrication System -
SQR477F Ignition System Yes
SQR477F Starting System Yes

02 - INTRODUCTION
Service Manual Chapter If There Is Any Circuit Diagram

SQR477F Charging System Yes
QR515MHA Transmission -
Clutch -
Drive Shaft -
Differential -
02
Axle -
Suspension -
Tire and Wheel -
Brake Control System Yes
Brake Yes
Parking Brake Yes
Steering Column -
Hydraulic Assist Steering -
Air Conditioning Yes
Supplemental Restraint System Yes
Seat Belt Yes
Engine Immobilizer Yes
Lighting System Yes
Wiper and Washer Yes
Door Lock Yes
Instrument Cluster Yes
Audio System Yes
Reversing Radar System Yes
Horn Yes
Other System Yes
Windshield/Window Glass Yes
Rear View Mirror Yes
Instrument Panel -
Seat -
Engine Hood/Door -
Exterior -
Interior -
Body Dimensions -
Wire Harness Yes

02 - INTRODUCTION
ABBREVIATION TABLE
Abbreviation Table
Term Abbreviation
Anti-lock Brake System ABS
02 Acceleration Sensor AES
Accelerator Pedal Position Sensor APS
Automatic Temperature Control ATC
Automatic Transmission Fluid ATF
Body Control Module BCM
Brake Pressure Sensor BPS
Camshaft Position Sensor CMP
Clutch Pedal Position Switch CPP Switch
Crankshaft Position Sensor CKP
Data Link Connector DLC
Diagnostic Trouble Code DTC
Engine Control Module ECM
Engine Coolant Temperature ECT
Engine Speed RPM
Evaporative Emission EVAP
Evaporative Emission Canister EVAP Canister
Evaporative Emission System EVAP System
Exhaust Gas Recirculation Valve EGR Valve
Front Left Wheel Speed Sensor FLS
Front Right Wheel Speed Sensor FRS
Rear Left Wheel Speed Sensor RLS
Rear Right Wheel Speed Sensor RRS
Ground GND
Heated Oxygen Sensor O2S
Idle Air Control IAC
Intake Temperature IAT
Ignition IGN
Ignition Control IC
Immobilizer Control Module ICM
Injector INJ
Input Shaft Speed Sensor ISS Sensor
Knock Sensor KS
Manifold Absolute Pressure MAP

02 - INTRODUCTION
Term Abbreviation
Mass Air Flow MAF
Malfunction Indicator Light MIL
Oil Pressure Switch OPS
Output Shaft Speed Sensor OSS Sensor
Positive Crankcase Ventilation Valve PCV Valve
02
Power Supply PWR
Supplemental Restraint System SRS
Throttle Position Sensor TPS
Transaxle Control Module TCM
Turbine Speed Sensor TSS
Vehicle Identification Number VIN
Vehicle Speed Sensor VSS

- MEMO -

PREPARATION
SQR477F ENGINE MANAGEMENT  PARKING BRAKE 03-29
SYSTEM 03-3 Tool 03-29
Tools 03-3
STEERING COLUMN 03-30
SQR477F ENGINE MECHANICAL 03-5 Tools 03-30
Tools 03-5
HYDRAULIC ASSIST STEERING 03-31
SQR477F FUEL SUPPLY SYSTEM 03-11 Tools 03-31 03
Tools 03-11
AIR CONDITIONING 03-32
SQR477F EMISSION CONTROL  Tools 03-32
SYSTEM 03-12
SUPPLEMENTAL RESTRAINT 
Tool 03-12
SYSTEM 03-33
SQR477F INTAKE SYSTEM 03-13 Tools 03-33
Tools 03-13
SEAT BELT 03-34
SQR477F EXHAUST SYSTEM 03-14 Tool 03-34
Tools 03-14
LIGHTING SYSTEM 03-35
SQR477F COOLING SYSTEM 03-15 Tools 03-35
Tools 03-15
WIPER AND WASHER 03-36
SQR477F LUBRICATION SYSTEM 03-16 Tool 03-36
Tools 03-16
DOOR LOCK 03-37
SQR477F IGNITION SYSTEM 03-17 Tools 03-37
Tool 03-17
INSTRUMENT CLUSTER 03-38
SQR477F STARTING SYSTEM 03-18 Tools 03-38
Tool 03-18
AUDIO SYSTEM 03-39
SQR477F CHARGING SYSTEM 03-19 Tool 03-39
Tool 03-19
REVERSING RADAR SYSTEM 03-40
QR515MHA TRANSMISSION 03-20 Tool 03-40
Tools 03-20
HORN 03-41
CLUTCH 03-22 Tool 03-41
Tools 03-22
WINDSHIELD/WINDOW GLASS 03-42
DIFFERENTIAL 03-23 Tools 03-42
Tools 03-23
REAR VIEW MIRROR 03-43
AXLE 03-24 Tool 03-43
Tools 03-24
INSTRUMENT PANEL 03-44
SUSPENSION 03-26 Tools 03-44
Tools 03-26
ENGINE HOOD/DOOR 03-45
BRAKE CONTROL SYSTEM 03-27 Tool 03-45
Tools 03-27
EXTERIOR 03-46
BRAKE 03-28 Tool 03-46
Tools 03-28
INTERIOR 03-47
Tool 03-47

03

03 - PREPARATION
SQR477F ENGINE MANAGEMENT SYSTEM

PREPARATION
Tools
Special Tool
03
ཽ⪔⊳䖜
X-431 3G Diagnostic Tester
RCH0000001
General Tools
Fuel Injector Cleaning Analyzer
RCH0000062
Ignition Timing Light
RCH0000016
Digital Multimeter
RCH0000002

03 - PREPARATION
6
4
60 80
100
40
8
2
120
20
140
0
10
0
Vacuum Gauge
RCH0000036
03
Cylinder Pressure Gauge
RCH0000044
Fuel Pressure Gauge
RCH0000048
Oscilloscope YES ENTER
ESC
NO
1 2 3 4 5
6 7 8 9 0
RCH0000061

03 - PREPARATION
SQR477F ENGINE MECHANICAL

Tools
Special Tools
03
Crankshaft Front Oil Seal Guide Tool
RCH0000049
Crankshaft Front Oil Seal Installer
RCH0000067
Camshaft Oil Seal Installer
RCH0000017
Valve Spring Compression Adapter
RCH0000050
Valve Spring Compressor
RCH0000028

03 - PREPARATION
Crankshaft Rear Oil Seal Installer
RCH0000031
03
Valve Oil Seal Installer
RCH0000034
Valve Oil Seal Guide Sleeve
RCH0000035
Driven Plate Assembly & Clutch Cover Assembly

Guide Special Tool
RCH0000018
Valve Oil Seal Remover
RCH0000037

03 - PREPARATION
Valve Cotter Installer
RCH0000029
03
Flywheel Holding Tool
RCH0000040
Oil Filter Remover
RCH0000054
General Tools
Piston Installer
RCH0000039
20
10
30
0
40
90
50
80
Dial Indicator and Magnetic Holder

60
70
RCH0000023

03 - PREPARATION
1.5
50
1.0
5
0
Outer Diameter Micrometer 0.01mm
50 75mm
RCH0000064
03
Vernier Caliper
RCH0000019
Inner Diameter Micrometer
RCH0000068
Precision Straightedge
RCH0000063
Feeler Gauge
RCH0000060

03 - PREPARATION
Cylinder Gauge
RCH0000065
03
Piston Ring Remover
RCH0000066
Digital Multimeter
RCH0000002
Flexional Magnetic Rod
RCH0000042
Engine Hoist
RCH0000043

03 - PREPARATION
Engine Equalizer
RCH0000026
03
Transmission Carrier
RCH0000005
Fuel System Pressure Tester
RCH0000048
RCH0000044
Engine Service Platform
RCH0000057

03 - PREPARATION
SQR477F FUEL SUPPLY SYSTEM

Tools
Special Tool
03
Fuel Tank Pressure Cap Remover
RCH0000004
General Tools
Digital Multimeter
RCH0000002
RCH0000048
RCH0000005

03 - PREPARATION
SQR477F EMISSION CONTROL SYSTEM

Tool
Special Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
SQR477F INTAKE SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
SQR477F EXHAUST SYSTEM

Tools
Special Tools
03
Precision Ruler
RCH0000063
Feeler Gauge
RCH0000060

03 - PREPARATION
SQR477F COOLING SYSTEM

Tools
General Tools
03
Digital Multimeter
RCH0000002
Cooling System Pressure Tester
RCH0000055
Freezing Point Tester
RCH0000007

03 - PREPARATION
SQR477F LUBRICATION SYSTEM

Tools
Special Tools
03
Oil Pan Remover and Scraper
RCH0000056
Oil Filter Remover
RCH0000054
General Tool
Oil Pressure Tester
RCH0000006

03 - PREPARATION
SQR477F IGNITION SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
SQR477F STARTING SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
SQR477F CHARGING SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
QR515MHA TRANSMISSION
Tools
Special Tools
03
Input Shaft Oil Seal Installer
RCH0000008
Differential Oil Seal Installer
RCH0000009
Installation Joint
RCH0000010
Bearing Remover
RCH0000011
Punch
RCH0000015

03 - PREPARATION
Puller
RCH0000059
03
General Tools
RCH0000005
Engine Equalizer
RCH0000026
Hydraulic Press
RCH0000012

03 - PREPARATION
CLUTCH
Tools
Special Tool
03
Clutch Pressure Plate Installer
RCH0000018
General Tools
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002

03 - PREPARATION
DIFFERENTIAL
Tools
Special Tools
03
Bearing Remover
RCH0000011
Punch
RCH0000015
General Tools
20
10
30
0
40
90
50
80

60
70
RCH0000023
Hydraulic Press
RCH0000012

03 - PREPARATION
AXLE
PREPARATION
Tools
Special Tool
03
Ball Pin Separator
RCH0000024
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
RCH0000005
Hydraulic Press
RCH0000012

03 - PREPARATION
Bearing Remover
RCH0000011
03
Engine Equalizer
RCH0000043

03 - PREPARATION
SUSPENSION
Tools
Special Tool
03
Spring Compressor
RCH0000021
General Tools
RCH0000005
Engine Equalizer
RCH0000026

03 - PREPARATION
BRAKE CONTROL SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
BRAKE
Tools
Special Tool
03
Brake Caliper Piston Pressing Tool
RCH0000053
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002

03 - PREPARATION
PARKING BRAKE
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
STEERING COLUMN
Tools
Special Tool
03
Steering Wheel Remover
RCH0000014
General Tool
Electric Drill
RCH0000013

03 - PREPARATION
HYDRAULIC ASSIST STEERING

Tools
Special Tool
03
Ball Pin Separator
RCH0000024
General Tools
RCH0000005
Engine Equalizer
RCH0000026

03 - PREPARATION
AIR CONDITIONING
Tools
General Tools
03
Refrigerant Recycling Machine
RCH0000046
Digital Multimeter
RCH0000002

03 - PREPARATION
SUPPLEMENTAL RESTRAINT SYSTEM

Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
SEAT BELT
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
LIGHTING SYSTEM
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
WIPER AND WASHER

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
DOOR LOCK
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
INSTRUMENT CLUSTER
Tools
Special Tool
03
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
AUDIO SYSTEM
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
REVERSING RADAR SYSTEM

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
HORN
Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
WINDSHIELD/WINDOW GLASS
Tools
Special Tool
03
Interior Crow Plate
RCH0000025
General Tool
Digital Multimeter
RCH0000002

03 - PREPARATION
REAR VIEW MIRROR

Tool
General Tool
03
Digital Multimeter
RCH0000002

03 - PREPARATION
INSTRUMENT PANEL
Tools
Special Tools
03
RCH0000014
Interior Crow Plate
RCH0000025

03 - PREPARATION
ENGINE HOOD/DOOR
Tool
Special Tool
03
Interior Crow Plate
RCH0000025

03 - PREPARATION
EXTERIOR
Tool
Special Tool
03
Interior Crow Plate
RCH0000025

03 - PREPARATION
INTERIOR
Tool
Special Tool
03
Interior Crow Plate
RCH0000025

- MEMO -

SERVICE SPECIFICATIONS
SQR477F ENGINE MANAGEMENT  BRAKE CONTROL SYSTEM 04-29
SYSTEM 04-3 Specifications 04-29
Specifications 04-3
BRAKE 04-30
SQR477F ENGINE MECHANICAL 04-4 Specifications 04-30
Specifications 04-4
PARKING BRAKE 04-32
SQR477F FUEL SUPPLY SYSTEM 04-10 Specifications 04-32
Specifications 04-10
STEERING COLUMN 04-33 04
SQR477F EMISSION CONTROL  Specifications 04-33
SYSTEM 04-11
HYDRAULIC ASSIST STEERING 04-34
SQR477F INTAKE SYSTEM 04-12
AIR CONDITIONING 04-35
SQR477F EXHAUST SYSTEM 04-13
SUPPLEMENTAL RESTRAINT 
SYSTEM 04-37
SQR477F COOLING SYSTEM 04-14 Specifications 04-37
SEAT BELT 04-38
SQR477F LUBRICATION SYSTEM 04-15 Specifications 04-38
LIGHTING SYSTEM 04-39
SQR477F IGNITION SYSTEM 04-16 Specifications 04-39
WIPER AND WASHER 04-40
SQR477F STARTING SYSTEM 04-17 Specifications 04-40
DOOR LOCK 04-41
SQR477F CHARGING SYSTEM 04-18 Specifications 04-41
INSTRUMENT CLUSTER 04-42
QR515MHA TRANSMISSION 04-19 Specification 04-42
AUDIO SYSTEM 04-43
CLUTCH 04-21 Specifications 04-43
REVERSING RADAR SYSTEM 04-44
DRIVE SHAFT 04-22 Specification 04-44
HORN 04-45
DIFFERENTIAL 04-23 Specification 04-45
WINDSHIELD/WINDOW GLASS 04-46
AXLE 04-24 Specifications 04-46
REAR VIEW MIRROR 04-47
SUSPENSION 04-26 Specification 04-47
INSTRUMENT PANEL 04-48
TIRE AND WHEEL 04-28 Specifications 04-48

SEAT 04-50 EXTERIOR 04-53
Specifications 04-50 Specifications 04-53
ENGINE HOOD/DOOR 04-51 INTERIOR 04-54

Specifications 04-51 Specifications 04-54
04

04 - SERVICE SPECIFICATIONS

Specifications
Torque Specifications
Description Torque (N·m)

Coolant Temperature Sensor 11 - 16
Knock Sensor Mounting Bolt 17 - 23
Oxygen Sensor 45 ± 5 04
Crankshaft Position Sensor Mounting Bolt 8±2
Camshaft Position Sensor Mounting Bolt 10 ± 2
Accelerator Pedal Mounting Bolt 10 ± 2
Intake Pressure/Temperature Sensor Mounting Bolt 8±1
Engine Control Module Mounting Bolt 7±1


Specifications
SQR477F Engine Specifications
Item Specification
Engine Type Vertical, in-line 4-cylinder, water-cooled, 4-stroke, SOHC
Engine Model SQR477F
04 Valve Number Per Cylinder 4

Cylinder Diameter (mm) 77.40
Piston Stroke (mm) 79.52
Displacement (ml) 1497
Compression Ratio 10.5:1
Combustion Chamber Type Pentroof type
Fuel Supply Type Electronic controlled sequential multiport fuel injection
Ignition Type Electrical control
Ignition Sequence 1-3-4-2
Idle Speed (r/min) 650 ± 50
Rated Power (kW) 80
Max. Torque (N·m) 140
Max. Torque Speed (r/min) 4500
Max. Permissible Speed (r/min) 6000
Min. Fuel Consumption Rate (g/kW·h) 260
Oil and Fuel Consumption Percentage ≤ 0.15
Max. Intake Valve Lift (mm) 8.56
Max. Exhaust Valve Lift (mm) 8
Intake Valve Opening Angle 
372°
(1 mm)
Exhaust Valve Closing Angle (1 mm) 354°
Intake Valve Closing Angle (1 mm) 573°
Exhaust Valve Opening Angle (1 mm) 178°
Fuel Octane Number (Not Less Than) Unleaded gasoline, octane number 93
In summer SAE 10W-40 (grade SL or higher)
Oil Octane Number
In winter SAE 5W-40 (grade SL or higher)
Oil Capacity (L) 3.9 ± 0.5
Counterclockwise (viewed from cross section of engine
Crankshaft Rotation Direction
flywheel)
Starting Type Electrical starting
Cooling Type Forced circulation type antifreeze cooling

Item Specification
Lubrication Type Compound type (pressure, splash lubrication)
Net Weight (kg) 110
Cylinder Compression Pressure (bar)
10 - 13.5
(180 - 250) r/min
Idle Speed (650 ± 50 r/min) Higher than 1.5
Oil Pressure (bar)
High Speed (4000 ± 50 r/min) Higher than 3.5
Boundary Dimension (Length x Width x
615 × 580 × 695
Height) (mm)
04
With atmospheric temperature at -30°C, engine can start
smoothly within 8 seconds without taking special measures.
Starting Performance Starting test shows that starting can be performed 3 times
consecutively. If it fails to start once, perform starting again
after 2 minutes.
Engine Mechanical Specifications
Item Specification
Rocker Arm Shaft Hole Diameter for Intake Left +0.035
19 +0.017
Rocker Arm Assembly (mm)
Rocker Arm Shaft Hole Diameter for Intake Right +0.035
19 +0.017
Rocker Arm Shaft -0.002
Intake Rocker Arm Shaft Diameter (mm) 19 -0.015
Rocker Arm Shaft Hole Diameter for Exhaust Rocker +0.035
19 +0.017
Arm Assembly (mm)
-0.002
Exhaust Rocker Arm Shaft Diameter (mm) 19 -0.015
Intake Camshaft Lift (mm) 5.09
Exhaust Camshaft Lift (mm) 5.34
Camshaft -0.02
Camshaft Journal Diameter (mm) 26 -0.033
Camshaft Thrust Clearance (mm) 0.095 - 0.153
Lower Surface Flatness (mm) 0.055
Cylinder Head
Overall Height (mm) 97
Valve Lifter Diameter Intake Valve 5.972 - 5.988

(mm) Exhaust Valve 5.952 - 5.968
Valve Head Margin Intake Valve 0.012 - 0.043

Thickness (mm) Exhaust Valve 0.032 - 0.063
Valve
Clearance Between Intake Valve 0.012 - 0.043
Valve Lifter and Guide
(mm) Exhaust Valve 0.032 - 0.063
Intake Valve 107.998

Valve Height (mm)
Exhaust Valve 117.410
Free Height (mm) 47.7
Valve Spring
Preload (N) 249 - 271

Item Specification
Piston Piston Diameter (mm) 77.325 - 77.365
First Ring 0.04 - 0.08
Piston Ring Side
Second Ring 0.03 - 0.07
Clearance (mm)
Oil Ring 0.03 - 0.16
Piston Ring
Piston Ring End Gap
(mm)
Oil Ring 0.2 - 0.6
04 Diameter (mm) 48.99 ± 0.01
Main Bearing Shell +0.007
2.131 0
Thickness (mm)
Radial Clearance (mm) 0.011 - 0.058
Crankshaft Main Journal
Thrust Clearance (mm) 0.093 - 0.303
Crankshaft
Runout (mm) 0.05
Cylindricity (mm) 0.008
Roundness (mm) 0.005
Crankshaft Connecting
Diameter (mm) 48.99 ± 0.01
Rod Journal (mm)
Cylinder Bore Roundness (mm) 0.008
Cylinder Block Upper Surface Flatness (mm) 0.05
Cylinder Diameter (mm) 77.36 - 77.40
Big End Thrust Clearance (mm) 0.333 - 0.387
Connecting Rod Bearing Shell Radial Clearance
Connecting Rod 0.006 - 0.06
(mm)
+0.007
Connecting Rod Bearing Shell Thickness (mm) 1.48 0
Engine Torque Specifications

Inner Torx Fixing Bolt for Power Steering Pump 25 ± 3
Locking Nut for Power Steering Pump Tension Bolt 30 ± 3
Coupling Bolt Between Steering Pump Fixing
25 ± 3
Bracket and Power Steering Pump
Coupling Bolt Between Idler Pulley and Generator 20 ± 5
Inner Torx Round Fixing Bolt for Idler Pulley 20 ± 5
Torx Flange Fixing Bolt for Idler Pulley 40 ± 5
Inner Torx Round Fixing Bolt for Tensioner 20 ± 5
Timing Belt Upper Cover Fixing Bolt 8 - 11
Crankshaft Pulley Fixing Bolt 105 - 115
Timing Belt Lower Cover Fixing Bolt 8 - 11


Timing Belt Tensioner Fixing Bolt 16 - 20
Camshaft Timing Pulley Fixing Bolt 100 ± 10
Worm Clamp 2.5 ± 0.5
Camshaft Position Sensor Fixing Bolt 10 ± 2
Rear Right Bracket Fixing Bolt 7±1
Coolant Pipe Assembly Fixing Bolt 7±1
1st step: Tighten to 3 - 5
Cylinder Head Cover Fixing Bolt
2nd step: Tighten to 8 - 11 04
1st step: 15 ± 1.5
Rocker Arm Shaft Fixing Bolt
2nd step: 30 ± 1.5
First Bearing Cap Fixing Bolt 9.5 ± 1
Coupling Bolt Between Small Circulation Coolant
8±1
Pipe and Cylinder Head
1st step: 20 - 25
2nd step: 40 - 45
Cylinder Head Fixing Bolt
3rd step: Rotate 90°clockwise
4th step: Rotate 90°clockwise
1st step: 50 - 60
Flywheel Fixing Bolt
2nd step: 105 - 115
Coupling Bolt Between Rear Mounting Bracket and
55 ± 5.5
Left Side of Transmission Case
55 ± 5.5
Right Side of Transmission Case
Locking Nut for Through Bolt Between Rear
Mounting Bracket and Rear Mounting Cushion 85 ± 8.5
Assembly
Coupling Bolt Between Rear Mounting Cushion
85 ± 8.5
Assembly and Front Sub Frame Welding Assembly
Bracket I Fixing Bolt 8±1
Locking Nut for Through Bolt Between Left Mounting
80 ± 8
Cushion Assembly and Left Mounting Bracket
Coupling Bolt Between Left Mounting Cushion
60 ± 6
Assembly and Body
Coupling Bolt Between Left Mounting Bracket and
55 ± 5.5
Transmission Case
Coupling Bolt Between Right Mounting Bracket and
60 ± 6
Right Mounting Cushion Assembly
Fixing Nut Between Right Mounting Bracket and
60 ± 6
60 ± 6
Engine Block
Expansion Tank Fixing Bolt 7 ± 1.5


Right Mounting Cushion Assembly Fixing Bolt 60 ± 6
Coupling Nut Between Main Catalytic Converter
45 ± 5
Assembly and Precatalytic Converter Assembly
Clutch Release Cylinder Pipe Coupling Plug 18 ± 2
Positive Wire Harness Fixing Nut 7±1
Battery Negative Wire Harness Fixing Bolt 20 ± 3
Ground Fixing Bolt of Engine Wire Harness on ECM
7±1
Side
04
Fixing Bolt for Power Steering Pump Fixing Bracket 55 ± 5
A/C Compressor Bracket Fixing Bolt 55 ± 5
Knock Sensor Fixing Bolt 17 - 23
Oil Pressure Switch 20 ± 2
Exhaust Manifold Fixing Bolt 45 ± 5
40 ± 4
Pipe and Cylinder Block
Crankshaft Rear Oil Seal Bracket Fixing Bolt 8 - 11
Connecting Rod Bearing Cap Fixing Bolt 20 + 5
Crankshaft Main Bearing Cap Fixing Bolt 90 - 100
Crankshaft Main Bearing Cap Fixing Nut 90 - 100
Piston Cooling Nozzle Fixing Bolt 20 - 25
Lubrication Areas during Engine Assembly
Lubrication Area Note

Piston Pin SL10W-40
Piston Ring SL10W-40
Piston SL10W-40
Cylinder Bore SL10W-40
Main Bearing Shell and Crankshaft Main Journal SL10W-40
Crankshaft Thrust Washer (Oil Groove Side) SL10W-40
Connecting Rod Bearing Cap Bolt Head and Thread
SL10W-40
Part
Connecting Rod Bearing Shell and Crankshaft
SL10W-40
Connecting Rod Journal
Main Bearing Cap Bolt Head SL10W-40
Crankshaft Front Oil Seal Lip and Crankshaft Oil
SL10W-40
Seal Journal
Crankshaft Rear Oil Seal Lip and Crankshaft Oil Seal
SL10W-40
Journal


Valve Guide Hole SL10W-40
Valve Lifter SL10W-40
Camshaft Cam and Journal SL10W-40
Valve Rocker Arm Head SL10W-40
Valve Small End, Valve Rocker Arm Head SL10W-40
Valve Retainer Hole (Cylinder Head Assembly) SL10W-40
Valve Guide or Guide Bottom Hole (Cylinder Head) SL10W-40
Camshaft Oil Seal Lip and Camshaft Journal SL10W-40 04
Oil Filter Gasket Surface SL10W-40
All engine lubricants should be 5W-40 (for winter)/10W-40 (for summer) SL grade or higher.
Areas with Seal Gum Applied during Engine Assembly
Area with Seal Gum Applied Seal Gum Type

Cylinder Block Bowl Plug Loctite 648
Semi-circle Joint Surface Between Oil Pan Gasket
Loctite 5910
and Oil Pump
Loctite 5910
and Rear Oil Seal Bracket
Joint Surface Between Oil Pump Bottom and
Loctite 5910
Cylinder Block Bottom
Joint Surface Between Rear Oil Seal Bracket Bottom
Loctite 5910
and Cylinder Block Bottom
Loctite 5910
and Oil Pan
Cylinder Head Bowl Plug Loctite 648
First Camshaft Bearing Cap Loctite 574
Spark Plug Socket Loctite 243
Coolant Temperature Sensor Loctite 243
Oil Pressure Switch Loctite 243
Intake/Exhaust Manifold Stub Loctite 271
Flywheel Bolt Precoated Seal Gum
Cylinder Head Cover Gasket and Bolt Loctite 5910
Cylinder Block - Sleeve - Oil Dipstick Tube Loctite 648


Specifications

Fuel Filter Bracket Fixing Screw 7 ± 1.5
Fuel Tank Pressure Cap 75 ± 5
04 Filler Tube Assembly Lower End Bracket Fixing Bolt 7 ± 1.5

Filler Tube Assembly Fixing Nut 7 ± 1.5
Fuel Tank Fixing Bolt 23 ± 2.5
Fuel Rail Fixing Bolt 8 - 11
Fuel Pressure Specifications
SQR477F Pressure (kPa)

Fuel Pressure on Fuel Rail - Key (ON) 400
Fuel Pressure on Fuel Rail - Engine Idling 400
Fuel Pressure on Fuel Rail - Key (LOCK) 400


Specifications

Activated Charcoal Canister Bracket Fixing Bolt 7 ± 1.5
Connecting Bolt Between Activated Charcoal
7 ± 1.5
Canister and Bracket
Exhaust Manifold Heat Insulator Fixing Bolt 25 ± 5
04
Upstream Oxygen Sensor 45 ± 5
Downstream Oxygen Sensor 45 ± 5


Specifications

Coupling Screw Between Air Filter Upper and Lower
3±1
Housing
Air Filter Fixing Bolt 7 ± 1.5
04 Resonant Cavity Assembly Fixing Bolt 7 ± 1.5
Air Direct Pipe Right Fixing Bolt 7 ± 1.5
Air Direct Pipe Left Fixing Bolt 7 ± 1.5
Electronic Throttle Assembly Fixing Bolt 8 - 11
Intake Pressure/Temperature Sensor Fixing Bolt 8±1
Intake Manifold Fixing Nut 22.5 ± 2.5
Canister Solenoid Valve Bracket Fixing Bolt 10 ± 2
Intake Manifold Upper Bracket Fixing Bolt 18 ± 2
Electronic Accelerator Pedal Fixing Bolt 10 ± 2


Specifications

Exhaust Manifold Fixing Nut 45 ± 5
Coupling Nut Between Exhaust Manifold and
Precatalytic Assembly
45 ± 5 04
Coupling Nut Between Main Catalytic Assembly and
45 ± 5
Precatalytic Assembly
Coupling Nut Between Main Catalytic Assembly and
45 ± 5
Front Muffler Assembly
Coupling Nut Between Front Muffler Assembly and
45 ± 5
Rear Muffler Assembly


Specifications

Wire Harness Bracket Fixing Bolt 8 - 11
04 Thermostat Housing Fixing Bolt 8 - 11

Thermostat Seat Fixing Bolt 8 - 11
Cooling Fan Assembly Fixing Bolt 7 ± 1.5
Radiator Upper Crossmember Fixing Bolt 10 ± 1
Radiator Upper Crossmember Fixing Nut 5±1
Water Pump Fixing Bolt 11
Coolant Capacity
Item Capacity (L)

Cooling System 7.5
Coolant Concentration
G11 Additive Soft Water

50% 50%
Coolant Freezing Point
Item Freezing Point Value (°C)

Coolant -35
Cooling System Pressure
Item System Pressure (bar)

Cooling System (Test Pressure) 1.3 ± 0.2


Specifications
System Pressures
Condition Pressure (kPa)

Idling Speed (650 ± 50 r/min, oil temperature 90°C) Above 1.5
High Speed (4000 ± 50 r/min, oil temperature 100°C) Above 3.5
04
Oil Specifications
Engine Type SQR477F

Summer: SAE 10W-40 (SL or higher)
Oil Specifications
Winter: SAE 5W-40 (SL or higher)

Drain Plug 35 ± 3
Oil Filter 25 ± 3
Coupling Bolt Between Oil Pan and Transmission
45 ± 5
Housing
Fixing Bolt of Baffle Plate Between Oil Pan and
45 ± 5
Transmission
Oil Pan Fixing Bolt 11 ± 1
Oil Pan Baffle Plate Fixing Bolt 8+3
Oil Strainer Bracket Fixing Bolt 17 - 23
Oil Strainer Bracket Fixing Nut 17 - 23
Coupling Bolt Between Oil Strainer and Oil Pump
17 - 23
Assembly
Oil Pump Assembly Fixing Bolt 8 - 11


Specifications

Spark Plug 30 ± 3
Ignition Coil Fixing Bolt 8 - 11
04 Rear Left Bracket Assembly Fixing Bolt 7±1

Spark Plug Specifications
Engine Type SQR477F

Spark Plug Type FR7DTC
Spark Plug Gap (mm) 0.8 - 0.9


Specifications

Starter Power Cable Nut 18 ± 2
Starter Fixing Bolt 40 ± 5
Ignition Starting Switch Fixing Screw 13 ± 2 04


Specifications

Battery Pressure Plate Fixing Bolt 7 ± 1.5
Coupling Bolt Between Battery Tray and Air Filter
7±1
Assembly
04 Battery Tray Fixing Bolt 25 ± 4
Generator Output Cable Fixing Nut 18 - 22
Generator Field Wiring Harness Fixing Nut 8±1
Generator Fixing Bolt 20 ± 5
Generator Bracket Fixing Nut 40 ± 5
Generator Bracket Fixing Bolt 40 ± 5
Battery Specification
Name Type Specification

SQR477F L2 400 12V, 60Ah, 480A

Specifications

Reverse Shift Fork Fixing Bolt 25 ± 2
Transmission Case Fixing Bolt 25 ± 2
Clutch Case Fixing Bolt 25 ± 2 04
Reverse Gear Fixing Bolt 38 ± 2.5
Gear Shift Control Mechanism Fixing Bolt 20 ± 3
Select and Shift Cable Boot Fixing Nut 7 ± 1.5
Select and Shift Cable Locating Nut 7 ± 1.5
Coupling Bolt Between Gear Shift Mechanism and
25 ± 2
Transmission Case
Gear Shift Mechanism Locating Bolt 32 ± 2.5
Clutch Line Bracket Fixing Bolt 25 ± 2
Shift Shaft Locating Bolt 20 ± 2
Back-up Light Switch 25 ± 2
Starter Wire Harness Bracket Fixing Bolt 25 ± 2
Oxygen Sensor Connector Bracket Fixing Bolt 20 ± 3
Ground Wire Fixing Bolt 20 ± 3
Drain/Retaining Plug 44 ± 3
Select and Shift Cable Mounting Bracket Fixing Bolt 25 ± 3
Transmission Fixing Bolt 45 ± 5
Fixing Bolt Between Front and Lower Side of Engine
45 ± 5
and Transmission
Fixing Bolt Between Engine Rear Side and
45 ± 5
Transmission

Transmission Gear Ratio Table
Gear Ratio Type

QR515MHA
Gear
1st 3.545
2nd 2.050
3rd 1.423
4th 1.065
5th 0.865
04
Reverse 3.364
Final Drive 3.550

CLUTCH
Specifications

Clutch Pressure Plate Fixing Bolt 23 ± 2
Clutch Fork Fixing Bolt 20 ± 2
Clutch Master Cylinder Fixing Nut 25 ± 4 04
Clutch Release Cylinder and Oil Pipe II 18 ± 2
Fixing Bolt Between Clutch Release Cylinder and
25 ± 4
Transmission
Clutch Pedal Upper Fixing Bolt 20 ± 3
Clutch Driven Plate Specifications
Measurement Item Specification (mm)

Clutch Driven Disc Standard Thickness 7.3 ± 0.3
Minimum Rivet Depth 0.8

DRIVE SHAFT
Specifications

Speed Sensor Fixing Bolt 10 ± 1.5
Front Brake Hose Bracket Fixing Bolt 10 ± 1.5
04 Coupling Bolt Between Steering Knuckle and Shock

Absorber
110 ± 10
Drive Shaft Assembly Fixing Nut 240 ± 20

DIFFERENTIAL
Specifications

Final Drive Driven Gear Bolt 137 ± 3
Clearance Specification
04
Description Acceptable Range (mm)
Clearance Between Differential Case and Planetary
0.025 - 0.150
Gear

AXLE
Specifications

Front Drive Shaft Assembly Locking Nut 240 ± 20
Coupling Bolt Between Front Dust Guard and Front
10 ± 1
Steering Knuckle Assembly
04 Coupling Bolt Between Front Wheel Speed Sensor
10 ± 1.5
and Front Steering Knuckle Assembly
Self-locking Nut Between Steering Tie Rod
Assembly Ball Pin and Front Steering Knuckle 35 ± 3
Assembly
Coupling Nut Between Control Arm Assembly Ball
120 ± 10
Pin and Front Steering Knuckle Assembly
Coupling Bolt Between Front Shock Absorber
110 ± 10
Assembly and Front Steering Knuckle Assembly
Coupling Nut Between Front Shock Absorber
110 ± 10
Coupling Nut Between Front Stabilizer Bar and Front
50 ± 5
Stabilizer Bar Connecting Rod Assembly
Coupling Bolt and Nut Between Rear Mounting
85 ± 8.5
Cushion and Rear Mounting Bracket
Coupling Nut Between Front of Front Sub-frame
120 ± 10
Welding Assembly and Body
Coupling Bolt Between Rear of Front Sub-frame
120 ± 10
Coupling Bolt Between Steering Mechanism
100 ± 10
Assembly and Front Sub-frame Welding Assembly
Coupling Bolt Between High Pressure Return Pipe
7 ± 1.5
Assembly and Front Sub-frame Welding Assembly
Coupling Bolt Between Rear Mounting Cushion and
85 ± 8.5
Front Sub-frame Welding Assembly
Coupling Bolt Between Front Stabilizer Bar and Front
50 ± 5
Sub-frame Welding Assembly
Rear Shaft Assembly Locking Nut 240 ± 20
Rear Brake Wheel Cylinder Pipe Fixing Plug 18 ± 2
Coupling Bolt Between Rear Wheel Speed Sensor
10 ± 1.5
and Rear Hub Shaft
Coupling Bolt and Nut Between Rear Shock
110 ± 10
Absorber Assembly and Rear Shaft Assembly
Coupling Nut Between Parking Brake Cable Fixing
10 ± 1.5
Bracket and Body


Coupling Bolt Between Rear Brake Assembly and
60 ± 5
Rear Hub Shaft
Coupling Bolt Between Rear Shaft Assembly and
120 ± 10
Body
04

SUSPENSION
Specifications
Wheel Mounting Bolt 110 ± 10
Coupling Nut Between Front Stabilizer Bar
Connecting Rod Assembly and Front Shock 50 ± 5
04 Absorber Assembly
Coupling Nut Between Front Stabilizer Bar
Connecting Rod Assembly and Front Stabilizer Bar 50 ± 5
Assembly
Coupling Bolt Between Front Brake Hose Assembly
10 ± 1.5
and Front Shock Absorber Assembly
110 ± 10
110 ± 10
60 ± 5
Assembly and Body
Front Shock Absorber Assembly Locking Nut 60 ± 5
Coupling Nut Between Front Control Arm Ball Pin
120 ± 10
Coupling Bolt Between Front Part of Front Control
Arm Assembly and Front Sub Frame Welding 180 ± 10
Assembly
Coupling Bolt Between Rear Part of Front Control
Assembly
Coupling Bolt Between Front Control Arm Ball Pin
50 ± 5
Assembly and Front Control Arm Assembly
50 ± 5
85 ± 8.5
Rear Mounting Bracket
Coupling Nut Between Rear Mounting Cushion and
85 ± 8.5
Coupling Nut Between Front Part of Front Sub
120 ± 10
Frame Welding Assembly and Body
Coupling Bolt Between Rear Part of Front Sub
120 ± 10
Coupling Bolt Between Front Sub Frame Welding
100 ± 10
Assembly and Steering Mechanism


Assembly and Steering Mechanism High Pressure 7 ± 1.5
Fluid Return Pipe Assembly
Coupling Bolt Between Front Stabilizer Bar
50 ± 5
Coupling Bolt Between Rear Shock Absorber
110 ± 10
Assembly and Rear Shaft Assembly
Coupling Nut Between Rear Shock Absorber
110 ± 10
04
Coupling Nut Between Upper Part of Rear Shock
20 ± 3
Absorber Assembly and Body
Steering Tie Rod Locking Nut 47 ± 3
Steering Wheel Locking Nut 35 ± 3

TIRE AND WHEEL

Specifications
Torque Specification

Tire Type
04
Description Parameter
Tire Type 185/60 R15 84H
Rim Type
Rim Type (Steel Rim) 15 × 6J
Rim Type (Aluminum Rim) 15 × 5.5J
Tire Pressure Specifications of Cold Tire
Description Pressure (kPa)

Front Tire (Unloaded) 230
Rear Tire (Unloaded) 220
Spare Tire 250


Specifications

Brake Pipe Coupling Plug 18 ± 2
ABS Control Module Assembly Mounting Bracket
Fixing Bolt
25 ± 4 04
ABS Control Module Assembly Bottom Fixing Bolt 10 ± 1.5
ABS Control Module Assembly Side Fixing Screw 10 ± 1.5
Front Wheel Speed Sensor Fixing Bolt 10 ± 1.5
Rear Wheel Speed Sensor Fixing Bolt 10 ± 1.5

BRAKE
Specifications

Coupling Plug Between Brake Master Cylinder
18 ± 2
Assembly and Brake Pipe
04 Coupling Nut Between Brake Master Cylinder
13 - 17
Assembly and Vacuum Booster
Coupling Nut Between Vacuum Booster Assembly
25 ± 4
and Brake Pedal Assembly
Coupling Bolt Between Instrument Panel
25 ± 4
Crossmember and Brake Pedal Assembly
Coupling Bolt Between Front Brake Caliper
25 ± 4
Assembly and Front Brake Hose Assembly
100 ± 10
Front Brake Disc Fixing Screw 7-9
Front Brake Caliper Bleeder Plug 5.88 - 9.8
Locating Bolt Between Brake Caliper Fixing Bracket
25 ± 4
and Brake Cylinder Assembly
Coupling Plug Between Front Brake Hose Assembly
18 ± 2
and Front Brake Pipe
25 ± 4
Rear Drum Brake Positioning Screw 10 ± 1
Rear Brake Wheel Cylinder Bleeder Plug 5.88 - 9.8
Coupling Plug Between Rear Brake Wheel Cylinder
18 ± 2
and Rear Brake Pipe
Coupling Bolt Between Rear Brake Bottom Board
60 ± 5
and Rear Shaft Assembly
Coupling Plug Between Rear Part of Rear Brake
18 ± 2
Hose Assembly and Rear Brake Pipe
Coupling Plug Between Front Part of Rear Brake
18 ± 2

Front Disc Brake
Standard Thickness Minimum Thickness

Description Maximum Runout (mm)
(mm) (mm)
Front Brake Disc 18 16 0.025
Front Brake Lining 10.5 2 -
Rear Drum Brake
Description Standard Thickness (mm) Minimum Thickness (mm)

Rear Brake Shoe Lining 5 1 04
Standard Inner Maximum Inner

Diameter (mm) Diameter (mm)
Rear Brake Drum 220 221.4 0.05

PARKING BRAKE
Specifications

Coupling Nut Between Parking Brake Control
25 ± 3
Mechanism Assembly and Vehicle Body
04 Coupling Bolt Between Armrest Box Fixing Bracket
Assembly and Parking Brake Control Mechanism 25 ± 3
Assembly
Coupling Nut Between Armrest Box Fixing Bracket
25 ± 3
Assembly and Vehicle Body
Coupling Bolt Between Parking Brake Rear Cable
10 ± 1.5
Assembly Bracket and Vehicle Body
Coupling Nut Between Parking Brake Rear Cable
10 ± 1.5
10 ± 1.5
Assembly Bracket and Rear Shaft Assembly

STEERING COLUMN
Specifications
Description Tightening Torque (N·m)

Steering Wheel Assembly Fixing Nut 35 ± 3.5
Combination Switch Cover Fixing Screw 1.5 ± 0.5
Steering Column Upper Bracket Fixing Nut 23 ± 2.5 04
Steering Column Assembly Lower Bracket Fixing
25 ± 3
Bolt
Coupling Bolt Between Steering Column Assembly
and Intermediate Shaft with Universal Joint 23 ± 2.5
Assembly
Ignition Starting Switch Fixing Screw 13 ± 2
Coupling Bolt Between Intermediate Shaft with
Universal Joint Assembly and Steering Gear Input 30 ± 3
Shaft
Ignition Switch Illumination Light Fixing Screw 2 ± 2.5
Data Specifications
Description Standard Value

Steering Wheel Free Play (Rotation Angle) ≤15°
Steering Wheel Centering/Returnability (Rotation
>70°
Angle)


Specifications

Fluid Suction Pipe Upper Bracket Fixing Bolt 7 ± 1.5
Fluid Suction Pipe Lower Bracket Fixing Bolt 7 ± 1.5
04 High Pressure Fluid Pipe Joint Hollow Bolt 45 ± 5

Coupling Bolt Between Upper Bracket of Fluid
Return Pipe and High Pressure Pipe and Front Sub 9±1
Frame Welding Assembly
Joint Bolt Between High Pressure Pipe and Steering
30 ± 3
Gear Assembly
Joint Bolt Between Fluid Return Pipe and Steering
30 ± 3
Gear Assembly
Lower Bracket Fixing Nut Between Fluid Return Pipe
9±1
and High Pressure Pipe
Fluid Return Pipe Bracket Nut 7 ± 1.5
Power Steering Pump Tensioning Bracket Fixing Bolt 20 ± 3
Power Steering Pump Assembly Inner Torx Bolt 25 ± 3
Coupling Bolt Between Power Steering Pump
20 ± 3
Assembly and Right Side of Steering Pump Bracket
20 ± 3
Assembly and Left Side of Steering Pump Bracket
Power Steering Pump Assembly Pulley Inner Torx
20 ± 3
Round Bolt
Locking Nut Between Ball Pin Assembly and
35 ± 3
Steering Tie Rod Adjustment Nut 47 ± 3
Coupling Bolt Between Intermediate Shaft and Input
25 ± 3
Shaft of Steering Gear Assembly
Locking Nut of Rear Mounting Bracket and Rear
85 ± 8.5
Mounting Cushion Assembly Through Bolt
Coupling Bolt Between Body and Rear Part of Front
120 ± 10
Sub Frame Welding Assembly
Assembly
Coupling Bolt Between Steering Gear Assembly and
100 ± 10
Front Sub Frame Welding Assembly

AIR CONDITIONING
Specifications

A/C Control Panel Assembly Fixing Screw 1.5 ± 0.5
Blower Assembly Fixing Screw 1.5 ± 0.5
Blower Speed Resistor Fixing Screw 1.5 ± 0.5 04
Coupling Nut Between A/C High/Low Pressure Line
9 ± 1.5
and Expansion Valve
A/C Wire Harness Assembly Ground Point Fixing
20 ± 3
Nut
Coupling Nut Between Upper Part of HVAC
3.5 ± 0.5
Assembly and Body
Coupling Bolt Between Lower Part of HVAC
3.5 ± 0.5
Assembly and Body
Coupling Bolt Between Expansion Valve and
9 ± 1.5
Expansion Valve Mounting Pressure Plate
Left Foot Fan Shield Fixing Screw 1.5 ± 0.5
Right Foot Fan Shield Fixing Screw 1.5 ± 0.5
Inner/Outer Circulation Damper Motor Fixing Screw 1.5 ± 0.5
Air Inlet Housing Assembly Fixing Screw 1.5 ± 0.5
Blower Case Assembly Fixing Screw 1.5 ± 0.5
Evaporator Cover Plate Fixing Screw 1.5 ± 0.5
Evaporator Cover Housing Assembly Fixing Screw 1.5 ± 0.5
Temperature Damper Adjustment Mechanism Fixing
1.5 ± 0.5
Screw
Mode Damper Servo Motor Fixing Screw 1.5 ± 0.5
Mode Damper Servo Motor Bracket Fixing Screw 1.5 ± 0.5
Mode Damper Adjustment Mechanism Set Fixing
1.5 ± 0.5
Screw
Heater Core Line Pressure Plate Fixing Screw 1.5 ± 0.5
7 ± 1.5
Set Bracket and Body
Fixing Bolt Between A/C Low Pressure Line and
25 ± 4
Compressor Assembly
Fixing Bolt Between A/C High Pressure Line and
25 ± 4
Compressor Assembly
Fixing Nut Between A/C High Pressure Line I and
9 ± 1.5
Condenser Assembly
Fixing Nut Between A/C High Pressure Line II and
9 ± 1.5
Condenser Assembly


Fixing Bolt Between Compressor Assembly and
25 ± 4
Mounting Bracket
Fixing Nut Between Condenser Assembly and Tank
5±1
Upper Crossmember
Refrigerant Charging Specification
Description Charging Capacity (g)

R134a Refrigerant 400 ± 10
04
Refrigerant Oil Charging Specifications
Description Charging Capacity (ml)

It is necessary to pour out 50 ml of refrigerant oil
Compressor Assembly Replacement
from the new compressor assembly
Condenser Replacement 40
Evaporator Replacement 30
A/C Line Replacement 10


Specifications

Driver Airbag Fixing Bolt 10 ± 1.5
Spiral Cable Fixing Screw 1.5 ± 0.5
Coupling Bolt Between Front Passenger Airbag and
Instrument Panel Crossmember Assembly
10 ± 1.5 04
Coupling Bolt Between SRS Control Module
10 ± 1.5
Assembly and Body

SEAT BELT
Specifications

Height Adjuster Fixing Bolt 50 ± 5
Front Seat Belt Assembly Fixing Bolt 50 ± 5
04 Front Seat Belt Assembly Fixing Screw 3 ± 0.5

Rear Seat Belt Assembly Fixing Bolt 50 ± 5
Center Seat Belt Assembly Fixing Bolt 50 ± 5
Double Buckle Belt Assembly Fixing Bolt 50 ± 5
Front Seat Belt Buckle Fixing Bolt 50 ± 5

LIGHTING SYSTEM
Specifications
Bulb Specifications
Bulb Name Nominal Light Source (Model/Type)

Headlight H1
Front Position Light LED
Front Turn Signal Light HY21 04
Brake Light LED
Rear Fog Light P21W
License Plate Light C5W
High Mounted Stop Light LED
Rear Position Light LED
Rear Turn Signal Light PY21W
Back-up Light P21W
Side Turn Signal Light WY5W

Front Combination Light Fixing Bolt 3.5 ± 0.5
Rear Combination Light Fixing Nut 3.5 ± 0.5
Dome Light Fixing Screw 2±1
High Mounted Stop Light Fixing Screw 2±1

WIPER AND WASHER

Specifications

Wiper Arm Assembly Fixing Nut 25 ± 4
Wiper Motor and Link Rod Assembly Fixing Bolt 7 ± 1.5
04 Wiper Motor Fixing Bolt 8±2

Wiper Motor Fixing Nut 8±2
Guide Pipe Assembly Fixing Bolt 7 ± 1.5
Washer Fluid Reservoir Assembly Fixing Bolt 7 ± 1.5
Rain Gutter Front End Plate Assembly Fixing Bolt 10 ± 1.5
ECM (Engine Control Module) Fixing Bolt 7±1

DOOR LOCK
Specifications

Front Power Door Lock Assembly Fixing Screw 7 ± 1.5
Front Door Key Cylinder Protective Cover Fixing
7 ± 1.5
Screw
Front Door Lock Striker Fixing Screw 7 ± 1.5
04
Rear Power Door Lock Assembly Fixing Screw 7 ± 1.5
Rear Door Lock Striker Fixing Screw 20 ± 2
Luggage Compartment Lock Assembly Fixing Screw 7 ± 1.5
Luggage Compartment Lock Latch Fixing Screw 12 ± 2
Engine Hood Lock Assembly Fixing Nut 7 ± 1.5
Wireless Key Upper Cover Fixing Screw 1.5 ± 0.5

INSTRUMENT CLUSTER
Specification

Instrument Cluster Fixing Screw 2 ± 0.2
04

AUDIO SYSTEM
Specifications

Single Disc CD Player + USB Fixing Screw 8±1
Electrically Modulating Radio Receiver + USB Fixing
8±1
Screw
Front Speaker Fixing Screw 1.5 ± 0.5
04
Rear Speaker Fixing Screw 1.5 ± 0.5
Antenna Assembly Fixing Nut 5±1
Steering Wheel Quick Button Cover Fixing Screw 1.5 ± 0.5
Steering Wheel Quick Button Fixing Screw 1 ± 0.5


Specification

Fixing Bolt Between Reversing Radar Control
7 ± 1.5
Module Assembly and Body
04

HORN
Specification

Horn Fixing Bolt 7 ± 1.5
04

Specifications

Glass Regulating Control Master Switch Assembly
1.5 ± 0.5
Fixing Screw
Front Door Glass Front Guide Rail Fixing Bolt 7 ± 1.5
04 Front Door Glass Rear Guide Rail Fixing Bolt 7 ± 1.5
Rear Door Glass Front Guide Rail Fixing Bolt 7 ± 1.5
Rear Door Glass Rear Guide Rail Fixing Screw 3.5 ± 0.5
Front Door Glass Assembly Fixing Bolt 7 ± 1.5
Rear Door Glass Fixing Bolt 7 ± 1.5
Front Door Power Glass Regulator Fixing Bolt 7 ± 1.5
Rear Door Power Glass Regulator Fixing Bolt 7 ± 1.5
Front Door Glass Outer Weatherstrip Fixing Screw 1.5 ± 0.5
Rear Door Glass Outer Weatherstrip Fixing Screw 1.5 ± 0.5
Blower Speed Switch Fixing Screw 1.5 ± 0.5
Fog Switch Set Fixing Screw 1.5 ± 0.5
Air Spring Hinge Fixing Bolt 7 ± 1.5
Fixing Bolt Between Luggage Compartment Door
7 ± 1.5
Hinge and Rear Windshield Assembly
Luggage Compartment Outside Handle Assembly
7 ± 1.5
Fixing Bolt

REAR VIEW MIRROR

Specification

Outside Rear View Mirror Assembly Fixing Nut 7 ± 1.5
04

INSTRUMENT PANEL
Specifications

Auxiliary Fascia Console Assembly Rear Armrest
9±1
Box Fixing Bolt
04 Box Fixing Screw
2 ± 0.2
Auxiliary Fascia Console Extension Panel Assembly

2 ± 0.2
Fixing Screw
Auxiliary Fascia Console Rear Cover Plate
2 ± 0.2
Assembly Fixing Screw
Auxiliary Fascia Console Rear Storage Box Fixing
2 ± 0.2
Screw
Armrest Box Cover Assembly Fixing Screw 2 ± 0.2
Gearshift Front Cover Plate Fixing Screw 2 ± 0.2
Instrument Panel Left Lower Protector Assembly
2 ± 0.2
Fixing Screw
Single Disc CD Player/Electrically Modulating Radio
8±1
Receiver + USB Fixing Screw
A/C Control Panel Fixing Screw 1.5 ± 0.5
Instrument Panel Upper Body Assembly Fixing
2 ± 0.2
Screw
Instrument Panel Upper Body Assembly Fixing Bolt 9±1
Instrument Panel Lower Body Assembly Fixing Bolt 9±1
Instrument Panel Lower Body Assembly Fixing Nut 7±1
Outlet Assembly Fixing Screw 2 ± 0.2
Instrument Panel Storage Box Fixing Screw 2 ± 0.2
Glove Box Lock Fixing Screw 2 ± 0.2
Instrument Panel Front Storage Box Fixing Screw 2 ± 0.2
Center Main Duct Cover Plate Fixing Screw 2 ± 0.2
A/C Duct Assembly Fixing Screw 2 ± 0.2
Glove Box Upper Trim Board Fixing Screw 2 ± 0.2
Glove Box Holder Fixing Screw 2 ± 0.2
Diagnostic Interface Fixing Screw 2 ± 0.2
Body Control Module Fixing Bolt 7±1
Instrument Panel Fuse and Relay Box Fixing Bolt 7±1
Front Passenger Airbag Fixing Bolt 10 ± 1.5
Steering Column Fixing Bolt 25 ± 3


Steering Column Fixing Nut 25 ± 3
Instrument Panel Crossmember Assembly Fixing
25 ± 4
Bolt
04

SEAT
Specifications

Front Seat Assembly Fixing Bolt 25 ± 4
Front Seat Belt Buckle Assembly 50 ± 5
04 Seat Inner Shield Fixing Screw 2 ± 0.2

Seat Outer Shield Fixing Screw 2 ± 0.2
Coupling Bolt Between Seatback Assembly and Left
40
Side of Seat Cushion Assembly
Coupling Bolt Between Seatback Assembly and
27
Right Side of Seat Cushion Assembly
Rear Seatback Assembly Fixing Bolt 25 ± 4
Rear Seatback Lock Fixing Bolt 27
Rear Seat Cushion Support Fixing Bolt 25 ± 4
Rear Seatback Support Fixing Bolt 25 ± 4

ENGINE HOOD/DOOR
Specifications

Fixing Bolt Between Hood and Hood Hinge 32 ± 3
Fixing Bolt Between Hood Hinge and Front Fender 10 ± 1
Fixing Bolt Between Hood Hinge and Body 32 ± 3 04
Fixing Bolt Between Front Door Hinge Assembly and
32 ± 3
Door
32 ± 3
Body
Fixing Bolt Between Rear Door Hinge Assembly and
32 ± 3
Door
32 ± 3
Body
Front Speaker Bracket Fixing Screw 1.5 ± 0.5
Hood Lock Assembly Fixing Nut 7 ± 1.5
Front Door Protector Bracket Fixing Screw 1.5 ± 0.5
Rear Door Protector Bracket Fixing Screw 1.5 ± 0.5
Front Door Key Cylinder Protection Cover Fixing
7 ± 0.7
Screw
Fixing Screw of Rear Door Protective Cover Without
7 ± 0.7
Key Cylinder
Front Door Outside Handle Base Assembly Fixing
7 ± 0.7
Screw
Rear Door Outside Handle Base Assembly Fixing
7 ± 0.7
Screw
Front Door Lock Striker Fixing Screw 20 ± 2
Luggage Compartment Lock Cylinder Fixing Screw 12 ± 2
Front Door Inner Triangular Block Assembly Fixing
1.5 ± 0.5
Screw
Front Door Inside Handle Assembly Fixing Screw 1.5 ± 0.5
Rear Door Inside Handle Assembly Fixing Screw 1.5 ± 0.5
Front Door Inner Protector Assembly Fixing Screw 1.5 ± 0.5
Fixing Bolt Between Front Door Check Assembly
10 ± 2
and Door
22 ± 3.5
and Body
Fixing Bolt Between Rear Door Check Assembly and
10 ± 2
Door


22 ± 3.5
Body
Assembly and Luggage Compartment Door Hinge 10 ± 1.5
Assembly
10 ± 1.5
Hinge Assembly and Body
04

EXTERIOR
Specifications

Front Wheel House Protector Assembly Fixing
2.5 ± 0.5
Screw
Front Bumper Assembly Lower Fixing Screw 5±1
Front Bumper Assembly Upper Fixing Bolt 10 ± 2
04
Radiator Grille Fixing Screw 5
Intake Grille Fixing Screw 5
Front Fog Light Assembly Fixing Screw 2±1
Front Bumper Mounting Bracket Assembly Fixing
10 ± 2
Bolt
Rear Bumper Bracket Assembly Fixing Bolt 10
Oil Filler Cap Assembly Fixing Bolt 10 ± 1.5
Front Bumper Crossmember Assembly Fixing Bolt 7±1
Front Bumper Crossmember Assembly Fixing Nut 30 ± 4.5
Rear Bumper Anti-collision Crossmember Assembly
23 ± 2
Fixing Nut
Lower Deflector Fixing Screw 7 ± 1.5
Lower Deflector Fixing Screw 2.5 ± 0.5
Fender Fixing Bolt 10 ± 1
Rear Bumper Assembly Fixing Screw 1.5 ± 0.5
Rear Wheel Rear Fender Apron Fixing Screw 2.5 ± 0.5
Rear Wheel Rear Fender Apron Fixing Screw 10 ± 1.5
Camera Fixing Screw 2±1
Front Windshield Lower Garnish Assembly Fixing
5±1
Bolt
Rear Towing Hook Assembly Fixing Bolt 45 ± 7

INTERIOR
Specifications

Sun Visor Assembly Fixing Screw 3 ± 0.5
Sun Visor Holder B Fixing Screw 3 ± 0.5
04 Passenger Grip Assembly Fixing Screw 5±1

Interior Front Dome Light Assembly Fixing Screw 2±1
A-pillar Upper Protector Assembly Fixing Screw 5±1
B-pillar Upper Protector Assembly Fixing Screw 5±1
C-pillar Upper Protector Assembly Fixing Screw 5±1
Fuel Tank Opening Bracket Assembly Fixing Bolt 10 ± 1.5

MAINTENANCE
MAINTENANCE ITEMS 05-3 INSPECTION ITEMS 05-8
Maintenance Schedule Table 05-3 Off-vehicle Inspection 05-8
On-vehicle Inspection 05-9
REPLACEMENT INSTRUCTION 05-6
Engine Inspection 05-11
ADJUSTMENT ITEM 05-7 Brake System Inspection 05-12
Power Steering System Inspection 05-13
Chassis Inspection 05-14
05

05

05 - MAINTENANCE
MAINTENANCE ITEMS
MAINTENANCE
Maintenance Schedule Table

The maintenance schedule table lists the vehicle maintenance items required to be performed. Please take
your vehicle to a Chery authorized service station for maintenance service according to the mileage specified
in the maintenance schedule table.
Maintenance Schedule Table (Note: I = Inspect, adjust and replace as necessary; R = Replace; C = Clean; 
L = Lubricate)
Mileages
Maintenance Items
Every 5000 km Every 15000 km Every 30000 km
Lights, hazard lights, horn: Check operation. I I I 05
Windshield wiper and washer system: Check
I I
operation and add washer fluid if necessary.
Check clutch free travel: Adjust if necessary. I I
Cooling system: Check coolant level and lines. Add
I I I
coolant if necessary.
Engine oil: Replace R R R
Engine oil filter: Replace R R R
Engine: Check for fluid leakage (engine oil, coolant,
I I I
fuel, etc.).
Air conditioning system: Check for air conditioning
line leakage and contaminated filter element. Add I I I
refrigerant and replace filter element if necessary.
Hood hinges and lock: Lubricate L L L
Door hinges and door locks: Lubricate L L L
Window glass regulator: Check that regulator
I I I
works properly. Adjust or replace if necessary.
Air filter: Clean cover and filter element. Replace if
R R R
necessary.
Spark plugs: Check spark plugs. Replace if
I I
necessary.
Fuel filter: Replace R R
Exhaust system: Check for air leakage and
I I
damage.
Drive belt: Check tension. Adjust or replace if
I I
necessary.
Transmission: Check for fluid leakage and damage. I I
Constant velocity universal joint boot: Check for
I I
damage of boot.
Steering tie rod end: Check for proper clearance
I I I
and boot damage.
Steering universal joint assembly boot: Check for
I I
misalignment or damage.

05 - MAINTENANCE
Mileages
Maintenance Items
Every 5000 km Every 15000 km Every 30000 km
Power steering system: Check power steering fluid
level and whether clearance between steering gear I I
and rack is proper.
Brake system: Check brake fluid level and system
I I I
for leakage and damage.
Parking brake: Check stroke. Adjust if necessary. I I I
Brake lining: Check thickness of brake lining.
I I I
Replace if necessary.
Underbody protection layer: Visually check
05 protection layer for damage.
I
Seat belt: Check seat belts for damage. I I

Toe-in and camber: Check and adjust if necessary. I I
Ball pin: Check clearance of ball pin. I I
Rear axle rubber bush: Check for damage. I I
Engine oil pan set bolts: Check bolts for looseness.
I
Tighten bolts to specified torque if necessary.
Control arm rubber boot: Check for damage. I I
Brake hoses: Check for aging or damage. I I
Brake pipes: Check for damage, corrosion and
I I
check each connection for leakage.
Fuel system connections: Check each connection
for aging, damage, abnormal looseness or I
abrasion.
Tires (including spare tire): Check tire tread depth
and torque of wheel bolts. Adjust tire inflation I I I
pressure if necessary.
Coupling bolts between chassis and vehicle body:
Check torque of bolts. Tighten bolts to specified I I
torque if necessary.
Wheels: Check torque. I I I
Inspection while engine idling: Check if engine
working condition, electronic injection parameter I I I
and emission are proper while idling.
Test driving: Check if mechanisms function
I I I
properly.
HINT:
 It is recommended to replace the transmission oil every year or every 40000 km (whichever comes first).
 It is recommended to replace the brake fluid every 2 years or every 40000 km (whichever comes first).
 It is recommended to check the power steering fluid every 5000 km and replace it every 2 years or every
30000 km (whichever comes first).
 It is recommended to check the coolant every 5000 km. Add or replace it if necessary.
 It is recommended to rotate tires every 10000 km.
 It is recommended to check four-wheel alignment every 20000 km and adjust if necessary.
 It is recommended to clean the throttle valve body every 15000 km.

05 - MAINTENANCE
 It is recommended to check the air filter every 5000 km. Clean or replace the filter element if necessary.
 It is recommended to replace the timing belt every 40000 km.
 The battery is maintenance-free.
CAUTION
 Depending on different surrounding environment and road conditions, the replacing intervals may be
shortened.
05

05 - MAINTENANCE
REPLACEMENT INSTRUCTION
Replacement Item See page

Wiper Blade Replacement 34-10
Air Filter Element Replacement 10-10
Fuel Filter Replacement 08-13
Engine Oil Replacement 13-11
Oil Filter Replacement 13-13
Transmission Oil Replacement 17-12
05 Power Steering Fluid Replacement 28-9
Coolant Replacement 12-14
Brake Fluid Replacement 25-13
Electronic Throttle Replacement 10-12
Electronic Throttle Cleaning 10-12
Spark Plug Replacement 14-12

05 - MAINTENANCE
ADJUSTMENT ITEM
Adjustment Item See page

Front Combination Light Adjustment 33-67
05

05 - MAINTENANCE
INSPECTION ITEMS
Off-vehicle Inspection
1. Check the wheel nut.
a. Check the wheel nuts for looseness or missing. Tighten them if necessary.
2. Check the wheel and tire (spare tire included) (See page 23-6).
3. Rotate the tires.
a. Chery recommends you to rotate the tires every 10000 km. However, the best suitable time for tire
rotation differs depending on driver's driving habits and road conditions.
Tire rotation method (See page 23-13).
4. Check the wiper blade (See page 34-10).
05 5. Check the hood and door.
a. Check the hood assembly (See page 45-9).
b. Check the front doors (See page 45-23).
c. Check the rear doors (See page 45-37).
d. Check the luggage compartment door (See page 45-46).

05 - MAINTENANCE
On-vehicle Inspection
1. Check the seat belt.
a. Check the seat belt buckle and retractor.
 Pull out the seat belt quickly and repeatedly when the seat belt is static. If the seat belt retractor
cannot lock the seat belt at one time, replace the seat belt assembly.
 Engage the tab on the seat belt buckle, and pull the seat belt by hand repeatedly to check the
engagement. If the buckle cannot lock the seat belt at one time, replace the seat belt assembly.
WARNING
 When inspecting the vehicle that has been involved in a collision, be sure to check the seat belt system.
If there is any damage or malfunction in the seat belt system, replace it.
05
b. Pull out the seat belt and check the belt for oil stains or damage. Clean or replace it if necessary.
c. Replace the seat belt as soon as possible if any of the following occurs.
 The seat belt is broken, cracked or worn.
RA19050010
 The seat belt webbing is cracked.
RA19050020
 There is burnt mark by cigarette on the seat belt.
RA19050030
2. Check the horn.

a. Check that the horn operates.

05 - MAINTENANCE
3. Check the vehicle lights.

a. Check that the headlights, brake lights, taillights, turn signal lights and other vehicle lights illuminate or
blink. Furthermore, check the brightness of vehicle lights.
4. Check the windshield.
a. Check for scratch, dent or wear.
5. Check the windshield wiper and washer.
a. Check that the washers are aimed properly. Also, check that the washer fluid hits the center of the
operating range of each wiper on the windshield.
b. Check the wiper blades for cracks. Replace the wiper blades if necessary (See page 34-10).
6. Check the windshield defroster.
a. When the air conditioning defroster mode switch is pressed, check that the air comes out of the
defroster outlets.
05 b. Press the rear defroster switch for a period of time, then check that the rear windshield heats.
WARNING
 DO NOT touch the heated rear windshield for a long time to prevent burns.
7. Check the rear view mirror.

a. Check that the rear view mirrors are securely installed.
8. Check the sun visor.
a. Check that the sun visors are securely installed and move freely.
9. Check the seat.
a. Check the front seat assembly (See page 44-7).
b. Check the rear seat assembly (See page 44-14).
10.Check the clutch pedal (See page 18-9).
11. Check the accelerator pedal.
a. Check that the accelerator pedal operates smoothly. Check that the pedal does not have uneven
resistance or stick in certain position.

05 - MAINTENANCE
Engine Inspection
1. Check the engine oil level (See page 13-9).
2. Check the engine drive belt (See page 07-21).
3. Check the engine for oil leakage.
a. Turn off all the electrical equipment and ignition switch, and remove the key.
b. Support and raise the vehicle.
c. Check the crankshaft pulley for oil stains. If there are oil stains, check the crankshaft front oil seal for
leakage. If there are leaks, replace the crankshaft front oil seal.
d. Check the oil pan and drain plug for oil stains. Repair or replace the related parts if necessary.
e. Check the transmission filler plug, drain plug and case for oil stains. Repair or replace the related parts
if necessary.
f. If the crankshaft front oil seal leaks after repair, it may be caused by the following 3 reasons:
05
 Crankshaft thrust washer wear
 Crankcase ventilation system blockage
 Excessive engine oil
4. Check the battery.
a. Check the battery and battery voltage (See page 16-7).
b. Check the charging voltage of charging system (See page 16-6).
5. Check the cooling system hose.
a. Check that there are no cracks, bent, corrosion or loose connections on the cooling system hose.

05 - MAINTENANCE
Brake System Inspection

1. Check the brake fluid level.
CAUTION
 Generally, the brake fluid level will change slightly because of the wear of brake pad, but it must be kept
between "MIN" and "MAX" lines.
a. Park the vehicle on a level ground.

b. Make sure that there is no air in the brake system and the depressing feel of brake pedal is well.
Perform brake bleeding procedures if necessary (See page 25-12).
c. Check if the brake fluid level is between "MAX" and
05 "MIN" lines.
d. If the brake fluid level drops to the "MIN" line or below,
add brake fluid and check the brake system for MAX
leakage. MIN
RA19250050
HINT:
 When the brake fluid level drops close to the "MIN" line, the wear of brake pad may approach its
limit.
 After the brake pad is replaced, the brake fluid level should be at the upper limit between MAX and
"MIN" lines.
2. Check the brake pedal assembly (See page 25-22).
3. Check the brake lines and hoses.
HINT:
Work in a well-lighted area. Turn the front wheels fully to the right or left before beginning the inspection.
a. As shown in the illustration, check the entire
circumferential surface of the brake lines and hoses
with a mirror. Check for the following conditions:
 Damage
 Wear
 Deformation
 Crack
 Corrosion
 Leakage RA19050040
 Bent
 Twists
b. Check all the clamps for tightness and check the connections for leakage.
c. Check that the hoses and lines are not near sharp edges, moving parts or the exhaust system.
4. Check the parking brake.
a. Check that the parking brake can stop the vehicle steadily on a slight grade.
5. Check the front disc brake assembly (See page 25-26).
6. Check the rear drum brake assembly (See page 25-39).

05 - MAINTENANCE
Power Steering System Inspection

1. Check the steering wheel free play (See page 27-7).
2. Check the steering wheel centering/returnability (See page 27-8).
3. Check the power steering fluid level.
a. Park the vehicle on a level ground.
b. Start the engine. With the engine running, turn the steering wheel left or right to the maximum stroke
and repeat the operation several times.
c. Check if the fluid in the steering fluid reservoir is foamed or emulsified. Perform bleeding procedures if
necessary.
d. If the fluid is normal, check if the steering fluid level is between "MIN" and "MAX" lines.
e. If the fluid level is above the "MAX" line, drain the
excessive steering fluid. If the fluid level is below the
"MIN" line, add steering fluid to the proper level, and 05
check the power steering system for leakage.
MAX
COLD
MIN
RA19280030
4. Remove the ball pin assembly (See page 28-20).

5. Check the steering tie rod assembly and tie rod boot (See page 28-22).
6. Check the power steering system for leakage.
CAUTION
 Generally, the leakage of power steering system commonly occurs on the high pressure line.
a. Turn off all the electrical equipment and ignition switch, and remove the key.
b. Support and raise the vehicle.
c. Check the power steering system.
If power steering fluid is found on the steering system lines or other components, check the steering
system for leakage. Replace the related parts if necessary.
Components to be checked mainly include:
 Power steering pump assembly
 Steering fluid reservoir assembly
 Steering gear assembly
 Steering gear high pressure line
 Steering gear return line
 Steering gear suction line

05 - MAINTENANCE
Chassis Inspection
1. Check the front axle hub (See page 21-15).
2. Check the control arm and control arm ball pin (See page 21-10).
3. Check the rear axle hub (See page 21-19).
4. Check the stabilizer bar assembly and stabilizer bar assembly rubber support and bush (See page 22-25).
5. Check the rear coil spring (See page 22-38).
6. Check the rear shaft support rod assembly.
7. Check the rear trailing arm assembly.
8. Check the exhaust pipe.
a. Visually check the pipes, hanger blocks and connections for corrosion, leakage or damage.
05

GENERAL INFORMATION 06-3 P0202-13 06-78
Description 06-3 P0264-11 06-78
System Function 06-4 P0265-12 06-78
Precautions 06-5 P0203-13 06-84
Specifications 06-6 P0267-11 06-84
Tools 06-6 P0268-12 06-84
ECM Pin Definition 06-8 P0204-13 06-90
Circuit Diagram 06-10 P0270-11 06-90
P0271-12 06-90
DIAGNOSIS & TESTING 06-18
P0221-29 06-96
Diagnostic Help 06-18
P0222-16 06-96
Intermittent DTC Troubleshooting 06-18
P0223-17 06-96 06
Ground Inspection 06-18
P0300-21 06-102
Throttle Self-learning 06-19
P0300-22 06-102
Diagnostic Trouble Code (DTC) 
P0300-29 06-102
Chart 06-19
P0301-21 06-102
P0030-13 06-23
P0301-22 06-102
P0031-11 06-23
P0301-29 06-102
P0032-12 06-23
P0302-21 06-102
P0053-1E 06-23
P0302-22 06-102
P0036-13 06-30
P0302-29 06-102
P0037-11 06-30
P0303-21 06-102
P0038-12 06-30
P0303-22 06-102
P0054-1E 06-30
P0303-29 06-102
P0105-28 06-37
P0304-21 06-102
P0106-00 06-37
P0304-22 06-102
P0107-11 06-37
P0304-29 06-102
P0108-12 06-37
P0322-00 06-110
P0112-16 06-44
P0327-16 06-115
P0113-17 06-44
P0328-17 06-115
P0116-00 06-49
P0341-00 06-120
P0117-16 06-49
P0420-00 06-126
P0118-17 06-49
P0444-13 06-128
P0121-29 06-54
P0458-16 06-128
P0122-16 06-54
P0459-17 06-128
P0123-17 06-54
P0480-13 06-135
P0130-00 06-60
P0481-13 06-135
P0131-16 06-60
P0691-11 06-135
P0132-17 06-60
P0692-12 06-135
P0134-00 06-60
P0693-11 06-135
P0136-00 06-66
P0694-12 06-135
P0137-16 06-66
P0560-00 06-141
P0138-17 06-66
P0562-16 06-141
P0140-00 06-66
P0563-17 06-141
P0201-13 06-72
P0627-13 06-148
P0261-11 06-72
P0628-11 06-148
P0262-12 06-72

P0629-12 06-148 Installation 06-202
P0645-13 06-153 Intake Pressure/Temperature 
P0646-11 06-153 Sensor 06-203
P0647-12 06-153 Description 06-203
P0688-91 06-158 Operation 06-203
P0688-92 06-158 Removal 06-203
Engine Problem Symptom  Installation 06-203
Diagnosis 06-163 Ignition Coil 06-204
Description 06-204
ON-VEHICLE SERVICE 06-196
Operation 06-204
Coolant Temperature Sensor 06-196
Removal 06-204
Description 06-196
Installation 06-204
Operation 06-196
Electric Fuel Pump 06-205
Removal 06-196
Description 06-205
Installation 06-197
06 Knock Sensor 06-198
Operation 06-205
Removal 06-205
Description 06-198
Installation 06-205
Operation 06-198
Fuel Injector 06-206
Removal 06-198
Description 06-206
Installation 06-199
Operation 06-206
Oxygen Sensor 06-200
Removal 06-206
Description 06-200
Installation 06-206
Operation 06-200
Electric Throttle Assembly 06-207
Upstream Oxygen Sensor 06-200
Description 06-207
Downstream Oxygen Sensor 06-200
Operation 06-207
Removal & Installation - 
Removal 06-207
Upstream Oxygen Sensor 06-200
Installation 06-207
Removal & Installation - 
Downstream Oxygen Sensor 06-200 Canister Solenoid Valve 06-208
Camshaft Position Sensor 06-201 Description 06-208
Description 06-201 Operation 06-208
Operation 06-201 Removal 06-208
Removal 06-201 Installation 06-208
Installation 06-201 Engine Control Module (ECM) 06-209
Engine Speed Sensor 06-202 Description 06-209
Description 06-202 Operation 06-209

06 - SQR477F ENGINE MANAGEMENT SYSTEM
GENERAL INFORMATION
Description
The engine of A19 model adopts UAES engine management system. This system mainly consists Engine
Control Module (ECM), sensors and actuators, which controls intake air amount, injection volume and ignition
timing, etc. when the engine is operating.
In the engine management system, the sensors are used as the input part to measure the various physical
signals (temperature and pressure, etc.), and converts them into corresponding electrical signals; the function
of ECM is to receive the input signals from the sensors and perform calculation according to the set
procedure, producing corresponding control signals and outputting them to the power drive circuit. The power
drive circuit drives each actuator to perform various actions, thus making the engine run according to the
preset program.
Also, the trouble diagnosis system of ECM monitors each component and control function in the system.
Once detecting and confirming a fault, it will store the trouble code and recall the "Limp Home" function. When
detecting that the fault has been eliminated, it will return to use the normal value. 06
Basic Components of Engine Management System
10
4
13
2 11
7
9 7
6
5
12
RA19060010

1 - Engine Control Module (ECM) 2 - Intake Pressure/Temperature Sensor

3 - Electronic Throttle 4 - Camshaft Position Sensor
5 - Coolant Temperature Sensor 6 - Crankshaft Position Sensor
7 - Oxygen Sensor 8 - Accelerator Pedal Position Sensor
9 - Knock Sensor 10 - Ignition Coil
11 - Fuel Injector 12 - Electric Fuel Pump
13 - Canister Solenoid Valve
System Function
 Calculate air flow by engine aerothermodynamics
ECM calculates the air flow entering the cylinder by the signals from intake pressure/temperature sensor,
06 and then adjusts the injection volume to make the air-fuel ratio meet the requirements of various operating
conditions.
 Measure crankshaft position and engine speed
ECM determines the crankshaft position and engine speed according to the signals from ring gear and
accurately controls the engine ignition and injection timing.
 Determine operating sequence of cylinders
ECM recognizes the top dead center of No.1 cylinder by the camshaft position sensor, so as to determine
the operating sequence of cylinders.
 Fuel control
There are two modes of fuel control: closed-loop fuel control and open-loop fuel control. The closed-loop
fuel control can accurately regulate the air-fuel ratio of engine, thus effectively controlling emissions. The
open-loop fuel control is applied when the engine is starting or warming up and the oxygen sensor is
malfunctioning.
 Ignition control
The ignition control system of engine adopts sequential control.
 Knock control
When a knocking is detected by the knock sensor, the system will calculate the ignition advance angle that
needs to be delayed or advanced according to current operating conditions and knock intensity and
adjusts the ignition angle, thus avoiding or reducing knocking.
 Emission control
The three-way catalytic converter can convert the engine exhaust gas into harmless gas and discharge it
into the atmosphere. When the engine temperature becomes normal after warming up, ECM will activate
the closed-loop fuel control to correct the air-fuel ratio, thus realizing the optimum conversion efficiency of
three-way catalytic converter.
 Three-way catalytic converter protection
The engine management system has the function to protect the three-way catalytic converter. The ECM
estimates the three-way catalytic converter temperature according to engine operating conditions. When it
is estimated that the exhaust temperature will exceed the converter's maximum permissible temperature
for a long time, ECM will automatically activate the protection function of three-way catalytic converter to
keep the temperature normal.
 System voltage protection
When the system voltage becomes extremely high due to the charging system malfunction, the engine
management system will activate the protection program to limit the engine speed, thus avoiding damage
to ECM and battery.

Precautions
General service requirements
 Only digital multimeter can be used to perform inspection for the engine management system.
 Use genuine components to perform service work, otherwise, the appropriate engine management system
operation cannot be guaranteed.
 Only use unleaded gasoline during servicing.
 Please observe normative service and diagnostic flowchart to perform service work.
 Never disassemble the components of engine management system during servicing.
 When holding electronic elements (ECM, sensor, etc.) during servicing, take extra care not to drop them on
the ground.
 Set up a consciousness of environmental protection and dispose of the waste effectively that is produced
during servicing.
Precautions during servicing 06

1. Do not causally remove any component or its connector of engine management system from its installation
position to prevent damage accidentally, or the foreign matter, such as moisture, oil from entering the
connector, which will affect the normal operation of engine management system.
2. Be sure to turn the ignition switch off when disconnecting and connecting the connector. Otherwise,
electronic elements may be damaged.
3. When simulating the hot operating condition of malfunction and performing other service work that may
cause the temperature to rise, never allow ECM temperature to exceed 80°C.
4. As the supplying pressure of fuel system is high (approximately 400 kPa), all the fuel pipes are high
pressure resistant pipe. The fuel pressure in the fuel lines is still high even when the engine is not running.
Therefore, be careful not to casually remove the fuel pipe during servicing; when it is necessary to service
the fuel system, discharge the pressure in the fuel system before removing the fuel pipe. The way to
discharge the pressure is as follows:
Remove the fuel pump relay, start the engine and idle it until the engine stops running by itself. Then
attempt to start the engine 2 - 3 times to ensure the fuel pressure is discharged completely. The removal of
fuel pipe and replacement of fuel filter should be performed in a well-ventilated area by professional
service men.
5. Do not energize the electric fuel pump when removing it from the fuel tank to prevent electric sparks, which
will cause a fire.
6. Running test for the fuel pump is prohibited when it is empty or in the water; otherwise, it will shorten the
service life. Never connect the positive and negative of fuel pump in reverse.
7. When checking the ignition system, only perform the spark jump test when it is necessary and the time
should be shortened as much as possible. Do not open the throttle during test; otherwise, a large amount
of unburned gasoline will enter the exhaust pipe, causing damage to the three-way catalytic converter.
8. As the idling adjustment is performed by the engine management system completely, the manual
adjustment is not required. The accelerator pedal stopper screw of throttle body has been adjusted at the
factory, and the user is not allowed to change its original position.
9. Do not connect the battery with its polarity reversed to prevent damage to electronic elements. This system
adopts negative ground.
10.Never remove the battery cable when the engine is running.
11. The positive, negative battery cables and ECM must be removed before performing welding on the
vehicle.
12.Do not puncture the wire outer coat to detect the electric signals input and output by the components.

Specifications

Knock Sensor Mounting Bolt 17 - 23
Oxygen Sensor 45 ± 5
Crankshaft Position Sensor Mounting Bolt 8±2
Camshaft Position Sensor Mounting Bolt 10 ± 2
Accelerator Pedal Mounting Bolt 10 ± 2
Intake Pressure/Temperature Sensor Mounting Bolt 8±1
06 Engine Control Module Mounting Bolt 7±1
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tools
Fuel Injector Cleaning Analyzer
RCH0000062
Ignition Timing Light
RCH0000016

Digital Multimeter
RCH0000002
6
4
60 80
100
40
8
2
120
20
140
0
10
0
Vacuum Gauge
06
RCH0000036
RCH0000044
Fuel Pressure Gauge
RCH0000048
Oscilloscope YES ENTER
ESC
NO
1 2 3 4 5
6 7 8 9 0
RCH0000061

ECM Pin Definition

Pin No. Definition Pin No. Definition
1 CAN Bus Line High 33 -
2 - 34 -
3 - 35 Ignition Switch
5 V Power Supply of Accelerator
4 - 36
Pedal Position Sensor 2
5 V Power Supply of Accelerator
5 Main Relay 37
Pedal Position Sensor 1
6 Clutch Switch 38 -
Accelerator Pedal Position Sensor 1
06 7
Ground
39 -
8 - 40 -
9 - 41 Fuel Pump Relay
10 - 42 A/C Compressor Relay
11 - 43 Oxygen Sensor Ground
12 - 44 -
13 KL50 State 45 Accelerator Pedal Position Sensor 1
14 Power Steering Pump Switch 46 -
15 Noncontinuous Power Supply 47 -
16 Noncontinuous Power Supply 48 Downstream Oxygen Sensor Heater
17 CAN Bus Line Low 49 -
18 - 50 -
19 - 51 -
20 Continuous Power Supply 52 -
21 Downstream Oxygen Sensor 53 -
22 - 54 -
23 Brake Switch 55 -
A/C Compressor Medium Pressure
24 56 Fan Control 1
Switch
25 Brake Light Switch 57 -
26 - 58 Starting Control Relay
Accelerator Pedal Position Sensor 2
27 - 59
Ground
28 A/C Switch 60 -
29 - 61 -
30 Accelerator Pedal Position Sensor 2 62 -
31 Fan Control 2 63 ECU Ground 2
32 - 64 ECU Ground 1

Pin No. Definition Pin No. Definition

65 - 89 Knock Sensor B
66 - 90 Knock Sensor A
67 Fuel Injector 2 91 Intake Pressure Sensor
68 Fuel Injector 1 92 -
69 - 93 Camshaft Position Sensor
70 - 94 Canister Control Valve
71 - 95 Camshaft Position Sensor Ground
72 Fuel Injector 3 96 Crankshaft Position Sensor A
73 Upstream Oxygen Sensor Heater 97 Crankshaft Position Sensor B
74 Fuel Injector 4 98 5 V Power Supply 1
06
75 Throttle Actuator 99 Ignition Coil Drive 2
76 - 100 Ignition Coil Drive 1
77 Throttle Position Sensor 1 101 Coolant Temperature Sensor
78 Throttle Position Sensor 2 102 Intake Temperature Sensor
79 - 103 -
80 Oxygen Sensor Ground 104 Upstream Oxygen Sensor
81 - 105 -
82 - 106 -
83 - 107 Throttle 5 V Power Supply
84 Coolant Temperature Sensor Ground 108 -
85 Intake Manifold Ground 109 Intake Manifold 5 V Power Supply
86 Throttle Ground 110 -
87 Throttle Actuator 111 ECU Ground 4
88 - 112 ECU Ground 3

Circuit Diagram
SQR477F Engine Management System (Page 1 of 8)
BATTERY
EF35
10A 86 30
ECM
MAIN
RELAY
ENGINE
85 87 COMPARTMENT
B FUSE AND
06 RELAY BOX
EF17 EF15 B-012
15A 15A B-013
C1 C17 D6 D5 C4
RL
R
B-020
11 14
E-012
R
RL
R
1 4 1 4
DOWNSTREAM UPSTREAM
OXYGEN OXYGEN
RB
YV
R
SENSOR SENSOR
E-008 E-006
2 3 2 3
RG
BR
YB
RW
PW
E-012
BY
6 5 15
B-020
RG
BR
YB
20 5 15 16 43 21 48 80 104 73
ECM
B-001
E-001
C1 C2 C3 C4 C5 C6 C7 D1 D2 D3 D4 D5 D6 D7 D8 1 2 3 4 5 6 7 8
C11 C12 C13 C14 D13 D14 D15 D16
C8 C9 C10 C15 C16 C17 C18 D9 D10 D11D12 D17 D18 D19 D20 16 15 14 13 12 11 10 9
B-013 B-012
W W B-020
B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 1 2 3 4
112 111 110 109 108 107 106 105 104 103 102 101
E-006 E-008
B-001 B B
E-001
B B
EA19060010

A A
ENGINE
B B COMPARTMENT
FUSE AND
RELAY BOX
EF16 EF20
B-013
15A 10A
B-017
H4 C6 06
RB
B-020
16 9
E-012
RB
R
RB
RB
RG
RG
RG
RG
CYL1 CYL4 CYL3 CYL2
3 4 1 1 1 1
IGNITION
COIL
E-010
1 2 2 INJECTOR 1 2 INJECTOR 2 2 INJECTOR 3 2 INJECTOR 4
E-004 E-020 E-017 E-016
GrG
GBr
GW
GrL
GY
GB
100 99 68 67 72 74
ECM
E-001
C1 C2 C3 C4 C5 C6 C7 H1 H2 H3 H4 H5 H6 H7
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18 H8 H9 H10 H11H12H13H14 1 2
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77 B-013 B-017 E-004 E-017

W W B B
100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101 E-016 E-020
B B
B-020 E-010
1 2 3 4 5 6 7 8
B 1 2 3 4 B
E-001 16 15 14 13 12 11 10 9
B
EA19060020

A A
B B
EF18 EF23 EF22

10A 30A 40A
ENGINE
C COMPARTMENT
30 86 30 86 FUSE AND
RELAY BOX
LOW FAN HIGH FAN
RELAY B-013
RELAY
B-017
87 85 87 85 E-039
H6 B11 C15 B9 C9
06
R
B-020
BrG
VR
12
R
E-012
L
1 2
R
COOLING COOLING
1 FAN 1 FAN 2
CANISTER
SOLENOID E-031 E-032
VALVE
E-018
2 3 3
M M
2 1
R
R
B
B
WG
E-036
94 56 31
ECM
B-001
E-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
3 2
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101
E-031
B
B-001 E-001
B B
1
E-039 B-017
B1 B2 B3 B4 B5 W H1 H2 H3 H4 H5 H6 H7 W
B8 B9 B10 B11 2 3
B6 B7 B12 B13 B14 H8 H9 H10 H11H12H13H14 1 2
E-018 E-032
B B
1 2 3 4 5 6 7 8
C1 C2 C3 C4 C5 C6 C7 B-013 B-020
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18 W 16 15 14 13 12 11 10 9 B
EA19060030

EF21 EF22 EF05 EF13

15A 40A 40A 30A ENGINE
COMPARTMENT
C FUSE AND
RELAY BOX
30 86 30 86 30 86
FUEL B-010
A/C STARTER
PUMP CLUTCH RELAY B-012
RELAY RELAY B-013
87 85 87 85 87 85 B-014
A15 C5 D14 C16 E3 D13 C3 A8

06
R
RB
R
R
B-008 B-021 8 B-020
1
WL
YG
E-038 1 I-047 E-012
R
RG
R
R
5 E
1
FUEL LEVEL A/C
R
SENSOR AND PRESSURE
FUEL PUMP M SWITCH 1
STARTER
B-027 E-027 SOLENOID
1 2 SWITCH
E-012
B
B-035
E-026
41 42 58
ECM
B-001
D1 D2 D3 D4 D5 D6 D7 D8 A1 A2 A3 A4 A5 A6
D13 D14 D15 D16 A10 A11 A12 A13
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 D9 D10 D11D12 D17 D18 D19 D20 A7 A8 A9 A14 A15 A16
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B-012 B-014
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
W W
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C1 C2 C3 C4 C5 C6 C7
B-001 C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18 E4 E3 E2 E1
B
B-013
W B-010
W
1 2 3 4 5 6 7 8
1 2 3 4
1
16 15 14 13 12 11 10 9 5 6 7 8 1 2
1 2 3 4 5
B-020 B-008 B-021 B-027 E-027 E-011

B B W B B B
EA19060040

IGNITION SWITCH IGNITION SWITCH

START ON OR START
INSTRUMENT
PANEL FUSE
RF24 RF21 RF01 RF04 AND RELAY
10A 10A 10A 10A BOX
I-005
24 22 21 1 4
RB
I-004
06 33
RW
RW
B-053
R
E
1 4
BRAKE STOP
SWITCH BRAKE
LAMP
SWITCH
SWITCH
DEP- I-044
RESSED RELEASED
3 2
RB
BR
RY
I-003
35 33 34
B-050
BrW
RW
BR
13 25 23 35
ECM
B-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 13 14 15 16 17 18 19 20 21 22 23 24 4
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 25 26
87 3 1
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
85 86 86 86
85
87 30
85
87 30 2
30
B-001 I-005 I-044

B B Lg
29 30 31 32 33 34 35 36 37 38 39 40 41 42 29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003 I-004
W L
EA19060050

TO HVAC
CONTROL
CAMSHAFT POSITION PANEL
SENSOR
E-009 THROTTLE POSITION SENSOR
3 1
E-015
(HIGH)
A/C
(MID) HIGH/LOW
M
OPEN CLOSE PRESSURE
CLOSE (LOW) SWITCH
06
OPEN
B-004
1 2 3 1 4 2 5 3 6
OPEN CLOSE
4 2
RGr
RBr
BW
GR
LW
RB
RY
RL
LR
BL
Gr
95 93 98 87 75 86 78 107 77 24 28
ECM
B-001
E-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101
B-001 E-001
B B
1 2 3
4 5 6 2 1
1 2 3 4 3
E-009 E-015 B-004

B B B EA19060060

ECM
B-001
E-001
109 91 102 85 101 84 6 14
BBr
06
B-008
BGr
BW
LW
14
LG
YB
LR
LB
E-038
BBr
3 4 2 1 1 2 1 1
POWER
CLUTCH STEERING
ON SWITCH CLOSE PUMP
COOLANT B-054 SWITCH
OFF OPEN E-029
TEMPERATURE
SENSOR 2
INTAKE PRESSURE/TEMPERATURE E-014
SENSOR
B
E-019
B-023
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89 1 2
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101
E-014
B
B-001 E-001
B B
4 3 2 1 1 2 3 4 5 6 7 8
1 2 1
16 15 14 13 12 11 10 9
B-054 E-029
E-019 B G
B B-008
B EA19060070

ECM
B-001
E-001
45 37 7 30 36 59 96 97 90 89 63 64 111 112 17 1
G
06
Y
TO CAN
SYSTEM
WR
YW
GY
LW
RB
YR
YR
YB
Br
B
B
B
3 2 4 6 1 5 1 2 1 2
B-003 E-002
S
N KNOCK
ELECTRONIC SENSOR
ACCELERATOR PEDAL ENGINE E-003
B-058 SPEED
SENSOR
E-013
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101
B-001 E-001
B B
6 5 4 3 2 1 1 2 3
B-058 E-003 E-013

B B B
EA19060080

DIAGNOSIS & TESTING

Diagnostic Help
1. Connect the X-431 3G Diagnostic tester (the latest software) to the Data Link Connector (DLC), and make
it communicate with the vehicle electronic module by the data network.
2. Confirm that the malfunction is current, and carry out the diagnostic test and repair procedures.
3. If the DTC cannot be deleted, the malfunction is current.
4. Only use a digital multimeter to measure the voltage of electronic system.
5. Refer to any Technical Bulletin that may apply to the malfunction.
6. Visually check the related wire harness.
7. Check and clean all the Engine Control Module (ECM) grounds related to the current DTC.
8. If multiple trouble codes were set, use the circuit diagrams and look for any common ground circuit or
power supply circuit applied to the DTC.
06
Intermittent DTC Troubleshooting
If the malfunction is intermittent, perform the following:
 Check if the connectors are loose.
 Check if the wire harnesses are worn, pierced, pinched or partially broken.
 Monitor the X-431 3G diagnostic tester (the latest software) data that is related to this circuit.
 Wiggle the related wire harnesses and connectors and observe if the signal is interrupted in the related
circuit.
 If possible, try to duplicate the conditions under which the DTC was set.
 Look for the data that has changed or the DTC to reset during the wiggle test.
 Look for broken, bent, protruded or corroded terminals.
 Inspect the sensors and mounting areas for damage, foreign matter, etc. that will cause incorrect signals.
 Use data recorder and/or oscilloscope to help diagnose intermittent malfunctions.
 Remove the Engine Control Module (ECM) from the malfunctioning vehicle and install it on a new car to
perform test. If the DTC cannot be cleared, ECM is malfunctioning. If the DTC can be cleared, reinstall
ECM to the original vehicle.
Ground Inspection
Ground points are very important to the proper operation of circuits. Ground points are often exposed to
moisture, dirt and other corrosive environments. Corrosion (rust) can increase resistance which will change
the way in which a circuit works.
The electrical control circuits are very sensitive to proper grounding. A loose or corroded ground can affect the
control circuit. Perform the following operations when checking the ground points:
1. Remove the ground bolt or screw.
2. Check all the contact surfaces for tarnish, dirt and rust, etc.
3. Clean as necessary to ensure that the contacting is in a good condition.
4. Reinstall the ground bolt or screw securely.
5. Check if the add-on accessories interfere with the ground circuit.
6. If several wire harnesses are crimped into one ground eyelet terminal, check if they are installed correctly.
Make sure all the wire harnesses are clean, securely fastened and well contacted without crimping any
excessive insulation coat.

Throttle Self-learning
Perform the throttle self-learning in the following conditions:
 Battery is removed and negative battery cable is disconnected.
 ECM is replaced.
 ECM is disconnected and reconnected.
 Throttle is replaced or cleaned.
Throttle self-learning conditions:
 Engine intake temperature > 5°C
 100.5°C > coolant temperature > 5°C
 Engine speed not more than 250 rpm
 Vehicle speed = 0
 Battery voltage > 10 V
 Accelerator pedal opening angle < 14.9%
Throttle self-learning procedures:
06
Turn the ignition switch off and then to ON. Wait for 1 minute to finish the throttle self-learning.
Diagnostic Trouble Code (DTC) Chart

DTC Code DTC Definition
P0030-13 HO2S Heater Control Circuit (Upstream of the Catalyzer)
P0031-11 HO2S Heater Control Circuit Low (Upstream of the Catalyzer)
P0032-12 HO2S Heater Control Circuit High (Upstream of the Catalyzer)
P0036-13 HO2S Heater Control Circuit (Downstream of the Catalyzer)
P0037-11 HO2S Heater Control Circuit Low (Downstream of the Catalyzer)
P0038-12 HO2S Heater Control Circuit High (Downstream of the Catalyzer)
P0053-1E Nernst Resistance Sensor Upstream of the Catalyzer Too Large
P0054-1E Nernst Resistance Sensor Downstream of the Catalyzer Too Large
P0105-28 Manifold Absolute Pressure/Barometric Pressure Circuit
P0106-00 Manifold Abs. Pressure or Bar. Pressure Range/Performance
P0107-11 Manifold Abs. Pressure or Bar. Pressure Low Input
P0108-12 Manifold Abs. Pressure or Bar. Pressure High Input
P0112-16 Intake Air Temp. Circ. Low Input
P0113-17 Intake Air Temp. Circ. High Input
P0116-00 Engine Coolant Temp. Circ. Range/Performance
P0117-16 Engine Coolant Temp. Circ. Low Input
P0118-17 Engine Coolant Temp. Circ. High Input
P0121-29 Throttle/Pedal Pos. Sensor A Circ. Range/Performance
P0122-16 Throttle/Pedal Pos. Sensor A Circ. Low Input
P0123-17 Throttle/Pedal Pos. Sensor A Circ. Low Input
P0130-00 O2 Sensor Circ. Malfunction (Upstream of the Catalyzer)
P0131-16 O2 Sensor Circ. Low Voltage (Upstream of the Catalyzer)


P0132-17 O2 Sensor Circ. High Voltage (Upstream of the Catalyzer)
P0133-00 O2 Sensor Circ. Slow Response (Upstream of the Catalyzer)
P0134-00 O2 Sensor Circ. No Activity Detected (Upstream of the Catalyzer)
P0136-00 O2 Sensor Circ. Malfunction (Downstream of the Catalyzer)
P0137-16 O2 Sensor Circ. Low Voltage (Downstream of the Catalyzer)
P0138-17 O2 Sensor Circ. High Voltage (Downstream of the Catalyzer)
P0140-00 O2 Sensor Circ. No Activity Detected (Downstream of the Catalyzer)
P0170-00 Fuel Trim, Bank1 Malfunction
P0171-00 Fuel Trim, Bank1 System Too Lean
P0172-00 Fuel Trim,Bank1 System Too Rich
06
P0201-13 Cylinder 1 - Injector Circuit
P0219-00 Engine Overspeed Condition
P0221-29 Throttle/Pedal Position Sensor/Switch B Range/Performance
P0222-16 Throttle/Pedal Position Sensor/Switch B Low Input
P0223-17 Throttle/Pedal Position Sensor/Switch B High Input
P0261-11 Cylinder 1 - Injector Circuit Low
P0262-12 Cylinder 1 - Injector Circuit High
P0300-21 Random/Multiple Cylinder Misfire Detected (Over Emission Limit)
P0300-22 Random/Multiple Cylinder Misfire Detected (Harmful to Catalyst)
P0300-29 Random/Multiple Cylinder Misfire Detected (During First Statistic Cycle)
P0301-21 Cylinder 1 Misfire Detected (Over Emission Limit)
P0301-22 Cylinder 1 Misfire Detected (Harmful to Catalyst)
P0301-29 Cylinder 1 Misfire Detected (During First Statistic Cycle)
P0302-29 Cylinder 2 Misfire Detected (During First Statistic Cycle)


P0303-29 Cylinder 3 Misfire (During First Statistic Cycle)
P0304-29 Cylinder 4 Misfire (During First Statistic Cycle)
P0322-00 EPM - Crankshaft Signal Fault
P0327-16 Knock Sensor 1 Circ. Low Input
P0328-17 Knock Sensor 1 Circ. High Input
P0341-00 EPM - Camshaft Signal Fault
P0420-00 Catalyst Conversion Insufficient
P0444-13 Evaporative Emission System Purge Control Valve Circuit Open
06
P0458-16 Evaporative Emission System Purge Control Valve Circuit Low
P0459-17 Evaporative Emission System Purge Control Valve Circuit High
P0480-13 Cooling Fan 1 Control Circuit
P0481-13 Cooling Fan 2 Control Circuit
P0501-00 Vehicle Speed Sensor Signal Fault
P0506-00 Idle Control System RPM Lower than Expected
P0507-00 Idle Control System RPM Higher than Expected
P0532-16 A/C Refrigerant Pressure Sensor Circuit Low
P0533-17 A/C Refrigerant Pressure Sensor Circuit High
P0560-00 Non-plausible Error of Battery Voltage
P0562-16 System Voltage Low
P0563-17 System Voltage High
P0571-1C Brake Light Signal Circuit Error
P0571-29 Brake Signal Synchronization Error
P0604-43 Internal Contr. Module RAM Error
P0605-43 Internal Contr. Module ROM Error
P0606-00 Safety Monitoring Fuel Cutoff Error
P0606-1C Throttle Signal, Wiring Harness or ECU Error
P0606-47 Monitoring Module Feedback Error
P0606-48 Monitoring Fault Reaction Error
P0606-49 Monitoring Module Inquiry Error
P0606-55 Variant Coding Monitoring Error
P0606-61 Ignition Angle Signal, Wiring Harness or ECU Error
P0606-62 Pedal Signal Implausibility Error in Level 2
P0606-64 Load Signal, Wiring Harness or ECU Error
P0606-67 ECU Fault Reaction Monitoring Error
P0606-75 Shut Off Path Test Error


P0606-92 Engine Speed Monitoring Error in Level 2
P0606-94 Torque Monitoring Error in Level 2
P0606-96 AD Convertor Monitoring Error
P0627-13 Fuel Pump Control Circuit/Open
P0628-11 Fuel Pump Control Circuit Low
P0629-12 Fuel Pump Control Circuit High
P0645-13 A/C Clutch Relay Circuit
P0646-11 A/C Clutch Relay Control Circuit Low
P0647-12 A/C Clutch Relay Control Circuit High
P0688-91 Power Relay Sense Circuit Non-plausible Error
06
P0688-92 Power Relay Sense Circuit Signal Error
P0691-11 Fan 1 Control Circuit Low
P0692-12 Fan 1 Control Circuit High
P0693-11 Fan 2 Control Circuit Low
P0694-12 Fan 2 Control Circuit High
P0704-00 Clutch Switch Input Circuit
P2106-12 Throttle Power Stage Max Error
P2106-13 Throttle Power Stage Signal Error
P2106-19 Throttle Power Stage Min Error
P2106-29 Load Monitoring Error
P2106-92 Throttle Power Stage Non-plausible Error
P2122-16 Pedal Pos. Sensor 1 Circ. Low Input
P2123-17 Pedal Pos. Sensor 1 Circ. High Input
P2127-16 Pedal Pos. Sensor 2 Circ. Low Input
P2128-17 Pedal Pos. Sensor 2 Circ. High Input
P2138-00 Pedal Movement Check Error
P2138-29 Pedal Pos. Sensor 1/2 Implausible
P2177-00 System Too Lean Off Idle
P2178-00 System Too Rich Off Idle
P2187-00 System Too Lean at Idle
P2188-00 System Too Rich at Idle
P2195-00 O2 Sensor Signal Stuck Lean Bank 1 Sensor 1
P2196-00 O2 Sensor Signal Stuck Rich Bank 1 Sensor 1
P2270-00 O2 Sensor Signal Stuck Lean Bank 1 Sensor 2
P2271-00 O2 Sensor Signal Stuck Rich Bank 1 Sensor 2

DTC P0030-13 HO2S Heater Control Circuit (Upstream of the Catalyzer)
HO2S Heater Control Circuit Low (Upstream of the

DTC P0031-11
Catalyzer)
HO2S Heater Control Circuit High (Upstream of the

DTC P0032-12
Catalyzer)
Nernst Resistance Sensor Upstream of the Catalyzer

DTC P0053-1E
Too Large
06

BATTERY
86 30
ECM
MAIN
RELAY ENGINE
COMPARTMENT
85 87
FUSE AND
RELAY BOX
B-013
EF15
15A
06 C17 C4
RL
B-020
14
E-012
RL
1 4
UPSTREAM
OXYGEN
YV
SENSOR
E-006
2 3
RW
PW
BY
5 80 104 73
ECM
B-001
E-001
1 2 3 4 5 6 7 8
C1 C2 C3 C4 C5 C6 C7
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18 1 2 3 4 16 15 14 13 12 11 10 9
B-013
E-006
W B-020
B
B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101
B-001 E-001
B B EA19060090

DTC Detection
DTC Code DTC Definition Possible Cause
Condition
HO2S Heater Control
P0030-13 Circuit (Upstream of
the Catalyzer)
HO2S Heater Control
P0031-11 Circuit Low (Upstream  Upstream oxygen sensor
of the Catalyzer)
Ignition switch ON  Wire harness or connector
HO2S Heater Control Engine running  Fuse
P0032-12 Circuit High (Upstream
of the Catalyzer)  ECM
Nernst Resistance
Sensor Upstream of
P0053-1E
the Catalyzer Too 06
Large
DTC Confirmation Procedure

Confirm that the battery voltage is over 12 V before performing the following procedures.
 Turn the ignition switch to LOCK.
 Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC).
 Turn the ignition switch to ON.
 Use the X-431 3G diagnostic tester to record and clear the DTCs stored in the ECM.
 Start the engine and warm it up to normal operating temperature, and then select Read Code.
 If the DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis 
procedure - Step 1.
 If the DTC is not detected, the malfunction indicated by the DTC is intermittent (See page 06-18).
CAUTION
 When performing the circuit diagnosis and test, always refer to the circuit diagram for the specific circuit
and the component information.

Diagnosis Procedure
1 Check ECM ground point
a. Turn the ignition switch to LOCK.

b. Check the ECM grounds GND113 and GND114 (See page 06-18).
NG Repair or replace ground wire harness or

ground point
OK
2 Check upstream oxygen sensor connector
06 a. Disconnect the upstream oxygen connector E-006.

b. Check the upstream oxygen sensor connector.
NG Repair or replace connector
RA19090081
OK
3 Check upstream oxygen sensor heater power supply voltage
a. Turn the ignition switch to ON.

b. Check the voltage between of upstream oxygen sensor
connector E-006 terminal 4 and body ground.
V
Multimeter Specified + -
Condition
Connection Condition
E-006 (4) - Body
Ignition switch ON 11 to 14 V
ground
1 2 3 4
OK Go to step 5
E-006
RA19060150
NG

4 Check upstream oxygen sensor power supply circuit

b. Check the fuse EF15 and main relay.
c. Disconnect the engine compartment fuse and relay box
connector B-013.
+ -
d. Check the wire harness between upstream oxygen
sensor connector terminals and engine compartment
fuse and relay box connector terminals.
Check for Open
1 2 3 4
Multimeter Specified
Condition E-006
E-006 (4) - B-013
(C4)
Always Continuity 06
C1 C2 C3 C4 C5 C6 C7
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18
Check for Short
B-013
Multimeter Specified RA19060160
Condition
E-006 (4) - Body
Always No continuity
ground
E-006 (4) or
B-013 (C4) - Always No continuity
Battery positive
NG Replace wire harness or connector

(upstream oxygen sensor - engine
compartment fuse and relay box)
OK
5 Check upstream oxygen sensor heater control circuit
a. Disconnect the ECM connector E-001.

b. Check the wire harness between upstream oxygen
sensor connector terminals and ECM connector
terminals.
Check for Open + -
Condition 1 2 3 4
E-006 (3) - E-001 E-006
Always Continuity
(73)
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-001 RA19060170

Check for Short
Condition
E-006 (3) or
E-001 (73) - Body Always No continuity
ground
E-006 (3) or
E-001 (73) - Always No continuity
Battery positive
NG Repair or replace wire harness or

connector (upstream oxygen 
sensor - ECM)
06 OK
6 Check upstream oxygen sensor heater
a. Measure the resistance of upstream oxygen sensor.

+ -
Multimeter
Condition Specification (Ω)
Connection D C B A
Terminal C -
20°C 7 - 11
Terminal D
Terminal A -
Terminal B
Terminal A -
RA19090100
Terminal C
Terminal A -
Always 
Terminal D
Terminal B -
Terminal C
Terminal B -
Terminal D
NG Replace upstream oxygen sensor
OK
7 Check for DTCs
a. Use the X-431 3G diagnostic tester to read the ECM DTC.

b. Refer to "DTC Confirmation Procedure".
c. Check if DTC P0030-13, P0031-11, P0032-12 or P0053-1E still exists.
NG Replace ECM
OK

System is operating normally.

Reassemble vehicle and perform a road test to confirm that malfunction reported by customer has
been repaired.
06

HO2S Heater Control Circuit (Downstream of the

DTC P0036-13
Catalyzer)
HO2S Heater Control Circuit Low (Downstream of the

DTC P0037-11
Catalyzer)
HO2S Heater Control Circuit High (Downstream of the

DTC P0038-12
Catalyzer)
Nernst Resistance Sensor Downstream of the Catalyzer

DTC P0054-1E
Too Large
06

BATTERY
86 30
ECM
MAIN
RELAY
ENGINE
85 87 COMPARTMENT
FUSE AND
RELAY BOX
EF15 B-012
15A B-013
C17 D5 06
R
B-020
11
E-012
R
1 4
DOWNSTREAM
OXYGEN
YV
SENSOR
E-008
2 3
RG
BR
YB
E-012
6 5 15
B-020
RG
BR
YB
5 43 21 48
ECM
B-001
C11 C12 C13 C14 D13 D14 D15 D16
B-013 B-012
W W B-020
B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
1 2 3 4
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
E-008
B
B-001
B
EA19060100

DTC Detection
Condition
HO2S Heater Control
P0036-13 Circuit (Downstream of
the Catalyzer)
HO2S Heater Control
Circuit Low
P0037-11
(Downstream of the  Downstream oxygen sensor
Catalyzer)
Ignition switch ON  Wire harness or connector
HO2S Heater Control Engine running  Fuse
Circuit High
P0038-12  ECM
(Downstream of the
Catalyzer)
06 Nernst Resistance
Sensor Downstream of
P0054-1E
the Catalyzer Too
Large

procedure - Step 1.
CAUTION

Diagnosis Procedure


ground point
OK
2 Check downstream oxygen sensor connector
a. Disconnect the downstream oxygen connector E-008 (1). 06

b. Check the downstream oxygen sensor connector.
RA19090110
OK
3 Check downstream oxygen sensor heater power supply voltage

b. Check the voltage between downstream oxygen sensor
connector E-008 terminal 4 and body ground.
V
Condition
E-008 (4) - Body
ground
1 2 3 4
OK Go to step 5
E-008
RA19060180
NG

4 Check downstream oxygen sensor power supply circuit

c. Disconnect the engine compartment fuse and relay box connector B-012.
d. Check the wire harness between downstream oxygen
sensor connector terminals and engine compartment
fuse and relay box connector terminals.
Check for Open
+ -
Condition
E-008 (4) - B-012
Always Continuity
06 (D5) 1 2 3 4
Check for Short E-008
Condition
D1 D2 D3 D4 D5 D6 D7 D8
D13 D14 D15 D16
E-008 (4) or D9 D10 D11D12 D17 D18 D19 D20
B-012 (D5) - Body Always No continuity
B-012
ground RA19060190
E-008 (4) or
B-012 (D5) - Always No continuity
Battery positive

(downstream oxygen sensor - engine
OK
5 Check downstream oxygen sensor heater control circuit
a. Disconnect the ECM connector B-001.

b. Check the wire harness between downstream oxygen
terminals.
Check for Open + -
Condition 1 2 3 4
E-008 (3) - B-001 E-008
Always Continuity
(48)
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
RA19060200

Check for Short
Condition
E-008 (3) or
B-001 (48) - Body Always No continuity
ground
E-008 (3) or
B-001 (48) - Always No continuity
Battery positive

connector (downstream oxygen 
sensor - ECM)
OK
06
6 Check downstream oxygen sensor heater
a. Measure the resistance of downstream oxygen sensor.

+ -
Multimeter
Connection D C B A
Terminal C -
20°C 7 - 11
Terminal D
Terminal A -
Terminal B
Terminal A -
RA19090100
Terminal C
Terminal A -
Always 
Terminal D
Terminal B -
Terminal C
Terminal B -
Terminal D
NG Replace downstream oxygen sensor
OK

7 Check for DTCs

c. Check if DTC P0036-13, P0037-11, P0038-12 or P0054-1E still exists.
NG Replace ECM
OK

been repaired.
06

Manifold Absolute Pressure/Barometric Pressure

DTC P0105-28
Circuit
Manifold Abs. Pressure or Bar. Pressure Range/

DTC P0106-00
Performance
DTC P0107-11 Manifold Abs. Pressure or Bar. Pressure Low Input
DTC P0108-12 Manifold Abs. Pressure or Bar. Pressure High Input
06

ECM
E-001
109 91 102 85
06
LW
LG
LR
LB
3 4 2 1
INTAKE PRESSURE/TEMPERATURE
SENSOR
E-019
76 75 74 73 72 71 70 69 68 67 66 65
4 3 2 1
88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-019
B
E-001
B
EA19060110

DTC Detection
Condition
Manifold Absolute
P0105-28 Pressure/Barometric
Pressure Circuit
Manifold Abs.
Pressure or Bar.
P0106-00
Pressure Range/  Intake pressure sensor
Performance Ignition switch ON
 Wire harness or connector
Engine running
Manifold Abs.  ECM
P0107-11 Pressure or Bar.
Pressure Low Input
Manifold Abs.
P0108-12 Pressure or Bar. 06
Pressure High Input

procedure - Step 1.
CAUTION

Diagnosis Procedure


ground point
OK
2 Check intake pressure/temperature sensor connector
06 a. Disconnect the intake pressure/temperature sensor

connector E-019 (1).
b. Check the intake pressure/temperature sensor
connector.

1
RA19060950
OK
3 Check intake pressure sensor signal circuit
a. Connect the intake pressure/temperature sensor connector E-019.

b. Turn the ignition switch to ON and start the engine.
c. Using the diagnostic tester, measure the intake pressure sensor signal voltage, or using the multimeter,
measure the voltage between connector E-019 terminal 4 and body ground.
Multimeter Connection Condition Specified Condition

Voltage is about 1.3 V (value
Idle
changes with model)
E-019 (4) - Body ground
Instantaneous voltage is about
Rapidly depress accelerator pedal
4 V (value changes with model)
OK Go to step 8
NG

4 Check intake pressure sensor power supply voltage
a. Disconnect the intake pressure/temperature sensor

connector E-019.
b. Check the voltage between intake pressure/temperature
sensor connector terminals and body ground. V
+ -
Condition
E-019 (3) - Body
Ignition switch ON 5V 4 3 2 1
ground
E-019
NG Go to step 6
06
RA19060210
OK
5 Check intake pressure sensor power supply circuit

b. Disconnect the ECM connector E-001.
c. Check the wire harness between intake pressure/
temperature sensor connector terminals and ECM
connector terminals. + -
4 3 2 1
Check for Open
Multimeter Specified E-019

Condition
E-019 (3) - E-001
Always Continuity
(109) 76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
Check for Short 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
Condition
E-001
RA19060220
E-019 (3) or
Body ground
E-019 (3) or
Battery positive
NG Replace wire harness or connector (intake

pressure/temperature sensor - ECM)
OK

6 Check intake pressure sensor signal circuit
a. Check the wire harness between intake pressure/

connector terminals.
Check for Open
+ -
Multimeter 4 3 2 1
Condition Specification
Connection
E-019 (4) - E-001 E-019
Always Continuity
(91)
Check for Short

76 75 74 73 72 71 70 69 68 67 66 65
Multimeter 88 87 86 85 84 83 82 81 80 79 78 77
06 Connection
Condition Specification 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-019 (4) or
ground E-001
RA19060230
E-019 (4) or
Battery positive

connector (intake pressure/temperature
sensor - ECM)
OK
7 Check intake pressure sensor
a. Remove the intake pressure/temperature sensor.

b. Check the inlet of connector for debris and damage.
NG Clean or replace intake pressure/

temperature sensor
OK
8 Check for DTCs

c. Check if DTC P0105-28, P0106-00, P0107-11 or P0108-12 still exists.

NG Replace ECM
OK

been repaired.
06

DTC P0112-16 Intake Air Temp. Circ. Low Input
DTC P0113-17 Intake Air Temp. Circ. High Input
ECM
E-001
109 91 102 85
06
LW
LG
LR
LB
3 4 2 1
INTAKE PRESSURE/TEMPERATURE
SENSOR
E-019
76 75 74 73 72 71 70 69 68 67 66 65
4 3 2 1
88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-019
B
E-001
B
EA19060110

DTC Detection
Condition
Intake Air Temp. Circ.
P0112-16  Intake temperature sensor
Low Input Ignition switch ON
Intake Air Temp. Circ. Engine running
P0113-17  ECM
High Input

 Use the X-431 3G diagnostic tester to record and clear the DTCs stored in the ECM. 06
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK
2 Check intake pressure/temperature sensor connector

b. Check the intake pressure/temperature sensor
connector.

1
RA19060950

OK
3 Check intake temperature sensor signal
a. Connect the intake pressure/temperature sensor

connector E-019.
b. Turn the ignition switch to ON and start the engine.
c. Using the diagnostic tester, measure the intake
temperature sensor signal voltage, or using the
multimeter, measure the voltage between connector E-
Datastream
Datastream name Value Unit
019 terminal 2 and body ground. engine coolant temperature sensor voltage 2.25 volts
intake air temperature sensor voltage 2.61 volts
Multimeter Specified intake manifold pressure sensor voltage 1.52 volts
Condition throttle position sensor voltage 0.53 volts
06 average injection pulse 3.84 ms
Voltage is about
desired idle speed 860 Rpm
intake air mass flow 4 kg/h
2.5 V (value relative air charge 21.75 %
changes with
E-019 (2) - Body Engine running
model); signal
ground after warming up
does not change
when increasing
speed. RA19060700
OK Go to step 8
NG
4 Check intake temperature sensor voltage

connector E-019.
b. Turn the ignition switch to ON.
c. Check the voltage between intake temperature sensor V
connector terminal and body ground. + -
Condition
4 3 2 1
E-019 (2) - Body

Ignition switch ON 5V
ground
E-019
OK Go to step 6
RA19060240
NG

5 Check intake temperature sensor signal circuit

c. Check the wire harness between intake pressure/
Check for Open
+ -
Multimeter Specified 4 3 2 1
Condition
E-019 (2) - E-001 E-019
Always Continuity
(102)
Check for Short

76 75 74 73 72 71 70 69 68 67 66 65
06
Multimeter Specified 88 87 86 85 84 83 82 81 80 79 78 77
Condition
Connection Condition 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-019 (2) or
Body ground E-001
RA19060250
E-019 (2) or
Battery positive
NG Replace wire harness or connector (intake

pressure/temperature sensor - ECM)
OK
6 Check intake pressure sensor ground circuit
a. Check the wire harness between intake pressure/

Check for Open
+ -
Multimeter Specified 4 3 2 1
Condition
E-019 (1) - E-001 E-019
Always Continuity
(85)
Check for Short

76 75 74 73 72 71 70 69 68 67 66 65
Condition
112 111 110 109 108 107 106 105 104 103 102 101
E-019 (1) or
ground E-001
RA19060260

Condition
E-019 (1) or
Battery positive

connector (intake pressure/temperature
sensor - ECM)
OK
7 Check intake temperature sensor

06
a. Remove the intake pressure/temperature sensor.
b. Check the resistance of intake temperature sensor. + -
Check for Open
1 2 3 4
Multimeter
Specified Condition
Connection
1-2 Resistance is 2.5 kΩ ± 5% (20°C)
NG Replace intake pressure/temperature RA19060710

sensor
OK
8 Check for DTCs

c. Check if DTC P0112-16 or P0113-17 still exists.
NG Replace ECM
OK

been repaired.

DTC P0116-00 Engine Coolant Temp. Circ. Range/Performance
DTC P0117-16 Engine Coolant Temp. Circ. Low Input
DTC P0118-17 Engine Coolant Temp. Circ. High Input
ECM
E-001
101 84
06
BGr
BW
1 2
COOLANT
TEMPERATURE
SENSOR
E-014
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89 1 2
112 111 110 109 108 107 106 105 104 103 102 101
E-014
B
E-001
B
EA19060120

DTC Detection
Condition
Engine Coolant Temp.
P0116-00 Circ. Range/
Performance  Engine coolant temperature sensor
Ignition switch ON
Engine Coolant Temp.  Wire harness or connector
P0117-16 Engine running
Circ. Low Input  ECM
Engine Coolant Temp.
P0118-17
Circ. High Input

06
 If the DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis procedure - Step
1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check engine coolant temperature sensor connector
a. Disconnect the engine coolant temperature sensor

b. Check the engine coolant temperature sensor connector.
NG Repair or replace connector + -
C1 C2 C3 C4 C5 C6 C7
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18
B-013
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
06
B-001
RA19060600
OK
3 Check engine coolant temperature sensor power supply voltage

b. Check the voltage between engine coolant temperature
sensor terminal and body ground.
V
Condition
E-014 (1) - Body
ground 1 2
OK Go to step 5 E-014
RA19060270
NG

4 Check engine coolant temperature sensor power supply

c. Check the wire harness between engine coolant
+ -
Check for Open 1 2
Condition E-014
E-014 (1) - E-001
Always Continuity
(101) 76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
06 Check for Short 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
Condition
E-001
RA19060280
E-014 (1) or E-
001 (101) - Body Always No continuity
ground
E-014 (1) or E-
001 (101) - Always No continuity
Battery positive

(engine coolant temperature sensor -
ECM)
OK
5 Check engine coolant temperature sensor ground circuit
a. Check the wire harness between engine coolant

Check for Open
+ -
Condition
Connection Condition 1 2
E-014 (2) - E-001

Always Continuity E-014
(84)
Check for Short

76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
Condition 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-014 (2) or
ground E-001
RA19060290

Condition
E-014 (2) or
Battery positive

connector (engine coolant temperature
sensor - ECM)
OK
6 Check engine coolant temperature sensor

06
a. Remove the engine coolant temperature sensor.
b. Check the resistance of engine coolant temperature + -
sensor.
1 2
Multimeter
Specified Condition
Connection
Resistance is 2.5 kΩ ± 5% (20°C)
1-2 300 - 400 Ω in boiled water (value
changes with the boiled water
temperature) RA19060720
NG Replace engine coolant temperature

sensor
OK
7 Check for DTCs

c. Check if DTC P0116-00, P0117-16 or P0118-17 still exists.
NG Replace ECM
OK

been repaired.

DTC P0121-29 Throttle/Pedal Pos. Sensor A Circ. Range/Performance
DTC P0122-16 Throttle/Pedal Pos. Sensor A Circ. Low Input
DTC P0123-17 Throttle/Pedal Pos. Sensor A Circ. Low Input
THROTTLE POSITION SENSOR

E-015
06 M
1 4 2 5 3 6
RGr
RBr
GR
RB
RY
RL
87 75 86 78 107 77
ECM
E-001
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77 1 2 3
100 99 98 97 96 95 94 93 92 91 90 89 4 5 6
112 111 110 109 108 107 106 105 104 103 102 101
E-015
B
E-001
B
EA19060130

DTC Detection
Condition
Throttle/Pedal Pos.
P0121-29 Sensor A Circ. Range/
Performance
Throttle/Pedal Pos.  Throttle position Sensor 1
Ignition switch ON
P0122-16 Sensor A Circ. Low  Wire harness or connector
Engine running
Input  ECM
Throttle/Pedal Pos.
P0123-17 Sensor A Circ. Low
Input

Confirm that the battery voltage is over 12 V before performing the following procedures. 06
1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check throttle position sensor connector
a. Disconnect the throttle position sensor connector E-015

(1).
b. Check the throttle position sensor connector.
1
2
RA19100080
OK
06
3 Check throttle position sensor 1 signal voltage
a. Connect the throttle position sensor connector E-015.

b. Turn the ignition switch to ON. Datastream
c. Using the diagnostic tester, check the throttle position multiplicative correction of the mixture adaptation 1.00
sensor 1 signal voltage. Lambda controller output bank 2 0.00
sensor voltage from throttle potentiometer 1 0.78 V
Standard Value sensor voltage from throttle potentiometer 2 4.21 V
Condition additive correction of the mixture adaptation 0.00 %

(V) Voltage PWG potentiometer 1 0.99 V
Accelerator pedal released 0.78

Voltage PWG potentiometer 2 0.50 V
Doubled PWG potentiometer-2 voltage 1.00 V
Accelerator pedal depressed 4.25 RA19100071
OK Go to step 8
NG
4 Check throttle position sensor power supply voltage

b. Disconnect the throttle position sensor connector E-015.
c. Turn the ignition switch to ON and check the voltage
between throttle position sensor connector terminal and V
+ -
body ground.
Check for Open
1 2 3
Multimeter Specified 4 5 6
Condition
E-015 (3) - Body E-015
ground
OK Go to step 6
RA19060300

NG
5 Check throttle position sensor power supply circuit

c. Check the wire harness between throttle position sensor
connector terminals and ECM connector terminals.
+ -
Check for Open 1 2 3
4 5 6
Condition
E-015
E-015 (3) - E-001
Always Continuity
(107) 06
76 75 74 73 72 71 70 69 68 67 66 65
Check for Short 88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89
Condition
E-015 (3) or E- E-001
RA19060310
ground
E-015 (3) or E-
Battery positive

(throttle position sensor - ECM)
OK

6 Check throttle position sensor 1 signal circuit and ground circuit
a. Check the wire harness between throttle position sensor

Check for Open
Condition
Connection Condition 1 2 3
4 5 6
E-015 (6) - E-001

Always Continuity
(77)
E-015
E-015 (2) - E-001
Always Continuity
(86)
76 75 74 73 72 71 70 69 68 67 66 65
Check for Short 88 87 86 85 84 83 82 81 80 79 78 77
06 100 99 98 97 96 95 94 93 92 91 90 89
Condition
E-015 (6) or E- E-001
RA19060320
ground
E-015 (6) or E-
001 (77) - Battery Always No continuity
positive
E-015 (2) or E-
ground
E-015 (2) or E-
positive

connector (throttle position sensor - ECM)
OK
7 Check throttle position sensor 1
a. Check the resistance of throttle position sensor 1.
Multimeter
Specified Condition
Connection
Resistance changes continuously
2-6 when throttle valve is moved by
hands.
NG Replace electronic throttle
OK

8 Check for DTCs

NG Replace ECM
OK

been repaired.
06

DTC P0130-00 O2 Sensor Circ. Malfunction (Upstream of the Catalyzer)
DTC P0131-16 O2 Sensor Circ. Low Voltage (Upstream of the Catalyzer)
O2 Sensor Circ. High Voltage (Upstream of the

DTC P0132-17
Catalyzer)
O2 Sensor Circ. No Activity Detected (Upstream of the

DTC P0134-00
Catalyzer)
06

BATTERY
86 30
ECM
MAIN
RELAY ENGINE
COMPARTMENT
85 87
FUSE AND
RELAY BOX
B-013
EF15
15A
C17 C4 06
RL
B-020
14
E-012
RL
1 4
UPSTREAM
OXYGEN
YV
SENSOR
E-006
2 3
RW
PW
BY
5 80 104 73
ECM
B-001
E-001
1 2 3 4 5 6 7 8
C1 C2 C3 C4 C5 C6 C7
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18 1 2 3 4 16 15 14 13 12 11 10 9
B-013
E-006
W B-020
B
B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101
B-001 E-001
B B EA19060090

DTC Detection
Condition
O2 Sensor Circ.
P0130-00 Malfunction (Upstream
of the Catalyzer)
O2 Sensor Circ. Low
P0131-16 Voltage (Upstream of
the Catalyzer)  Upstream oxygen sensor
Ignition switch ON
O2 Sensor Circ. High  Wire harness or connector
Engine running
P0132-17 Voltage (Upstream of  ECM
the Catalyzer)
O2 Sensor Circ. No
Activity Detected
P0134-00
06 (Upstream of the
Catalyzer)

1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check upstream oxygen sensor connector
a. Disconnect the upstream oxygen connector E-006.

b. Check the upstream oxygen sensor connector.
RA19090081
OK
06
3 Check upstream oxygen sensor signal
a. Connect the upstream oxygen connector E-006.

b. Turn the ignition switch to ON, start the engine and idle it
for about 3 minutes.
c. Using the diagnostic tester, measure the upstream
oxygen sensor signal voltage, or using the multimeter, Datastream
measure the voltage between terminals 2 and 1 of the Datastream name Value Unit
connector E-006. outputed ignition angle 188.25 Gradkw
intake air temperature 36.75 GradC
Multimeter
absolute throttle position 6.01 %
Specified upstream oxygen sensor voltage 0.48 volts
Condition downstream oxygen sensor voltage 0.82 volts
Terminal distance travelled while MIL is activated 0 KM
system battery voltage 14.29 volts
Fluctuates fast relative throttle position 0 %
between 0.1 and

E-006 (2) - E-006 0.9 V (when
Engine running
(1) operating
temperature is
350°C) RA19060730
OK Go to step 8
NG

4 Check upstream oxygen sensor signal circuit

c. Disconnect the upstream oxygen connector E-006.
d. Check the wire harness between upstream oxygen + -
terminals.
1 2 3 4
Check for Open
E-006
Condition
76 75 74 73 72 71 70 69 68 67 66 65
E-006 (2) - E-001
Always Continuity 88 87 86 85 84 83 82 81 80 79 78 77
06 (104)
100 99 98 97 96 95 94 93 92 91 90 89
Check for Short 112 111 110 109 108 107 106 105 104 103 102 101
Condition E-001
Connection Condition RA19060330
E-006 (2) or E-
ground
E-006 (2) or E-
Battery positive

(upstream oxygen sensor - ECM)
OK
5 Check upstream oxygen sensor ground circuit
a. Check the wire harness between upstream oxygen

terminals.
Check for Open
+ -
Condition
Connection Condition 1 2 3 4
E-006 (1) - E-001

(80)
Check for Short

76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
Condition 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-006 (1) or E-
ground E-001
RA19060340

Condition
E-006 (1) or E-
positive

connector (upstream oxygen sensor -
ECM)
OK
6 Check upstream oxygen sensor

06
a. Remove the upstream oxygen sensor.
b. Check the upstream oxygen sensor for the following problems.
 Moisture enters the internal of sensor, temperature changes greatly, and probe is broken.
 Oxygen sensor is "poisoned" (Pb, S, Br, Si).
NG Replace upstream oxygen sensor
OK
7 Check for DTCs

NG Replace ECM
OK

been repaired.

O2 Sensor Circ. Malfunction (Downstream of the

DTC P0136-00
Catalyzer)
O2 Sensor Circ. Low Voltage (Downstream of the

DTC P0137-16
Catalyzer)
O2 Sensor Circ. High Voltage (Downstream of the

DTC P0138-17
Catalyzer)
O2 Sensor Circ. No Activity Detected (Downstream of

DTC P0140-00
the Catalyzer)
06

BATTERY
86 30
ECM
MAIN
RELAY
ENGINE
85 87 COMPARTMENT
FUSE AND
RELAY BOX
EF15 B-012
15A B-013
C17 D5
06
R
B-020
11
E-012
R
1 4
DOWNSTREAM
OXYGEN
YV
SENSOR
E-008
2 3
RG
BR
YB
E-012
6 5 15
B-020
RG
BR
YB
5 43 21 48
ECM
B-001
C11 C12 C13 C14 D13 D14 D15 D16
B-013 B-012
W W B-020
B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
1 2 3 4
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
E-008
B
B-001
B
EA19060100

DTC Detection
Condition
O2 Sensor Circ.
Malfunction
P0136-00
(Downstream of the
Catalyzer)
O2 Sensor Circ. Low
P0137-16 Voltage (Downstream
 Downstream oxygen sensor
of the Catalyzer) Ignition switch ON
O2 Sensor Circ. High Engine running
 ECM
P0138-17 Voltage (Downstream
of the Catalyzer)
O2 Sensor Circ. No
06 P0140-00
Activity Detected
(Downstream of the
Catalyzer)

1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check downstream oxygen sensor connector
a. Disconnect the downstream oxygen connector E-008 (1).

b. Check the downstream oxygen sensor connector.
RA19090110
OK
06
3 Check downstream oxygen sensor signal
a. Connect the downstream oxygen connector E-008.

b. Turn the ignition switch to ON, start the engine and idle it
for about 3 minutes.
c. Using the diagnostic tester, measure the downstream
oxygen sensor signal voltage, or using the multimeter, Datastream
measure the voltage between terminals 2 and 1 of the Datastream name Value Unit
connector E-008. outputed ignition angle 188.25 Gradkw
intake air temperature 36.75 GradC
absolute throttle position 6.01 %
Condition upstream oxygen sensor voltage 0.48 volts
Connection Condition downstream oxygen sensor voltage 0.82 volts
distance travelled while MIL is activated 0 KM
E-008 (2) - Fluctuates slightly

Engine running system battery voltage 14.29 volts
E-008 (1) at about 0.45 V relative throttle position 0 %
OK Go to step 8
RA19060740
NG

4 Check downstream oxygen sensor signal circuit

b. Disconnect the ECM connector B-001.
c. Disconnect the downstream oxygen connector E-008.
d. Check the wire harness between downstream oxygen + -
terminals.
1 2 3 4
Check for Open
E-008
Condition
E-008 (2) - B-001 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Always Continuity
06 (21) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
Check for Short 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Condition B-001
Connection Condition RA19060350
E-008 (2) or B-
ground
E-008 (2) or B-
positive

(downstream oxygen sensor - ECM)
OK
5 Check downstream oxygen sensor ground circuit
a. Check the wire harness between downstream oxygen

terminals.
Check for Open
+ -
Condition
E-008 (1) - B-001

(43)
Check for Short

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Multimeter Specified 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Condition
Connection Condition 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
E-008 (1) or B-
ground B-001
RA19060360

Condition
E-008 (1) or B-
positive

connector (downstream oxygen sensor -
ECM)
OK
6 Check downstream oxygen sensor

06
a. Remove the downstream oxygen sensor.
b. Check the upstream oxygen sensor for the following problems.
 Moisture enters the internal of sensor, temperature changes greatly, and probe is broken.
 Oxygen sensor is "poisoned" (Pb, S, Br, Si).
OK
7 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0201-13 Cylinder 1- Injector Circuit
DTC P0261-11 Cylinder 1- Injector Circuit Low
DTC P0262-12 Cylinder 1- Injector Circuit High
06

BATTERY
86 30
ECM
MAIN
RELAY
ENGINE
85 87 COMPARTMENT
FUSE AND
EF20 RELAY BOX
10A B-013
C17 R C6
06
B-020
9
E-012
RG
YV
1
INJECTOR 1
E-004
2
GY
5 68
ECM
B-001
E-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
1 2
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101 E-004
B
B-001 E-001
B B
C1 C2 C3 C4 C5 C6 C7 1 2 3 4 5 6 7 8 B-020
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18
16 15 14 13 12 11 10 9 B
B-013
W EA19060140

DTC Detection
Condition
Cylinder 1- Injector
P0201-13
Circuit
 Injector of cylinder 1
P0261-11 Engine running  Wire harness or connector
Circuit Low
 ECM
P0262-12
Circuit High

06  Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC).
1.
CAUTION
Diagnosis Procedure


ground point
OK
2 Check injector connector of cylinder 1
a. Disconnect the injector connector E-004 of cylinder 1.

b. Check the injector connector.
OK

3 Check injector power supply voltage of cylinder 1

c. Check the voltage between injector connector terminal of
cylinder 1 and body ground. V
+ -
Condition
E-004 (1) - Body 1 2
ground
E-004
OK Go to step 5
06
RA19060370
NG
4 Check injector power supply circuit of cylinder 1

b. Check the main fuse EF20 and main relay.
connector B-013.
+ -
d. Check the wire harness between injector connector
terminals and engine compartment fuse and relay box 1 2
E-004
Check for Open
Condition
C1 C2 C3 C4 C5 C6 C7
E-004 (1) - B-013 C11 C12 C13 C14
Always Continuity C8 C9 C10 C15 C16 C17 C18
(C6)
B-013
Check for Short

Condition
E-004 (1) or B-
013 (C6) - Body Always No continuity
ground
E-004 (1) or B-
013 (C6) - Battery Always No continuity
positive


connector (injector of cylinder 1 - engine
OK
5 Check injector control circuit of cylinder 1

b. Check the wire harness between injector connector
terminals and ECM connector terminals.
Check for Open
+ -
06 Connection
Condition
Condition
1 2
E-004
E-004 (2) - E-001
Always Continuity
(68)
Check for Short 76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77

Condition
E-004 (2) or E-
001 (68) - Body Always No continuity E-001
ground RA19060390
E-004 (2) or E-
positive

connector (injector of cylinder 1 - ECM)
OK
6 Check injector of cylinder 1
a. Check the resistance of injector of cylinder 1.
Multimeter + -
Specified Condition 1 2
Connection
1-2 11 - 16 Ω ( at 20°C)
NG Replace injector of cylinder 1
RA19080280
OK

7 Check for DTCs

NG Replace ECM
OK

been repaired.
06

06

BATTERY
86 30
ECM
MAIN
RELAY
ENGINE
85 87 COMPARTMENT
FUSE AND
EF20 RELAY BOX
10A B-013
C17 R C6
06
B-020
9
E-012
RG
YV
INJECTOR 2
E-020
2
GBr
5 67
ECM
B-001
E-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
1 2
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101 E-020
B
B-001 E-001
B B
C1 C2 C3 C4 C5 C6 C7 1 2 3 4 5 6 7 8 B-020
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18
16 15 14 13 12 11 10 9 B
B-013
W EA19060150

DTC Detection
Condition
P0202-13
Circuit
Circuit Low
 ECM
P0265-12
Circuit High

1.
CAUTION
Diagnosis Procedure


ground point
OK

OK


+ -
Condition
E-020 (1) - Body 1 2
ground
E-020
OK Go to step 5
06
RA19060400
NG

connector B-013.
+ -
E-020
Check for Open
Condition
C1 C2 C3 C4 C5 C6 C7
E-020 (1) - B-013 C11 C12 C13 C14
(C6)
B-013
Check for Short

Condition
E-020 (1) or B-
013 (C6) - Body Always No continuity
ground
E-020 (1) or B-
013 (C6) - Battery Always No continuity
positive


OK

Check for Open
+ -
06 Connection
Condition
Condition
1 2
E-020
E-020 (2) - E-001
Always Continuity
(67)
Check for Short 76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77

Condition
E-020 (2) or E-
001 (67) - Body Always No continuity E-001
ground RA19060420
E-020 (2) or E-
positive

OK
Multimeter + -
Connection
1-2 11 - 16 Ω ( at 20°C)
RA19080280
OK

7 Check for DTCs

NG Replace ECM
OK

been repaired.
06

06

BATTERY
86 30
ECM
MAIN
RELAY
ENGINE
85 87 COMPARTMENT
FUSE AND
EF20 RELAY BOX
10A B-013
C17 R C6 06
B-020
9
E-012
RG
YV
1
INJECTOR 3
E-017
2
GB
5 72
ECM
B-001
E-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
1 2
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101 E-017
B
B-001 E-001
B B
C1 C2 C3 C4 C5 C6 C7 1 2 3 4 5 6 7 8 B-020
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18
16 15 14 13 12 11 10 9 B
B-013
W EA19060160

DTC Detection
Condition
P0203-13
Circuit
Circuit Low
 ECM
P0268-12
Circuit High

 If the DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

OK


+ -
Condition
E-017 (1) - Body 1 2
ground
E-017
OK Go to step 5
06
RA19060430
NG

connector B-013.
+ -
E-017
Check for Open
Condition
C1 C2 C3 C4 C5 C6 C7
E-017 (1) - B-013 C11 C12 C13 C14
(C6)
B-013
Check for Short

Condition
E-017 (1) or
B-013 (C6) - Body Always No continuity
ground
E-017 (1) or
Battery positive


OK

Check for Open
+ -
06 Connection
Condition
Condition
1 2
E-017
E-017 (2) - E-001
Always Continuity
(72)
Check for Short 76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77

Condition
E-017 (2) or
E-001 (72) - Body Always No continuity E-001
ground RA19060450
E-017 (2) or
Battery positive

OK
Multimeter + -
Connection
1-2 11 - 16 Ω ( at 20°C)
RA19080280
OK

7 Check for DTCs

NG Replace ECM
OK

been repaired.
06

06

BATTERY
86 30
ECM
MAIN
RELAY
ENGINE
85 87 COMPARTMENT
FUSE AND
EF20 RELAY BOX
10A B-013
C17 R C6 06
B-020
9
E-012
RG
YV
1
INJECTOR 4
E-016
2
GW
5 74
ECM
B-001
E-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
1 2
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101 E-016
B
B-001 E-001
B B
C1 C2 C3 C4 C5 C6 C7 1 2 3 4 5 6 7 8 B-020
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18
16 15 14 13 12 11 10 9 B
B-013
W EA19060170

DTC Detection
Condition
P0204-13
Circuit
Circuit Low
 ECM
P0271-12
Circuit High

CAUTION
Diagnosis Procedure


ground point
OK

OK


+ -
Condition
E-016 (1) - Body 1 2
ground
E-016
OK Go to step 5
06
RA19060460
NG

connector B-013.
+ -
E-016
Check for Open
Condition
C1 C2 C3 C4 C5 C6 C7
E-016 (1) - B-013 C11 C12 C13 C14
(C6)
B-013
Check for Short

Condition
E-016 (1) or
B-013 (C6) - Body Always No continuity
ground
E-016 (1) or
Battery positive


OK

Check for Open
+ -
06 Connection
Condition
Condition
1 2
E-016
E-016 (2) - E-001
Always Continuity
(74)
Check for Short 76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77

Condition
E-016 (2) or
ground RA19060480
E-016 (2) or
Battery positive

OK
Multimeter + -
Connection
1-2 11 - 16 Ω ( at 20°C)
RA19080280
OK

7 Check for DTCs

NG Replace ECM
OK

been repaired.
06

Throttle/Pedal Position Sensor/Switch B Range/

DTC P0221-29
Performance
DTC P0222-16 Throttle/Pedal Position Sensor/Switch B Low Input
DTC P0223-17 Throttle/Pedal Position Sensor/Switch B High Input
06

THROTTLE POSITION SENSOR

E-015
1 4 2 5 3 6
06
RGr
RBr
GR
RB
RY
RL
87 75 86 78 107 77
ECM
E-001
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77 1 2 3
100 99 98 97 96 95 94 93 92 91 90 89 4 5 6
112 111 110 109 108 107 106 105 104 103 102 101
E-015
B
E-001
B
EA19060130

DTC Detection
Condition
Throttle/Pedal Position
P0221-29 Sensor/Switch B
Range/Performance
Throttle/Pedal Position  Throttle position Sensor 2
Ignition switch ON
P0222-16 Sensor/Switch B Low  Wire harness or connector
Input Engine running
 ECM
Throttle/Pedal Position
P0223-17 Sensor/Switch B High
Input

06 Confirm that the battery voltage is over 12 V before performing the following procedures.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check throttle position sensor connector
a. Disconnect the throttle position sensor connector E-015

(1).
b. Check the throttle position sensor connector.
1
2
RA19100080
OK
06
3 Check throttle position sensor 2 signal voltage
a. Connect the throttle position sensor connector E-015.

b. Turn the ignition switch to ON. Datastream
c. Using the diagnostic tester, check the throttle position multiplicative correction of the mixture adaptation 1.00
sensor 2 signal voltage. Lambda controller output bank 2 0.00
Standard Value sensor voltage from throttle potentiometer 2 4.21 V
Condition additive correction of the mixture adaptation 0.00 %
(V) Voltage PWG potentiometer 1 0.99 V
Accelerator pedal released 4.21

Accelerator pedal depressed 0.75 RA19100071
OK Go to step 8
NG
4 Check throttle position sensor power supply voltage

b. Disconnect the throttle position sensor connector E-015.
c. Turn the ignition switch to ON and check the voltage
between throttle position sensor connector terminal and V
+ -
body ground.
Condition 1 2 3
E-015 (3) - Body

ground E-015
OK Go to step 6
RA19060300

NG
5 Check throttle position sensor power supply circuit

c. Check the wire harness between throttle position sensor
+ -
4 5 6
Condition
E-015
E-015 (3) - E-001
Always Continuity
06 (107)
76 75 74 73 72 71 70 69 68 67 66 65
Check for Short 88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89
Condition
E-015 (3) or E-001
RA19060310
Body ground
E-015 (3) or
Battery positive

(throttle position sensor - ECM)
OK
6 Check throttle position sensor 2 signal circuit and ground circuit
a. Check the wire harness between throttle position sensor

Check for Open
Condition
4 5 6
E-015 (5) - E-001

Always Continuity
(78)
E-015
E-015 (2) - E-001
Always Continuity
(86)
76 75 74 73 72 71 70 69 68 67 66 65
Check for Short 88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89
Condition
E-015 (5) or E-001
RA19060481
ground

Condition
E-015 (5) or
Battery positive
E-015 (2) or
ground
E-015 (2) or
Battery positive

connector (throttle position sensor - ECM)
06
OK
7 Check throttle position sensor 2
a. Check the resistance of throttle position sensor 2.
Multimeter
Specified Condition
Connection
Resistance changes continuously
2-5 when throttle valve is moved by
hands.
NG Replace electronic throttle
OK
8 Check for DTCs

NG Replace ECM
OK

been repaired.

Random/Multiple Cylinder Misfire Detected (Over

DTC P0300-21
Emission Limit)
Random/Multiple Cylinder Misfire Detected (Harmful to

DTC P0300-22
Catalyst)
Random/Multiple Cylinder Misfire Detected (During First

DTC P0300-29
Statistic Cycle)
DTC P0301-21 Cylinder 1 Misfire Detected (Over Emission Limit)
06 DTC P0301-22 Cylinder 1 Misfire Detected (Harmful to Catalyst)
DTC P0301-29 Cylinder 1 Misfire Detected (During First Statistic Cycle)
DTC P0302-22 Cylinder 2 Misfire Detected (Harmful to Catalyst)
DTC P0302-29 Cylinder 2 Misfire Detected (During First Statistic Cycle)
DTC P0303-29 Cylinder 3 Misfire (During First Statistic Cycle)
DTC P0304-29 Cylinder 4 Misfire (During First Statistic Cycle)

BATTERY
86 30
ECM
MAIN
RELAY ENGINE
COMPARTMENT
85 87
FUSE AND
RELAY BOX
EF16 B-013
15A B-017
C17
RB
H4
06
B-020
16
E-012
RB
RB
RB
YV
CYL1 CYL4 CYL3 CYL2

3 4
IGNITION
COIL
E-010
1 2
GrG
GrL
5 100 99
ECM
B-001
E-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
1 2 3 4
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101
E-010
B
B-001 E-001
B B
H1 H2 H3 H4 H5 H6 H7
C1 C2 C3 C4 C5 C6 C7 1 2 3 4 5 6 7 8 B-020
C11 C12 C13 C14 H8 H9 H10 H11H12H13H14
C8 C9 C10 C15 C16 C17 C18
16 15 14 13 12 11 10 9 B
B-017
B-013 W
W EA19060180

DTC Detection
Condition
Random/Multiple
Cylinder Misfire
P0300-21
Detected (Over
Emission Limit)
Random/Multiple
Cylinder Misfire
P0300-22
Detected (Harmful to
Catalyst)
Random/Multiple
Cylinder Misfire
P0300-29
Detected (During First
Statistic Cycle)
06 Cylinder 2 Misfire
P0301-21 Detected (Over
Emission Limit)
Cylinder 2 Misfire
P0301-22 Detected (Harmful to
Catalyst)
Cylinder 1 Misfire
P0301-29 Detected (During First
Statistic Cycle)
Cylinder 1 Misfire
P0302-21 Detected (Over  Ignition coil
Emission Limit)  Spark plug
Engine running
Cylinder 1 Misfire  Wire harness or connector
P0302-22 Detected (Harmful to  ECM
Catalyst)
Cylinder 2 Misfire
P0302-29 Detected (During First
Statistic Cycle)
Cylinder 3 Misfire
Emission Limit)
Cylinder 3 Misfire
Catalyst)
Cylinder 3 Misfire
P0303-29 (During First Statistic
Cycle)
Cylinder 4 Misfire
Emission Limit)
Cylinder 4 Misfire
Catalyst)
Cylinder 4 Misfire
P0304-29 (During First Statistic
Cycle)


CAUTION
06
Diagnosis Procedure


ground point
OK
2 Check ignition coil connector

b. Disconnect the ignition coil connector E-010.
c. Check the ignition coil connector.
OK
3 Check spark plug of misfiring cylinder
a. Remove the spark plug of misfiring cylinder.

b. Check the spark plug for burns, cracks or deposits.
c. Check the spark plug gap.
OK: 0.8 - 0.9 mm
NG Clean or replace spark plug
OK

4 Check spark
a. Connect the ignition coil connector.

b. Connect the spark plug and ignition coil, and ground the spark plug housing.
c. Start and run the engine for no more than 2 seconds, and check if spark is generated.
NG Go to step 6
OK
5 Check compression of misfiring cylinder
a. Measure the compression of misfiring cylinder (See page 07-17).

06 NG Check engine to confirm cause of low
compression
OK Check injectors, valve clearance, intake

system and fuel pressure, etc. of misfiring
cylinder
6 Check spark of misfiring cylinder with a normally functioning spark plug
a. Replace the spark plug with a normally functioning one.

b. Perform spark test.
 Connect the ignition coil connector.
 Connect the spark plug and the ignition coil, and ground the spark plug housing.
 Start and run the engine for no more than 2 seconds, and check if spark is generated.
OK Replace spark plug
NG
7 Check ignition coil
a. Check the resistance of primary winding of ignition coil.
Multimeter + -
1 2 3 4
Connection
Terminal 1 - Normal
0.50 - 0.64
Terminal 3 temperature
Terminal 2 - Normal
0.50 - 0.64
RA19140080

b. Check the resistance of secondary winding of ignition

coil.
Multimeter Specification
Condition
Connection (kΩ) 3 1
Normal
Post 1 - Post 4 8.36 - 10.64
temperature 2 4
Normal
Post 2 - Post 3 8.36 - 10.64
temperature
RA19140090
NG Replace ignition coil
OK
06
8 Check ignition coil power supply voltage

b. Check the voltage between ignition coil connector
terminals and body ground.
V
Condition
E-010 (3), E-010
Ignition switch ON 11 to 14 V 1 2 3 4
(4) - Body ground
E-010
OK Go to step 10
RA19060490
NG

9 Check ignition coil power supply circuit

c. Check the wire harness between ignition coil connector
terminals and engine compartment fuse and relay box
+ -
Check for Open
1 2 3 4
Condition
E-010
E-010 (3), E-010
Always Continuity
(4) - B-017 (H4)
06 Check for Short H1 H2 H3 H4 H5 H6 H7

H8 H9 H10 H11H12H13H14
Condition B-017
RA19060500
E-010 (3), E-010
(4) or B-017 (H4) - Always No continuity
Body ground
E-010 (3), E-010
(4) or B-017 (H4) - Always No continuity
Battery positive

(ignition coil - engine compartment fuse
and relay box)
OK
10 Check ignition coil control circuit

c. Check the wire harness between ignition coil connector
+ -
Check for Open
1 2 3 4
Condition
Connection Condition E-010
E-010 (1) - E-001

(100) 76 75 74 73 72 71 70 69 68 67 66 65
Always Continuity
E-010 (2) - E-001 88 87 86 85 84 83 82 81 80 79 78 77
(99) 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-001
RA19060510

Check for Short
Condition
E-010 (1) or
Body ground
E-010 (1) or
Battery positive
E-010 (2) or
ground
E-010 (2) or
E-001 (99) - Always No continuity 06
Battery positive

connector (ignition coil - ECM)
OK
11 Check for DTCs

c. Check if DTC P0300-21, P0300-22, P0300-29, P0301-21, P0301-22, P0301-29, P0302-21, P0302-22,
P0302-29, P0303-21, P0303-22, P0303-29, P0304-21, P0304-22 or P0304-29 still exists?
NG Replace ECM
OK

been repaired.

DTC P0322-00 EPM - Crankshaft Signal Fault
ECM
E-001
96 97
06
YW
YR
1 2
ENGINE
SPEED
S
SENSOR
N E-013
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77 1 2 3
100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101 E-013
B
E-001
B
EA19060190

DTC Detection
Condition
 Engine speed sensor
EPM - Crankshaft  Flywheel ring gear
Signal Fault  Wire harness or connector
 ECM

CAUTION
Diagnosis Procedure


ground point
OK
2 Check engine speed sensor signal waveform
a. Turn the ignition switch to ON, start the engine and observe the signal waveform of engine speed sensor
with an oscilloscope.

Normal Waveform of Engine Speed Senor Signal
Oscilloscope
RA19060750
OK Go to step 9
06
NG
3 Check engine speed sensor connector

b. Disconnect the engine speed sensor connector E-013.
c. Check the engine speed sensor connector.
NG Repair or replace engine speed sensor

connector
OK
4 Check installation of engine speed sensor
a. Remove the engine speed sensor.

b. Check and clean the engine speed sensor and installation area, and check for damage, foreign matter or
excessive movement, etc. that cause signal incorrectness.
NG Clean or replace engine speed sensor
OK
5 Check resistance of engine speed sensor
a. Check the resistance between engine speed sensor

terminals 1 and 2.  3 2 1
+ -
Normal resistance: 860 Ω ± 20% (at normal temperature)
NG Replace engine speed sensor
RA19060760

OK
6 Check engine speed sensor circuit
a. Disconnect the engine speed sensor connector E-013.

c. Check the wire harness between engine speed sensor
connector terminals and body ground.
+ -
Condition E-013
E-013 (1) - E-001
(96) 76 75 74 73 72 71 70 69 68 67 66 65
06
Always Continuity
E-013 (2) - E-001 88 87 86 85 84 83 82 81 80 79 78 77
(97) 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
Check for Short
Multimeter Specified E-001

Condition RA19060520
E-013 (1) or E-
ground
E-013 (1) or E-
positive
E-013 (2) or E-
ground
E-013 (2) or E-
positive

(engine speed sensor - ECM)
OK
7 Install a normal engine speed sensor and observe signal waveform
a. Install a normal engine speed sensor.

b. Connect the engine speed sensor connector.
c. Turn the ignition switch to ON, start the engine and observe the signal waveform of the engine speed
sensor with an oscilloscope.
OK Replace engine speed sensor
NG

8 Check flywheel ring gear
a. Turn the crankshaft and check the crankshaft and flywheel ring gear for damage and foreign matter, etc.
that cause signal incorrectness.
NG Remove debris and clean flywheel ring

gear or replace flywheel (See page 07-55)
OK
9 Check for DTCs

06
c. Check if DTC P0322 still exists.
NG Replace ECM
OK

been repaired.

DTC P0327-16 Knock Sensor 1 Circ. Low Input
DTC P0328-17 Knock Sensor 1 Circ. High Input
ECM
E-001
90 89
06
YR
YB
1 2
KNOCK
SENSOR
E-003
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
1 2 3
100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-003
B
E-001
B
EA19060200

DTC Detection
Condition
Knock Sensor 1 Circ.
P0327-16  Knock sensor
Low Input
Engine running  Wire harness or connector
Knock Sensor 1 Circ.
P0328-17  ECM
High Input

06  Use the X-431 3G diagnostic tester to record and clear the DTCs stored in the ECM.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check knock sensor connector
a. Disconnect the knock sensor connector E-003 (1).

b. Check the knock sensor connector.

V
+ -
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
06
B-001
RA19060610
OK
3 Check installation of knock sensor
a. Remove the knock sensor.

b. Check the installation area of the knock sensor for damage, foreign matter and excessive movement, etc.
that cause signal incorrectness.
NG Clean installation area or replace knock

sensor
OK
4 Check resistance of knock sensor
a. Check the resistance between knock sensor terminals 1 and 2.

OK: Above 1 MΩ (at normal temperature)
NG Replace knock sensor
OK

5 Check knock sensor signal circuit
a. Disconnect the ECM wire harness connector E-001.

b. Check the wire harness between terminals of connector
E-001 and connector E-003.
Check for Open
+ -
1 2 3
Specified
Multimeter Connection
Condition
E-003
E-001 (90) - E-003 (1) Continuity
E-001 (89) - E-003 (2) Continuity
76 75 74 73 72 71 70 69 68 67 66 65
Check for Short 88 87 86 85 84 83 82 81 80 79 78 77
06 Specified
100 99 98 97 96 95 94 93 92 91 90 89
Multimeter Connection 112 111 110 109 108 107 106 105 104 103 102 101
Condition
E-001 (90) or E-003 (1) - Body ground No continuity
E-001
E-001 (90) or E-003 (1) - Battery RA19060530
No continuity
positive
E-001 (89) or E-003 (2) - Body ground No continuity
E-001 (89) or E-003 (2) - Battery
No continuity
positive
NG Replace wire harness or connector (knock

sensor - ECM)
OK
6 Check knock sensor signal
a. Install the knock sensor.

b. Slightly strike around the knock sensor with a rubber hammer, and measure if voltage is generated
between the 2 terminals of knock sensor with the multimeter at the same time.
NG Replace knock sensor
OK
7 Check for DTCs

NG Replace ECM
OK


been repaired.
06

DTC P0341-00 EPM - Camshaft Signal Fault
CAMSHAFT POSITION SENSOR

E-009
06
1 2 3
LW
BL
Gr
95 93 98
ECM
E-001
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
1 2 3 100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-009
B
E-001
B
EA19060210

DTC Detection
Condition
 Camshaft position sensor
EPM - Camshaft  Camshaft
Signal Fault  Wire harness or connector
 ECM

CAUTION
Diagnosis Procedure


ground point
OK
2 Check camshaft position sensor signal waveform
a. Turn the ignition switch to ON, start the engine and observe the signal waveform of camshaft position

Normal Waveform
Oscilloscope
2.00 V 10.0 ms
RA19060770
OK Go to step 9
06
NG
3 Check camshaft position sensor connector

b. Disconnect the camshaft position sensor connector E-009.
c. Check the camshaft position sensor connector.
NG Repair or replace camshaft position

sensor connector
OK
4 Check camshaft position sensor power supply voltage

b. Check the voltage between camshaft position sensor
connector E-009 and body ground.
V
Condition
E-009 (3) - Body
ground 1 2 3
E-009
OK Go to step 6
RA19060540
NG

5 Check camshaft position sensor power supply circuit

c. Check the wire harness between camshaft position
+ -
terminals.
1 2 3
Check for Open
E-009
Condition
E-009 (3) - E-001
Always Continuity 76 75 74 73 72 71 70 69 68 67 66 65
(98) 88 87 86 85 84 83 82 81 80 79 78 77
Check for Short 100 99 98 97 96 95 94 93 92 91 90 89

06
112 111 110 109 108 107 106 105 104 103 102 101
Condition
RA19060550
E-009 (3) or
ground
E-009 (3) or
Battery positive
NG Repair or replace wire harness or connector

(camshaft position sensor - ECM)
OK Replace ECM
6 Check camshaft position sensor signal circuit and ground circuit
a. Check the wire harness between camshaft position

terminals.
Check for Open
+ -
Condition 1 2 3
E-009
E-009 (2) - E-001
(93)
Always Continuity
E-009 (1) - E-001 76 75 74 73 72 71 70 69 68 67 66 65
(95) 88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89
Check for Short
112 111 110 109 108 107 106 105 104 103 102 101
Condition
RA19060560
E-009 (2) or
ground

Condition
E-009 (2) or
Battery positive
E-009 (1) or
ground
E-009 (1) or
Battery positive

06 (camshaft position sensor - ECM)
OK
7 Check installation of camshaft position sensor
a. Remove the camshaft position sensor.

b. Check and clean the camshaft position sensor and installation area, and check for damage, foreign matter
and excessive movement, etc. that cause signal incorrectness.
NG Clean installation area or replace

camshaft position sensor
OK
8 Check camshaft ring gear
a. Check the camshaft ring gear for damage and foreign matter (such as debris), etc. that cause signal
incorrectness.
NG Remove debris and clean camshaft ring

gear or replace camshaft
OK
9 Install a normal camshaft position sensor and observe signal waveform
a. Install a normal camshaft position sensor.

b. Connect the camshaft position sensor connector.
c. Turn the ignition switch to ON, start the engine and observe the signal waveform of the camshaft position
OK Replace camshaft position sensor
NG

10 Check for DTCs

c. Check if DTC P0341-00 still exists.
NG Replace ECM
OK

been repaired.
06

DTC P0420-00 Catalyst Conversion Insufficient
DTC Detection
Condition
 Three-way catalytic converter
 Leakage in exhaust system
Catalyst Conversion
P0420-00 Engine running  Upstream oxygen sensor
Insufficient
 Downstream oxygen sensor
 ECM

06  Turn the ignition switch to LOCK.
 If the DTC is detected, the malfunction indicated by the DTC is current. Go to the diagnosis
procedure - Step 1.
Diagnosis Procedure
1 Check for any other DTCs output (in addition to DTC P0420-00)
a. Connect the X-431 3G diagnostic tester to the Data Link Connector (DLC).
b. Turn the ignition switch to ON. Start the engine and warm it up to the normal operating temperature, and
then select Read Code.
Display (DTC Output) Proceed to

DTC P0420-00 A
DTC P0420-00 and other DTCs B
B Go to DTC chart, and perform

troubleshooting for other DTCs first
2 Read datastream
a. Read datastream using the diagnostic tester.

b. Check the datastream below.
Item OK (Idling) If it is NG, proceed to

Quickly fluctuates between 0.1 to
Upstream Oxygen Sensor Voltage A
0.9 V
Downstream Oxygen Sensor
Fluctuates slightly at about 0.45 V B
Voltage
Average Injection Pulse Width About 3.5 ms C
A Replace upstream oxygen sensor
C Check injector, fuel pressure and other

causes for abnormal injection pulse width
B
06
3 Check exhaust system
a. Turn the ignition switch to ON and start the engine.

b. Check the exhaust system for leakage.
NG Repair or replace related exhaust system

components
OK
4 Check downstream oxygen sensor
OK Replace three-way catalytic converter
5 Check for DTCs

c. Check if DTC P0420-00 still exists.
NG Replace ECM
OK

been repaired.

Evaporative Emission System Purge Control Valve

DTC P0444-13
Circuit Open

DTC P0458-16
Circuit Low

DTC P0459-17
Circuit High
06

BATTERY
86 30
ECM
MAIN
RELAY ENGINE
COMPARTMENT
85 87
FUSE AND
RELAY BOX
B-013
EF18 B-017
10A
C17 H6 06
R
B-020
12
E-012
R 1
CANISTER
SOLENOID
VALVE
YV
E-018
2
WG
5 94
ECM
B-001
E-001
C1 C2 C3 C4 C5 C6 C7 H1 H2 H3 H4 H5 H6 H7 1 2 3 4 5 6 7 8
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18 H8 H9 H10 H11H12H13H14 16 15 14 13 12 11 10 9
B-013 B-017
W W
B-020
B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 76 75 74 73 72 71 70 69 68 67 66 65
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
1 2
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
112 111 110 109 108 107 106 105 104 103 102 101
E-018
B
B-001 E-001
B B EA19060220

DTC Detection
Condition
Evaporative Emission
P0444-13 System Purge Control
Valve Circuit Open
Evaporative Emission  Canister solenoid valve
P0458-16 System Purge Control Engine running  Wire harness or connector
Valve Circuit Low  ECM
Evaporative Emission
P0459-17 System Purge Control
Valve Circuit High

06 Confirm that the battery voltage is over 12 V before performing the following procedures.
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
NG

2 Check canister solenoid valve connector
a. Disconnect the canister solenoid valve connector E-018.

b. Check the canister solenoid valve connector.
RA19090030
OK
06
3 Check canister solenoid valve power supply voltage

b. Measure the voltage between canister solenoid valve
connector terminal and body ground.
V
Condition
E-018 (1) - Body
Ignition switch ON 11 to 14 V 1 2
ground
E-018
OK Go to step 5
RA19060570
NG

4 Check canister solenoid valve power supply circuit

connector B-017.
+ -
d. Check the wire harness between canister solenoid valve
connector terminals and engine compartment fuse and
relay box connector terminals.
1 2
Check for Open
E-018
Condition
06 E-018 (1) - B-017

(H6)
Always Continuity H1 H2 H3 H4 H5 H6 H7
H8 H9 H10 H11H12H13H14
Check for Short B-017

Condition
E-018 (1) or
B-017 (H6) - Body Always No continuity
ground

connector (canister solenoid valve - engine
OK

5 Check canister solenoid valve control circuit

b. Check the wire harness between canister solenoid valve
Check for Open
+ -
Multimeter Specified 1 2
Condition
E-018
E-018 (2) - E-001
Always Continuity
(94)
Check for Short 76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
Multimeter
Condition
Specified 100 99 98 97 96 95 94 93 92 91 90 89
06
E-018 (2) or
ground RA19060590
E-018 (2) or
Battery positive

connector (canister solenoid valve - ECM)
OK
6 Check canister solenoid valve
a. Check the resistance of canister solenoid valve.
Multimeter + -
Connection
1-2 26 ± 4 Ω (at 20°C)
b. With battery voltage applied between terminals 1 and 2,

the valve should open when air is sucked into the valve;
With battery voltage applied, the valve should close when
air is sucked into the valve.
RA19090050
NG Replace canister solenoid valve
OK

7 Check for DTCs

NG Replace ECM
OK

been repaired.
06

DTC P0480-13 Cooling Fan 1 Control Circuit
DTC P0481-13 Cooling Fan 2 Control Circuit
DTC P0691-11 Fan 1 Control Circuit Low
DTC P0692-12 Fan 1 Control Circuit High
DTC P0693-11 Fan 2 Control Circuit Low
DTC P0694-12 Fan 2 Control Circuit High

06

BATTERY
86 30
ECM EF23 EF22
MAIN 30A 40A
RELAY
ENGINE
85 87 COMPARTMENT
30 86 30 86 FUSE AND
EF18 LOW HIGH RELAY BOX
10A FAN FAN B-013
RELAY RELAY E-039
87 85 87 85
06 C17 B11 C15 B9 C9

L
BrG
VR
R
L
1 2
COOLING COOLING
FAN 1 FAN 2
E-031 E-032
YV
3 3
M M
2
R
1
R
B
E-036
5 56 31
ECM
B-001
C1 C2 C3 C4 C5 C6 C7 B1 B2 B3 B4 B5
C11 C12 C13 C14 B8 B9 B10 B11
C8 C9 C10 C15 C16 C17 C18 B6 B7 B12 B13 B14
B-013 E-039
W W
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
3 2 2 3
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
E-031 E-032
B B
B-001
B
EA19060230

DTC Detection
Condition
Cooling Fan 1 Control
P0480-13
Circuit
Cooling Fan 2 Control
P0481-13
Circuit
Fan 1 Control Circuit  Cooling fan relay
P0691-11
Low  Fuse
Ignition switch ON
Fan 1 Control Circuit  Wire harness or connector
P0692-12
High  ECM
Fan 2 Control Circuit
P0693-11
Low
P0694-12
Fan 2 Control Circuit 06
High

procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check cooling fan connector
a. Disconnect the cooling fan connectors E-031 and E-032.

b. Check the cooling fan connectors.
OK
3 Check cooling fan relay
a. Unplug the cooling fan high speed and low speed relays
from the engine compartment fuse and relay box.
06 b. Check the cooling fan high speed relay.
+ -
30 86
Multimeter
Specified Condition
Connection
30 - 87 No continuity 87 85
Continuity
30 - 87 (when battery voltage is applied 87
between terminals 85 and 86)
86
85
30
RA19060780
c. Check the cooling fan low speed relay.
Multimeter + -
Specified Condition
Connection 30 86
30 - 87 No continuity
Continuity
30 - 87 (when battery voltage is applied
87 85
NG Replace relay
85
30
87
86
RA19060790
OK
4 Check cooling fan relay circuit voltage

a. Check the terminal voltage of cooling fan relay (engine

compartment fuse and relay box side).
Condition V
Connection Condition + -
Terminal 30 and
86 (low speed
11 to 14 V
fan) - Body
ground Low
Ignition switch ON
speed fan
relay
Terminal 30 and
86 (high speed High
speed fan
11 to 14 V relay
fan) - Body
ground
NG Check cooling fan fuse, repair or replace

wire harness or connector (fan relay - 06
RA19060800
battery)
OK
5 Check wire harness and connector (engine compartment fuse and relay box - ECM)
a. Disconnect the engine compartment fuse and relay box

connectors B-013.
c. Check the wire harness between ECM connector
+ -
connector terminals. C1 C2 C3
C11 C12 C13 C14
C4 C5 C6 C7
C8 C9 C10 C15 C16 C17 C18
Check for Open
B-013
Specified
Condition
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-001 (56) - B-013 (C15) Continuity 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B-001 (31) - B-013 (C9) Continuity 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33

64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Check for Short
Specified B-001
Multimeter Connection RA19060600
Condition
B-001 (56) or B-013 (C15), B-001 (31)
No continuity
or B-013 (C9) - Body ground
B-001 (56) or B-013 (C15), B-001 (31)
No continuity
or B-013 (C9) - Battery positive

connector
6 Check for DTCs


c. Check if DTC P0480-13, P0481-13, P0691-11, P0692-12, P0693-11 or P0694-12 still exists.
NG Replace ECM
OK

been repaired.
06

DTC P0560-00 Non-plausible Error of Battery Voltage
DTC P0562-16 System Voltage Low
DTC P0563-17 System Voltage High
06

BATTERY
IGNITION SWITCH
ON OR START
EF35
10A 86 30
ECM
MAIN INSTRUMENT
RELAY PANEL FUSE
ENGINE RF04 AND RELAY
85 87 COMPARTMENT BOX
10A
FUSE AND I-005
RELAY BOX
EF17 B-012
4
15A B-013
06 C1 C17 D6
RW
R
I-003
34
B-050
RB
YV
R
RW
20 5 15 16 35
ECM
B-001
C1 C2 C3 C4 C5 C6 C7 D1 D2 D3 D4 D5 D6 D7 D8
C11 C12 C13 C14 D13 D14 D15 D16
C8 C9 C10 C15 C16 C17 C18 D9 D10 D11D12 D17 D18 D19 D20
B-013 B-012
W W
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 13 14 15 16 17 18 19 20 21 22 23 24
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 25 26
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 87
85 86 86 86
87 30 87 30
30 85 85
B-001 I-005
B B EA19060240

DTC Detection
Condition
Non-plausible Error of  Fuse
P0560-00
Battery Voltage  Wire harness or connector
P0562-16 System Voltage Low Ignition switch ON  Battery
 Battery terminal
P0563-17 System Voltage High
 ECM

 Turn the ignition switch to ON. 06
procedure - Step 1.
CAUTION
Diagnosis Procedure
1 Check battery
a. Check if the battery voltage is normal.
NG Recharge or replace battery
OK
2 Check battery terminals
a. Check if the battery terminals are loose or corroded.
NG Tighten or replace battery terminals
OK



ground point
OK
4 Check ECM connector

06 b. Check the ECM connector.
NG Repair or replace ECM connector
OK
5 Check ECM power supply voltage (battery voltage)
a. Measure the voltage between ECM connector B-001

terminal and body ground.
Condition V
Connection Condition + -
B-001 (20) - Body

Always 11 to 14 V
ground 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
NG Go to step 8 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
RA19060610
OK

6 Check ECM fuse
a. Unplug the ECM fuse EF35 (10 A) from the engine compartment fuse and relay box.
b. Check the resistance of fuse EF35.
Standard resistance: less than 1 Ω
NG Replace ECM fuse
OK
7 Check wire harness and connector (ECM - engine compartment fuse and relay box)

connector B-013. 06
b. Check the wire harness between the connector
terminals.
+ -
Check for Open
C1 C2 C3 C4 C5 C6 C7
C11 C12 C13 C14
Specified C8 C9 C10 C15 C16 C17 C18
Condition B-013
B-001 (20) - B-013 (C1) Continuity
Check for Short 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Specified 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
Condition 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
E-001 (20) or B-013 (C1) - Body

No continuity
ground B-001
RA19060620
E-001 (20) or B-013 (C1) - Battery
No continuity
positive

connector
OK
Repair or replace engine compartment fuse and relay box or wire harness (engine compartment fuse
and relay box - battery)

8 Check ECM power supply voltage (ignition switch voltage)

b. Check the voltage between terminals of ECM connector
B-001.
V
Condition
B-001 (35) -
B-001 (63) or Ignition switch ON 11 to 14 V 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-001 (64) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
NG Go to step 11
06 B-001
RA19060630
OK
9 Check ECM fuse
a. Unplug the fuse RF04 (10 A) from the instrument panel fuse and relay box.
b. Check the resistance of fuse RF04.
Standard resistance: less than 1 Ω
NG Replace fuse
OK

10 Check wire harness and connector (ECM - instrument panel fuse and relay box)
a. Disconnect the instrument pane fuse and relay box

connector I-005.
b. Check the wire harness between the terminals of the wire
harness side connector. 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
+ -
Check for Open 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
Specified 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Condition
B-001 (35) - I-005 (4) Continuity B-001
Check for Short 1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
Specified 25 26 06
Condition 87
85 86 86 86
87 30 87 30
B-001 (35) or I-005 (4) - Body ground No continuity 30 85 85
B-001 (35) or I-005 (4) - Battery I-005

No continuity RA19060640
positive

connector
OK
11 Check ignition switch assembly (See page 15-11)
NG Replace ignition switch assembly
OK
Repair or replace instrument panel fuse and relay box or wire harness (instrument panel fuse and
relay box - ignition switch)
12 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0627-13 Fuel Pump Control Circuit/Open
DTC P0628-11 Fuel Pump Control Circuit Low
DTC P0629-12 Fuel Pump Control Circuit High
06

BATTERY
86 30
ECM EF21
MAIN 15A
RELAY
ENGINE
85 87 COMPARTMENT
30 86 FUSE AND
EF18 FUEL RELAY BOX
10A PUMP B-013
RELAY B-014
87 85
C17 A15 C5 06
WL
R
5
FUEL LEVEL
SENSOR AND
M FUEL PUMP
YV
B-027
1
B
B-035
5 41
ECM
B-001
C1 C2 C3 C4 C5 C6 C7 A1 A2 A3 A4 A5 A6
C11 C12 C13 C14 A10 A11 A12 A13
C8 C9 C10 C15 C16 C17 C18 A7 A8 A9 A14 A15 A16
B-013 B-014
W W
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
1 2 3 4 5
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-027
B
B-001
B
EA19060250

DTC Detection
Condition
Fuel Pump Control
P0627-13  Fuel pump relay
Circuit/Open
Fuel Pump Control
P0628-11 Ignition switch ON  ECM
Circuit Low
 Engine compartment fuse and relay
Fuel Pump Control box
P0629-12
Circuit High

procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check fuel pump relay
a. Unplug the fuel pump relay from the engine compartment

fuse and relay box.
+ -
b. Check the fuel pump relay terminals.
30 86
Multimeter
Specified Condition
Connection
87 85
Continuity
85
06
30
87
NG Replace fuel pump relay
86
RA19060790
OK
3 Check fuel pump relay control circuit

connector B-013.
c. Check the wire harness between connector terminals.
+ -
Check for Open
C1 C2 C3 C4 C5 C6 C7
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18
Specified
Condition B-013
B-001 (41) - B-013 (C5) Continuity

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Check for Short 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
Specified 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Condition
E-001 (41) or B-013 (C5) - Body
No continuity B-001
ground RA19060650
E-001 (41) or B-013 (C5) - Battery

No continuity
positive

connector (engine compartment fuse and
relay box - ECM)
OK

4 Check fuel pump relay terminal voltage

b. Measure the voltage between terminal of fuel pump relay
and body ground.
V
Condition
Fuel pump relay
terminal 86 Fuel
pump
relay
(engine
compartment fuse Ignition switch ON 11 to 14 V
and relay box
side) - Body
06 ground
NG Go to step 6
RA19060810
OK
5 Check main relay and fuse EF18
NG Replace main relay or fuse
OK
Repair or replace engine compartment fuse and relay box or wire harness (engine compartment fuse
and relay box - battery)
6 Check for DTCs

NG Replace ECM
OK

been repaired.

DTC P0645-13 A/C Clutch Relay Circuit
DTC P0646-11 A/C Clutch Relay Control Circuit Low
DTC P0647-12 A/C Clutch Relay Control Circuit High
06

BATTERY
86 30
ECM EF22
MAIN 40A
RELAY
ENGINE
85 87 COMPARTMENT
FUSE AND
30 86 RELAY BOX
A/C B-012
CLUTCH
B-013
RELAY
87 85
06 C17 R D14 C16
B-008
E-038 1
RG
R
1
A/C
PRESSURE
SWITCH
YV
E-027
2
B
E-026
5 42
ECM
B-001
C1 C2 C3 C4 C5 C6 C7 1 2
D1 D2 D3 D4 D5 D6 D7 D8
C11 C12 C13 C14 D13 D14 D15 D16
E-027
B-013 B-012 B
W W
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
16 15 14 13 12 11 10 9
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-008
B
B-001
B
EA19060260

DTC Detection
Condition
A/C Clutch Relay
P0645-13
Circuit
 A/C compressor relay
A/C Clutch Relay
P0646-11 Ignition switch ON  Wire harness or connector
Control Circuit Low
 ECM
A/C Clutch Relay
P0647-12
Control Circuit High

 Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC). 06
procedure - Step 1.
CAUTION
Diagnosis Procedure


ground point
OK

2 Check A/C compressor relay
a. Unplug the A/C compressor relay from the engine

compartment fuse and relay box.
+ -
b. Check the A/C compressor relay terminals.
30 86
Multimeter
Specified Condition
Connection
87 85
Continuity
85
06
30
87
NG Replace A/C compressor relay
86
RA19060790
OK
3 Check A/C compressor relay control circuit

connector B-013.
c. Check the wire harness between ECM connector
+ -
connector terminals. C1 C2 C3
C11 C12 C13 C14
C4 C5 C6 C7
C8 C9 C10 C15 C16 C17 C18
Check for Open
B-013
Condition
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-001 (42) -
Always Continuity 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B-013 (C16) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Check for Short
Multimeter Specified B-001

E-001 (42) or
Body ground
B-001 (42) or
Battery positive

connector (ECM - engine compartment
fuse and relay box)

OK
4 Check for DTCs

NG Replace ECM
OK
System is operating normally. 06

been repaired.

DTC P0688-91 Power Relay Sense Circuit Non-plausible Error
DTC P0688-92 Power Relay Sense Circuit Signal Error
06

BATTERY
86 30
ECM
MAIN
RELAY
ENGINE
85 87 COMPARTMENT
FUSE AND
RELAY BOX
EF17 B-012
15A B-013
C17 D6 06
R
RB
YV
5 15 16
ECM
B-001
C1 C2 C3 C4 C5 C6 C7 D1 D2 D3 D4 D5 D6 D7 D8
C11 C12 C13 C14 D13 D14 D15 D16
B-013 B-012
W W
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
B
EA19060270

DTC Detection
Condition
Power Relay Sense
P0688-91 Circuit Non-plausible  Main Relay
Error Ignition switch ON  Wire harness or connector
Power Relay Sense  ECM
P0688-92
Circuit Signal Error

 Turn the ignition switch to ON, start the engine and warm it up to the normal operating temperature.
06
 Using the X-431 3G diagnostic tester to select Read Datastream.
 If the datastream is not detected, the malfunction indicated by the DTC is current. Go to the diagnosis
procedure - Step 1.
 If the datastream is detected, the malfunction indicated by the DTC is intermittent (See page 06-18).
CAUTION
Diagnosis Procedure


ground point
OK

2 Check main relay
a. Unplug the main relay from the engine compartment fuse

and relay box.
+ -
b. Check for continuity between the terminals of main relay.
30 86
Multimeter
Specified Condition
Connection
87 85
Continuity
85
06
30
87
NG Replace main relay
86
RA19060790
OK
3 Check main relay circuit voltage
a. Measure the voltage between the terminals of main relay

(engine compartment fuse and relay box side) and body
ground.
V
Condition + -
Main relay
ECU
Main
relay
terminals 30 and
86 (engine
compartment fuse Always 11 to 14 V
and relay box
side) - Body
ground

connector (main relay - battery)
RA19060820
OK

4 Check wire harness and connector (ECM - engine compartment fuse and relay box)

connectors B-013.
c. Check the wire harness between the connector
+ -
terminals.
C1 C2 C3 C4 C5 C6 C7
Check for Open C8 C9 C10
C11 C12 C13 C14
C15 C16 C17 C18
Specified B-013
Condition
B-001 (5) - B-013 (C17) Continuity
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Check for Short 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
06 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Specified
Condition
E-001 (5) or B-013 (C17) - Body B-001
No continuity RA19060670
ground
B-001 (5) or B-013 (C17) - Battery
No continuity
positive
NG Replace ECM
OK
5 Check for DTCs


connector
OK

been repaired.

Engine Problem Symptom Diagnosis

Perform the primary inspection first before performing the malfunction diagnosis procedures:
1. Confirm that the engine malfunction indicator operates normally;
2. Using the diagnostic tester, check that no error messages are recorded;
3. Confirm that the malfunction complained by customer is present, and confirm the condition under which
the malfunction occurs.
Then, perform appearance inspection:
1. Check the fuel line for leakage;
2. Check if the vacuum line is broken or twisted, and if the connection is correct;
3. Check the intake line for blockage, air leakage, crush or damage;
4. Check if the high-voltage cable of ignition system is broken or deteriorated, and if the ignition order is
correct;
5. Check if the wire harness ground points are clean and secure;
6. Check each sensor or actuator connector for looseness or poor contact. 06
HINT:
If the above conditions exist, repair the trouble areas first. Otherwise, it will affect the repair work for the
following trouble diagnosis.
Diagnostic Help
1. Confirm that there are no trouble records for the engine;
2. Confirm that the complained trouble symptoms are present;
3. There are no abnormal conditions after performing the inspection according to the above procedures;
4. During servicing, do not ignore the vehicle maintenance condition, cylinder pressure, mechanical ignition
timing and fuel condition, etc. that can affect the system;
5. Replace ECM, and perform the test. If the trouble can be eliminated, the trouble area is in ECM; if the
trouble symptom still exists, reuse the original ECM, repeat the procedures, and perform service again.
Problem Symptoms Table
Symptom Suspected Area See page

 Battery
Engine does not crank or cranks slowly  Starter motor
06-166
while starting  Wire harness or ignition switch
 Engine mechanical
 No fuel in tank
 Fuel pump
Engine cranks normally but cannot start
 Engine speed sensor 06-168
successfully while starting
 Ignition coil
 Water in fuel
 Fuel pump
Difficult to start with hot engine  Coolant temperature sensor 06-170
 Fuel pressure regulator
 Ignition coil


 Water in fuel
 Fuel pump
 Coolant temperature sensor
Difficult to start with cold engine  Injector 06-172
 Ignition coil
 Throttle
 Water in fuel
 Fuel pump
 Injector
06 Engine speed is normal, but it is difficult to  Ignition coil
06-174
start at anytime  Throttle
 Intake pipe
 Ignition timing
 Spark plug
 Water in fuel
 Injector
 Spark plug
Engine starts normally, but idles roughly at
 Throttle 06-177
anytime
 Intake pipe
 Ignition timing
 Water in fuel
Engine starts normally, but idles roughly  Spark plug
06-179
during warming up  Throttle
 Intake pipe
 Water in fuel
Engine starts normally, but idles roughly  Spark plug
06-181
after warming up  Throttle body
 Intake pipe
Engine starts normally, but idles roughly or  Air condition system
stalls with part load (for example, A/C is 06-183
ON)  Injector
 Throttle
Engine starts normally, but idle speed is too  Vacuum pipe
06-185
high  Coolant temperature sensor
 Ignition timing


 Water in fuel
 Intake pressure/temperature sensor
and throttle position sensor
 Spark plug
Low engine speed or stalls when  Throttle 06-187
accelerating
 Intake pipe
 Injector
 Ignition timing
 Exhaust pipe
 Water in fuel
 Intake pressure sensor and throttle
position sensor
 Spark plug
06
Slow response when accelerating 06-190
 Throttle inlet pipe
 Injector
 Ignition timing
 Exhaust pipe
 Water in fuel
 Intake pressure sensor and throttle
position sensor
 Spark plug
Lack of power and poor performance when  Ignition coil
06-193
accelerating  Throttle
 Intake pipe
 Injector
 Ignition timing
 Exhaust pipe

Engine does not crank or cranks slowly while starting
Diagnosis Procedure
1 Check voltage between two battery posts when engine starts
OK: Voltage is 8 to 12 V.
NG Replace battery
OK
06 2 Check voltage of positive post of starter motor
a. The ignition switch remains in START position and check the voltage of positive post of starter motor.
OK: Voltage is 8 to 12 V.
NG Repair or replace wire harness
OK
3 Check operation of starter motor
a. Remove the starter motor.

b. Check if the there is an open circuit or if it is stuck due to poor lubrication.
NG Repair or replace starter
OK
4 Check engine lubricant and gear oil
a. If the malfunction only occurs in winter, check if the starter motor resistance is too strong because of
improper engine lubricant and gear oil selection.
NG Replace lubricant with appropriate

number
OK
5 Check engine internal mechanical resistance
a. Check if the engine internal mechanical resistance is too strong, causing the starter motor not to run or run
slowly.
NG Check and repair engine internal

resistance

OK
Go to Diagnostic Help
06

Engine cranks normally but cannot start successfully while starting
Diagnosis Procedure
1 Check fuel pressure
a. Using a fuel pressure gauge, check the fuel pressure (See page 08-12).
Standard Fuel Pressure
Condition Fuel System Pressure (kPa)

Key ON 400
Engine Idling 400
06 Key LOCK 400
NG Repair or replace fuel system
OK
2 Using diagnostic tester, observe if any speed signal is output
a. Connect the diagnostic tester, start the engine and select Read Datastream.
b. Observe if any speed signal is output.
NG Check and repair crankshaft position

sensor wire harness
OK
3 Check spark
a. Remove the ignition coil and spark plug of one cylinder, and ground the spark plug housing. Start the
engine, and check if spark is generated.
OK: Spark is generated.
NG Check and repair ignition system
OK
4 Check pressure of cylinder
NG Check engine to confirm cause of low

compression
OK

5 Check ECM power supply and ground

b. Turn the ignition switch to ON and check the ECM
V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
NG Repair or replace related wire harness 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
06
RA19060680
OK

Difficult to start with hot engine
Diagnosis Procedure

Key ON 400
Engine Idling 400
06 Key LOCK 400
OK
2 Check spark
OK
Disconnect coolant temperature sensor connector, start engine and observe if engine starts
3 successfully at this time
NG Check and repair wire harness or replace

sensor
OK
4 Check fuel pressure regulator
NG Replace fuel pressure regulator
OK
5 Check fuel condition
a. Observe if the trouble occurs just after fuel is filled.

NG Replace fuel
OK

V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 06
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
NG Repair or replace related wire harness 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
RA19060680
OK

Difficult to start with cold engine
Diagnosis Procedure

Key ON 400
Engine Idling 400
06 Key LOCK 400
OK
2 Check spark
OK
OK Check and repair wire harness or replace

sensor
NG
4 Depress accelerator pedal slightly, and observe if it is easy to start
OK Clean throttle
NG

5 Check injector for leakage or blockage
NG Clean or replace injector
OK
NG Replace fuel
OK 06

compression
OK

V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
NG Repair or replace related wire harness
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
RA19060680
OK

Engine speed is normal, but it is difficult to start at anytime
Diagnosis Procedure
1 Check air filter for blockage, and intake pipe for air leakage
NG Check and repair intake system
OK

06

Key ON 400
Engine Idling 400
Key LOCK 400
OK
3 Check spark
a. Check the spark plug of each cylinder, and observe if the type and gap are as specified.
NG Replace spark plug
OK
4 Check spark
OK


sensor
NG
6 Depress accelerator pedal slightly, and observe if it is easy to start
OK Clean throttle
NG 06
OK
NG Replace fuel
OK

compression
OK
10 Check engine ignition order and ignition timing
a. Check if the engine ignition order and ignition timing are as specified.
NG Check and repair ignition timing
OK


V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
06 B-001
RA19060680
OK

Engine starts normally, but idles roughly at anytime
Diagnosis Procedure
OK
2 Check if throttle is stuck

06
NG Repair or replace throttle
OK
3 Check spark
OK
4 Check throttle for carbon deposits
NG Clean throttle
OK
OK
NG Replace fuel
OK


compression
OK

06
OK

V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
RA19060680
OK

Engine starts normally, but idles roughly during warming up
Diagnosis Procedure
OK
2 Check spark
06
OK
NG Clean throttle
OK
Unplug coolant temperature sensor connector, start engine and observe if engine idles
4 normally during warming up

sensor
NG
OK

NG Replace fuel
OK

compression
06
OK

V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
RA19060680
OK

Engine starts normally, but idles roughly after warming up
Diagnosis Procedure
OK
2 Check spark
06
OK
NG Clean throttle
OK
Unplug coolant temperature sensor connector, start engine and observe if engine idles
4 normally after warming up

sensor
NG
OK

NG Replace fuel
OK

compression
06
OK

V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
RA19060680
OK

Engine starts normally, but idles roughly or stalls with part load (for example,
A/C is ON)
Diagnosis Procedure
NG Clean throttle
OK
Observe if engine output increases when A/C is turned on. This means that observe 06
2 changes of ignition advance angle, injection pulse width and intake air volume using
diagnostic tester
OK Go to step 4
NG
Connect ECM adapter, and disconnect pin cable of ECM corresponding terminal. Check if
3 wire harness side is HIGH-level signal with A/C ON
NG Check and repair A/C system
OK
Check if A/C system pressure, compressor magnetic clutch and A/C compressor pump are
4 normal
NG Check and repair A/C system
OK
OK


V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
06 B-001
RA19060680
OK

Engine starts normally, but idle speed is too high
Diagnosis Procedure
1 Check if accelerator pedal is stuck
NG Adjust or replace accelerator pedal
OK
2 Check intake system and connected vacuum pipe for air leakage
06
OK
NG Clean throttle
OK
Disconnect coolant temperature sensor connector, start engine and observe if engine idle is
4 normal at this time

sensor
NG
5 Check engine ignition timing
a. Check if the engine ignition timing is as specified.
OK


V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
06 B-001
RA19060680
OK

Low engine speed or stalls when accelerating
Diagnosis Procedure
OK

06

Key ON 400
Engine Idling 400
Key LOCK 400
OK
3 Check spark
OK
NG Clean throttle
OK
5 Check intake pressure/temperature sensor and throttle position sensor and wire harness

sensor
OK

OK
NG Replace fuel
06 OK
OK
a. Check exhaust system for leakage or blockage.

components
OK


V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
06
RA19060680
OK

Slow response when accelerating
Diagnosis Procedure
OK

06

Key ON 400
Engine Idling 400
Key LOCK 400
OK
3 Check spark
OK
NG Clean throttle
OK

sensor
OK

OK
NG Replace fuel
OK 06
OK

components
OK


V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
06
RA19060680
OK

Lack of power and poor performance when accelerating
Diagnosis Procedure
Check if malfunctions that clutch slipping, low tire inflation pressure, brake dragging,
1 incorrect tire size, and incorrect four-wheel alignment are present
NG Check malfunctioning component
OK
06
OK

Key ON 400
Engine Idling 400
Key LOCK 400
OK
4 Check spark
OK

5 Check spark
OK
06 NG Clean throttle
OK

sensor
OK
OK
NG Replace fuel
OK
OK


components
OK

connector terminals. 06
V
Condition
B-001 (15, 16) -
B-001 (63, 64) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-001
RA19060680
OK

ON-VEHICLE SERVICE
Coolant Temperature Sensor
Description
The coolant temperature sensor is a negative temperature coefficient sensor, which is installed into the
mounting hole in the thermostat holder.
Operation
The coolant temperature sensor provides an input signal for Engine Control Module (ECM). As the
temperature increases, the resistance of sensor decreases. As the coolant temperature changes, the
resistance of the coolant temperature sensor varies accordingly, resulting in a change in the voltage of coolant
temperature sensor signal circuit. The ECM uses the input signal to control the air-fuel mixture, ignition timing,
A/C compressor and radiator fan on/off timing.
06
Removal
1. Turn off all the electrical equipment and ignition switch.
2. Disconnect the negative battery cable.
3. Drain the coolant (See page 12-14).
WARNING
 Make sure the engine is in low temperature before operating the cooling system. Never open the
expansion tank cover and remove the drain cock plug when the engine is operating or the cooling system
is in high temperature. High-pressurized hot engine coolant and steam may flow out and cause serious
injury.
4. Remove the engine trim cover.

5. Remove the intake hose with crankcase ventilation hose assembly.
a. Loosen the worm clamps (1) at both ends of intake
hose to disconnect the intake hose. 1
(Tightening torque: 2.5 ± 0.5 N·m)
b. Loosen the elastic clamp (2) to disconnect the
crankcase ventilation hose from the cylinder head
cover.
RA19140020
c. Remove the intake hose with crankcase ventilation hose assembly.

6. Remove the coolant temperature sensor.

a. Disconnect the coolant temperature sensor connector
(1).
b. Remove the fixing bolt (arrow) from the engine speed
sensor bracket, and move the sensor bracket to one
side.
(Tightening torque: 8 ± 1 N·m) 1
RA19060900
c. Remove the coolant temperature sensor from the thermostat holder.

(Tightening torque: 11 - 16 N·m)
WARNING 06
 Remove the coolant temperature sensor when the engine cools down.
Installation
Installation is in the reverse order of removal.
CAUTION
 Perform sealing with the anaerobic seal gum.

 Confirm that the sensor is tightened fully during installation.
 After installing the engine coolant temperature sensor, add coolant and check the coolant level.

Knock Sensor
Description
The knock sensor is installed on the cylinder block, and used to detect the engine vibration caused by
detonation.
Operation
The sensitive element of knock sensor is a piezoelectric ceramic. Vibration of engine cylinder block is
transferred to the piezoelectric ceramic through a mass block in the sensor. Due to the pressure generated by
vibration of mass block, the piezoelectric ceramic generates a voltage at both electrode faces, and converts
the vibration signal to an AC voltage signal to output it. As the intensity of vibration increases, the knock
sensor output voltage increases accordingly.
Because the frequency of vibration signal caused by engine knocking is far more than that of normal engine
vibration signal, the Engine Control Module (ECM) can distinguish between the knock or non-knock signals by
06 processing these signals from the knock sensor.
Removal
4. Remove the knock sensor.
a. Disconnect the knock sensor connector (1), and move
away the knock sensor cable from the bracket.
RA19060910
b. Remove the knock sensor fixing bolt (arrow) and

knock sensor.
RA19060920

Installation
CAUTION
 Never allow any kinds of gasket and washer between sensor and engine block. Only the metal part of
sensor can contact with the engine block directly.
 DO NOT apply lubricant, grease or seal gum when installing the knock sensor. Keep the engine block
clean and dry, and never allow any foreign matter (such as oil) on the installation area of knock sensor.
 Never tap the knock sensor when installing it.
06

Oxygen Sensor
Description
This vehicle is equipped with two oxygen sensors (upstream oxygen sensor and downstream oxygen sensor).
The oxygen sensors continually monitor the oxygen concentration in the exhaust gas.
Operation
The oxygen sensor generates voltage depending on the oxygen content in the exhaust gas. The sensor
generates low voltage when the oxygen content is high, and high voltage when the oxygen content is low.
Therefore, the sensor acts as a rich-lean switch.
The oxygen sensor is equipped with a heating element that keeps the sensor at proper operating temperature
under all operating conditions.
Upstream Oxygen Sensor

06 The input signal from the upstream heated oxygen sensor informs the Engine Control Module (ECM) of the
oxygen content in the exhaust gas. Based on this input signal, the Engine Control Module (ECM) adjusts the
air-fuel ratio finely by adjusting injector pulse width.

The downstream heated oxygen sensor signal is used to detect the catalytic converter deterioration. As the
converter deteriorates, the signal from the downstream sensor begins to match the upstream sensor signal
except for a slight time delay. By comparing the signal from the upstream heated oxygen sensor to the signal
from the downstream sensor, the Engine Control Module (ECM) calculates the efficiency of catalytic
converter.
Removal & Installation - Upstream Oxygen Sensor

(See page 09-11)
Removal & Installation - Downstream Oxygen Sensor

(See page 09-13)

Camshaft Position Sensor

Description
This vehicle is equipped with an intake camshaft position sensor, which is installed on the cylinder head cover.
Operation
The camshaft position sensor is a Hall type sensor. The Hall type sensor is fixed, and the sensor plate is
installed on the camshaft. When the sensor plate is in high teeth, the applicable circuit output is low; when the
sensor plate is in missing teeth, the applicable circuit output is high. As a result, the crankshaft phase
information is provided to the Engine Control Module (ECM) so that the compression top dead center and
exhaust top dead center of the crankshaft can be distinguished.
Removal
2. Disconnect the negative battery cable. 06
4. Remove the camshaft position sensor.
a. Disconnect the camshaft position sensor connector
(1).
b. Remove the camshaft position sensor fixing bolt
(arrow).
RA19070240
c. Remove the camshaft position sensor from the cylinder head cover.
Installation
CAUTION
 Apply engine oil before installation to ensure that it is installed smoothly.

 The sensor should be pressed into the mounting hole. Never use tools (such as a hammer) to strike the
sensor into the mounting hole forcibly.

Engine Speed Sensor

Description
The engine speed sensor is installed on the clutch case, against the flywheel teeth. It is used to detect the
speed and position of crankshaft.
Operation
The engine speed sensor operates by using the magnetoelectric effect. When the crankshaft rotates, it drives
the flywheel to rotate. The flywheel teeth will cut the magnetic line of sensor, and the change of magnetic flux
causes the both ends of the sensor coil to generate output voltage with a certain frequency that is sent to
Engine Control Module (ECM). And the output signal can indicate the speed and position of crankshaft.
Removal
06 2. Disconnect the negative battery cable.
4. Remove the engine speed sensor.
a. Disconnect the engine speed sensor connector
(arrow), and move away the engine speed sensor
cable from the bracket.
RA19060930
b. Cut the band (1) of engine speed sensor cable and

remove the engine speed sensor fixing bolt (2).
(Tightening torque: 8 ± 2 N·m)
RA19060940
c. Remove the engine speed sensor from the transmission.
Installation
CAUTION
 Press in the engine speed sensor rather than tap when installing it.

Intake Pressure/Temperature Sensor

Description
The intake pressure/temperature sensor integrates with the intake manifold absolute pressure sensor and
intake temperature sensor, which is installed on the intake manifold upper body assembly.
Operation
The intake manifold absolute pressure sensing element consists of a piece of silicon chip, which will deform
mechanically as the intake manifold absolute pressure changes. The piezoresistor in the sensor will also
deform, thus changing the resistance. Voltage signal linearly related to the pressure is generated after
processing by the signal circuit of the silicon chip.
The intake temperature sensor is a negative temperature coefficient thermistor, whose resistance changes
with the intake temperature. This sensor sends the voltage of intake temperature change to the Engine
Control Module (ECM), thus monitoring the change of intake temperature.
06
Removal
4. Remove the intake pressure/temperature sensor.
connector (1).
b. Remove the intake pressure/temperature sensor
fixing bolt (arrow).
RA19060950
c. Remove the intake pressure/temperature sensor from the intake manifold.
Installation
CAUTION
 Remove the foreign matter on the sensor before installation.

 Apply grease to the O-ring before installation to prevent it from being damaged during installation.

Ignition Coil
Description
The ignition coil converts the low voltage of primary winding into the high voltage of secondary winding, and
discharges the spark plug electrode to produce sparks which will ignite the combustible air-fuel mixture in the
cylinder.
Operation
An ignition coil consists of primary winding, secondary winding, iron core and housing etc. The primary and
secondary windings form an induced circuit. An instant induced voltage generated by turning the primary
circuit switch on and off and an instant high voltage generated by secondary circuit will cause the spark plugs
to discharge, thus igniting the combustible air-fuel mixture. The primary winding will recharge when its ground
passage is on through an Engine Control Module (ECM) signal. If the Engine Control Module (ECM) cuts off
the control signal to primary winding circuit, it will stop charging and a high voltage will be induced in the
secondary winding.
06
Removal
(See page 14-10)
Installation
(See page 14-10)

Electric Fuel Pump

Description
The electric fuel pump consists of DC motor, vane pump and end cover (integrated with check valve, pressure
regulator and anti-electromagnetic interference element) etc. The pump and motor are installed coaxially, and
sealed in the same housing. Fuel is filled around the pump and motor in the housing and used for heat
dissipation and lubrication.
Operation
The battery supplies power to the electric fuel pump via the electric fuel pump relay, which can turn on the
electric fuel pump circuit only when starting and engine running. When the engine stops running because of
an accident, the fuel pump stops running automatically. The maximum pressure at the electric fuel pump
outlet is adjusted by the pressure regulator to keep the whole fuel system pressure at 400 kPa.
Removal 06
(See page 08-15)
Installation
(See page 08-15)

Fuel Injector
Description
The fuel injector is located on the cylinder head near to the intake valve, and the nozzle end is located directly
above the intake port.
Operation
The Engine Control Module (ECM) sends electric pulse to the injector coil, forming magnetic field force. When
the magnetic field force increases enough to overcome the resultant force from return spring pressure, needle
gravity and friction force, the needle begins to rise up and the injector starts to inject fuel. The pressure of
return spring forces the needle to close again when the injection pulse stops.
Removal
(See page 08-25)
06
Installation
(See page 08-25)
CAUTION
 It is necessary to replace the grommets with new ones during installation.

 Throttle self-learning must be performed after installation (See page 06-19). After self-learning is
completed, start the vehicle and check for proper functioning.

Electric Throttle Assembly

Description
The electric throttle assembly is located on the intake manifold assembly.
Operation
The electric throttle assembly is a critical part for the engine intake system. Its main function is to adjust the
intake passage area according to the driver's driving intention, and control the intake air volume to meet the
intake requirement for the engine in different operating conditions, and send back the position signals of the
throttle valve plate to the control unit to achieve accurate control. The throttle valve plate will stop at the limp
home position determined in a mechanical way.
The electric throttle assembly consists of four parts: drive module, train module, executive module and
feedback module, and all the components are integrated into the same throttle valve housing. Two-way
redundant structure is used for throttle feedback module.
06
Removal
(See page 10-12)
Installation
(See page 10-12)

Canister Solenoid Valve

Description
The canister solenoid valve is located on the canister solenoid valve bracket of the intake manifold assembly.
It opens when power is on, and closes when power is off.
Operation
The Engine Control Module (ECM) controls the opening and closing of canister solenoid valve and adjusts the
vapor flow speed from the canister to the intake manifold according to the information, such as engine load,
temperature and speed.
Removal
(See page 09-7)
06 Installation
(See page 09-7)

Engine Control Module (ECM)

Description
The Engine Control Module (ECM), mounted on the lower right side of engine compartment rain gutter front
end panel assembly, can be removed only as a unit for replacement.
Operation
The Engine Control Module (ECM) is a pre-programmed microprocessor digital computer, which is used to
adjust the ignition timing, air-fuel ratio, emission control, speed control, A/C compressor and idle speed etc.
The Engine Control Module (ECM) enables the program to suit the ever-changing operation conditions.
Removal
3. Remove the engine trim cover. 06
4. Remove the Engine Control Module (ECM).
a. Remove 2 connectors (arrow) from the Engine Control
Module (ECM).
RA19060960
b. Remove 4 Engine Control Module (ECM) fixing bolts

(arrow) and the Engine Control Module (ECM). 
RA19060970
Installation
CAUTION
 Pay attention to the static electricity protection when installing.

 Take care to protect the connector pins.
 To prevent water droplets from accumulating on the connector joint, face it down.

- MEMO -

GENERAL INFORMATION 07-3 Installation 07-39
Description 07-3 Camshaft & Rocker Arm Shaft 07-40
Operation 07-3 Description 07-40
Specifications 07-3 Removal 07-41
Tools 07-11 Inspection 07-42
Installation 07-44
Cylinder Head 07-47
Problem Symptoms Table 07-17
Description 07-47
Inspection 07-18
Removal 07-48
ON-VEHICLE SERVICE 07-21 Disassembly 07-49
Drive Belt 07-21 Inspection 07-50
Description 07-21 Assembly 07-53
Removal 07-22 Installation 07-54 07
Inspection 07-23 Flywheel 07-55
Installation 07-23 Removal 07-55
Adjustment 07-24 Inspection 07-55
Idler Pulley 07-25 Installation 07-56
Removal 07-25 Crankshaft Rear Oil Seal 07-57
Inspection 07-25 Removal 07-57
Installation 07-26 Installation 07-57
Tensioner 07-27 Engine Mounting Assembly 07-58
Removal 07-27 Removal & Installation - Rear 
Inspection 07-27 Mounting Assembly 07-58
Installation 07-27 Removal & Installation - Left 
Mounting Assembly 07-59
Engine Timing Belt 07-28
Removal & Installation - Right 
Description 07-28
Mounting Assembly 07-60
Removal 07-29
Inspection 07-30 ENGINE UNIT REPAIR 07-62
Installation 07-31 Engine Assembly 07-62
Crankshaft Front Oil Seal 07-33 Removal 07-62
Installation 07-33 Engine Block 07-67
Camshaft Oil Seal 07-35 Description 07-67
Removal 07-35 Disassembly 07-69
Installation 07-35 Inspection 07-75
Cylinder Head Cover 07-37 Selection of Bearing Shell 07-83
Removal 07-37 Assembly 07-84

07

07 - SQR477F ENGINE MECHANICAL
GENERAL INFORMATION
Description
SQR477F engine has the following features:
 Vertical and water-cooled type
 In-line SOHC with 4 cylinders
 Four valves per cylinder
 Aluminum cylinder head
 Cast iron cylinder block
Operation
SQR477F engine adopts vertical, in-line 4-cylinder, water-cooled, 4-stroke, four valves per cylinder, SOHC
and electronic controlled sequential multiport fuel injection, etc. The engine adopts electronic controlled coil
double ignition system.
The engine uses cast iron cylinder block. The aluminum oil pan is fixed on the bottom of cylinder block with 07
bolts. The aluminum cylinder head is fixed on the cylinder block with bolts.
The camshafts are installed in the cylinder head. The power output from the crankshaft drives the camshaft to
rotate by the crankshaft pulley and timing belt to make the camshaft interact with the valve lifter to open and
close the valve. The piston assembly is an aluminum piston with cast iron connecting rod. This engine has
reliable structure and good performance.
Specifications
SQR477F Engine Specifications
Item Specification
Engine Type Vertical, in-line 4-cylinder, water-cooled, 4-stroke, SOHC
Engine Model SQR477F
Valve Number Per Cylinder 4
Cylinder Diameter (mm) 77.40
Piston Stroke (mm) 79.52
Displacement (ml) 1497
Compression Ratio 10.5:1
Combustion Chamber Type Pentroof type
Fuel Supply Type Electronic controlled sequential multiport fuel injection
Ignition Type Electrical control
Ignition Sequence 1-3-4-2
Idle Speed (r/min) 650 ± 50
Rated Power (kW) 80
Max. Torque (N·m) 140
Max. Torque Speed (r/min) 4500
Max. Permissible Speed (r/min) 6000
Min. Fuel Consumption Rate 
260
(g/kW·h)

Item Specification
Oil and Fuel Consumption
≤ 0.15
Percentage
Max. Intake Valve Lift (mm) 8.56
Max. Exhaust Valve Lift (mm) 8
Intake Valve Opening Angle (1 mm) 372°
Exhaust Valve Closing Angle (1 mm) 354°
Intake Valve Closing Angle (1 mm) 573°
Exhaust Valve Opening Angle 
178°
(1 mm)
Fuel Octane Number (Not Less
Unleaded gasoline, octane number 93
Than)
In summer SAE 10W-40 (grade SL or higher)
07 Oil Octane Number
In winter SAE 5W-40 (grade SL or higher)
Crankshaft Rotation Direction Counterclockwise (viewed from cross section of engine flywheel)
Starting Type Electrical starting
Cooling Type Forced circulation type antifreeze cooling
Lubrication Type Compound type (pressure, splash lubrication)
Net Weight (kg) 110
Cylinder Compression Pressure
(bar) 10 - 13.5
(180 - 250) r/min
Idle Speed (650 ± 50 r/min) Higher than 1.5
Oil Pressure (bar)
High Speed (4000 ± 50 r/min) Higher than 3.5
Boundary Dimension (Length ×
615 × 580 × 695
Width × Height) (mm)
With atmospheric temperature at -30°C, engine can start smoothly
within 8 seconds without taking special measures. Starting test
Starting Performance
shows that starting can be performed 3 times consecutively. If it fails
to start once, perform starting again after 2 minutes.

Engine Mechanical Specifications
Item Specification
Rocker Arm Shaft Hole Diameter for Intake Left +0.035
19 +0.017
Rocker Arm Shaft Hole Diameter for Intake Right +0.035
19 +0.017
Rocker Arm Shaft -0.002
Intake Rocker Arm Shaft Diameter (mm) 19 -0.015
Rocker Arm Shaft Hole Diameter for Exhaust Rocker +0.035
19 +0.017
Arm Assembly (mm)
-0.002
Exhaust Rocker Arm Shaft Diameter (mm) 19 -0.015
Intake Camshaft Lift (mm) 5.09
Exhaust Camshaft Lift (mm) 5.34
Camshaft -0.02
Camshaft Journal Diameter (mm) 26 -0.033
07
Camshaft Thrust Clearance (mm) 0.095 - 0.153
Lower Surface Flatness (mm) 0.055
Cylinder Head
Overall Height (mm) 97
Valve Lifter Diameter Intake Valve 5.972 - 5.988

(mm) Exhaust Valve 5.952 - 5.968
Valve Head Margin Intake Valve 0.012 - 0.043

Thickness (mm) Exhaust Valve 0.032 - 0.063
Valve
Clearance Between Intake Valve 0.012 - 0.043
Valve Lifter and Guide
(mm) Exhaust Valve 0.032 - 0.063
Intake Valve 107.998

Valve Height (mm)
Exhaust Valve 117.410
Free Height (mm) 47.7
Valve Spring
Preload (N) 249 - 271
Piston Piston Diameter (mm) 77.325 - 77.365
Piston Ring Side
Clearance (mm)
Oil Ring 0.03 - 0.16
Piston Ring
Piston Ring End Gap
(mm)
Oil Ring 0.2 - 0.6

Item Specification
Diameter (mm) 48.99 ± 0.01
Main Bearing Shell +0.007
2.131 0
Thickness (mm)
Radial Clearance (mm) 0.011 - 0.058
Thrust Clearance (mm) 0.093 - 0.303
Crankshaft
Runout (mm) 0.05
Cylindricity (mm) 0.008
Roundness (mm) 0.005
Crankshaft Connecting
Diameter (mm) 44.90 ± 0.01
Rod Journal (mm)
Cylinder Bore Roundness (mm) 0.008
Cylinder Block Upper Surface Flatness (mm) 0.05
07
Cylinder Diameter (mm) 77.36 - 77.40
Big End Thrust Clearance (mm) 0.333 - 0.387
Connecting Rod Bearing Shell Radial Clearance
Connecting Rod 0.006 - 0.06
(mm)
+0.007
Connecting Rod Bearing Shell Thickness (mm) 1.48 0

Engine Torque Specifications

Inner Torx Fixing Bolt for Power Steering Pump 25 ± 3
Locking Nut for Power Steering Pump Tension Bolt 30 ± 3
Coupling Bolt Between Steering Pump Fixing
25 ± 3
Bracket and Power Steering Pump
Coupling Bolt Between Idler Pulley and Generator 20 ± 5
Inner Torx Round Fixing Bolt for Idler Pulley 20 ± 5
Torx Flange Fixing Bolt for Idler Pulley 40 ± 5
Inner Torx Round Fixing Bolt for Tensioner 20 ± 5
Timing Belt Upper Cover Fixing Bolt 8 - 11
Crankshaft Pulley Fixing Bolt 105 - 115
Timing Belt Lower Cover Fixing Bolt 8 - 11 07
Timing Belt Tensioner Fixing Bolt 16 - 20
Camshaft Timing Pulley Fixing Bolt 100 ± 10
Camshaft Position Sensor Fixing Bolt 10 ± 2
Coolant Pipe Assembly Fixing Bolt 7±1
1st step: Pretighten to 3 - 5
Cylinder Head Cover Fixing Bolt
2nd step: Tighten to 8 - 11
1st step: 15 ± 1.5
Rocker Arm Shaft Fixing Bolt
2nd step: 30 ± 1.5
First Bearing Cap Fixing Bolt 9.5 ± 1
8±1
Pipe and Cylinder Head
1st step: 20 - 25
2nd step: 40 - 45
Cylinder Head Fixing Bolt
3rd step: Rotate 90° clockwise
4th step: Rotate 90° clockwise
1st step: 50 - 60
Flywheel Fixing Bolt
2nd step: 105 - 115
55 ± 5.5
Left Side of Transmission Case
55 ± 5.5
Right Side of Transmission Case
Locking Nut for Through Bolt Between Rear
Mounting Bracket and Rear Mounting Cushion 85 ± 8.5
Assembly
Coupling Bolt Between Rear Mounting Cushion
85 ± 8.5


Bracket I Fixing Bolt 8±1
Locking Nut for Through Bolt Between Left Mounting
80 ± 8
Cushion Assembly and Left Mounting Bracket
Coupling Bolt Between Left Mounting Cushion
60 ± 6
Assembly and Body
Coupling Bolt Between Left Mounting Bracket and
55 ± 5.5
Transmission Case
60 ± 6
Fixing Nut Between Right Mounting Bracket and
60 ± 6
60 ± 6
Engine Block
07 Expansion Tank Fixing Bolt 7 ± 1.5
Right Mounting Cushion Assembly Fixing Bolt 60 ± 6
45 ± 5
Clutch Release Cylinder Pipe Coupling Plug 18 ± 2
Positive Wire Harness Fixing Nut 7±1
Battery Negative Wire Harness Fixing Bolt 20 ± 3
Ground Fixing Bolt of Engine Wire Harness on ECM
7±1
Side
Fixing Bolt for Power Steering Pump Fixing Bracket 55 ± 5
A/C Compressor Bracket Fixing Bolt 55 ± 5
Knock Sensor Fixing Bolt 17 - 23
Exhaust Manifold Fixing Bolt 45 ± 5
40 ± 4
Pipe and Cylinder Block
Crankshaft Rear Oil Seal Bracket Fixing Bolt 8 - 11
Connecting Rod Bearing Cap Fixing Bolt 20 + 5
Crankshaft Main Bearing Cap Fixing Bolt 90 - 100
Crankshaft Main Bearing Cap Fixing Nut 90 - 100
Piston Cooling Nozzle Fixing Bolt 20 - 25

Lubrication Areas during Engine Assembly

Piston Pin SL10W-40
Piston Ring SL10W-40
Piston SL10W-40
Cylinder Bore SL10W-40
Main Bearing Shell and Crankshaft Main Journal SL10W-40
Crankshaft Thrust Washer (Oil Groove Side) SL10W-40
Connecting Rod Bearing Cap Bolt Head and Thread
SL10W-40
Part
Connecting Rod Bearing Shell and Crankshaft
SL10W-40
Connecting Rod Journal
Main Bearing Cap Bolt Head SL10W-40 07
Crankshaft Front Oil Seal Lip and Crankshaft Oil
SL10W-40
Seal Journal
Crankshaft Rear Oil Seal Lip and Crankshaft Oil Seal
SL10W-40
Journal
Valve Guide Hole SL10W-40
Valve Lifter SL10W-40
Camshaft Cam and Journal SL10W-40
Valve Rocker Arm Head SL10W-40
Valve Small End, Valve Rocker Arm Head SL10W-40
Valve Retainer Hole (Cylinder Head Assembly) SL10W-40
Valve Guide or Guide Bottom Hole (Cylinder Head) SL10W-40
Camshaft Oil Seal Lip and Camshaft Journal SL10W-40
Oil Filter Gasket Surface SL10W-40
All engine lubricants should be 5W-40 (for winter)/10W-40 (for summer) SL grade or higher.

Areas with Seal Gum Applied during Engine Assembly
Area with Seal Gum Applied Seal Gum Type

Cylinder Block Bowl Plug Loctite 648
Loctite 5910
and Oil Pump
Loctite 5910
and Rear Oil Seal Bracket
Joint Surface Between Oil Pump Bottom and
Loctite 5910
Cylinder Block Bottom
Joint Surface Between Rear Oil Seal Bracket Bottom
Loctite 5910
and Cylinder Block Bottom
Loctite 5910
and Oil Pan
07 Cylinder Head Bowl Plug Loctite 648
First Camshaft Bearing Cap Loctite 574
Spark Plug Socket Loctite 243
Coolant Temperature Sensor Loctite 243
Oil Pressure Switch Loctite 243
Intake/Exhaust Manifold Stub Loctite 271

Flywheel Bolt Precoated Seal Gum
Cylinder Head Cover Gasket and Bolt Loctite 5910
Cylinder Block - Sleeve - Oil Dipstick Tube Loctite 648

Tools
Special Tools
Crankshaft Front Oil Seal Guide Tool
RCH0000049
Crankshaft Front Oil Seal Installer

07
RCH0000067
Camshaft Oil Seal Installer
RCH0000017
Valve Spring Compression Adapter
RCH0000050
Valve Spring Compressor
RCH0000028

Crankshaft Rear Oil Seal Installer
RCH0000031
Valve Oil Seal Installer
07 RCH0000034
Valve Oil Seal Guide Sleeve
RCH0000035
Driven Disc Assembly & Clutch Cover Assembly

Guide Special Tool
RCH0000018
Valve Oil Seal Remover
RCH0000037

Valve Cotter Installer
RCH0000029
Flywheel Holding Tool
RCH0000040 07
Oil Filter Remover
RCH0000054
General Tools
Piston Installer
RCH0000039
20
10
30
0
40
90
50
80

60
70
RCH0000023

1.5
50
1.0
5
0
Outer Diameter Micrometer 0.01mm
50 75mm
RCH0000064
Vernier Caliper
07 RCH0000019
Inner Diameter Micrometer
RCH0000068
Precision Straightedge
RCH0000063
Feeler Gauge
RCH0000060

Cylinder Gauge
RCH0000065
Piston Ring Remover
RCH0000066 07
Digital Multimeter
RCH0000002
Flexional Magnetic Rod
RCH0000042
Engine Hoist
RCH0000043

Engine Equalizer
RCH0000026
07 RCH0000005
RCH0000048
RCH0000044
Engine Service Platform
RCH0000057

DIAGNOSIS & TESTING

HINT:
Use the table below to help determine the cause of problem symptoms. Check each suspected area in
sequence. Repair or replace the faulty components, or adjust them as necessary.

Engine oil (oil level high or low, oil lean or
13-9
rich)
Cam 07-40
Valve mechanism noise
Valve spring seat (excessive runout) 07-47
Valve (excessive clearance between valve
07-47
and guide)
07
Engine oil (low pressure) 13-10
Engine oil (lean) 13-11
Connecting rod bearing cap (loose fixing
07-67
nut)
Connecting rod noise
Connecting rod (misaligned) 07-67
Connecting rod bearing shell (excessive
07-67
radial clearance)
Connecting rod journal (out-of roundness) 07-67
Engine oil (low pressure) 13-10
Engine oil (lean) 13-11
Main bearing shell (excessive clearance) 07-67
Main bearing noise Crankshaft thrust clearance (excessive) 07-67
Crankshaft journal (out-of roundness or
07-67
worn)
Flywheel or clutch (loose) 07-55
Piston ring (worn, scratched or damaged) 07-67
Piston ring groove (fouled) 07-67
Oil loss or spark plug blockage Valve oil seal (worn or damaged) 07-47
Valve (excessive clearance between valve
07-47
and guide)


Spark plug (dirt, burns or incorrect gap) 14-12
Electric fuel pump assembly 08-15
Ignition coil 14-10
Valve timing (incorrect) -
Cylinder head (leaked) 07-18
Engine power loss
Valve (burns, deformation or excess
07-47
clearance)
Low cylinder pressure -
Fuel system (dirty) -
Exhaust system (blocked) -
07 Inspection
1. Check the coolant (See page 12-13).
2. Check the engine oil (See page 13-9).
3. Check the battery (See page 16-7).
4. Check the air filter.
a. Remove the air filter element (See page 10-9).
b. Visually check that there is no dirt, blockage or damage in the air filter element.
HINT:
 If there is any dirt or blockage in the air filter element, clean it with compressed air.
 If any dirt or blockage remains even after cleaning the air filter element with compressed air, replace it.
5. Check the spark plugs (See page 14-12).
6. Test the cylinder compression pressure.
 Cylinder pressure is the main index to judge the engine operation and also can be used to judge
definitely whether some system of engine operates well or not. Therefore, it is necessary to perform the
measurement of cylinder pressure when servicing the engine.
 Ensure that the battery is fully charged and the engine starter is in good operating condition. Otherwise,
the indicated compression pressure used for diagnosis may be invalid.
CAUTION
 The recommended compression pressure is only used as a guide for diagnosing engine malfunction.
 Never determine the causes of low pressure by disassembling the engine unless there are some
malfunctions.

Measurement procedures
CAUTION
 Select the cylinder pressure gauge with accurate reading and reset it to zero. Otherwise, it will affect the
accuracy of reading.
a. Turn off all the electrical equipment and ignition switch.

b. Unplug all the high-voltage cables (arrow) from the
spark plugs side.
07
RA19140031
c. Disconnect all the injector connectors.

d. Remove the spark plugs (See page 14-12).
e. Slowly screw the cylinder pressure gauge joint
vertically into the spark plug hole. Do not tighten it
excessively to prevent difficult removal.
RA19070010
CAUTION
 DO NOT screw the cylinder pressure gauge excessively to prevent difficult removal.
f. With the transmission in neutral position, release the accelerator pedal fully, then start the engine and
keep it racing for 3 to 5 seconds to measure and record the pressure value.
g. Press the bleeder button of cylinder pressure gauge to reset it to zero. Measure three times in the same
way and take the average.
Standard value for cylinder pressure: 10 - 13.5 bar
CAUTION
 During measurement, do not turn the ignition switch to "START" for more than 10 seconds. Otherwise,
the engine may be damaged.
 Ensure that the battery is fully charged when cranking the engine. The correct cylinder pressure can be
measured only when the engine is running at 200 - 300 r/min.
 Use the same method to measure the pressure of other cylinders.

Cylinder Pressure Value Judgment

 Correct cylinder pressure
Standard cylinder pressure value is between 10 and 13.5 bar and will drop slightly with the using of
engine. But the lowest value cannot be below 9 bar and the pressure difference between each
cylinder should not be above 3 bar.
 If the cylinder pressure of engine is lower than the standard value, it indicates that the cylinder
pressure is insufficient. Add a small amount of engine oil through the spark plug hole and perform
measurement again.
If the pressure increases after adding oil, the piston ring or cylinder bore may be worn or damaged.
If the pressure remains low, the valve may be stuck or not properly installed or there is air leakage
from the cylinder head gasket.
h. Install the spark plugs (See page 14-13).
i. Connect all the injector connectors (See page 08-25).
j. Install the high-voltage cables.
7. Test the cylinder head gasket.
The cylinder head gasket leakage may be present between adjacent cylinders, between cylinder and
07 adjacent water jacket or from an oil passage to the external of engine.
 Possible indications of cylinder head gasket leakage between adjacent cylinders are as follows:
- Engine power loss
- Engine stall
- Low fuel economy
 Possible indications of cylinder head gasket leakage between cylinder and adjacent water jacket are as
follows:
- Engine overheat
- Coolant loss
- Excessive steam (white smoke) emitted from the exhaust system
- Coolant foaming

ON-VEHICLE SERVICE
Drive Belt
Description
1
07
3
8
RA19070020
1 - Generator 2 - V-ribbed Belt

3 - Idler Pulley 4 - A/C Compressor
5 - Power Steering Pump Pulley 6 - Power Steering Pump Belt
7 - Crankshaft Pulley 8 - V-ribbed Belt Tensioner

Removal
4. Remove the lower right deflector (See page 46-20).
5. Remove the power steering pump belt.
a. Loosen the inner Torx fixing bolt (arrow) for power
steering pump.
07 RA19070030
b. Remove the locking nut (1) from the tension bolt.

c. Remove the adjustment bolt (2) and tension bolt.
d. Remove the coupling bolt (3) between power steering
pump fixing bracket and power steering pump.
3
2 1
RA19070040
e. Push the power steering pump in the direction of

arrow as shown in the illustration, and remove the
power steering pump belt (1).
RA19070050
6. Remove the V-ribbed belt.

a. Turn the V-ribbed belt tensioner in the direction of
arrow as shown in the illustration with a wrench (2), 1
and insert the lock pin (1) while aligning the lock hole
of tensioner with the lock hole of bracket to lock the
3
tensioner.
b. Remove the V-ribbed belt (3).
2
RA19160040

Inspection
1. Check the power steering pump drive belt.
Replace the power steering pump drive belt if the following occurs.
a. There are cracks on the back of belt: as shown in the
illustration (1).
b. There are cracks at the bottom of cord fabric layer of
1
belt: as shown in the illustration (2), (3), (5) and (6).
c. Belt worn: as shown in the illustration (5).
d. Belt teeth missing and damaged: as shown in the 2
illustration (4) and (6).
4
3
6
07
RA19070150
2. Check the V-ribbed belt.

Visually check the V-ribbed belt for excessive wear, frayed cords, etc. If any of the defects is found, replace
the V-ribbed belt.
HINT:
 Cracks on the rib side of a V-ribbed belt are
considered acceptable. If the V-ribbed belt has chunks
missing from the ribs, it should be replaced.
 After installing the V-ribbed belt, check that it fits
properly in the ribbed grooves. Confirm that the belt
has not slipped out of bottom slot of the crank pulley
by hand.
Right Wrong Wrong

RA19070070
Installation

Adjustment
1. Adjust the tension of power steering pump drive belt.
Apply 100 N of force to center part of the belt between
crankshaft pulley and power steering pump pulley with
your thumb as shown in the illustration. The belt
compression amount should not more than 10 mm.
100 N
RA19070080
07

Idler Pulley
Removal
3. Loosen the V-ribbed belt.
3
tensioner.
b. Move away the V-ribbed belt (3).
2
RA19160040
07
4. Remove the idler pulley.
a. Remove the coupling bolt (arrow) between idler pulley
and generator.
RA19070083
b. Remove the inner Torx round fixing bolt (1) and the
Torx flange fixing bolt (2) from the idler pulley.
(Tightening torque for inner Torx round fixing bolt: 
20 ± 5 N·m)
1
(Tightening torque for Torx flange bolt: 40 ± 5 N·m)
RA19070081
c. Remove the idler pulley.
Inspection
1. Rotate the idler pulley by hands and check if the rotation is smooth and if abnormal noise occurs.
2. Wiggle the idler pulley in the axial and radial direction to check the bearing for looseness.
3. Check if there is damage on the idler pulley operating surface.

Installation
CAUTION
 After installation, turn the crankshaft with a wrench to run the V-ribbed belt several circles, and check if
the crankshaft turns smoothly and the belt runs well. If it does not turn smoothly, reinstall the V-ribbed
belt.
 Make sure to install the V-ribbed belt in place, and it does not interfere with other components.
07

Tensioner
Removal
3
tensioner.
2
RA19160040
07
4. Remove the idler pulley (See page 07-25).
5. Remove the tensioner.
a. Remove 2 inner Torx round fixing bolts (arrow) from
the tensioner.
(Tightening torque for inner Torx round fixing bolt: 
20 ± 5 N·m)
RA19070082
b. Remove the tensioner.
Inspection
1. Rotate the tensioner by hands and check if the rotation is smooth and if abnormal noise occurs.
2. Wiggle the tensioner in the axial and radial direction to check the bearing for looseness.
3. Check if there is damage on the tensioner operating surface.
Installation
CAUTION
 After installation, turn the crankshaft with a wrench to run the V-ribbed belt several circles, and check if
the crankshaft turns smoothly and the belt runs well. If it does not turn smoothly, reinstall the V-ribbed
belt.
 Make sure to install the V-ribbed belt in place, and it does not interfere with other components.

Engine Timing Belt

Description
2 3 4
07 5
6
×4
11
7
12
8
9
10
RA19070090
1 - Timing Belt Upper Cover 2 - Timing Belt

3 - Camshaft Timing Pulley Fixing Bolt Washer 4 - Camshaft Timing Pulley
5 - Timing Belt Tensioner 6 - Water Pump Assembly
7 - Engine Assembly 8 - Crankshaft Timing Pulley Washer
9 - Crankshaft Timing Pulley 10 - Timing Belt lower Cover
11 - Crankshaft Pulley 12 - Crankshaft Pulley Fixing Bolt Washer

Removal
4. Remove the drive belt (See page 07-21).
5. Remove the timing belt cover.
a. Loosen and remove 2 fixing bolts (arrow) from the
timing belt upper cover, and then remove the timing
belt upper cover (1).
1
RA19070100
07
b. Rotate the crankshaft pulley to align the mark (arrow)
on the camshaft timing pulley (1) with the mark (2) on
the cylinder head as shown in the illustration. Also,
align the mark (3) on the crankshaft pulley with the
fifth protrusion mark (4) on the timing belt lower cover 2
(4).
4
3
RA19070110
c. Loosen and remove the crankshaft pulley fixing bolt

(arrow), and then remove the crankshaft pulley.
HINT:
Shift the transmission into 5th gear when loosening
the crankshaft pulley fixing bolt to engage the
crankshaft and propeller shaft. The other technician
depresses the brake pedal, which can lock the
crankshaft by the mechanical gear train.
RA19070120

d. Loosen and remove 2 fixing bolts (arrow) from the

timing belt lower cover, and then remove the timing
belt lower cover (1).
1
RA19070130
6. Remove the timing belt.

a. Remove 2 fixing bolts (arrow) from the timing belt
tensioner, and then remove the timing belt tensioner.
b. Remove the timing belt (1).
1
07
RA19070140
Inspection
1. Check the timing belt.
CAUTION
 Check the timing belt carefully before installation, and replace it to prevent any of the following
symptoms.
If the timing belt has the following conditions, replace it.

a. There are cracks on the back of belt: as shown in the

illustration (1).
b. There are cracks at the bottom of cord fabric layer of
1
belt: as shown in the illustration (2), (3) and (5).
c. Belt worn: as shown in the illustration (6).
d. Belt teeth missing and damaged: as shown in the 2
illustration (4) and (6).
4
3
6
5 07
RA19070150
2. Check the timing belt tensioner.

a. Rotate the timing belt tensioner by hands and check if
the rotation is smooth and if abnormal noise occurs.
b. Wiggle the timing belt tensioner in the axial and radial
direction to check if there is slackness.
c. Check if there is damage on the timing belt tensioner
surface.
RA19070160
Installation
1. Install the timing belt (2) and be sure to align the arrow
mark on the camshaft pulley hole with the upper mark on
the cylinder (upper left partial view). Also, align the
1
protrusion mark on the crankshaft timing pulley with the
mark on the oil pump housing (lower right partial view). 2
5
2. Check if the timing belt is installed to the camshaft timing
pulley (1), timing belt tensioner (5), water pump pulley (4) 4
and crankshaft timing pulley (3) correctly.
3
RA19070170

3. Using an auxiliary fixture, apply 300 ± 50 N of load to the

timing belt tensioner (2) in the horizontal direction so that
the timing belt (1) can bear the proper tension (the timing
belt tension should be 250 - 350 N when the camshaft
has no load and the engine does not crank), then tighten 1
2
the 2 timing belt tensioner fixing bolts (arrow).
RA19070180
CAUTION
 Lock the crankshaft and camshaft when assembling the timing belt.
07 4. Rotate the crankshaft one turn to check the timing mark for offset. If necessary, remove the belt and
reinstall it.
Other installation procedures are in the reverse order of removal.

Crankshaft Front Oil Seal

Removal
5. Remove the engine timing belt (See page 07-28).
6. Remove the crankshaft timing pulley (1) and crankshaft
timing pulley washer (2) from the crankshaft.
2
1
FRONT
07
RA19130171
7. Remove the crankshaft front oil seal.

a. Using a flat tip screwdriver with the tip wrapped with
tape, pry out the crankshaft front oil seal (arrow).
RA19070190
CAUTION
 Be careful not to damage the oil seal retainer and surface of crankshaft when removing the crankshaft
front oil seal.
Installation
1. Install the crankshaft front oil seal guide tool (3) to the
crankshaft (4).
2. Install the new oil seal (2) to the crankshaft front oil seal 4
guide tool, then install the new oil seal fully into the oil 3
seal retainer with the crankshaft front oil seal installer (1). 2
1
RA19070200

CAUTION
 Apply a coat of engine oil to the crankshaft front oil seal guide tool before installing the new oil seal.
 Remove the dirt on the oil seal retainer and apply a coat of engine oil to the oil seal retainer and oil seal
lip before installation.
 Be sure to prevent the lip of crankshaft front oil seal from being scratched during installation. If it is
damaged, replace it immediately.
07

Camshaft Oil Seal

Removal
6. Remove the camshaft timing pulley.
a. Hold the camshaft timing pulley with a tool, then turn
the wrench in the direction of arrow as shown in the
illustration to remove the camshaft timing pulley fixing
bolt. 
07
RA19070210
b. Remove the camshaft timing pulley.

7. Remove the camshaft oil seal.
a. Using a flat tip screwdriver with the tip wrapped with
tape, pry out the camshaft oil seal (arrow).
RA19070220
CAUTION
 Be careful not to damage the oil seal retainer and surface of camshaft when removing the camshaft oil
seal.
Installation
1. Using a special tool (camshaft oil seal installer) (1), install
the new oil seal (2) to the camshaft (3).
2 3
1
RA19070230

CAUTION
 Remove the dirt on the oil seal retainer and apply a coat of engine oil to the oil seal retainer and oil seal
lip before installation.
 Be sure to prevent the lip of camshaft oil seal from being scratched during installation. If it is damaged,
replace it immediately.
07

Cylinder Head Cover

Removal
4. Blow the dirt and debris away from the upper surface of cylinder head cover with compressed air.
a. Loosen the worm clamps (1) on both ends of the
intake hose and disconnect the intake hose. 1
b. Loosen the elastic clamp (2) and disconnect the
cover.
2
07
RA19140020

6. Remove the high-voltage cables (See page 14-8).
7. Remove the PCV valve (See page 09-10).
8. Remove the camshaft position sensor.
a. Disconnect the camshaft position sensor connector
(1).
b. Remove the fixing bolt (arrow) from the camshaft
position sensor.
RA19070240
c. Remove the camshaft position sensor from the cylinder head cover.
9. Remove the cylinder head cover.
a. Loosen the elastic clamp (arrow) and disconnect the
hose from the cylinder head cover.
RA19070250

b. Remove 2 fixing bolts (arrow) from the rear right

bracket, and then remove the rear right bracket.
RA19070260
c. Remove 4 fixing bolts (arrow) from the coolant pipe

assembly, and then remove the 2 front bracket 1
assemblies (1).
07
RA19070270
d. Loosen 2 fixing bolts (arrow) on the timing belt upper

cover, and then move away the timing belt upper
cover (1).
1
RA19070100
e. Remove the cylinder head cover fixing bolts in the

order shown in the illustration.
1 6 9 13 10 5
(Tightening torque: step 1: Tighten to 3 - 5 N·m; step
2: Tighten to 8 - 11 N·m)
2
7 8 12 11 4
RA19070280
f. Remove the cylinder head cover from the cylinder head.
CAUTION
 Remove the oil and seal gum on the cylinder head cover with a special tool.
10.Remove the cylinder head cover gasket and semi-circle tight plug.

Installation
1. Replace the cylinder head cover gasket, semi-circle tight
plug and spark plug guide washer.
2. Apply seal gum to the contact surface between semi-circle
tight plug (1) and cylinder head, and install the semi-circle
tight plug to the cylinder head. Align the semi-circle tight 1
plug limit groove with the upper opening during installation,
then press it down.
RA19070290
CAUTION
 During installation, align the corner side of semi-circle tight plug with the inside of cylinder head.
07
3. Install the cylinder head cover gasket into the groove of
cylinder head, and then apply seal gum to the cylinder
head cover gasket in the oval areas as shown in the
illustration.
RA19070300
4. Hold the cylinder head cover by hands, make the spark plug protection pipe pass through the seal ring and
press it down firmly, which can match the head cover with the bolt hole of the cylinder head. Then install it
to the cylinder head after alignment. During assembly, take it carefully to prevent the gasket from falling off
the head cover and the assembly should be completed in one time to prevent the seal gum offset.
5. Install the head cover bolts to the cylinder head cover in
the sequence shown in the illustration by following the
operation procedures: 13 8 5 1 4 9
a. Install the bolts in place by hand;

b. Tighten them to 3 - 5 N·m in order; 12
c. Retighten them to 8 - 11 N·m in order. 11
7 6 2 3 10
RA19070310

Camshaft & Rocker Arm Shaft

Description
2 1
4 3
×4 ×4
×4
5
6 ×4
9 8 7
10
07 11
16
12 15
13
14
RA19070311

1 - Intake Rocker Arm Shaft 2 - Intake Right Rocker Arm Assembly

3 - Intake Rocker Arm Retaining Sleeve 4 - Intake Left Rocker Arm Assembly
5 - Exhaust Rocker Arm Shaft 6 - Exhaust Rocker Arm Assembly
7 - 5th Bearing Cap 8 - 4th Bearing Cap
9 - 3rd Bearing Cap 10 - 2nd Bearing Cap
11 - 11th Bearing Cap 12 - Camshaft Timing Pulley Fixing Bolt
13 - Camshaft Timing Pulley Fixing Bolt Washer 14 - Camshaft Timing Pulley
15 - Camshaft Oil Seal 16 - Camshaft
Removal
3. Remove the engine trim cover. 07
7. Remove the camshaft oil seal (See page 07-35).
8. Remove the cylinder head cover assembly (See page 07-37).
9. Remove the rocker arm shaft and camshaft.
a. Remove the rocker arm shaft fixing bolts in the
sequence shown in the illustration and remove the 1st 2 8 10 6 4
bearing cap fixing bolts (arrow). Remove the rocker
arm shafts with rocker arms and place them aside
carefully.
3 5 9 7 1
RA19070320
b. Remove the camshaft bearing caps from (1) to (5),

and then remove the camshaft (6).
5
1 2 3 4 RA19070330

c. Arrange the removed parts orderly on the workbench.
RA19070340
d. Arrange the disassembled intake and exhaust rocker

arms and rocker arm shafts in the assembly order on
the workbench.
07
RA19070350
Inspection
1. Check the rocker arm shaft.
a. Check the rocker arm shaft diameter.
Measure the intake/exhaust rocker arm shaft diameter
with the outer diameter micrometer.
Specification
Measurement Item
(mm)
+0.035
Intake Rocker Arm Shaft Diameter 19 +0.017
+0.035
Exhaust Rocker Arm Shaft Diameter 19 +0.017
If the intake/exhaust rocker arm shaft diameter is not RA19070350
within the specified range, replace the intake/exhaust

rocker arm shaft.
2. Check the valve rocker arm assembly.
a. Check if the rocker arm retainer is damaged or if the
rocker arm tappet ball is damaged or falls out. If this
occurs, replace the intake rocker arm assembly (1) or
exhaust rocker arm assembly (2). 1
b. Check if the rocker arm tappet ball rotates freely. If it

cannot rotate freely or is loose excessively, replace
the intake rocker arm assembly (1) or exhaust rocker
arm assembly (2).
c. Check the valve rocker arm hole. If it is damaged or
tightened excessively, replace the intake rocker arm
assembly (1) or exhaust rocker arm assembly (2). 2
RA19070370

d. Check the hole diameter of rocker arm shaft for intake

rocker arm assembly.
Measure the hole diameter of rocker arm shaft for
intake left/right rocker arm assembly with the inner
diameter micrometer.
Specification
Measurement Item
(mm)
Hole Diameter of Rocker Arm Shaft for +0.035
19 +0.017
Intake Left Rocker Arm Assembly RA19070380

19 +0.017
Intake Right Rocker Arm Assembly
If the hole diameter of rocker arm shaft for intake left/

right rocker arm assembly is not within the specified
range, replace the intake left/right rocker arm
assembly.
e. Check the hole diameter of rocker arm shaft for 07
exhaust rocker arm assembly.
Measure the hole diameter of rocker arm shaft for
exhaust rocker arm assembly with the inner diameter
micrometer.
Specification
Measurement Item
(mm)
19 +0.017
Exhaust Rocker Arm Assembly RA19070390
If the hole diameter of rocker arm shaft for exhaust

rocker arm assembly is not within the specified range,
replace the exhaust rocker arm assembly.
3. Check the camshaft.
a. Check the appearance.
 Check if there are scratches on the camshaft bearing and cam surface. If there are scratches, repair
or replace the camshaft.
 Check if there are leaking holes and cracks on the camshaft bearing cap. If there are leaking holes
or cracks, replace the camshaft.
b. Check the camshaft journal diameter.
Measure the camshaft journal diameter with the outer
diameter micrometer.
Specification
Measurement Item
(mm)
-0.02
Camshaft Journal Diameter 26 -0.033
If the camshaft journal diameter is not within the

specified range, replace the camshaft. RA19070400

c. Check the cam lift. A

Measure the cam lift with the outer diameter
micrometer as shown in the illustration.
 Camshaft lift height:  B B
Measurement value A - Measurement value B
Specification A
Measurement Item
(mm)
Intake Cam Lift 5.09
RA19070410
Exhaust Cam Lift 5.34
If the camshaft cam lift is not within the specified

range, replace the camshaft.
d. Check the camshaft thrust clearance.
 Reinstall the camshaft.
 Remove the rocker arm and reinstall the rocker
07 arm shaft and rocker arm shaft bolts, then tighten
the bolts in two steps. 1st step: tighten them to 
70
80
60
90
15 ± 1.5 N·m; 2nd step: retighten them to 
50
0
40
10
30
20
30 ± 1.5 N·m. After the rocker arm shaft bolts are
pre-tightened, tighten the bolts on both sides of 1st
bearing cap. 
(Tightening torque: 9.5 ± 1 N·m) RA19070420
 Keep the measuring rod of dial indicator contacting
with the front end of camshaft. Push the camshaft
forward and backward gently (do not rotate the
camshaft) and read the value from the dial
indicator.
Specification
Measurement Item
(mm)
Camshaft Thrust Clearance 0.095 - 0.153
If the camshaft thrust clearance is not within the

specified range, replace the camshaft.
Installation
1. Clean the intake and exhaust rocker arm shafts, camshaft and camshaft bearing caps.
2. Install the camshaft semi-circle key (1).
RA19070430

CAUTION
 The camshaft semi-circle key (1) and the camshaft key slot is matched in transition fit along the width
direction. The matching clearance is -0.051 - 0.004 mm.
 Check the protrusion height of semi-circle key after installing the key. The protrusion height of semi-circle
key should be 1.64 - 2.11 mm.
3. Check if there are residues and foreign matter in the

rocker arm shaft oil hole. 1
2 07
RA19070440
CAUTION
 Distinguish the intake and exhaust rocker arm shafts. There are four grooves on the intake rocker arm
shaft (1) (to avoid the spark plug socket). There is no groove on the exhaust rocker arm shaft (2). During
assembly, check that there are no burrs, fins and chips in the chamfer at both ends of each rocker arm
shaft oil groove and oil hole. The surface of rocker arm shaft should be clean without any residues and
foreign matter.
4. Check if the intake/exhaust rocker arm ball and intake

rocker arm retaining sleeve are normal. Apply engine oil
to the rocker arm shaft and install the rocker arm to the
rocker arm shaft.
RA19070450
5. Apply engine oil to the contact surface of camshaft (1)

and install the camshaft.
RA19070460

6. Clean the camshaft bearing cap. Apply seal gum to the

seal areas (arrow) of 1st camshaft bearing cap as shown
in the illustration.
RA19070470
7. Apply engine oil to the cam and camshaft journal and

install the camshaft bearing caps in the order from (1) to
(5).
6
07
5
1 2 3 4 RA19070330
CAUTION
 The dowel pin of camshaft bearing cap is matched with the clearance of cylinder head. When installing
the camshaft bearing cap, put it in right position by hands and tap it lightly in place with a rubber hammer.
Rotate the camshaft (6) by hands until some resistance can be felt.
8. Install the intake rocker arm shaft assembly (the largest groove end faces toward 1st camshaft bearing cap
and it should not be reversed) and adjust the rocker arm position, so that the rocker arm shaft contacts the
bearing seat bracket.
9. Install the exhaust rocker arm shaft assembly (the large angle end surface faces toward 1st camshaft
bearing cap and it should not be reversed) and with the camshaft not rotated, adjust the rocker arm
position, and ensure that the exhaust rocker arm does not interfere with the bearing retainer and intake
rocker arm.
10.Install the rocker arm shaft bolts. As shown in the
illustration, tighten the rocker arm shaft fixing bolts from (1) 9 3 1 5 7
to (10).
(Tightening torque: 1st step: tighten them to 15 ± 1.5 N·m;
2nd step: retighten them to 30 ± 1.5 N·m)
11. After the rocker arm shaft bolts are pre-tightened, tighten
the bolts (arrow) on both sides of 1st bearing cap.
(Tightening torque: 9.5 ± 1 N·m)
8 6 2 4 10
RA19070480
12.After the rocker arm shaft bolts are tightened, apply an appropriate amount of engine oil to the tappet ball
of rocker arm and ensure that there are an appropriate amount of engine oil at the contacting position
between tappet ball and camshaft.

Cylinder Head
Description
1
2
4
5 ×10
8
6
×4
9 ×10
18 ×2
7 07
×8
10
×8
11
17
12
16 13
15
14
RA19070490

1 - Valve Cotter 2 - Valve Spring Upper Seat

3 - Valve Spring 4 - Valve Oil Seal
5 - Valve Spring Lower Seat 6 - Valve Guide
7 - Spark Plug Socket 8 - Cylinder Head Fixing Bolt
9 - Cylinder Head Fixing Bolt Washer 10 - Cylinder Head
11 - Stud 12 - Cylinder Head Gasket
13 - Intake Valve Retainer 14 - Intake Valve
15 - Exhaust Valve 16 - Exhaust Valve Retainer
17 - Bowl Plug 18 - Bush
Removal
1. Release the fuel system pressure (See page 08-11).
07 2. Turn off all the electrical equipment and ignition switch.
cover.
RA19140020

7. Remove the spark plugs (See page 14-12).
8. Remove the ignition coil (See page 14-10).
9. Remove the thermostat (See page 12-18).
10.Remove the thermostat seat (See page 12-21).
11. Remove the fuel rail injector assembly (See page 08-25).
12.Remove the electronic throttle assembly (See page 10-12).
13.Remove the intake manifold assembly (See page 10-15).
14.Remove the exhaust manifold assembly (See page 11-7).
15.Remove the generator and generator bracket (See page 16-9).
16.Remove the engine timing belt (See page 07-28).
17.Remove the camshaft oil seal (See page 07-35).

18.Remove the coupling bolt (arrow) between small

circulation coolant pipe and cylinder head, and then
remove the speed sensor bracket.
RA19070880
19.Remove the cylinder head cover (See page 07-37).

20.Remove the camshaft and rocker arm shaft (See page 07-40).
21.Remove the cylinder head fixing bolts in the sequence
from (1) to (10) shown in the illustration. 1 5 9 7 3
07
2 6 10 8 4
RA19070500
CAUTION
 Failure to follow the sequence to remove the cylinder head bolts will cause cylinder head deformation.
22.Remove the cylinder head and cylinder head gasket.
CAUTION
 Replace the used gasket with a new one.
Disassembly
1. Using a special tool (valve spring compressor), compress
the valve spring and remove the valve cotter with a
flexional magnetic rod.
RA19070510

2. Remove the valve spring upper seat (1), valve spring (2)
and valve (3) from the cylinder head. 1
2
RA19070520
07 3. Using a valve oil seal remover (1), remove the valve oil
seal (2).
1
RA19070530
4. Using a flexional magnetic rod, remove the valve spring lower seat.
Inspection
1. Check the cylinder head.
a. Check the appearance.
 Check if there are scratches on the camshaft bearing journal.
 Remove the carbon deposits and varnish inside the valve guide with the valve guide cleaner.
 Make sure that the valve cotter can move and rotate in the cylinder bore freely.
b. Check the cylinder head flatness.
Using a precision straightedge and feeler gauge,
check the cylinder head flatness. The cylinder head
flatness must be within 0.04 mm.
Specification
Measurement Item
(mm)
Cylinder Head Flatness 0.04
If the cylinder head flatness is not within the specified RA19070540

range, repair or replace the cylinder head.

c. Check the cylinder head height.

Using a precision straightedge, measure the cylinder
head height.
Specification
Measurement Item
(mm) a
Cylinder Head Height 97
If the cylinder head height is not within the specified

range, replace the cylinder head. RA19070550
CAUTION
 During replacement, the cylinder head should be fully equipped with valves, oil seals, springs, retainers,
cotters, hydraulic tappets and crankshafts.
07
2. Check the valve spring.
Using a vernier caliper, measure the free length of valve
spring and the length of valve spring with the pre-pressure
between 249 N and 271 N.
Specification
Measurement Item
(mm)
Valve Spring Free Length 47.70
Valve Spring Length under
32 RA19070560
Pre-pressure
If the valve spring length is not within the specified

range, replace the valve spring.
3. Check the valve.
a. Clean the valve.
 Using a scraper, remove the carbon deposited on
the valve head.
 Using a wire brush, clean the valve thoroughly.
RA19070570
b. Check the valve height.

Using a micrometer, measure the valve height.
Specification
Measurement Item
(mm) Total Height
Intake Valve Height 107.998

Exhaust Valve Height 117.410
If the height is less than the specified value, replace

the valve. RA19070580

c. Check the valve head.

Using a vernier caliper, measure the valve head.
Specification
Measurement Item
(mm)
Intake Valve Head Thickness 0.6
b
Exhaust Valve Head Thickness 0.4
Grommet Width a of Intake Valve 2.83 a
Grommet Width b of Exhaust Valve 2.26

RA19070590
If it is not within the specified range, replace the valve.
d. Check the valve lifter diameter.
Using a micrometer, measure the valve lifter diameter.
Specification
Measurement Item
(mm)
07
Intake Valve Lifter Diameter 5.972 - 5.988
Exhaust Valve Lifter Diameter 5.952 - 5.968
If the valve lifter diameter is not within the specified

range, check the clearance between valve lifter and RA19070591
valve guide.
e. Check the clearance between valve lifter and valve
guide.
 Install the dial indicator (1) to the holder (2). Install 1
the intake valve or exhaust valve to the guide to be
checked.
 Using the dial indicator, check the clearance
between valve lifter and valve guide. Pull the valve 2
to be checked out of the valve guide approximately
10 mm, and shake the valve gently to measure the
clearance between valve and guide. RA19070592
Specification
Measurement Item
(mm)
Clearance Between Intake Valve and
0.012 - 0.043
Guide
Clearance Between Exhaust Valve
0.032 - 0.063
and Guide
If the clearance is not within the specified range,

replace the valve or valve guide.

Assembly
HINT:
Clean all the components to be assembled thoroughly before assembly.
1. Install the valve (1) into the cylinder head.
HINT: 5
 Distinguish the intake valves and exhaust valves 4
during installation. 3
2
 Apply a light coat of engine oil to the valve lifter end
when assembling the valve.
2. Install the new valve spring lower seat (2) if necessary.
3. Install the valve oil seal.
HINT:
Apply a light coat of engine oil to the installation surface
of valve oil seal end when assembling the valve oil seal.
a. Install the valve oil seal guide sleeve (3) to the valve
lifter.
1
07
b. Install the valve oil seal (4) to the valve oil seal guide RA19070593
sleeve.
c. Tap the valve oil seal installer (5) lightly with a rubber
hammer to install the valve oil seal in place.
4. Install the valve cotter (1) to the valve cotter installer (2).
2
1
RA19070594
5. Install the valve spring (1) and valve spring upper seat
(2).
6. Using a valve spring compressor, compress the valve 3
spring and install the valve cotter (3) in place. 2
RA19070511
7. Tap the valve cotter lightly with a rubber hammer to make sure the cotter is installed in place after
assembly.

Installation
CAUTION
 Remove the residual seal gum and oil on the cylinder head and cylinder block.
 Replace the O-ring and cylinder head gasket.
 Check that the cylinder head gasket is neat and clean without any chips and scratches. The side
stamped with part number of cylinder gasket should face upward.
 Install the cylinder gasket to the flat surface of cylinder block with a dowel pin.
 Clean the joint surface between cylinder head and combustion chamber, together with the flat surface of
cylinder block top and thread hole. There should be no accumulated oil at the bottom of cylinder block
thread hole.
 During installation, the piston should not be located at the top dead center, in order to prevent it from
being impacted by the opening valve when installing the rocker arm.
 Install the cylinder head bolt washer with the chamfering surface facing upward and the flat side facing
cylinder head.
07
1. Make sure to tighten the cylinder head fixing bolts in the
sequence from (1) to (10) shown in the illustration: 10 6 2 4 8
a. Apply a small amount of oil to the bolt head and root.

b. Install the bolts and tighten them in place by hands.
c. Tighten the cylinder head fixing bolts in the following
procedures:
 1st step: Tighten the bolts to 20 - 25 N·m in the
sequence from (1) to (10) shown in the illustration.
9 5 1 3 7
 2nd step: Tighten the bolts to 40 - 45 N·m in the
RA19070595
sequence from (1) to (10) shown in the illustration.
 3rd step: Rotate the bolts by 90° in tightening
sequence.
 4th step: Rotate the bolts by 90° again in tightening
sequence.
CAUTION
 Check the cylinder head fixing bolts before installation. If they are damaged, replace them immediately.
 Be sure to tighten the cylinder head bolts by following the operating procedures above strictly to achieve
the technology standard for vehicle usage.

Flywheel
Removal
3. Remove the transmission assembly (See page 17-21).
4. Remove the clutch assembly (See page 18-16).
5. Using the special tool (flywheel holding tool) (7), lock the
flywheel and remove the flywheel fixing bolts in the
sequence from (1) to (6) shown in the illustration, then 5
remove the flywheel (8). 3
7
1
8
6 2
4 07
RA19070596
WARNING
 Pay attention to personal safety when operating.

 DO NOT remove all the fixing bolts without any assist measure.
CAUTION
 The flywheel fixing bolts must be disposed after removal. Never reuse them.
Inspection
1. Check if the crankshaft position signal gear is distorted or deformed. If damaged, replace the flywheel.
Clean the signal gear before installation.
2. Check if the starter drive gear ring is worn. If excessively worn, replace the flywheel.
3. Check the contact surface of clutch lining. If the contact surface is damaged or excessively worn, replace
the flywheel.
4. Measure the flywheel end surface runout with the dial
indicator. If the measured value exceeds the limit, replace
the flywheel with a new one.
Limit value for the end surface runout: 0.1 mm
RA19070597

Installation
WARNING
 Never reuse the flywheel fixing bolts after removal.

 Make sure to use the new flywheel fixing bolt with seal gum before installation.
CAUTION
 The six bolt holes on the flywheel have asymmetrical positions. There are matchmark holes on the
flywheel. The mark hole is located right above when 1st cylinder of engine is at the top dead center and
flywheel fixing bolts are aligned with the bolt holes of crankshaft.
07 The installation procedures are in the reverse order of removal, and pay attention to the followings:
1. Align the flywheel installation hole with the crankshaft
positioning journal and then push lightly during assembly.
DO NOT tap the flywheel with a hammer. 5
2. Replace the flywheel fixing bolts with precoated seal gum 3
with new ones.
3. Install the flywheel (8) and bolts, and then lock the 7
1
flywheel with the flywheel lock tool (7). Tighten the
8
flywheel fixing bolts in two steps in the sequence from (1)
6 2
to (6).
4
 1st step: 50 - 60 N·m RA19070596
 2nd step: 105 - 115 N·m

Crankshaft Rear Oil Seal

Removal
4. Remove the clutch assembly (See page 18-16).
5. Remove the flywheel (See page 07-55).
6. Remove the crankshaft rear oil seal.
a. Using a screwdriver with the tip wrapped with tape,
remove the crankshaft rear oil seal (1). 1
07
RA19070598
CAUTION
 Be careful not to damage the surrounding parts and oil seal retainer when removing the oil seal.
 Be careful not to damage the oil pan gasket when removing the rear oil seal bracket.
Installation
CAUTION
 Be sure to clean the dirt around the oil seal retainer and on the inside wall before installation.
 Check the oil seal for damage before installation. If there is any damage, replace it.
 Be sure to prevent the lip of crankshaft rear oil seal from being scratched during installation.
 Be careful not to damage the oil seal retainer during installation.
1. Install the new gasket and rear oil seal bracket.

2. Using the crankshaft rear oil seal installer (1), install the
oil seal (2) with the part number side facing outward.
HINT:
Apply a coat of engine oil to the rear oil seal lip or
crankshaft rear oil seal journal. 2
1
RA19070599

Engine Mounting Assembly

Removal & Installation - Rear Mounting Assembly

3. Support the transmission with a transmission carrier.
4. Remove the engine rear mounting bracket.
a. Remove the coupling bolt (1) between rear mounting
bracket and left side of transmission case. 
(Tightening torque: 55 ± 5.5 N·m)
07
RA19070600
b. Remove 2 coupling bolts (1) between rear mounting

bracket and right side of transmission case. 
c. Remove the locking nut (2) for through bolt between
rear mounting bracket and rear mounting cushion
1
assembly, and then remove the through bolt (3).
3 2
RA19070610
d. Remove the rear mounting bracket.

5. Remove the engine rear mounting cushion assembly.
a. Remove the coupling bolt (arrow) between rear
mounting cushion assembly and front sub frame
welding assembly.
RA19070620
b. Remove the engine rear mounting cushion assembly from the front sub frame welding assembly.

Removal & Installation - Left Mounting Assembly

CAUTION
 Install the protector to prevent the body from being scratched.

3. Use an engine equalizer to hang the engine.
4. Remove the battery (See page 16-7).
5. Remove the battery tray (See page 16-8).
6. Remove the engine left mounting cushion assembly.
a. Remove the fixing bolt (arrow) from the bracket I, and
then move away the bracket I from the left mounting
cushion assembly.
RA19070630
b. Remove the locking nut (1) for through bolt between

left mounting cushion assembly and left mounting 1
bracket, and then remove the through bolt (2).
c. Remove 5 coupling bolts (arrow) between left
mounting cushion assembly and body.
2
RA19070640
d. Remove the left mounting cushion assembly.

7. Remove the left mounting bracket.
a. Remove 3 coupling bolts (arrow) between left
mounting bracket and transmission case. 
RA19070650
b. Remove the left mounting bracket.


Removal & Installation - Right Mounting Assembly

CAUTION

4. Use an engine equalizer to hang the lifting eyes on both
sides of the engine.
FUSE
& RELAY
BOX
07
RA19070800
5. Remove the engine right mounting bracket.

a. Remove 1 coupling bolt (1) and 2 fixing nuts (2)
between right mounting bracket and right mounting
cushion assembly. m
ax
1 2
RA19070670
b. Remove 3 coupling bolts (arrow) between right

mounting bracket and engine block. 
RA19070680
c. Remove the engine right mounting bracket.

6. Remove the engine right mounting cushion assembly.

a. Remove 2 fixing bolts (arrow) from the expansion tank
and move the expansion tank to one side.
RA19070690
b. Remove 3 fixing bolts (arrow) from the right mounting

cushion assembly.
07
RA19070700
c. Remove the engine right mounting cushion assembly.


ENGINE UNIT REPAIR

Engine Assembly
Removal
CAUTION
 Remove the engine and transmission as an assembly.

 Block the inlet of intake pipe after removing the air filter and engine trim cover to prevent the foreign
matter from entering. Otherwise, the foreign matter will block the intake passage when starting, which
may cause serious damage to the engine.
07 1. Remove the engine trim cover.

5. Drain the engine oil (See page 13-11).
6. Drain the transmission oil (See page 17-12).
7. Drain the brake fluid (See page 25-13).
9. Drain the steering fluid (See page 28-9).
10.Recover the refrigerant (See page 29-20).
11. Remove the engine hood assembly (See page 45-9).
12.Remove the intake hose with crankcase ventilation hose assembly.
cover.
RA19140020

13.Remove the air filter (See page 10-10).
14.Remove the battery (See page 16-7).
15.Remove the battery tray (See page 16-8).
16.Remove the fuel rail injector assembly (See page 08-25).
17.Remove the electronic throttle assembly (See page 10-12).
18.Remove the intake manifold assembly (See page 10-15).
19.Install the engine right lifting eye.

HINT:
When installing 2 fixing nuts of the engine right lifting eye, install a thick washer between the nut and the
lifting eye to make sure that the engine right lifting eye is securely fitted with nuts.
20.Remove the front wheel (See page 23-10).
21.Remove the drive shaft assembly (See page 19-5).
22.Disconnect the joint that connects the expansion tank and the coupling hose.
a. Loosen the elastic clamps (arrow) and disconnect the
connection between expansion tank and outlet hose.
RA19070710
07
23.Remove the drive belt (See page 07-21).
24.Remove the generator assembly (See page 16-9).
25.Remove the idler pulley (See page 07-25).
26.Remove the tensioner (See page 07-27).
27.Remove the generator bracket (See page 16-9).
28.Remove the compressor assembly (See page 29-54).
29.Remove the power steering pump assembly (See page 28-17).
30.Remove the coolant pipe (4-way).
a. Loosen the elastic clamp (1) and disconnect the
connection between coolant pipe (4-way) and
expansion tank outlet hose. 3
connection between coolant pipe (4-way) and engine 4
inlet pipe.
1
c. Loosen the elastic clamp (3) and disconnect the
connection between coolant pipe (4-way) and water
2
pump assembly inlet coupling hose.
d. Loosen the elastic clamp (4) and disconnect the RA19070720
connection between coolant pipe (4-way) and small
circulation coolant pipe coupling hose.
31.Disconnect the exhaust pipe connection.
a. Disconnect the downstream oxygen sensor connector
(1) and remove it from the bracket.
b. Remove 2 coupling nuts (2), disconnect the main
catalytic converter assembly and precatalytic
converter assembly, and then remove the gasket in
the connection. 2
RA19110090

32.Disconnect the joint that connects thermostat housing and hose.

a. Loosen the engine outlet hose elastic clamp (arrow),
and disconnect the connection between engine inlet
hose and thermostat housing.
RA19120110
33.Move away the gear select and shift cable.

a. Remove the cotter pins (arrow) that connect the gear
select and shift cable and the transmission gear shift
mechanism.
07
RA19170090
b. Remove the flexible shaft clamps (arrow) from the

gear select and shift cable.
RA19170100
c. Move away the gear select and shift cable from the flexible shaft bracket.
34.Disconnect the clutch hydraulic line connection.
a. Loosen the coupling plug (1) and disconnect the
connection between clutch release cylinder pipe
assembly II and hose assembly.
b. Remove the hose assembly clamp (2) and move
away the hose assembly from the bracket. 2
1
RA19070740

35.Disconnect the heater water pipe.

connection between heater inlet pipe and the
thermostat seat.
connection between heater outlet pipe and coolant
pipe assembly.
2
RA19070750
36.Move away the canister solenoid valve and its coupling hose from the bracket.
37.Disconnect the engine wire harness.
a. Open the fuse and relay block cover and remove the
positive wire harness fixing nut (arrow), then
disconnect the connection between positive wire 07
harness and fuse and relay block.
RA19070760
b. Disconnect the connector (1) that connects the engine

wire harness and the body floor wire harness.
1
c. Remove the fixing bolt (arrow) and disconnect the
negative battery cable from the transmission.
RA19070770
d. Remove the fixing bolt (arrow) to disconnect the engine wire harness on ECM side.
e. Disconnect the ECM wire harness connector (1).
max
min
RA19070780
f. Disconnect the fixing clip between engine wire harness and drain channel front end panel assembly.
38.Use an engine equalizer to hang the engine.

39.Remove the engine rear mounting through bolt.

a. Remove the locking nut (1) for through bolt between
assembly, and then remove the through bolt (2).
2
1
RA19070790
b. Disconnect the connection between rear mounting bracket and rear mounting cushion assembly.
40.Remove the engine equalizer, and use an engine hoist to
hang the lifting eyes on both sides of the engine.
07 FUSE
& RELAY
BOX
RA19070800
41.Remove the engine left mounting cushion assembly (See page 07-59).
42.Remove the engine right mounting cushion assembly (See page 07-60).
43.Confirm that all the components are disconnected from the engine.
44.Remove the engine with transmission from the engine compartment.
45.Remove the engine wire harness and positive battery cable from the engine.
46.Separate the engine and the transmission.
47.Install the engine on the engine service platform.
Installation

Engine Block
Description
07
2
RA19070801
1 - Crankshaft Main Bearing Cap 2 - Crankshaft Main Bearing Upper Shell

3 - Crankshaft 4 - Crankshaft Main Bearing Lower Shell
5 - Crankshaft Thrust Washer 6 - Cylinder Block

8
2
07
10
3 11
5 5
RA19070802
1 - Piston 2 - Connecting Rod

3 - Connecting Rod Bearing Shell 4 - Connecting Rod Bearing Cap
5 - Connecting Rod Fixing Bolt 6 - Piston Pin (Semi-floating)
7 - First Compression Ring 8 - Second Compression Ring
9 - Upper Rail 10 - Bushing Ring
11 - Lower Rail

Disassembly
1. Remove the engine assembly and install the engine on the engine service platform (See page 07-62).
2. Remove the high-voltage cable (See page 14-8).
4. Remove the spark plugs (See page 14-12).
5. Remove the thermostat seat (See page 12-21).
6. Remove the engine accessory bracket.
a. Remove 2 fixing bolts (1) from the power steering
pump fixing bracket, and then remove the power
steering pump fixing bracket.
b. Remove 2 fixing bolts (2) from the A/C compressor 2
bracket, and then remove the A/C compressor 1
bracket.
07
RA19070810
7. Remove the engine right mounting bracket.

a. Remove 3 fixing bolts (arrow) from the engine right 1
mounting bracket, and then remove the engine right
mounting bracket.
8. Remove the knock sensor.
a. Remove the knock sensor fixing bolt (1), and then
remove the knock sensor. 2
9. Remove the oil pressure switch. RA19070820
a. Remove the oil pressure switch (2) from the engine

block.
10.Remove the oil filter (See page 13-13).
11. Remove the coolant pipe and the front bracket assembly.
a. Remove 4 fixing bolts (arrow) from the coolant pipe,
and then remove the coolant pipe assembly.
RA19070840
b. Remove 2 front bracket assemblies.

12.Remove the exhaust manifold heat insulator (See page 11-7).

13.Remove the exhaust manifold with precatalytic converter assembly.

a. Remove 8 fixing nuts (arrow) and 6 nut washers from
the exhaust manifold.
RA19070860
b. Remove the engine left lifting eye and exhaust manifold with precatalytic converter assembly.
c. Remove the exhaust manifold gasket.
14.Remove the small circulation coolant pipe.
a. Remove the coupling bolt (arrow) between small
07 circulation coolant pipe and cylinder block.
477F-1002015HA
*SQR477F*AF8H01586*
RA19070870
b. Remove the coupling bolt (arrow) between engine

speed sensor bracket and cylinder head, and then
remove the engine speed sensor bracket.
RA19070880
c. Remove the small circulation coolant pipe.

15.Remove the rear right bracket.
a. Remove 2 fixing bolts (arrow) from the rear right
bracket.
RA19070890
b. Remove the rear right bracket.

16.Fix the flywheel with a flywheel holding tool (arrow).
RA19070900
17.Remove the crankshaft pulley bolt (arrow), and then

remove the crankshaft pulley.
07
RA19070120
18.Remove the clutch assembly (See page 18-16).

19.Remove the flywheel assembly (See page 07-55).
20.Remove the timing belt (See page 07-28).
21.Remove the water pump (See page 12-28).
22.Remove the cylinder head cover (See page 07-37).
23.Remove the camshaft and rocker arm shaft (See page 07-40).
24.Remove the cylinder head (See page 07-47).
25.Loosen the elastic clamp to remove the crankcase ventilation hose from the cylinder block.
26.Remove the oil pan (See page 13-17).
27.Remove the oil strainer (See page 13-20).
28.Remove the oil pump assembly (See page 13-21).
29.Remove 4 fixing bolts (arrow) from the crankshaft rear oil
seal bracket, and then remove the crankshaft rear oil seal
bracket with rear oil seal assembly and grommet.
RA19070850

30.Remove the oil deflector assembly inside the cylinder block.

a. Remove the oil deflector assembly with a screwdriver
as shown in the illustration.
RA19070851
31.Remove the piston connecting rod assembly.

a. Using a ridge reamer or equivalent, remove all the carbon from the top of the cylinder.
b. Remove the connecting rod bearing cap fixing bolts
(arrow), and then remove the connecting rod bearing
07 caps.
(Tightening torque: 1st step: tighten them to 20 ± 3 N·m;
2nd step: retighten them to 33 ± 3 N·m)
RA19070910
HINT:
Using the 2 removed connecting rod bearing cap bolts,
remove the connecting rod bearing cap with connecting
rod bearing lower shell assembly by wiggling the
connecting rod bearing cap right and left as shown in the
illustration.
RA19070920
c. Using a hammer handle (1), push the piston

connecting rod assembly (2) out of the top of the
1
cylinder.
RA19070930

32.Remove the connecting rod bearing.

a. Remove the connecting rod bearing (arrow).
HINT:
Arrange the removed parts in the correct order.
RA19070940
CAUTION
 Be careful not to scratch the cylinder wall during operation.

 Attach a label with the corresponding number to each piston connecting rod assembly to prevent
incorrect installation. 07
33.Remove the piston ring.

a. Using a piston ring remover (1), remove 2
compression rings (2).
2
RA19070950
CAUTION
 Before removing the piston ring, check the piston ring side clearance. If it is necessary to be reused, be
sure to mark the piston ring position.
b. Remove the oil ring rail and bushing ring by hands.

34.Remove the piston.
The piston pin is semi-floating and cannot be assembled by general process after removal, so it is not
allowable to be removed in service. If there are abnormal noises caused by improper piston pin clearance,
replace the piston connecting rod assembly.

35.Remove the crankshaft.

a. Evenly loosen and remove 9 crankshaft main bearing
cap fixing bolts and a fixing nut in the order shown in
4 8 9 5 1
the illustration. 
3 7 10 6 2
RA19070951
b. Using 2 removed main bearing cap bolts, remove 5

main bearing caps.
07
RA19070960
HINT:
 Store the bearing lower shell and main bearing cap as a set.
 Arrange the main bearing caps in the correct order.
CAUTION
 Insert the bolts into the bearing caps in turn. Pull the bearing cap out by gently pulling up and applying
force toward the front and back sides of cylinder block as shown in the illustration. Be careful not to
damage the contact surfaces of bearing cap and cylinder block.
c. Remove the crankshaft.

36.Remove the crankshaft thrust washer.
a. Remove the crankshaft thrust washers (1) from the
cylinder block.
1
RA19070970

37.Remove the crankshaft main bearing lower shell.

a. Slightly push the crankshaft main bearing lower shell
(1) in the direction of arrow and remove it carefully.
HINT:
Remove other crankshaft main bearing lower shells in the
1
same way.
RA19070980
CAUTION
 Pay attention to the clearance position. Push out the bearing carefully as shown in the illustration. It is
difficult to push out the bearing and the parts may be damaged if pushing in the opposite direction.
07
38.Remove the piston cooling nozzle.

a. Remove the piston cooling nozzle fixing bolts (arrow),
and then remove the piston cooling nozzle from the
cylinder block.
RA19070981
Inspection
1. Check the cylinder block.
 Clean the engine block thoroughly and check all the hole passages for leakage.
 Check the engine block and cylinder bore for cracks.
 Check the bottom surface of engine block for cracks.
CAUTION
 DO NOT wash the cylinder at high temperature; otherwise, the cylinder liner will stick out beyond the
engine block.

2. Check the flatness of engine block upper surface.

a. Clean the engine block upper surface.
b. Using a precision straightedge and feeler gauge,
measure the flatness of engine block upper surface.
Specification
Measurement Item
(mm)
Engine Block Upper Surface Flatness 0.05
RA19070990
If the flatness of engine block upper surface is not as specified, adjust it. If it exceeds the limit, replace the
engine block.
 The maximum allowable wear thickness of engine block is 0.15 mm.
07  The maximum allowable wear thickness of engine block and cylinder head is 0.20 mm.
3. Check the cylinder.
a. Standard cylinder bore diameter and service size.
 Generally, divide the cylinder bores into four
groups by 0.04 mm of tolerance.
 The cylinder bore group marks are printed on the
small plane at the rear end of cylinder block intake
manifold side (shown in illustration). The printed
mark consists of numbers. Mark the cylinder bore
groups in the order of "4 - 3 - 2 - 1" from left to
right.
RA19071000
 Under the special conditions, enlarge the cylinder bore for service. The tolerance for cylinder bore is
0.03 mm and the bores are divided into three groups when servicing. When one cylinder bore is
serviced to the service size, the diameter for the remaining three cylinder bores should also be
processed to the service size.
Production Group No. Cylinder Bore Diameter (mm)

1 77.36 - 77.37
2 77.37 - 77.38
Normal Production
3 77.38 - 77.39
4 77.39 - 77.40
A 77.63 - 77.64
Production Service B 77.64 - 77.65
C 77.65- 77.66

b. Check the cylindricity of cylinder.

Using a cylinder gauge, measure the cylinder bore at
positions A, B and C in the thrust and axial directions.
Specification
Measurement Item
(mm)
Cylindricity 0.008
Cylindricity calculation method (for general

measurement):
Measure the cylinder bore at A, B and C and obtain 6
values. The cylindricity is half of the difference Thrust Direction
between maximum and minimum values among 6 Front
values.
Cylindricity = (maximum diameter - minimum Axial Direction
diameter)/2 A 10 mm
If the average bore diameter value measured at B
positions A, B and C exceeds the specified cylinder C
Center
07
10 mm
bore diameter or the cylindricity exceeds the specified
value, replace the engine block. RA19071010
4. Check the piston.

a. Using a scraper, remove the carbon deposits on the
top of piston.
RA19071020
b. Using a piston ring, remove the carbon deposits in the

piston ring groove.
RA19071030

c. Using a brush and solvent, thoroughly clean the

piston.
RA19071040
CAUTION
 DO NOT use a wire brush to clean.
07 d. Measure the piston diameter with a micrometer at the

position that is approximately 10 mm under the piston
skirt portion in the vertical direction of the piston pin.
10 mm
RA19071050
Corresponding Cylinder Bore

Group No. Piston Diameter (mm)
Diameter (mm)
1 77.325 - 77.335 77.36 - 77.37
2 77.335 - 77.345 77.37 - 77.38
3 77.345 - 77.355 77.38 - 77.39
4 77.355 - 77.365 77.39 - 77.40
If the piston diameter is not within the specified range, replace the piston connecting rod assembly.
5. Check the clearance between piston ring and ring groove
side.
Using a feeler gauge, measure the clearance between
the new piston ring and the ring groove side.
Specification
Measurement Item
(mm)
Piston Ring Side
Clearance
Oil Ring 0.03 - 0.16
RA19071060
If the piston ring side clearance is not within the specified
range, replace the piston connecting rod assembly.

6. Check the piston ring end gap.

a. Using a piston, push the piston ring from the top of
cylinder to a place that is 45 mm from the top of the
cylinder bore.
b. Using a feeler gauge, measure the end gap.
Specification
Measurement Item
(mm)
First Ring 0.2 - 0.35 45 mm
Piston Ring End
Gap
Oil Ring 0.2 - 0.6
If the piston ring end gap is not within the specified

range, replace the piston ring with a new one.
If the end gap is still not within the specified range
after replacement, replace the engine block.
07
RA19071070
7. Check the diameter of crankshaft main journal.

a. Measure the main journal diameter with the outer
diameter micrometer, and measure again after
rotating the crankshaft 90°.
Specification
Measurement Item
(mm)
Crankshaft Main Journal Diameter 48.99 ± 0.01
If the crankshaft main journal diameter is not within

the specified range, replace the main bearing shells
RA19071080
with new ones, and check the radial clearance of
crankshaft (See page 07-80).
If the radial clearance of the main bearing shell is still
not within the specified range after replacement,
replace the crankshaft.
b. Calculate the roundness and cylindricity by the measured values (measured area is shown in the
illustration). 
Roundness and cylindricity calculation method (for general measurement):
 Measure the diameter twice on the same cross section, and the roundness is half of the difference
between maximum and minimum values.
Roundness = (maximum diameter - minimum diameter)/2
 As shown in the illustration, measure the diameter twice in different directions on two cross sections
separately to obtain four values. The cylindricity is the half of the difference between the maximum
and minimum values among the four values.
Cylindricity = (maximum diameter - minimum diameter)/2


Cylindricity 0.008
Roundness 0.005
If the roundness or cylindricity of crankshaft main journal exceeds the specified value, replace the
crankshaft.
8. Check the crankshaft radial clearance.
a. Clean the crankshaft main journals and main bearing shells.
b. Install the crankshaft. Place the plastic feeler gauge
(1) on the crankshaft main journal, and make it
parallel to the crankshaft center axis and cover the
installation width range of main bearing cap
completely.
07 1
RA19071090
c. Install all the main bearing caps and tighten the cap fixing bolts to 90 - 100 N·m in the specified
sequence.
d. Remove the main bearing caps. Using the feeler
gauge, measure the widest part of compressed feeler
gauge. The measured value is the crankshaft radial
clearance.
RA19071100
If the crankshaft radial clearance is not within the specified range, install the new main bearing shell.
Replace the crankshaft if necessary.
CAUTION
 Replace the bearing shells in pairs.
For selection of main bearing shell, refer to 07-83.

9. Check the crankshaft thrust clearance.
a. Clean the crankshaft main journals and main bearing shells.
b. Install all the main bearing caps and tighten the cap fixing bolts to 90 - 100 N·m in the specified
sequence.

c. Push the crankshaft forward and backward and read

the value from the dial indicator.
Specification
Measurement Item
(mm)
80
70
90
Crankshaft Thrust Clearance 0.093 - 0.303
60
0
50
10
40
20
30
If the crankshaft thrust clearance is not within the N
OFF
specified range, replace the thrust washer as a set.
RA19071110
10.Check the crankshaft runout.

a. Install the crankshaft onto the tester and keep it level
as shown in the illustration.
b. Rotate the crankshaft slowly and read the max.
change value from the dial indicator. (Reading from
the dial indicator)/2 is the coaxiality of crankshaft.
Specification
07
Measurement Item
(mm)
Crankshaft Runout 0.05
RA19071120
If the crankshaft main journal runout is not within the
specified range, replace the crankshaft.
11. Check the diameter of crankshaft connecting rod journal.
Using an outer diameter micrometer, measure the
diameter of crankshaft connecting rod journal.
Specification
Measurement Item
(mm)
Crankshaft Connecting Rod Journal
44.90 ± 0.01
Diameter (mm)
If the connecting rod journal diameter is not within the RA19071130

specified range, replace the connecting rod bearing
shells with new ones, and check the radial clearance of
connecting rod bearing shell.
If the radial clearance of connecting rod bearing shell is
still not within the specified range after replacement,
replace the crankshaft.
For selection of connecting rod bearing shell, refer to 07-83.
12.Check the radial clearance of crankshaft connecting rod bearing shell.
a. Clean the connecting rod journals and the connecting rod bearing shells.
b. Place a feeler gauge (arrow) on the connecting rod
journal as shown in the illustration.
RA19071140

c. Install the connecting rod bearing caps, and tighten the connecting rod bearing cap fixing bolts to 20 + 5 N·m.
CAUTION
 DO NOT turn the crankshaft during installation.
d. Remove the connecting rod bearing caps (See page 07-67).

e. Using the gauge scale of feeler gauge, measure the
widest part of the compressed feeler gauge to obtain
the radial clearance of connecting rod bearing shell as
shown in the illustration.
Specification
Measurement Item
(mm)
Connecting Rod Bearing Shell Radial
0.006 - 0.06
Clearance
07 RA19071150
If the radial clearance of connecting rod bearing shell
is not within the specified range, replace the
connecting rod bearing shell. Replace the crankshaft
if necessary.
13.Check the connecting rod big end thrust clearance.
a. Install the connecting rod bearing caps, and tighten the connecting rod bearing cap fixing bolts to 20 + 5 N·m.
b. Install a dial indicator (2) with its measuring rod
contacting the side of connecting rod cap (1).
c. Turn the dial of dial indicator to reset it to zero. 1
d. Push the connecting rod forward and backward (do
not move the crankshaft forward and backward) and
read the value on the dial indicator.
Specification
Measurement Item 2
(mm)
Connecting Rod Big End Thrust RA19071160
0.333 - 0.387
Clearance
If the thrust clearance of connecting rod big end is not

within the specified range, replace the piston
connecting rod assembly.

Selection of Bearing Shell

SQR477F engine adopts the "standard type" main bearing shell and connecting rod bearing shell without any
color marks, only the "STD" mark is printed on the back side of bearing shell.
There are three types of main bearing shell and two types of connecting rod bearing shell for service.
Selection of main bearing shell
Production Symptom Shell Description

"0.4" mark is printed on the back side of
Engine block main bearing hole enlarges
bearing shell and a black mark is on
0.4 mm.
bearing shell.
A mark is printed on the back side of
Production Crankshaft journal is worn by 0.25 mm. bearing shell and a green mark is on
Service bearing shell.
A "0.02" mark is printed on the back side of
the main bearing shell that is used for gap
Noise from bearing shell is too loud.
correction and a yellow mark is on the 07
shell.
Selection of connecting rod bearing shell
Production Symptom Shell Description

A "0.25" mark is printed on the back side of
Crankshaft journal is worn by 0.25 mm. bearing shell and a green mark is on
bearing shell.
Production
Service A "0.025" mark is printed on the back side
of the main bearing shell that is used for
Noise from bearing shell is too loud.
gap correction and a yellow mark is on the
shell.
Precautions for bearing shell assembly:

 There is shell groove and oil hole on the main bearing upper shell, and the oil hole should be aligned with
that the engine block, but the main bearing lower shell has no oil hole.
 The connecting rod upper and lower bearing shells without oil grooves are universal, but one of the
connecting rod bearing shells has oil hole.
 It is necessary to use a set of connecting rod bearing shell and main bearing shell that are provided by the
same manufacturer on the same engine.
 Apply a coat of engine oil to the inner surface of connecting rod bearing shell and main bearing shell
before installation. The back side and inner surface of the bearing shell should be clean without any oil or
foreign matter during assembly.

Assembly
1. Install the piston cooling nozzle.
a. Install the piston cooling nozzle to the engine block,
and tighten the piston cooling nozzle fixing bolts
(arrow).
RA19070981
2. Install the crankshaft main bearing shell.
CAUTION
07
 Apply a coat of engine oil to the inner surface of main bearing shell before installation.
a. Carefully install the crankshaft bearing (1) in the

direction of arrow, and the notch of each main bearing
should be aligned with the cylinder block. The oil 1
passage hole on crankshaft main bearing (2) should
be aligned with the passage hole on cylinder block
after installation.
RA19071170
3. Install the crankshaft thrust washer.

a. Clean the crankshaft thrust washers and cylinder block inner wall before installation.
b. Apply a coat of engine oil to the crankshaft thrust washers.
c. There are 2 crankshaft thrust washers on the cylinder, which are installed on the front and rear sides of
thrust surface (both sides of 3rd bearing) respectively.
d. As shown in the illustration, the two grooves on one
side of crankshaft thrust washers (1) face outward
1
while the other side without groove is jointed with the
cylinder block inside wall.
RA19070970

4. Install the crankshaft.

a. Place the crankshaft on the cylinder block carefully.
b. There are "1 - 2 - 3 - 4 - 5" and "arrow" stamped on
the crankshaft main bearing cap. Install the crankshaft
main bearing caps from the timing belt side and make
sure that the "arrow" points to the timing belt side. 1 2 3 4 5
RA19071180
c. Install the crankshaft main bearing cap fixing bolts in

place by hands, and then tighten the crankshaft main 8 4 1 5 9
bearing cap fixing bolts in the sequence shown in the
illustration.  07
7 3 2 6 10
RA19071190
5. Install the piston ring.

a. The first compression ring is rectangular ring (1), the
second compression ring is conical ring (2), and the
oil ring is steel band combination ring. Apply a small
amount of engine lubricant to the piston ring groove
1
and piston. Note that the side with words for first
2
compression ring should face upward and the outer
cutting of second compression ring should face
downward. 3
b. The oil ring is steel band combination oil ring and 4
composed of upper rail (3), lower rail (5) and bushing
5
ring (4). When installing the oil ring, first install the
bushing ring into the oil groove, then install the two Openings of Each Ring：
rails with the two rails opening of steel band Lower Rail
combination oil ring staggered by 90° from the First Compression Second Compression
bushing ring closed gap, and the upper and lower rails Ring Ring
180°. Then install the second compression ring, and Front Rear
install the first compression ring finally with the two Bushing Ring
compression rings staggered by 120° from the upper
rail opening. The piston ring should rotate in the ring Upper Rail
groove freely without any stuck condition.

RA19071200
c. Rotate the piston ring several turns after applying engine oil to the piston ring groove, and note that the
position of ring notch should be the same with that described above; clean the crankshaft connecting
rod journal and cylinder bore with a non-woven fabric cloth.

6. Install the connecting rod bearing shell.
CAUTION
 Apply a coat of engine oil to the inner surface of connecting rod bearing shell before installation.
 The back side of connecting rod bearing shell should be clean without any oil or foreign matter during
assembly.
a. Carefully install the connecting rod bearing upper

shell (1) in the direction of arrow, and keep the groove 1
opening of each connecting rod bearing upper shell
face the piston and connecting rod assembly.
07
RA19071210
b. Carefully install the connecting rod bearing lower shell

(1) in the direction of arrow, and keep the groove
opening of each connecting rod bearing lower shell
face the connecting rod bearing cap.
1
RA19071220
7. Install the piston connecting rod assembly.

a. Rotate the crankshaft to the top dead center of 1st and 4th cylinder.
b. Apply a coat of engine oil to the piston surface and cylinder inside wall.
c. As shown in the illustration, install the piston
connecting rod assembly to the cylinder with the
piston installer (1).
RA19071230
CAUTION
 Pay attention to the front marks of piston and connecting rod during assembly without being reversed.
Install them with the side stamped with letter "F" on the connecting rod and piston top arrow facing
toward pulley side as shown in the illustration.

AD
1
AD
R
RA19071240
8. Install the connecting rod bearing cap.

HINT:
The direction of the number on one side of connecting
rod is the same as that of the number on the connecting
rod bearing cap. These numbers are cylinder numbers
indicating at which cylinder are located. For example, 07
number 3 indicates that the mounting position is at No.3
cylinder.
RA19071250
a. Install the connecting rod bearing caps in place, and

screw the connecting rod bearing cap fixing bolts
(arrow) by hands, then tighten the connecting rod
bearing cap fixing bolts to 20 + 5 N·m with a torque
wrench.
RA19070910
CAUTION
 Apply a small amount of engine lubricant to the connecting rod, connecting rod bearing cap and thread
joint surface.
Other assembly is in the reverse order of disassembly.

- MEMO -

GENERAL INFORMATION 08-3 Electric Fuel Pump Assembly 08-15
Description 08-3 On-vehicle Inspection 08-15
Tools 08-5 Installation 08-18
Fuel Supply System Line Connection  Filler Tube Assembly 08-19
Diagram 08-7 Removal 08-19
Circuit Diagram 08-8 Installation 08-20
Fuel Tank 08-21
Removal 08-21
Fuel Tank Accessories Description 08-24
Fuel System Pressure Release 08-11
Installation 08-24
Fuel Supply System Pressure Test 08-12
Fuel Rail Injector Assembly 08-25
ON-VEHICLE SERVICE 08-13 Removal 08-25
Fuel Filter 08-13 Inspection 08-26
Removal 08-13 Installation 08-27 08
Installation 08-14

08

08 - SQR477F FUEL SUPPLY SYSTEM
GENERAL INFORMATION
Description
14 2
5
15
7 4
13
08
8
12
11
9 ×4
10
×2
RA19080010

1 - Fuel Filler Cap 2 - Filler Tube Assembly

3 - Fuel Filler Hose 4 - Fuel Breather Hose
5 - Fuel Pump Pressure Cap 6 - Electric Fuel Pump Assembly
7 - Fuel Tank Seal Ring 8 - Fuel Tank
9 - Fuel Vapor Pipe VI 10 - Inlet Pipe II
11 - Inlet Pipe III 12 - Fuel Rail Injector Assembly
13 - Inlet and Return Pipe Assembly 14 - Fuel Filter
15 - Inlet Pipe I
The engine fuel supply system provides a certain amount and concentration of combustible air-fuel mixture
and supplies it to the cylinders according to the requirements under various operating conditions of engine.
The fuel supply system consists of fuel tank, electric fuel pump assembly, fuel filter, delivery pipe, fuel rail and
injector, and is used for fuel storage, filtration, delivery and injection. The function of fuel supply system is to
provide gasoline with sufficient pressure to the fuel injector by using electric fuel pump assembly, and the
injector injects a certain amount of gasoline to the top of intake valve in the intake manifold in accordance with
08 the control signals from ECM.

Specifications

Fuel Filter Bracket Fixing Screw 7 ± 1.5
Fuel Tank Pressure Cap 75 ± 5
Filler Tube Assembly Lower End Bracket Fixing Bolt 7 ± 1.5
Filler Tube Assembly Fixing Nut 7 ± 1.5
Fuel Tank Fixing Bolt 23 ± 2.5
Fuel Rail Fixing Bolt 8 - 11
SQR477F Pressure (kPa) 08

Tools
Special Tool
Fuel Tank Pressure Cap Remover
RCH0000004
General Tools
Digital Multimeter
RCH0000002

RCH0000048
RCH0000005
08

Fuel Supply System Line Connection Diagram
3 4
2 1
08
RA19080050
1 - Electric Fuel Pump Assembly 2 - Electric Fuel Pump Assembly Pressure Regulator
3 - Fuel Filter 4 - Inlet and Return Pipe Assembly
5 - Fuel Rail Injector Assembly
When engine operates properly, the electric fuel pump assembly (1) sucks fuel from the fuel tank and filters it
through the fuel filter (3), and then deliveries it to the inlet and return pipe assembly (4). Some fuel enters the
fuel rail (5) and is supplied to the injector. Some fuel flows back to the electric fuel pump assembly pressure
regulator (2) directly. When the fuel supply system pressure is high, the diaphragm spring in the regulator is
jacked up by the pressure, then the valve opens and the fuel flows out from the regulator. When the pressure
reaches normal value, the regulator shuts off and the fuel stops flowing out. Finally, the system pressure
reaches a steady state.

Circuit Diagram
Fuel Supply System (Page 1 of 2)
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT
PANEL FUSE
AND RELAY RF01 86 30
EF33 EF21 EF18 ENGINE
BOX 10A COMPARTMENT
ECM
I-005 15A 15A 10A
1 MAIN FUSE AND
EF20 RELAY EF35 RELAY BOX
30 86 10A 85 87 10A B-012
FUEL
B-013
PUMP
RELAY EF17 B-014
87 85 15A
A11 A15 C5 C6 C17 D6 C1

R
R
B-050
30
RW
I-003 A
08
R
R
13 11
INSTRUMENT CLUSTER
I-043
5 22 21
VB
B
I-003
WL
I-004
RB
YV
R
B-050 10 32 20
B-053
YB
B
2 4 3 5
FUEL LEVEL
M SENSOR AND 41 5 15 16 20
FUEL PUMP
B-027 ECM
1 B-001
B
B-035
42 41 40 39 38 37 36 35 34 33 32 31 30 29
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 B-050
28 27 26 25 24 23 22 21 20 19 18 17 16 15
W
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 B-001 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 B
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
A1 A2 A3 A4 A5 A6
A10 A11 A12 A13
C1 C2 C3 C4 C5 C6 C7 B-013 A7 A8 A9 A14 A15 A16
C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18 W
1 2 3 4 5 6 7 8 9 10 11 12
B-014
13 14 15 16 17 18 19 20 21 22 23 24 W
I-005
25 26 B
87 B-012
85 86 86 86 D1 D2 D3 D4 D5 D6 D7 D8 W 1 2 3 4 5
87 30 87 30 D13 D14 D15 D16
30 85 85
D9 D10 D11D12 D17 D18 D19 D20
B-027
B
29 30 31 32 33 34 35 36 37 38 39 40 41 42
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-043 I-004
15 16 17 18 19 20 21 22 23 24 25 26 27 28
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 L L
1 2 3 4 5 6 7 8 9 10 11 12 13 14
EA19080010

Fuel Supply System (Page 2 of 2)
R
B-020
9
E-012
R
RG
RG
RG
RG
1 1 1 1
08
2 INJECTOR 1 2 INJECTOR 2 2 INJECTOR 3 2 INJECTOR 4
E-004 E-020 E-017 E-016
GBr
GW
GY
GB
68 67 72 74
ECM
E-001
76 75 74 73 72 71 70 69 68 67 66 65
88 87 86 85 84 83 82 81 80 79 78 77
100 99 98 97 96 95 94 93 92 91 90 89 1 2
1 2 3 4 5 6 7 8
112 111 110 109 108 107 106 105 104 103 102 101
16 15 14 13 12 11 10 9 E-004 E-017
B B
E-001 B-020 E-016 E-020

B B B B
EA19080020

DIAGNOSIS & TESTING

HINT:

Fuel filter (blocked) 08-13
Fuel pressure in fuel supply system is too
low Electric fuel pump assembly (strainer
08-15
blocked)
Fuel pressure in fuel supply system is too Fuel injector (clogged) 08-25
high Electric fuel pump assembly 08-15
Low fuel level -
Electric fuel pump assembly has loud
Electric fuel pump assembly relay -
08 operating noise and operates delay
Electric fuel pump assembly 08-15
Fuel filter (blocked) 08-13
Fuel injector 08-25
Injector is clogged and leaks
Poor fuel quality -
Excessive foreign matter in fuel tank -
Fuel supply system line (broken) -
Injector does not work Fuel injector (short in coil) 08-25
Wire harness -

Fuel System Pressure Release

WARNING
 When engine is not operating, the fuel pressure in fuel supply system is still high. Before repairing or
disconnecting the fuel line or fuel supply system components, it is necessary to release the fuel supply
system pressure to prevent the fuel from spraying out accidentally. Failure to follow these instructions
may result in serious personal injury or death.
Perform the following procedures to release the fuel pressure in fuel supply system:
1. Recognize and remove the electric fuel pump assembly
relay from the engine compartment fuse and box. 10
15
15
10 15
15
10 15
10
FUEL PUMP 15
RELAY
10
30 15
20 20
30
40
30
40
40
40
08
RA19080060
2. Start and run the engine until it stalls.

3. Restart the engine until it does not run.
4. Turn the ignition switch to LOCK.
6. Insert the electric fuel pump assembly relay into the original place.

Fuel Supply System Pressure Test

SQR477F Pressure (kPa)

WARNING
 When operating the fuel supply system, work area should be in good ventilation and keep fire sources or
open flames away from the work area, in which fire extinguisher should be equipped.
 Before operating the fuel supply system, please touch the vehicle body to discharge static electricity;
failure to do so will cause a fire, even result in an explosion.
 Before removing and installing the fuel pipes, release the fuel supply system pressure.
08
CAUTION
 Make sure that the battery voltage is 11 - 12 V.

 The service life of fuel filter should be within 30000 km.
 Make sure that the fuel supply system lines are securely connected, preventing the fuel supply system
from leaking.

3. Disconnect the inlet hose connector and connect the fuel
supply system pressure tester to a position between inlet
hose and fuel rail.
Fuel Hose
RA19080070
4. Start the engine and run it at idle, and then read the value on the pressure tester.
Start the engine and read the value while idling:
- The standard pressure at idle should be higher than 400 kPa.
- If the measured pressure value is lower than 400 kPa, check the fuel filter for blockage.
Replace the fuel filter if necessary (See page 08-13).
- If the measured pressure value is lower than 400 kPa and the fuel filter operates properly, check the
electric fuel pump assembly. Replace it as necessary.
- If the measured pressure value is too high, the injector may be clogged or the electric fuel pump
assembly pressure modulating valve may be malfunctioning.
Replace the injector (See page 08-25) or electric fuel pump assembly (See page 08-15) if necessary.

ON-VEHICLE SERVICE
Fuel Filter
Removal
WARNING
 When operating the fuel supply system, work area should be in good ventilation and keep the fire
sources or open flames away from the work area, in which fire extinguisher should be equipped.
 After performing the procedures for the fuel system pressure release, there still remains some pressure
in the fuel line. When disconnecting the fuel line, cover the joint with a piece of cloth or equivalent to
prevent the fuel from spraying out.
 If fuel leakage occurs when operating the fuel supply system, please handle the leaked fuel in time.
08
CAUTION
 DO NOT damage the disconnected fuel system line or connectors. Cover the line joints or connectors
with plastic bags or equivalent, preventing foreign matter from entering.
The disconnection way for all the fuel pipe coupling joints in
the following procedures is shown in the illustration.
RA19080080
1. Release the fuel pressure in the fuel supply system (See page 08-11).
4. Remove the fuel filter.
a. Disconnect the connecting joints (arrow) on both ends
of the fuel filter.
b. Loosen the fuel filter bracket fixing screw (1). 
(Tightening torque: 7 ± 1.5 N·m )
RA19080090

c. Disconnect the fuel filter from the fuel filter bracket.
CAUTION
 Cover both ends of the fuel filter with plastic bags or equivalent to prevent foreign matter from entering.
ENVIRONMENTAL PROTECTION
 The removed fuel filter should be handled by the specialized department according to local laws and
regulations. Never discard it at will.
Installation
CAUTION
08
 Before connecting the hose, check if there is any damage or foreign matter on the hose or joint.
 During installation, push in the fuel pipe joint clip until a click sound is heard from the coupling joint, then
check that the fuel pipe joint clip is on the collar of the fuel pipe joint. After installing the pipe joint clip,
check that the fuel pipe joint cannot be pulled out. Be careful not to damage the joint. If the clip is
damaged, replace it.
 Turn the ignition switch to ON (without starting the engine) to apply fuel pressure to the fuel supply
system, and then check the connections for leakage.

Electric Fuel Pump Assembly

1. Inspect the electric fuel pump assembly oil level sensor.
a. Using a flat tip screwdriver, pry up the electric fuel pump assembly protective cap, and disconnect the
electric fuel pump assembly connector.
b. Using the digital multimeter, measure the resistance
of oil level sensor based on the fuel volume in the fuel
tank.
+ -
Tester
Oil Level Indictor Specification (Ω)
Connection
5 4 3 2 1
Terminal 3 -
E 275 ± 5
Terminal 2
Terminal 3 -
1/4 165 ± 5
Terminal 2 RA19080100
Terminal 3 -
1/2 97 ± 4
Terminal 2 08
Terminal 3 -
3/4 79 ± 3
Terminal 2
Terminal 3 -
F 32 ± 3
Terminal 2
If the result is not as specified, replace the electric fuel

pump assembly.
2. Check the electric fuel pump assembly operation.
a. Using a flat tip screwdriver, pry up the electric fuel pump assembly protective cap, and disconnect the
electric fuel pump assembly connector.
b. Apply battery voltage to terminals 5 and 1. Check if the electric fuel pump assembly operates in 10
seconds.
HINT:
 These tests must be finished within 10 seconds to
prevent the coils from being burnt. + -
 Leave the electric fuel pump assembly as far as

possible from the battery.
 Always switch the voltage on and off on the battery 5 4 3 2 1
side, rather than the electric fuel pump assembly
side
Tester Connection Specification

RA19080110
Battery positive (+) to Terminal 5 Fuel pump
Battery negative (-) to Terminal 1 operates
If the electric fuel pump assembly does not operate,

replace it.

Removal
WARNING
CAUTION
 Only use parts approved by Chery Automobile Co., Ltd. to replace the electric fuel pump assembly.
08  As the electric fuel pump assembly radiates through fuel, low fuel level in the fuel tank will directly
shorten the service life of the electric fuel pump assembly.
 Keep the electric fuel pump assembly and work area clean when replacing the electric fuel pump
assembly; otherwise the electric fuel pump assembly element will be clogged.
 DO NOT operate the electric fuel pump assembly when it is dry or in the water. Failure to do so will
damage the electric fuel pump assembly.
 Keep the fuel tank and line clean, and replace the fuel filter if the electric fuel pump assembly has been
replaced.
The disconnection way for all the coupling joints in the

following procedures is as shown in the illustration.
RA19080080

4. Open the fuel filler cap and discharge the fuel vapor in the fuel tank.
5. Remove the rear seat cushion (See page 44-14).
6. Remove the electric fuel pump assembly.

a. Using a flat tip screwdriver (1), pry up the electric fuel

pump assembly protective cap (2).
2
RA19080120
b. Disconnect the electric fuel pump assembly connector

(arrow).
c. Disconnect the coupling joint (1) between electric fuel
pump assembly and inlet pipe I.
d. Disconnect the coupling joint (2) between electric fuel
pump assembly and inlet and return pipe assembly. 1
2
08
RA19080130
CAUTION
 Before disconnecting the joint, remove all the dirt and foreign matter from the electric fuel pump
assembly pressure cap.
 DO NOT forcefully bend or twist the delivery pipe.
e. Using the special tool (fuel tank pressure cap

remover), remove the fuel tank pressure cap.
RA19080140
f. Pull the electric fuel pump assembly up and out of fuel

tank.
RA19080150

CAUTION
 To keep the fuel tank clean, cover it completely with a plastic bag or equivalent to prevent foreign matter
from entering.
 The electric fuel pump assembly can be put into a container and taken out of the cabin, thus preventing
fuel in the pump from dropping into the cabin.
7. Drain the fuel in the electric fuel pump assembly.
CAUTION
 Cover the electric fuel pump assembly completely with a plastic bag or equivalent to prevent foreign
matter from entering.
Installation
08
CAUTION
 During installation, push in the fuel pipe connector until a click sound is heard, then check that the fuel
pipe joint clip is on the collar of the fuel pipe joint. After installing the pipe joint clip, check that the fuel
pipe joint cannot be pulled out. Be careful not to damage the joint. If the clip is damaged, replace it.

Filler Tube Assembly

Removal
WARNING

3. Remove the filler tube assembly.
a. Open the fuel filler door, turn the oil filler cap in the
direction of arrow as shown in the illustration. 08
RA19080160
b. Loosen the worm clamp (1) and disconnect the connection between fuel breather hose and fuel filler
tube assembly. 
c. Loosen the worm clamp (2) and disconnect the connection between fuel filler hose and fuel filler tube
assembly. 
CAUTION
 Cover the joint with a plastic bag after disconnecting the fuel breather hose and fuel filler hose, in order to
prevent foreign matter from entering the fuel tank and fuel from evaporating or leaking.
d. Remove the filler tube assembly lower end bracket

fixing bolt (arrow).
2
1
RA19080170

e. Remove the filler tube assembly fixing nut (arrow).

RA19080180
f. Remove the filler tube assembly.
Installation
08

Fuel Tank
Removal
WARNING
CAUTION
08
The disconnection way for all the fuel pipe coupling joints in
the following procedures is shown in the illustration.
RA19080080

4. Open the fuel filler cap and discharge the fuel vapor in the fuel tank.
5. Disconnect the electric fuel pump assembly side pipe and the line connection.
a. Turn over the rear seat cushion (See page 44-14).
b. Using a flat tip screwdriver (1), pry up the electric fuel
pump assembly protective cap (2).
2
RA19080120

c. Disconnect the electric fuel pump assembly connector

(arrow).
d. Disconnect the inlet pipe I joint (1) and inlet and return
pipe assembly joint (2).
RA19080130
6. Remove the fuel filter (See page 08-13).

7. Remove the fuel tank.
a. Loosen the worm clamp (1) and disconnect the
connection between the fuel breather hose and fuel
filler tube assembly. 
b. Loosen the worm clamp (2) and disconnect the
08 connection between the fuel filler hose and fuel filler 1
tube assembly. 
2
RA19080190
CAUTION
 Cover the joint with a plastic bag after disconnecting the fuel breather hose and fuel filler hose, in order to
prevent foreign matter from entering the fuel tank and fuel from evaporating or leaking.
c. Disconnect the connecting joint (1) between inlet and

return pipe assembly and inlet pipe II.
d. Disconnect the coupling joint (2) between fuel vapor 1
pipe VI and fuel vapor pipe V. 2
RA19080200
CAUTION
 Before disconnecting the joint, remove any dirt and foreign matter from the retainer.
 DO NOT forcefully bend or twist the delivery pipe.

e. Support the fuel tank with a transmission carrier.
RA19080210
f. Remove 4 fixing bolts (arrow) from the fuel tank.

08
RA19080220
g. Slowly lower the carrier to remove the fuel tank.

8. Remove the fuel pump pressure cap (1), electric fuel
pump assembly (2) and fuel tank seal ring (3) from the
1
fuel tank.
RA19080230

Fuel Tank Accessories Description

1. Fuel Vapor Valve
Function of fuel vapor valve: 1
When fuel vapor is produced in the fuel tank, the vapor
3
will enter the charcoal canister through the fuel vapor
valve (1) by the fuel vapor pipe (2). When the vehicle
body bumps or overturns, the fuel vapor valve will
automatically lock to prevent fuel overflow.
2. Fuel Breather Pipe
2
Function of fuel breather pipe:
RA19080231
When filling the fuel tank through the fuel filler, the fuel
vapor will get out of the fuel tank through the fuel
breather pipe (3).
3. Fuel Tank Cushion
Pay attention to the installation positions of fuel tank
cushions (arrow). Incorrect installation will damage the
fuel tank or fuel pipe due to friction between fuel tank and
body.
08
Installation
CAUTION
 Return the fuel pipe and vent pipe to their original positions, or the fuel pipe will be damaged due to
friction generated by the body shock, causing fuel leak.
 During installation, push in the fuel pipe connector until a click sound is heard, then check that the fuel
pipe joint clip is on the collar of the fuel pipe joint. After installing the pipe joint clip, check that the fuel
pipe joint cannot be pulled out. Be careful not to damage the joint. If the clip is damaged, replace it.

Fuel Rail Injector Assembly

Removal
WARNING
CAUTION
08
 The injector is a part of high accuracy, featuring good anti-clogging, anti-pollution and atomization, so be
careful to avoid damage to the injector during removal of the fuel rail.
1. Release the fuel pressure in the fuel supply system (See page 08-11).
CAUTION

5. Remove the fuel rail injector Assembly.
a. Disconnect the coupling joint (arrow) between delivery
pipe and fuel rail.
RA19080240

b. Disconnect 4 connectors of the injectors separately.
RA19080250
c. Loosen and remove 2 fixing bolts (arrow) from the fuel

rail.
08
RA19080260
d. Remove the fuel rail and fuel injectors.

6. Separate the injector clamps and remove the injectors
(arrow) from the fuel rail.
RA19080270
Inspection
1. Disconnect the injector connector.
2. Measure the resistance between 2 terminals (injector
side) of the injector with a digital multimeter.
+ -
Measurement 1 2
Specification (Ω)
Temperature
20°C 11 - 16
RA19080280

Installation
CAUTION
 Install a new seal to the injector sealing surface.

 Before installing the injector, apply clean grease or gasoline to the O-ring sealing surface for easy
installation, preventing damage to the O-ring.
08

- MEMO -

GENERAL INFORMATION 09-3 Activated Charcoal Canister 
Tool 09-4 Installation 09-9
Circuit Diagram 09-5 PCV Valve 09-10
Removal 09-10
DIAGNOSIS & TESTING 09-6 Inspection 09-10
Leakage Inspection 09-6 Installation 09-10
Activated Charcoal Canister  Upstream Oxygen Sensor 09-11
Inspection 09-6
Removal 09-11
Fuel Tank Cap Inspection 09-6
Inspection 09-12
ON-VEHICLE SERVICE 09-7 Installation 09-12
Activated Charcoal Canister  Downstream Oxygen Sensor 09-13
Solenoid Valve 09-7 Removal 09-13
Removal 09-7 Inspection 09-13
Inspection 09-8 Installation 09-13
Installation 09-8 09

09

09 - SQR477F EMISSION CONTROL SYSTEM
GENERAL INFORMATION
Description
4
3
09
RA19090010
1 - Fuel Tank Assembly 2 - Activated Charcoal Canister Solenoid Valve

3 - PCV Valve 4 - Activated Charcoal Canister
The emission control system recovers and burns the fuel vapor to prevent the vapor in the fuel tank from
being discharged into the atmosphere. It monitors the oxygen content in the exhaust gas, so as to guarantee
the maximum efficiency of the catalyst assembly in converting the HC, CO and NOx in the exhaust gas.
The activated charcoal canister plays an important role in the emission control system. The activated charcoal
canister can be used to absorb and filter the moisture and fuel vapor. The fresh air enters the bottom of
activated charcoal canister while the fuel vapor enters the top of activated charcoal canister through the pipe.
When the engine is stopped, the fuel vapor and fresh air will be stored in the activated charcoal canister.
When the canister solenoid valve opens, the fuel vapor will enter the intake manifold to burn.

The oxygen sensor consists of upstream oxygen sensor and downstream oxygen sensor. The upstream
oxygen sensor is installed on the exhaust manifold, and the downstream oxygen sensor is installed on the
main catalyst assembly. The oxygen sensor can detect the oxygen content in the exhaust gas, and determine
whether the combustible air-fuel mixture is completely burnt out or not, so as to guarantee the maximum
efficiency of the catalyst assembly in converting the HC, CO and NOx in the exhaust gas.
Specifications

Activated Charcoal Canister Bracket Fixing Bolt 7 ± 1.5
Connecting Bolt Between Activated Charcoal
7 ± 1.5
Canister and Bracket
09 Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Emission Control System
BATTERY
EF35
10A 86 30
ECM
MAIN ENGINE
RELAY COMPARTMENT
FUSE AND
85 87
RELAY BOX
B-012
B-013
EF17 EF15 EF18
B-017
15A 15A 10A
C1 C17 D6 D5 C4 H6
RL
R
R
11 14 12
B-020
E-012 09
R
RL
R
R
3 4 DOWN- 3 4 1
UPSTREAM CANISTER
STREAM OXYGEN
OXYGEN SOLENOID
SENSOR VALVE
SENSOR E-006 E-018
2 1 E-008 2 1 2
RG
RB
BR
YV
YB
R
RW
PW
E-012
BY
WG
15 5 6
B-020
RG
BR
YB
20 5 15 16 48 21 43 73 104 80 94
ECM
B-001
E-001
76 75 74 73 72 71 70 69 68 67 66 65
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 112 111 110 109 108 107 106 105 104 103 102 101 1 2 3 4
E-006 E-008
B-001 E-001 B B
B B
D1 D2 D3 D4 D5 D6 D7 D8 B-012 C1 C2 C3 C4 C5 C6 C7 B-013
D13 D14 D15 D16 W C11 C12 C13 C14 W
D9 D10 D11D12 D17 D18 D19 D20 C8 C9 C10 C15 C16 C17 C18
B-020 B-017 E-018

1 2 3 4 5 6 7 8 H1 H2 H3 H4 H5 H6 H7
B W 1 2 B
16 15 14 13 12 11 10 9 H8 H9 H10 H11H12H13H14
EA19090010

DIAGNOSIS & TESTING

Leakage Inspection
Visually check that the hoses, connections and gaskets have no cracks, leaks or damage.
CAUTION
 Removal of the engine oil dipstick, filler cap, PCV hose and other components or other problems in them
may cause the engine to run improperly.
 Air suction caused by disconnections, looseness or cracks in the intake system pipes related to throttle
assembly will result in engine failure or abnormal operation. Replace the parts as necessary.
Activated Charcoal Canister Inspection

1. Close port C and blow compressed air into port A, check that the air flows from port B. If the result is not as
specified, replace the canister.
2. Close port C and blow compressed air into port B, check
that the air flows from port A. If the result is not as B
09
C
specified, replace the canister.
RA19090020
Fuel Tank Cap Inspection

1. Visually check that the fuel tank cap assembly is not deformed or damaged.
2. If the result is not as specified, replace the fuel tank cap.

ON-VEHICLE SERVICE
Activated Charcoal Canister Solenoid Valve
Removal
CAUTION
 Before removal, mark the air inlet and outlet hoses to avoid confusion.

4. Remove the activated charcoal canister solenoid valve.
a. Disconnect the canister solenoid valve connector
(arrow).
09
RA19090030
b. Disengage the elastic clamps (arrow) and disconnect

both ends of canister solenoid valve from the hose.
RA19090040
CAUTION
 Positioning distance from hose end to clamp is 3 - 5 mm.
c. Remove the canister solenoid valve from the bracket.

Inspection
Measure the resistance between the 2 pins of canister
solenoid with the digital multimeter.
+ -
1 2
Measurement
Specification (Ω)
Temperature
20°C 26 ± 4
RA19090050
Installation
09

Activated Charcoal Canister Assembly

Removal
3. Remove the front right wheel house (See page 46-15).
4. Remove the activated charcoal canister assembly.
a. Loosen the elastic clamps (arrow), and disconnect the connection between activated charcoal canister
and hoses.
CAUTION
 Positioning distance from hose end to clamp is 3 - 5 mm.
b. Remove 2 fixing bolts (1) from the activated charcoal

canister bracket, and remove the activated charcoal
canister with bracket assembly.
1 09
RA19090060
c. Remove the connecting bolt (arrow) between the

activated charcoal canister and bracket, and separate
the activated charcoal canister and bracket.
RA19090070
 The abandoned activated charcoal canister should be handled by the specialized department according
to local laws and regulations. Never discard it at will.
Installation

PCV Valve
Removal
4. Remove the PCV valve.
a. Disconnect the spring clamp (1) between the PCV
valve side and hose.
b. Take out the PCV valve in the PCV valve rubber boot
(2). 1
RA19090080
c. Remove the PCV valve rubber boot.

09
Inspection
1. Install a clean hose to the PCV valve.
2. Check the PCV valve operation.
a. Blow air into the cylinder head side, and check that the air flows smoothly.
WARNING
 DO NOT suck air through the valve. Petroleum substances inside the valve are hazardous to your
health.
b. Blow air into the intake manifold side, and check that the air flows difficultly.
If the result is not as specified, replace the PCV valve.
3. Remove the clean hose from the PCV valve.
Installation
CAUTION
 Press the PCV valve rubber boot into the cylinder head cover, then press in the PCV valve.
 Positioning distance from hose end to spring clamp is 3 - 5 mm.

Upstream Oxygen Sensor

Removal
WARNING
 The temperature of exhaust system is very high when the engine is running. Before removal, you must
make sure that the engine has shut off, and the exhaust system has cooled down sufficiently, otherwise,
there is a risk of scald injury.

4. Remove the upstream oxygen sensor.
a. Remove and disconnect the upstream oxygen sensor
connector (arrow) from bracket.
09
RA19090081
b. Remove 3 fixing bolts (arrow) from the exhaust

manifold heat insulator, and remove the exhaust
manifold heat insulator.
RA19090082
c. Remove the upstream oxygen sensor (arrow) from the

exhaust manifold.
RA19090090

Inspection
1. Measure the resistance of the upstream oxygen sensor
with the digital multimeter.
+ -
Multimeter D C B A
Connection
Pin C - Pin D 20°C 7 - 11
Pin A - Pin B
Pin A - Pin C
Pin A - Pin D Always ∞ RA19090100
Pin B - Pin C
Pin B - Pin D
If the result is not as specified, replace the upstream

oxygen sensor.
Installation
09


Removal
WARNING
 The temperature of exhaust system is very high when the engine is running. Before removal, you must
make sure that the engine has shut off, and the exhaust system has cooled down sufficiently, otherwise,

3. Raise the vehicle to the proper position.
4. Remove the downstream oxygen sensor.
a. Remove and disconnect the downstream oxygen
sensor connector (1) from bracket.
b. Remove the downstream oxygen sensor (arrow) from
the main catalyst assembly.
1
RA19090110
Inspection
1. Measure the resistance of the downstream oxygen
sensor with the digital multimeter.
+ -
Multimeter D C B A
Connection
Pin C - Pin D 20°C 7 - 11
Pin A - Pin B
Pin A - Pin C
Pin A - Pin D Always ∞ RA19090100
Pin B - Pin C
Pin B - Pin D
If the result is not as specified, replace the downstream

oxygen sensor.
Installation

- MEMO -

GENERAL INFORMATION 10-3 Electronic Throttle Assembly 10-12
Circuit Diagram 10-6 Cleaning 10-13
Installation 10-14
Intake Manifold Assembly 10-15
Removal 10-15
ON-VEHICLE SERVICE 10-9 Inspection 10-16
Air Filter Element 10-9 Installation 10-16
Replacement 10-9 Electronic Accelerator Pedal 10-17
Air Filter 10-10 Installation 10-17
Removal 10-10
Installation 10-11
10

10

10 - SQR477F INTAKE SYSTEM
GENERAL INFORMATION
Description
2
4
3 5
1 6 7
×4
×8 13
12
14
×4 8
15
10
×3
×3
10
11
RA19100010

1 - Intake Manifold 2 - Intake Pressure/Temperature Sensor

3 - Electronic Throttle Assembly Grommet 4 - Electronic Throttle Assembly
5 - Worm Clamp 6 - Intake Hose
7 - Air Filter Upper Housing 8 - Air Filter Element
9 - Air Filter Lower Housing 10 - Air Direct pipe
11 - Resonant Cavity Assembly 12 - Crankcase Ventilation Hose
13 - Canister Solenoid Valve Bracket 14 - Intake Manifold Upper Bracket
15 - Intake Manifold Gasket
The intake system mainly consists of the air filter, intake hose assembly, electronic throttle assembly, intake
pressure/temperature sensor, intake manifold assembly, etc.
The intake system uses the air filter to filter the particles and dust in the air. The air filtered flows into the intake
manifold through the throttle assembly and mixes with the fuel at the end of the intake manifold port to form
flammable gas mixture, which is transmitted to each cylinder uniformly to coordinate with the operation of the
engine.
The electronic throttle is a critical part for the engine intake system. Its main function is to adjust the intake
passage area according to the driver's driving intention. It controls the intake air volume to meet the intake
requirement of the engine in different operating conditions, sends back the position signals of the throttle
10 valve plate to the control unit to achieve accurate control, and the engine runs under the optimal control state.
Specifications

Coupling Screw Between Air Filter Upper and Lower
3±1
Housing
Air Filter Fixing Bolt 7 ± 1.5
Resonant Cavity Assembly Fixing Bolt 7 ± 1.5
Air Direct Pipe Right Fixing Bolt 7 ± 1.5
Air Direct Pipe Left Fixing Bolt 7 ± 1.5
Electronic Throttle Assembly Fixing Bolt 8 - 11
Intake Pressure/Temperature Sensor Fixing Bolt 8±1
Intake Manifold Fixing Nut 22.5 ± 2.5
Canister Solenoid Valve Bracket Fixing Bolt 10 ± 2
Intake Manifold Upper Bracket Fixing Bolt 18 ± 2
Electronic Accelerator Pedal Fixing Bolt 10 ± 2

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
10
RCH0000002

Circuit Diagram
Intake System (Page 1 of 2)
ECM
E-001
87 75 86 78 107 77 109 91 102 85 101 84

RGr
BGr
RBr
BW
GR
LW
RB
RY
LG
RL
LR
LB
10
1 4 2 5 3 6 3 4 2 1 1 2
COOLANT
TEMPERATURE
THROTTLE POSITION SENSOR INTAKE PRESSURE/TEMPERATURE SENSOR
E-015 SENSOR E-014
E-019
76 75 74 73 72 71 70 69 68 67 66 65
1 2 3
88 87 86 85 84 83 82 81 80 79 78 77 4 5 6 4 3 2 1
1 2
100 99 98 97 96 95 94 93 92 91 90 89
112 111 110 109 108 107 106 105 104 103 102 101
E-015 E-019 E-014
B B B
E-001
B
EA19100010

Intake System (Page 2 of 2)
ECM
B-001
E-001
45 37 7 30 36 59 96 97
WR
YW
GY
LW
RB
YR
Br
3 2 4 6 1 5 1 2 10
ELECTRONIC ENGINE
ACCELERATOR SPEED
S
PEDAL SENSOR
B-058 N E-013
76 75 74 73 72 71 70 69 68 67 66 65
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 112 111 110 109 108 107 106 105 104 103 102 101
B-001 E-001
B B
6 5 4 3 2 1 1 2 3
B-058 E-013
B B
EA19100020

DIAGNOSIS & TESTING

HINT:
Symptom Possible Cause See page

Throttle assembly (dirty) 10-12
Intake manifold (broken, leaked) 10-15
Canister solenoid valve (remains open) 09-7
Engine idles roughly Intake pressure/temperature sensor 06-203
Throttle assembly grommet (damaged) 10-12
Fuel rail injector assembly (incorrect
08-25
installation)
10

ON-VEHICLE SERVICE
Air Filter Element
Replacement
3. Remove the air filter assembly (See page 10-10).
4. Remove the air filter element.
a. Remove 2 coupling screws (arrow) between the air
filter upper housing and lower housing.
RA19100020
b. Remove the air filter upper housing.

10
c. Remove the air filter element.
RA19100030
Installation
1. Clean the air filter assembly and install a new air filter element.
2. Other installation procedures are in the reverse order of removal.
 The waste air filter element should be disposed by the specialized department according to local laws
and regulations. Never discard it at will.

Air Filter
Removal
3. Remove the air filter assembly.
a. Loosen the worm clamp (1) and disconnect the
connection between air filter and intake hose.
b. Remove 3 fixing bolts (arrow) from the air filter.
1
RA19100040
c. Remove the air filter assembly.

4. Remove the resonant cavity assembly.
a. Remove the resonant cavity assembly fixing bolt
10 (arrow).
RA19100050
b. Remove the resonant cavity assembly from the air direct pipe.
5. Remove the air direct pipe.
a. Remove 2 fixing bolts (arrow) from the right side of air
direct pipe.
RA19100060

b. Remove the fixing bolt (arrow) from the left side of air
direct pipe.
RA19100070
c. Remove the air direct pipe.
Installation
10

Electronic Throttle Assembly

1. Check the electronic throttle assembly
a. When the power is off, the throttle valve plate should be in NLP position, flip it by hand, the valve plate
can rotate smoothly. If sticking occurs, it indicates that the internal components may be damaged,
replace the electronic throttle assembly.
b. Connect the X-431 3G diagnostic tester to the Data Link Connector (DLC).
c. Turn the ignition switch to ON and turn on the X-431 3G diagnostic tester.
d. Read the datastream on the X-431 3G diagnostic tester.
 Release the accelerator pedal
Datastream
Datastream Name Specification (V) Datastream name Value Unit
multiplicative correction of the mixture adaptation 1.00
Sensor voltage from throttle

0.78
Lambda controller output bank 2 0.00
potentiometer 1 sensor voltage from throttle potentiometer 1 0.78 V

4.21
additive correction of the mixture adaptation 0.00 %
potentiometer 2 Voltage PWG potentiometer 1 0.99 V
RA19100071
10
 Depress the accelerator pedal
Datastream
Datastream Name Specification (V) Datastream name Value Unit
multiplicative correction of the mixture adaptation 1.00

4.25
Lambda controller output bank 2 0.00
potentiometer 1 sensor voltage from throttle potentiometer 1 4.25 V

0.75
additive correction of the mixture adaptation 0.00 %
potentiometer 2 Voltage PWG potentiometer 1 4.27 V
If the result is not as specified, check the wiring Doubled PWG potentiometer-2 voltage 4.29 V
harness and ECM, or replace the electronic throttle RA19100072

assembly.
Removal
4. Move away the intake hose on the electronic throttle assembly side.
a. Loosen the worm clamp (arrow) between intake hose
and electronic throttle assembly.
RA19100073
b. Disconnect the connection between intake hose and electronic throttle assembly, and move the intake
hose to one side.

5. Remove the electronic throttle assembly.

a. Disconnect the electronic throttle assembly connector
(1).
b. Loosen the spring clamp (2), and disconnect the
1
connection between canister solenoid valve output
pipe and electronic throttle assembly.
c. Remove 4 fixing bolts (arrow) from the electronic
throttle assembly.
2
RA19100080
d. Remove the electronic throttle assembly.

6. Remove the electronic throttle assembly grommet
(arrow) from intake manifold.
10
RA19100090
Inspection
1. Check the electronic throttle assembly grommet.
If the electronic throttle assembly grommet is
deteriorated or damaged, replace it.
RA19100100
Cleaning
Cleaning Tool
1. Thin stick: used to support throttle valve plate to clean the carbon deposited on contact wall between valve
plate and throttle. Please use plastic, wooden or bamboo thin stick. Do not use metal thin stick to avoid
scratching or deforming the valve plate.
2. Clean cloth or paper towel
Cleaning Process
1. Remove the throttle body, and make the valve plate face upward in free condition. Avoid the cleaner
flowing into the electronic element through valve plate shaft, resulting in functional failure.

2. Start to clean when it is as shown in the illustration.
RA19100110
WARNING
 The cleaner is a kind of flammable and corrosive fluid. Follow the safety cautions to prevent accidents,
and avoid skin contacting with the cleaner.
3. Apply appropriate amount of cleaner to the inner wall of throttle valve body, and remove the carbon with
clean cloth.
4. Support the throttle valve with thin stick, and clean the
carbon on the valve plate and the throttle valve body
10 inner wall.
RA19100120
5. Turn over the throttle 180°, the cleaning procedures are same as above. Repeat several times until it is
clean.
6. Push the valve plate by hand, and check if the valve plate rotates smoothly. If it is stuck, clean the valve
plate again following the cleaning procedures.
7. After cleaning it, wipe off the cleaner in throttle valve body with absorbent paper.
Installation
CAUTION
 Replace with a new grommet during installation.

 Perform the throttle self-learning procedures after installation (See page 06-19). After the self-learning
completed, start the vehicle and observe if it operates properly.

Intake Manifold Assembly

Removal
5. Remove the fuel rail injector assembly (See page 08-25).
6. Remove the electronic throttle assembly (See page 10-12).
7. Remove the intake manifold assembly.
connector (1), loosen and remove the intake pressure/ 3
2
temperature sensor fixing bolt (arrow), and remove
the intake pressure/temperature sensor.
connection between PCV valve hose and intake 1
manifold.
c. Loosen the elastic clamp (3) and disconnect the 4
connection between vacuum booster hose and intake RA19100130
manifold. 10
d. Disconnect the canister solenoid valve connector (4),
and move away the canister solenoid valve from the
bracket.
e. Disconnect the oil pressure switch connector (arrow)
and wiring harness clip.
RA19100140
f. Remove 8 fixing nuts (arrow) from the intake manifold.

RA19100150
g. Move away the oil dipstick tube and engine wiring harness bracket, and remove the engine right lifting
eye and intake manifold assembly.
HINT:
Pull out the oil dipstick from the oil dipstick tube if necessary.

8. Disassemble the intake manifold.

a. Remove the canister solenoid valve bracket fixing bolt
(1), and remove the canister solenoid valve bracket.
1
b. Remove the intake manifold upper bracket fixing bolt
(2), and remove the intake manifold upper bracket.
c. Remove the gaskets (arrow) from the intake manifold.
RA19100160
Inspection
1. Check the intake manifold gasket, if it is deteriorated or
damaged, replace it.
10
RA19100170
Installation
CAUTION
 Clean all the surfaces of the intake manifold and cylinder head.
 If the intake manifold gasket is damaged, replace it.

Electronic Accelerator Pedal

Removal
3. Remove the electronic accelerator pedal.
a. Disconnect the electronic accelerator pedal connector
(1).
b. Remove 3 fixing bolts (arrow) from the electronic
accelerator pedal. 1
RA19100180
c. Remove the electronic accelerator pedal.
Installation
Installation is in the reverse order of removal. 10

- MEMO -

GENERAL INFORMATION 11-3 Precatalytic Converter Assembly 11-10
Description 11-3 Removal 11-10
Specifications 11-5 Installation 11-10
Tools 11-5 Main Catalytic Converter Assembly 11-11
Removal 11-11
Installation 11-12
Front Muffler Assembly 11-13
Exhaust System Gas Leakage 
Removal 11-13
Inspection 11-6
Installation 11-14
ON-VEHICLE SERVICE 11-7 Rear Muffler Assembly 11-15
Exhaust Manifold Assembly 11-7 Removal 11-15
Inspection 11-8
Installation 11-9
11

11

11 - SQR477F EXHAUST SYSTEM
GENERAL INFORMATION
Description
×3
14 1
×8
13
×3
3
4
×3
5
12
×2
6
11
7
×2
11
10
×2
×2
9
×3
RA19110010

1 - Exhaust Manifold Assembly 2 - Exhaust Manifold Heat Insulator

3 - Gasket 4 - Precatalytic Converter Assembly
5 - Gasket 6 - Main Catalytic Converter Assembly
7 - Diamond Shaped Hanger Block 8 - Front Muffler Assembly
9 - Rear Muffler Assembly 10 - Muffler Heat Insulator II
11 - Muffler Heat Insulator I 12 - Downstream Oxygen Sensor
13 - Exhaust Manifold Gasket 14 - Upstream Oxygen Sensor
The exhaust system is used to control the engine exhaust, reducing vehicle emissions by the precatalytic
converter and main catalytic converter, and eliminating exhaust noise by the muffler. When the exhaust
system discharges the exhaust gas, the oxygen sensor monitors the oxygen content in the exhaust gas. The
engine control module adjusts the air-fuel ratio of the flammable gas mixture to control the vehicle emissions
and achieve optimal fuel economy according to the feedback signals of the oxygen sensor and combining with
other sensor signals.
11

Specifications

Exhaust Manifold Fixing Nut 45 ± 5
Coupling Nut Between Exhaust Manifold and
45 ± 5
Precatalytic Converter Assembly
45 ± 5
45 ± 5
Assembly and Front Muffler Assembly
Coupling Nut Between Front Muffler Assembly and
45 ± 5
Tools
General Tools 11
Precision Ruler
RCH0000063
Feeler Gauge
RCH0000060

DIAGNOSIS & TESTING

HINT:

Exhaust pipe (loose connection) -
Precatalytic converter assembly (damaged
11-10
or leaked)
Main catalytic converter assembly
11-11
(damaged or leaked)
Excessive exhaust noise Front muffler assembly (damaged or
11-13
leaked)
Rear muffler assembly (damaged or
11-15
leaked)
Exhaust manifold assembly (broken or
11-7
leaked)
Precatalytic converter assembly (blocked) 11-10
11
Main catalytic converter assembly
11-11
Excessive exhaust temperature (blocked)
Incorrect ignition timing in ignition system 07-28
Inadequate gas mixture combustion -
Exhaust pipe gasket (damaged) -
Exhaust pipe leakage
Exhaust pipe (damaged) -
Exhaust System Gas Leakage Inspection

Method to check the gas leakage in the exhaust system joints:
Warm up the engine for a while, and check for gas leakage in the exhaust system joints. A certain amount of
gas leakage at the exhaust pipe joint is allowed, but gas leakage at the joint between the exhaust manifold
and the cylinder head is prohibited. The judging standard is that the engine does not shudder and no "poof"
sound can be heard at the joints.

ON-VEHICLE SERVICE
Exhaust Manifold Assembly
Removal
WARNING
 The temperature of exhaust system is very high when the engine is running.
 Before removal, you must make sure that the engine has stopped running; otherwise, there is a risk of
scald injury.
CAUTION

4. Remove and disconnect the upstream oxygen sensor 11
connector (arrow) from bracket.
RA19110020
5. Remove the exhaust manifold heat insulator.

a. Remove 3 fixing bolts from exhaust manifold heat
insulator (arrow).
(Tightening torque: 25 ± 5N·m)
RA19110030
b. Remove the exhaust manifold heat insulator.

6. Remove the exhaust manifold assembly.

a. Remove 3 coupling nuts (arrow), then disconnect the
connection between exhaust manifold assembly and
precatalytic converter assembly, and take off the
gasket in the connecting part. 
RA19110040
b. Remove 8 fixing nuts from the exhaust manifold

assembly (arrow).
RA19110050
11 c. Remove the engine lifting eye and exhaust manifold assembly, and take off the gasket in the manifold
assembly.
7. Remove the upstream oxygen sensor (arrow) from the
exhaust manifold assembly.
RA19110060
Inspection
1. Measure warpage on the surface of the exhaust manifold
assembly with a precision ruler and a feeler gauge. If the
warpage on the surface is greater than 0.5 mm, replace
it.
RA19110070

2. Measure warpage on the surface of the cylinder head

exhaust side with a ruler and a feeler gauge. If the
warpage on the surface is greater than 0.4 mm, replace
it.
RA19110080
3. Check that there are no scratches and roughness on the

exhaust manifold gasket. Otherwise, replace it.
RA19110100
Installation
CAUTION
 When the installation is completed, check that there is no exhaust gas leakage between the exhaust
manifold assembly and the cylinder head, precatalytic converter assembly.
 Check that there is no exhaust gas leakage in the upstream oxygen connection.

Precatalytic Converter Assembly

Removal
WARNING
 Before removal and installation, you must make sure that the engine has stopped running; otherwise,

3. Remove the precatalytic converter assembly.
b. Remove 2 coupling nuts (2), then disconnect the
connection between main catalytic converter assembly
and precatalytic converter assembly, and take off the
gasket in the connecting part. 2
11 RA19110090
c. Remove 3 coupling nuts (arrow), then disconnect the

connection between precatalytic converter assembly
and exhaust manifold assembly, and take off the
gasket in the connecting part. 
RA19110040
4. Remove the precatalytic converter assembly.
Installation
CAUTION
 If the gasket is damaged, replace it, and remove the foreign matters on the joints and threads.
 If there are any cracks or leakage in the precatalytic converter assembly, replace the precatalytic
converter assembly.
 Inspect for exhaust gas leaks. If gas leaks, tighten the defective area to prevent leaking. Replace the
damaged parts as necessary.

Main Catalytic Converter Assembly

Removal
WARNING

3. Remove the main catalytic converter assembly.
b. Remove 2 coupling nuts (2), then disconnect the
and precatalytic converter assembly, and take off the
gasket in the connecting part. 2
RA19110090
11
c. Remove 2 coupling nuts (arrow), then disconnect the

and front muffler assembly, and take off the gasket in
the connecting part. 
RA19110130
d. Detach 2 diamond shaped hanger blocks (arrow)

between the main catalytic converter assembly and
the body hooks.
RA19110110
e. Remove the main catalytic converter assembly.

4. Remove the downstream oxygen sensor (arrow) from the

main catalyst assembly.
RA19110120
Installation
CAUTION
 If there are any cracks or leakage in the main catalytic converter assembly, replace the main catalytic
converter assembly.
 Keep sufficient space between the main catalytic converter assembly and the vehicle body during
installation.
 Apply lubricant to the joints firstly, which can be helpful in disconnecting the connection between the front
exhaust pipe assembly and the diamond shaped hanger block.
11  Inspect for exhaust gas leaks. If gas leaks, tighten the defective area to prevent leaking. Replace the

Front Muffler Assembly

Removal
WARNING

3. Remove the front muffler assembly.
and front muffler assembly, and take off the gasket in
the connecting part. 
RA19110130
11
b. Remove 2 coupling nuts (arrow), then disconnect the

connection between front muffler assembly and rear
muffler assembly, and take off the gasket in the
connecting part. 
RA19110161
c. Detach 2 diamond shaped hanger blocks (arrow)

between the front muffler assembly and the body
hook.
RA19110150
d. Take off the front muffler assembly.

4. Remove the muffler heat insulator I.

a. Remove 7 muffler heat insulator I clamping pieces
(arrow).
RA19440160
b. Remove the muffler heat insulator I.
Installation
CAUTION
 If there are cracks or leaks, replace the damaged parts.
 During installation, check that the exhaust system components do not contact with the muffler heat
insulator I or the vehicle underbody. Make sure that the clearance between the exhaust system
11 components and the muffler heat insulator I or the vehicle underbody is more than 25 mm.


Removal
WARNING
 Before removal, you must make sure that the engine has stopped running; otherwise, there is a risk of
scald injury.

3. Remove the rear muffler assembly.
connection between front muffler assembly and rear
muffler assembly, and take off the gasket in the
connecting part.
RA19110161
11
b. Detach 3 diamond shaped hanger blocks (arrow)

between the rear muffler assembly and the body
hooks.
RA19110170
c. Remove the rear muffler assembly.

4. Remove the muffler heat insulator II.
a. Remove 4 muffler heat insulator II clamping pieces
(arrow).
RA19110180
b. Remove the muffler heat insulator II.

Installation
CAUTION
 If there are cracks or leaks, replace the damaged parts.
 During installation, make sure that the clearance between the tailpipe of the rear muffler assembly and
the bumper on the rear body is more than 30 mm.
11

GENERAL INFORMATION 12-3 Thermostat 12-18
Specifications 12-5 Inspection 12-19
Cooling System Operation Flowchart 12-7 Thermostat Seat 12-21
Circuit Diagram 12-9 Removal 12-21
Installation 12-22
Cooling Fan Assembly 12-23
Cooling System Pressure Test 12-12
Removal 12-24
Coolant Concentration Test 12-13
Installation 12-25
ON-VEHICLE SERVICE 12-14 Radiator 12-26
Coolant Replacement 12-14 Removal 12-26
Coolant Draining 12-14 Installation 12-27
Coolant Adding 12-15 Water Pump 12-28
Expansion Tank 12-17 Removal 12-28
12

12

12 - SQR477F COOLING SYSTEM
GENERAL INFORMATION
Description
1
27
×4
×2
10 2
26
25
9 6
4
3
×4
8 7
×4
×4 12
24 23
13
14
11 12
×4 15
16 18
17
22
21
×3
20
19
RA19120010

1 - Expansion Tank 2 - Expansion Tank Outlet Hose

3 - Water Pump Assembly 4 - Water Pump Assembly Inlet Connecting Hose
5 - Water Pump Assembly Gasket 6 - Coolant Pipe (4-way)
7 - Small Circulation Water Pipe Connecting Hose 8 - Engine Inlet Pipe
9 - Cooling Fan Assembly 10 - Radiator Discharge Hose
11 - Discharge Hose 12 - Cooling Water Pipe Assembly
13 - Discharge Hose 14 - Heater Inlet Pipe
15 - Thermostat Seat Gasket 16 - Coolant Temperature Sensor
17 - Small Circulation Water Pipe 18 - Heater Outlet Pipe
19 - Small Circulation Hose 20 - Thermostat Seat
21 - Thermostat 22 - Thermostat Housing
23 - Engine Outlet Hose 24 - Rubber Cushion
25 - Rubber Bushing 26 - Radiator
27 - Radiator Upper Crossmember
The engine cooling system adjusts the engine operating temperature by the flow of coolant and makes the
engine operate normally under various operating conditions.
The engine cooling system is a forced circulation system, which supplies circulation pressure for the system
by water pump and forces the coolant to circulate in the engine cylinder block, and distributes the excessive
12 heat to the radiator by the flow of coolant, and radiates it to the air by the cooling fan. Also, the engine cooling
system provides heat to the heater core in the cabin to improve the driving comfort.

Specifications

Wire Harness Bracket Fixing Bolt 8 - 11
Thermostat Housing Fixing Bolt 8 - 11
Thermostat Seat Fixing Bolt 8 - 11
Cooling Fan Assembly Fixing Bolt 7 ± 1.5
Radiator Upper Crossmember Fixing Bolt 10 ± 1
Radiator Upper Crossmember Fixing Nut 5±1
Water Pump Fixing Bolt 11
Coolant Capacity
Item Capacity (L)

Cooling System 7.5
12
50% 50%
Coolant Freezing Point
Item Freezing Point Value (°C)

Coolant -35
Cooling System Pressure
Item System Pressure (bar)

Cooling System (Test Pressure) 1.3 ± 0.2

Tools
General Tools
Digital Multimeter
RCH0000002
Cooling System Pressure Tester
RCH0000055
12
Freezing Point Tester
RCH0000007

Cooling System Operation Flowchart
1 2 4
15
5
14
13
16
17
12
12
11
10
8 7
9
RA19120020
1 - Expansion Tank Cap 2 - Cylinder Block

3 - Heating Inlet Pipe 4 - Heater Core
5 - Heating Outlet Pipe 6 - Engine Outlet Pipe
7 - Black Solid Arrow (Indicates High Temperature 8 - Hollow Arrow (Indicates Low Temperature
Coolant) Coolant)
9 - Radiator 10 - Engine Inlet Pipe
11 - Small Circulation Metal Tube 12 - Engine Return Pipe
13 - Radiator Discharge Hose 14 - Expansion Tank
Small circulation: when the coolant temperature is below 82 ± 2°C, the thermostat closes. The coolant only
circulates inside the cylinder block, and warms up other engine parts where need heat. The coolant, which
flows out of the cylinder block, enters the water pump directly through the small circulation water pipe, and
then enters the cylinder block through the water pump. The coolant does not radiate heat through the radiator.

Large circulation: when the coolant temperature is higher than 103 ± 1°C, the thermostat opens fully, and all the
coolant, which flows out of the cylinder block, enters the radiator where coolant heat is lost, then, the heat-radiated
coolant returns to the cylinder block for circulation by the pump. Due to the heat lost in the radiator, the engine
coolant temperature decreases quickly to prevent the engine from overheating.
The cooling fan operates under the following conditions:
a. When the coolant temperature is higher than 93.8°C, the cooling fan starts to operate at low speed;
b. When the coolant temperature is higher than 96.8°C, the cooling fan starts to operate at high speed;
c. When the coolant temperature is below 92.3°C, the cooling fan stops at high speed;
d. When the coolant temperature is below 89.3°C, the cooling fan stops at low speed.
12

Circuit Diagram
Cooling System (Page 1 of 2)
BATTERY
EF23 EF22 EF18

30A 40A 10A ENGINE
COMPARTMENT
FUSE AND
RELAY BOX
30 86 30 86
B-013
LOW FAN HIGH FAN E-039
RELAY RELAY
87 85 87 85
B11 C15 B9 C9
L
BrG
VR
R
L
1 2
COOLING
FAN 1
COOLING
FAN 2 12
E-031 E-032
3 3
M M
2
R
1
R
B
B
B
E-036
56 31
ECM
B-001
1 1
B1 B2 B3 B4 B5 3 2 2 3
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 B8 B9 B10 B11
B6 B7 B12 B13 B14
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 E-039 E-031 E-032
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 W B B
B-001 C1 C2 C3 C4 C5 C6 C7
B C11 C12 C13 C14
C8 C9 C10 C15 C16 C17 C18
B-013
W
EA19120010

Cooling System (Page 2 of 2)
86 30
ENGINE
ECM
COMPARTMENT
MAIN
FUSE AND
RELAY EF35 RELAY BOX
85 87 10A
B-012
B
B-013
EF17
15A
C17 D6 C1
COOLANT
TEMPERATURE
R
SENSOR
E-014
1 2
BGr
BW
RB
YV
12
5 15 16 20 101 84
ECM
B-001
E-001
76 75 74 73 72 71 70 69 68 67 66 65
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 112 111 110 109 108 107 106 105 104 103 102 101
B-001 E-001
B B
D1 D2 D3 D4 D5 D6 D7 D8 C1 C2 C3 C4 C5 C6 C7
D13 D14 D15 D16 C11 C12 C13 C14 1 2
B-012 B-013 E-014

W W B
EA19120020

DIAGNOSIS & TESTING

HINT:

Coolant pipe (deteriorated and leaked) -
Expansion tank (leaked) 12-17
Radiator (leaked) 12-26
Insufficient coolant Water pump (bearing loose and leaked) 12-28
Engine cylinder head gasket (damaged) 07-47
Engine cylinder head (water jacket leaked) 07-47
Engine block (water jacket leaked) 07-67
Low coolant level 12-12
Air resistance exists in pipe -
Expansion tank cap (damaged) -
Engine overheating Cooling fan assembly 12-23
Radiator 12-26 12
Thermostat 12-18
Leakage in engine -
Unable to reach normal engine Cooling fan (constantly operating) 12-23

temperature Thermostat 12-18
Open in fuse -
Relay failure -
Cooling fan does not operate or abnormal
Cooling fan assembly 12-23
air speed
Wire harness -
ECM (Engine Control Module) failure -

Cooling System Pressure Test

WARNING
 Always make sure the engine is cold before operating the cooling system.
 Never open the expansion tank cap or remove the drain cock plug when the engine is operating or the
cooling system overheats. The overheated engine coolant and steam with high-pressure may flow out
and cause serious personal injury.
CAUTION
 When testing the cooling system, please pressurize the system to the specified pressure. Otherwise, it
may damage the system components.
 Before testing the cooling system, do not perform operation until the coolant temperature drops to the
normal level. Otherwise, it may cause scald.
Test Procedures
2. Check if the coolant level is between "MAX" and "MIN"
lines. If the coolant level is below "MIN" line, add coolant.
12
RA19120030
3. Connect the cooling system pressure tester to the

coolant pressure release cap opening (expansion tank
cap opening) and tighten it slowly.
RA19120040
CAUTION
 Make sure there is no leakage in the connecting part of coolant system pressure tester, in order to avoid
pressure leakage during test.

4. Pressurize the cooling system to 1.3 ± 0.2 bar with the cooling system pressure tester, and then observe
the pressure changes. If the system pressure does not drop within 2 minutes, it indicates there is no
leakage in the system. If the pressure changes greatly, it indicates that there is a leakage in the system;
find the leaking area and perform troubleshooting.
Coolant Concentration Test

CAUTION
 DO NOT mix different colors or types of coolant.

 Please select coolant which is suitable for local climate in different areas.
 Please read the measured value at the scale line. In order to distinguish the scale line more clearly, drip
a drop of water on the glass of freezing point tester with a pipette, then the scale line can be clearly
distinguished via "waterline".
Test Procedures
1. As shown in the illustration, drip a drop of coolant on the
glass of freezing point tester with a pipette, and then
observe the freezing point value of coolant.
12
RA19120050
2. As shown in the illustration, observe the scale 3 of

freezing point tester to read the ethylene glycol coolant
freezing point value. The freezing point value must be
ETHYLENE
PROPYLENE GLYCOL
GLYCOL -50
2 1.40
kept at -35°C or lower.

-50
1.35
-40 -40
1 1.30 3
GOOD
-30 -30
1.25
FAIR
-20 1.20 -20

RECHARGE
1.15
-10 BATTERY -10
ELECTROLYTE 1.10 d 20
20
0( C)
O
WATERLINE 0( C)
O
ANTIFREEZE
RA19120060
If the freezing point is beyond the specified value, replace the coolant.
HINT:
Scale 1 is used to measure the freezing point value of propylene glycol coolant, and scale 2 is used to
measure the battery electrolyte concentration.

ON-VEHICLE SERVICE
Coolant Replacement
Coolant Draining
WARNING

3. Remove the expansion tank cap when the engine temperature and radiator temperature are low.
4. Remove lower right deflector (See page 46-20).
5. Put a coolant collector under the vehicle, rotate the
radiator drain cock plug (arrow) and drain the coolant in
the radiator and expansion tank.
HINT:
Put a drainage device or similar tool at the radiator outlet,
12 so that the coolant can flow into the collector smoothly.
RA19120070
6. After the coolant stops flowing, retighten the radiator drain cock plug.
CAUTION
 Tighten the drain cock plug to prevent leakage.
 The wasted coolant should be handled by the specialized department according to local laws and

Coolant Adding
Only use coolant that meets Chery specifications.
Coolant Capacity
Item Capacity (L)

Cooling System 7.5

50% 50%
WARNING
 If it is necessary to add coolant when the engine is hot, loosen the expansion tank cap slightly first to
release the internal pressure and loosen the cover completely after waiting for a while, and then add
coolant.
 If your body contacts the coolant accidentally, clean it with water immediately. If it is serious, please go to
hospital.
12
CAUTION
 DO NOT use inferior coolant.

 DO NOT mix different colors or types of coolant.
 Be careful when adding coolant; avoid spilling the coolant on any area of engine.
1. Open the expansion tank cap and add coolant until the
coolant level reaches the "MAX" line.
RA19120030
2. Tighten the expansion tank cap, start and run the engine. Maintain the engine speed between 2000 and
2500 rpm to warm up the engine until the cooling fan operates.

CAUTION
 If there is no coolant in the expansion tank after the engine just starts, perform the followings:
- Stop the engine;
- Wait until the coolant cools down;
- Add coolant to the "MAX" line on expansion tank.
 Run the engine at 2500 rpm until the coolant level becomes stable.
3. Stop the engine and wait until the coolant temperature drops to the ambient temperature. Check that the
coolant level is between "MAX" and "MIN" lines. If the coolant level is below the "MIN" line, repeat all the
above procedures. If the coolant level is above the "MAX" line, drain the coolant until the level is between
"MAX" and "MIN" lines.
12

Expansion Tank
Removal
WARNING

3. Remove the expansion tank.
connection between expansion tank and discharge
hose.
connection between expansion tank and radiator
1
discharge hose.
c. Remove 2 fixing bolts (arrow) from the expansion 2
tank.
RA19120080 12
d. Pull out the expansion tank upward, loosen the elastic
clamp (arrow) and disconnect the connection between
expansion tank and expansion tank outlet hose.
RA19120090
e. Remove the expansion tank.
Installation

Thermostat
Removal
WARNING

5. Move away the wire harness bracket.
a. Remove 2 fixing bolts (arrow) from the wire harness
bracket, and move the wire harness bracket to one
side. 
12
RA19120100
6. Remove the thermostat housing.

a. Loosen the engine outlet hose elastic clamp (arrow),
and disconnect the connection between engine inlet
hose and thermostat housing.
RA19120110
b. Remove 4 fixing bolts (arrow) from the thermostat

housing.
RA19120120

c. Remove the thermostat housing.

7. Remove the thermostat.
a. Take out the thermostat (arrow) from the thermostat
seat.
RA19120130
Inspection
1. As show in the illustration, check if the protrusion (2) of
thermostat grommet and chock (1) of thermostat are
1
installed at an angle of 180°.
If the result is not as specified, adjust the thermostat
grommet to the specified position or replace the
thermostat with a new one.
2
RA19120131
2. Check the opening temperature and maximum lift of thermostat.

12
HINT:
The valve opening temperature is engraved in the
thermostat.
B
3
87 C
0
87 0
RA19120140
a. Soak the thermostat in water, heat the water gradually

and perform inspection.
RA19120150
 The opening temperature of thermostat is 87 ± 2°C.

 The maximum lift of thermostat is no less than 8 mm.
 The temperature is 103 ± 1°C when the thermostat opens fully.

b. Check that the thermostat closes when the temperature is low (5°C lower than the opening
temperature).
c. If the above conditions are not met, replace the thermostat.
Installation
CAUTION
 As shown in the illustration, align the protrusion (1) of thermostat grommet and groove (2) of thermostat
seat during installation.
 Check that the coolant has been added to the specified level after installation.
RA19120160
12

Thermostat Seat
Removal
WARNING

6. Remove the thermostat (See page 12-18).
7. Remove the thermostat seat.
a. Disconnect the coolant temperature sensor connector
(arrow).
connection between thermostat seat and engine
discharge hose.
2
12
connection between thermostat seat and heater inlet 3
pipe.
1
d. Loosen the elastic clamp (3) and disconnect the
connection between thermostat seat and small RA19120170
circulation hose.
e. Remove the engine wire harness fixing bolt, and disconnect the engine wire harness.
f. Remove 3 fixing bolts (arrow) from the thermostat
seat.
RA19120180
g. Remove the thermostat seat and thermostat seat shim.

8. Remove the coolant temperature sensor (arrow) from the

thermostat seat.
RA19120190
Installation
CAUTION
 Replace the thermostat seat shim with a new one during installation, and the removed shim cannot be
reused.
12

Cooling Fan Assembly

1. Measure the cooling fan resistance with a digital multimeter.
a. Cooling fan I
Multimeter + -
3 2
Condition Specification (Ω) 1
Connection
Terminal 1 - Normal
1.8
Terminal 3 - Normal
2.5
If the inspection result is not as specified, replace the RA19120191

cooling fan assembly.
b. Cooling fan II
Multimeter + -
1
Connection
3 2
Terminal 2 - Normal
1.8
Terminal 3 - Normal
2.5
If the inspection result is not as specified, replace the

RA19120192
12
2. Apply the battery voltage to the specified connector
terminals of cooling fan respectively according to the + -
table below, and check that the cooling fan operates 3 2

1
smoothly when applying the battery voltage.
a. Cooling fan I
Condition
Battery positive
(+) - Terminal 1 Operates RA19120200
Always smoothly at low
Battery negative speed
(-) - Terminal 2
Battery positive
(+) - Terminal 3 Operates
Always smoothly at high
(-) - Terminal 2


b. Cooling fan II
+ -
Measurement Specified 1
Condition 3 2
Condition Condition
Battery positive
(+) - Terminal 2 Operates
Always smoothly at low
(-) - Terminal 1
Battery positive
(+) - Terminal 3 Operates RA19120210
Always smoothly at high
(-) - Terminal 1

Removal
WARNING
12
5. Remove the air filter (See page 10-10).
6. Remove the condenser left deflector.
a. Remove 3 plastic clamps (arrow) from the condenser
left deflector.
RA19120220
b. Remove the condenser left deflector.

7. Remove the cooling fan assembly.

connection between engine outlet hose and radiator
assembly.
RA19120230
b. Disconnect the cooling fan assembly connectors

(arrow).
RA19120240
c. Remove 4 fixing bolts (arrow) from the cooling fan

assembly.
(Tightening torque: 7 ± 1.5 N·m) 12
RA19120250
d. Remove the cooling fan assembly from the radiator assembly.
Installation

Radiator
Removal
WARNING

5. Remove the front bumper assembly (See page 46-7).
7. Remove the cooling fan assembly (See page 12-23).
8. Remove the radiator upper crossmember.
a. Remove 5 joint clips (arrow) between engine
compartment wire harness and radiator upper
crossmember.
12
RA19120260
b. Remove the engine hood lock (See page 45-15).

c. Remove the horn (See page 39-15).
d. Remove 4 fixing bolts (1) from the radiator upper
crossmember.
1
e. Remove 2 fixing nuts (2) from the radiator upper
2
crossmember.
RA19120270

9. Remove the radiator.

connection between radiator discharge hose and 1
radiator assembly.
connection between engine inlet pipe and radiator
assembly.
2
RA19120280
c. Remove the radiator.
Installation
12

Water Pump
Removal
WARNING

5. Remove the generator and generator bracket (See page 16-9).
7. Remove the water pump.
a. Loosen the elastic clamp (arrow) and disconnect the
connection between water pump assembly inlet hose
and water pump.
12
RA19120290
b. Remove the water pump fixing bolts (arrow).

(Tightening torque: 11 N·m)
RA19120300
c. Remove the water pump and gasket.

Inspection
1. Check the water pump gasket for wear or bent. If wear or
bent is found, replace the gasket.
RA19120310
2. Check if the water pump bearing is loose. If it is loose, replace the water pump assembly.
Installation
CAUTION
 If the water pump is damaged, replace it, rather than attempt to repair it.
12

- MEMO -

GENERAL INFORMATION 13-3 Oil Filter 13-13
Tools 13-6 Oil Pressure Switch 13-15
Lubrication System Flowchart 13-7 Removal 13-15
Installation 13-16
Oil Pan 13-17
Removal 13-17
Engine Oil Level Inspection 13-9
Installation 13-18
Oil Pressure Inspection 13-10
Oil Strainer 13-20
Engine Oil Replacement 13-11 Installation 13-20
Engine Oil Draining 13-11 Oil Pump Assembly 13-21
Engine Oil Adding 13-12 Removal 13-21
Installation 13-22
13

13

13 - SQR477F LUBRICATION SYSTEM
GENERAL INFORMATION
Description
2
1
4
5
7 8
6
×2 13
×6
×6
10
11
×14
×4
RA19130010

1 - Engine Assembly 2 - Oil Dipstick

3 - Oil Dipstick Tube 4 - Oil Pressure Switch
5 - Oil Filter 6 - Oil Pump Assembly
7 - Oil Pump Assembly Gasket 8 - Oil Strainer
9 - Oil Pan Gasket 10 - Oil Baffle Plate
11 - Oil Pan
The function of the lubrication system is that the crankshaft, when the engine is operating, drives the oil pump
assembly to suck oil from the oil pan. The oil sucked out is filtered by the oil filter, then it flows to the friction
surfaces of all drive parts through the oil passage and forms oil films between the friction surfaces to realize
liquid friction, and finally returns to the oil pan, thus reducing friction resistance of drive parts, power
consumption and wear of part and increasing the reliability and durability of engine operation.
WARNING
 Prolonged and repeated contact with engine oil will result in the removal of natural oils from skin, leading
to dryness, irritation and dermatitis. In addition, the used engine oil contains potentially harmful
contaminants, which may cause skin cancer.
 Precautions should be followed when replacing engine oil to minimize the risk of your skin making
contact with used engine oil.
 Wear protective clothing and gloves.
 Wash your skin thoroughly with soap and water, or use waterless hand cleaner to remove any used
engine oil.
 Never use gasoline, thinners or solvents.
13

Specifications
System Pressures
Condition Pressure (kPa)

Idling Speed (650 ± 50 r/min, oil temperature 90°C) Above 1.5
High Speed (4000 ± 50 r/min, oil temperature 100°C) Above 3.5
Oil Specifications
Engine Type SQR477F

Oil Specifications

Drain Plug 35 ± 3
Oil Filter 25 ± 3
Coupling Bolt Between Oil Pan and Transmission
45 ± 5
Housing
Fixing Bolt of Baffle Plate Between Oil Pan and
45 ± 5
Transmission 13
Oil Pan Fixing Bolt 11 ± 1
Oil Pan Baffle Plate Fixing Bolt 8+3
Oil Strainer Bracket Fixing Bolt 17 - 23
Oil Strainer Bracket Fixing Nut 17 - 23
Coupling Bolt Between Oil Strainer and Oil Pump
17 - 23
Assembly
Oil Pump Assembly Fixing Bolt 8 - 11

Tools
Special Tools
Oil Pan Remover and Scraper
RCH0000056
Oil Filter Remover
RCH0000054
General Tool
13
Oil Pressure Tester
RCH0000006

Lubrication System Flowchart
11
13
10
7
9 8
RA19130020
1 - Oil Filler Cap 2 - Cylinder Head

3 - Oil Pressure Switch 4 - Oil Filter
5 - Cylinder Block 6 - Oil Pump Assembly
7 - Engine Oil 8 - Drain Plug
9 - Oil Strainer 10 - Oil Pan
11 - Crankshaft
Description
1. Solid arrow: indicates the flow of high-pressure lubricant.
2. Hollow arrow: indicates the flow of low-pressure lubricant.
3. Dark area: indicates the high-pressure lubricant.
4. Bright area: indicates the low-pressure lubricant.

DIAGNOSIS & TESTING

HINT:

Oil pan (dirty, leaked) 13-17
Oil strainer (mesh dirty, blocked) 13-20
Low pressure in lubrication system
Oil pump assembly 13-21
Line (blocked) -
Engine oil (excessive oil filling capacity) 13-11
Oil filter 13-13
High oil consumption
Each engine seal surface leakage -
Engine oil leakage -
Engine oil (insufficient oil, low oil viscosity) 13-11
Oil filter (blocked) 13-13
Leakage in lubrication system -
Oil pressure switch 13-15
13 Oil pressure warning light comes on Instrument cluster (oil pressure warning
light)
36-34
Cylinder block (cracks occur in water

jacket, resulting in coolant leaking into the 07-67
oil pan, which will cause oil dilution )
Line (blocked) -
Engine oil (high oil viscosity, excessive oil
After engine cranked, the engine produces 13-11
filling capacity)
clunk sound
Cylinder block (oil passage blocked) 07-67

Engine Oil Level Inspection

HINT:
Check the oil level indicated by the oil dipstick with the engine at operating temperature and stopped.
1. Park the vehicle on level ground, stop the engine after warming up and wait for 5 minutes.
2. Open the engine hood and pull out the oil dipstick, and wipe it clean with a piece of clean cloth.
CAUTION
 Please put a piece of cloth under the oil dipstick end to prevent the oil from splashing onto the engine
and body.
3. Reinsert the oil dipstick, check if the oil level is proper.

4. Pull out the oil dipstick again, check if the oil level is proper.
If the engine oil level is too low, check for leakage and add oil up to the full level mark.
a. If the oil level is at or above the "MAX" mark, drain the
excessive engine oil.
MAX MIN
b. If the oil level is between "MIN" mark and "MAX" mark,
it shows that the oil level is proper.
c. If the oil level is below the "MAX" mark, it is necessary
to add engine oil.
RA19130030
13
CAUTION
 When adding engine oil, the oil level should not be above the "MAX" mark.

Oil Pressure Inspection

Preconditions
1. The engine oil level is normal.
2. The oil filter is used within 5000 km.
3. The engine reaches the normal operating temperature.
Inspection
1. Disconnect the oil pressure switch connector (1) and
remove the oil pressure switch (2).
2
RA19130040
2. Screw the oil pressure tester into the thread hole of oil
pressure switch as shown in the illustration.
13
RA19130050
3. Start the engine. When the engine inspection conditions are met, read the oil pressure values at idling
speed and high speed respectively. If the lubrication system pressure is low, clean the oil pan and oil
strainer mesh, and then test again. If the lubrication system pressure is still low, it shows there is a
malfunction in the oil pump assembly and the oil pump assembly must be replaced.
Oil pressure at idling speed (650 ± 50 r/min): higher than 1.5 bar.
Oil pressure at high speed (4000 ± 50 r/min): higher than 3.5 bar.
4. Install the oil pressure switch.
HINT:
Apply a small amount of seal gum to the threads when installing the oil pressure switch.
5. Connect the oil pressure switch connector and check the engine oil for leakage.

ON-VEHICLE SERVICE
Engine Oil Replacement
Engine Oil Draining
3. Open the oil filler cap.
RA19130060
4. Unscrew the drain plug (arrow), and drain the oil into a
container.
13
RA19130070
WARNING
 Apply a certain pushing force to the drain plug while loosening the plug by hand, and have the drain plug
attached to the thread tightly to prevent the oil from overflowing in advance. Move away the hand quickly
to prevent burn by the oil with a certain temperature.
 The wasted engine oil should be handled by the specialized department according to local laws and
5. Wipe off the drain plug and tighten it.


Engine Oil Adding

Only use engine oil that meets Chery specifications
Engine Type SQR477F

Oil Specifications
CAUTION
 DO NOT use inferior engine oil.

 DO NOT mix different types of engine oil.
 Be careful not to spill engine oil on any part of the engine when adding the engine oil.
1. Add a proper amount of oil, and check that the oil level is
between "MIN" mark and "MAX" mark with oil dipstick.
MAX MIN
13 RA19130030
2. Turn off the engine after running for 1 to 2 minutes, park the vehicle on a level surface and wait for
approximately 5 minutes. Check if the oil level is between "MIN" mark and "MAX" mark. Refill the oil if
necessary.
3. Check the vehicle for leakage after replacing the oil.

Oil Filter
Removal
WARNING
 DO NOT remove the oil filter until the engine cools down.
 Prolonged and repeated contact with engine oil will be harmful to your skin. If the engine oil spills on your
skin, wash it off immediately with water. In addition, the used engine oil contains potentially harmful
contaminants, which may cause skin cancer. Therefore, always take proper skin protection measures
when performing vehicle service.
CAUTION
 When repairing the oil filter, use the special oil filter installer to prevent the oil filter from deforming.

4. Remove the oil filter.
a. Using the oil filter remover (1), remove the oil filter (2). 
1
13
RA19130080
 The removed oil filter should be handled by the specialized department according to local laws and

Installation
CAUTION
 Check the oil filter bracket grommet for damages and cracks. If there are damages or cracks, replace the
grommet.
 Check and clean the installation surface between oil filter and oil filter bracket.
 Apply a layer of clean engine oil to the new oil filter grommet.
 Slightly rotate the oil filter in place by hand, and tighten the oil filter until the grommet contacts with the oil
filter bracket base.
 Using a special tool to tighten the oil filter.
13

Oil Pressure Switch

Removal
WARNING
 DO NOT remove the oil pressure switch until the engine cools down.

3. Remove the oil pressure switch.
a. Disconnect the oil pressure switch connector (1) and
remove the oil pressure switch (2).
2
RA19130040
13
Inspection
CAUTION
 Before inspecting the oil pressure switch, please make sure that the oil level is proper and coolant
temperature is up to above 90°C, and that the oil filter is used within 5000 km and electrical fan stops
operating.
1. Use an oil pressure tester as shown in the illustration.
RA19130090

2. Install the oil pressure tester into the thread hole (4) of oil
1
pressure switch as shown in the illustration. 3
3. Install the oil pressure switch (2) onto the tester (1) and
connect the oil pressure switch connecter.
4. Connect the oil pressure switch to the body.
+ -
5. Start the engine and the oil pressure warning light (3)
comes on, then observe the pressure reading on the
tester. If the oil pressure warning light still comes on 4
when oil pressure is more than 75 kPa, replace the oil 2
pressure switch. RA19130100
Installation
1. Remove the oil and impurities on the oil pressure switch and its thread hole.
2. Apply a small amount of seal gum to the threads when
installing the oil pressure switch as shown in the
illustration.
a
Width of a: 3 mm
RA19130110
13

Oil Pan
Removal
WARNING
 DO NOT remove the oil pan until the engine cools down.

3. Remove the main catalytic converter assembly (See page 11-11).
5. Remove the baffle plate between oil pan and transmission.

a. Remove 2 coupling bolts (1) between oil pan and
transmission housing.  13
b. Remove the fixing bolt (2) of baffle plate between oil 2
pan and transmission.
1 RA19130120
c. Remove the baffle plate between oil pan and transmission.

6. Remove the oil pan.
a. Pre-loosen the oil pan fixing bolts first, and then
remove them in the order shown in the illustration. 5 9 13 18 15 11 7
4
1
2
3
8 12 16 17 14 10 6
RA19130130
b. Pry the oil pan at specific prying locations on the oil pan with the oil pan remover and scraper and
remove it.

CAUTION
 Because the seal gum is sealed between oil pan and cylinder block, never use hard objects, such as a
hammer, to tap it during removal, but it can be tapped slowly from left and right with a rubber hammer.
 A transmission carrier can be used to support the oil pan during removal, to prevent personal injury from
sudden dropping of oil pan.
c. Remove the oil pan gasket.

d. Remove the fixing bolts (arrow) from the oil pan baffle
plate, and remove the oil pan baffle plate. 
(Tightening torque: 8 + 3 N·m)
RA19130140
Installation
CAUTION
 When applying seal gum, check the type and expiration date of the seal gum.
13  Remove the impurities, iron chips and residue of seal gum on the oil pan.
 Remove the oil stain and residue of seal gum on the thread hole of the oil pan and cylinder block.
 The seal gum should not be applied too thick; otherwise, the seal gum will overflow into the oil pan due to
squeezing, which will block the oil strainer.
 DO NOT add engine oil until the seal gum becomes dry after installing the oil pan.
1. Apply seal gum to the semicircular matching surfaces

between oil pan gasket and oil pump, rear oil seal bracket
and oil pan as shown in the illustration.
Recommended seal gum: Loctite 5910
RA19130150
2. Replace the oil pan gasket with a new one.

3. Pre-tighten the oil pan fixing bolts until they are enough
for press fit, and then tighten the oil pan fixing bolts in the 14 10 6 1 4 8 12
order shown in the illustration.
18
17
16
11 7 3 2 5 9 13
RA19130160
13

Oil Strainer
Removal
WARNING
 DO NOT remove the oil strainer until the engine cools down.

3. Remove the oil pan (See page 13-17).
4. Remove the oil strainer.
a. Remove the fixing bolt and nut (1) from the oil strainer
bracket.
b. Remove the coupling bolts (2) between oil strainer
and oil pump assembly.  1
(Tightening torque: 17 - 23 N·m) 2
13 RA19130170
c. Remove the oil strainer and its grommet.
Installation
CAUTION
 Check the oil strainer grommet for damage and cracks. If there are damage or cracks, replace the
grommet.

Oil Pump Assembly

Removal
WARNING
 DO NOT remove the oil pump assembly until the engine cools down.

4. Remove the engine accessory drive belt (See page 07-21).
6. Remove the crankshaft timing pulley (1) and crankshaft
timing pulley washer (2) from the crankshaft.
2
1
FRONT
13
RA19130171
7. Remove the crankshaft front oil seal (See page 07-33).

9. Remove the oil pan (See page 13-17).
10.Remove the oil pump assembly.
a. Remove the coupling bolts (2) between oil strainer
and oil pump assembly. 
RA19130172

b. Remove 6 fixing bolts (arrow) from the oil pump

assembly.
RA19130180
c. Remove the oil pump assembly and its gasket.
Installation
CAUTION
 When installing the crankshaft timing pulley, the side with "FRONT" should face forward.
 Rotate the oil pump until the oil in the oil passage flows out of the outlet.
 Replace the oil pump assembly gasket.
13
 Apply seal gum to the surface between oil pump assembly bottom and cylinder block before installing the
oil pump assembly.
 Replace the oil strainer grommet before installing the oil strainer.
 Replace the oil pan gasket before installing the oil pan.

GENERAL INFORMATION 14-3 ON-VEHICLE SERVICE 14-8
Description 14-3 High-voltage Cable 14-8
Circuit Diagram 14-5 Ignition Coil 14-10
Removal 14-10
Inspection 14-11
Installation 14-11
Service Precautions 14-6
Spark Plug 14-12
Removal 14-12
Inspection 14-13
Installation 14-13
14

14

14 - SQR477F IGNITION SYSTEM
GENERAL INFORMATION
Description
2
3
8
6
7
×4
14
RA19140010
1 - Cylinder 1 High-voltage Cable Assembly 2 - Cylinder 2 High-voltage Cable Assembly

3 - Cylinder 3 High-voltage Cable Assembly 4 - Cylinder 1 Spark Plug
5 - Cylinder 2 Spark Plug 6 - Cylinder 3 Spark Plug
7 - Cylinder 4 Spark Plug 8 - Cylinder 4 High-voltage Cable Assembly
9 - Ignition Coil

Operation
This model uses the distributorless ignition system which mainly consists of ignition coils, spark plugs, etc.
Ignition advance angle is controlled by Engine Control Module (ECM) directly.
Ignition coil consists of two primary windings, two secondary windings, iron core and housing. When the
primary winding is connected to ground, it is charged. Once ECM cuts off the primary winding circuit, charging
stops, and at the same time, a high voltage is induced in the secondary winding to enable the spark plug to
discharge. The difference from the ignition coil with distributor is that a spark plug is connected to the ignition
coil secondary winding at each end, which makes the 2 spark plugs ignite simultaneously. Two primary
windings turn on/off alternately, and two secondary windings alternately discharge accordingly.
Specifications

Spark Plug 30 ± 3
Ignition Coil Fixing Bolt 8 - 11
Rear Left Bracket Assembly Fixing Bolt 7±1
Spark Plug Specifications
Engine Type SQR477F

Spark Plug Type FR7DTC
Spark Plug Gap (mm) 0.8 - 0.9
14
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Ignition System
BATTERY
86 30
ECM
EF35 MAIN ENGINE
RELAY COMPARTMENT
10A FUSE AND
85 87
RELAY BOX
B-012
B-013
EF17 EF16
B-017
15A 15A
C1 C17 D6 H4
RB
R
B-020
16
E-012
RB
RB
YV
R
RB
RB
CYL1 CYL4 CYL3 CYL2

3 4
IGNITION
COIL
E-010
1 2 14
GrG
GrL
20 5 15 16 100 99
ECM
B-001
E-001
D13 D14 D15 D16 C11 C12 C13 C14 1 2 3 4 5 6 7 8
16 15 14 13 12 11 10 9
B-012 B-013
W W
B-020
B
76 75 74 73 72 71 70 69 68 67 66 65
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 88 87 86 85 84 83 82 81 80 79 78 77
H1 H2 H3 H4 H5 H6 H7
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 100 99 98 97 96 95 94 93 92 91 90 89
H8 H9 H10 H11H12H13H14
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 112 111 110 109 108 107 106 105 104 103 102 101
B-017
W
B-001 E-001
B B
E-010
1 2 3 4 B
EA19140010

DIAGNOSIS & TESTING

HINT:

Ignition coil 14-10
Spark plug 14-12
Stall
Camshaft position sensor 06-201
Wire harness -
Ignition coil 14-10
Knock Knock sensor 06-198
ECM 06-209
Battery 16-7
Difficult to start Ignition coil 14-10
Spark plug 14-12
Spark plug 14-12
Engine hesitation, power drop, unstable Engine speed sensor 06-202

performance Camshaft position sensor 06-201
ECM 06-209
14
Spark plug 14-12
Rough, unstable idling or stall Ignition coil 14-10
ECM 06-209
Service Precautions
Visual inspection can reduce the unnecessary test and diagnostic time, so pay attention to the inspection of
the following items:
1. Check the line and hose for obvious looseness, and if they are disconnected or routed improperly.
2. Make sure that the battery connections are clean and firm.
3. Check if the generator wire and belt are installed correctly and securely.
4. Confirm that the ignition coils are installed securely.
5. Check if the engine wire harness connectors are inserted fully.
6. Check if all the electrical connectors are installed correctly and securely.
7. Check the following electrical connections:
a. Engine speed sensor;
b. Oxygen sensor;
c. Intake pressure/temperature sensor;
d. Oil pressure switch;
e. Ignition coil;
f. Canister solenoid valve;

g. Throttle wire and main wire harness;

h. Electronic throttle valve;
i. Fuel injector.
8. Check the routing of all vacuum hoses.
9. Confirm that the following vacuum hoses are connected securely without any leakage:
a. Canister solenoid valve;
b. Charcoal canister;
c. PCV valve;
d. Warm damper vacuum system;
e. Brake booster.
10.Check the fuel pump hose and wire connection to make sure that they are connected securely.
14

ON-VEHICLE SERVICE
High-voltage Cable
Removal
a. Loosen the worm clamps (1) on both ends of intake
hose, and disconnect the intake hose.  1
crankcase ventilation hose from the valve chamber
cover.
RA19140020

5. Remove the high-voltage cable.
a. Remove the wire harness clamp (arrow) and 2 fixing
bolts (1) from the rear left bracket assembly and
remove it.
14
1
RA19140030
b. Remove 4 high-voltage cable clips (arrow).

c. Loosen the high-voltage cables (1) in order and pull
them out from the spark plug sockets.
2
HINT:
Move the oil scale pipe to one side when pulling
upward the cylinder 1 high-voltage cable.
d. Disconnect the high-voltage cables (2) for each
1
cylinder in order from the ignition coil.
RA19140040
e. Remove the high-voltage cables.
CAUTION
 Be careful not to damage the high-voltage cables when pulling it upward.

Inspection
Turn the digital multimeter to ohm band, and measure the
resistance of high-voltage cables in the method shown in the
illustration.
If the result is not as specified, replace the high-voltage
cables.
Measurement Specification
Condition
Item (kΩ)
Cylinder 1
Normal
High-voltage 7.5 - 11.2 RA19140050
temperature
Cable
Cylinder 2
Normal
High-voltage 5.8 - 8.3
temperature
Cable
Cylinder 3
Normal
High-voltage 4.2 - 6.7
temperature
Cable
Cylinder 4
Normal
High-voltage 4 - 6.5
temperature
Cable
Installation
14

Ignition Coil
Removal
4. Remove the ignition coil.
a. Loosen the worm clamp (arrow) to disconnect the
intake hose from the air filter, and move the intake
hose to one side.
RA19140051
b. Disconnect the ignition coil connector (1).

c. Disconnect the high-voltage cables (arrow) for each
cylinder, and put them aside.
14 RA19140060
d. Loosen and remove 4 fixing bolts (arrow) from the

ignition coil assembly.
RA19140070
e. Remove the ignition coil.

Inspection
1. Inspect the resistance of ignition coil primary winding.
Turn the digital multimeter to ohm band, and check the
resistance between terminals 1 and 3, 2 and 3.
+ -
If the result is not as specified, replace the ignition coil. 1 2 3 4
Multimeter
Connection
Terminal 1 - Normal
0.50 - 0.64
Terminal 2 - Normal
0.50 - 0.64 RA19140080
2. Inspect the resistance of ignition coil secondary winding.

Turn the digital multimeter to ohm band, and check the
resistance between the high-voltage posts 1 and 4, 2 and
3 of ignition coil secondary winding.
If the result is not as specified, replace the ignition coil.
3 1
Multimeter Specification
Condition
Connection (kΩ) 2 4
Normal
Post 1 - Post 4 8.36 - 10.64
temperature
RA19140090
Normal
Post 2 - Post 3 8.36 - 10.64
temperature
Installation
CAUTION
 Make sure the connection between the high-voltage cable and the ignition coil high-voltage terminal,
spark plug is reliable, or it may cause the high-voltage leakage, resulting in poor ignition.

Spark Plug
Removal
CAUTION
 DO NOT remove the spark plugs when the engine is hot; failure to do this may cause damage to the
spark plug thread holes on the cylinder head.
 Before removal, remove the dirt and foreign matter around the spark plug holes to prevent them from
dropping into the cylinders.
1. Turn off all the electrical equipment and ignition switch. Wait until the engine cools down.
a. Loosen the worm clamps (1) on both ends of intake
hose, and disconnect the intake hose. 1
crankcase ventilation hose from the valve chamber
cover.
RA19140020
14 c. Remove the intake hose with crankcase ventilation hose assembly.

5. Move the high-voltage cables for each cylinder to one side.
a. Remove the wire harness clamp (1) and 2 fixing bolts
(arrow) from the rear left bracket assembly and
remove it.
RA19140030
b. Loosen and pull up the high-voltage cables (arrow) for

each cylinder in order, and put them aside.
HINT:
Move the oil scale pipe to one side when pulling
upward the cylinder 1 high-voltage cable.
RA19140031

CAUTION
 Be careful not to damage the high-voltage cables when pulling it upward.
6. Remove the spark plug.

a. Using a special spark plug socket wrench (1), loosen
the spark plug.
b. Remove the spark plug (2). 1
RA19140100
Inspection
Check the spark plug gap a: 0.8 - 0.9 mm.
RA19140110 14
Installation
CAUTION
 Check the spark plug type to confirm if it is suitable.

 Please install the spark plug with the special spark plug socket wrench, and never touch the spark plug
socket. DO NOT damage the normal spark plug gap.
1. Install 4 spark plugs respectively into the cylinder head mounting holes for pre-tightening, and then
retighten the spark plugs with a torque wrench. 
Other procedures are in the reverse order of removal.

- MEMO -

Description 15-3 Starter 15-8
Circuit Diagram 15-5 Ignition Starting Switch 15-11
Removal 15-11
Inspection 15-11
Installation 15-11
Starter Relay Inspection 15-6
Precautions for Starting System 15-7
15

15

15 - SQR477F STARTING SYSTEM
GENERAL INFORMATION
Description
FUSE
& RE
LAY BO
X
4
15
RA19150010
1 - Battery 2 - Fuse and Relay Box

3 - Ignition Starting Switch 4 - Starter
The starting system consists of battery, ignition switch, starter, etc. The function of starting system is to
convert electrical energy from the battery into mechanical energy by starter so as to crank the engine initially,
and disconnect the power transmission between starter and engine when the engine runs normally.

Operation
The starter consists of three parts: control mechanism, drive train mechanism and DC motor.
1. Control mechanism (solenoid switch): it controls the engagement and disengagement between starter
drive gear and engine flywheel gear and switches on/off the DC motor circuit; the solenoid switch can also
short out the ignition coil additional resistance when starting.
2. Drive train mechanism: it makes the starter drive gear get engaged with the flywheel gear ring when the
engine starts and transmits the torque of starter to the engine crankshaft; after the engine starts, the drive
gear and flywheel gear disengage automatically, so that the engine cannot drive the starter to run at a high
speed in reverse by flywheel, avoiding damage to the starter.
3. DC motor: it converts electrical energy from the battery into electromagnetic moment.
Specifications

Starter Power Cable Nut 18 ± 2
Starter Fixing Bolt 40 ± 5
Tool
General Tool
Digital Multimeter
15
RCH0000002

Circuit Diagram
Starting System
IGNITION SWITCH
BATTERY
START
EF13 ENGINE
30A COMPARTMENT INSTRUMENT
FUSE AND PANEL FUSE
30 86 RELAY BOX RF24 AND RELAY
B-012 10A BOX
STARTER
RELAY B-013 I-005
B-014 24
RB
87 85
D13 C3 A8
I-004
R
33
R
B-053
RB
B-020
E-012 1
R
YG
RY
B 1
STARTER 58 13
B M POWER
SUPPLY
(STARTER ECM
S B-001
M SOLENOID
SWITCH)
P-003
E-011 15
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
A1 A2 A3 A4 A5 A6 C1 C2 C3 C4 C5 C6 C7
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 A10 A11 A12 A13 C11 C12 C13 C14
A7 A8 A9 A14 A15 A16 C8 C9 C10 C15 C16 C17 C18
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 B-014 B-013
W W
B-001
B
29 30 31 32 33 34 35 36 37 38 39 40 41 42 1 2 3 4 5 6 7 8
D1 D2 D3 D4 D5 D6 D7 D8 15 16 17 18 19 20 21 22 23 24 25 26 27 28
D13 D14 D15 D16 16 15 14 13 12 11 10 9
D9 D10 D11D12 D17 D18 D19 D20 1 2 3 4 5 6 7 8 9 10 11 12 13 14
B-012
B-020
W I-004
B
L
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
1
25 26
87
85 86 86 86
85
87 30
85
87 30 E-011
30 P-003
B
I-005
B EA19150010

DIAGNOSIS & TESTING

HINT:

When ignition switch is turned to START,
Battery (weak battery, poor contact of
solenoid switch makes a "clanking" sound -
battery cable)
and engine cannot start
Battery (depleted) -
Starter 15-8
Starter does not run
Ignition starting switch 15-11
Starting system wire harness -
Battery (weak battery, internal fault) 16-7
Starter runs weakly
Starter -
Starter (incorrect installation, internal fault) 15-8
Starter is racing
Flywheel ring gear (gear teeth broken) 07-55
Starter Relay Inspection

1. Recognize and remove the starter relay from the engine
compartment fuse and relay box. 10
15
15
10 15
15
10 15
10
15
10
30 15
15
STARTER 20 20
RELAY
30
40
30
40
40
40
RA19150012

2. Check the starter relay.

a. Using a digital multimeter, measure the resistance
according to the value below. 30 85
+ -
Standard Resistance
Multimeter
Specified Condition
Connection
87 86
30 - 87 10 kΩ or more
Below 1 Ω (when battery voltage is
30 - 87
applied to terminals 85 and 86) 30
If the result is not as specified, replace the starter
85
86
relay.
87
RA19150011
Precautions for Starting System

1. Shift the transmission to neutral and apply parking brake before starting, and depress the clutch pedal
while starting.
2. Make sure that the battery is fully charged to reduce the repeat operating time of starter.
3. Do not start the engine for more than 5 seconds each time, the repeated starting time should not be less
than 10 - 15 seconds, and the consecutive starting is not allowed more than 3 times.
4. If the starter cannot stop, turn off the ignition switch immediately, or remove the negative battery cable to
find the problem.
5. Check the starter circuit frequently to make sure that each wire for starting system is connected securely
and in good insulation.
6. Generally, perform maintainable service for the starter when servicing the vehicle. Also, the maintenance
interval can be shortened or extended properly depending on actual conditions.
7. Remove the negative battery cable before removing the starter. 15

ON-VEHICLE SERVICE
Starter
Removal
5. Remove the starter.
a. Disconnect the starter connector (1).
b. Move away the terminal cap, remove the starter
power cable nut (2) and disconnect the starter power
cable. 
c. Remove 2 starter fixing bolts (arrow). 
RA19150020
d. Remove the starter.
Inspection
1. Check the starter solenoid switch.
a. Check the pull-in coil.
 Measure the resistance between the terminal 50 Terminal 50
and the terminal C.
15
Terminal C
RA19150030
 The standard resistance should be below 2 Ω.

If the result is not as specified, replace the starter.
b. Check the hold-in coil.
 Measure the resistance between terminal 50 and Terminal 50 Switch Body
starter solenoid switch body.
RA19150040
 The standard resistance should be below 2 Ω.


2. Check the starter assembly.
CAUTION
 These measurements must be performed within 3 to 5 seconds to avoid coil burnout.

 Place the starter assembly onto a vise. The jaws of vise should be covered by aluminum sheet or brass
plate; otherwise, the starter assembly will be easily damaged when clamping it.
a. Perform pull-in test.

 Remove the nut and disconnect the field coil lead
from terminal C. Terminal 50
 As shown in the illustration, connect the battery to

the solenoid switch, and check that the starter
clutch pinion sticks out.
Terminal C Body
- +
RA19150050
If the starter clutch pinion does not move, replace the starter assembly.
b. Perform hold-in test.
 Keep the starter clutch pinion sticking out and the
connection condition of battery mentioned above, Terminal 50
and disconnect the negative battery cable from
terminal C.
 Check that the starter clutch pinion keeps sticking
out.
15
Terminal C Body
- +
RA19150060
If the starter clutch pinion moves inward, replace the starter assembly.

c. Check if the starter clutch pinion returns back.

 Disconnect the negative battery cable from the
starter body. Check that the starter clutch pinion Terminal 50
returns back.
Terminal C Body
- +
RA19150070
If the starter clutch pinion does not return back, replace the starter assembly.
d. Check if the starter rotates smoothly.
 Connect the field coil lead to terminal C, and
tighten it with a nut. Terminal 50
 As shown in the illustration, connect the battery to
the starter. Check that the starter rotates smoothly
when the starter clutch pinion moves outward.
Terminal 30 Body
- +
RA19150080
CAUTION
 The lead to be connected should avoid the pinion side to prevent the lead stuck as the pinion rotaes.
15
Installation

Ignition Starting Switch

Removal
3. Remove the steering column cover assembly (See page 27-12).
4. Remove the ignition starting switch.
a. Disconnect the ignition starting switch assembly
connecting wire harness joint (1).
b. Remove the ignition starting switch fixing screw
(arrow).
RA19150090
c. Remove the ignition starting switch.
Inspection
1. Check for continuity of the ignition starting switch.
ST B1 IG2
Multimeter Switch Specified + -
Connection Condition Condition

All terminals LOCK No continuity
ACC B2 IG1
Terminal B1 -
ACC Continuity
Terminal ACC
Terminal B1 - 15
Terminal IG1 RA19150100
Terminal B1 -
Terminal ACC
ON Continuity
Terminal IG2 -
Terminal B2
Terminal IG1 -
Terminal ACC
Terminal ST -
Terminal B2
START Continuity
Terminal IG1 -
Terminal B1
If the result is not as specified, replace the ignition

starting switch.
Installation

- MEMO -

Description 16-3 Battery 16-7
Generator Operation 16-4 Inspection 16-7
Circuit Diagram 16-5 Battery Tray 16-8
Removal 16-8
Installation 16-8
Generator and Generator Bracket 16-9
Charging System Charging Voltage 
Removal 16-9
Inspection 16-6
Installation 16-9
16

16

16 - SQR477F CHARGING SYSTEM
GENERAL INFORMATION
Description
3 2
FU
SE
&R
ELAY
BO
X
16
RA19160010
1 - Fuse and Relay Box 2 - Battery

3 - Generator 4 - ECM
The generator is a key component of charging system. It is a device that converts mechanical energy into
electrical energy and generates DC voltage as one of main power sources of the vehicle. The generator
operates as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced.

Generator Operation
The generator is a silicon rectifying generator, which mainly consists of rotor, stator and rectifier.
When direct current flows to the rotor winding, rotor claw establishes magnetic field to produce alternating
induced electromotive force. The stator is installed on the outside of the rotor, and it is secured together with
the front and rear end covers of generator. When the generator rotor is rotated by the drive belt, magnetic pole
lines cuts the stator winding, causing a change in the magnetic flux of the stator winding; thus, the stator
winding generates alternating induced electromotive force, producing alternating current. The three-phase
alternating current generated by the generator is converted to direct current from alternating current by the
rectifier and transmitted to the vehicle electrical system and battery.
Specifications

Battery Pressure Plate Fixing Bolt 7 ± 1.5
Coupling Bolt Between Battery Tray and Air Filter
7 ± 1.5
Assembly
Battery Tray Fixing Bolt 25 ± 4
Generator Output Cable Fixing Nut 18 - 22
Generator Field Wiring Harness Fixing Nut 8±1
Generator Fixing Bolt 20 ± 5
Generator Bracket Fixing Nut 40 ± 5
Generator Bracket Fixing Bolt 40 ± 5
Battery Specification
Name Type Specification
16 SQR477F L2 400 12 V, 60 Ah, 480 A
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Charging System
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT
POWER PANEL FUSE
BF01 RF01
FUSE BOX AND RELAY
150A 10A BOX
P-002
I-005
5
1
RW
13
INSTRUMENT
CLUSTER
I-043
16
R
L
I-003
38
B-050
RG
B-008
15
B E-038
L
L
16
GENERATOR
P-004
E-030
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 29 30 31 32 33 34 35 36 37 38 39 40 41 42
25 26 15 16 17 18 19 20 21 22 23 24 25 26 27 28
87
1 2 3 4 5 6 7 8 9 10 11 12 13 14
85 86 86 86
87 30 87 30
30 85 85
P-002
I-003
I-005 W
B
1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
16 15 14 13 12 11 10 9
E-030 P-004
I-043
B-008 L
B EA19160010

DIAGNOSIS & TESTING

HINT:
Symptom Suspected area See page

Generator 16-9
Charging system warning light comes on
Instrument cluster 36-34
after engine starts
Wire harness -
Fixing bolt (loose) 16-4
Noises are heard from generator after
V-ribbed belt (misaligned, loose or fault) 07-21
engine starts
Generator 16-9
Charging System Charging Voltage Inspection

1. Leave the vehicle under no load test condition and idle the engine. Measure the battery voltage with the
digital multimeter.
Standard voltage: 13 ± 0.3 V
If the result is not as specified, replace the generator (See page 16-9).
2. Leave the vehicle under load test condition and idle the engine. Measure the battery voltage with the digital
multimeter.
Load test condition:
 Set headlight to high beam;
 Turn on the blower and switch the blower speed switch to "4" position;
 Turn on the "A/C" switch;
 Turn the cold and hot switch to set the temperature of outlet to the highest.
16
Standard voltage: 13 ± 0.3 V
If the result is not as specified, replace the generator (See page 16-9).
CAUTION
 If the charging system warning light comes on, the charging system may have a malfunction.
 If noises are heard from the generator or generating capacity is extremely high or low, repair or replace
the generator assembly.

ON-VEHICLE SERVICE
Battery
Inspection
1. Check that the battery terminals are not loose or corroded.
If the battery terminals are corroded, clean them.
2. Check the battery for damage, deformation or leakage. If serious damage, deformation or leakage is
found, replace the battery.
3. Check the battery voltage.
Turn the ignition switch to ON, and turn it off 20 to 30 seconds after turning on the headlights. This will
eliminate the electric charge on the surface of battery. Measure the battery voltage with the digital
multimeter.
Testing Temperature Specification

20°C 12 - 13 V
Removal
2. Remove the battery.
a. Open the negative battery terminal cover, loosen the
negative battery cable locking nut, and remove the
negative (-) battery cable (1).
b. Open the positive battery terminal cover, loosen the 1
positive battery cable locking nut, and remove the
positive (+) battery cable (2).
c. Remove 2 battery pressure plate fixing bolts (3) and
remove the battery pressure plate and the fixing rod. 2
RA19160020
16
CAUTION
 Please be careful to prevent metal tools from contacting both electrodes of battery at the same time or
accidentally touching the positive electrode and vehicle body.
d. Remove the battery.
Installation
CAUTION
 Replace the battery with one that has the same specification.
 The used battery contains sulfuric acid and lead, so never discard it at will. Please dispose of it at a
qualified local waste treatment station.

Battery Tray
Removal
2. Disconnect the negative battery cable (See page 16-7).
3. Remove the battery tray.
a. Disconnect the connecting clamps (arrow) between
wire harness and battery tray.
b. Remove 2 connecting bolts (1) between battery tray
and air filter assembly.
2
c. Remove 5 battery tray fixing bolts (2). 
1 RA19160030
d. Remove the battery tray.
Installation
16

Generator and Generator Bracket

Removal
a. Rotate the V-ribbed belt tensioner in the direction of
arrow with the wrench (2) to align the locking holes of 1
tensioner and bracket. Insert the locking pin (1) to lock
the tensioner at the same time.
3
RA19160040
5. Remove the generator.

a. Move away the terminal cap, remove the generator
output cable fixing nut (1) and move away the
generator output cable.
b. Remove the generator field wire harness fixing nut (2)
and move away the generator field wire harness.
1
2
c. Remove 2 generator fixing bolts (arrow). 
RA19160050
d. Remove the generator. 16

6. Remove the generator bracket.
a. Remove the idle pulley (See page 07-25).
b. Remove the tensioner (See page 07-27).
c. Remove the generator bracket fixing nut (1) and 2
fixing bolts (2). 1
(Tightening torque for nut: 40 ± 5 N·m)
(Tightening torque for bolt: 40 ± 5 N·m)
RA19160060
Installation

- MEMO -

GENERAL INFORMATION 17-3 Gear Shift Mechanism 17-34
Description 17-3 Disassembly 17-34
Operation 17-6 Assembly 17-35
Specifications 17-6 Shift Fork 17-36
Daily Maintenance 17-7 Disassembly 17-36
Assembly 17-38
Input Shaft 17-39
Disassembly 17-39
Inspection 17-43
ON-VEHICLE SERVICE 17-12 Assembly 17-44
Transmission Oil 17-12 Output Shaft 17-49
Replacement 17-12 Disassembly 17-49
Differential Oil Seal 17-14 Inspection 17-52
Installation 17-14 Transmission External Accessory 17-58
Select and Shift Cable 17-16 Removal 17-58
Installation 17-18 Transmission Case 17-61
Gear Shift Control Mechanism 17-19 Disassembly 17-61
Inspection 17-20
Installation 17-20
Transmission Assembly 17-21
Removal 17-21
Disassembly 17-24
Assembly 17-29
Installation 17-33
17

17

17 - QR515MHA TRANSMISSION
GENERAL INFORMATION
Description
Transmission
16
15
14
13 20
12
11
10
4
5
9
6
8 3
2
19
17
17 7
18
RA19170010
1 - Linear Bearing 2 - Differential Oil Seal

3 - Differential Bearing Outer Race 4 - Output Shaft Front Bearing Outer Race
5 - Oil Guide 6 - Input Shaft Oil Seal
7 - Clutch Case Groove 8 - Oil Deflector
9 - Transmission Case 10 - Washer
11 - Retaining Plug 12 - Washer
13 - Drain Plug 14 - Differential Bearing Outer Race
15 - Adjusting Washer 16 - Differential Oil Seal
17 - Output Shaft Assembly 18 - Input Shaft Assembly
19 - Shift Fork Assembly 20 - Differential

Input Shaft
4
5
2
6
1
8 7
9
10
23
11
22
12
21
14 13
19 20
18
17
16
15
17
RA19170570
1 - Input Shaft Front Bearing 2 - Input Shaft

3 - 3rd Needle Roller Bearing 4 - 3rd Drive Gear Assembly
5 - 3rd Synchronizer Ring 6 - 3rd-4th Synchronizer Gear Hub
7 - Guide Block 8 - 3rd-4th Synchronizer Outer Race
9 - Snap Ring 10 - 4th Synchronizer Ring
11 - 4th Needle Roller Bearing 12 - 4th Drive Gear Assembly
13 - Gear Baffle Plate 14 - Ball
15 - Gear Baffle Plate Spring Clamp 16 - 5th Needle Roller Bearing
17 - 5th Drive Gear 18 - 5th Synchronizer Ring
19 - 5th Synchronizer Outer Race 20 - Guide Block
21 - 5th Synchronizer Gear Hub 22 - Snap Ring
23 - Input Shaft Rear Bearing

Output Shaft
4 5
3
1 2
9
8
10
10
10
12 11
13
13
17
16
14
15
13
17
RA19170870
1 - Output Shaft Rear Bearing 2 - Snap Ring

3 - 5th Driven Gear 4 - 4th Driven Gear
5 - Gear Shaft Bushing 6 - 3rd Driven Gear
7 - 2nd Driven Gear 8 - 2nd Needle Roller Bearing
9 - 1st-2nd Synchronizer Outer Race 10 - Synchronizer Ring Set
11 - Snap Ring 12 - 1st-2nd Synchronizer Gear Hub
13 - Synchronizer Ring Set 14 - 1st Driven Gear
15 - 1st Needle Roller Bearing 16 - Output Shaft
17 - Output Shaft Front Bearing

Operation
The transmission operates five forward gears and one reverse gear by three sets of synchronizers and two
shafts (input shaft and output shaft). All the forward gears use the conventional engagement, and the reverse
gear uses a sliding idler gear device. 1st-2nd gear synchronizer is installed on the output shaft and 3rd-4th
and 5th gear synchronizers are installed on the input shaft. The transmission will engage with its
corresponding gear hub separately when it is shifted to each different gear position, thus realizing the
transmission of power. The drive gear of final drive, which is on the output shaft, rotates the driven gear of
final drive and differential assembly, thus the propeller shaft is driven to turn the wheels.
Specifications

Reverse Shift Fork Fixing Bolt 25 ± 2
Transmission Case Fixing Bolt 25 ± 2
Clutch Case Fixing Bolt 25 ± 2
Reverse Gear Fixing Bolt 38 ± 2.5
Gear Shift Control Mechanism Fixing Bolt 20 ± 3
Select and Shift Cable Boot Fixing Nut 7 ± 1.5
Select and Shift Cable Locating Nut 7 ± 1.5
Coupling Bolt Between Gear Shift Mechanism and
25 ± 2
Transmission Case
Gear Shift Mechanism Locating Bolt 32 ± 2.5
Clutch Line Bracket Fixing Bolt 25 ± 2
Shift Shaft Locating Bolt 20 ± 2
Starter Wire Harness Bracket Fixing Bolt 25 ± 2
Oxygen Sensor Connector Bracket Fixing Bolt 20 ± 3
17
Ground Wire Fixing Bolt 20 ± 3
Drain/Retaining Plug 44 ± 3
Select and Shift Cable Mounting Bracket Fixing Bolt 25 ± 3
Transmission Fixing Bolt 45 ± 5
Fixing Bolt Between Front and Lower Side of Engine
45 ± 5
and Transmission
Fixing Bolt Between Engine Rear Side and
45 ± 5
Transmission

Transmission Gear Ratio Table
Gear Ratio Type

QR515MHA
Gear
1st 3.545
2nd 2.050
3rd 1.423
4th 1.065
5th 0.865
Reverse 3.364
Final Drive 3.550
Daily Maintenance
For transmission, generally it is not necessary to perform special maintenance, and the most normal
maintenance is to change the gear oil. Transmission of QR515MHA series must use the gear lubricant of GL-4
75W-90 grade or above. If improper lubricant is used, the transmission will be seriously damaged. Never replace
the transmission lubricant with engine lubricant. Also, please note that the lubricant has a strict requirement for
filling amount.
Filling method:
Park the vehicle on the service platform or lifter levelly without removing the transmission. Prepare a container
to recover the used lubricant. Remove the transmission drain plug, and then drain the used transmission oil.
Replace the washer with a new one after draining the transmission oil and tighten the drain plug. Loosen the
transmission retaining plug and fill QR515MHA transmission lubricant with a special filling device until the oil
flows out from the retaining plug, then tighten the retaining plug.
17

Tools
Special Tools
Input Shaft Oil Seal Installer
RCH0000008
Differential Oil Seal Installer
RCH0000009
Installation Joint
RCH0000010
17
Bearing Remover
RCH0000011
Punch
RCH0000015

Puller
RCH0000059
General Tools
RCH0000005
Engine Equalizer
RCH0000026
Hydraulic Press
17
RCH0000012

DIAGNOSIS & TESTING

HINT:

Oil level (too low) 17-11
Oil wrong grade 17-11
Noise Gears (worn or damaged) -
Bearing (worn or damaged) -
Gear thrust position and clearance improper -
Drain plug -
Drain plug gasket -
Oil leakage Differential oil seal 17-14
Joint surface damaged and not reamed in
-
time
Oil level (too low) 17-11
Gears (worn or damaged) -
Hard shifting or impossible to shift
Synchronizer ring (worn or damaged) -
Shift key spring (worn or damaged) -
Detent ball spring -
Shift fork (worn) 17-36
Jumps out of gear
Gears (worn or damaged) -
Bearing (worn or damaged) -
17 Lubricant contains any metal impurities -
Insufficient lubrication or lubricant not
Bearing irregular damaged -
complying with the regulations
Use irregular bearing -
Insufficient lubrication at joint surface of
Release fork makes a "click" sound when release fork and hydraulic sub cylinder or
-
clutch pedal is depressed joint surface of release fork and ball joint
housing.
Shift drive train (loose) -
No gear change
Driver swing arm (loose) -

CAUTION
 To guarantee the service quality of transmission, perform operations carefully and keep each component
of transmission clean.
 Select appropriate or special tools.
 The transmission can achieve a good operation condition only when strictly performing service according
to the technical requirements of assembly or adjustment.
Transmission Oil
1. Check the transmission oil level.
a. Raise the vehicle with a lifter.
WARNING
 Be sure to wear the necessary safety equipment to prevent accidents.

 Check if the safety lock of lifter is locked when performing the vehicle lift repair and check.
b. Remove the transmission filler plug and gasket.

c. Check if the oil level is at the opening of retaining plug.
Transmission oil type: GL-4
Viscosity: 75W-90
Standard capacity: 2.3 L
CAUTION
 An excessively large or small amount of oil may affect proper functioning of transmission.
 After filling oil, run the vehicle, and then check the oil level.
17

ON-VEHICLE SERVICE
Transmission Oil
Replacement
CAUTION
 Replace the transmission oil only when the engine stops and the transmission cools down.
 Before installation, replace the drain/retaining plug washer with a new one.

2. Raise the vehicle to the proper height.
3. Place a recovering container under the transmission drain hole.
4. Using a wrench, loosen the transmission filler plug
(arrow).
RA19170020
5. Using a wrench, remove the transmission drain plug

(arrow). Replace the drain plug gasket and tighten the
drain plug after draining the transmission oil.
17
RA19170030
6. Fill transmission oil.
CAUTION
 Only use transmission oil approved by Chery Automobile Co., Ltd.
a. Make sure that the transmission drain plug has been tightened in place.

b. Using a filling tool, fill transmission oil to the

transmission filler until it overflows.
RA19170040
c. Replace the filler plug gasket and tighten the filler plug after filling.
Transmission Oil Type
Model 1.5 L MT
Transmission Oil Type API GL-4, 75W-90
Filling Capacity 2.3 L
17

Differential Oil Seal

Removal
HINT:
 Use the same procedures for the right side and left side.
 The procedures listed below are for the left side.
1. Raise the vehicle with a lifter.
WARNING
 Make sure to wear necessary safety safety equipment to prevent accidents.

2. Drain transmission oil.

a. Remove the retaining plug and gasket.
b. Remove the drain plug and gasket, and drain the transmission oil.
 The drained transmission oil should be collected with a recovering tool.
c. Install the new gasket and drain plug.

3. Remove the front left wheel (See page 23-10).
4. Remove the left drive shaft (See page 19-5).
5. Pull the oil seal with a puller.
17
RA19170050
Installation
1. Apply an appropriate amount of transmission oil to the lip of new oil seal.
2. Using a special tool and a hammer, tap in the oil seal.
RA19170060

CAUTION
 DO NOT damage the oil seal during installation.
3. Fill transmission oil.

Other procedures are in the reverse order of removal.
17

Select and Shift Cable

Removal
1. Place the vehicle on a lifter, and support the vehicle with the lifter.
WARNING


3. Open the engine hood.
7. Remove the cotter pins (arrow) connecting select and
shift cable with transmission gear shift mechanism.
RA19170090
8. Remove the flexible shaft clamps (arrow) from the select

and shift cable.
17
RA19170100
9. Remove the auxiliary fascia console assembly (See page 43-10).

10.Remove the front muffler assembly (See page 11-13).
11. Remove the heat insulator.
a. Remove 7 locks (arrow) from the heat insulator, and
remove the heat insulator.
RA19170101

12.Remove the select and shift cable.

a. Remove the locating nuts (arrow) from the select and
shift cable.
RA19170110
b. Remove the fixing nuts (arrow) from the select and

shift cable boot.
RA19170111
c. Remove the clamp and cotter pin (arrow) connecting

select and shift cable with gear shift control
mechanism.
RA19170120
17
d. Remove the flexible shaft clamps (arrow) connecting
mechanism.
RA19170130
e. Remove the select and shift cable.

Installation
CAUTION
 DO NOT install the select and shift cable in reverse position during installation.
17

Gear Shift Control Mechanism

Removal
CAUTION
 Wear protective gloves when removing or installing the shift lever, and be careful to prevent the fingers
from being injured.

3. Remove the gear shift control mechanism.
a. Remove the clamp and cotter pin connecting select
and shift cable with gear shift control mechanism.
RA19170120
b. Remove the flexible shaft clamps (arrow) connecting

mechanism.
RA19170130 17
c. Remove the fixing bolts (arrow) from the gear shift
control mechanism, and remove the gear shift control
mechanism.
RA19170140

Inspection
1. Visually check if the gear shift control mechanism is deformed. If it is deformed or damaged, replace it.
2. Check if the shift lever ball is stuck. If it is stuck, apply grease or replace it.
Installation
17

Transmission Assembly
Removal
WARNING


6. Drain transmission oil.
 The drained transmission oil should be collected with a recovering tool.
7. Remove the front wheel (See page 23-10).

8. Remove the drive shaft assembly (See page 19-5).
10.Remove the oxygen sensor connector bracket.
a. Remove the fixing bolts (arrow) from the oxygen
sensor connector bracket, and remove the oxygen
sensor connector bracket.
17
RA19170160

11. Remove the clutch line bracket.

a. Remove the fixing bolt (arrow) from the clutch line
bracket.
RA19170170
12.Remove the clamp and cotter pin connecting select and shift cable with gear shift control mechanism.
13.Remove the starter wire harness bracket.
a. Remove the fixing bolt (arrow) from the starter wire
harness bracket, and remove the starter wire harness
bracket.
RA19170180
14.Disconnect the crankshaft position sensor connector

(arrow).
17
RA19170190
15.Remove the starter (See page 15-8).

16.Remove the transmission ground wire.
a. Remove the ground wire fixing bolt (arrow) and
ground wire from the transmission.
RA19170200

17.Remove the select and shift cable mounting bracket.

a. Remove the fixing bolts from the select and shift cable
mounting bracket, and remove the select and shift
cable mounting bracket.
RA19170210
18.Disconnect the back-up light switch connector (arrow).
RA19170070
19.Remove the clutch release cylinder from the transmission (See page 18-12).
20.Remove the left mounting assembly (See page 07-59).
21.Remove the rear mounting assembly (See page 07-58).
22.Remove the front lower deflector (See page 46-20).
23.Remove the transmission assembly.
a. Remove the transmission fixing bolts (arrow) from the
transmission side.
17
RA19170230
b. Support the transmission assembly with a transmission carrier.

c. Remove the fixing bolts (arrow) between the front and
lower side of engine and the transmission.
RA19170250

d. Remove the fixing bolts (arrow) between engine rear

side and transmission.
RA19170260
Disassembly
1. Remove the locating bolt of gear shift mechanism.
a. Remove the locating bolt (arrow) of gear shift
mechanism from the transmission assembly.
RA19170301
2. Remove the back-up light switch.

a. Remove the back-up light switch (arrow) from the
transmission assembly.
17
RA19170300
3. Remove the gear shift mechanism.

a. Remove the gear shift mechanism fixing bolts (arrow).
RA19170270

b. Remove the gear shift mechanism (1) in the direction

of the arrow.
1
RA19170280
HINT:
It is difficult to remove the gear shift mechanism because of the seal gum, so tap the protrusion on the side
of gear shift mechanism case with a rubber hammer.
4. Remove the shift shaft locating bolt.
a. Remove the shift shaft locating bolts (1) from the
RA19170302
5. Remove the reverse idler gear shaft locating bolt.

a. Remove the reverse idler gear shaft locating bolt
(arrow) from the transmission assembly.
17
RA19170310
6. Remove the transmission case.

a. Remove the clutch case fixing bolts (arrow) from the
RA19170290

b. Remove the transmission case fixing bolts (arrow)

from the transmission assembly.
RA19170320
c. Separate the transmission case and clutch case, and

remove the transmission case.
RA19170330
HINT:
It is difficult to separate the transmission case and clutch case because of the seal gum, so tap the
protrusion on the transmission case side with a rubber hammer or equivalent for easy removal.
7. Remove the reverse gear fork.
a. Remove the fixing bolts (arrow) from the reverse gear
fork, and remove the reverse gear fork (1).
17
RA19170340
8. Remove the reverse gear shaft and reverse gear.

a. Remove the reverse gear shaft (1) and reverse gear
(2) together from the clutch case.
RA19170350

9. Remove the input shaft rear washer.

a. Remove the input shaft rear washer (1) from the input
shaft.
RA19170360
10.Remove the magnet.

a. Remove the magnet (1) from the clutch case.
RA19170370
11. Remove the input shaft, output shaft and fork mechanism.
a. Remove the input shaft, output shaft and fork
mechanism (1) together from the clutch case.
1
17
RA19170380

HINT:
Gently jiggle them during removal.
CAUTION
 Prevent the input shaft spline from damaging the input shaft front oil seal during removal.
 Prevent the interference between output shaft bearing cage and differential big ring gear and avoid
damaging the bearing cage during removal.
12.Remove the shift fork assembly.

a. Remove the shift fork assembly (1) from the input
shaft and output shaft (2).
2
1
RA19170390
13.Remove the differential assembly.

a. Remove the differential assembly (1) from the clutch
case.
1
RA19170400
17

Assembly
CAUTION
 Before assembling the components, wash them clean.

 Remove the seal gum residues from the case.
 Make sure the joint surface of case is free of oil, and uniformly apply seal gum.
 Make sure the joint surface of case and shift assembly is free of oil, and uniformly apply seal gum.
 Tighten the bolts to the specified torque.
1. Install the differential assembly.

a. Apply transmission oil to the each slide part of
differential, and install the differential (1) to the clutch
case in the direction of arrow. 1
RA19170410
2. Install the shift fork assembly.

a. Install the shift fork assembly (1) to the input shaft and
output shaft (2).
2
1
RA19170390
17

3. Install the input shaft, output shaft and fork mechanism.

a. Apply transmission oil to the each slide part of input
shaft and output shaft, and install the input shaft,
output shaft and fork mechanism (1) together to the
clutch case in the direction of arrow.
RA19170420
CAUTION
 Prevent the input shaft spline from damaging the input shaft front oil seal during installation.
4. Install the reverse idler gear and reverse gear.

a. Apply transmission oil to the each slide part of reverse
gear and reverse gear shaft, and install the reverse
idler gear (1) and reverse gear (2) together to the
clutch case.
1
17
RA19170350
5. Install the reverse gear fork.

a. Install the reverse gear fork (1) to the clutch case, and
tighten the reverse gear fork fixing bolts (arrow).
RA19170340

6. Install the input shaft rear washer.

a. Apply an appropriate amount of transmission oil, and
put the input shaft rear washer (1) onto the input shaft
rear bearing.
1
RA19170360
CAUTION
 Evenly put the input shaft rear washer onto the input shaft rear bearing without the washer edge out of
the input shaft rear bearing.
7. Install the magnet.

a. Install the magnet (1) to the clutch case in the
direction of arrow.
RA19170430
8. Install the transmission case.

a. Install the transmission case to the clutch case.
17
RA19170440
CAUTION
 Remove the seal gum residues from the case.

 Make sure the joint surface of case is free of oil, and uniformly apply seal gum.

b. Install the transmission case fixing bolts (arrow) and

tighten them.
RA19170320
c. Install the clutch case fixing bolts (arrow) and tighten

them.
RA19170290
9. Install the reverse gear fixing bolt.

a. Install the reverse gear fixing bolt (arrow) to the
transmission case.
RA19170310
17
10.Install the gear shift mechanism.
a. Install the gear shift mechanism (1) to the
transmission case.
RA19170450
CAUTION
 Clean the engagement portion of shifter case and transmission case, and apply seal gum evenly.

b. Install the coupling bolts (arrow) between gear shift

mechanism and transmission case. 
RA19170270
11. Install the shift shaft locating bolts (1).

RA19170302
12.Install the locating bolt (arrow) of gear shift mechanism.

RA19170301
13.Install the back-up light switch (arrow).

17
RA19170300
Installation

Gear Shift Mechanism

Disassembly
1. Loosen the shift arm bracket bolts (A).
2. Remove the shift arm bracket (1).
3. Using the snap spring calipers (2), remove the snap ring 1
(3).
4. Loosen the fixing bolts (B) of reverse gear lock
B
mechanism. 4
5. Remove the reverse gear lock mechanism (4).
RA19170460
6. Tap out the dowel pin (2) with a punch (1).

1
7. Remove the shift arm (3) and plate (4).
2
3
RA19170470
17
8. Tap out the dowel pin (2) with a punch (1).
9. Remove the shift finger (3).
1 3
RA19170480

Assembly
Assembly is in the reverse order of disassembly.
CAUTION

 Replace the damaged dowel pins.
17

Shift Fork
Disassembly
1. Remove the reverse gear fork.
a. Using the snap spring calipers, remove the snap
ring (1).
RA19170490
b. Remove the reverse gear fork (1) and return spring

(2).
17 1
RA19170500
2. Remove the 3rd-4th gear shift fork.

a. Using a punch (1), tap out the dowel pin (3) from the
3rd-4th gear shift shaft (2).
1
RA19170510

b. Separate the 3rd-4th gear shift fork (1) from the shift
shaft (2).
RA19170520
3. Remove the 1st-2nd gear shift fork.

shift shaft (2).
1
3
RA19170530
b. Separate the 1st-2nd gear shift fork (1) from the shift
shaft (2).
RA19170540
17
4. Remove the fork.
shift shaft (2).
1 3
RA19170550

b. Separate the fork (1) from the shift shaft (2).
RA19170560
Inspection
1. Check the shift shaft for excessive wear or damage. If damaged, replace it.
2. Check the release fork for excessive wear or damage. If damaged, replace it.
Assembly
CAUTION
 When installing the dowel pin, if there is excessive wear or damage, replace it with a new one.
17

Input Shaft
Disassembly
1. Remove the input shaft (See page 17-21).
2. Remove the 5th synchronizer outer race and 3rd-4th synchronizer outer race.
a. Remove the 5th synchronizer outer race (1) and 
3rd-4th synchronizer outer race (2) from the input
1
shaft.
RA19170580
3. Remove the input shaft rear bearing.

a. Using a special tool (1), secure the input shaft rear
bearing (2). 2
RA19170590
b. Using a hydraulic press (1), press out the input shaft

(2) and remove the input shaft rear bearing (3).
1
3
17
2
RA19170600
4. Remove the 5th drive gear and 5th synchronizer gear hub.
a. Using the snap spring calipers, remove the rear snap
ring.
RA19170610

b. Using a special tool (1), secure the 5th drive gear (2).
RA19170620
c. Using a hydraulic press (1), press out the input shaft

(2), and remove the 5th drive gear and 5th 1
synchronizer gear hub (3). 2
RA19170630
5. Remove the 5th gear needle roller bearing.

a. Remove the 5th gear needle roller bearing (1) from
the input shaft.
RA19170640
17
6. Remove the gear baffle plate and gear baffle plate spring clamp.
a. Remove the gear baffle plate (2) and gear baffle plate
spring clamp (1) from the input shaft.
1 2
RA19170650
7. Remove the 4th drive gear.

a. Using a magnetic rod, remove the balls (1) from the

input shaft.
1
RA19170660
b. Remove the 4th drive gear (1) from the input shaft.
RA19170670
8. Remove the 4th gear needle roller bearing.

a. Remove the 4th gear needle roller bearing (arrow)
from the input shaft.
RA19170681
17
9. Remove the 3rd drive gear and 3rd-4th synchronizer gear hub.
a. Remove the synchronizer ring (arrow) from the 
3rd-4th synchronizer gear hub.
RA19170680

b. Using the snap spring calipers (1), remove the snap

ring (2).
RA19170690
c. Using a special tool (1), secure the 3rd drive gear (2).
2
1
RA19170700
d. Using a hydraulic press (1), press out the input shaft

(2), and remove the 3rd drive gear and 3rd-4th 1
synchronizer gear hub (3).
2
RA19170710
17 10.Remove the 3rd gear needle roller bearing.

a. Remove the 3rd gear needle roller bearing (1) from
the input shaft.
RA19170720
11. Remove the input shaft front bearing.

a. Using a special tool (1), secure the input shaft front

bearing (2).
2
RA19170730
b. Using a hydraulic press (1), press out the input shaft

(2) and remove the input shaft front bearing (3). 1
RA19170740
Inspection
1. Check the outer surface of input shaft and needle roller bearing for excessive wear or damage. If
excessively worn or damaged, replace them.
2. Check the input shaft spline for excessive wear or damage. If excessively worn or damaged, replace it.
3. Check the synchronizer ring for damage. If damaged, replace it.
4. Check the synchronizer gear shaft bushing for damage. If damaged, replace it.
CAUTION
 If the synchronizer gear shaft bushing or synchronizer gear hub needs to be replaced, replace them as a
set.
17

Assembly
1. Install the input shaft front bearing.
a. Using a hydraulic press (1), press the input shaft (2)
into the input shaft front bearing (3). 1
RA19170750
CAUTION
 When pressing the input shaft front bearing, make sure that the pressure is applied to the bearing inner
race as the bearing may be damaged due to uneven force.
2. Install the 3rd gear needle roller bearing.

a. Apply transmission oil to the needle roller bearing (1),
and install it to the input shaft.
RA19170720
3. Install the 3rd drive gear.

17 a. Apply transmission oil to the 3rd drive gear (arrow),
and install it to the input shaft.
RA19170760
4. Install the 3rd synchronizer ring.

a. Apply transmission oil to the 3rd synchronizer ring

(arrow), and install it to the input shaft.
RA19170770
5. Install the 3rd-4th synchronizer gear hub.

a. Using a hydraulic press (3), press the 3rd-4th
synchronizer gear hub (1) into the input shaft. 3
2
1
RA19170780
CAUTION
 When pressing the synchronizer gear hub, prevent the 3rd drive gear (2) from disengaging.
b. Using the snap spring calipers (1), install the front

snap ring (2) to the input shaft.
2
17
1
RA19170690
6. Install the 4th synchronizer ring.

a. Apply transmission oil to the 4th synchronizer ring
(arrow), and install it to the input shaft.
RA19170790

7. Install the 4th gear needle roller bearing.

a. Apply transmission oil to the 4th gear needle roller
bearing (arrow), and install it to the input shaft.
RA19170800
8. Install the 4th drive gear.

a. Apply transmission oil to the 4th drive gear (1), and
install it to the input shaft.
RA19170670
9. Install the ball.

a. Apply transmission oil to the balls (arrow), and install
them to the input shaft.
1
17
RA19170660
10.Install the gear baffle plate.

a. Apply transmission oil to the gear baffle plate (1), and
install it to the input shaft.
HINT:
1
When installing the gear baffle plate, be careful to
install the locating ball of input shaft in place correctly.
RA19170810

b. Install the gear baffle plate spring clamp (1).
RA19170820
11. Install the 5th gear needle roller bearing.

a. Apply transmission oil to the 5th gear needle roller
bearing (1), and install it to the input shaft.
RA19170640
12.Install the 5th drive gear and 5th synchronizer ring.

a. Apply transmission oil to the 5th drive gear (1) and 5th
synchronizer ring (2), and install them to the input
shaft.
2
RA19170830
17
13.Install the 5th synchronizer gear hub.
a. Using a hydraulic press (3), press the 5th drive gear
3
(2) and 5th synchronizer gear hub (1) together into the
input shaft.
1 2
RA19170840
CAUTION
 When pressing the synchronizer gear hub, prevent the 5th drive gear (2) from disengaging.

b. Using the snap spring calipers, install the rear snap

ring.
RA19170610
14.Install the input shaft rear bearing.

a. Using a hydraulic press (1), press the input shaft (2)
1
into the input shaft rear bearing (3).
2
3
RA19170850
15.Install the 5th synchronizer outer race and 3rd-4th synchronizer outer race.
a. Apply transmission oil to the 5th synchronizer guide
block (1) and 3rd-4th synchronizer guide block (2),
and install them to the synchronizer gear hub. 1
17 RA19170860
b. Apply transmission oil to the 5th synchronizer outer

race (1) and 3rd-4th synchronizer outer race (2), and
1
install them to the input shaft.
RA19170580
CAUTION
 Check the gears on the input shaft for smooth rotation after installation.
 Check the fitting of input shaft gears for looseness or sticking.

Output Shaft
Disassembly
1. Remove the output shaft (See page 17-21).
2. Remove the output shaft rear bearing.
a. Using a special tool (1), secure the output shaft rear
bearing (2).
2
1
RA19170880
b. Using a hydraulic press (1), press out the output shaft

1
(2) and remove the output shaft rear bearing (3).
2 3
RA19170890
3. Remove the 4th and 5th driven gears.

a. Using the snap spring calipers (1), remove the snap
ring (2).
2
17
RA19170900
b. Using a special tool (1), secure the 4th and 5th driven
gears (2).
2
RA19170910

c. Using a hydraulic press (1), press out the output shaft

(2), and remove the 4th and 5th driven gears (3). 1
RA19170920
4. Remove the gear shaft bushing.

a. Remove the gear shaft bushing (1) from the output
shaft.
RA19170930
5. Remove the 2nd-3rd driven gear.

a. Using a special tool (1), secure the 2nd driven gear
(2).
1 2
17 RA19170940

(2), and remove the 2nd-3rd driven gear (3).
1
RA19170950
6. Remove the 2nd gear needle roller bearing.

a. Remove the 2nd gear needle roller bearing (arrow)

from the output shaft.
RA19170961
7. Remove the 1st driven gear and 1st-2nd synchronizer gear hub.
a. Remove the 1st-2nd synchronizer ring set (2).
b. Remove the 1st-2nd synchronizer outer race (1).
2
RA19170960
c. Using the snap spring calipers (1), remove the snap

ring (2).
RA19170970
17
d. Secure the special tool to the 1st driven gear.
RA19170980

e. Using a hydraulic press (1), press out the output shaft

1
(2), and remove the 1st driven gear and 1st-2nd
synchronizer (3).
RA19170990
8. Remove the 1st gear needle roller bearing.

a. Remove the 1st gear needle roller bearing (1).
RA19171000
9. Remove the output shaft front bearing.

a. Using a special tool (1), secure the output shaft front
bearing (2).
2
17 RA19171010

(2) and remove the front bearing (3). 1
RA19171020
Inspection
1. Check the surface of output shaft and needle roller bearing for excessive wear or damage. If excessively
worn or damaged, replace them.
2. Check the output shaft spline for excessive wear or damage. If excessively worn or damaged, replace it.
3. Check the synchronizer ring set for damage. If damaged, replace it.

4. Check the synchronizer gear shaft bushing for damage. If damaged, replace it.
‘
CAUTION
 If the synchronizer gear shaft bushing or synchronizer gear hub needs to be replaced, replace them as a
set.
Assembly
1. Install the output shaft front bearing.
a. Using a hydraulic press (1), press the output shaft
front bearing (3) into the output shaft (2). 1
3 RA19171030
CAUTION
 When pressing the output shaft front bearing, make sure that the pressure is applied to the bearing inner
race as the bearing may be damaged due to uneven force.
2. Install the 1st gear needle roller bearing.

a. Apply transmission oil to the 1st gear needle roller
bearing (1), and install it to the output shaft.
17
RA19171000
3. Install the 1st driven gear.

a. Apply transmission oil to the 1st driven gear (1), and
install it to the output shaft.
RA19171040

4. Install the 1st synchronizer ring set.

a. Apply transmission oil to the 1st synchronizer ring set
(arrow), and install it to the output shaft.
RA19171050
5. Install the 1st-2nd synchronizer gear hub and 1st driven gear.
a. Place the 1st-2nd synchronizer gear hub in place (1),
and then press the 1st-2nd synchronizer gear hub (1)
into the output shaft with a hydraulic press.
RA19171060
b. Using the snap spring calipers (1), install the snap ring
(2).
17 RA19170970
6. Install the synchronizer ring set.

a. Apply transmission oil to the synchronizer ring set
RA19171070
7. Install the synchronizer outer race.

a. Apply transmission oil to the synchronizer outer race

RA19171080
8. Install the 2nd gear needle roller bearing.

a. Apply transmission oil to the 2nd gear needle roller
bearing (arrow), and install it to the output shaft.
RA19171090
9. Install the 2nd driven gear.

a. Apply transmission oil to the 2nd driven gear (1), and
install it to the output shaft.
RA19171100
17
10.Install the 3rd driven gear.
a. Using a hydraulic press, press the 3rd driven gear (1)
into the output shaft.
RA19171110
11. Install the gear shaft bushing.

a. Apply transmission oil to the gear shaft bushing (1),

and install it to the output shaft.
RA19170930
12.Install the 4th and 5th driven gears.

a. Using a special tool (1), secure the 4th and 5th driven
gears (2).
1
RA19171120
b. Using a hydraulic press (1), press the 4th and 5th

1
driven gears (3) into the output shaft (2).
2
RA19171130
17
c. Using the snap spring calipers (1), install the snap ring
(2).
RA19170900
13.Install the output shaft rear bearing.

a. Using a hydraulic press (1), press the output shaft

rear bearing (3) into the output shaft (2). 1
3
RA19171140
CAUTION
 Check the gears on the output shaft for smooth rotation after installation.
 Check the fitting of input shaft gears for looseness or sticking.
17

Transmission External Accessory

Removal
1. Shift the transmission to the neutral position.
2. Remove the shift shaft locating bolt.
a. Remove the shift shaft locating bolts (1) from the
transmission case.
RA19170302

a. Remove the back-up light switch (arrow) from the
transmission case.
RA19170300
4. Remove the locating bolt of gear shift mechanism.

a. Remove the locating bolt (arrow) of gear shift
mechanism from the transmission case.
17
RA19170301
5. Remove the reverse idler gear shaft locating bolt.

a. Remove the reverse idler gear shaft locating bolt
(arrow) from the transmission case.
RA19171160

Installation
1. Install the reverse idler gear shaft locating bolt.
a. Install the reverse idler gear shaft locating bolt (arrow)
to the transmission case.
RA19171160
2. Install the locating bolt of gear shift mechanism.

HINT:
Before installation, apply thread locker to the threads.
a. Install the locating bolt (arrow) of gear shift
mechanism to the transmission case.
RA19170301
3. Install the back-up light switch.

HINT:
a. Install the back-up light switch (arrow) to the
RA19170300
4. Install the shift shaft locating bolt.

HINT:

a. Install the shift shaft locating bolts (1) to the

1
RA19170302
17

Transmission Case
Disassembly
CAUTION
 Use the same removal procedures for the differential bearing out race of transmission case and clutch
case and the oil seal.
 The oil seal cannot be reused. After removal, it must be replaced.
1. Remove the differential bearing outer race.

a. Secure the bearing outer race puller joint (1) to the
bearing outer race (2). 1
RA19171170
b. Install the puller (1) to the bearing outer race remover

(2), and pull out bearing outer race (3) with the puller.
17
RA19171180
2. Remove the drive shaft oil seal.

a. Using a flat tip screwdriver (1), pry out the drive shaft
oil seal (2).
RA19171190
3. Remove the input shaft oil seal.

a. Using a flat tip screwdriver (1), pry out the input shaft
oil seal (2).
RA19171200
4. Remove the output shaft bearing outer race.

a. Secure the bearing outer race puller joint (1) of output
shaft end to the output shaft bearing outer race (2).
17 RA19171210

b. Install the puller (1) to bearing outer race remover (2).

c. Using the puller, pull out the output shaft bearing outer
race (3).
1
RA19171220
5. Remove the oil guide.

a. Remove the oil guide (1) from the clutch case.
RA19171230
6. Remove the magnet.

17
a. Remove the magnet (1) from the clutch case.
RA19171240
7. Remove the oil deflector.

a. Remove the oil deflector (1) from the transmission

case.
RA19171250
Assembly
1. Install the drive shaft oil seal.
CAUTION
 Apply a proper amount of transmission oil to the lip when installing the oil seal.
a. Using a drive shaft oil seal installer (1), install the drive
shaft oil seal (2) to the transmission case (3).
17
3
RA19171260
2. Install the oil guide.

a. Install the oil guide (1) to the clutch case.
RA19171270

3. Install the input shaft oil seal.

a. Using a input shaft oil seal installer (1), install the input
shaft oil seal (2) to the clutch case (3).
1
2
3
RA19171280
4. Install the differential bearing outer race.

a. Install the joint (1) to the bearing outer race (2), and
install the bearing outer race (2) to the case (3) with a
rubber hammer (4).
RA19171290
17
5. Install the magnet.
a. Install the magnet (1) to the clutch case.
RA19171300
6. Install the oil deflector.

a. Install the oil deflector (1) to the transmission case.
RA19171310
17

CLUTCH
GENERAL INFORMATION 18-3 Clutch Pedal 18-9
Operation 18-4 Installation 18-9
Specifications 18-5 Clutch Master Cylinder 18-10
Tools 18-5 Removal 18-10
Installation 18-11
Clutch Release Cylinder 18-12
Removal 18-12
Clutch Switch 18-8 Bleeding Hydraulic Clutch 18-14
Removal 18-8 Clutch Unit 18-16
Installation 18-18
18

18

18 - CLUTCH
GENERAL INFORMATION
CLUTCH
Description
×6
3
4
7
6
18
8
RA19180010
1 - Flywheel 2 - Clutch Driven Disc

3 - Clutch Pressure Plate 4 - Release Bearing
5 - Release Fork 6 - Return Spring
7 - Wear Bushing 8 - Clutch Arm

18 - CLUTCH
5 6 7
4
1
2
3
RA19180020
1 - Clutch Pedal Assembly Clutch Master Cylinder 2 - Clutch Release Cylinder Assembly
Inlet Hose Assembly
3 - Pipe Assembly II 4 - Hose Assembly
5 - Pipe Assembly I 6 - Clutch Master Cylinder Assembly
7 - Clutch Switch
Operation
The hydraulic clutch system mainly consists of clutch pedal, clutch master cylinder, clutch release cylinder,
clutch hydraulic line, etc. When depressing the clutch pedal, the clutch master cylinder generates pressure,
and this pressure is transmitted to the release bearing which is fitted with the pressure plate diaphragm
spring. As the external force is applied, the release bearing presses the release finger of diaphragm spring
18 inward until it reaches the fulcrum. The operation makes pressure plate move backward, thus releasing the
clamping force from the clutch driven disc.
Clutch Master Cylinder Assembly

The clutch master cylinder consists of piston, cylinder block, push rod and hydraulic line. When depressing
the pedal, the push rod pushes the piston in the master cylinder and the fluid in the hydraulic line is drained
into the release cylinder.

18 - CLUTCH
Specifications

Clutch Pressure Plate Fixing Bolt 23 ± 2
Clutch Fork Fixing Bolt 32 ± 3
Clutch Master Cylinder Fixing Nut 25 ± 4
Clutch Release Cylinder and Oil Pipe II 18 ± 2
Fixing Bolt Between Clutch Release Cylinder and
25 ± 4
Transmission
Clutch Pedal Upper Fixing Bolt 20 ± 3
Clutch Driven Plate Specifications

Clutch Driven Disc Standard Thickness 7.3 ± 0.3
Minimum Rivet Depth 0.8
Tools
Special Tool
Clutch Pressure Plate Installer
RCH0000018
18

18 - CLUTCH
General Tools
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002
18

18 - CLUTCH
DIAGNOSIS & TESTING

HINT:
Symptoms Possible Causes See page

Engine mounting (loose) 07-58
Clutch driven disc (oily) 18-16
Clutch driven disc (worn) 18-16
Clutch chatters Clutch driven disc torsion spring
18-16
(damaged)
Clutch driven disc (glazed) 18-16
Diaphragm spring (tip is out of alignment) 18-16
Clutch release bearing (worn, dirty, or
18-16
damaged)
Clutch is noisy
Clutch driven disc torsion spring
18-16
(damaged)
Clutch pedal (free play is out of
18-9
adjustment)
Clutch slips Clutch driven disc (worn) 18-16

Diaphragm spring (damaged) 18-16
Pressure plate (distorted) 18-16
Flywheel (distorted) -
Clutch driven disc (out of true) 18-16
Clutch driven disc (runout is excessive) 18-16
Clutch driven disc (lining is broken) 18-16 18
Clutch does not disengage completely
Clutch driven disc (dirty or burned) 18-16
Clutch pedal (free play out of adjustment) 18-9

18 - CLUTCH
ON-VEHICLE SERVICE
Clutch Switch
Removal
3. Remove the clutch switch.
a. Turn the clutch switch in the direction of arrow as
shown in the illustration, and remove it.
RA19180021
b. Disconnet the clutch switch connector (arrow).
RA19180022
Inspection
Check the continuity between terminals when the clutch
switch is turned on or off.
18
+ -
Multimeter 1 2
Switch Position Continuity State
Connection
Terminal 1 and
ON (not pushed) Continuity
Terminal 2
Terminal 1 and
OFF (pushed) No continuity
Terminal 2
RA19180023
Installation

18 - CLUTCH
Clutch Pedal
Removal
3. Remove the clutch master cylinder (See page 18-10).
4. Remove the clutch switch (See page 18-8).
5. Remove the clutch pedal upper fixing bolt (arrow).
RA19180090
6. Remove the clutch pedal.
Installation
18

18 - CLUTCH
Clutch Master Cylinder

Removal
WARNING
 The brake fluid in the clutch master cylinder is harmful to your skin, be sure to wear protective gloves
before operation.
 Once the brake fluid contacts with your skin, wash it off with water immediately.
CAUTION
 Collect the brake fluid with a container while servicing.

 Make sure the fluid level in the reservoir is at "MAX" after replacing the release cylinder.
 DO NOT allow the brake fluid to spray onto the body surface, or it will damage the painted surfaces; if
any brake fluid is get onto the painted surfaces, wash it off with water immediately.

4. Remove the clutch master cylinder.
a. Disconnet the joint (arrow) from the clutch master
cylinder hydraulic pipe assembly I.
RA19180030
18
b. Remove the rubber hose clamp (arrow) from the
reservoir, and disconnect the rubber hose.
RA19180040

18 - CLUTCH
c. Remove the set lock plate connecting the clutch

master cylinder and clutch pedal, and take out the set
shaft.
RA19180060
d. Remove the fixing nuts (arrow) from the clutch master

cylinder, and remove the clutch master cylinder.
RA19180050
Installation
CAUTION
 After installation, perform the bleeding procedure for hydraulic clutch and check the brake fluid for
leakage.
18

18 - CLUTCH
Clutch Release Cylinder

Removal
WARNING
 The brake fluid in the release cylinder is harmful to your skin, be sure to wear protective gloves before
operation.
CAUTION
 Collect the brake fluid with a container while servicing.

 Make sure the fluid level in the reservoir is at "MAX" after replacing the release cylinder.
 DO NOT allow the brake fluid to spray onto the body surface, or it will damage the painted surfaces; If
any brake fluid is get onto the painted surfaces, wash it off with water immediately.
1. Raise the vehicle with a lifter.
CAUTION

 Check if the safety lock of lifter is locked when repairing the chassis parts.
2. Loosen the joint (arrow) from the clutch release cylinder

pipe assembly II.
18
RA19180070
3. Remove the fixing bolts (arrow) between clutch release

cylinder and transmission.
RA19180080
4. Remove the clutch release cylinder.

18 - CLUTCH
Installation
CAUTION
 Connect the pipe joint of pipe assembly II to the clutch release cylinder assembly first, then tighten it after
installation.
 Be sure to align the push rod of clutch release cylinder assembly with the hole in the transmission case
release fork, and tighten the bolts to the specified value.
 After installation, perform the bleeding procedure for hydraulic clutch and check the system line for
leakage.
18

18 - CLUTCH
Bleeding Hydraulic Clutch

WARNING
 The brake fluid is harmful to your skin, be sure to wear protective gloves before operation.
CAUTION
 Collect the brake fluid with a container.

 DO NOT allow the brake fluid to spray onto the body surface, or it will damage the painted surface; if any
brake fluid is get onto the painted surfaces, wash it off with water immediately.
 Only use the brake fluid recommended by Chery Automobile Co., Ltd, or the line may be subjected to a
severe corrosion.
 The brake fluid type should be DOT4.
HINT:
An assistant will be required to assist when bleeding the hydraulic clutch.
2. Confirm the level in the reservoir, and add DOT4 brake fluid as necessary. Keep the cap open.
CAUTION
 Before bleeding, make sure that there is sufficient brake fluid in the reservoir.
3. Remove the discharge port protective cap and connect a

clear plastic hose to the bleeder screw, and submerge
the end of hose into the clear container which is full of
new brake fluid.
18
RA19180140
4. Release the discharge port (arrow).
RA19180150

18 - CLUTCH
5. Depress the clutch pedal until the brake fluid is drained from the discharge port.
 Collect the brake fluid with a container.
6. Fully depress the clutch pedal and tighten the discharge port.
7. Depress the clutch pedal until there is pressure in the clutch system.
8. Depress the clutch pedal, then release the discharge port and bleed the clutch system.
9. Repeat steps from 6 to 8 for several times, until there is no air in the hydraulic clutch system any more.
CAUTION
 Never drain the brake fluid in the reservoir while bleeding the hydraulic clutch.
 During bleeding, make sure the level in the reservoir is always at "MAX".
10.Close the hydraulic discharge port, then remove the discharge hose and replace the discharge port dust
cover.
11. Check the brake fluid in the brake master cylinder, and add DOT4 brake fluid up to "MAX" as necessary,
then tighten the reservoir cap.
12.Check the clutch pedal stroke. If there is excessive clutch pedal stroke, or the condition does not improve,
the air may be still in the system. Bleed the clutch again as necessary.
13.Test the vehicle again and make sure the clutch operates normally and the depressing feel is good.
18

18 - CLUTCH
Clutch Unit
Removal
2. Remove the release fork fixing bolt (arrow).
RA19180170
3. Pull out the clutch arm in the direction of arrow.
RA19180180
4. Remove the clutch fork and release bearing (arrow).
18 RA19180160
5. Remove the wear bushing.
RA19180161

18 - CLUTCH
6. Remove the clutch pressure plate bolts (arrow), and

remove the clutch pressure plate and clutch driven disc. 1
6
3
4
5
2
RA19180190
Inspection
1. Check the clutch driven disc.
a. Visually check the clutch driven disc for dirt or glazing. Clean or replace the clutch driven disc as
necessary.
b. Use a vernier caliper to measure the thickness of clutch driven disc.
Standard thickness: 7.3 ± 0.3 mm
Minimum rivet depth: 0.8 mm
If the result is not as specified, replace the clutch
driven disc.
RA19180200
2. Check the clutch release bearing assembly.

a. Visually check the surface of release bearing for dirt, glazing or damage. Clean or replace the release
bearing assembly as necessary.
b. Check that the bearing operates smoothly by rotating
the sliding part of bearing (the side contacting with
clutch).
Replace the release bearing assembly if necessary.
18
RA19180210

18 - CLUTCH
Installation
1. Insert the special tool into the clutch driven disc, and
insert it into the flywheel.
RA19180220
2. Install the clutch pressure plate and install the clutch

1
pressure plate fixing bolts (arrow). 
6
3
4
5
2
RA19180230
3. Install the wear bushing.
RA19180240
4. Install the clutch fork and release bearing (arrow).

18
RA19180160
CAUTION
 DO NOT install the clutch fork in reverse, and secure it in place.

 Apply a proper amount of grease to the release bearing cone during installation.

18 - CLUTCH
5. Insert the clutch arm in the direction of arrow.
RA19180250
6. Install the release fork fixing bolt (arrow).

RA19180170
18

- MEMO -

DRIVE SHAFT
GENERAL INFORMATION 19-3 Inner Ball Cage 19-8
Description 19-3 Disassembly 19-8
Operation 19-4 Inspection 19-9
Specifications 19-4 Assembly 19-9
Outer Ball Cage 19-10
Disassembly 19-10
Drive Shaft Assembly 19-5
Inspection 19-11
Removal 19-5
Assembly 19-11
Installation 19-7
19

19

19 - DRIVE SHAFT
GENERAL INFORMATION
DRIVE SHAFT
Description
5
6
7
12
8 13
9
14
10
11
19
RA19190010
1 - Nut 2 - Outer Ball Cage

3 - Outer Dust Boot Clamp 4 - Outer Dust Boot
5 - Outer Dust Boot Clamp 6 - Right Drive Shaft
7 - Left Drive Shaft 8 - Inner Dust Boot Clamp
9 - Inner Dust Boot 10 - Inner Dust Boot Clamp
11 - Tripod 12 - Positioning Snap Spring
13 - Inner Ball Cage 14 - Set Ring

19 - DRIVE SHAFT
Operation
The drive shaft assembly, which is a solid shaft, transmits the torque between differential and drive wheels.
Generally, the inner end of the drive shaft is connected with the differential assembly gear by spline, and the
outer end is connected with the wheel hub by spline. The drive shaft assembly transmits the torque from the
differential to the wheels, thus rotating the wheels to run the vehicle.
Specifications

Speed Sensor Fixing Bolt 10 ± 1.5
Front Brake Hose Bracket Fixing Bolt 10 ± 1.5
Coupling Bolt Between Steering Knuckle and Shock
110 ± 10
Absorber
Drive Shaft Assembly Fixing Nut 240 ± 20
19

19 - DRIVE SHAFT
ON-VEHICLE SERVICE
Drive Shaft Assembly
Removal
HINT:
Use the same removal and installation procedures for the left and right drive shaft assemblies.
3. Remove the front wheel (See page 23-10)
4. Drain the transmission oil (See page 17-12)
 The drained transmission fluid should be collected with a recovering tool.
5. Remove the wheel speed sensor

a. Remove the fixing bolt (arrow) from the wheel speed
sensor, and remove the wheel speed sensor.
RA19190020
6. Remove the fixing nut from the drive shaft assembly.

a. Using a nut chisel and hammer, loosen the staked
part of nut.
19
RA19190030
CAUTION
 Be sure to loosen the staked part of fixing nut completely, as the threads of drive shaft assembly may be
damaged.

19 - DRIVE SHAFT
b. While applying brake, remove the drive shaft

assembly fixing nut (arrow).
RA19190040
7. Remove the drive shaft assembly.

a. Remove the front brake hose bracket fixing bolt
(arrow) from the shock absorber.
RA19190041
b. Separate the wheel speed sensor connecting wire

(arrow) from the shock absorber.
RA19190042
c. Remove the coupling nuts (arrow) between steering

knuckle and shock absorber, take out the coupling
bolts and separate the shock absorber from the
steering knuckle.
19 (Tightening torque: 110 ± 10 N·m)
RA19190050

19 - DRIVE SHAFT
d. Using an auxiliary tool, pry out the drive shaft

assembly.
RA19190070
CAUTION
 DO NOT damage the differential oil seal when prying out the drive shaft assembly.
 DO NOT use excessive force to pull the drive shaft assembly to prevent the inner ball cage from
dropping.
e. Remove the set ring.
RA19190060
Installation
CAUTION
 If the staked part of the drive shaft fixing nut is damaged, replace it with a new fixing nut.
 Adjust the wheel alignment if necessary.
19

19 - DRIVE SHAFT
Inner Ball Cage

Disassembly
HINT:
Use the same disassembly and assembly procedures for the left and right drive shaft assemblies.
CAUTION
 DO NOT put matchmarks on the inner wall of inner ball cage.

 Operate carefully to prevent the dust boot from being damaged.

2. Remove the inner ball cage dust boot clamps.
a. Using needle nose pliers, remove the inner ball cage
dust boot clamps.
RA19190080
3. Remove the inner ball cage.

a. Separate the dust boot from the inner ball cage in the
direction of arrow.
19
RA19190090
b. Remove the inner ball cage in the direction of arrow,

and place it on a clean piece of cloth.
RA19190100

19 - DRIVE SHAFT
4. Remove the tripod.

a. Using snap spring calipers, remove the positioning
snap spring from the tripod.
RA19190110
b. Put matchmarks on the tripod and drive shaft, and

remove the tripod.
Matchmark
RA19190120
5. Remove the dust boot.

a. Wrap the spline of drive shaft with tape, and remove
the dust boot.
7DSH
RA19190130
Inspection
1. Check if the spline of drive shaft is in good condition. If it is deformed or damaged, replace it.
2. Check if the dust boot is in good condition. If it is scratched or broken, replace it. 19
3. Check if the positioning snap spring of tripod is deformed. If it is deformed, replace it.
Assembly
CAUTION
 Refill the grease during installation.


19 - DRIVE SHAFT
Outer Ball Cage

Disassembly
HINT:
Use the same disassembly and assembly procedures for the left and right drive shaft assemblies.
2. Remove the outer ball cage dust boot outer clamp.
a. Using a screwdriver, pry out the striker of outer ball
cage dust boot outer clamp and remove the outer ball
cage dust boot outer clamp.
RA19190140
3. Remove the outer ball cage dust boot inner clamp.

a. Using a screwdriver, pry out the striker of outer ball
cage dust boot inner clamp and remove the outer ball
cage dust boot inner clamp.
RA19190150
4. Remove the outer ball cage.

a. Slide the outer dust boot carefully into the inner ball
cage side in the direction of arrow.
19
RA19190160
b. Put matchmarks (1) on the area with the same height

as the drive shaft assembly (2) and the edge of outer
ball cage (3) for correct installation. 1
2
RA19190170

19 - DRIVE SHAFT
c. Wrap the drive shaft assembly with a piece of cloth

and put it onto a vise. Secure the vise to prevent the 1
drive shaft assembly from shaking. Tap the outer ball
cage (1) forcibly with a hammer, and remove the outer
ball cage (1).
RA19190180
5. Remove the left drive shaft from the vise.

6. Remove the retaining ring (1).
RA19190190
7. Remove the outer ball cage dust boot.

a. Wrap the spline of drive shaft with tape, and remove
the dust boot.
7DSH
RA19190200
b. Remove the tape.
Inspection
1. Check if the spline of drive shaft is in good condition. If it is deformed or damaged, replace it.
19
2. Check if the dust boot is in good condition. If it is scratched or broken, replace it.
Assembly
CAUTION
 Refill the grease during installation.

 Install them with new clamps.

- MEMO -

DIFFERENTIAL
GENERAL INFORMATION 20-3 Differential Bearing 20-8
Specifications 20-4 Differential Planetary Gear 20-9
Tools 20-5 Removal 20-9
Installation 20-9
Differential Parts Inspection 20-10
Differential Gear Clearance Inspection 20-6

Driven Gear of Final Drive 20-7
Removal 20-7
Installation 20-7
20

20

20 - DIFFERENTIAL
GENERAL INFORMATION
DIFFERENTIAL
Description
1
2
3
5
14
6
7
8
10
11
20
12
13
RS19200010

20 - DIFFERENTIAL
1 - Differential Tapered Roller Bearing Outer Race 2 - Differential Tapered Roller Bearing
3 - Driven Gear of Final Drive 4 - Differential Case
5 - Dowel Pin 6 - Speedometer Drive Gear
7 - Differential Tapered Roller Bearing 8 - Differential Tapered Roller Bearing Outer Race
9 - Planetary Gear Washer 10 - Planetary Gear
11 - Planetary Gear Shaft 12 - Drive Shaft Gear
13 - Drive Shaft Gear Washer 14 - Bolt
The differential case contains drive shaft gears, planetary gear shaft and planetary gears. The driven gear of
final drive is linked up with the differential case by bolts. The planetary gear shaft, which is fixed on the
differential case, drives the planetary gears to rotate when the differential operates, thus driving the drive shaft
gears to turn. The drive shaft gears are connected with the drive shaft to transmit the effort to the wheels.
Operation
When driving on a bumpy road or turning, the travel distance of the outside wheels is longer than that of the
inside wheels, so the speed of the outside wheels is faster, which breaks the balance of vehicle drive train.
The planetary gear mechanism in the differential can transmit the speed difference between the outside and
inside wheels via the drive shaft when turning. It forces the planetary gears to rotate, thus allowing the inside
and outside wheels to spin at two different speeds in order to balance the speed difference and keep the
vehicle moving smoothly.
Specifications

Final Drive Driven Gear Bolt 137 ± 3
Clearance Specification
Description Acceptable Range (mm)

Clearance Between Differential Case and Planetary
0.025 - 0.150
Gear
20

20 - DIFFERENTIAL
Tools
Special Tools
Bearing Remover
RCH0000011
Punch
RCH0000015
General Tools 10
20
30
0
40
90
50
80

60
70
RCH0000023
Hydraulic Press
20
RCH0000012

20 - DIFFERENTIAL
DIAGNOSIS & TESTING

Differential Gear Clearance Inspection
Inspection Method
1. Remove the differential (See page 17-21).
2. Check the clearance of differential drive shaft gear (2)
with the dial indicator (1).
1
2 RA19200020
Gear clearance: 0.025 - 0.150 mm
CAUTION
 If the clearance is not as specified, replace and adjust the drive shaft gear washer.
 After replacing the drive shaft gear washer, measure and adjust the clearance again to ensure that it is
as specified.
20

20 - DIFFERENTIAL
ON-VEHICLE SERVICE
Driven Gear of Final Drive
Removal
2. Remove the driven gear of final drive.
a. Hold the differential in a vise.
b. Remove the final drive driven gear bolts and then take
off the final drive driven gear.
RA19200030
Installation
CAUTION
 Apply seal gum to the bolts during installation.
20

20 - DIFFERENTIAL
Differential Bearing
Removal
2. Remove the differential bearing.
a. Using a hydraulic press (1), separate the bearing (2)
from the differential.
1
2
RA19200040
Installation
1. Install the differential bearing.
a. Using a hydraulic press, press the bearing (1) into the
differential.
RA19200050
20

20 - DIFFERENTIAL
Differential Planetary Gear

Removal
2. Remove differential planetary gear.
a. Tap out the dowel pin (2) with a punch (1).
1
RA19200060
b. Remove planetary gear shaft (1), planetary gear (2)

and drive shaft gear (3).
1
3
2
RA19200070
Installation
CAUTION
 Adjust clearance until the gear clearances of both sides are the same during installation.
 The drive shaft gears and planetary gears should operate normally after tapping in the dowel pin.
20

20 - DIFFERENTIAL
Differential Parts Inspection

1. Clean all the components.
2. Check the following components for wear:
 Driven gear of final drive
 Planetary gear washer
 Drive shaft gear
 Planetary gear
 Planetary gear shaft
 Drive shaft gear washer
20

AXLE
GENERAL INFORMATION 21-3 Front Axle Hub 21-15
Tools 21-7 Front Sub Frame Welding Assembly 21-16
Removal 21-16
Installation 21-18
Rear Axle Hub 21-19
Front Steering Knuckle Assembly 21-10 Installation 21-19
Removal 21-10 Rear Shaft Assembly 21-20
Disassembly 21-12 Removal 21-20
Assembly 21-13
Installation 21-14
21

21

21 - AXLE
GENERAL INFORMATION
AXLE
Description
Front Axle
2
8
×3 3
×3
9
4
6
10
11
12 ×3
13
14 ×3 5
×3
15
16
17
18 21
19
×3
20
RA19210010

21 - AXLE
1 - Front Stabilizer Bar Assembly 2 - Front Stabilizer Bar Assembly Washer

3 - Front Stabilizer Bar Assembly Rubber Boot 4 - Front Left Control Arm Assembly
5 - Front Left Control Arm Ball Pin Assembly 6 - Front Sub Frame Welding Assembly
7 - Front Right Control Arm Assembly 8 - Front Right Control Arm Ball Pin Assembly
9 - Front Right Brake Disc 10 - Front Right Axle Hub
11 - Front Right Axle Hub Bearing 12 - Front Right Axle Hub Bearing Retainer
13 - Front Right Dust Guard 14 - Front Right Steering Knuckle Assembly
15 - Front Left Steering Knuckle Assembly 16 - Front Left Dust Guard
17 - Front Left Axle Hub Bearing Retainer 18 - Front Left Axle Hub Bearing
19 - Front Left Axle Hub 20 - Front Left Brake Disc
21

21 - AXLE
Rear Axle
1
2 3
5
6
×4
8
9
×4
10
11
12
13
RA19210020
1 - Rear Right Bearing End Cover 2 - Rear Shaft Assembly Right Locking Nut
3 - Rear Right Brake Drum 4 - Rear Right Hub Assembly
5 - Rear Right Hub Ring Gear 6 - Rear Right Hub Shaft 21
7 - Rear Shaft Assembly 8 - Rear Left Hub Shaft
9 - Rear Left Hub Ring Gear 10 - Rear Left Hub Assembly
11 - Rear Left Brake Drum 12 - Rear Shaft Assembly Left Locking Nut
13 - Rear Left Bearing End Cover
The axle (also referred as axle shaft) is connected to the integral body through the suspension, and wheels
are installed on both ends of it. The function is to transmit the force of all directions between the integral body
and the wheels.

21 - AXLE
Specifications

Front Drive Shaft Assembly Locking Nut 240 ± 20
Coupling Bolt Between Front Dust Guard and Front
10 ± 1
Coupling Bolt Between Front Wheel Speed Sensor
10 ± 1.5
and Front Steering Knuckle Assembly
Self-locking Nut Between Steering Tie Rod Assembly
35 ± 3
Ball Pin and Front Steering Knuckle Assembly
Coupling Nut Between Control Arm Assembly Ball
120 ± 10
Pin and Front Steering Knuckle Assembly
110 ± 10
110 ± 10
Coupling Nut Between Front Stabilizer Bar and Front
50 ± 5
Stabilizer Bar Connecting Rod Assembly
Coupling Bolt and Nut Between Rear Mounting
85 ± 8.5
Cushion and Rear Mounting Bracket
Coupling Nut Between Front of Front Sub Frame
120 ± 10
Coupling Bolt Between Rear of Front Sub Frame
120 ± 10
Coupling Bolt Between Steering Mechanism
100 ± 10
Coupling Bolt Between High Pressure Return Pipe
7 ± 1.5
85 ± 8.5
Coupling Bolt Between Front Stabilizer Bar and Front
50 ± 5
Rear Shaft Assembly Locking Nut 240 ± 20
Rear Brake Wheel Cylinder Pipe Fixing Plug 18 ± 2
21
Coupling Bolt Between Rear Wheel Speed Sensor
10 ± 1.5
and Rear Hub Shaft
Coupling Bolt and Nut Between Rear Shock
110 ± 10
Absorber Assembly and Rear Shaft Assembly
Coupling Nut Between Parking Brake Cable Fixing
10 ± 1.5
Bracket and Body
Coupling Bolt Between Rear Brake Assembly and
60 ± 5
Rear Hub Shaft
Coupling Bolt Between Rear Shaft Assembly and
120 ± 10
Body

21 - AXLE
Tools
Special Tool
Ball Pin Separator
RCH0000024
General Tools
20
10
30
0
40
90
50
80
60
70 RCH0000023
RCH0000005
Hydraulic Press
RCH0000012 21
Bearing Remover
RCH0000011

21 - AXLE
Engine Equalizer
RCH0000043
21

21 - AXLE
DIAGNOSIS & TESTING

HINT:

Tire (worn or improperly inflated) 23-8
Front wheel alignment (wrong) 22-40
Rear wheel alignment (wrong) 22-40
Pulls
Front hub bearing (loose or worn) 21-12
Steering gear (misaligned or damaged) 28-24
Suspension component (worn) 22-11
Wheel (imbalanced) 23-12
Front shock absorber assembly (stuck or
22-11
damaged)
Front wheel shimmy Front wheel alignment (wrong) 22-40
Control arm assembly ball pin (stuck or
22-23
damaged)
Front hub bearing (loose or worn) 21-12
Steering gear (misaligned or damaged) 28-24
Wheel (imbalanced) 23-12
Rear shock absorber assembly (stuck or
Rear wheel shimmy 22-31
damaged)
Rear hub bearing (loose or worn) 21-19
Rear wheel alignment (wrong) 22-40
21

21 - AXLE
ON-VEHICLE SERVICE
Front Steering Knuckle Assembly
Removal
WARNING

 It is not permitted to weld or modify the bearing parts of wheel suspension and the guide parts of wheel.
 When removing the chassis parts, replace the self-locking nuts and the rusted nuts for safety.
HINT:
2. Remove the front drive shaft assembly locking nut.
a. Using a nut punch and a hammer, loosen the staked
part of nut.
RA19210030
CAUTION
 Loosen the staked part of nut completely, or it will damage the threads of the drive shaft assembly.
b. Remove the front drive shaft assembly locking nut

(arrow) while applying brake securely.
21
RA19210040

21 - AXLE
3. Remove the front left brake caliper assembly (See page 25-27).
CAUTION
 Place the front brake caliper assembly to a proper position after removal, and be careful not to extend
the front brake hose excessively.
4. Remove the front left brake disc (See page 25-27).

5. Remove the front left steering knuckle assembly.
a. Remove 3 fixing bolts (arrow) between front left dust
guard and front left steering knuckle assembly, and
remove the front left dust guard.
RA19210050
b. Remove the coupling bolt (arrow) between front left

wheel speed sensor and front left steering knuckle
assembly, and disengage the front left wheel speed
sensor carefully.
RA19210060
c. Remove the self-locking nut (arrow) between left

steering tie rod assembly ball pin and front left
steering knuckle assembly.
RA19210070
21
d. Install the ball pin separator (1), and tighten the ball
pin separator bolt with a wrench (2) to separate the 1
steering tie rod ball pin from the steering knuckle
assembly.
RA19210080

21 - AXLE
e. Remove the coupling nut (arrow) between the front

left control arm assembly ball pin and front left
RA19210090
f. Remove 2 coupling bolts and nuts (arrow) between

front left shock absorber assembly and front left
RA19210100
g. Detach the left drive shaft and remove the front left steering knuckle assembly.
Disassembly
1. Remove the front steering knuckle assembly, front axle hub and front hub bearing.
a. Remove the front axle hub bearing retainer (arrow)
with snap spring pliers.
RA19210110
CAUTION
 Please note that the opening of retainer must face the opening of front wheel speed sensor when
21 installing the front axle hub bearing retainer.

21 - AXLE
b. Place the front steering knuckle assembly on the

hydraulic press, install the bearing remover and
adapter, and press out the front axle hub with a
hydraulic press.
RA19210120
c. Remove the front axle hub carefully.
RA19210130
d. Place the steering knuckle assembly on the hydraulic

press, install the bearing remover and adapter, and
press out the front axle hub bearing with a hydraulic
press.
RA19210140
e. Take out the front axle hub bearing carefully.
21
RA19210150
Inspection
1. Check the steering knuckle assembly and dust guard.
a. Check if the steering knuckle assembly is worn, cracked, deformed or damaged. Replace it as
necessary.
b. Check if the dust guard is dirty, worn, cracked, deformed or damaged. Replace it as necessary.
Assembly

21 - AXLE
Installation
CAUTION
 Always tighten the coupling bolts and nuts to the specified torque.
 Check and adjust the front wheel alignment after installation.
21

21 - AXLE
Front Axle Hub

Removal
WARNING

HINT:
2. Remove the front left drive shaft assembly locking nut (See page 21-10).
3. Remove the front left brake caliper assembly (See page 25-27).
4. Remove the front left brake disc (See page 25-27).
5. Remove the front left steering knuckle assembly (See page 21-10).
6. Remove the front left axle hub.
a. Place the front left steering knuckle assembly on the
hydraulic press, install the bearing remover and
adapter, and press out the front left axle hub with a
hydraulic press.
RA19210120
b. Remove the front axle hub carefully.
21
RA19210130
Installation
CAUTION

21 - AXLE

Removal
WARNING

 When removing the front sub frame welding assembly, an engine equalizer needs to be used to support
the engine and transmission assembly securely to prevent them from being damaged.
HINT:
3. Remove the front control arm assembly (See page 22-21).
4. Remove the front sub frame welding assembly.
a. Using an engine equalizer, support the engine and transmission assembly securely.
b. Remove the coupling nut (arrow) between front left
stabilizer bar and front left connecting rod assembly,
and detach the front left connecting rod assembly.
RA19210180
RA19030000
c. Remove the coupling bolt and nut (arrow) between

rear mounting cushion and rear mounting bracket.
21
RA19210190

21 - AXLE
d. Remove the coupling nut and washer (arrow) between

the front left part of front sub frame welding assembly
and the body.
RA19210200
e. Remove the coupling bolt (arrow) between the rear

left part of front sub frame welding assembly and the
body.
RA19210210
f. Remove the coupling bolt (arrow) between the left

side of front sub frame welding assembly and the
steering mechanism.
RA19210220
g. Remove the coupling bolt (arrow) between front sub

frame welding assembly and steering mechanism
high pressure return pipe assembly.
21
RA19210230

21 - AXLE
h. Support with a transmission carrier and carefully

remove the front sub frame welding assembly with
front stabilizer bar.
RA19210240
i. Remove the coupling bolt (arrow) between rear

mounting cushion and front sub frame welding
assembly, and remove the rear mounting cushion.
RA19210250
j. Remove the coupling bolts (arrow) between front

stabilizer bar and front sub frame welding assembly
and separate them.
RA19210260
k. Remove the front sub frame welding assembly.
Installation
CAUTION
21  Always tighten the coupling bolts and nuts to the specified torque.

21 - AXLE
Rear Axle Hub

Removal
HINT:
1. Remove the rear left wheel (See page 23-10).
2. Remove the rear left brake drum (See page 25-39).
3. Remove the rear left axle hub.
a. Using a screwdriver wrapped with tape, pry out the
rear left bearing end cover (arrow) carefully.
RA19210290
b. Remove the rear shaft assembly left locking nut

(arrow).
RA19210300
c. Slightly wiggle the rear left axle hub and pull it out.
21
RA19210310
Installation
CAUTION
 Be sure to tighten the locking nut to the specified torque.

 Make sure that the rear axle hub rotates smoothly and freely after installation.

21 - AXLE
Rear Shaft Assembly

Removal
WARNING

HINT:
2. Remove the rear wheel (See page 23-10).
3. Remove the rear brake drum (See page 25-39).
4. Remove the rear axle hub (See page 21-19).
5. Remove the rear shaft assembly.
a. Using a transmission carrier and a wooden block, support the rear shaft assembly securely.
b. Disconnect the fixing plug (arrow) from the rear left
brake wheel cylinder pipe.
RA19210320
c. Remove the coupling bolt (arrow) between rear left

wheel speed sensor and rear left hub shaft.
21
RA19210330

21 - AXLE
d. Remove the coupling bolt and nut (arrow) between

rear left shock absorber assembly and rear shaft
assembly.
RA19210340
e. Detach the rear left wheel speed sensor wire harness

(arrow) from the rear shaft assembly, remove the 1
fixing clamp (1) from the rear left brake hose
assembly and disconnect the fixing plug (2) from the 2
rear left brake pipe.
RA19210350
f. Remove the coupling nuts (arrow) between the rear

fixing bracket of left parking brake rear cable and the
rear shaft assembly.
RA19210360
g. Remove the coupling bolts (arrow) between rear left

brake assembly and rear hub shaft, take off the rear
left hub shaft and place the rear left brake assembly to
a proper position.
21
RA19210370

21 - AXLE
h. Remove the fixing clips (arrow) from the rear left

wheel front mudguard, and remove the rear left wheel
front mudguard.
RA19210380
i. Remove the coupling bolt (arrow) between the left

side of rear shaft assembly and the body.
RA19210390
j. Slowly lower the transmission carrier, and remove the

rear coil springs and cushions.
RA19210400
k. Remove the rear shaft assembly.
Installation
CAUTION
21  Always tighten the coupling bolts and nuts to the specified torque.
 Bounce the vehicle up and down several times to stabilize the rear suspension after installation.

SUSPENSION
GENERAL INFORMATION 22-3 Front Stabilizer Link Assembly 22-29
Rear Shock Absorber Assembly 22-31
Removal 22-32
Inspection 22-36
Front Shock Absorber Assembly 22-11 Disposal 22-36
On-vehicle Inspection 22-12 Rear Coil Spring 22-38
Removal 22-13 Removal 22-38
Disassembly 22-15 Inspection 22-39
Assembly 22-19
WHEEL ALIGNMENT 22-40
Installation 22-19
Description 22-40
Disposal 22-20
Front Control Arm Assembly 22-21
Removal 22-21
Inspection before Wheel Alignment 22-41
Installation 22-22
Front Wheel Camber 22-42
Front Control Arm Ball Pin Assembly 22-23
Inspection 22-42
Removal 22-23
Adjustment 22-42
Inspection 22-24
Front Wheel Toe-in 22-43
Installation 22-24
Inspection 22-43
Front Stabilizer Bar Assembly 22-25
Adjustment 22-43
Removal 22-25
Kingpin Caster & Kingpin Inclination 22-44
Inspection 22-28
Rear Wheel Camber & Rear Wheel 
Installation 22-28 Toe-in 22-44
22

22

22 - SUSPENSION
GENERAL INFORMATION
SUSPENSION
Description
Front Suspension
10
×2 3
2
×3 4
9
×2
×3
5
×2
×2
11
12
8
7
13
14 15
×3 6
16
×3
×3
17 22
×3
22
18 19
20
21
RA19220010

22 - SUSPENSION
1 - Front Right Shock Absorber Assembly 2 - Front Right Stabilizer Link Assembly
3 - Front Stabilizer Bar Assembly 4 - Front Left Shock Absorber Assembly
5 - Front Left Stabilizer Link Assembly 6 - Front Left Control Arm Ball Pin Assembly
7 - Front Left Control Arm Assembly 8 - Front Sub Frame Welding Assembly
9 - Front Right Control Arm Assembly 10 - Front Right Control Arm Ball Pin Assembly
11 - Front Right Brake Disc 12 - Front Right Axle Hub
13 - Front Right Axle Hub Bearing 14 - Front Right Axle Hub Bearing Retainer
15 - Front Right Dust Guard 16 - Front Right Steering Knuckle Assembly
17 - Front Left Steering Knuckle Assembly 18 - Front Left Dust Guard
19 - Front Left Axle Hub Bearing Retainer 20 - Front Left Axle Hub Bearing
21 - Front Left Axle Hub 22 - Front Left Brake Disc
In this model, Macpherson independent suspension is used for front suspension, which is equipped with
cylindrical coil spring, double action telescopic shock absorber, with lateral stabilizer and the height is not
adjustable. Front suspension has driving and steering functions. The upper end of suspension is connected to
the body, and the lower end is connected to the front steering knuckle. The sub frame is connected to the
body with bolts, thus improving driving stability and safety.
22

22 - SUSPENSION
Rear Suspension
1
2 3
5
6
×4
10
7 16
17
13
×4
18
19
8
14
9 20
12 21
15
11
RA19220020
22

22 - SUSPENSION
1 - Rear Right Bearing End Cover 2 - Rear Shaft Assembly Right Locking Nut
3 - Rear Right Brake Drum 4 - Rear Right Hub Assembly
5 - Rear Right Hub Ring Gear 6 - Rear Right Hub Shaft
7 - Rear Right Coil Spring Upper Cushion 8 - Rear Right Coil Spring
9 - Rear Right Coil Spring Lower Cushion 10 - Rear Right Shock Absorber Assembly
11 - Rear Shaft Assembly 12 - Rear Left Shock Absorber Assembly
13 - Rear Left Coil Spring Upper Cushion 14 - Rear Left Coil Spring
15 - Rear Left Coil Spring Lower Cushion 16 - Rear Left Hub Shaft
17 - Rear Left Hub Ring Gear 18 - Rear Left Hub Assembly
19 - Rear Left Brake Drum 20 - Rear Shaft Assembly Left Locking Nut
21 - Rear Left Bearing End Cover
In this model, the torsion beam type semi-independent suspension is used for rear suspension, which is
equipped with cylindrical coil spring, double action telescopic shock absorber, without lateral stabilizer and the
height is not adjustable. The upper end of suspension is connected to the body, and the lower end is
connected to the rear shaft assembly, thus improving driving stability and safety.
Specifications

Coupling Nut Between Front Stabilizer Link
50 ± 5
Assembly and Front Shock Absorber Assembly
Coupling Nut Between Front Stabilizer Link
50 ± 5
Assembly and Front Stabilizer Bar Assembly
Coupling Bolt Between Front Brake Hose Assembly
10 ± 1.5
and Front Shock Absorber Assembly
110 ± 10
110 ± 10
60 ± 5
Assembly and Body
Front Shock Absorber Assembly Locking Nut 60 ± 5
22
120 ± 10
Coupling Bolt Between Front Part of Front Control
Assembly
Assembly

22 - SUSPENSION

Coupling Bolt Between Front Control Arm Ball Pin
50 ± 5
50 ± 5
85 ± 8.5
Coupling Nut Between Rear Mounting Cushion and
85 ± 8.5
Coupling Nut Between Front Part of Front Sub
120 ± 10
Coupling Bolt Between Rear Part of Front Sub
120 ± 10
100 ± 10
Assembly and Steering Mechanism
Assembly and Steering Mechanism High Pressure 7 ± 1.5
Fluid Return Pipe Assembly
Coupling Bolt Between Front Stabilizer Bar
50 ± 5
Coupling Bolt Between Rear Shock Absorber
110 ± 10
Coupling Nut Between Rear Shock Absorber
110 ± 10
Coupling Nut Between Upper Part of Rear Shock
20 ± 3
Absorber Assembly and Body
Steering Tie Rod Locking Nut 47 ± 3
Steering Wheel Locking Nut 35 ± 3
22

22 - SUSPENSION
Tools
Special Tool
Spring Compressor
RCH0000021
General Tools
RCH0000005
Engine Equalizer
RCH0000026
22

22 - SUSPENSION
DIAGNOSIS & TESTING

HINT:
Front Suspension

Front tire (worn or improperly inflated) 23-8
Front wheel alignment (incorrect) 22-40
Control arm ball pin assembly (loose) 22-23
Vehicle pulls
Front hub bearing (excessively worn) 21-12
Front suspension components (excessively
22-11
worn or deformed)
Vehicle (overloaded) -
Front coil spring (weak) 22-15
Bottoming Front shock absorber assembly (worn or

22-11
damaged)
Front suspension components (excessively
22-11
worn or deformed)
Front stabilizer bar assembly (bent or
22-25
Sways/Pitches broken)
Front shock absorber assembly (worn or
22-11
damaged)
Front wheel (out of balance) 23-12
Front shock absorber assembly (worn or
22-11
damaged)
Wheel shimmy Front wheel alignment (incorrect) 22-40
Control arm ball pin assembly (loose) 22-23
Front hub bearing (excessively worn) 21-12
Steering gear (out of adjustment or
damaged)
28-24 22
Front tire (improperly inflated) 23-8
Abnormal tire wear Front shock absorber assembly (worn or

22-11
deformed)
Front suspension components (worn or
22-11
deformed)

22 - SUSPENSION
Rear Suspension

Rear tire (worn or improperly inflated) 23-8
Rear wheel alignment (incorrect) 22-40
Vehicle pulls Rear hub bearing (excessively worn) 21-19
Rear suspension components (worn or
22-31
deformed)
Vehicle (overloaded) -
Rear coil spring (weak) 22-38
Bottoming Rear shock absorber assembly (worn or

22-31
damaged)
Rear suspension components (excessively
22-31
worn or deformed)
Rear tire (worn or improperly inflated) 23-8
Rear shaft assembly (bent or broken) 21-20
Sways/pitches
Rear shock absorber assembly (worn or
22-31
deformed)
Rear tire (improperly inflated) 23-8
Abnormal tire wear Rear shock absorber assembly (worn or

22-31
deformed)
Rear suspension components (worn or
22-31
deformed)
22

22 - SUSPENSION
ON-VEHICLE SERVICE
Front Shock Absorber Assembly
3 7
RA19220021
22
1 - Front Shock Absorber Assembly Cover Cap 2 - Front Connecting Plate Assembly
3 - Front Insulator Assembly 4 - Front Spring Upper Tray with Bearing Assembly
5 - Front Buffer Block 6 - Front Dust Boot with Spring Upper Cushion
7 - Front Coil Spring 8 - Front Spring Lower Cushion
9 - Front Shock Absorber Assembly Strut

22 - SUSPENSION
1. Check the front shock absorber assembly.
a. Park the vehicle on level ground, and bounce the vehicle up and down, then check if the vehicle shakes
up and down when the body bounds. If the vehicle shakes up and down consecutively, the shock
absorber assembly may be damaged and should be replaced.
2. Check the front shock absorber assembly for leakage.
a. As the shock absorber assembly operates frequently while driving the vehicle, the shock absorber fluid
temperature rises and oil gas is formed and adheres to the dust boot. This is a normal phenomenon,
and it is not necessary to replace the shock absorber assembly.
b. The shock absorber is designed with a thin layer of oil film on the surface of piston rod. While the shock
absorber is being compressed, the oil film will be scraped off by the dust plate on the shock absorber oil
seal and a small amount of oil will remain on the upper part of oil seal. Due to high oil permeability, the
oil remaining on the upper part of oil seal spreads slowly from the upper part of shock absorber to the
lower part of shock absorber, thus forming a thin coat of oil film. When any of the following conditions
occurs: 
Oil film is between dust boot and spring seat; 
Oil traces in the circumferential direction are even.
For the above conditions, oil traces are formed through volatilization, so we can judge it as minor leaks.
This is a normal phenomenon, and it is not necessary to replace the shock absorber assembly.
c. If the following conditions occur: 
Oil traces in the circumferential direction are uneven; 
Oil traces reach the lower connecting positions.
The above conditions indicate that there may be leakage in the shock absorber assembly, and it is
necessary to replace the shock absorber assembly.
d. If it is difficult to accurately judge the shock absorber assembly for leakage from appearance, perform
road test after wiping off the oil on the surface of the malfunctioning shock absorber. Under normal road
conditions, drive the vehicle for 5 to 10 minutes and perform inspection. If there are oil traces at the
shock absorber assembly surface, it indicates oil leakage, and it is necessary to replace the shock
absorber assembly.
22

22 - SUSPENSION
Removal
WARNING

 Make sure that the safety lock of lifter has been locked when removing and installing the chassis parts.
 It is not permitted to weld or modify the suspension bearing parts and guide parts.
 When removing and installing the chassis parts, replace the self-locking nuts and rusted nuts for safety.
 Operate carefully when removing and installing the coil spring, preventing the spring from jumping out
and causing personal injury.
HINT:
2. Remove the front left shock absorber assembly.
a. Remove the coupling nut (arrow) between front left
stabilizer link assembly and front left shock absorber
assembly. 
RA19220030
b. Disengage the front left wheel speed sensor (arrow)

from the front left shock absorber assembly, and
remove the front left brake hose assembly fixing bolt
(1). 
RA19220040
c. Remove 2 coupling bolts and nuts (arrow) between

front left shock absorber assembly and front left
steering knuckle assembly.  22
RA19210100

22 - SUSPENSION
d. Remove the front left shock absorber assembly cover

cap (arrow).
RA19220050
e. Hold the end of front shock absorber assembly lever

with an inner hexagon wrench, and then remove the
fixing nut from the front left shock absorber assembly
with a fixing wrench. 
RA19220060
f. Remove the front connecting plate assembly (arrow)

from the upper part of front left shock absorber
assembly.
RA19220070
g. Remove the front left shock absorber assembly with coil spring.
22

22 - SUSPENSION
Disassembly
HINT:
1. Remove the front insulator assembly.
a. Remove the front insulator assembly (arrow) from the
upper part of front left shock absorber assembly.
RA19220080
2. Remove the locking nut from the front left shock absorber assembly.
a. Install the spring compressor (1), and tighten the end
1
lever of spring compressor with a wrench (2) to
compress the front coil spring.
1
RA19220090
WARNING
 When removing the front coil spring, compress the spring until the locking nut can be rotated. DO NOT
compress the coil spring more than necessary, avoid damaging the spring and personal injury. 22

22 - SUSPENSION
b. Hold the end of front left shock absorber assembly

lever with an inner hexagon wrench, and then remove
the locking nut (arrow) from the front left shock
absorber assembly with a fixing wrench. 
RA19220100
3. Remove the front spring upper tray with bearing assembly.

a. Remove the front spring upper tray with bearing
assembly (arrow) from the upper part of front left
shock absorber assembly.
RA19220110
22

22 - SUSPENSION
4. Remove the front dust boot with spring upper cushion.

a. Remove the front dust boot with spring upper cushion
(arrow) from the upper part of front left shock absorber
assembly.
RA19220120
5. Remove the front coil spring.

a. Remove the front left coil spring (1) with spring
compressor (arrow) from the front left shock absorber
assembly. 1
RA19220130
b. Slowly loosen the spring compressor, and carefully remove the front left coil spring.
22

22 - SUSPENSION
6. Remove the front buffer block.

a. Detach the front buffer block (arrow) from the front left
shock absorber assembly, and remove it.
RA19220140
7. Remove the front spring lower cushion.

a. Detach the front spring lower cushion (arrow) from the
positioning hole in the lower end of front left shock
absorber assembly strut and remove it.
22 RA19220150

22 - SUSPENSION
Inspection
1. Check the front shock absorber assembly.
Manual inspection:
a. Install the locking nut (1) to the upper end of front
shock absorber assembly strut, and then install the 
T-wrench (2) or equivalent. 1
2
b. Compress and extend the front shock absorber

assembly strut several times by hands in the direction
of arrow as shown in the illustration. Check that there
is no abnormal resistance or unusual sound during
operation. If there is any abnormality, replace the front
shock absorber assembly with a new one.
RA19220160
2. Check the other components of front shock absorber assembly.

a. Check the front insulator assembly, front dust boot with spring upper cushion, front buffer block and
front spring lower cushion for cracks, wear or deformation. Replace them as necessary.
b. Check the front connecting plate assembly and front spring upper tray with bearing assembly for
damage. Replace them as necessary.
c. Check the front coil spring for wear, cracks or deformation. Replace it as necessary.
Assembly
CAUTION
 Make sure to align the protrusion of front dust boot with spring upper cushion and the positioning hole of
front spring upper tray with bearing assembly during installation.
 Make sure to align the protrusion of front spring lower cushion and the positioning hole in the lower end
of front shock absorber assembly strut during installation.
Installation
CAUTION
 Check the wheel alignment after installation. Adjust the wheel alignment to standard range as necessary.
22

22 - SUSPENSION
Disposal
WARNING
 The shock absorber assembly contains nitrogen and oil which are under negative pressure. Before
handling, be sure to wear goggles and release the pressure inside the shock absorber assembly to avoid
personal injury.
1. Disposal of the front shock absorber assembly.

a. Extend the front shock absorber assembly strut fully, and clamp it in the vise at an angle.
b. Using a drill or equivalent, make a hole slowly at area
A shown in the illustration to discharge the gas in the
front shock absorber assembly.
A
RA19220170
CAUTION
 The gas discharged from the shock absorber is colorless and harmless. Be careful when drilling,
because the iron chips may fly out.
c. Handle the shock absorber assembly properly after discharging the gas.
 Recycle the disposed front shock absorber assembly according to the local environmental regulations.
22

22 - SUSPENSION
Front Control Arm Assembly

Removal
CAUTION

HINT:
2. Remove the front left control arm assembly.
control arm ball pin assembly and front left steering
knuckle. 
RA19210090
CAUTION
 If it is difficult to remove the control arm ball pin end from the steering knuckle, disengage the ball pin by
uniformly striking the end of steering knuckle slightly with a hammer or equivalent.
b. Remove the coupling bolt (arrow) between front part

of front left control arm assembly and front sub frame
welding assembly. 
22
RA19220180

22 - SUSPENSION
c. Remove the coupling bolt (arrow) between rear part of

front left control arm assembly and front sub frame
welding assembly. 
RA19220190
d. Remove the front left control arm assembly with ball pin.
Installation
CAUTION
 Make sure that the ball pin rotates smoothly and is not stuck after installation.
22

22 - SUSPENSION
Front Control Arm Ball Pin Assembly

Removal
CAUTION

HINT:
2. Remove the front left control arm ball pin assembly.
knuckle. 
RA19210090
CAUTION
b. Remove the coupling bolts and nuts (arrow) between

front left control arm ball pin assembly and front left
control arm assembly.
22
RA19220185
c. Remove the front left control arm ball pin assembly.

22 - SUSPENSION
Inspection
1. Check the control arm ball pin assembly.
a. Check the control arm ball pin assembly bushes for wear, cracks, deformation, damage or grease
leakage. Replace it as necessary.
b. Check if the control arm ball pin assembly rotates smoothly. Replace it as necessary.
Installation
CAUTION
 Make sure that the ball pin rotates smoothly and is not stuck after installation.
22

22 - SUSPENSION
Front Stabilizer Bar Assembly

Removal
CAUTION

 It is not permitted to weld or modify the suspension bearing parts.
 When lowering the front sub frame welding assembly, it needs to support the engine and transmission
assembly securely with the engine equalizer to avoid damage.

3. Remove the front stabilizer bar assembly.
a. Support the engine and transmission assembly securely with the engine equalizer.
b. Hold the lower end of front left link assembly with an
inner hexagon wrench, remove the coupling nut
(arrow) between front left stabilizer bar and front left
link assembly with a fixing wrench and disengage the
front left link assembly. Use the same removal
procedure for the right side.
RA19210180
RA19030000
c. Remove the coupling nut (arrow) between front left

knuckle. Use the same removal procedure for the
right side.
RA19210090
CAUTION 22

22 - SUSPENSION
d. Remove the coupling bolt and nut (arrow) between

rear mounting cushion and rear mounting bracket. 
RA19210190
e. Remove the coupling nut and washer (arrow) between

front left part of front sub frame welding assembly and
body. Use the same removal procedure for the right
side.
RA19210200
f. Remove the coupling bolt (arrow) between rear left

part of front sub frame welding assembly and body.
Use the same removal procedure for the right side.
RA19210210
g. Remove the coupling bolt (arrow) between rear part of

front left control arm assembly and front sub frame
welding assembly. Use the same removal procedure
for the right side.
22 RA19220190

22 - SUSPENSION
h. Remove the coupling bolt (arrow) between the left

side of front sub frame welding assembly and steering
mechanism. Use the same removal procedure for the
right side.
RA19210220
i. Remove the coupling bolt (arrow) between front sub

frame welding assembly and steering mechanism
high pressure fluid return pipe assembly. 
RA19210230
j. Support the front sub frame welding assembly with

front stabilizer bar assembly with a transmission
carrier, and lower it carefully.
RA19210240
k. Remove the coupling bolts (arrow) between front

stabilizer bar assembly and front sub frame welding
assembly, and separate them. 
RA19210260 22

22 - SUSPENSION
l. Detach the left and right fixing clamps (arrow) from the
front stabilizer bar assembly.
RA19220200
m. Detach the left and right rubber bushes (arrow) from

the front stabilizer bar assembly.
RA19220210
Inspection
1. Check the front stabilizer bar assembly.
a. Check the front stabilizer bar assembly fixing clamps for wear, cracks, deformation or damage. Replace
them as necessary.
b. Check the front stabilizer bar assembly rubber bushes for dirt, wear, cracks, deformation or damage.
Replace them as necessary.
Installation
CAUTION
22

22 - SUSPENSION
Front Stabilizer Link Assembly

Removal
CAUTION

HINT:
2. Remove the front left stabilizer link assembly.
a. Hold the lower end of front left stabilizer link assembly
with an inner hexagon wrench, and remove the
coupling nut (arrow) between front left stabilizer bar
assembly and front left stabilizer link assembly with a
fixing wrench. 
RA19210180
RA19030000
b. Hold the upper end of front left stabilizer link assembly

with an inner hexagon wrench, and remove the
coupling nut (arrow) between front left stabilizer link
assembly and front left shock absorber assembly with
a fixing wrench. 
RA19220030
c. Remove the front left stabilizer link assembly.
Inspection 22
1. Check the front stabilizer link assembly.
a. Check the front stabilizer link assembly bushes for wear, cracks, deformation, damage or grease
leakage. Replace them as necessary.
b. Check if the end of front stabilizer link assembly rotates smoothly. Replace it as necessary.

22 - SUSPENSION
Installation
CAUTION
 Always tighten the coupling nuts to the specified torque.

 Make sure that the front stabilizer link assembly rotates smoothly and is not stuck after installation.
22

22 - SUSPENSION
Rear Shock Absorber Assembly
1
7
2
8
9
6
RA19220181
1 - Rear Shock Absorber Assembly Cover Cap 2 - Rear Shock Absorber Assembly Fixing Nut
3 - Circular Shim 4 - Rear Insulator Upper Body
5 - Rear Insulator Lower Body 6 - Rear Dust Boot
7 - Set Ring 8 - Rear Buffer Block 22
9 - Rear Shock Absorber Assembly

22 - SUSPENSION
Removal
CAUTION

HINT:
1. Remove the rear left shock absorber assembly.
a. Support the rear shaft assembly with a wooden block and a transmission carrier securely to avoid
damage.
b. Remove the coupling bolt and nut (arrow) between
assembly. 
RA19210340
c. Fold back the rear left seat, remove the rear seat left
trim cover assembly, and then take out the rear left
shock absorber assembly cover cap (arrow).
RA19220220
d. Remove the coupling nut (arrow) between upper part

of rear left shock absorber assembly and body. 
22
RA19220230

22 - SUSPENSION
e. Remove the circular shim (arrow) from the upper part

of rear left shock absorber assembly.
RA19220240
f. Remove the rear insulator upper body (arrow) from

the rear left shock absorber assembly.
RA19220250
22

22 - SUSPENSION
g. Remove the rear insulator lower body (arrow) from the

rear left shock absorber assembly.
RA19220260
h. Remove the rear dust boot (arrow) from the rear left
RA19220270
22

22 - SUSPENSION
i. Remove the set ring (arrow) from the rear left shock
absorber assembly.
RA19220280
j. Remove the rear buffer block (arrow) from the rear left
RA19220290
22

22 - SUSPENSION
Inspection
1. Check the rear shock absorber assembly.
Manual inspection:
a. Install the nut (1) to the upper end of rear shock
absorber assembly strut, and then install the T-wrench 2
(2) or equivalent. 1
b. Compress and extend the rear shock absorber

assembly strut several times by hands in the direction
of arrow as shown in the illustration. Check that there
is no abnormal resistance or unusual sound during
operation. If there is any abnormality, replace the rear
shock absorber assembly with a new one.
RA19220300
2. Check the other components of rear shock absorber assembly.

a. Check the rear shock absorber assembly cover cap, rear insulator upper body, rear insulator lower
body, rear dust boot and rear buffer block for cracks, wear or deformation. Replace them as necessary.
b. Check the circular shim or set ring for damage. Replace them as necessary.
Installation
CAUTION
 Make sure to align the set ring with the groove on the upper part of rear buffer block during installation.
 Bounce the vehicle up and down several times to stabilize the rear suspension after installation.
Disposal
1. Disposal of the rear shock absorber assembly.
a. Extend the rear shock absorber assembly strut fully.
b. Using a drill, make a hole between A and B in the strut
as shown in the illustration to discharge the gas inside
the rear shock absorber assembly.
A B
22 RA19220310
CAUTION
 Be careful when drilling, because iron chips may fly out. Always perform the operations with the proper
safety equipment to avoid personal injury.
 The gas is colorless, odorless and nonpoisonous.

22 - SUSPENSION
c. After discharging the gas inside the rear shock absorber assembly, handle the rear shock absorber
assembly properly.
 Recycle the disposed rear shock absorber assembly according to the local environmental regulations.
22

22 - SUSPENSION
Rear Coil Spring

Removal
CAUTION

HINT:
1. Remove the rear left coil spring.
a. Support the rear shaft assembly with a wooden block and a transmission carrier to avoid damage.
b. Remove the coupling bolt and nut (arrow) between
assembly. 
RA19210340
c. Lower the transmission carrier slowly to the

appropriate height and take off the rear coil spring
carefully.
RA19220320
CAUTION
22  If it is difficult to remove the rear coil spring, have an assistant to press the rear shaft assembly, and the
other remove the rear coil spring.

22 - SUSPENSION
d. Detach the rear coil spring upper cushion (arrow) from

the body.
RA19220330
e. Detach the rear coil spring lower cushion (arrow) from

the left side of rear shaft assembly, and remove it.
RA19220340
Inspection
1. Check the rear coil spring assembly.
a. Check the rear coil spring for wear, cracks and permanent deformation due to excessive use. Replace
it as necessary.
b. Check the rear coil spring upper cushion and lower cushion for dirty, wear, cracks, deformation or
damage. Replace them as necessary.
Installation
CAUTION
 Always align the protrusion of rear coil spring lower cushion with the positioning hole of rear shaft
assembly during installation.
 After installation, lower the vehicle and bounce the vehicle up and down several times to stabilize the
rear suspension.
22

22 - SUSPENSION
WHEEL ALIGNMENT
Description
CAUTION
 Be sure to perform the wheel alignment procedure according to the operating instructions of four-wheel
alignment device.
 Periodic maintenance and service for four-wheel alignment device should be performed.
In general, the wheel alignment has the following 6 parameters:

1. Front wheel camber
2. Front wheel toe-in
3. Kingpin caster
4. Kingpin inclination
5. Rear wheel camber
6. Rear wheel toe-in
If the following components have been removed, installed or replaced, check and perform the wheel
alignment procedures:
 Front control arm assembly
 Front steering knuckle
 Front shock absorber assembly
 Steering gear and steering tie rod
 Drive shaft
 Front sub frame welding assembly
Specifications
Specifications (parameters standard for four-wheel alignment)
Item Specified Value

Front Wheel Camber 5′ ± 45′
Front Wheel Toe-in 9′ ± 12′
Front Wheel
Kingpin Inclination 10°48′ ± 30′
Kingpin Caster 4°26′ ± 45′
Rear Wheel Camber -1°15′ ± 20′
Rear Wheel
22 Rear Wheel Toe-in 7′ ± 20′
Sideways Sliding ≤ 3m/km

22 - SUSPENSION

HINT:

Vehicle pulls
Wheel shimmy
Abnormal tire wear Front wheel alignment (incorrect) 22-40
Inspection before Wheel Alignment

1. Vehicle is in unloaded state.
2. Use a lifter to support and raise the vehicle to the proper height.
3. Check the hub bearing for excessive clearance, and replace the hub bearing as necessary.
4. Check the suspension components, power steering tie rod and ball pin for wear, deformation or damage.
Replace the malfunctioning part as necessary.
5. Check if the shock absorber assembly operates normally.
6. Check if the tire pressure is within the specified range and adjust it to specified pressure as necessary.
Standard Inflation Pressure of Cold Tire (kPa)
Item Front Wheel Rear Wheel Spare Tire

Tire (Unloaded) 230 220 250
7. Check the rim and tire.

a. Visually check the rim and tire for scratches, wear or damage.
b. Perform the wheel dynamic balance procedures (See page 23-12).
22

22 - SUSPENSION
Front Wheel Camber

Incorrect front wheel camber will cause abnormal tire wear. Check and adjust the front wheel camber as
necessary.
In normal conditions, it is not necessary to adjust the camber after assembling the independent suspension
and the wheel steering knuckle. It can be adjusted through the coupling bolt between independent suspension
and steering knuckle if the camber is not within the tolerance due to other reasons.
Specified Value for Front Wheel Camber

Front Wheel Camber 5′ ± 45′
Inspection
1. Check (visually) the driving system components for deformation and damage before adjustment. Replace
any deformed or damaged component as necessary.
2. Install the wheel alignment device onto the front wheel, and perform the inspection procedures according
to the operating instructions for wheel alignment device.
Adjustment
1. If the front wheel camber is not within the tolerance of the
specified value, loosen the coupling bolts (1) between
front shock absorber assembly and front steering
knuckle, and move the wheel to adjust.
RA19220350
2. Tighten the coupling bolts to the specified torque after adjusting the front wheel camber. 
22

22 - SUSPENSION
Front Wheel Toe-in

Incorrect front wheel toe-in will cause wheel pull and abnormal tire wear. Check and adjust the front wheel
toe-in as necessary.
Adjust the length of steering tie rod to the specified valve if the front wheel toe-in is not within the tolerance
due to other reasons.
Specified Value for Front Wheel Toe-in

Front Wheel Toe-in 9′ ± 12′
Inspection
1. Perform the inspection with the four-wheel alignment device (perform the inspection procedures referring
to the operating instructions for four-wheel alignment device).
2. Manual inspection:
a. Park the vehicle on level ground, check if the front tire pressure is within the specified range and adjust
it to specified value as necessary.
b. Place marks on the center position in front of the front
wheels, and measure the distance A between marks
with a tape measure. B
c. Push the vehicle to rotate the wheels 180°, and
measure the distance B between marks with the tape
measure when the marks are turned to the rear of
wheels.
d. Calculation method: front wheel toe-in = A - B ≤ 1 mm
A
RA19220360
Adjustment
1. Make adjusting preparation for wheel alignment according to the requirement of tester.
2. Loosen the steering tie rod locking nut (1) and the elastic
jacket snap ring (2), and turn the tie rod to adjust the
length according to the requirement until the front wheel
toe-in reaches the specified value.
2
RA19220370
22
3. Tighten the steering tie rod locking nut and reinstall the elastic jacket snap ring. Check if the locking nut is
tightened in place and if the jacket position is correct. 

22 - SUSPENSION
CAUTION
 If the elasticity of elastic jacket snap ring is not enough, replace it.
4. After adjusting the front wheel toe-in, check the steering wheel for eccentricity. If necessary, loosen the
steering wheel locking nut and adjust the steering wheel to the horizontal position, and then tighten the
steering wheel locking nut to the specified torque. 
Kingpin Caster & Kingpin Inclination

1. The kingpin caster and kingpin inclination can only be checked by using the four-wheel alignment device.
2. The kingpin caster and kingpin inclination are assured by the design structure and cannot be adjusted. If
the measured value is not within the specified range, check if the other components that connect to the
steering knuckle are deformed or damaged. Also, check if the connected part of steering knuckle is
deformed or damaged. If it is, replace the corresponding components.

Kingpin Caster 4°26′ ± 45′
Kingpin Inclination 10°48′ ± 30′
Rear Wheel Camber & Rear Wheel Toe-in

The rear wheel camber and rear wheel toe-in are assured by the design structure and cannot be adjusted. If
the measured value is not within the specified range, check if the rear suspension components are deformed
or damaged. Replace them as necessary. If the rear shaft assembly is deformed due to a strong shock and
the rear wheel alignment parameters are changed or exceed the specified range, replace the rear shaft
assembly.

Rear Wheel Camber -1°15′ ± 20′
Rear Wheel
Rear Wheel Toe-in 7′ ± 20′
22

TIRE AND WHEEL
Precautions 23-3 Tire Replacement 23-8
Tire Identification 23-4 Wheel 23-10
Installation 23-10
Wheel Balance 23-12
Adjustment 23-12
Inspection 23-6
Tire Rotation 23-13
Description 23-13
Rotation Method 23-13
23

23

23 - TIRE AND WHEEL
GENERAL INFORMATION
TIRE AND WHEEL
Precautions
 Use the tires as same as standard specification and type, because they have excellent reliability and skid
resistance. Non-standard tire may lead to vehicle malfunction, causing accident or even serious injury and
death.
 The contact surface between rim and tire should be cleaned before installing a new tire.
 When installing the wheel bolts, firstly, pre-tighten the bolts by hand, and then tighten them to the specified
torque with a wrench.
 Do not apply grease to the wheel bolts.
 Some bad driving habits will shorten the tire life:
Rapid acceleration
Sudden braking
High-speed driving
High-speed turning
Striking curbs or other obstacles
Too high or too low tire pressure when driving vehicle
23

23 - TIRE AND WHEEL
Tire Identification
 Letter number code of tire type, size, load index and speed level are stamped on the side wall of tire as
Steel rim tire: 185/60 R15 84H
185/60 R15 84H
185/60 R15
84H
RA19230010
Aluminum rim tire: 185/60 R15 84H

185/60 R15 84H
185/60 R15
84H
RA19230020
23

23 - TIRE AND WHEEL
Specifications

Tire Type
Tire Type 185/60 R15 84H
Rim Type
Rim Type (Steel Rim) 15 × 6J
Rim Type (Aluminum Rim) 15 × 5.5J
Tire Pressure Specifications of Cold Tire
Description Pressure (kPa)

Front Tire (Unloaded) 230
Rear Tire (Unloaded) 220
Spare Tire 250
23

23 - TIRE AND WHEEL
DIAGNOSIS & TESTING

HINT:

Wear on one side of tire Wheel alignment (wrong) 22-40
Wear on both sides of tire Tire pressure (insufficient) 23-8
Tire center wear Tire pressure (excessive) 23-8
Serrated wear Wheel alignment (wrong) 22-40
Severe wear of some area of tire Brake (too hard) -
Sharp objects on road
Scratches on side wall of tire 23-8
(scratched)
Tire pressure (incorrect) 23-8
Excessive tire noise
Tire (worn) 23-8
Inspection
CAUTION
 Be sure to refer to the instruction when installing non-standard tires and rims.
 Use the tires as same as standard specification and type.
1. Check if tires are damaged or scratched as shown in the

illustration.
2. Check if rims are damaged or scratched as shown in the
illustration.
23
RA19230030

23 - TIRE AND WHEEL
3. Check if tires are worn abnormally as shown in the

illustration.
Wear on Both Sides Center Wear
Serrated Wear Wear on One Side

RA19230040
4. Check the tread wear indicators (arrow) as shown in the

illustration. When tires are worn to the indicating mark,
replace them.
RA19230050
5. Use tire pressure gauge to check if the pressures of all tires (including spare tire) are normal. Inflate tires to
specified tire pressure as necessary.
6. Check the air cock for leakage.
23

23 - TIRE AND WHEEL
ON-VEHICLE SERVICE
Tire Replacement
WARNING
 The speed level of new replaced tire must meet the specified values for safe operation; otherwise, the
tire may blow out.
1. Remove the wheel (See page 23-10).

2. Use a tire remover to remove the tires according to the instructions.
CAUTION
 Before installing the air cock, check if the air cock hole of wheel is smooth without any burrs, and apply
glycerin on the air cock rubber surface or soak the air cock in the glycerin fluid, and then using a special
tool to pull or press the locating ring of air cock with a force of 200 - 400 N, to pass it through the air cock
hole and install it into place (it is possible to use soapy water instead of glycerin).
 Apply glycerin or soapy water around the tire before assembling it.
 When there is "dark point" mark on the rim, align the dynamic balance testing mark (white dot, namely
light point) on the tire with the "dark point" mark on the rim.
 When there is no "dark point" mark on the rim, align the dynamic balance testing mark on the tire with the
air cock.
 When there is no "dark point" mark on the rim, and no dynamic balance testing mark but static balance
testing mark on the tire, align the air cock with the static balance testing mark.
3. The white dot on tire edge must be aligned with the air cock on the rim when installing the tires as shown in
the illustration.
Steel rim tire:
RA19230060
Aluminum rim tire:
23
RA19230070

23 - TIRE AND WHEEL
4. Adjust the tire pressure to the specified value.
CAUTION
 Be sure to inflate the tires as specified air pressure. The maximum air pressure cannot exceed 10% of
the rated air pressure during inflating the tire.
 Please replace the tire with standard one of same size and type.
5. Check the air cock and tire & rim contact surface for leakage.
6. Using a dynamic balancer, adjust the wheel balance (See page 23-12).
7. Install the wheel (See page 23-10).
CAUTION
 Avoid scratching the tires and rims when removing the tires.
 The tire & rim contact surface should be cleaned when installing the tires.
23

23 - TIRE AND WHEEL
Wheel
Removal
1. Remove the wheel.
a. Stop the vehicle on a level surface and apply parking brake.
b. Steel rim tire: using a screwdriver wrapped with tape,
carefully pry off the wheel trim cover.
RA19230080
c. Using a tire wrench, loosen the wheel mounting bolts.

d. Firmly support and raise the vehicle to the proper height.
e. Using a tire wrench, remove 5 wheel mounting bolts.
Steel rim tire:
RA19230090
Aluminum rim tire:
RA19230100
f. Remove the wheel.

23 Installation
1. Install the wheel.
a. Anticorrosion treatment is conducted on the contact surface between wheel and brake disc.
b. Install the wheel and pre-tighten the wheel mounting bolts by hand.
c. Using a torque wrench, tighten the wheel mounting bolts evenly to the specified torque in the order
shown in the illustration.

23 - TIRE AND WHEEL
Steel rim tire:
4 1
2
5
RA19230110
Aluminum rim tire:
1
4
2 5
RA19230120
d. Steel rim tire: align the groove of wheel trim cover with
the air cock and install the wheel trim cover in place.
RA19230130
CAUTION
 DO NOT attempt to repair wheels by striking, heating or welding.

 Replace wheel mounting bolts with the special wheel mounting bolts, rather than those with different
specifications or inferior quality.
 Be careful not to damage the coating on the wheel.
 To avoid damage to the tire or over/under tightening the mounting bolts, never use an impact wrench.
 DO NOT apply grease to the tire mounting bolts.
 To ensure the wheel mounting bolts are tightened in place, the wheel mounting bolts should be tightened
after driving 100 km at the first time.
23

23 - TIRE AND WHEEL
Wheel Balance
Adjustment
CAUTION
 The dynamic balancer must be calibrated before adjusting wheel balance.

 Remove impurities inside the tread pattern and original balance blocks to ensure the wheel balance.
1. Remove the wheel (See page 23-10).

2. Adjust tire pressure to the specified value.
3. Install the wheel to the balancer with the balance block removed. Install the balance shaft with mounting
surface of wheel facing inward, choose a suitable taper body, and firmly lock the wheels using a locking
device (align the taper body with the center hole, otherwise data may be incorrect).
4. Turn on the power source of balancer, and input parameters such as the measured distance from rim to
balancer, rim width and rim diameter.
5. Put down the wheel protector, and proceed to balance test procedure automatically (start button should be
pushed for some balancers). When the measurement is completed, the unbalanced weight for both sides
of tire will be displayed on the balancer automatically, and the wheel brakes automatically until it stops. Do
not open the protector before stopping. Failure to do this may lead to accident.
6. According to the measurement result, corresponding
balance blocks should be installed on the outside (1) and
inside (2) of rim edge as shown in the illustration.
2
RA19230140
7. Perform the test again after assembly is completed, until the balancer displays 0.
8. After dynamic balance is completed, remove the wheel.
CAUTION
 When installing balance blocks, the final assembly unbalanced degree should be less than 100 g·cm,
23 which means the balance allowance of the inside and outside rim edges should be less than 10 g and the
distance between installation position of the balance blocks and dynamic balancer testing position
should not exceed ± 30 mm.
 Only one balance block should be used on each side of each wheel, and the maximum weight for one
side should be less than 65 g.
 DO NOT tap the balance blocks forcibly when installing them in order to prevent the balance blocks from
deforming.
 DO NOT reuse the deformed balance blocks. Replace them in time.

23 - TIRE AND WHEEL
Tire Rotation
Description
Front and rear tires operate at different loads and perform different steering, driving and braking functions. For
these reasons, different wear rate is formed, causing irregular wear patterns. These effects can be reduced by
rotating the tires at regular time.
Advantages of tire rotation:
 Improving tread life
 Maintaining traction levels
 Maintaining a smooth and quiet ride
CAUTION
 Chery recommends you rotate your tires every 10000 km. However, the best suitable time for tire rotation
differs depending on driver's driving habits and road conditions.
Rotation Method
The suggested method of tire rotation is as shown in the illustration.
Steel rim tire:
RA19230150
Aluminum rim tire:
RA19230160
23

- MEMO -

GENERAL INFORMATION 24-3 C0037-01 24-38
Description 24-3 C0037-01 24-38
Operation 24-4 C0037-01 24-38
Specifications 24-9 C003A-01 24-43
Tools 24-9 C003A-01 24-43
Circuit Diagram 24-10 C003A-01 24-43
C1000-16 24-48
C1000-17 24-48
C1001-04 24-52
Diagnosis Procedure 24-13
C1020-96 24-52
Problem Repair (No DTC) 24-15
U0073-88 24-53
DTC Confirmation Procedure 24-15
Intermittent DTC Troubleshooting 24-16 ON-VEHICLE SERVICE 24-57
Ground Inspection 24-16 ABS Bleeding 24-57
ABS Control Module Assembly  ABS Control Module Assembly 24-58
Terminal List 24-17 Removal 24-58
Diagnostic Trouble Code (DTC)  Disassembly 24-59
Chart 24-18 Assembly 24-59
C0020-01 24-19 Installation 24-60
C0020-49 24-23 Front Wheel Speed Sensor 24-61
C0040-49 24-24 Removal 24-61
C0031-01 24-28 Inspection 24-62
C0031-07 24-28 Installation 24-62
C0031-29 24-28 Rear Wheel Speed Sensor 24-63
C0034-01 24-33 Removal 24-63
C0034-01 24-33 Inspection 24-64
C0034-01 24-33 Installation 24-64
24

24

24 - BRAKE CONTROL SYSTEM
GENERAL INFORMATION
Description
4
2
5
RA19240010
1 - Rear Right Wheel Speed Sensor 2 - Rear Left Wheel Speed Sensor
3 - Front Left Wheel Speed Sensor 4 - ABS Control Module Assembly
5 - Front Right Wheel Speed Sensor
The brake control system equipped on this vehicle is ABS (Anti-lock Brake System) + EBD (Electronic Brake
Force Distribution). It mainly consists of the following components:
 ABS control module assembly (hydraulic control module and electronic control module)
 Wheel speed sensors (each wheel has one sensor)
24
The primary purpose of ABS is to prevent the wheels from being locked when sudden braking. It has the
following effects:
1. Improve vehicle driving stability.
2. Improve vehicle steering ability.
3. Maintain optimal brake pressure.
4. Shorten brake distance effectively.

Operation
ABS Braking
1. If the ABS system detects that the wheels may be locked when applying brake, the brake system will enter
ABS control mode. During braking, ABS control module outputs signal from each wheel speed sensor to
each solenoid valve after analysis in order to adjust the fluid pressure in each line, to prevent the wheels
from being locked.
2. There are some operating symptoms of ABS that seem to be abnormal at first, but in fact they are normal.
The symptoms are as follows:
a. If the electronic control module is malfunctioning, the fail-safe function will be activated, the ABS
system will not be operating and the ABS warning light will come on.
b. After vehicle is power on or engine is started, short "buzz" sound can be heard, which is the ABS
self-check sound, and this is normal.
c. Noise caused by the corresponding solenoid valve movement when EBD is involved in braking can be
heard, but this is normal.
d. The brake pedal may vibrate slightly and mechanical noise can be heard during ABS operation, but this
is normal.
e. Braking distance may be longer than that of vehicles without ABS when braking on rough, sandy, or
snow-covered roads.
ABS Control Mode
MC1 MC2
NO NO EME NO
NO
NC NC NC NC
FL RR RL FR
LPA LPA
RA19240020
24

Description Definition Description Definition

MC1 Master Cylinder Outlet 1 LPA Low Pressure Accumulator
MC2 Master Cylinder Outlet 2 FL Front Left Wheel
EME Return Pump RR Rear Right Wheel
NO Normal Open (Solenoid Valve) RL Rear Left Wheel
NC Normal Close (Solenoid Valve) FR Front Right Wheel
1. General Brake Operating Condition

For vehicles equipped with ABS, if the brake pressure applied to wheels is not enough to lock the wheels,
the oil pressure generated by the master cylinder will be transmitted to the wheel cylinder through the
normal open valve, producing regular braking effect. When it is not necessary to continue braking, and if
the driver reduces the pressure to the brake pedal, the brake fluid of each wheel returns to the master
cylinder and the brake pressure decreases.
Solenoid Valve Powered Condition Solenoid Valve Condition

Normal Open Valve OFF OPEN
Normal Close Valve OFF CLOSE
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RA19240030
24

2. ABS Operating (Relief) Condition

For vehicles equipped with ABS, if brake pressure is applied excessively, the friction coefficient between
wheels and road will decrease, and the wheels will be decelerated earlier than the vehicle, which could
cause the wheels to lock first. In this case, the ABS control module transmits the command that reduces
the wheel pressure to the hydraulic control module. In other words, the normal open valve cuts off oil
passage and the oil passage of normal close valve is open, in order to reduce the wheel cylinder pressure.
At this time, the brake fluid drained from the wheel cylinder is temporarily stored in the low pressure
accumulator. Then, the brake fluid stored in the low pressure accumulator returns to the master cylinder
with the rotation of motor.

Normal Open Valve ON CLOSE
Normal Close Valve ON OPEN
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RA19240030
24

3. ABS Operating (Maintaining) Condition

When appropriate pressure is applied to the wheel cylinder, the ABS system enters maintaining pressure
state. In other words, the normal open valve cuts off oil passage and the normal close valve also cuts off
the oil passage, the wheel cylinder pressure is maintained.

Normal Open Valve ON CLOSE
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RA19240050
24

4. ABS Operating (Boost) Condition

When the ABS operates under relief pressure condition, if brake fluid is drained excessively or friction
coefficient between wheel and road surface increases, it needs to increase each wheel pressure. In this
case, the ABS control module transmits the command that increases the wheel pressure to the hydraulic
control module. In other words, the normal open valve opens oil passage and the normal close valve cuts
off oil passage, in order to increase the wheel cylinder pressure. The brake fluid stored in the low pressure
accumulator is supplied to each wheel cylinder through the master cylinder and normal open valve.

Normal Open Valve OFF OPEN
MC1 MC2
NO NO NO NO
EME
NC NC NC NC
FL RR RL FR
LPA LPA
RA19240060
The ABS system operates circularly under relief, maintaining and boost pressure conditions until vehicle is
stopped completely, so the vehicle braking and turning performance will be guaranteed.
24

Specifications

Brake Pipe Coupling Plug 18 ± 2
ABS Control Module Assembly Mounting Bracket
25 ± 4
Fixing Bolt
ABS Control Module Assembly Bottom Fixing Bolt 10 ± 1.5
ABS Control Module Assembly Side Fixing Screw 10 ± 1.5
Front Wheel Speed Sensor Fixing Bolt 10 ± 1.5
Rear Wheel Speed Sensor Fixing Bolt 10 ± 1.5
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002
24

Circuit Diagram
Brake Control System (Page 1 of 3)
IGNITION SWITCH
BATTERY
ON OR START
ENGINE INSTRUMENT
COMPARTMENT PANEL
EF06 EF05 RF21 RF01 RF05 FUSE AND
FUSE AND
40A 40A 10A 10A 5A RELAY BOX
RELAY BOX
B-010 I-005
E4 E3 21 1 5
R
RW
RG
R
8
B-021 I-047 A
B
RL
I-003
3 B-050
TO CAN
SYSTEM
RG
1 20 21 23
ABS
CONTROL
MODULE
B-007
1 2 3 4 42 41 40 39 38 37 36 35 34 33 32 31 30 29
5 6 7 8 B-021 B-010
W E4 E3 E2 E1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
W
14 13 12 11 10 9 8 7 6 5 4 3 2 1
24 1 2 3 4 5 6 7 8 9 10 11 12
B-050
13 14 15 16 17 18 19 20 21 22 23 24 W
14 15 16 17 18 19 20 21 22 23 24 25 26
25 26
87
1 2 3 4 5 6 7 8 9 10 11 12 13
85 86 86 86
87 30 87 30
30 85 85
I-005 B-007
B B EA19240010

A
RW
R
4 1
BRAKE
SWITCH
I-044 DIAGNOSTIC
RELEASED DEPRESSED INTERFACE
I-013
2 3 7
RB
BR
RB
RB
L
I-003 I-004
33 35
RB
B-050 12 B-053 I-003

5 B-050
BR
BrW
23 25 B16
ECM BCM
L
B-001 I-006
16 18
ABS
CONTROL
MODULE
B-007
4
16 15 14 13 12 11 10 9
3 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
2 B-001
I-013 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 B
B 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
I-044
Lg
42 41 40 39 38 37 36 35 34 33 32 31 30 29 42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-050 28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-053
14 13 12 11 10 9 8 7 6 5 4 3 2 1
W L
14 13 12 11 10 9 8 7 6 5 4 3 2 1
24
14 15 16 17 18 19 20 21 22 23 24 25 26
B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
I-006 B-007
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 1 2 3 4 5 6 7 8 9 10 11 12 13 B
L
EA19240020

ABS
CONTROL
MODULE
B-007
9 8 5 6 2 3 12 11 26
BBr
WY
LW
YB
LY
VW
P
RB
B
B-006
2 1 2 1 2 1 2 1
FRONT LEFT FRONT RIGHT REAR LEFT REAR RIGHT

WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED
SENSOR SENSOR SENSOR SENSOR
B-015 B-005 B-033 B-046
14 15 16 17 18 19 20 21 22 23 24 25 26 1 2 1 2 1 2 1 2
1 2 3 4 5 6 7 8 9 10 11 12 13
B-015 B-005 B-046 B-033
B B W W
B-007
24 B
EA19240030

DIAGNOSIS & TESTING

HINT:

ABS fuse 49-27
When turning the ignition switch to ON, Wire harness or connector -

ABS warning light does not come on ABS control module assembly 24-58
ABS fuse 49-27
Wire harness or connector -
ABS warning light remains on
ABS control module assembly 24-58
Wheel speed sensor (damaged, improper
24-61
installed, foreign matter attached)
Hub ring gear (damaged, improper
-
installed, foreign matter attached)
ABS operation is abnormal
Brake line (blocked or leaked) -
ABS fuse 49-27
Communication with diagnostic tester Wire harness or connector -

cannot be performed X-431 3G diagnostic tester -
Diagnosis Procedure
HINT:
Use the following procedures to troubleshoot the Anti-lock Brake System (ABS).
1 Vehicle brought to workshop
NEXT
24
2 Check battery voltage
Standard voltage: 11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step.

NEXT
3 Customer problem analysis
NEXT
4 Check and clear DTCs
NEXT
Confirm and duplicate malfunction: accelerate vehicle to 15 km/h or more, simulate

5 malfunction conditions and read DTCs again
DTC
occurs For current DTC, go to step 7
No
DTC For history DTC, go to step 8
6 Problem repair (no DTC), then go to step 9
NEXT
7 Troubleshoot according to Diagnostic Trouble Code (DTC) chart, then go to step 9
NEXT
8 Troubleshoot according to Problem Symptoms Table, then go to step 9
NEXT
9 Confirm troubleshooting, perform test
NEXT
24
10 End

Problem Repair (No DTC)

If there is a problem in the brake system, but no DTC is stored in the ABS control module assembly, this
problem is called a problem without DTC. A problem without DTC is caused by basic brake system
malfunction. For example:
1. Brake fluid leakage (it may result in weak braking, brake pedal overtravel, or even ineffective braking).
2. Using inferior brake fluid (it can result in corrosion of brake line and ABS hydraulic regulating module
internal elements, or even ineffective braking).
3. Air in the brake line (it may result in weak braking, or even ineffective braking).
4. Brake line blockage (it may result in hard braking, or even ineffective braking).
5. Excessive wear of brake disc (it may result in weak braking, brake pedal overtravel).
6. Brake booster malfunction (it may result in weak or hard braking, brake pedal overtravel, or even
ineffective braking).
7. Wrong brake line connection (it may result in braking performance decreasing, drift, long braking distance
etc.).
HINT:
ABS interrupted due to no power supply or power supply abnormality will cause the ABS warning light
remains on without storing DTC.
Troubleshooting method: check the corresponding component according to the malfunction, repair or replace
it as necessary.

Confirm that the battery voltage is normal before performing the following procedures.
 Using the X-431 3G diagnostic tester to record and clear the DTCs stored in the ABS control module
assembly.
 Turn the ignition switch to LOCK and wait for a few seconds.
 Start the engine, drive the vehicle at 20 km/h or more and perform the road test with the X-431 3G
diagnostic tester connected to the Data Link Connector (DLC).
 Using the X-431 3G diagnostic tester to select "Read Code".
1.
 If no DTC is detected, the malfunction indicated by the DTC is intermittent. Refer to the intermittent DTC
troubleshooting procedure.
24


If the malfunction is intermittent, perform the followings:
circuit.
 Inspect the wheel speed sensor and mounting areas for damage, foreign matter, etc. that will cause
incorrect signals.
 Check and clean all the wire harness connectors and grounds related to the current DTC.
 Remove the ABS control module assembly from the malfunctioning vehicle and install it to a new vehicle
and perform a test. If the DTC cannot be cleared, the ABS control module assembly is malfunctioning. If
the DTC can be cleared, reinstall the ABS control module assembly to the original vehicle.
 If multiple trouble codes were set, refer to the circuit diagrams to look for any common ground circuit or
 Refer to the Technical Bulletin that is applied to the malfunction.
Ground Inspection
moisture, dirt and other corrosive environments. Corrosion (rust) can increase load resistance. This situation
may change the way in which a circuit works.
Circuits are very sensitive to proper grounding. A loose or corroded ground can affect the control circuit.
Perform the following operations when checking the ground points:
1. Remove the ground bolt or nut.
4. Reinstall the ground bolt or nut securely.
6. If several wire harnesses are crimped into one ground eyelet terminal, check if the wire harnesses are
installed correctly. Make sure all the wire harnesses are clean, securely fastened and providing a good
ground path.
24

ABS Control Module Assembly Terminal List

Terminal No. Terminal Definition Terminal No. Terminal Definition
1 Battery Power (Pump Motor) 14 -
Rear Left Wheel Speed Sensor
2 15 -
Ground
Rear Left Wheel Speed Sensor
3 16 Brake Light Switch Signal
Signal
4 - 17 -
Front Right Wheel Speed Sensor
5 18 Diagnosis K Wire
Signal
Front Right Wheel Speed Sensor
6 19 -
Ground
7 - 20 Power Supply (Ignition Switch)
Front Left Wheel Speed Sensor
8 21 CAN L
Ground
Front Left Wheel Speed Sensor
9 22 -
Signal
10 - 23 CAN H
Rear Right Wheel Speed Sensor
11 24 -
Signal
Rear Right Wheel Speed Sensor
12 25 -
Ground
13 - 26 Ground
24


C0020-01 ABS Pump Motor Control General Electrical Failure
C0020-49 ABS Pump Motor Control Internal Electronic Failure
C0022-00 Brake Booster Solenoid No Subtype Information
C0040-49 Brake Lamp Switch Control Circuit Internal Electronic Failure
C0031-01 Left Front Wheel Speed Sensor General Electrical Failure
C0031-07 Left Front Wheel Speed Sensor Mechanical Failure
C0031-29 Left Front Wheel Speed Sensor Signal Invalid
C0034-01 Right Front Wheel Speed Sensor General Electrical Failure
C0034-01 Right Front Wheel Speed Sensor Mechanical Failure
C0034-01 Right Front Wheel Speed Sensor Signal Invalid
C0037-01 Left Rear Wheel Speed Sensor General Electrical Failure
C0037-01 Left Rear Wheel Speed Sensor Mechanical Failure
C0037-01 Left Rear Wheel Speed Sensor Signal Invalid
C003A-01 Right Rear Wheel Speed Sensor General Electrical Failure
C003A-01 Right Rear Wheel Speed Sensor Mechanical Failure
C003A-01 Right Rear Wheel Speed Sensor Signal Invalid
C1000-16 ECU Voltage Supply Circuit Voltage Below Threshold
C1000-17 ECU Voltage Supply Circuit Voltage Above Threshold
C1001-04 ECU System Internal Failures
C1020-96 ABS Operation Component Internal Failures
U0073-88 Control Module Communication Bus Off
U0100-87 Lost Communication with ECM Missing Message
U0100-87 Lost Communication with Body Control Module Missing Message
24

DTC C0020-01 ABS Pump Motor Control General Electrical Failure
BATTERY
ENGINE
COMPARTMENT
EF06
FUSE AND
40A RELAY BOX
B-010
E4
RL
ABS
CONTROL
MODULE
B-007
26
B
B-006
14 15 16 17 18 19 20 21 22 23 24 25 26
E4 E3 E2 E1
1 2 3 4 5 6 7 8 9 10 11 12 13
B-010
24
B-007
W
B
EA19240040

DTC Detection
Condition
When vehicle speed  Pump motor has poor ground
exceeds 20 km/h and connection.
ABS control module  System overheat protection.
ABS Pump Motor
assembly detects that
C0020-01 Control General  Power supply for pump motor is
the electrical motor
Electrical Failure abnormal.
cannot work properly,
this DTC will be  Pump motor relay is malfunctioning.
recorded.  Pump motor is malfunctioning.
CAUTION
 When performing electrical equipment diagnosis and test, always refer to the circuit diagram for related
circuit and component information.
Diagnosis Procedure
1 Check for DTCs
a. Leave the vehicle for 5 minutes, clear and read the ABS control module assembly DTC again with the
X-431 3G diagnostic tester.
b. Refer to DTC Confirmation Procedure.
c. Check if the same DTC is output.
NO Problem indicated by DTC is intermittent

(system overheat protection)
YES
2 Check ABS fuse

b. Disconnect the negative battery cable.
c. Remove the ABS fuse EF-06 (40 A) from the engine compartment fuse and relay box.
d. Check if the fuse is blown.
NG Replace ABS fuse
OK
24 3 Check wire harness and connector
Use the circuit diagram as a guide to perform the following procedures:

 Disconnect the negative battery cable.
 Disconnect the ABS control module assembly connector B-007 and engine compartment fuse and relay
box connector B-010.

 Check that the related connector pins are in good condition.
NG Repair or replace body wire harness and

connector
OK
4 Check wire harness and connector (ABS control module assembly - battery)
a. Connect the negative battery terminal cable.

b. Turn the ignition switch to LOCK.
c. Disconnect the ABS control module assembly connector
B-007. V
+ -
d. Using a digital multimeter, measure the supply voltage
between ABS control module assembly and body ground
to check if the power supply circuit is normal according to
the table below.
Standard Voltage 14 15 16 17 18 19 20 21 22 23 24 25 26
Multimeter Specified 1 2 3 4 5 6 7 8 9 10 11 12 13
Condition
B-007
B-007-1 - Body
Always 9 to 16 V
ground
NG Repair or replace body wire harness and RA19240160

connector
OK
5 Check wire harness and connector (ABS control module assembly - body ground)

B-007.
+ -
d. Using a digital multimeter, check for continuity between
ABS control module assembly and body ground to check
if the system ground circuit is normal according to the
table below.
Standard Condition 14 15 16 17 18 19 20 21 22 23 24 25 26
Condition
Connection Condition 24
B-007
B-007-26 - Body
Always Continuity
ground

connector

OK
6 Reconfirm DTCs
a. Use the X-431 3G diagnostic tester to clear the DTC.

b. Start the engine.
c. Drive the vehicle at 20 km/h or more, read the ABS control module assembly DTC again with the X-431 3G
diagnostic tester.
d. Check if the same DTC is output.
NO System operates normally
YES
Replace ABS control module assembly
24

DTC C0020-49 ABS Pump Motor Control Internal Electronic Failure
DTC Detection
Condition
This DTC occurs when
the following condition
ABS Pump Motor is met:  ABS control module assembly
C0020-49 Control Internal
1. ABS pump motor malfunction
Electronic Failure
has an internal
malfunction.
CAUTION
Diagnosis Procedure
1 Reconfirm DTCs

diagnostic tester.
YES
24

Brake Lamp Switch Control Circuit Internal Electronic

DTC C0040-49
Failure
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT ENGINE
PANEL COMPARTMENT
RF01 RF21 FUSE AND EF05 FUSE AND
10A 10A RELAY BOX 40A RELAY BOX
I-005 B-010
1 21 E3
RW
R
8
I-047 B-021
4 1
BRAKE
SWITCH
I-044
RELEASED DEPRESSED
2 3
RB
BR
RB
RB
I-003
33 35
B-050 I-004
12 B-053
BR
BrW
23 25
W
ECM
B-001
16
ABS
CONTROL
MODULE
B-007
1 2 3 4 5 6 7 8 9 10 11 12
14 15 16 17 18 19 20 21 22 23 24 25 26
13 14 15 16 17 18 19 20 21 22 23 24 E4 E3 E2 E1
1 2 3 4 5 6 7 8 9 10 11 12 13 25 26
87
85 86 86 86 B-010
87 30 87 30
B-007 30 85 85 W
B
I-005
B
42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
1 2 3 4
14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 5 6 7 8
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B-050 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
W
24 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 B-021
W
4
42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-001 3
28 27 26 25 24 23 22 21 20 19 18 17 16 15 1
B
14 13 12 11 10 9 8 7 6 5 4 3 2 1 2
B-053 I-044
L Lg
EA19240050

DTC Detection
Condition
This DTC occurs when  Brake switch malfunction.
the following condition
Brake Lamp Switch is met:  Wire harness or connector
C0040-49 Control Circuit Internal malfunction.
Electronic Failure 1. Brake light switch
control circuit  ABS control module assembly
malfunction. malfunction.
CAUTION
Diagnosis Procedure
1 Check brake switch

c. Remove the brake switch from the vehicle.
d. Check the brake switch for proper operation (See page 25-24).
NO Replace brake switch
YES
2 Check wire harness and connector

 Disconnect the negative battery cable.
 Disconnect the ABS control module assembly connector B-007 and brake switch connector I-044.
 Disconnect the instrument panel wire harness connector I-004 and body wire harness connector B-053.
 Check that the related connector pins are in good condition.
NG Repair or replace body/instrument panel

wire harness and connector
OK
24

3 Check brake switch control circuit (ABS control module assembly - brake switch)
a. Disconnect the negative battery terminal cable.

B-007 and brake switch connector I-044.
+ -
terminals of ABS control module assembly and brake
switch to check for an open circuit according to the 14 15 16 17 18 19 20 21 22 23 24 25 26
value(s) in the table below.
1 2 3 4 5 6 7 8 9 10 11 12 13
Standard Condition
B-007
Condition
4
B-007-6 - I-044-3 Always Continuity 3 1
I-044 RA19240180
e. Disconnect the instrument panel wire harness connector

I-004 and body wire harness connector B-053.
f. Using a digital multimeter, check for continuity between
terminals of ABS control module assembly connector
B-007 and body wire harness connector B-053 to + -
check for an open circuit according to the value(s) in

the table below.
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard Condition
1 2 3 4 5 6 7 8 9 10 11 12 13
Condition
Connection Condition B-007
B-007-6 -
Always Continuity
B-053-12 42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-053
RA19240190
24

g. Using a digital multimeter, check for continuity between

terminals of brake switch connector I-044 and instrument
panel wire harness connector I-004 to check for an open
circuit according to the value(s) in the table below.
Standard Condition + -
Condition 29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
I-004-12 - I-044-3 Always Continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-004
wire harness and connector 4
3 1
I-044
RA19240200
OK
4 Reconfirm DTCs

diagnostic tester.
YES
24

Left Front Wheel Speed Sensor General Electrical

DTC C0031-01
Failure
DTC C0031-07 Left Front Wheel Speed Sensor Mechanical Failure
DTC C0031-29 Left Front Wheel Speed Sensor Signal Invalid
ABS
CONTROL
MODULE
B-007
9 8
WY
YB
2 1
FRONT LEFT
WHEEL SPEED
SENSOR
B-015
14 15 16 17 18 19 20 21 22 23 24 25 26 1 2
24 1 2 3 4 5 6 7 8 9 10 11 12 13
B-015
B-007 B
B
EA19240060

DTC Detection
Condition
 Wheel speed sensor signal wire is
connecting with power wire in reverse.
These DTCs occur  Wheel speed sensor signal wire is
Left Front Wheel when any of the short to ground.
C0031-01 Speed Sensor General following conditions is
met:  Wheel speed sensor line is open, and
Electrical Failure
connector is loose or broken.
1. Wheel speed
sensor line is open.  Wheel speed sensor signal wire is
short to power supply.
2. Wheel speed
sensor line is short.  Wheel speed sensor power supply
wire is short to ground.
3. Wheel speed
sensor signal is  Sensor head or plug pin is damaged.
Left Front Wheel abnormal.  Wheel speed sensor is interfered by
C0031-07 Speed Sensor magnetic field outside. (wheel or axle
4. No signal is output
Mechanical Failure is not demagnetized).
when open circuit
cannot be detected  Wheel speed sensor body is
and the vehicle malfunctioning.
speed is more than  Ring gear is not installed, has teeth
15 km/h. missing, dirty, demagnetized or off
5. When vehicle center.
speed exceeds 20  Clearance between sensor and ring
Left Front Wheel km/h, the sensor gear is excessive.
C0031-29 Speed Sensor Signal signal exceeds the  Number of ring gear teeth is wrong.
Invalid tolerance of
specified value.  Tire size is not as specified.
 ABS control module assembly is
damaged.
CAUTION
Diagnosis Procedure
1 Check front left wheel speed sensor wire harness and connector

c. Disconnect the front left wheel speed sensor connector B-015.
d. Check if the wire harnesses are worn, pierced, pinched or partially broken.
e. Look for broken, bent, protruded or corroded terminals. 24
f. Check that the related connector pins are in good condition.
NG Repair or replace front left wheel speed

sensor wire harness and connector

OK
2 Check installation of front left wheel speed sensor

c. Check the front left wheel speed sensor fixing bolt for looseness.
d. Check if excessive clearance exists between the installation position of front left wheel speed sensor and
front steering knuckle.
e. Check the installation position of front left wheel speed sensor for dirt.
NG Tighten fixing bolt properly, clean and

replace front left wheel speed sensor
OK
3 Check front left wheel speed sensor
a. Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC).
b. Drive the vehicle straight ahead, and read the datastream of front left wheel speed sensor with the X-431
3G diagnostic tester.
c. Check if the data change of front left wheel speed sensor is the same with that of other wheel speed
sensors.
NG Replace front left wheel speed sensor
OK
4 Replace front left hub ring gear
a. Remove the front left hub assembly.

b. Check for foreign matter, missing teeth or damage on the front left hub ring gear.
c. Check if the front left hub assembly is securely installed.
NG Replace front left hub ring gear
OK
24

Check wire harness and connector (front left wheel speed sensor - ABS control module
5 assembly)

B-007.
+ -
d. Disconnect the front left wheel speed sensor connector
B-015.
e. Using a digital multimeter, check for continuity between
the terminals of connector B-007 and connector B-015 to 14 15 16 17 18 19 20 21 22 23 24 25 26
check if there is an open in the wire harness and

1 2 3 4 5 6 7 8 9 10 11 12 13
connector according to the table below.
Standard Condition B-007
Condition
B-007-8 - B-015-1 Always Continuity B-015

B-007-9 - B-015-2 Always Continuity RA19240210
B-007-9 - B-015-1 Always No continuity


connector B-007 and body ground to check if the front left
wheel speed sensor is short to ground according to the
table below.
Condition
B-007-8 - Body
ground 14 15 16 17 18 19 20 21 22 23 24 25 26
B-007-9 - Body 1 2 3 4 5 6 7 8 9 10 11 12 13
ground
B-007
RA19240220
24

g. Connect the negative battery cable.

h. Turn the ignition switch to ON.
i. Using a digital multimeter, measure the voltage between
connector B-007 and body ground to check if the front left V
wheel speed sensor is short to power supply according to + -
the table below.

Standard Condition
Condition
Connection Condition 1 2 3 4 5 6 7 8 9 10 11 12 13
B-007-8 - Body
Ignition switch ON Approximately 0 V
ground B-007
B-007-9 - Body
ground
NG Repair or replace wire harness and RA19240230
connector between front left wheel speed

sensor and ABS control module assembly
OK
6 Reconfirm DTCs

diagnostic tester.
YES
24

Right Front Wheel Speed Sensor General Electrical

DTC C0034-01
Failure
DTC C0034-01 Right Front Wheel Speed Sensor Mechanical Failure
DTC C0034-01 Right Front Wheel Speed Sensor Mechanical Failure
ABS
CONTROL
MODULE
B-007
5 LW 6
LY
2 1
FRONT RIGHT
WHEEL SPEED
SENSOR
B-005
14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 24
B-005
B-007 B
B
EA19240070

DTC Detection
Condition
Right Front Wheel when any of the short to ground.
C0034-01 Speed Sensor General following conditions is  Wheel speed sensor line is open, and
Electrical Failure met: connector is loose or broken.
1. Wheel speed sensor  Wheel speed sensor signal wire is
line is open. short to power supply.
2. Wheel speed sensor  Wheel speed sensor power supply
line is short. wire is short to ground.
3. Wheel speed sensor  Sensor head or plug pin is damaged.
Right Front Wheel signal is abnormal.  Wheel speed sensor is interfered by
C0034-01 Speed Sensor 4. No signal is output magnetic field outside. (wheel or axle
Mechanical Failure when open circuit is not demagnetized).
speed is more than
15 km/h.  Ring gear is not installed, has teeth
missing, dirty, demagnetized or off
5. When vehicle speed center.
exceeds 20 km/h,
the sensor signal  Clearance between sensor and ring
Right Front Wheel gear is excessive.
C0034-01 Speed Sensor Signal exceeds the
tolerance of the  Number of ring gear teeth is wrong.
Invalid
damaged.
CAUTION
Diagnosis Procedure
1 Check front right wheel speed sensor wire harness and connector

c. Disconnect the front right wheel speed sensor connector B-005.
24 e. Look for broken, bent, protruded or corroded terminals.
NG Repair or replace front right wheel speed

OK

2 Check installation of front right wheel speed sensor

c. Check the front right wheel speed sensor fixing bolt for looseness.
d. Check if excessive clearance exists between the installation position of front right wheel speed sensor and
front steering knuckle.
e. Check the installation position of front right wheel speed sensor for dirt.

replace front right wheel speed sensor
OK
3 Check front right wheel speed sensor
b. Drive the vehicle straight ahead, and read the datastream of front right wheel speed sensor with the X-431
c. Check if the data change of front right wheel speed sensor is the same with that of other wheel speed
sensors.
NG Replace front right wheel speed sensor
OK
4 Check front right hub ring gear
a. Remove the front right hub assembly.

b. Check for foreign matter, missing teeth or damage on the front right hub ring gear.
c. Check if the front right hub assembly is securely installed.
NG Replace front right hub ring gear
OK
Check wire harness and connector (front right wheel speed sensor - ABS control module
5 assembly)
24


B-007.
+ -
d. Disconnect the front right wheel speed sensor connector
B-005.
connector according to the table below. 1 2 3 4 5 6 7 8 9 10 11 12 13
Standard Condition
B-007
Condition
B-007-6 - B-005-1 Always Continuity

B-005


connector B-007 and body ground to check if the front
right wheel speed sensor is short to ground according to
the table below.
Condition
B-007-5 - Body 14 15 16 17 18 19 20 21 22 23 24 25 26
ground
1 2 3 4 5 6 7 8 9 10 11 12 13
B-007-6 - Body
ground B-007
RA19240250

24


connector B-007 and body ground to check if the front
right wheel speed sensor is short to power supply
according to the table below.
V
Standard Voltage + -
Condition
B-007-5 - Body 14 15 16 17 18 19 20 21 22 23 24 25 26
ground
1 2 3 4 5 6 7 8 9 10 11 12 13
B-007-6 - Body
ground B-007
NG Repair or replace wire harness and

connector between front right wheel
speed sensor and ABS control module RA19240260
assembly
OK
6 Reconfirm DTCs

diagnostic tester.
YES
24

DTC C0037-01 Left Rear Wheel Speed Sensor General Electrical Failure
DTC C0037-01 Left Rear Wheel Speed Sensor Mechanical Failure
DTC C0037-01 Left Rear Wheel Speed Sensor Signal Invalid
ABS
CONTROL
MODULE
B-007
2 3
VW
RB
2 1
REAR LEFT
WHEEL SPEED
SENSOR
B-033
14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
24 1 2 3 4 5 6 7 8 9 10 11 12 13
B-007
B B-033
W
EA19240080

DTC Detection
Condition
Left Rear Wheel Speed when any of the short to ground.
C0037-01 Sensor General following conditions is  Wheel speed sensor line is open, and
Left Rear Wheel Speed signal is abnormal.  Wheel speed sensor is interfered by
C0037-01 Sensor Mechanical 4. No signal is output magnetic field outside. (wheel or axle
Failure when open circuit is not demagnetized).
speed is more than
exceeds 20 km/h,
Left Rear Wheel Speed exceeds the gear is excessive.
C0037-01
Sensor Signal Invalid tolerance of the  Number of ring gear teeth is wrong.
damaged.
CAUTION
Diagnosis Procedure
1 Check rear left wheel speed sensor wire harness and connector

c. Disconnect the rear left wheel speed sensor connector B-014.
e. Look for broken, bent, protruded or corroded terminals. 24
NG Repair or replace rear left wheel speed

OK

2 Check installation of rear left wheel speed sensor

c. Check the rear left wheel speed sensor fixing bolt for looseness.
d. Check if excessive clearance exists between the installation position of rear left wheel speed sensor and
rear axle hub ring gear.
e. Check the installation position of rear left wheel speed sensor for dirt.

replace rear left wheel speed sensor
OK
3 Check rear left wheel speed sensor
b. Drive the vehicle straight ahead, and read the datastream of rear left wheel speed sensor with the X-431
c. Check if the data change of rear left wheel speed sensor is the same with that of other wheel speed
sensors.
NG Replace rear left wheel speed sensor
OK
4 Check rear left hub ring gear
a. Remove the rear left hub assembly.

b. Check for foreign matter, missing teeth or damage on the rear left hub ring gear.
c. Check if the rear left hub assembly is securely installed.
NG Replace rear left hub ring gear
OK
24

Check wire harness and connector (rear left wheel speed sensor - ABS control module
5 assembly)

B-007.
+ -
d. Disconnect the rear left wheel speed sensor connector 
B-033.

1 2 3 4 5 6 7 8 9 10 11 12 13
connector according to the table below.
Condition
B-007-3 - B-033-1 Always Continuity B-033


connector B-007 and body ground to check if the rear left
wheel speed sensor is short to ground according to the
table below.
Condition
B-007-2 - Body 14 15 16 17 18 19 20 21 22 23 24 25 26
ground
1 2 3 4 5 6 7 8 9 10 11 12 13
B-007-3 - Body
ground B-007
RA19240280
24


connector B-007 and body ground to check if the rear left V
wheel speed sensor is short to power supply according to + -
the table below.

Standard Voltage
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13
B-007-2 - Body
ground B-007
B-007-3 - Body
ground
connector between rear left wheel speed

OK
6 Reconfirm DTCs

diagnostic tester.
YES
24

Right Rear Wheel Speed Sensor General Electrical

DTC C003A-01
Failure
DTC C003A-01 Right Rear Wheel Speed Sensor Mechanical Failure
DTC C003A-01 Right Rear Wheel Speed Sensor Signal Invalid
ABS
CONTROL
MODULE
B-007
12 11
BBr
2 1
REAR RIGHT
WHEEL SPEED
SENSOR
B-046
14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13
24
B-046
B-007 W
B
EA19240090

DTC Detection
Condition
Right Rear Wheel when any of the short to ground.
C003A-01 Speed Sensor General following conditions is  Wheel speed sensor line is open, and
Right Rear Wheel signal is abnormal.  Wheel speed sensor is interfered by
C003A-01 Speed Sensor 4. No signal is output magnetic field outside. (wheel or axle
Mechanical Failure when open circuit is not demagnetized).
speed is more than
exceeds 20 km/h,
Right Rear Wheel gear is excessive.
C003A-01 Speed Sensor Signal exceeds the
tolerance of the  Number of ring gear teeth is wrong.
Invalid
damaged.
CAUTION
Diagnosis Procedure
1 Check rear right wheel speed sensor wire harness and connector

c. Disconnect the rear right wheel speed sensor connector B-046.
24 e. Look for broken, bent, protruded or corroded terminals.
NG Repair or replace rear right wheel speed

OK

2 Check installation of rear right wheel speed sensor

c. Check the rear right wheel speed sensor fixing bolt for looseness.
d. Check if excessive clearance exists between the installation position of rear right wheel speed sensor and
rear axle hub ring gear.
e. Check the installation position of rear right wheel speed sensor for dirt.

replace rear right wheel speed sensor
OK
3 Check rear right wheel speed sensor
b. Drive the vehicle straight ahead, and read the datastream of rear right wheel speed sensor with the X-431
c. Check if the data change of rear right wheel speed sensor is the same with that of other wheel speed
sensors.
NG Replace rear right wheel speed sensor
OK
4 Check rear right hub ring gear
a. Remove the rear right hub assembly.

b. Check for foreign matter, missing teeth or damage on the rear right hub ring gear.
c. Check if the rear right hub assembly is securely installed.
NG Replace rear right hub ring gear
OK
Check wire harness and connector (rear right wheel speed sensor - ABS control module
5 assembly)
24


B-007.
+ -
d. Disconnect the rear right wheel speed sensor connector
B-046.
connector according to the table below. 1 2 3 4 5 6 7 8 9 10 11 12 13
Condition
B-007-11 - B-046-1 Always Continuity

B-046


connector B-007 and body ground to check if the rear
right wheel speed sensor is short to ground according to
the table below.
Condition
B-007-11 - Body 14 15 16 17 18 19 20 21 22 23 24 25 26
ground 1 2 3 4 5 6 7 8 9 10 11 12 13
B-007-12 - Body
ground B-007
RA19240310
24


connector B-007 and body ground to check if the rear V
right wheel speed sensor is short to power supply + -

Standard Voltage
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13
B-007-11 - Body
ground B-007
B-007-12 - Body
ground
connector between rear right wheel speed

OK
6 Reconfirm DTCs

diagnostic tester.
YES
24

DTC C1000-16 ECU Voltage Supply Circuit Voltage Below Threshold
DTC C1000-17 ECU Voltage Supply Circuit Voltage Above Threshold
IGNITION SWITCH
BATTERY
ON OR START
ENGINE INSTRUMENT
COMPARTMENT PANEL
EF06 RF05 FUSE AND
FUSE AND
40A 5A RELAY BOX
RELAY BOX
B-010 I-005
E4 5
RG I-003
RL
3 B-050
RG
1 20
ABS
CONTROL
MODULE
B-007
26
B
B-006
1 2 3 4 5 6 7 8 9 10 11 12
42 41 40 39 38 37 36 35 34 33 32 31 30 29
13 14 15 16 17 18 19 20 21 22 23 24
28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-050 E4 E3 E2 E1
25 26
24 85
87
86 86 86
14 13 12 11 10 9 8 7 6 5 4 3 2 1 W
87 30 87 30
30 85 85 B-010
W
I-005
B 14 15 16 17 18 19 20 21 22 23 24 25 26
B-007
1 2 3 4 5 6 7 8 9 10 11 12 13 B
EA19240100

DTC Detection
Condition
These DTCs occur
ECU Voltage Supply when the supply
C1000-16 Circuit Voltage Below voltage of ECU meets
Threshold the following  Abnormal battery voltage
conditions:  Charging system malfunction.
1. No supply voltage of  Wire harness or connector damaged.
ECU.
 ABS control module assembly
ECU Voltage Supply 2. Supply voltage of malfunction.
C1000-17 Circuit Voltage Above ECU is too low.
Threshold
3. Supply voltage of
ECU is too high.
CAUTION
Diagnosis Procedure
1 Check ABS fuse

c. Remove the ABS fuse EF-06 (40 A) from the engine compartment fuse and relay box.
NG Replace ABS fuse
OK
2 Check battery
a. Using the digital multimeter, measure the voltage between the positive battery terminal and negative
battery terminal.
b. The battery voltage should be between 9 and 16 V.
NG Check charging system (See page 16-6)
OK
24

3 Check wire harness and connector (ABS control module assembly - battery)

B-007. V
+ -
d. Connect the negative battery terminal cable.
e. Turn the ignition switch to ON.
f. Using a digital multimeter, measure the supply voltage
between ABS control module assembly connector B-007
14 15 16 17 18 19 20 21 22 23 24 25
and body ground to check if the power supply circuit is 26
normal according to the table below. 1 2 3 4 5 6 7 8 9 10 11 12 13
Standard Voltage
B-007
Condition
B-007-20 - Body
ground RA19240330
NG Repair or replace related wire harness and

connector
OK
4 Check wire harness and connector (ABS control module assembly - body ground)

b. Disconnect the negative battery terminal cable.
B-007.
+ -
ABS control module assembly connector B-007 and body
ground to check if the system ground circuit is normal
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard Condition
1 2 3 4 5 6 7 8 9 10 11 12 13
Condition
B-007-26 - Body
Always Continuity
ground
NG Repair or replace ABS control module RA19240340

24 assembly wire harness and connector
OK

5 Reconfirm DTCs

diagnostic tester.
YES
24

DTC C1001-04 ECU System Internal Failures
DTC C1020-96 ABS Operation Component Internal Failures
DTC Detection
Condition
These DTCs occur
ECU System Internal
C1001-04 when the following
Failures
condition is met:  ABS control module assembly
ABS Operation 1. ECU power supply malfunction.
C1020-96 Component Internal malfunction.
Failure 2. ECU is damaged.
CAUTION
Diagnosis Procedure
1 Reconfirm DTCs

diagnostic tester.
YES
24

DTC U0073-88 Control Module Communication Bus Off
IGNITION SWITCH
BATTERY
ON OR START
ENGINE INSTRUMENT
PANEL DIAGNOSTIC
COMPARTMENT
EF06 RF05 FUSE AND INTERFACE
FUSE AND
40A 5A RELAY BOX I-013
RELAY BOX
B-010 I-005 7 14 6
E4 5
RG
Y
L
I-003 I-004
RL
B-050 3 5 11 25 B-053
RG
Y
L
1 20 18 21 23
ABS
CONTROL
MODULE
B-007
26
B
B-006
42 41 40 39 38 37 36 35 34 33 32 31 30 29
16 15 14 13 12 11 10 9
28 27 26 25 24 23 22 21 20 19 18 17 16 15 8 7 6 5 4 3 2 1 I-013 E4 E3 E2 E1 B-010
14 13 12 11 10 9 8 7 6 5 4 3 2 1 B W
B-053
L 42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-050
14 13 12 11 10 9 8 7 6 5 4 3 2 1
W
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 24
25 26
87
85 86 86 86
87 30 87 30 14 15 16 17 18 19 20 21 22 23 24 25 26
30 85 85
B-007
1 2 3 4 5 6 7 8 9 10 11 12 13 B
I-005
B
EA19240110

DTC Detection
Condition
When bus line is  High frequency electromagnetic

abnormal or other waves interference.
Control Module  Wire harness or connector damaged.
joints on bus line
U0073-88 Communication Bus
cannot transmit data  CAN bus line electrical failure.
Off
properly, this type of  ABS control module assembly
DTC occurs. malfunction.
CAUTION
Diagnosis Procedure
1 Check wire harness and connector (ABS control module assembly - diagnostic interface)

c. Disconnect the ABS control module assembly connector B-007 and body wire harness connector B-053.
d. Disconnect the diagnostic interface connector I-013 and instrument panel wire harness connector I-004.
e. Check if the wire harnesses are worn, pierced, pinched or partially broken.
f. Look for broken, bent, protruded or corroded terminals.
g. Check that the related connector pins are in good condition.

wire harness and connector
OK
24

Check CAN communication control circuit (ABS control module assembly - diagnostic
2 interface)
a. Disconnect the negative battery terminal cable.

B-007 and diagnostic interface connector I-013.
+ -
terminals of ABS control module assembly and
diagnostic interface to check for an open circuit according
to the value(s) in the table below.
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard Condition
1 2 3 4 5 6 7 8 9 10 11 12 13
Condition
B-007-21 -
Always Continuity 16 15 14 13 12 11 10 9
I-013-14 8 7 6 5 4 3 2 1
B-007-23 - I-013-6 Always Continuity I-013

RA19240350
e. Disconnect the instrument panel wire harness connector

I-004 and body wire harness connector B-053.
terminals of ABS control module assembly connector B-
007 and body wire harness connector B-053 to check for + -
an open circuit according to the value(s) in the table

below.
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard Condition
1 2 3 4 5 6 7 8 9 10 11 12 13
Condition
B-007-21 -
Always Continuity 42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-053-11
28 27 26 25 24 23 22 21 20 19 18 17 16 15
B-007-23 - 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Always Continuity
B-053-25
B-053
RA19240360
24

g. Using a digital multimeter, check for continuity between

terminals of diagnostic interface connector I-013 and
instrument panel wire harness connector 
I-004 to check for an open circuit according to the
value(s) in the table below. + -
Standard Condition
Condition
Connection Condition 29 30 31 32 33 34 35 36 37 38 39 40 41 42
I-013-14 - I-004-11 Always Continuity 15 16 17 18 19 20 21 22 23 24 25 26 27 28

1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-013-6 - I-004-25 Always Continuity
I-004
NG Repair or replace body/instrument panel 16 15 14 13 12 11 10 9

wire harness and connector 8 7 6 5 4 3 2 1
I-013
RA19240370
OK
3 Reconfirm DTCs

diagnostic tester.
YES
24

ON-VEHICLE SERVICE
ABS Bleeding
WARNING
 When bleeding the brake system, wear safety glasses. If the brake fluid gets on your eyes or skin, wash
off with water completely.
 DO NOT drop the brake fluid onto the body paint, as the brake fluid can corrode the body paint.
CAUTION
 The brake fluid should meet the Chery specified type (DOT4). DO NOT mix the brake fluid with other
types of brake fluid.
 The brake fluid has strong water absorbability, be sure to place it in the original sealed container.
 To prevent dust and other foreign matter from entering the reservoir, wipe it off before removing the
reservoir cap.
The bleeding procedures for brake system with the X-431 3G diagnostic tester are as follows:
1. Make sure all the brake lines have been installed properly and tighten them in place.
2. Check that the battery voltage is normal.
3. Turn the ignition switch to LOCK.
4. Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC).
5. Turn the ignition switch to ON.
6. Using the X-431 diagnostic tester, record and clear the DTCs stored in the ABS control module assembly.
7. Using the X-431 3G diagnostic tester, enter Brake Control System, select Repair Bleed Function, and then
perform the operation according to the information and procedures displayed on the diagnostic tester.
HINT:
 If the bleeder plug is open, never depress the brake pedal repeatedly. Doing so will increase the
amount of air in the system.
 Do not drain brake fluid from the brake fluid reservoir while bleeding the system. Otherwise, low fluid
level in the brake reservoir will cause additional air to enter the brake system.
 Always check the brake fluid level at all times to ensure that the brake fluid level in the brake reservoir
is always close to the "MAX" level.
8. For X type brake circuit, the bleeding order is: rear left wheel, front right wheel, rear right wheel and front
left wheel.
9. After bleeding is completed, fill the brake reservoir with brake fluid to the MAX level .
10.Drive the vehicle to perform a road test, confirm that the ABS system operates normally and brake pedal
feel is good.
24

ABS Control Module Assembly

Removal
WARNING
 When repairing the ABS system, first release the pressure of high pressure brake fluid in the
accumulator, to prevent the high pressure brake fluid from spraying out and causing injury.
 Operation procedures: turn the ignition switch off first, and then depress and release the brake pedal
repeatedly until the brake pedal becomes hard.
 In addition, never turn the ignition switch on before the ABS system is installed completely to prevent the
hydraulic pump from energizing and running.

CAUTION
 Wash off the brake fluid immediately if it comes in contact with any paint surface.
 The drained brake fluid should be well kept in a container. Never discard it at will.

5. Remove the ABS control module assembly.
a. Press the lock area of ABS control module assembly
connector, move the connector lock bracket upward
and disconnect the ABS control module assembly
connector (arrow).
RA19240070
b. Using a fixing wrench, carefully disconnect 6 brake

pipe coupling plugs (arrow).
24
RA19240080

CAUTION
 When removing the brake line, prevent the foreign matter form entering the ABS control module
assembly thread holes.
 After disconnecting the brake line, sealing measure should be taken to prevent the foreign matter form
entering.
c. Remove the coupling bolts (arrow) between ABS

control module assembly mounting bracket and body.
RA19240090
d. Remove the ABS control module with mounting bracket assembly.
Disassembly
1. Remove the ABS control module assembly.
a. Remove the ABS control module assembly side fixing
screw (1).
1
b. Remove the shock pads (2) from the bottom of ABS
control module assembly.
c. Remove the ABS control module assembly bottom 3
fixing bolts (arrow).
d. Detach the ABS control module assembly (4) from the
2
mounting bracket (3). RA19240100
Assembly
CAUTION
 Check if the shock pads are deteriorated or damaged. Replace them if necessary.
24

Installation
CAUTION
 ABS control module assembly consists of hydraulic control module and electronic control module. As a
unit, they cannot be repaired or replaced individually.
 When installing the fixing bolts and nuts, make sure to tighten them to the specified torque.
 Perform the ABS bleeding procedures for brake system after completing the installation 
(See page 24-57).
 Using the X-431 3G diagnostic tester, enter Brake Control System, record and clear the trouble code,
then drive the vehicle to perform the road test, confirming that the ABS system operates normally and
brake pedal feel is good.
24

Front Wheel Speed Sensor

Removal
CAUTION
 Keep the wheel speed sensor away from oil or other dirt. Otherwise, the speed signal generated by the
wheel speed sensor may be inaccurate, and the system may fail to operate normally.
HINT:
3. Remove the front left wheel speed sensor.
a. Remove the coupling bolt (arrow) between front left
wheel speed sensor and front left steering knuckle
assembly, and detach the front left wheel speed
sensor carefully. 
RA19210060
CAUTION
 Keep the head and installation hole of the sensor free of foreign matter.
b. Detach the attachment parts (arrow) of front left wheel

speed sensor wire harness from the front left shock
absorber assembly and body.
HINT:
Observe the winding direction of sensor wire harness
to prevent incorrect installation.
RA19240101
24

c. Disconnect the front left wheel speed sensor wire

harness connector (arrow).
RA19240110
d. Remove the fixing clip (arrow) between front left

wheel speed sensor wire harness and body, and 1
detach the wire harness cover (1) from the body.
RA19240120
e. Remove the front left wheel speed sensor.
Inspection
1. Check the front wheel speed sensor.
a. Check the front wheel speed sensor surface for breakage, dents or notch.
b. Check the front wheel speed sensor connector or wire harness for scratches, breakage or damage.
c. If any of the above conditions occurs, replace the front wheel speed sensor with a new one.
Installation
CAUTION
 When installing the coupling bolt, make sure to tighten it to the specified torque.
24

Rear Wheel Speed Sensor

Removal
CAUTION
 Keep the wheel speed sensor away from oil or other dirt. Otherwise, the speed signal generated by the
wheel speed sensor may be inaccurate, and the system may fail to operate normally.
HINT:
3. Remove the rear left wheel speed sensor.
a. Remove the coupling bolt (arrow) between rear left
wheel speed sensor and rear left hub shaft.
RA19210330
CAUTION
 Keep the head and installation hole of sensor free of foreign matter.
b. Detach the attachment parts (arrow) of rear left wheel

speed sensor wire harness from the rear shaft
assembly.
RA19240130
24

c. Detach the attachment part (arrow) between rear left

wheel speed sensor wire harness and body, and
detach the wire harness cover (1). 1
RA19240140
d. Turn over the rear left seat, remove the seat rear left
trim cover assembly, then disconnect the rear left
wheel speed sensor wire harness connector (arrow).
RA19240150
e. Remove the rear left wheel speed sensor.
Inspection
1. Check the rear wheel speed sensor.
a. Check the rear wheel speed sensor surface for breakage, dents or notch.
b. Check the rear wheel speed sensor connector or wire harness for scratches, breakage or damage.
c. If any of the above conditions occurs, replace the rear wheel speed sensor with a new one.
Installation
CAUTION
 When installing the coupling bolt, make sure to tighten it to the specified torque.
24

BRAKE
GENERAL INFORMATION 25-3 Brake Pedal Assembly 25-22
Front Disc Brake Assembly 25-26
Removal 25-27
Inspection 25-11
Disassembly 25-28
Brake Bleeding 25-12 Assembly 25-33
Brake Fluid Replacement 25-13 Installation 25-36
Brake Fluid Reservoir Assembly 25-14 Front Brake Hose Assembly 25-37
On-vehicle Inspection 25-14 Removal 25-37
Installation 25-15 Rear Drum Brake Assembly 25-39
Brake Master Cylinder Assembly 25-16 On-vehicle Inspection 25-40
Installation 25-17 Disassembly 25-41
Vacuum Booster with Brake Master  Inspection 25-45
Cylinder Assembly 25-18 Assembly 25-46
On-vehicle Inspection 25-18 Installation 25-46
Removal 25-19 Rear Brake Hose Assembly 25-47
25

25

25 - BRAKE
GENERAL INFORMATION
BRAKE
Description
Front Disc Brake Assembly
5
6
1
×3
3
2
4
RA19250010
1 - Front Steering Knuckle 2 - Front Dust Guard

3 - Hub Bearing Retainer 4 - Front Hub Bearing
5 - Front Hub Assembly 6 - Front Brake Disc
7 - Front Brake Caliper Assembly
25

25 - BRAKE
Rear Drum Brake Assembly
1 2
×4
3
4 5
6
7
RA19250020
1 - Rear Hub Shaft 2 - Rear Drum Brake Assembly

3 - Rear Hub Ring Gear 4 - Rear Hub Assembly
5 - Rear Brake Drum 6 - Rear Shaft Locking Nut
7 - Rear Bearing End Cover
The brake system uses the following configuration: disc brake is used for front wheels, and drum brake,
double as parking brake, is used for rear wheels.
Using the lever principle, the brake pedal pushes the pushrod into the vacuum booster, which boosts the force
of the pushrod by using the vacuum and then transmits the force to the brake master cylinder assembly. The
hydraulic pressure, produced in the brake master cylinder assembly, is transmitted to the ABS Hydraulic
Control Unit (HCU) through the brake tube, and then distributed to individual brake calipers and wheel
cylinders. The brake calipers apply force to the brake linings and shoes using hydraulic pressure. The brake
linings and shoes will cause the wheel speed to decrease or stop depending on the amount of brake pressure
applied.
25

25 - BRAKE
Specifications

Coupling Plug Between Brake Master Cylinder
18 ± 2
Assembly and Brake Pipe
Coupling Nut Between Brake Master Cylinder
13 - 17
Assembly and Vacuum Booster
Coupling Nut Between Vacuum Booster Assembly
25 ± 4
and Brake Pedal Assembly
Coupling Bolt Between Instrument Panel
25 ± 4
Crossmember Assembly and Brake Pedal Assembly
25 ± 4
100 ± 10
Front Brake Disc Fixing Screw 7-9
Front Brake Caliper Bleeder Plug 5.88 - 9.8
Locating Bolt Between Brake Caliper Fixing Bracket
25 ± 4
and Brake Cylinder Assembly
Coupling Plug Between Front Brake Hose Assembly
18 ± 2
and Front Brake Pipe
25 ± 4
Rear Drum Brake Positioning Screw 10 ± 1
Rear Brake Wheel Cylinder Bleeder Plug 5.88 - 9.8
Coupling Plug Between Rear Brake Wheel Cylinder
18 ± 2
and Rear Brake Pipe
Coupling Bolt Between Rear Brake Bottom Board
60 ± 5
and Rear Shaft Assembly
Coupling Plug Between Rear Part of Rear Brake
18 ± 2
Coupling Plug Between Front Part of Rear Brake
18 ± 2
25

25 - BRAKE
Front Disc Brake
Standard Thickness Minimum Thickness

(mm) (mm)
Front Brake Disc 18 16 0.025
Front Brake Lining 10.5 2 -
Rear Drum Brake
Description Standard Thickness (mm) Minimum Thickness (mm)

Rear Brake Shoe Lining 5 1
Standard Inner Maximum Inner

Diameter (mm) Diameter (mm)
Rear Brake Drum 220 221.4 0.05
Tools
Special Tool
Brake Caliper Piston Pressing Tool
RCH0000053
25

25 - BRAKE
General Tools
20
10
30
0
40
90
50
80
60
70
RCH0000023
Vernier Caliper
RCH0000019
Digital Multimeter
RCH0000002
25

25 - BRAKE
Circuit Diagram
Brake System
IGNITION SWITCH
ON OR START
INSTRUMENT
PANEL FUSE
RF01 AND RELAY
10A BOX
I-005
1
RW
13
BRAKE INSTRUMENT
CLUSTER
UNIFIED METER CONTROL UNIT I-043
26
LW
I-004
6 B-053
LW
1
BRAKE
FLUID
CLOSE LEVEL
SENSOR
OPEN B-018
2
B
B-016
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
29 30 31 32 33 34 35 36 37 38 39 40 41 42
25 26 15 16 17 18 19 20 21 22 23 24 25 26 27 28
87
85 86 86 86 1 2 3 4 5 6 7 8 9 10 11 12 13 14
87 30 87 30
30 85 85
I-005 I-004
B L
25
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 2 1
I-043
B-018
L
W
EA19250010

25 - BRAKE
DIAGNOSIS & TESTING

HINT:

Front brake lining (cracked, deformed, dirty
25-28
or burnished)
Rear brake shoe lining (cracked, deformed,
25-41
dirty or burnished)
Front disc brake locating bolt guide pin
25-28
(worn)
Front disc brake fixing bolt (loose) 25-27
Front brake disc (scored) 25-27
Noise in brake
Excessive brake disc runout 25-27
Rear brake drum (scored) 25-41
Brake shoe regulating device (damaged) 25-41
Brake shoe return tension spring
25-41
(damaged or insufficient elasticity)
Foreign matter on brake disc -
Foreign matter on rear brake drum -
Front brake lining (worn, cracked,
25-28
deformed, oily or burnished)
Rear brake shoe lining (worn, cracked,
25-41
deformed, oily or burnished)
Hard pedal but brake inefficient Front brake disc (unevenly worn) 25-27
Rear brake drum (unevenly worn) 25-40
Vacuum booster pushrod position
25-18
(incorrect)
Vacuum leaks in booster system 25-21
Hard pedal (firm-depress unable to lock-up
Vacuum booster (bounce) 25-18
wheels)
Pedal overtravel (vehicle stops normally) Air in brake system 25-12
Pedal pulsates/bounces during braking Brake disc (unevenly worn) 25-27
25

25 - BRAKE

Air in brake system 25-12
Leak in brake system -
Front brake piston seal (worn or damaged) 25-28
Low or spongy pedal Rear brake piston seal (worn or damaged) 25-41
Brake master cylinder assembly
25-16
(malfunction)
25-18
(incorrect)
Front brake piston (stuck or frozen) 25-28
Rear brake piston (stuck or frozen) 25-41
Front brake lining (dirty, cracked or
25-28
deformed)
Vehicle pulls during braking
Rear brake shoe lining (dirty, cracked or
25-41
deformed)
Front brake disc (unevenly worn) 25-27
Rear brake drum (unevenly worn) 25-40
Brake pedal free play (minimum) 25-22
Parking brake lever stroke (in need of
26-7
adjustment)
Parking brake cable (stuck) 26-14
Parking brake shoe clearance (in need of
26-7
adjustment)
Front brake lining (cracked or deformed) 25-28
Rear brake shoe lining (cracked or
25-41
deformed)
Brake stuck
Front brake piston (stuck or frozen) 25-28
Rear brake piston (stuck or frozen) 25-41
Brake shoe return tension spring (loose or
25-41
damaged)
25-18
(incorrect)
Vacuum leaks in booster system 25-21
Brake master cylinder assembly
25-16
(malfunction)
25

25 - BRAKE
Inspection
CAUTION
 Use the tightly sealed brake fluid DOT4 or equivalent. DO NOT use oily solution, or the brake system
seal may be damaged.
 Brake fluid may damage the paint surface. If the brake fluid spills on the paint surface, wash it off
immediately with water.
 DO NOT use gasoline, kerosene, alcohol, engine oil, transmission oil or any other fluid that contains
mineral oil to clean the system components. These kinds of fluid will damage the rubber cover and seal.
 During servicing, make sure to clean the grease or other foreign matter on the outer surface of the brake
caliper assembly, brake lining, brake disc and wheel hub.
 When operating the brake disc and the brake caliper, be careful to prevent damaging the brake disc and
the brake caliper or scratching or cutting the brake shoe linings.
1. Check the conditions of the tires and wheels. Damaged or worn wheels and tires can cause a pull,
shudder, vibration and a condition similar to sudden braking.
2. If noise occurs while braking, check the suspension components. Bounce the vehicle up and down several
times and check the suspension or steering components for any looseness, wear or damage.
3. Check the brake fluid level and condition.
a. If the brake fluid level is low, check the ABS control unit assembly, brake wheel cylinder, brake caliper,
brake line, brake master cylinder assembly and brake fluid reservoir, etc. for leakage.
b. If the brake fluid is contaminated, drain certain amount of fluid to check. Replace it with new fluid as
necessary.
HINT:
It's normal that the brake fluid will become dark after being used for a period of time. Do not mistake this for
contamination.
25

25 - BRAKE
ON-VEHICLE SERVICE
Brake Bleeding
WARNING
 When bleeding the brake system, wear safety glasses.

 Be careful when bleeding air, as the brake fluid at high pressure may spray out from the bleeder plug.
CAUTION
 Before removing the brake fluid reservoir, wipe it off to prevent dust and other foreign matter from
dropping into the brake fluid reservoir.
 Use fresh, clear and tightly sealed brake fluid of specified type or equivalent.
 DO NOT allow the brake fluid to adhere to any paint surface, such as vehicle body. If brake fluid leaks
onto any paint surface, immediately wash it off.
 During bleeding, do not depress the brake pedal repeatedly at any time with the bleeder plug open;
otherwise, the amount of air in the system will increase, and further bleeding is needed.
 DO NOT drain the brake fluid in the brake fluid reservoir while bleeding the brake system.
HINT:
 An assistant will be required to assist when bleeding the brake system.
 Open the service cover of the front windshield lower garnish sub-assembly to fill the brake fluid
expediently.
1. Fill the brake fluid reservoir with the brake fluid to the proper level.
2. Loosen the bleeder plug cap and connect a clear plastic
hose to the bleeder plug. Submerge the end of the hose
into the clear container filled with new brake fluid.
3. Have an assistant depress the brake pedal 3 to 4 times
repeatedly; depress and hold the brake pedal to a lower
position. Then loosen the bleeder plug, and rotate it at
least one turn.
RA19250030
4. Tighten the bleeder plug every time the brake pedal

moves down quickly. Then release the brake pedal.
25
RA19250040

25 - BRAKE
5. Repeat the above steps, and bleed the brake lines of each wheel in the same manner in the order of rear
left wheel, front right wheel, rear right wheel and front left wheel, until all the air is bled from the brake line. 
Empty sign: a stream of fresh brake fluid flows into the clear container without bubbles.
HINT:
During bleeding the brake system, make sure the brake
fluid level is always near the "MAX" mark. Check the
brake fluid level at all times during bleeding. Add brake MAX
fluid as necessary. MIN
RA19250050
6. Check and adjust the brake fluid level to the "MAX" mark.
7. Check the brake pedal effect. If the braking effect is improper or the pedal is spongy, air may still exist in
the system. Perform the bleeding procedures for the brake system again as necessary.
8. Have the vehicle tested to confirm that the brake operates properly and the pedal feel is correct.
Brake Fluid Replacement

1. Drain the brake fluid.
a. Start the engine and run it at idle.
b. Remove the filler cap of the brake fluid reservoir
assembly. Remove the bleeder plug cap and connect
a clear plastic hose to the bleeder plug, and submerge
the end of the hose into the clear container filled with
new brake fluid.
c. Loosen the bleeder plug, and depress the brake pedal
continuously until the brake fluid stops coming out.
RA19250030
2. Add brake fluid.

a. Tighten the bleeder plug after confirming that the brake fluid is drained. Fill the brake fluid reservoir with
new brake fluid to the proper level.
3. Perform bleeding procedures.
a. After replacing with the new brake fluid, make sure to bleed the brake system for normal operation. See
page 25-12 for detail information about brake bleeding.
25

25 - BRAKE
Brake Fluid Reservoir Assembly

1. Check the brake fluid level warning switch.
a. Remove the brake fluid reservoir filler cap. + - 1 2
b. Disconnect the brake fluid level warning switch wire
harness connector.
c. Using the ohm band of digital multimeter, check for
MAX
continuity between the brake fluid level warning switch
terminals according to the conditions shown in the MIN
table below.
Standard Condition
RA19250060
Condition
Terminal 1 - Float upward
No continuity
Terminal 2 (switch ON)
Terminal 1 - Float downward
Continuity
Terminal 2 (switch OFF)
HINT:
 There is a float in the fluid reservoir. The position of the float changes according to the increasing or
decreasing brake fluid level.
 If the result is not as specified, replace the brake fluid reservoir assembly.
d. Add brake fluid to the "MAX" mark.
Removal
CAUTION
2. Remove the brake fluid reservoir assembly.

a. Loosen the brake hose fixing clamp (arrow) and
disengage the brake hose from the brake fluid
reservoir assembly.
25
RA19250070

25 - BRAKE
b. Disconnect the brake fluid level warning switch

connector (arrow).
RA19250080
c. Loosen the coupling bolt (arrow) between brake fluid

reservoir assembly and brake master cylinder
assembly.
(Tightening torque: 1.5 - 5 N·m)
RA19250090
d. Using a screwdriver wrapped with tape, pry the

sealing parts (arrow) between brake fluid reservoir
assembly and brake master cylinder assembly, and
separate them.
RA19250100
e. Remove the brake fluid reservoir assembly.
Installation
HINT:
Perform the bleeding procedures for the brake system and add brake fluid to the proper level after completing
installation.
25

25 - BRAKE
Brake Master Cylinder Assembly

Removal
CAUTION
 Remove the vacuum in the vacuum booster before removing the brake master cylinder assembly to
avoid damaging the brake master cylinder assembly and prevent the booster from sucking in any
pollutant.
 When the engine is not running, remove the vacuum by depressing the brake pedal repeatedly until the
brake pedal can be depressed firmly.
 When removing the brake line, sealing measures should be taken to prevent foreign matter from
entering.
CAUTION
2. Remove the brake fluid reservoir assembly (See page 25-14).

3. Remove the brake master cylinder assembly.
a. Loosen 2 fixing plugs (arrow) between brake master
cylinder assembly and brake pipes.
RA19250110
b. Loosen 2 fixing nuts and washers (arrow) between

brake master cylinder assembly and vacuum booster.
25
RA19250120
c. Slide the brake master cylinder assembly vertically out of the vacuum booster carefully.

25 - BRAKE
CAUTION
 The design of brake master cylinder assembly and piston makes the piston fall out easily. To prevent this,
make sure that the brake master cylinder is horizontal or the end surface is placed upside down (piston
surface facing upward) when handling.
 Make sure that no foreign matter adheres to the brake master cylinder assembly piston. If foreign matter
adheres, clean it off with a piece of clean cloth. Then, apply grease to the entire outer edge contact
surface of the master cylinder piston.
 The master cylinder should be handled carefully. Avoid any impact to the master cylinder, such as falling.
The fallen master cylinder cannot be reused.
 DO NOT tap or pinch the master cylinder piston, and avoid damaging the master cylinder piston in any
other ways.
Installation
CAUTION
 Make sure to tighten the fixing plugs and nuts to the specified torque during installation.
 Perform the bleeding procedures for the brake system and add brake fluid to the proper level after
completing installation.
25

25 - BRAKE
Vacuum Booster with Brake Master Cylinder Assembly

1. Check the vacuum booster assembly.
a. Air tightness check.
 Start the engine and stop it after 1 or 2 minutes. Slowly depress the brake pedal several times.
 Make sure that the booster is airtight. Check that the distance every time the pedal is depressed is
decreased gradually compared to the previous time.
If the pedal operation is not as specified, check the check valve. If the check valve is normal, replace
the vacuum booster assembly.
 Start the engine. Depress and hold the pedal, and then stop the engine.
 Make sure that the booster is airtight. Depress and hold the pedal for 30 seconds, and check that
the pedal reserve distance does not change. 
b. Operation check.
 Stop the engine.
 Depress the pedal several times and check that
the pedal reserve distance does not change.
RA19250130
 Depress and hold the pedal, and then start the

engine. Check that the pedal can only be
depressed lightly.
RA19250140
25

25 - BRAKE
Removal
CAUTION

3. Remove the vacuum booster with brake master cylinder assembly.
a. Loosen the brake hose fixing clamp (arrow) and
disengage the brake hose from the brake fluid
reservoir assembly.
RA19250070
b. Disconnect the brake fluid level warning switch

connector (arrow).
RA19250080
c. Loosen 2 fixing plugs (arrow) between brake master

cylinder assembly and brake pipes.
RA19250110 25

25 - BRAKE
d. Disengage the vacuum hose assembly with check

valve (arrow) from the vacuum booster assembly.
RA19250150
e. Using the needle-nose pliers, remove the return

spring (arrow), locking pin (1) and the pushrod pin (2)
from the vacuum booster pushrod and detach the
brake pedal assembly.
2 1
RA19250160
f. Remove 4 fixing nuts (arrow) between vacuum

booster assembly and brake pedal assembly. 
RA19250170
g. Remove the vacuum booster with brake master

cylinder assembly from the engine compartment.
RA19250180
25

25 - BRAKE
Inspection
1. Check the check valve.
a. Remove the check valve from the vacuum hose assembly.
b. Check that there is airflow (A) from the vacuum
booster to the engine, and no airflow (B) from the A B
engine to the vacuum booster.
RA19250190
If the result is not as specified, replace the vacuum hose assembly.
Installation
CAUTION
 Make sure to tighten the fixing plugs and nuts to the specified torque during installation.
 Perform the bleeding procedures for the brake system and add brake fluid to the proper level after
completing installation.
25

25 - BRAKE
Brake Pedal Assembly

1. Check the brake pedal free play.
a. Stop the engine. Depress the brake pedal several
times until no vacuum is left in the vacuum booster,
then release the brake pedal.
b. Depress the brake pedal until the resistance is felt.
c. As shown in the illustration, check the brake pedal
free play by measuring the distance between pedal
position in the above step and pedal position when it Pedal Free Play
is released.
Standard brake pedal free play: 1 - 9 mm RA19250240
2. Adjust the brake pedal free play.

a. As shown in the illustration, loosen the vacuum booster
pushrod locking nut (arrow) and rotate the vacuum
booster pushrod clockwise or counterclockwise to
adjust the brake pedal free play to the specified value.
RA19250250
3. Check the brake pedal height.

a. As shown in the illustration, turn over the carpet and
measure the distance between brake pedal center
and dash panel, which is the brake pedal height.
Standard brake pedal height: 139.9 mm
Pedal Height
RA19250260
4. Adjust the brake pedal height.

a. As shown in the illustration, loosen the vacuum booster
pushrod locking nut (arrow) and rotate the vacuum
booster pushrod clockwise or counterclockwise to
adjust the brake pedal height to the specified value.
RA19250250
25

25 - BRAKE
Removal
1. Remove the brake light switch assembly.
a. Disconnect the brake light switch assembly wire
RA19250200
b. Remove the brake light switch assembly by rotating it

90° clockwise or counterclockwise.
RA19250210
2. Remove the brake pedal assembly.

a. Using the needle-nose pliers, remove the return
spring (arrow), locking pin (1) and the pushrod pin (2)
from the vacuum booster pushrod and detach the
brake pedal assembly.
2 1
RA19250160
b. Remove 4 fixing nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
RA19250170
25

25 - BRAKE
c. Remove the fixing bolt (arrow) between instrument

panel crossmember and brake pedal assembly.
RA19250220
d. Remove the brake pedal assembly from the inside of

the vehicle.
RA19250230
Inspection
1. Check the brake light switch assembly.
a. Using the ohm band of digital multimeter, check for
continuity between the brake light switch assembly
+ -
terminals in accordance with the table below. 1 2
Standard Condition 3 4
Multimeter Switch Specified

Brake pedal
Terminal 1 -
depressed (switch Continuity
Terminal 3
pin released) RA19250270
Brake pedal
Terminal 2 -
depressed (switch No continuity
Terminal 4
pin released)
Brake pedal
Terminal 1 -
released (switch No continuity
Terminal 3
pin pushed)
Brake pedal
Terminal 2 -
released (switch Continuity
Terminal 4
pin pushed)
If the result is not as specified, replace the brake light

switch assembly.
25

25 - BRAKE
Installation
CAUTION
 Make sure to tighten the fixing bolt and nuts to the specified torque during installation.
 Check that the brake light operates properly after completing installation.
25

25 - BRAKE
Front Disc Brake Assembly
1 3
4
2 5 12
6
7
8
9
10
11
RA19250280
1 - Outer Brake Lining 2 - Inner Brake Lining

3 - Front Disc Brake Caliper Fixing Bracket 4 - Brake Caliper Guide Pin Rubber Dust Boot
5 - Brake Caliper Locating Bolt Guide Pin 6 - Brake Cylinder Assembly Retainer Plate
7 - Front Disc Brake Piston Dust Boot 8 - Front Disc Brake Piston
9 - Front Disc Brake Piston Seal Ring 10 - Front Disc Brake Cylinder
11 - Brake Caliper Locating Bolt 12 - Front Disc Brake Bleeder Plug
25

25 - BRAKE
1. Check the brake disc runout.
a. Remove the front wheel (See page 23-10).
b. Secure the dial indicator (1) to the proper position.
Position the dial indicator pointer approximately 10 2
mm from the outer edge of the brake disc.
c. Slowly rotate the brake disc (2) and check the runout.
Mark the lowest and highest points and record these
measurements.
RA19250281
d. Check the runout on the opposite side of the brake disc in the same way. Mark the lowest and highest
points and record these measurements.
e. Compare the recorded runout value and limit value.
Maximum runout for front brake disc: 0.025 mm
f. If the runout exceeds the maximum value, replace the brake disc.
Removal
HINT:
CAUTION

3. Remove the front left brake caliper assembly.
a. Remove the coupling bolt and washer (arrow)
between front left brake caliper assembly and front left
brake hose assembly.
25
RA19250290

25 - BRAKE
CAUTION
 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing the brake hose, as the
brake fluid is corrosive.
b. Remove 2 coupling bolts (arrow) between front left

brake caliper assembly and front left steering knuckle.
RA19250300
c. Remove the front left brake caliper assembly.

4. Remove the front left brake disc.
a. Remove the fixing screw (arrow) from the front left
brake disc and remove the front left brake disc. 
RA19250310
Disassembly
HINT:
WARNING
 Never use high pressure when removing the piston from the bore of the brake caliper. Otherwise, this
may cause personal injuries.
 If it is needed to remove the piston with compressed air, DO NOT face the piston to yourself or place
your hands around the brake caliper and piston.
25

25 - BRAKE
1. Remove the bleeder plug (w/ bleeder plug cap).

a. Remove the bleeder plug (w/ bleeder plug cap)
(arrow) from the brake caliper assembly.
(Tightening torque: 5.88 - 9.8 N·m)
RA19250320
2. Remove the brake cylinder assembly.

a. Remove 2 locating bolts (arrow) between brake
caliper fixing bracket and brake cylinder assembly.
RA19250330
b. Detach the brake cylinder assembly and brake caliper fixing bracket.
3. Remove the front brake lining.
a. Remove the inner brake lining and outer brake lining
(arrow) from the brake caliper fixing bracket.
RA19250340
4. Remove the brake caliper locating bolt guide pin.

a. Remove 2 brake caliper locating bolt guide pins
RA19250350
25

25 - BRAKE
5. Remove the brake caliper guide pin rubber dust boot.

a. Remove 2 brake caliper guide pin rubber dust boots
RA19250360
6. Remove the brake cylinder assembly retainer plate.

a. Remove the retainer plate from the brake cylinder
assembly.
RA19250370
7. Remove the brake cylinder dust boot.

a. Using a screwdriver wrapped with protective tape, pry
out the dust boot carefully.
RA19250380
CAUTION
 Be careful not to damage the brake piston and the brake cylinder.
8. Remove the front disc brake piston.

a. Place a wooden board (1) between front disc brake
piston and front disc brake cylinder.
b. Use compressed air (2) to carefully press out the 1
piston from the front disc brake cylinder through the
attachment hole.
2
25
RA19250390

25 - BRAKE
CAUTION
 Be careful not to splash the brake fluid.

 DO NOT hold the piston by hands to prevent injury.
 DO NOT remove or install the brake piston casually, and always perform these operations by the
professional.
c. Clean the piston bore with the alcohol or proper solution. Then wipe it with a piece of lint.
9. Remove the front disc brake piston seal ring.
a. Using a screwdriver wrapped with protective tape,
carefully pry out the front disc brake piston seal ring
(arrow) from the brake cylinder rear ring groove.
RA19250400
Inspection
1. Check the brake cylinder and the piston.
a. Check the piston and the bore for scratches or corrosion. If there are scratches or corrosion, remove
them with fine sand cloth.
b. Remove the dirt on the piston with a soft brass wire brush and coarse cloth. Do not clean the piston with
polishing cloth or sand cloth, as this may damage its surface. When the surface of piston is damaged,
replace it. When the piston is stuck or the bore is worn or corroded, replace the entire brake caliper
assembly. Using the polishing cloth, remove the small corrosion points inside the bore.
2. Check the brake caliper fixing bracket and brake caliper guide pin set.
a. Clean the brake caliper fixing bracket with brake cleaner. Check for deformation, cracks, rust and
foreign matter which is difficult to remove.
b. Check the brake caliper guide pin rubber dust boot for deformation, cracks, worn and foreign matter
which is difficult to remove.
c. Install the brake caliper guide pin and brake caliper guide pin rubber dust boot to the brake caliper fixing
bracket. The brake caliper guide pin set should move smoothly without being stuck when pushing it with
hand; otherwise replace it.
d. After installing the brake lining, check if it is easy to fall out. Replace it as necessary.
3. Check the brake lining.
a. Visually check the brake lining for flatness, and also check for excessive wear. If the condition of the
lining cannot be confirmed accurately only by visual inspection, a physical check will be used as
necessary.
25

25 - BRAKE
b. Measure the minimum brake lining thickness. When

the minimum thickness of the brake lining is 2 mm or
less, replace the brake lining.
RA19250410
c. When replacing the excessively worn brake linings (inner and outer), it is also necessary to replace the
linings on the opposite side of the vehicle as well as the unchecked linings to maintain proper braking
performance. If it is unnecessary to replace the brake linings, be sure to reinstall the brake linings to the
original positions.
4. Check the brake disc.
a. Minor scratch or wear on the brake disc surface is acceptable. If severe scratch or deformation exists,
the brake disc must be replaced.
b. Excessive wear of the brake disc may cause poor contact between brake lining and surface of brake
disc. If the protrusion on the disc is not removed before installing the new brake lining, abnormal wear
of the brake disc will be caused.
c. It is normal that the surface of brake disc is worn when replacing the brake lining. If cracks or burned
spots exist, the brake disc must be replaced.
5. Check the brake disc thickness.
a. Using a vernier caliper, measure the brake disc
thickness at the center of the brake lining contact
surface as shown in the illustration.
Standard thickness: 18 mm
Minimum thickness: 16 mm
RA19250420
b. If it is less than the minimum thickness due to the wear of brake disc, replace the brake disc.
CAUTION
 DO NOT machine the brake disc, because it may make the brake disc thickness less than the minimum
thickness.
25

25 - BRAKE
Assembly
HINT:
CAUTION
 When assembling the brake caliper assembly, always keep your hands clean.
 When assembling the brake caliper assembly, always use clean new brake fluid.
 Never use the used front disc brake piston seal ring.
1. Install the front disc brake piston seal ring.

a. Apply a light coat of grease to the entire inner and
outer circumferences of the new front disc brake
piston seal ring.
b. Install the front disc brake piston seal ring onto the
brake cylinder.
Grease RA19250430
CAUTION
 Securely install the front disc brake piston seal ring into the rear groove of the brake cylinder.
2. Install the front disc brake piston.

a. Apply a light coat of grease to the inner and outer
circumferences, and entire periphery of outer flange
top/bottom surfaces of the new brake cylinder dust
boot as shown in the illustration.
b. Apply a light coat of grease to the entire outer
circumference (the part contacting with the brake
cylinder dust boot and the front disc brake cylinder) of
the front disc brake piston.
Grease
RA19250440
c. Install the brake cylinder dust boot onto the front disc brake piston.
3. Install the brake cylinder dust boot.
a. Install the front disc brake piston to the front disc brake cylinder.
CAUTION 25
 DO NOT install the piston forcibly to the brake cylinder.

25 - BRAKE
b. Install the brake cylinder dust boot to the brake

cylinder.
RA19250450
CAUTION
 Securely install the brake cylinder dust boot into the front groove of the disc brake cylinder.
 DO NOT damage the brake cylinder dust boot.
4. Install the brake cylinder assembly retainer plate.

a. Correctly install the retainer plate to the brake cylinder
assembly.
RA19250370
5. Install the front brake caliper guide pin rubber dust boot.
a. Apply a small amount of grease to the contact surface
between the guide pin rubber dust boot and the
locating bolt guide pin, and securely install the dust
boot to the brake caliper fixing bracket.
RA19250360
6. Install the front brake caliper locating bolt guide pin.

a. Apply a small amount of grease to the contact surface
between the locating bolt guide pin and the guide pin
rubber dust boot, and securely install them to the
brake caliper fixing bracket.
25
RA19250350

25 - BRAKE
7. Install the front brake lining.

a. Securely install the inner brake lining and the outer
brake lining onto the brake caliper fixing bracket.
Make sure they are clamped in place.
RA19250340
CAUTION
 Make sure the contact surface of the lining and the brake disc is free of oil and grease.
8. Install the brake cylinder assembly.

a. Using the brake cylinder piston pressing tool, slightly
retract the brake cylinder piston.
RA19250460
b. Align the brake caliper locating bolts (arrow) with the

guide pin holes and securely install the brake cylinder
assembly.
RA19250330
9. Install the bleeder plug (w/ bleeder plug cap).

a. Securely install the bleeder plug (w/ bleeder plug cap)
(arrow) to the front brake caliper assembly. 
(Tightening torque: 5.88 - 9.8 N·m)
25
RA19250320

25 - BRAKE
Installation
CAUTION
 Make sure to tighten the fixing bolts and nuts to the specified torque during installation.
 Before installing the brake linings, completely retract the brake caliper piston back into the bore of the
brake caliper.
 Depress the brake pedal several times to secure the brake linings to the brake disc in order to ensure
safety after installing the brake linings and before moving the vehicle.
 Replace the brake linings in pairs. DO NOT replace it alone.
 DO NOT install the inner brake lining and outer brake lining reversely.
 Be sure to check the brake system for leakage after installation. Repair or replace the malfunctioning
parts as necessary.
 Be sure to perform the bleeding procedures for the brake system after installation.
 Be sure to add brake fluid to the proper level after installation.
25

25 - BRAKE
Front Brake Hose Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment when repairing to prevent accidents.
 Try to prevent the body paint surface from being scratched during removal and installation.
HINT:
CAUTION
3. Remove the front left brake hose assembly.

a. Disengage the fixing clamp (arrow) and loosen the 1
coupling plug (1) between front left brake hose
assembly and front left brake pipe.
RA19250470
CAUTION
 DO NOT bend or damage the brake tube.

 DO NOT allow any foreign matter such as dirt and dust to enter the brake tube from the joint parts.
 After removing the brake line, perform sealing treatment to prevent foreign matter from entering.
25

25 - BRAKE
b. Remove the coupling bolt (arrow) between front left

shock absorber assembly and front left brake hose
assembly.
RA19250480
c. Remove the coupling bolt and washer (arrow)

between front left brake caliper assembly and front left
brake hose assembly.
RA19250290
CAUTION
 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing the brake hose, as the
brake fluid is corrosive.
d. Remove the front left brake hose assembly.
Installation
CAUTION
 Make sure to tighten the fixing bolts and plug to the specified torque during installation.
parts as necessary.
25

25 - BRAKE
Rear Drum Brake Assembly
15 4
14
7
8
13
9
10
12
11
RS19250540
25

25 - BRAKE
1 - Rear Brake Bottom Board 2 - Rear Drum Brake Assembly

3 - Rear Brake Drum 4 - Rear Brake Wheel Cylinder
5 - Brake Shoe Return Tension Spring (Upper) 6 - Brake Shoe Adjusting Unit
7 - Brake Shoe Adjusting Unit Return Tension Spring 8 - Brake Shoe Stopper Pin
9 - Brake Shoe Stopper Spring Blade 10 - Brake Shoe Link Rod Dowel Pin
11 - Clevis 12 - Brake Shoe Return Tension Spring (Lower)
13 - Brake Shoe Lining 14 - Brake Shoe Pushrod Return Tension Spring
15 - Brake Shoe Link Rod
1. Check the rear brake drum runout.
a. Remove the rear wheel (See page 23-10).
b. Secure the dial indicator (1) to the proper position.
Position the dial indicator pointer approximately 10 2
mm from the outer edge of the rear brake drum. 1
c. Slowly rotate the rear brake drum (2) and check the
runout. Mark the lowest and highest points and record
these measurements.
RA19250541
d. Check the runout on the opposite side of the rear brake drum in the same way. Mark the lowest and
highest points and record these measurements.
e. Compare the recorded runout value and limit value.
Maximum runout for rear brake drum: 0.05 mm
f. If the runout exceeds the maximum value, replace the rear brake drum.
Removal
CAUTION
1. Remove the rear left wheel (See page 23-10).
25 CAUTION

25 - BRAKE
3. Remove the rear brake drum.

a. Completely release the parking brake lever. Remove
the fixing screw (arrow) from the rear brake drum and
remove the rear brake drum by pulling it out. 
RA19250550
Disassembly
1. Remove the rear bearing end cover (See page 21-19).
2. Remove the rear shaft assembly locking nut (See page 21-19).
3. Remove the rear axle hub assembly (See page 21-19).
4. Remove the brake shoe return tension spring (upper).
a. Using the needle-nose pliers, remove the brake shoe
return tension spring (upper) as shown in the
illustration.
RA19250560
5. Remove the brake shoe return tension spring (lower).

return tension spring (lower) as shown in the
illustration.
RA19250570
25

25 - BRAKE
6. Remove the brake shoe stopper spring set.

a. Using the needle-nose pliers, press the brake shoe
stopper spring blade and rotate the brake shoe
stopper pin clockwise or counterclockwise to remove
the brake shoe stopper spring set on both sides as
RA19250580
7. Remove the brake shoe pushrod return tension spring.

pushrod return tension spring (arrow) as shown in the
illustration.
RA19250590
8. Remove the left brake shoe lining.

a. Disengage the left brake shoe lining from the brake
shoe adjusting unit as shown in the illustration.
RA19250600
9. Remove the brake shoe adjusting unit.

a. Disengage the brake shoe adjusting unit from the right
brake shoe lining as shown in the illustration.
RA19250610
25

25 - BRAKE
b. Using the needle-nose pliers, remove the return

tension spring (arrow) from the brake shoe adjusting
unit as shown in the illustration.
RA19250620
10.Remove the right brake shoe lining.

a. Using the needle-nose pliers, tighten the return spring
(arrow) on the end of parking brake rear cable and
disengage it from the brake shoe link rod as shown in
the illustration.
RA19250630
b. Remove the right brake shoe lining with brake shoe

link rod as shown in the illustration.
RA19250640
c. Remove the clevis (1) as shown in the illustration.

d. Remove the brake shoe link rod (2) from the right 1
brake shoe lining as shown in the illustration.
RA19250650
25

25 - BRAKE
11. Remove the rear brake wheel cylinder.

a. Unscrew the bleeder plug cap and remove the
3
bleeder plug (1) as shown in the illustration.
(Tightening torque: 5.88 - 9.8 N·m) 1
b. Loosen the coupling plug (2) of rear wheel brake pipe
as shown in the illustration. 
2
c. Remove the coupling bolts (3) between rear brake
wheel cylinder and rear brake bottom board as shown
RA19250660
CAUTION
d. Remove the rear brake wheel cylinder.
RA19250670
12.Remove the rear brake bottom board.

a. Using the needle-nose pliers, remove the parking
brake rear cable assembly fixing wire (arrow) and
disengage the parking brake rear cable assembly
from the rear brake bottom board as shown in the
illustration.
RA19260130
b. Remove 4 coupling bolts (arrow) between rear brake

bottom board and rear shaft assembly as shown in the
illustration. 
25
RA19250680

25 - BRAKE
c. Remove the rear brake bottom board.
RA19250690
Inspection
1. Check the thickness of brake shoe lining.
a. Using a ruler, measure the thickness of the brake
shoe lining as shown in the illustration.
Standard thickness: 5 mm
Minimum thickness: 1 mm
b. If the thickness of brake shoe lining is not more than
the minimum value, replace the brake shoe lining.
RA19250700
CAUTION
 Replace the brake shoe linings in pairs. DO NOT replace it alone.
2. Check the rear brake drum inner diameter.

a. Using a vernier caliper or equivalent, measure the
rear brake drum inner diameter.
Standard inner diameter: 220 mm
Maximum inner diameter: 221.4 mm
RA19250710
b. If the rear brake drum inner diameter is more than the maximum value, replace the rear brake drum.
3. Check the brake wheel cylinder.
a. Check the dust boots on both sides of rear brake
wheel cylinder for fluid leakage as shown in the
illustration.
25
RA19250720

25 - BRAKE
b. If there is fluid leakage, replace the rear brake wheel cylinder.

4. Check other components.
a. Check if the brake shoe return tension spring (upper) is broken, bent, damaged or weak elasticity.
Replace it as necessary.
b. Check if the brake shoe return tension spring (lower) is broken, bent, damaged or weak elasticity.
c. Check if the brake shoe pushrod return tension spring is broken, bent, damaged or weak elasticity.
d. Check if the brake shoe adjusting unit return tension spring is broken, bent, damaged or weak elasticity.
e. Check if the parking brake rear cable assembly return spring is broken, bent, damaged or weak
elasticity. Replace it as necessary.
f. Check if the brake shoe adjusting unit is struck, rusted, damaged or slides off. Replace it as necessary.
Assembly
CAUTION
 The rear brake shoe of this vehicle is equipped with gear type automatic adjusting mechanism. There is
no need to adjust brake shoe clearance manually. Depress the brake pedal and the brake shoe
clearance can be adjusted by the auto-adjust unit installed between the two brake linings, when the
brake shoe clearance is beyond some certain value.
Installation
HINT:
Adjust the parking brake lever stroke after replacing the brake shoe. Check if the parking brake is functioning
properly after completing adjustment.
CAUTION
 Make sure to tighten the fixing bolts and nuts to the specified torque during installation.
parts as necessary.
25

25 - BRAKE
Rear Brake Hose Assembly

Removal
CAUTION
HINT:
CAUTION
2. Remove the rear left brake hose assembly.

a. Disengage the fixing clamp (arrow) and loosen the
coupling plug (1) between rear part of rear brake hose
assembly and brake pipe. 
RA19250730
CAUTION

25

25 - BRAKE
b. Disengage the fixing clamp (arrow) and loosen the

coupling plug (1) between front part of rear brake
hose assembly and brake pipe. 
RA19250740
CAUTION

c. Remove the rear brake hose assembly.
Installation
CAUTION
 Make sure to tighten the brake pipe plug in place.

parts as necessary.
25

PARKING BRAKE
GENERAL INFORMATION 26-3 Parking Brake Control Mechanism 
Circuit Diagram 26-5 Parking Brake Front Cable Assembly 26-13
Removal 26-13
DIAGNOSIS & TESTING 26-6 Installation 26-13
Problem Symptoms Table 26-6 Parking Brake Rear Cable Assembly 26-14
Adjustment 26-7 Installation 26-16
Parking Brake Switch Assembly 26-9
Removal 26-9
Inspection 26-10
Installation 26-10
26

26

26 - PARKING BRAKE
GENERAL INFORMATION
PARKING BRAKE
Description
×3
3 2
6
RA19260010
1 - Parking Brake Control Mechanism Assembly 2 - Parking Brake Switch Assembly

3 - Parking Brake Front Cable Assembly 4 - Parking Brake Rear Cable Assembly
5 - Parking Brake Cable Fixing Wire 6 - Rear Left Brake Assembly
7 - Rear Right Brake Assembly
26

26 - PARKING BRAKE
All vehicles are equipped with a manually operated parking brake control mechanism assembly, which is
mounted between the front seats. The tension balance block is built into parking brake front cable assembly.
Each rear wheel has an individual parking brake rear cable assembly, which is respectively connected with
the parking brake front cable assembly, parking brake control mechanism and rear brake shoe assembly. The
parking brake cable is made of flexible wire.
Specifications

Coupling Nut Between Parking Brake Control
25 ± 3
Mechanism Assembly and Vehicle Body
Coupling Bolt Between Armrest Box Fixing Bracket
Assembly and Parking Brake Control Mechanism 25 ± 3
Assembly
Coupling Nut Between Armrest Box Fixing Bracket
25 ± 3
Assembly and Vehicle Body
Coupling Bolt Between Parking Brake Rear Cable
10 ± 1.5
10 ± 1.5
10 ± 1.5
Assembly Bracket and Rear Shaft Assembly
Tool
General Tool
Digital Multimeter
RCH0000002
26

26 - PARKING BRAKE
Circuit Diagram
Parking Brake System
IGNITION SWITCH
ON OR START
INSTRUMENT
PANEL FUSE
RF01 AND RELAY
10A BOX
I-005
1
RW
13
INSTRUMENT
PARK CLUSTER
BRAKE
I-043
18
RL
21 I-003
B-050
RL
PARKING
APPLIED BRAKE
SWITCH
RELEASED B-022
1 2 3 4 5 6 7 8 9 10 11 12
29 30 31 32 33 34 35 36 37 38 39 40 41 42
13 14 15 16 17 18 19 20 21 22 23 24
15 16 17 18 19 20 21 22 23 24 25 26 27 28
25 26
87 1 2 3 4 5 6 7 8 9 10 11 12 13 14
85 86 86 86
87 30 87 30
30 85 85
I-003
I-005 W
B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B-022
I-043
L
W
26
EA19260010

26 - PARKING BRAKE
DIAGNOSIS & TESTING

HINT:
Use the table below to help determine the cause of the problem symptoms. Check each suspected area in

Parking brake control mechanism stroke
26-7
(incorrect)
Parking brake stuck Parking brake shoe clearance (incorrect) 26-7
Parking brake shoe return tension spring
25-41
(damaged)
Parking brake shoe (worn) 25-41
Rear brake drum (excessively worn) 25-41
Parking brake front cable assembly
26-13
(improperly fixed)
Abnormal parking brake operation Parking brake rear cable assembly

26-14
(improperly fixed)
Parking brake control mechanism
26-11
assembly (improperly fixed)
Parking brake control mechanism
26-11
assembly (stuck)
Brake warning light does not come on
Warning light circuit (faulty) 26-9
when parking brake is applied
26

26 - PARKING BRAKE
ON-VEHICLE SERVICE
Adjustment
Abnormal parking brake operation may be caused by the worn brake shoe, incorrect brake shoe clearance
adjustment, incorrect parking brake control mechanism stroke or incorrect parking brake component
installation. Perform the following procedures to adjust the parking brake control mechanism stroke:
CAUTION
 The rear brake shoe of this model is equipped with gear type automatic adjustment mechanism, so it is
not necessary to adjust the brake shoe clearance manually. When the brake clearance exceeds the
specified value, depress the brake pedal to adjust it through the automatic adjustment unit installed
between the two brake shoe linings.
1. Check the parking brake control mechanism stroke.

a. Pull up the parking brake control mechanism 3 to 4 times with a force of 260 ± 20 N, and count the
clicking sounds.
Standard: 4 to 7 clicking sounds (no rear parking brake stuck)
2. Support and raise the vehicle to the proper height.
4. Remove the rear brake drum assembly (See page 25-39).
6. Adjust the parking brake control mechanism stroke:
a. Fully release the parking brake control mechanism.
b. Pull up the parking brake control mechanism until 3 or
4 clicking sounds are heard, then tighten the parking
brake control mechanism locking nut.
RA19260020
c. After tightening the parking brake control mechanism locking nut, pull the parking brake control
mechanism 3 times with a force of 200-300 N to eliminate the remaining force of the cable.
d. Correct judgment method: after adjustment, completely release the parking brake control mechanism
and rotate the rear wheel by hand.
OK: Rear wheel can be rotated freely without dragging.
Pull up the parking brake control mechanism until a clicking sound is heard. There is resistance when
rotating the rear wheel by hand. Pull up the parking brake control mechanism until 2 clicking sounds are
heard and the rear wheel cannot rotate.
e. When operating the parking brake control mechanism, check that the brake warning light illuminates at
the first click.
OK: Parking brake warning light always illuminates at the first click.
f. If the result is not as specified, repeat the above procedures until the parking brake control mechanism 26
stroke is proper.
7. Install the auxiliary fascia console assembly (See page 43-10).

26 - PARKING BRAKE
8. Install the rear brake drum (See page 25-39).

9. Install the rear wheel (See page 23-10).
26

26 - PARKING BRAKE
Parking Brake Switch Assembly

1. Disconnect the parking brake switch assembly connector, and check the continuity of the parking brake
switch assembly with the ohm band of digital multimeter as shown in the table below.
Standard Condition
Condition
Parking brake
applied (switch Continuity 1
Terminal 1 - Body pin released)
ground Parking brake
released (switch No continuity
pin pushed) RA19260030
If the result is not as specified, replace the parking brake

switch assembly.
Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when repairing.
1. Fix the tire and wheel assembly.

3. Remove the parking brake switch assembly.
a. Disconnect the parking brake switch assembly wire
harness connector (arrow) as shown in the illustration.
RA19260040
b. Using a cross screwdriver, loosen the fixing screw

(arrow) of parking brake switch assembly.
26
RA19260050

26 - PARKING BRAKE
c. Remove the parking brake switch assembly.
Inspection
1. Check the parking brake switch assembly.
a. Check the parking brake switch assembly for wear or break. Replace the parking brake switch
assembly as necessary.
b. Check if the parking brake switch assembly compressed spring is damaged or the spring force is
insufficient. Replace the parking brake switch assembly as necessary.
Installation
26

26 - PARKING BRAKE
Parking Brake Control Mechanism Assembly

Removal
CAUTION

3. Remove the parking brake switch assembly (See page 26-9).
4. Remove the parking brake control mechanism assembly.
b. Loosen the locking nut (arrow) of parking brake
control mechanism assembly to release the tension of
parking brake cable assembly as shown in the
illustration.
RA19260020
c. Remove the fixing bolts and the fixing nuts (arrow) of

armrest box fixing bracket assembly as shown in the
illustration.
RA19260060
d. Remove the coupling nuts (arrow) between the

parking brake control mechanism assembly and the
vehicle body.
RA19260070
e. Disengage the parking brake front cable assembly and remove the parking brake control mechanism
26
assembly.

26 - PARKING BRAKE
Installation
CAUTION
HINT:
Be sure to check the parking brake control mechanism stroke after installing the parking brake control
mechanism assembly. Adjust the parking brake control mechanism stroke to the proper position by adjusting
the parking brake control mechanism locking nut if necessary.
26

26 - PARKING BRAKE
Parking Brake Front Cable Assembly

Removal
CAUTION

3. Remove the parking brake front cable assembly.
illustration.
RA19260020
c. Disengage the parking brake rear cable assembly

from two grooves (arrow) on the rear of parking brake
front cable assembly.
RA19260080
d. Remove the parking brake front cable assembly.
Installation
HINT:
Be sure to check the parking brake control mechanism stroke after installing the parking brake front cable
assembly. Adjust the parking brake control mechanism stroke to the proper position by adjusting the parking
brake control mechanism locking nut if necessary.
26

26 - PARKING BRAKE
Parking Brake Rear Cable Assembly

Removal
CAUTION

2. Remove the rear brake drum assembly (See page 25-39).
3. Remove the rear axle hub (See page 21-19).
5. Remove the parking brake rear cable assembly.
illustration.
RA19260020
c. Disengage the parking brake rear cable assembly

from two grooves (arrow) on the rear of parking brake
front cable assembly.
RA19260080
d. Loosen the coupling bolts and nut (arrow) between

the front of parking brake rear cable assembly and the
vehicle body. 
26 RA19260090

26 - PARKING BRAKE
e. Loosen the coupling nuts (arrow) between the center

part on the left side of parking brake rear cable
assembly and the vehicle body, and disengage the
cable fixing bracket. 
RA19260100
f. Loosen the coupling nuts (arrow) between the rear left

fixing bracket of parking brake rear cable assembly
and the rear shaft assembly. 
RA19260101
g. Loosen the coupling nuts (arrow) between the center

part on the right side of parking brake rear cable
assembly and the vehicle body, and disengage the
cable fixing bracket. 
RA19260110
h. Loosen the coupling nuts (arrow) between the rear

right fixing bracket of parking brake rear cable
assembly and the rear shaft assembly.
RA19260120
26

26 - PARKING BRAKE
i. Remove the left side fixing wire (arrow) of parking

brake rear cable assembly with the needle nose
pliers, and use the same procedure to remove the
right side.
RA19260130
j. Using the needle-nose pliers, tighten the left side

return spring (arrow) of parking brake rear cable
assembly and disengage the spring ends from the
brake shoe interlock rod, and use the same procedure
to remove the right side.
RA19260140
k. Remove the parking brake rear cable assembly.
Installation
CAUTION
 During installation, make sure to align the positioning part of the parking brake rear cable assembly fixing
bracket and the positioning hole on the vehicle body.
HINT:
The parking brake should be adjusted after replacing the brake shoe or parking brake cable assembly. Check
if the parking brake is functioning properly after adjustment is completed.
 Fully pull up the parking brake control mechanism.
 Release the parking brake control mechanism and check if the rear wheels rotate freely.
 If the wheels are difficult to rotate freely, repeat the adjustment procedure.
 After driving for a period of time, the parking brake control mechanism stroke should be readjusted
because of the wear of rear brake shoes.
26

STEERING COLUMN
GENERAL INFORMATION 27-3 Combination Switch Cover 27-12
Steering Column Assembly 27-14
Removal 27-14
Disassembly 27-16
Steering Wheel Free Play Inspection 27-7
Inspection 27-17
Steering Wheel Centering/Returnability
Assembly 27-17
Inspection 27-8
Installation 27-18
ON-VEHICLE SERVICE 27-9 Intermediate Shaft with Universal 
Steering Wheel Assembly 27-9 Joint Assembly 27-19
Inspection 27-10 Inspection 27-19
27

27

27 - STEERING COLUMN
GENERAL INFORMATION
STEERING COLUMN
Description
×4
4
5
6 7
×2
8
9
×2
10
RA19270010
27

1 - Driver Airbag 2 - Steering Wheel Assembly Fixing Nut

3 - Steering Wheel Assembly 4 - Spiral Cable
5 - Combination Switch Upper Cover 6 - Wiper and Washer Combination Switch
7 - Light Combination Switch 8 - Steering Column with Ignition Switch Assembly
9 - Combination Switch Lower Cover 10 - Intermediate Shaft with Universal Joint
Assembly
Specifications
Description Tightening Torque (N·m)

Steering Wheel Assembly Fixing Nut 35 ± 3.5
Combination Switch Cover Fixing Screw 1.5 ± 0.5
Steering Column Upper Bracket Fixing Nut 23 ± 2.5
Steering Column Assembly Lower Bracket Fixing
25 ± 3
Bolt
Coupling Bolt Between Steering Column Assembly
and Intermediate Shaft with Universal Joint 23 ± 2.5
Assembly
Coupling Bolt Between Intermediate Shaft with
Universal Joint Assembly and Steering Gear Input 30 ± 3
Shaft
Ignition Switch Illumination Light Fixing Screw 2 ± 2.5
Data Specifications
Description Standard Value

Steering Wheel Free Play (Rotation Angle) ≤15°
Steering Wheel Centering/Returnability (Rotation
>70°
Angle)
27

Tools
Special Tool
RCH0000014
General Tool
Electric Drill
RCH0000013
27

DIAGNOSIS & TESTING

HINT:
Steering wheel assembly cannot lock or Ignition key cylinder 27-16

unlock Ignition switch lock body 27-16
Front axle hub bearing (seriously worn) 21-12
Intermediate shaft with universal joint
27-19
assembly (seriously worn)
Steering wheel assembly has no free play
Ball pin assembly (worn or loosen) 28-20
or is too large
Steering tie rod assembly 28-22
Steering gear assembly (improper
28-24
engagement gap of rack and pinion)
Front tire (improperly inflated or unevenly
23-8
worn)
Front sub frame welding assembly 21-16
Hard steering 27-19
assembly (insufficiently lubricated)
Ball pin assembly (insufficiently lubricated) 28-20
Steering column assembly 27-14
Steering gear assembly 28-24
Front tire (improperly inflated or unevenly
23-8
worn)
Front suspension 22-11
Ball pin assembly (loosen, insufficiently
28-20
Poor returnability lubricated)
27-19
assembly (loosen, insufficiently lubricated)
Steering column assembly (stuck) 27-14
Steering gear assembly (stuck) 28-24
27


27-19
assembly
Knocking (or clunking) sound occurs when
turning the steering wheel while steering Control arm ball pin 22-23
system is in operation Control arm 22-21
Steering Wheel Free Play Inspection

1. Stop the vehicle and position the front wheels straight ahead.
2. Gently turn the steering wheel left and right, and check
the rotation angle of steering wheel when the wheels start
to rotate.
Standard value of free play (rotation angle): a ≤ 15°.
SRS
AIRBAG
a
RA19270020
3. If the measured value exceeds the standard value, check the steering system.
27

Steering Wheel Centering/Returnability Inspection

The steering wheel centering/returnability inspection should be performed during the road test.
1. Perform the slow turn and sharp turn test.
Check for the deviation of steering wheel steering force required during left/right turn and centering/
returnability.
2. When the vehicle speed is between 20 and 30 km/h, turn
the steering wheel either to left or right by 90° and keep it
for 1 or 2 seconds, and then release the steering wheel. If
the steering wheel turns more than 70°, it is determined
that the steering wheel centering/returnability is in good 70° 70°
condition.
SRS
AIRBAG
RA19270030
3. If the steering wheel returning angle is not as specified, check the tire pressure, steering system and
suspension system.
27

ON-VEHICLE SERVICE
Steering Wheel Assembly
Removal
WARNING
 Be sure to read the precautions for SRS airbag before removing the steering wheel (See page 30-3).
1. Set the steering wheel to the straight-ahead position.

CAUTION
 Wait at least 90 seconds after disconnecting the negative battery cable to prevent the airbag and belt
pretensioner from being activated.
4. Remove the driver airbag (See page 30-41).

5. Remove the steering wheel assembly.
a. Disconnect the steering wheel quick button connector
(arrow) (if equipped).
H E F
C
3 4
100 120
140 2 5
80
60 160
6
40
180 1
200 7
20 0
220
0
MIST
MODE
MUTE
VOL
V A/C
SEEK
V
RA19270040
b. Secure the steering wheel assembly, and put

matchmarks on the steering wheel assembly and
steering column assembly, then remove the steering
wheel assembly fixing nut with a wrench. 
C H E F
100 120
80 140 3 4
60 160 2 1 RPT
5 4 RDM
40 180 2 UP
20
1 6 5 DN
200
3

0 220 6
0 7
TUNE
MUTE
SCAN
USB CD BAND
AUX AST
SET
2
1
3 4
A/C
0
CARD CARD
STORAGE BOX
RA19270050
27

c. As shown in the illustration, install the steering wheel

remover, and then tighten the steering wheel remover
with a wrench to loosen the steering wheel assembly
from the steering column assembly.
F
180
0
20
0
22
RA19270060
CAUTION
 When taking out the steering wheel assembly, be careful to avoid damaging the airbag connector, horn
connector and quick button connector on the spiral cable.
d. Remove the steering wheel assembly.
Inspection
1. Check the steering wheel assembly body for damage or deformation. Replace the steering wheel
assembly if necessary.
2. Check the spline in the steering wheel assembly for damage. Replace the steering wheel assembly if
necessary.
Installation
CAUTION
 Check that the front wheels are in the straight-ahead position before installing the steering wheel
assembly.
1. Adjust the spiral cable to the correct position.

100 120 3 4
HINT:
80 140 2 5
60 160
40 180 1 6
20 200
Fully turn the spiral cable inner circle clockwise, and turn
0 7
0 220
0
it 3.2 rotations counterclockwise to align the arrow marks. OFF

MIST
OFF
OFF
LO
HI
RA19270070
2. Pass the airbag connector, horn connector and quick button connector through the hole of steering wheel
assembly, and then align the matchmarks on the steering wheel assembly and the steering column
assembly to install the steering wheel assembly.
3. Other installation procedures are in the reverse order of removal.
27

CAUTION
 Tighten the steering wheel assembly fixing nut to the specified torque.
 Install each connector in place.
 After repairing, check that the airbag system operates normally.
27

Combination Switch Cover

Removal
3. Remove the combination switch cover.
HINT:
Remove the steering wheel assembly first, and then remove the combination switch cover if necessary.
a. Turn the steering wheel to the right, and remove the
right side fixing screw (arrow) from the combination
switch cover. 
3 4
5
MIST
OFF
LO
HI
S
AIRB
RAGS
2
1
34
0
RA19270080
b. Turn the steering wheel to the left, and remove the left
side fixing screw (arrow) from the combination switch
cover. 
100 120
80 140
60 160
40 180
20 200
0 220
MIST
AIRBAG
SRS
OFF OFF
OFF
LO
HI
RA19270090
c. Remove the lower fixing screw (arrow) from the

combination switch cover. 
RA19270100
27

d. First disengage the connecting clamps (1) on the top

of upper cover and lower cover, and then disengage
the connecting clamps (2) on both sides of upper
cover and lower cover.
1
2
1
2 RA19270101
CAUTION
 Operate carefully to prevent damage to the components during removal.
e. Remove the upper cover and lower cover.
Inspection
1. Check the combination switch upper and lower covers for damage or deformation. Replace the upper and
lower covers if necessary.
2. Check if the upper and lower cover clamps are normal. Replace the upper and lower covers if necessary.
Installation
1. Loosen the steering wheel adjusting handle, and adjust the steering column assembly to the uppermost
position, then tighten the adjusting handle to the uppermost position.
2. Insert the steering column lower cover from the right side of ignition switch at an angle, and then install the
adjusting handle into the cover hole.
3. After adjusting the lower cover, install the upper cover and fix the upper and lower cover clamps in place,
then install the tapping screws.
CAUTION
 Operate carefully to avoid damaging components during installation.

 Tighten the cover tapping screws in place.
27

Steering Column Assembly

Removal
4. Remove the driver airbag (See page 30-41).
5. Remove the steering wheel assembly (See page 27-9).
6. Remove the combination switch cover (See page 27-12).
7. Remove the spiral cable (See page 30-44).
8. Remove the combination switch assembly.
a. Disconnect the connector (1) from the light
combination switch and the connector (2) from the
wiper and washer combination switch.
2
1
RA19270110
b. Remove the light combination switch in the direction

of arrow as shown in the illustration.
RA19270120
c. Remove the wiper and washer combination switch in

the direction of arrow as shown in the illustration.
RA19270130
27

9. Remove the steering column with ignition switch assembly.

a. Disconnect the ignition starting switch connector (1).
RA19270140
b. Remove the coupling bolt (1) between steering

column assembly and intermediate shaft with
universal joint assembly. 
c. Remove the fixing bolt (2) from the steering column 2
assembly.  1
RA19270150
d. Remove 2 fixing nuts (arrow) from the steering

column assembly upper bracket, and remove the
steering column with ignition switch assembly. 
RA19270160
CAUTION
 DO NOT touch the interior ornament when taking out the steering column with ignition switch assembly
to avoid scratching the interior ornament.
27

Disassembly
1. Remove the ignition starting switch.
a. Remove the fixing screw (arrow) of ignition starting
switch, and then remove the ignition starting switch. 
RA19270170
2. Remove the ignition switch illumination light.

a. Remove the ignition switch illumination light connector
(1) from the ignition switch lock body.
b. Remove the fixing screw (2) from the ignition switch
illumination light, and then remove the ignition switch 1
illumination light.  2
RA19270180
3. Remove the ignition key cylinder.

a. Turn the ignition switch key cylinder to "ACC" position
with the key, and insert a small screwdriver or similar
tool to the ignition switch lock body hole, then pull out
the ignition key cylinder.
RA19270190
4. Remove the ignition switch lock body.

a. Set the steering column assembly onto a vise.
CAUTION
 DO NOT tighten the vise excessively.
27

b. Using an electric drill (1), drill a hole on the ignition

switch lock body anti-theft bolts (arrow).
1
RA19270200
c. Using a screw remover, remove the ignition switch

lock body anti-theft bolts.
RA19270201
d. Remove the ignition switch lock body and ignition switch fixing clamp.
Inspection
1. Check if the ignition switch lock body and key cylinder are normal. Replace the ignition switch lock body
and key cylinder if necessary.
2. Check the steering column assembly for wear, cracks or deformation, and welding or correction is not
allowed. Replace the steering column assembly if necessary.
3. Check the steering column bearing for looseness, wear or stuck. Replace the steering column assembly if
necessary.
Assembly
1. Install the ignition switch assembly.
a. Set the steering column assembly onto a vise.
CAUTION
 DO NOT tighten the vise excessively.
b. Install the ignition switch assembly to the steering

column assembly with new ignition switch lock anti-theft
bolts, and then tighten the anti-theft bolts until the heads
are disengaged.
RA19270210
27

2. Install the ignition key cylinder.

a. Push the ignition key cylinder into the ignition switch
lock body until the ignition key cylinder fixing block
locks in place.
RA19270220
b. Check if the ignition key cylinder operates normally. When the key is removed, the steering lock is
locked; when the key is inserted and the ignition switch is turned to "ACC" or "ON" position, the steering
lock is unlocked.
Installation
CAUTION
 Before installing the steering column assembly, slide the spline at the lower part of steering column
assembly onto the intermediate shaft upper universal joint first.
 Tighten the fixing nuts, bolts and screws in place.
27

Intermediate Shaft with Universal Joint Assembly

Removal
3. Remove the intermediate shaft with universal joint assembly.
a. Remove the coupling bolt (arrow) between
intermediate shaft with universal joint assembly and
steering column assembly. 
RA19270230
b. Remove the coupling bolt (arrow) between

intermediate shaft with universal joint assembly and
steering gear input shaft. 
RA19270240
c. Move the intermediate shaft with universal joint assembly upward to detach the lower universal joint
from the steering gear input shaft, and then move it downward to remove it.
Inspection
1. Check the intermediate shaft with universal joint assembly for rust, wear or deformation and the universal
joint spline for damage or insufficient lubrication. Apply grease or replace the intermediate shaft with
universal joint assembly if necessary.
2. Check the universal joint for wear or insufficient lubrication, and the welding part for breakage. Replace the
intermediate shaft with universal joint assembly if necessary.
3. Check if the intermediate shaft retracts smoothly, if it is stuck or cannot retract, replace the intermediate
shaft with universal joint assembly.
Installation
CAUTION
 Tighten each fixing bolt in place.
27

- MEMO -

Description 28-3 Power Steering Pump Assembly 28-17
Specifications 28-5 Disassembly 28-18
28
Assembly 28-18
Installation 28-19
Ball Pin Assembly 28-20
Steering Fluid Replacement 28-9
Removal 28-20
Steering Fluid Draining 28-9
Inspection 28-21
Steering Fluid Adding 28-10
Installation 28-21
Bleeding Procedures 28-11
Steering Tie Rod Assembly 28-22
Steering Fluid Reservoir Assembly 28-13 Inspection 28-23
Inspection 28-13 Steering Gear Assembly 28-24
Steering Fluid Pipe 28-14 Inspection 28-27
Inspection 28-16 Steering Gear Clearance Adjustment 28-27

28

28 - HYDRAULIC ASSIST STEERING
GENERAL INFORMATION
Description
28
3
×2
×2
×2 2
4
5
6
7
×2
×3
8
11
×3
9
×3
14 10
×2
12
13
15
16
17
18
19
×2
22
20
23
×2
24
21 25
×2
RA19280010

1 - Steering Fluid Reservoir Assembly 2 - Fluid Suction Pipe

3 - Tensioning Bracket 4 - Power Steering Pump Fixing Bolt
5 - Power Steering Pump Bracket 6 - Power Steering Pump Fixing Bracket
7 - Tensioning Bolt 8 - Adjustment Bolt
28 9 - Power Steering Pump Pulley 10 - Power Steering Pump Assembly
11 - Fluid Return Pipe 12 - High Pressure Fluid Pipe
13 - Steering Gear Boot 14 - Ball Pin Locking Nut
15 - Right Ball Pin Assembly 16 - Steering Tie Rod Adjustment Nut
17 - Right Steering Tie Rod Boot 18 - Clamping Ring
19 - Right Steering Tie Rod Assembly 20 - Steering Gear Assembly
21 - Steering Gear Assembly Fixing Bolt 22 - Left Steering Tie Rod Assembly
23 - Left Steering Tie Rod Boot 24 - Elastic Clamp
25 - Left Ball Pin Assembly
The hydraulic assist steering system consists of the power steering pump assembly, steering gear assembly,
steering fluid pipe and steering fluid reservoir assembly and so on. This system can reduce the steering force
when the driver operates the steering wheel, thus improving the operation convenience and driving safety.
Steering Gear Assembly

The steering gear assembly is rack & pinion type which is characterized by simple and compact construction
and high steering sensitivity. The piston rod is integrated with the rack, and there is a boot at the connection
between steering tie rod assembly and rack. The length of steering tie rod can be adjusted properly to match
with the toe-in. The tie rod ball pin assembly and steering knuckle are connected and tightened by the locking
nut.
Power Steering Pump Assembly

The power steering pump assembly is connected with steering gear assembly by the high pressure fluid pipe,
and connected with steering fluid reservoir assembly by the fluid suction pipe. Never operate the power
steering pump assembly without fluid. Try to avoid turning the steering wheel to the limit position for more than
5 seconds during operation.
Steering Fluid Pipe

The steering fluid pipe is used to deliver power steering fluid. Steering fluid pipes are divided into steel pipe,
hose and hybrid type according to the length and operating features of each component. Ferrule connection is
adopted between the steel pipe and hose of high pressure fluid pipe assembly. The joint bolt and O-ring are
used between steel pipe and component, and hose and clamp are used between hose and component. And
all these provide reliable sealing.
Steering Fluid Reservoir Assembly

The main functions of steering fluid reservoir assembly are to store the fluid and supply it to the steering fluid
pump and system.
Operation
The steering gear assembly converts the circular motion of steering wheel into linear motion of rack by
engaging the rack and pinion inside. The power steering pump assembly delivers the fluid into the steering
gear assembly to drive the pistons move toward the direction made by the driver. The piston transmits the
force to the steering knuckle by the steering tie rod assembly, thus reducing the steering effort when the driver
turns the steering wheel. If the steering assist is ineffective, more steering effort is needed.

Specifications

Fluid Suction Pipe Upper Bracket Fixing Bolt 7 ± 1.5
28
Fluid Suction Pipe Lower Bracket Fixing Bolt 7 ± 1.5
High Pressure Fluid Pipe Joint Hollow Bolt 45 ± 5
Coupling Bolt Between Upper Bracket of Fluid
Return Pipe and High Pressure Pipe and Front Sub 9±1
Frame Welding Assembly
Joint Bolt Between High Pressure Pipe and Steering
30 ± 3
Gear Assembly
Joint Bolt Between Fluid Return Pipe and Steering
30 ± 3
Gear Assembly
Lower Bracket Fixing Nut Between Fluid Return Pipe
9±1
and High Pressure Pipe
Fluid Return Pipe Bracket Nut 7 ± 1.5
Power Steering Pump Tensioning Bracket Fixing Bolt 20 ± 3
Power Steering Pump Assembly Inner Torx Bolt 25 ± 3
20 ± 3
Assembly and Right Side of Steering Pump Bracket
20 ± 3
Assembly and Left Side of Steering Pump Bracket
Power Steering Pump Assembly Pulley Inner Torx
20 ± 3
Round Bolt
Locking Nut of Through Bolt Between Ball Pin
35 ± 3
Assembly and Steering Knuckle Assembly
Steering Tie Rod Adjustment Nut 47 ± 3
Coupling Bolt Between Intermediate Shaft and Input
25 ± 3
Shaft of Steering Gear Assembly
Locking Nut of Rear Mounting Bracket and Rear
85 ± 8.5
Mounting Cushion Assembly Through Bolt
Coupling Bolt Between Body and Rear Part of Front
120 ± 10
Assembly
Coupling Bolt Between Steering Gear Assembly and
100 ± 10

Tools
Special Tool
28
Ball Pin Separator
RCH0000024
General Tools
RCH0000005
Engine Equalizer
RCH0000026

DIAGNOSIS & TESTING

HINT:
sequence. Repair or replace the faulty components, or adjust them as necessary. 28

Steering fluid (insufficient or dirty) 28-9
Steering tie rod boot (damaged or worn) 28-22
Stuck or sticking in some position occurs
Steering tie rod assembly (rust) 28-22
when turning
Power steering pump drive belt (loose) 07-21
Tire (unevenly worn, deformed) or wheel
23-8
(out of balance)
Ball pin assembly (worn or loose) 28-20
Steering tie rod assembly (worn or loose) 28-22
Steering wheel is not centered or centered Intermediate shaft (twisted and deformed)
improperly or universal joint (worn, loose or 27-19
insufficiently lubricated)
Front steering knuckle assembly 21-10
Steering gear assembly (incorrect
28-24
clearance)
Tire (unevenly worn, deformed) or wheel
23-8
(out of balance)
Brake disc and lining (deformed) 25-26
Steering shudders Intermediate shaft (twisted and deformed)

or universal joint (worn, loose or 27-19
insufficiently lubricated)
Front steering knuckle assembly 21-10
28-24
clearance)


Tire (improperly inflated) 23-8
Steering fluid (insufficient) 28-10
28 Fluid pipe (leaked or blocked) 28-14
Steering wheel turns heavily or steering Steering tie rod assembly (worn or loose) 28-22
effort is uneven
Front suspension 22-11
Power steering pump drive belt (loose or
07-21
damaged)
Power steering pump assembly 28-17
28-24
clearance)
Steering fluid (insufficient, air exsisting or
28-9
dirty)
Steering system fluid pressure fluctuates
-
abnormally
Abnormal noises from steering system Ball pin assembly (worn or loose) 28-20
Steering tie rod assembly (worn or loose) 28-22
28-24
clearance)
Power steering pump assembly 28-17

Steering Fluid Replacement

Steering Fluid Draining
3. Disconnect the negative battery cable. 28
4. Turn the ignition switch to ACC.
5. Open the steering fluid reservoir cap.
7. Remove the fluid suction pipe clamp (arrow) on the
power steering pump assembly side.
RA19280020
8. Place a fluid container under the fluid suction pipe, and disconnect the fluid suction pipe joint to collect the
steering fluid flowing out of the fluid suction pipe.
9. Turn the steering wheel left and right to the limit positions, and repeat the operation several times to drain
the steering fluid in the steering system.
WARNING
 If the steering fluid sprays on your skin, immediately wash it off with water.
 It is harmful to your skin contacting with power steering fluid for a long time.
 The wasted power steering fluid should be handled according to local environmental regulations.

Steering Fluid Adding

The proper steering fluid level is between "MAX" mark and
"MAX" mark. It affects the performance of power steering
system directly whether the fluid level in the fluid reservoir is
proper. If the fluid level drops below the "MIN" mark, it is
necessary to add steering fluid. MAX
28
COLD
MIN
RA19280030
CAUTION
 DO NOT use the foaming or expired steering fluid which may damage the power steering pump
assembly.
1. Open the steering fluid reservoir cap, and add steering fluid to the reservoir until it reaches the "MAX"
mark.
2. Start the engine and run it at idle to drive the power steering pump assembly, thus filling the whole steering
system with steering fluid.
3. Observe the fluid level while the engine is running. If the fluid level drops below the "MIN" mark, add
steering fluid to the proper level in time to avoid air entering the power steering pump assembly due to the
excessively low fluid level.
4. If bubbles occur in the steering fluid reservoir, perform the bleeding procedures. Check that the level is
between "MAX" mark and "MIN" mark when there are no bubbles in the fluid reservoir and the fluid level
does not change any longer.
WARNING
 If the steering fluid sprays on your skin, immediately wash it off with water.
 It is harmful to your skin contacting with power steering fluid for a long time.

Bleeding Procedures
It is necessary to perform bleeding procedures when bubbles occur in the steering fluid reservoir assembly
and the fluid is emulsifying or there is excessive noise in the power steering pump assembly.
Bleeding procedures are as follows:
1. Open the steering fluid reservoir cap.
2. Raise the vehicle with a lifter (with the front wheels off ground). 28
3. Start the engine (idling) and turn the steering wheel left and right to the limit positions (do not stay at the
limit positions more than 2 seconds). Repeat several times to completely bleed the air in the system from
the reservoir. Observe the fluid level in reservoir when bleeding. If the fluid level drops below the "MIN"
mark, add steering fluid to the proper level in time.
4. After repeatedly turning the steering wheel to the limit positions several times, center the steering wheel,
run the engine at idle for 3 to 5 minutes and observe whether there are still bubbles in the fluid reservoir. If
there are still bubbles, perform the above procedures again until no bubbles are bled. If there are still
problems, perform the steering system inspection.

ON-VEHICLE SERVICE
WARNING
 Be sure to wear the necessary safety equipment to prevent accidents when servicing.
28  When removing and installing the high temperature components and surrounding components, wait and
operate them until they cools down to normal temperature to avoid being burned.
 Prevent skin and eyes from contacting with steering fluid.
CAUTION
 After disconnecting the steering line, seal it immediately to prevent foreign matter from entering.
 Never run the power steering pump assembly when the steering fluid is insufficient.
 The steering wheel should not be in the limit position for more than 5 seconds.
 Never start the engine with the hose loosened or disconnected.
 Never allow the hose to contact with the high temperature exhaust pipe.

Steering Fluid Reservoir Assembly

Removal
2. Remove the steering fluid reservoir assembly.
a. Remove the fluid suction pipe clamp (1) on the 28
steering fluid reservoir and disconnect the connection
between fluid suction pipe assembly and steering fluid
reservoir assembly.
2
b. Remove the fluid return pipe clamp (2) on the steering
fluid reservoir and disconnect the connection between
fluid return pipe assembly and steering fluid reservoir
assembly.
1
RA19280040
CAUTION
 Using a plug, clog the disconnected pipe to prevent foreign matter from entering.
c. Pull upward to remove the steering fluid reservoir assembly.
Inspection
1. Check the steering fluid reservoir assembly for breakage or deformation. Replace the fluid reservoir if
necessary.
2. Check if there is contamination in the steering fluid reservoir assembly. Clean or replace it if necessary.
Installation
CAUTION
 Install the fluid suction pipe clamp and fluid return pipe clamp in place.
 Never tap or hit the fluid reservoir.

Steering Fluid Pipe

Removal
28  Collect the steering fluid flowing out of the line with a container when disconnecting the line.

2. Remove the fluid suction pipe.
a. Remove the fluid suction pipe clamp (arrow) on the
between fluid suction pipe and steering fluid reservoir
assembly.
RA19280041
b. Remove the fluid suction pipe upper bracket fixing bolt

(arrow). 
RA19280090
c. Remove the fluid suction pipe lower bracket fixing bolt

(arrow). 
RA19280100
d. Remove the fluid suction pipe.

3. Remove the fluid return pipe and high pressure fluid fluid.
a. Remove the hollow bolt (arrow) from the high
pressure fluid pipe joint on the power steering pump
assembly.
28
RA19280050
b. Remove the fluid return pipe clamp (arrow) on the

between fluid return pipe and steering fluid reservoir
assembly.
RA19280042
c. Remove the coupling bolt (arrow) between upper

bracket of fluid return pipe and high pressure fluid
pipe and front sub frame welding assembly.
RA19280060
d. Remove the high pressure fluid pipe joint bolt (1) and
fluid return pipe joint bolt (2) from the steering gear
assembly. 1
(Tightening torque for fluid return pipe joint bolt: 
30 ± 3 N·m)
(Tightening torque for high pressure fluid pipe joint
bolt: 30 ± 3 N·m)
2
RA19280070

e. Remove the lower bracket fixing nut of fluid return

pipe and high pressure fluid pipe (1) and fluid return
pipe bracket fixing nut (2).
(Tightening torque for lower bracket fixing nut of fluid 2
return pipe and high pressure fluid pipe: 9 ± 1 N·m) 1
(Tightening torque for fluid return pipe bracket fixing
nut: 7 ± 1.5 N·m)
28
RA19280080
f. Remove the fluid return pipe and high pressure fluid pipe.
Inspection
1. Check the steering fluid pipe for cracks, wear or blockage. Replace the steering fluid pipe assembly if
necessary.
2. Check the steering fluid pipe joint and O-ring for deformation or damage. Replace the steering fluid pipe
assembly if necessary.
3. Check if the steering fluid pipe bracket is normal. Replace it if necessary.
Installation
CAUTION
 Never tap or squeeze the steering fluid pipe.

 Tighten the fixing nut to the specified torque.

Power Steering Pump Assembly

Removal
 Collect the steering fluid flowing out of the line with a container when disconnecting the line. 28

2. Remove the power steering pump drive belt (See page 07-21).
3. Remove the power steering pump with bracket assembly.
a. Disconnect the power steering pump assembly
pressure switch connector (1).
2
b. Remove the high pressure fluid pipe joint hollow bolt
1
(2). 
(Tightening torque for high pressure fluid pipe joint
hollow bolt: 45 ± 5 N·m)
connection between fluid suction pipe and power 3
steering pump assembly.
RA19280110
CAUTION
 Using a plug, clog the disconnected steering system line to prevent foreign matter from entering.
d. Remove 2 fixing bolts (arrow) from the power steering

pump tensioning bracket.
RA19280120
e. Remove the power steering pump assembly inner

Torx bolt (arrow) and remove the power steering
pump with bracket assembly. 
RA19280130

Disassembly
1. Separate the power steering pump assembly and steering pump bracket.
2. Remove 3 coupling bolts (arrow) between power steering
pump assembly and right side of steering pump bracket.
28
RA19280140
3. Remove 3 coupling bolts (arrow) between power steering

pump assembly and left side of steering pump bracket.
RA19280141
4. Remove the power steering pump assembly pulley.

5. Remove 3 inner Torx round bolts from the power steering
pump assembly pulley as shown in the illustration.
RA19280150
Inspection
1. Check the power steering pump assembly for blockage or damage, and power steering pump bearing for
looseness and abnormal noise. Replace the power steering pump assembly if necessary.
2. Check if the power steering pump pulley is normal. Replace the power steering pump assembly if
necessary.
3. Check if the power steering pump bracket is normal. Replace the power steering pump bracket if
necessary.
Assembly
CAUTION

 DO NOT tap or hit the power steering pump assembly.

Installation
CAUTION
 Tighten the fixing bolts to the specified torque.

 DO NOT tap or hit the power steering pump assembly. 28

Ball Pin Assembly

Removal
HINT:
28  The procedures listed below are for the left side.
2. Remove the ball pin assembly.
a. Remove the locking nut (arrow) between left ball pin
assembly and front left steering knuckle assembly.
RA19280151
b. Screw the locking nut until it is flush with the thread

end surface, install the ball pin separator (1), and 1
tighten the ball pin separator bolt with a wrench (2) to
separate the ball pin assembly and the steering
knuckle assembly.
2
RA19280152
c. Loosen the steering tie rod adjustment nut (1), and

turn the ball pin assembly (2) counterclockwise to
remove it.
1
HINT:
When removing the ball pin assembly, record the 2
revolutions during removal to make the front wheel
toe-in closer to the setting value after installation.
RA19280160

Inspection
Check the ball pin assembly for looseness and insufficient lubrication and the bush rubber for damage.
Replace the ball pin assembly if necessary.
Installation
28
CAUTION
 After installation, it is necessary to perform the wheel alignment procedure (See page 22-40).

Steering Tie Rod Assembly

Removal
HINT:
28  The procedures listed below are for the left side.
4. Remove the ball pin assembly (See page 28-20).
5. Remove the steering tie rod assembly.
a. Remove the steering tie rod boot clamp (arrow).
RA19280170
b. Remove the steering tie rod boot clamping ring

(arrow) and remove the steering tie rod boot.
RA19280180
CAUTION
 Operate carefully to prevent damage to the boot.

 It is necessary to replace with new clamping ring when reinstall the steering tie rod boot.
c. Using a wrench, remove the steering tie rod ball pin

(arrow).
RA19280190

Inspection
1. Check the steering tie rod boot for damage, and if the clamp is normal. Replace the steering tie rod boot
and clamp if necessary to prevent water and micro dust from entering and causing parts failure
prematurely.
2. Check the steering tie rod assembly for deformation or wear and the ball for insufficient lubrication.
Replace the steering tie rod assembly or add grease if necessary.
28
Installation
CAUTION
 It is necessary to apply thread seal gum to the ball pin.

 It is necessary to fit the steering tie rod ball pin face and the rack face closely.

Steering Gear Assembly

Removal
WARNING
28  Be sure to wear the necessary safety equipment to prevent accidents when servicing.
 When removing and installing the high temperature components and surrounding components, wait and
operate them until they cools down to normal temperature to avoid being burned.
 Prevent skin and eyes from contacting with steering fluid when removing the steering system
components.
CAUTION
 After disconnecting the steering system line, seal it immediately to prevent foreign matter from entering.
 Never run the power steering pump assembly when the steering fluid is insufficient.
 The steering wheel should not be in the limit position for more than 5 seconds.
 Never start the engine with the hose loosened or disconnected.
 Never allow the hose to contact with the high temperature exhaust manifold or catalyst.

8. Remove the coupling bolt (arrow) between intermediate
shaft lower universal joint and input shaft of steering gear
assembly and disconnect the connection between
intermediate shaft lower universal joint and input shaft of
steering gear assembly. 
RA19280200
9. Separate the ball pin assembly and the steering knuckle.

HINT:

a. Loosen the locking nut (arrow) between left ball pin

assembly and front left steering knuckle assembly.
28
RA19280151
b. Screw the locking nut until it is flush with the thread

end surface, install the ball pin separator (1), and 1
tighten the ball pin separator bolt with a wrench (2) to
separate the ball pin assembly and the steering
knuckle assembly.
2
RA19280152
10.Remove the steering gear with tie rod assembly.

a. Remove the coupling bolt (arrow) between the upper
bracket of fluid return pipe and high pressure fluid
pipe and the front sub frame welding assembly.
RA19280060
b. Remove the high pressure fluid pipe joint bolt (1) and
fluid return pipe joint bolt (2) on the steering gear
assembly. Disconnect the connection between fluid 1
return pipe/high pressure pipe and steering gear
assembly separately. 
(Tightening torque for fluid return pipe joint bolt: 
30 ± 3 N·m)
(Tightening torque for high pressure fluid pipe joint 2
bolt: 30 ± 3 N·m)
RA19280070

c. Remove the locking nut (1) of through bolt between

assembly and remove the through bolt (2).
2
28 1
RA19280210
d. Support the front sub frame welding assembly with the transmission carrier.
e. Loosen the coupling nut (arrow) between the front left
part of front sub frame welding assembly and the
body. Use the same procedure to loosen the right side
nut.
RA19280211
f. Remove 2 coupling bolts (1) between rear part of front

control arm assembly and front sub frame welding
assembly. 
g. Remove 2 coupling bolts (2) between the rear part of
front sub frame welding assembly and the body.
2 RA19280220
h. Remove 2 coupling bolts between steering gear

assembly and front sub frame welding assembly. 
RA19280230
i. Lower the front sub frame welding assembly to the proper position slowly and remove the steering gear
boot and steering gear with tie rod assembly.

Inspection
1. Check the steering gear assembly housing for damage or deformation, and the rack and pinion for
sticking. Replace the steering gear assembly if necessary.
2. Check if the steering tie rod boot, clamp and clamping ring are normal. Replace them if necessary to
prevent water and micro dust from entering and causing parts failure prematurely.
3. Check the steering tie rod assembly and ball pin assembly for serious wear. Replace the steering tie rod
assembly and ball pin assembly if necessary.
28
Installation
CAUTION
 After installing the steering gear assembly, perform the front wheel alignment procedure (See page 22-40).
Steering Gear Clearance Adjustment

1. Set the wheels to the straight-ahead position.
2. Loosen the adjustment bolt locking nut (arrow).
RA19280240
3. Rotate the steering wheel clockwise and counterclockwise. If sound is heard from the steering gear
assembly, regulate the adjustment bolt until no clattering noise is heard when turning the steering wheel.
4. Tighten the adjustment bolt 1/8 rotation (approximately 45°).
5. Perform the road test.
6. If the steering mechanism cannot return to the central position, unscrew the bolt by 15°.
7. Perform the road test.

- MEMO -

AIR CONDITIONING
GENERAL INFORMATION 29-3 Inspection 29-28
Description 29-3 Installation 29-28
Specifications 29-5 Inner/Outer Circulation Damper 
Tools 29-7 Motor 29-29
Circuit Diagram 29-8 Removal 29-29 29
Inspection 29-29
DIAGNOSIS & TESTING 29-12 Installation 29-30
Problem Symptoms Table 29-12 Mode Damper Servo Motor 29-31
On-vehicle Inspection 29-15 Inspection 29-31
Compressor Assembly Noise  Installation 29-32
Inspection 29-15 HVAC Assembly 29-33
Refrigerant Leakage Inspection 29-16 Removal 29-33
Refrigerant Recovering/Draining 29-18 Disassembly 29-36
Vacuum Pumping 29-19 Inspection 29-45
Refrigerant Recharging 29-19 Assembly 29-48
Refrigerant Oil Recovering 29-20 Installation 29-48
Refrigerant Oil Charging 29-21 A/C Low Pressure Line 29-49
A/C Control Panel Assembly 29-22 Removal 29-49
Inspection 29-23 A/C High Pressure Line 29-51
A/C Element 29-25 Installation 29-53
Removal 29-25 Compressor Assembly 29-54
Blower Assembly 29-26 Installation 29-55
Removal 29-26 Condenser Assembly (w/Receiver 
Inspection 29-26 Drier) 29-56
Blower Speed Resistor 29-27 Inspection 29-57

29

29 - AIR CONDITIONING
GENERAL INFORMATION
AIR CONDITIONING
Description
29
A/C
7 6
1 2
0
3 4
8
×3
10
RA19290010

1 - HVAC Transition Duct 2 - HVAC Assembly

3 - Expansion Valve 4 - Condenser To Evaporator Line Assembly
5 - Evaporator To Compressor Line Assembly 6 - A/C Control Panel Assembly
7 - O-ring 8 - Compressor To Condenser Line Assembly
9 - Compressor Assembly 10 - Condenser Assembly (w/Receiver Drier)
29
1. System composition
The A/C system consists of the following four parts:
Air conditioning and distribution system: air mixing and distributor part of HVAC, inner/outer circulation
inlet, outlet, air filter.
Control system: A/C control panel assembly, inner/outer circulation damper motor, mode damper servo
motor, blower, blower speed resistor, A/C high/low pressure switch and evaporator temperature sensor.
Heating system: heater core assembly, heating inlet hose, heating outlet hose and engine cooling
circulation system.
Cooling system: compressor assembly, condenser assembly (w/receiver drier), expansion valve,
evaporator tank assembly and A/C high/low pressure line.
2. Operation
High-pressure Low-pressure
Gas Liquid
High-pressure Low-pressure
Liquid Gas
Compressor
Outside Air
Condenser
Evaporator
Blower Motor
Refrigerant
Expansion Valve
Pressure Sensor
RA19290020
Outside fresh air enters the air inlet filter assembly through the cowl top opening at the right side of
windshield base. The fresh air flows through the evaporator core and heater core, and then enters into the

vehicle through the outlets on the instrument panel and the floor. The intake air volume can be adjusted by
the blower speed switch on the A/C control panel assembly. Turn on the compressor assembly by pressing
the A/C switch on the A/C control panel assembly. The refrigerant is compressed by the compressor
assembly and converted into high temperature - high pressure gas, which is then condensed into high
pressure liquid in the condenser. Then the liquid is filtered and dried by the receiver drier and delivered to
the expansion valve and becomes low-pressure liquid through throttling and depressurization. Finally the
liquid enters the evaporator in the vehicle, absorbs the heat and evaporates, thus refrigeration is achieved.
The A/C heating is realized by the engine coolant circulation system. The heater core is the main
component of the heating system. With the engine running, engine coolant flows from the engine water
pump to the heater core, the heater core transmits the heat from engine coolant to the air that flows
29
through the heater core. At this time, the A/C switch is off. The air flowing through the heater core becomes
hot wind through the heat exchanger, thus providing heating. The temperature adjustment control
mechanism can be controlled by rotating the temperature adjustment knob, and the mix damper closes
when temperature adjustment knob is rotated counterclockwise to MAX COOL position. If the airflow does
not flow through the heater core, the heat transmission will not occur. When rotating the temperature
adjustment knob clockwise from the MAX COOL position, the mix damper will open slowly, allowing air
flows through the heater core. Most of the airflow is heated in this way and the discharged air becomes
warmer. When the temperature adjustment knob is rotated counterclockwise to the MAX HOT position, the
mix damper is opened fully and all the air flows through the heat core, thus the air is heated. Mode knob on
the A/C control panel is used to direct the air with temperature adjusted through selected outlets.
Specifications

A/C Control Panel Assembly Fixing Screw 1.5 ± 0.5
Blower Assembly Fixing Screw 1.5 ± 0.5
Blower Speed Resistor Fixing Screw 1.5 ± 0.5
9 ± 1.5
and Expansion Valve
A/C Wire Harness Assembly Ground Point Fixing
20 ± 3
Nut
Coupling Nut Between Upper Part of HVAC
3.5 ± 0.5
Assembly and Body
Coupling Bolt Between Lower Part of HVAC
3.5 ± 0.5
Assembly and Body
Coupling Bolt Between Expansion Valve and
9 ± 1.5
Expansion Valve Mounting Pressure Plate
Left Foot Fan Shield Fixing Screw 1.5 ± 0.5
Right Foot Fan Shield Fixing Screw 1.5 ± 0.5
Inner/Outer Circulation Damper Motor Fixing Screw 1.5 ± 0.5
Air Inlet Housing Assembly Fixing Screw 1.5 ± 0.5
Blower Case Assembly Fixing Screw 1.5 ± 0.5
Evaporator Cover Plate Fixing Screw 1.5 ± 0.5
Evaporator Cover Housing Assembly Fixing Screw 1.5 ± 0.5
Temperature Damper Adjustment Mechanism Fixing
1.5 ± 0.5
Screw
Mode Damper Servo Motor Fixing Screw 1.5 ± 0.5


Mode Damper Servo Motor Bracket Fixing Screw 1.5 ± 0.5
Mode Damper Adjustment Mechanism Set Fixing
1.5 ± 0.5
Screw
Heater Core Line Pressure Plate Fixing Screw 1.5 ± 0.5
7 ± 1.5
29 Set Bracket and Body
Fixing Bolt Between A/C Low Pressure Line and
25 ± 4
Compressor Assembly
Fixing Bolt Between A/C High Pressure Line and
25 ± 4
Compressor Assembly
Fixing Nut Between A/C High Pressure Line I and
9 ± 1.5
Condenser Assembly
Fixing Nut Between A/C High Pressure Line II and
9 ± 1.5
Condenser Assembly
Fixing Bolt Between Compressor Assembly and
25 ± 4
Mounting Bracket
Fixing Nut Between Condenser Assembly and Tank
5±1
Upper Crossmember
Refrigerant Charging Specification
Description Charging Capacity (g)

R134a Refrigerant 400 ± 10
Refrigerant Oil Charging Specifications
Description Charging Capacity (ml)

It is necessary to pour out 50 ml of refrigerant oil
Compressor Assembly Replacement
from the new compressor assembly
Condenser Replacement 40
Evaporator Replacement 30
A/C Line Replacement 10

Tools
General Tools
Refrigerant Recycling Machine 29
RCH0000046
Digital Multimeter
RCH0000002

Circuit Diagram
A/C Control System (Page 1 of 4)
BATTERY
29
86 30
ENGINE
EF35 ECM EF22 EF07 COMPARTMENT
10A MAIN 40A 30A FUSE AND
RELAY RELAY BOX
85 87 B-011
B-012
30 86 B-013
EF17 A/C
CLUTCH
15A
RELAY
87 85
C1 C17 D6 D14 C16 F2
RW
RW
5
R
B-021 I-047
R
B-008
1 B
E-038
R
L
1 3 1
A/C
RB
YV
PRESSURE (HIGH)
R
SWITCH A/C
E-027 (MID) HIGH/LOW
OPEN CLOSE PRESSURE
2
OPEN CLOSE (LOW) SWITCH
B-004
B
OPEN CLOSE
E-026 4 2
BW
LR
20 5 15 16 42 24 28
ECM
B-001
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
C1 C2 C3 C4 C5 C6 C7
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 C11 C12 C13 C14 16 15 14 13 12 11 10 9
C8 C9 C10 C15 C16 C17 C18
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
B-013
B-008
W
B
B-001
B
1 2 3 4 2 1 F1 1 2
D1 D2 D3 D4 D5 D6 D7 D8 5 6 7 8 4 3
D13 D14 D15 D16 F2
D9 D10 D11D12 D17 D18 D19 D20
B-012
W B-021 B-004 B-011 E-027
W B Lg B
EA19290010


ON OR ACC ON OR START
RF16 RF03
29
10A 10A
INSTRUMENT
PANEL FUSE
87 85
AND RELAY
BLOWER BOX
RELAY I-005
30 86
RF25
5A
25 3
RW
A
BCM
B I-046
RW
BY
L
A30 A29
B-053
8
I-004
GB
RB
L
I-031
14 1 12 4 6 9 10 K-003
BrO
RW
BW
BW
WB
OG
OR
A10 A20 B3 A8 A9 A19

HVAC CONTROL
PANEL AND
BLOWER SWITCH
K-007
K-008
1 2 3 4 5 6 7 8 9 10 11 12
42 41 40 39 38 37 36 35 34 33 32 31 30 29 B1 B2 B3
13 14 15 16 17 18 19 20 21 22 23 24
28 27 26 25 24 23 22 21 20 19 18 17 16 15
B-053 B4 B5 B6
25 26
14 13 12 11 10 9 8 7 6 5 4 3 2 1 L
87
K-007
85 86 86 86
87 30 87 30 W
30 85 85
I-005
B
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 1 2 3 4 5 6 7 8
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 9 10 11 12 13 14 15
K-008 I-031
I-046
B W
G
EA19290020

29
C
WB
1
BLOWER
M K-004
2
TO
INTERIOR
LAMPS
GV
SPEED RESISTOR
K-005 EVAPORATOR
4 TEMPERATURE I-026
R1 R2 R3 SENSOR
P
K-002
1 2 3
1 2 I-031
2 3 5
K-003
K-001
YGr
BrB
GV
YG
RY
GL
BY
Br
B1 B6 B4 B5 A4 A3 B2 A5 A6 A7
HVAC CONTROL
PANEL AND
BLOWER SWITCH
K-007
K-008
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 8 7 6 5 4 3 2 1
A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 B4 B5 B6 15 14 13 12 11 10 9
K-008 K-007 K-003

B W W
1
1 2
1 2
3 4 2
K-002
K-005 K-004
W
W W
EA19290030

29
HVAC CONTROL
PANEL AND
BLOWER SWITCH
K-008
A2 A1 A18 A17 A16 A15 A14
LW
VB
RL
LB
BL
V
5 6 5 7 3 6 2
INNER AND OUTER MODE DAMPER
CIRCULATION MOTOR MOTOR
M M
K-006 K-009
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 1 2 3
6 5 4 3 2 1
A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 4 5 6 7
K-006
K-008 L K-009
B
W
EA19290040

DIAGNOSIS & TESTING

HINT:
29
Blower fuse (damaged) 49-27
Blower relay (damaged) 49-27
Blower speed switch (damaged) 29-23
Blower motor (damaged) 29-26
Mix damper control mechanism (stuck or
29-36
damaged)
A/C no heating
Mix damper control knob (stuck or
29-22
damaged)
Warm air water pipe (blocked or damaged) 29-33
Heater core assembly (blocked or
29-36
damaged)
Wire harness or connector (open or short) -
Leak in system 29-16
Refrigerant (overcharged) 29-18
A/C high/low pressure switch (damaged) -
Evaporator temperature sensor (damaged) 29-36
A/C switch (damaged) 29-22
Compressor assembly fuse (damaged) 49-27
Compressor assembly relay (damaged) 49-27
A/C no cooling
Compressor assembly belt (loose) -
Compressor assembly (damaged) 29-54
Condenser assembly (blocked or
29-56
damaged)
Expansion valve (blocked or frosted) 29-36
Evaporator core assembly (blocked or
29-36
damaged)
Wire harness or connector (open or short) -
A/C intermittent cooling Moisture in system -


Leak in system 29-16
Refrigerant (insufficient) 29-18
Refrigerant (overcharged) 29-18
Air in refrigerant -
Moisture in refrigerant -
29
Condenser (dirty or blocked) 29-56
A/C insufficient cooling Expansion valve (dirty or blocked) 29-36
Evaporator core (dirty or blocked) 29-36
A/C high/low pressure line (dirty or
29-49
blocked)
Blower speed switch (damaged) 29-23
Blower motor (damaged) 29-26
Compressor assembly belt (loose) -
Compressor assembly belt (slip) -
Compressor assembly clutch bearing
-
(worn and excessive clearance)
Compressor assembly solenoid coil (faulty
-
or loose joint)
Too much noise in system
Compressor assembly belt (over tightened) -
Compressor assembly mounting bolt
29-54
(loose)
Cooling fan blade (distorted) -
Refrigerant oil (too low) 29-20
Pressure at low pressure side switches
between normal and vacuum during Moisture in refrigerant (excessive) -
operation
Pressure is too low for low pressure side A/C system (leaked) 29-16
and high pressure side, cooling
performance is insufficient Refrigerant (insufficient) 29-18
Pressure is too low for low pressure side

and high pressure side, frost exists on line Condenser (dirty or blocked) 29-56
from condenser to A/C unit
Moisture in refrigerant (excessive) -
Vacuum occurs at low pressure side, and
pressure at high pressure side is too low, Expansion valve (dirty or blocked) 29-36
frost exists on lines on both sides of A/C line (leaked) 29-49
condenser or expansion valve
Condenser (dirty or blocked) 29-56
Pressure is too high for low pressure side Expansion valve (faulty) 29-36
and high pressure side Refrigerant oil (excessive) 29-20


Condenser surface (dirty) 29-56
Cooling fan (not operating) -
Pressure at low pressure side is normal or
slightly low, and pressure at high pressure Refrigerant (overcharged) 29-18
side is too high
Air in refrigerant -
Engine (overheating) -
29
Pressure at low pressure side is too high, Compressor assembly belt (slip) -
and pressure at high pressure side is too
low Compressor assembly (faulty) 29-54
Pressure at low pressure side is too low, A/C high pressure line (blocked) 29-51
and pressure at high pressure side is too
high Expansion valve (faulty) 29-36

ON-VEHICLE SERVICE
HINT:
The A/C refrigerant lines and hoses are used to transfer the refrigerant among the A/C system components.
Any twist or bent in the refrigerant lines and hoses will reduce the performance of A/C system and refrigerant
flow in system.
29
There remains high pressure in refrigerant when the A/C compressor assembly is operating. It is necessary to
ensure that each connecting part in A/C system is sealed well. Check all the system lines at least once a year
to ensure that it is in good condition and properly routed. The refrigerant lines and hoses cannot be repaired
and must be replaced if leakage or damage exists.
1. General inspection
a. Check if there exists any oil or dust in each joint of the A/C line. If this occurs, there may exist leak.
b. Check if the condenser surface is dirty and the fins are deformed.
c. Check if there are harsh noises while the compressor assembly is operating normally.
d. Temperature difference should be noticeable by touching the intake line and exhaust line of compressor
assembly with hand. Normally, the intake line is cool while the exhaust line is hot. Feel the temperature
of intake duct and exhaust duct of condenser with hand. Normally, the temperature of intake duct is
higher than that of exhaust duct. Feel the temperature difference between expansion valve inlet and
outlet line with hand. Normally, the expansion valve inlet line is hot while the outlet line is cool, and
temperature difference is noticeable between the two.
2. Using the pressure gauge set, check the refrigerant pressure.
a. Connect the manifold pressure gauge set. After the following conditions are met, read the pressure on
pressure gauge. Measurement conditions are as following:
 Inner/Outer circulation switch is in outer circulation position.
 Engine runs at approximately 2000 rpm.
 Adjust temperature knob to Max. Cool.
 Blower speed control switch is in highest band.
 Turn on A/C switch.
Observe the pressure value on the pressure gauge. In normal condition, the pressure at low pressure side is
0.15 - 0.20 Mpa and the pressure at high pressure side is 1.5 - 1.8 Mpa.
Compressor Assembly Noise Inspection

When checking the noise related to the A/C system, you must first know the conditions under which the noise
occurs. These conditions include: weather, vehicle speed, engine speed, engine temperature and any other
special conditions. Louder noises during A/C operation can often mislead someone. For example, what
sounds like a failed bearing, may be caused by loose bolts, mounting brackets or a loose compressor
assembly.
CAUTION
 The A/C compressor assembly must be replaced if any abnormal compressor assembly noise is heard.
 Noise may occur from the drive belt at different engine speeds, and you may mistake it for a noise from
A/C compressor assembly. The noise occurs when the compressor assembly operates at the maximum
displacement, and it will not occur at the minimum displacement.
1. Select a quiet place for testing.

2. Duplicate the customer's feedback information as much as possible.
3. Turn the A/C system on and off several times to clearly identify the compressor assembly noise.

4. Listen to the operation sound of A/C compressor assembly while it is operating at maximum and minimum
displacement positions.
5. Using an engine sound scope or a long screwdriver with handle, hold the A/C compressor assembly near
your ear for detecting, in order to locate the noise source easier.
6. To duplicate a high temperature condition (high pressure), air is limited to flow through the A/C condenser.
Install a manifold pressure gauge set to ensure that the discharge pressure is lower than 2550 kPa.
7. Check the condition of compressor assembly belt.
8. Check the compressor assembly hub, pulley and bearing assembly. Make sure that the hub and pulley are
29 aligned correctly, and the pulley bearing is securely installed to the A/C compressor assembly.
9. Check if the refrigerant line routes incorrectly, is damaged or has an interference that could result in an
abnormal noise. Also, check the refrigerant line for twist or bend, otherwise the refrigerant will be limited to
flow, which will cause a noise.
10.Loosen all the compressor assembly tightening bolts and retighten them.
11. If noise occurs when the liquid refrigerant in the A/C suction line is under a slugging condition, replace the
condenser and check the refrigerant oil level and the charging condition for refrigerant.
12.If the slugging condition still exists after replacing the condenser, replace the A/C compressor assembly.
WARNING
 DO NOT race the engine when the vacuum pump operates or vacuum exists in the A/C system. Failure
to do so may result in a serious damage to the A/C compressor assembly.
Refrigerant Leakage Inspection

WARNING
 DO NOT perform a pressure test or a leakage test to R134a service device or vehicle A/C system with
compressed air. The air mixture and R134a is inflammable at high pressure. These mixtures have
potential danger, and it may cause a fire or explosion, resulting in vehicle damage, personal injury or
death.
 Avoid inhaling the vapor or moisture from the A/C refrigerant and refrigerant oil.
 Only use technical service device to discharge the R134a system. If the system discharges
unexpectedly, ventilate the work place before servicing.
CAUTION
 If the A/C refrigerant filling amount is empty or low, the A/C system may have leak. Check all the A/C
lines, joints and parts for remaining oil. The remaining oil is the indication mark of A/C system leaking
position.
Check the refrigerant for leakage.

1. After recharging the refrigerant, use the gas leak detector to check the refrigerant gas for leakage.
2. Perform operations under the following conditions:
 Stop the engine.
 Ensure the ventilation is well (the gas leak detector may react to volatile gases which are not from
refrigerant, such as gasoline vapor or exhaust gas).
 Repeat the test for 2 or 3 times.
 Make sure that there is some refrigerant remaining in the refrigeration system.

3. Place the air leakage tester near the joint of A/C line, and
check the A/C line for leakage. If the air leakage tester
makes a sound, it indicates that a leakage exists. Repair
or replace the leakage A/C line as necessary.
29
RA19290030
4. Disconnect the A/C high/low pressure switch connector, use the same procedures to check the A/C high/
low pressure switch for leakage. Replace the A/C high/low pressure switch as necessary.
5. Insert the air leakage tester into the evaporator tank assembly, use the same procedures to check the
evaporator for leakage. Clean or replace the evaporator core assembly as necessary.
6. Use the same procedures to check the condenser for leakage. Clean or replace the condenser assembly
as necessary.
RA19290040

Refrigerant Recovering/Draining
WARNING
 Take extra care when servicing the A/C system under high pressure.
 Because there is refrigerant under high pressure in the A/C system, it must be serviced by professional
technician. Otherwise, a wrong service procedure may cause a serious danger or fatal injury.
29  If the A/C system is released pressure unexpectedly, ventilate the work area before servicing. In a closed
work place, a large amount of refrigerant is discharged, which may cause oxygen reduction and result in
smothering, causing a serious or fatal injury.
CAUTION
 It is necessary to recover the refrigerant with R134a refrigerant special recycling machine.
 DO NOT work near the open flame.
 Always dispose of the recovered refrigerant as specified.
 Never charge R-12 to the refrigerant system which is designed to use R134a. These refrigerants are
incompatible, which could damage the A/C system.
 DO NOT race the engine when the vacuum pump operates or vacuum exists in the A/C system.
Otherwise, the A/C compressor assembly will be damaged seriously.
 Never drain the refrigerant in the A/C system into the atmosphere directly, and avoid environmental
contamination.
1. Open the hood and loosen the joint cover of A/C high/low pressure line.
2. Connect the refrigerant recycling machine to the A/C high/low pressure line joint.
a. Connect the red connector to the A/C high pressure
line joint (1).
b. Connect the blue connector to the A/C low pressure
line joint (2).
2
RA19290050
3. Open the high pressure valve and low pressure valve of refrigerant recycling machine.
4. Choose the "recovering" item on the machine and make it start to operate.
5. Check the low pressure value on the pressure gauge to ensure that the recycling is completed, and then
turn the machine off.
6. Disconnect the connection between refrigerant recycling machine and A/C line joint.
7. Reinstall the cover onto the refrigerant line joint.

Vacuum Pumping
1. Open the hood and loosen the joint cover of A/C high/low pressure line.
line joint (1).
line joint (2).
2
29
RA19290050
4. Choose the "vacuum pumping" item on the machine and the time setting is 15 minutes, then choose "OK"
and make it start to operate.
5. Wait for 10 minutes after completing the operation, check if there is any change in the A/C system vacuum.
If there is any change, the A/C system leakage may exist, you should check and repair the A/C system. If
there is no change, proceed to perform the refrigerant charging procedures.
Refrigerant Recharging
CAUTION
 A small amount of refrigerant oil in the A/C system will be discharged when recovering and draining the
refrigerant. Be sure to supplement the lost refrigerant oil during recovering when filling the A/C system.
 DO NOT fill excessive refrigerant. Otherwise, it will cause excessive pressure to the compressor
assembly, resulting in compressor assembly noise and A/C system failure.
 Always perform vacuum pumping before recharging refrigerant.
1. Perform vacuum pumping with the vacuum pump.

2. Add refrigerant oil after checking that there is no leakage in A/C system.
3. Perform vacuum pumping for 3 minutes again after adding refrigerant oil, then charge refrigerant.
4. Choose the "charging" item on the machine and set the amount of charging to the specified value, then
choose "OK" and make it start to operate.
5. Open the suction valve and close the discharging valve, and then open the charging valve to allow the
refrigerant to flow into the system.
6. When the delivery of refrigerant has stopped, close the charging valve.
7. If the charged refrigerant is not delivered to the specified position, start the engine to operate the A/C
compressor assembly.
8. Open the charging valve to deliver the remaining refrigerant to A/C system.
WARNING
 At this time, do not open the exhaust (high pressure) valve. Failure to do so may result in personal injury
or even death.
9. Perform the A/C system pressure test after charging.

10.Remove the connecting pipe for refrigerant charging after the test is completed.
11. Reinstall the cover onto the A/C line joint.
Refrigerant Oil Recovering

CAUTION
 Special service equipment for R134a refrigerant must be used.

29
 Always keep the work area in good ventilation, because the A/C system is easy to leak.
 Always dispose of the recovered refrigerant as specified.
 The refrigerant oil must be charged after replacing the A/C system components or recovering the
refrigerant.
1. Open the engine hood and loosen the joint cover of A/C high/low pressure line.
line joint (1).
line joint (2).
2
RA19290050
4. Recover the refrigerant oil according to the instructions on the machine.
5. Record the amount of recovered refrigerant oil.
6. Disconnect the connection between refrigerant recycling machine and A/C line joint.
7. Reinstall the joint cover onto the refrigerant line joint.

Refrigerant Oil Charging

Refrigerant Oil Charging Amount Specifications
A/C Compressor
Condenser Evaporator
Item Assembly Line Replacement
Replacement Replacement
Replacement
It is necessary to
pour out 50 ml of
29
Charging Capacity refrigerant oil from
40 30 10
(ml) the new
compressor
assembly
1. Perform vacuum pumping with the vacuum pump. Wait for 10 minutes after completing the operation,
check if there is any change in the A/C system pressure. If there is any change, the A/C system leakage
may exist, you should check and repair the A/C system. If there is no change, proceed to perform the
refrigerant oil charging procedures.
2. Open the suction valve and close the exhaust valve, and then open the charging valve to allow the
refrigerant oil to flow into the system.
3. Close the charging valve after the refrigerant oil charging is completed.
4. Perform the vacuum pumping again for 3 minutes.
5. Continue to perform refrigerant charging procedures after the operation is completed.

A/C Control Panel Assembly

Removal
3. Remove the A/C control panel assembly.
a. Using a flat tip screwdriver wrapped with protective
29 tape, pry off the console panel assembly carefully.
4 RDM
3 1 RPT
5 DN
2 UP
6
3
disc
mp3 TUNE
VOL
MUTE
USB CD BAND AST

SET
AUX
SEL
0 1
3
A/C
4
CARD CARD
RA19410510
b. Disconnect the hazard warning light connector

(arrow).
RA19410520
c. Remove 2 fixing screws (arrow) from the A/C control

panel assembly, disengage the dowel pins (1) and the
fixing clamps on the lower part. 
RA19290060
d. Disconnect the A/C control panel assembly CD
BAN
D
SCA
AST
N
connectors (arrow), and disengage the temperature

SET
damper adjustment mechanism assembly (1).

1
RA19290070
e. Remove the A/C control panel assembly.

Inspection
1. Check the blower speed switch.
a. Remove the A/C control panel assembly.
b. Using the ohm band of the digital multimeter, check
for continuity between each terminal of blower speed
+ -
switch according to the table below.
3 2 1
6 5 4
29
RA19290080
Standard Condition
Blower Speed Switch Condition Multimeter Connection Specified Condition

Terminal 2 - Terminal 3 No continuity
OFF Terminal 3 - Terminal 5 No continuity
Terminal 2 - Terminal 3 Continuity
1st Terminal 2 - Terminal 6 Continuity
2nd Terminal 2 - Terminal 5 Continuity
3rd Terminal 2 - Terminal 4 Continuity
4th Terminal 2 - Terminal 1 Continuity
If the result is not as specified, replace the A/C control panel assembly.
2. Check the A/C control panel assembly.
a. Remove the A/C control panel assembly.

b. Using the ohm band of digital multimeter, check for

continuity between each terminal according to the
+ -
table below. 10 9 8 7 6 5 4 3 2 1
Standard Condition 20 19 18 17 16 15 14 13 12 11
Condition
Terminal 3 -
29 Terminal 16
Always Continuity
RA19290090
c. Connect the positive (+) battery lead to terminal 7 and

-
negative (-) lead to terminal 6, then check if the A/C +
control panel assembly switch backlight comes on. 10 9 8 7 6 5 4 3 2 1
OK: Light comes on. 20 19 18 17 16 15 14 13 12 11
If the result is not as specified, replace the A/C control

panel assembly.
RA19290100
Installation
CAUTION
 Be sure to install the clamp on the lower part of A/C control panel assembly in place when installing.
 Be sure to align the positioning hole on the upper part of A/C control panel assembly with the dowel pin
of instrument panel when installing.

A/C Element
Removal
1. Remove the glove box assembly (See page 43-16).
2. Remove the A/C element.
a. Pull the claws on both sides of A/C element cover
outward, and remove the A/C element cover (arrow)
from the air inlet assembly. 29
RA19290110
b. Pull out the A/C element (arrow) slowly from the air
inlet assembly.
RA19290120
Installation
CAUTION
 Be sure to check the A/C element for dirt when installing. Clean it as necessary.
 If the A/C element is too dirty or damaged, replace it with a new one.

Blower Assembly
Removal
3. Remove the blower assembly.
a. Disconnect the blower assembly connector (arrow).
29
RA19290130
b. Remove 3 fixing screws (arrow) from the blower

assembly. 
RA19290140
c. Rotate it lightly to remove the blower assembly.
Inspection
1. Check the blower motor.
a. Remove the blower assembly.
b. Connect the positive (+) battery lead to terminal 1 and
-
negative (-) battery lead to terminal 2. Check that the +
blower motor operates smoothly. 1

2
RA19290150
If the operation is not as specified, replace the blower assembly.
Installation

Blower Speed Resistor

Removal
WARNING
 During normal operation, the blower speed resistor may be very hot. Turn off the blower and wait for a
few minutes to cool the blower speed resistor before diagnosing or servicing, in order to avoid burns.
29
CAUTION
 DO NOT operate the blower assembly when removing the blower speed resistor from the vehicle. Failure
to do so may result in damage to the blower assembly.

3. Remove the blower speed resistor.
a. Disconnect the blower speed resistor connector
(arrow).
RA19290160
b. Remove 2 fixing screws (arrow) from the blower

speed resistor.
RA19290170
c. Remove the blower speed resistor.

Inspection
1. Check the blower speed resistor.
a. Remove the blower speed resistor.
b. Using the ohm band of digital multimeter, measure the + -
resistance value between each terminal according to 2 1
4 3
the table below.
Standard Resistance
29
Multimeter Connection Specified Condition
Terminal 1 - Terminal 2 Approximately 2.8 Ω
Terminal 1 - Terminal 3 Approximately 2.1 Ω RA19290180

If the result is not as specified, replace the blower

speed resistor.
Installation

Inner/Outer Circulation Damper Motor

Removal
4. Remove the inner/outer circulation damper motor.
a. Disconnect the inner/outer circulation damper motor
29
connector (arrow).
RA19290231
b. Remove 3 fixing screws (arrow), and disengage the

inner/outer circulation damper motor (1) from the air
inlet housing assembly. 
1
RA19290340
Inspection
1. Check the inner/outer circulation damper motor.
a. Connect a few dry batteries (approximately 5 V) in
series. Connect the positive (+) battery lead to - +
terminal 5 and negative (-) lead to terminal 6. Check

that the inner/outer circulation damper motor operates 1 2 3 4 5 6
smoothly counterclockwise (rotation angle (a) is a

approximately 120 degrees).
b. Connect a few dry batteries (approximately 5 V) in
series. Connect the positive (+) battery lead to
that the inner/outer circulation damper motor operates
RA19290690
smoothly clockwise (rotation angle (a) is
approximately 120 degrees).
If the operation is not as specified, replace the inner/
outer circulation damper motor.

Installation
CAUTION
 Tighten the fixing screws to the specified torque.

 When installing, apply a small amount of grease to the contact surface of inner/outer circulation damper
motor lever and the inner/outer circulation damper set to ensure the motor operates smoothly.
29

Mode Damper Servo Motor

Removal
3. Remove the mode damper servo motor.
a. Disconnect the mode damper servo motor connector
(arrow). 29
RA19290210
b. Remove 3 fixing screws (arrow) from the mode

damper servo motor, and remove the mode damper
servo motor (1). 
RA19290460
Inspection
1. Check the mode damper servo motor.
a. Connect a few dry batteries (approximately 5 V) in
series. Connect the positive (+) battery lead to - +
3 2 1
a
terminal 7 and negative (-) lead to terminal 5. Check 7 6 5 4
that the mode damper servo motor operates smoothly
counterclockwise (rotation angle (a) is approximately
120 degrees).
b. Connect a few dry batteries (approximately 5 V) in
series. Connect the positive (+) battery lead to
that the mode damper servo motor operates smoothly
RA19290700
clockwise (rotation angle (a) is approximately 120
degrees).
If the operation is not as specified, replace the mode
damper servo motor.

Installation
CAUTION
 Tighten the fixing screws to the specified torque.

 When installing, apply a small amount of grease to the contact surface of mode damper servo motor
lever and the mode damper adjustment mechanism set to ensure the motor operates smoothly.
29

HVAC Assembly
Removal
CAUTION
 Special service equipment for R134a refrigerant must be used to recover/charge the refrigerant.
 Be careful not to damage hoses during removal and installation. 29
 Always keep the work area in good ventilation.
 The disconnected A/C line and connecting part should be sealed to prevent foreign matter from entering.
1. Drain the engine coolant (See page 12-14).

2. Recover the refrigerant from the A/C system (See page 29-18).
6. Remove the steering column (See page 27-14).
7. Remove the instrument panel body assembly (See page 43-16, 43-26).
8. Remove the instrument panel crossmember assembly (See page 43-28).
9. Remove the HVAC assembly.
a. Remove the fixing bolt (arrow) between A/C high/low
pressure line and expansion valve, and disengage the
A/C high/low pressure line.
RA19290190
b. Using snap spring calipers, disengage the fixing

clamps (arrow) from the heating inlet and outlet hoses
to detach the inlet hose (1) and outlet hose (2).
2
RA19290200

c. Disconnect the mode damper servo motor connector

(arrow).
29
RA19290210
d. Remove the A/C wire harness assembly ground point

fixing nut (arrow) and disengage the ground wire (1)
1
from the body. 
RA19290220
e. Disconnect the evaporator temperature sensor

connector (1), blower speed resistor connector (2),
inner/outer circulation damper motor connector (3),
connecting package (4) of A/C wire harness assembly 3
and instrument panel wire harness assembly.
2
1 4
RA19290230
f. Disconnect the blower assembly connector (arrow).
RA19290130

g. Disengage the instrument panel wire harness

assembly fixing clip (arrow) from the right foot fan
shield.
29
RA19290240
h. Disengage the claws (arrow) on both sides of HVAC

assembly transition duct and remove them from the
HVAC assembly.
RA19290250
i. Remove 3 fixing nuts (arrow) between the upper part

of HVAC assembly and the body.
RA19290260
j. Remove the fixing bolt (arrow) between the lower left

RA19290270

k. Remove the fixing bolt (arrow) between the lower right

29
RA19290280
l. Remove the fixing bolt (arrow) between the lower

center of HVAC assembly and the body, and
disengage the A/C drain pipe (1) from the body
positioning hole.
1
RA19290290
m. Carefully take off the HVAC assembly from the cabin.
Disassembly
1. Remove the A/C element (See page 29-25)
2. Remove the blower assembly (See page 29-26)
3. Remove the blower speed resistor (See page 29-27).
4. Remove the inner/outer circulation damper motor (See page 29-29).
5. Remove the mode damper servo motor (See page 29-31).
6. Remove the expansion valve.
a. Remove 2 fixing bolts (arrow) between expansion
valve and expansion valve mounting pressure plate. 
RA19290300

b. Disengage the A/C high/low pressure line and remove

the expansion valve carefully.
29
RA19290310
7. Remove the left foot fan shield.

a. Remove 2 fixing screws (arrow), and disengage the
left foot fan shield (1) from the HVAC assembly. 
RA19290320
8. Remove the right foot fan shield.

a. Remove 2 fixing screws (arrow), and disengage the
right foot fan shield (1) from the HVAC assembly. 
1
RA19290330
9. Remove the air inlet housing assembly.

a. Remove 2 fixing screws (arrow) between air inlet
housing assembly and blower case assembly (right
side). 
RA19290350

b. Remove 2 fixing screws (arrow) between air inlet

housing assembly and blower case assembly (left
side) and disengage the fixing clip (arrow). 
29
RA19290360
c. Detach the blower case assembly from the air inlet housing assembly.
10.Remove the inner/outer circulation damper set.
a. Remove the air inlet weatherstrip (arrow).
RA19290370
b. Remove 6 fixing screws (arrow) from the air inlet

housing assembly. 
RA19290380
c. Disengage the fixing claw and detach the air inlet

housing assembly, then take out the inner/outer
circulation damper set.
RA19290390

11. Remove the blower case assembly.

a. Remove the evaporator core line weatherstrip (arrow).
29
RA19290400
b. Remove 2 fixing screws (arrow) from the evaporator

cover plate. 
RA19290410
c. Remove the upper fixing screw and clip (arrow)

between blower case assembly and evaporator tank
assembly. 
RA19290420
d. Remove the lower fixing screw (arrow) between

blower case assembly and evaporator tank assembly. 
RA19290430
e. Detach the blower case assembly from the evaporator tank assembly.

12.Remove the temperature damper adjustment mechanism.

a. Remove the fixing screw (arrow) from the temperature
damper adjustment mechanism. 
29
RA19290440
b. Remove the temperature damper adjustment

mechanism from the evaporator tank assembly.
RA19290450
13.Remove the mode damper adjustment mechanism set.

a. Remove 3 fixing screws (arrow) from the mode
damper servo motor set bracket. 
RA19290470
b. Remove the mode damper adjustment mechanism

set I (arrow).
RA19290480

c. Remove the fixing screw (arrow) and mode damper

adjustment mechanism set II. 
29
RA19290490
14.Remove the heater core.

a. Remove the heater core line grommet (arrow).
RA19290500
b. Remove 2 fixing screws (arrow) from the heater core

line pressure plate. 
RA19290510
c. Carefully take out the heater core in the direction of

arrow.
RA19290520

15.Remove the A/C drain pipe.

a. Remove the A/C drain pipe (arrow) from the bottom of
evaporator tank assembly.
29
RA19290530
16.Remove the evaporator core.

a. Remove the expansion valve mounting pressure plate
(arrow) from the evaporator core line.
RA19290540
b. Remove 3 fixing screws (arrow) from the upper part of

evaporator tank assembly. 
RA19290550
c. Remove 3 fixing screws (arrow) from the lower part of

RA19290560

d. Carefully take out the evaporator core (arrow) from

the evaporator tank assembly.
29
RA19290570
17.Remove the evaporator temperature sensor.

a. Remove the evaporator temperature sensor (arrow)
from the evaporator core.
RA19290580
18.Remove the temperature/face/defrost/foot damper set.

a. Remove 2 fixing screws and fixing clip (arrow) from
the upper part of evaporator tank assembly. 
RA19290590
b. Remove 6 fixing screws (arrow) from the center of

RA19290600

c. Remove the fixing screw and fixing clip (arrow) from

the lower part of evaporator tank assembly. 
29
RA19290610
d. Disengage the fixing clamp and detach the evaporator

tank case, and remove the temperature damper set.
RA19290620
e. Remove the face damper set.
RA19290630
f. Remove the defrost damper set.
RA19290640

g. Remove the foot damper set.
29
RA19290650
Inspection
1. Check the evaporator temperature sensor.
a. Using the ohm band of digital multimeter, measure the
resistance of evaporator temperature sensor
according to the table below. + - 1 2
RA19290660
Standard Resistance
Multimeter Connection Temperature (°C) Specified Condition (kΩ)

Terminal 1 - Terminal 2 -6 9.1362
Terminal 1 - Terminal 2 0 6.6500

Multimeter Connection Temperature (°C) Specified Condition (kΩ)

29
HINT:
The resistance decreases as the temperature increases.
If the result is not as specified, replace the evaporator temperature sensor.
CAUTION
 The resistance value may change even if the sensor is touched slightly. Make sure that the connector of
sensor is held firmly.
 During measurement, the sensor temperature must be almost the same as the ambient temperature.
2. Check the evaporator core assembly.

a. Check if the evaporator core assembly is cracked, damaged and leaked.
 If any problem is found, replace the evaporator core assembly.
b. Check the fin for bends.
 If any fin (arrow) is bent, carefully straighten it with
a screwdriver or pliers.
RA19290670
3. Check the heater core assembly.

a. Check if the heater core assembly is cracked, damaged or leaked.
 If any problem is found, replace the heater core
assembly.

b. Check the fin for bends.

 If any fin (arrow) is bent, carefully straighten it with
a screwdriver or pliers.
29
RA19290680
4. Check the damper control mechanism assembly.

a. Check if the inner/outer circulation damper adjustment mechanism is stuck, fell out, deformed or
damaged. Replace it as necessary.
b. Check if the temperature damper adjustment mechanism is stuck, fell out, deformed or damaged.
c. Check if the mode damper adjustment mechanism set is stuck, fell out, deformed or damaged. Replace
it as necessary.
d. Check if the inner/outer circulation/temperature/face/defrost/foot damper set is stuck, fell out, deformed
or damaged. Replace it as necessary.

Assembly
CAUTION
 If the evaporator core is to be reused, do not insert the evaporator temperature sensor into a location
where the sensor was previously inserted. Insert it to a location that is 1 fin to the right or left of its
previous location.
29  During installation, apply a small amount of grease to the contact surface of inner/outer circulation
damper adjustment mechanism to ensure that it can operate smoothly.
 During installation, apply a small amount of grease to the contact surface of mode damper adjustment
mechanism set to ensure that it can operate smoothly.
 During installation, apply a small amount of grease to the contact surface of temperature damper
adjustment mechanism to ensure that it can operate smoothly.
 Always check that the inner/outer circulation damper mechanism assembly operates normally after
installation.
 Always check that the mode damper mechanism assembly operates normally after installation.
 Always check that the temperature damper mechanism assembly operates normally after installation.
Installation
CAUTION
 Tighten the fixing bolts and fixing nuts to the specified torque.
 It is necessary to replace the refrigerant line O-ring when installing the refrigerant line. Failure to do so
may result in refrigerant leaks.
 Lubricate the new rubber O-ring with clean refrigerant oil and install it to the refrigerant line joint.
 Only use the specified O-ring, as it is made of special materials for R134a system.
 Only use recommended refrigerant oil which is applicable to the A/C compressor assembly on vehicle.
 Be sure to recharge the refrigerant and check for refrigerant leakage after installation.
 Recharge the engine cooling system and check the coolant for leakage after installation.

A/C Low Pressure Line

Removal
CAUTION
 Always keep the work area in good ventilation. 29
4. Remove the A/C low pressure line (compressor to evaporator).
A/C low pressure line.
RA19290190
b. Remove the coupling nut (arrow) between A/C high/

low pressure line set bracket and body, and
disengage the A/C low pressure line.
RA19290810
c. Disengage the fixing clamps (arrow) between A/C low

pressure line and other lines.
RA19290820

d. Remove the coupling nut (arrow) between A/C high/

disengage the A/C low pressure line. 
29
RA19290830
e. Remove the fixing bolt (arrow) between A/C low

pressure line and compressor assembly, and
disengage the A/C low pressure line from the
compressor assembly. 
RA19290840
f. Remove the A/C low pressure line (compressor to evaporator).
Installation
CAUTION
 Perform recharging for the A/C system and check for refrigerant leakage.

A/C High Pressure Line

Removal
CAUTION
 Always keep the work area in good ventilation. 29
4. Remove the A/C high pressure line I (condenser to evaporator).
A/C high pressure line I. 
RA19290190
b. Remove the coupling nut (arrow) between A/C high/

disengage the A/C high pressure line I.
RA19290810
c. Disconnect the A/C high/low pressure switch wire

RA19290850

d. Remove the coupling nut (arrow) between A/C high/

disengage the A/C high pressure line I.
29
RA19290830
e. Remove the fixing nut (arrow) between A/C high

pressure line I and condenser assembly, and
disengage the A/C high pressure line I from the
condenser assembly. 
RA19290860
f. Remove the A/C high pressure line I (condenser to evaporator).

5. Remove the A/C high pressure line II (compressor to condenser).
a. Remove the fixing nut (arrow) between A/C high
pressure line II and condenser assembly, and
disengage the A/C high pressure line II from the
RA19290870
b. Remove the fixing bolt (arrow) between A/C high

pressure line II and compressor assembly, and
compressor assembly.
RA19290880
c. Remove the A/C high pressure line II (compressor to condenser).

Installation
CAUTION
29

Compressor Assembly
Removal
WARNING
 Be sure to follow the safety precautions before performing the procedure. Failure to do so may result in
serious personal injury or even death.
29
CAUTION
 Always keep the work area in good ventilation.
 If the A/C compressor assembly has an internal malfunction, it is necessary to replace the A/C fluid line.
Failure to do so may result in serious damage to the A/C compressor assembly after replacing.
 When replacing the compressor assembly, it is necessary to measure the refrigerant oil amount removed
from the new A/C compressor assembly.
4. Remove the compressor assembly.
a. Turn the V-ribbed belt tensioner indicated by the arrow
in the illustration with a wrench (2), and align the lock 1
hole of tensioner with the lock hole of bracket. At the
same time, insert the lock pin (1) to lock the tensioner.
3
RA19160040
c. Disconnect the compressor assembly wire harness

connector (arrow).
RA19290890

d. Remove 2 fixing bolts (arrow) between A/C high/low

pressure line and compressor assembly, and
disengage the A/C high/low pressure line from the
compressor assembly.
29
RA19290900
e. Remove 3 fixing bolts (arrow) between compressor

assembly and mounting bracket. 
RA19290910
f. Carefully remove the compressor assembly from the engine compartment.
Installation
CAUTION

 When installing a new compressor assembly, always remove a certain amount of refrigerant oil from the
new A/C compressor assembly as specified.

Condenser Assembly (w/Receiver Drier)

Removal
CAUTION
29  Always keep the work area in good ventilation.
5. Remove the lower left deflector (See page 46-20).
7. Remove the condenser assembly (w/ receiver drier).
a. Remove the fixing nut (arrow) between A/C high
pressure line I and condenser assembly, and
disengage the A/C high pressure line I from the
RA19290860
b. Remove the fixing nut (arrow) between A/C high

pressure line II and condenser assembly, and
RA19290870
c. Remove the 2 fixing nuts (arrow) between condenser

assembly and tank upper crossmember, and
disengage the upper part of condenser assembly from
the hole of tank upper crossmember. 
RA19290920

d. Disengage the lower part of condenser assembly from

the positioning holes (arrow) of tank lower
crossmember assembly.
29
RA19290930
e. Carefully remove the condenser assembly (w/receiver drier) from below.
Inspection
1. Check the condenser fins.
a. If the condenser fins are dirty, wash it with water. And then dry the fins with compressed air.
CAUTION
 DO NOT damage the condenser fins.
b. If the condenser fins are bent, straighten them with a

screwdriver or pliers.
RA19290940
Installation
CAUTION
 When installing the condenser assembly (w/receiver drier), be sure to align the upper part of it with the
positioning hole of tank upper crossmember.
 When installing the condenser assembly (w/receiver drier), be sure to align the lower part of it with the
positioning hole of tank lower crossmember.

- MEMO -

GENERAL INFORMATION 30-3 B0052 30-30
Description 30-3 B1000 30-30
Operation 30-3 B1001 30-31
Specifications 30-4 B0671 30-33
Tools 30-5 B0673 30-33
Circuit Diagram 30-6 B1328 30-37
B1327 30-37 30
SRS Control Module Assembly  ON-VEHICLE SERVICE 30-41
Terminal List 30-8 Driver Airbag 30-41
DTC Confirmation Procedure 30-8 On-vehicle Inspection 30-41
Intermittent DTC Troubleshooting 30-9 Removal 30-42
Ground Inspection 30-9 Installation 30-43
Diagnosis Procedure 30-10 Disposal 30-43
SRS Control Module Assembly  Spiral Cable 30-44
DTC List 30-12 Removal 30-44
B0026 30-13 Inspection 30-45
B0022 30-13 Installation 30-45
B0024 30-13 Front Passenger Airbag 30-46
B0025 30-13 On-vehicle Inspection 30-46
B0017 30-19 Removal 30-46
B0018 30-19 Disposal 30-48
B0019 30-19 SRS Control Module Assembly 30-49
B0049 30-25 Removal 30-49
B0051 30-30

30

30 - SUPPLEMENTAL RESTRAINT SYSTEM
GENERAL INFORMATION
Description
The vehicle adopts the occupant restraint system, which includes active and supplemental types. The active
restraint system requires the occupants to take some actions, such as fastening the seat belt; while the
supplemental restraint system requires no action from the occupants.
Active Restraint System:
 Driver seat belt and front passenger seat belt
 Rear seat belt 30
Supplemental Restraint System:
 Driver airbag
The driver airbag is installed in the steering wheel, which will inflate to protect the driver in the event of a
severe collision.
 Front passenger airbag
The front passenger airbag is installed in the upper right side of instrument panel, which will inflate to
protect the front passenger in the event of a severe collision.
 SRS control module assembly
The SRS control module assembly has a built-in collision sensor which is installed on the body floor of
auxiliary fascia console body assembly. It controls the inflation of airbag so as to protect the driver and the
front passenger in the event of a severe collision.
 Spiral cable
It is used to connect the driver airbag, as well as ensure that the steering wheel has enough steering
angle.
 Airbag malfunction indicator
After the ignition switch is turned to ON, if the malfunction indicator goes off after coming on for
approximately 4 seconds, it means that the supplemental restraint system operates normally. If the
malfunction indicator does not come on, remains on or flashes, it means that the supplemental restraint
system has a problem and it is necessary to perform testing and repairing.
 Wire harness
Generally, it is yellow and used to connect the elements of supplemental restraint system. The connector
has a safety mechanism.
Supplemental Restraint System Function:
 The airbag must work together with the seat belt, and it cannot substitute for the seat belt. The driver and
passengers should always fasten the seat belts during driving, and adjust the belts to the proper position
according to their sizes.
 Minor collision will not activate the airbag system. The airbags will quickly inflate to protect the driver and
front passenger only when severe frontal collision occurs.
Operation
The supplemental restraint system can improve the occupants safety only when used in combination with the
seat belts. The occupants must fasten the seat belts in order to gain full protection from the supplemental
restraint system.
The supplemental restraint system circuit is continuously monitored and controlled by SRS control module
assembly. The airbag indicator on the instrument cluster illuminates for approximately 4 seconds for a test
each time when the ignition switch is turned to ON. The airbag indicator goes off after the test is completed. If
the indicator comes on at any time other than the test time, it indicates that there is a problem in the
supplemental restraint system circuit.
Whether the airbag deploys or not depends on the angle and severity of the impact. When the vehicle is
subjected to severe collision, the microprocessor in the supplemental restraint system sends signals to the
corresponding inflator units of airbag to deploy the airbags quickly and protect the occupants.

WARNING
 Never expose the airbag components directly to hot air or open flames.
 Never attempt to disassemble or repair the airbag components.
 The removed airbag should be kept properly. Never put other objects on it. If the airbag is triggered
accidentally, it may cause personal injury.
 As a disposable component, the airbag must be replaced after deployment and avoid reusing it.
 Always dispose of the vehicle together with airbag, or the airbag may be triggered accidentally to cause
30 personal injury.
CAUTION
 Before removing the airbag system components, disconnect the negative battery cable at least 90
seconds. Before servicing the steering system, remove the driver airbag and spiral cable for
safekeeping.
 If the vehicle has been involved in a minor collision but the airbags do not deploy, always inspect the
airbag components.
 If the airbag may be touched during servicing, remove the airbag as necessary for safekeeping before
servicing.
 Never use the airbag components from another vehicle. When replacing the airbag components, replace
them with new ones.
 If an airbag component is dropped or if there are any cracks, dents or other defects in the case, bracket
or connector, replace the airbag component with a new one.
 Information labels are attached to the periphery of airbag components. Always follow the cautions and
instructions on the labels.
Specifications

Driver Airbag Fixing Bolt 10 ± 1.5
Spiral Cable Fixing Screw 1.5 ± 0.5
Coupling Bolt Between Front Passenger Airbag and
10 ± 1.5
Coupling Bolt Between SRS Control Module
10 ± 1.5
Assembly and Body

Tools
Special Tool
ཽ⪔⊳䖜
30
RCH0000001
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Supplemental Restraint System (Page 1 of 2)
IGNITION SWITCH
BATTERY
ON OR START
30 EF33
ENGINE
COMPARTMENT
RF01 RF02
INSTRUMENT
PANEL FUSE
FUSE AND AND RELAY
15A RELAY BOX 10A 10A BOX
B-014 I-005
A11 1 2
R
RW
RW
B-050
30 I-003
R
11 13
INSTRUMENT
AIRBAG
CLUSTER
17 3
RW
B
DIAGNOSTIC
BCM INTERFACE
I-006 I-013
GrL
I-026
B13 7
PW
17 26 22 1
SRS
CONTROL
MODULE
I-023
16 15 14 13 12 11 10 9
42 41 40 39 38 37 36 35 34 33 32 31 30 29
A1 A2 A3 A4 A5 A6 8 7 6 5 4 3 2 1
A10 A11 A12 A13 28 27 26 25 24 23 22 21 20 19 18 17 16 15
A7 A8 A9 A14 A15 A16
I-013 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-014 B
W
B-050
W
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
25 26 I-005 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 I-043
87 B L
85 86 86 86
87 30 87 30
30 85 85

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 I-006
I-023 B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 L
G
EA19300010

Supplemental Restraint System (Page 2 of 2)
SRS
CONTROL 30
MODULE
I-023
3 4 6 5 16
WL
GW
1 2 I-018
B
I-048
GW
WY
SPIRAL
CABLE
I-024
WL
GW
1 2 1 2
FRONT
DRIVER PASSENGER
AIRBAG AIRBAG
I-051
I-034
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2
I-023 I-018
G 1 2
Y
I-034
G I-051
Y
EA19300020

DIAGNOSIS & TESTING

SRS Control Module Assembly Terminal List
Terminal Terminal Terminal Terminal
Terminal Definition Terminal Definition
No. Name No. Name
1 Vbat Power Supply 17 Sys WL System Warning Light
2 NC - 18 NC -
30
3 ABFD+ Driver Airbag Positive 19 NC -
4 ABFD- Driver Airbag Negative 20 NC -
Front Passenger Airbag
5 ABFP- 21 NC -
Negative
6 ABFP+ 22 K-Line K-Line
Positive
7 NC - 23 NC -
8 NC - 24 NC -
9 NC - 25 NC -
10 NC - 26 CRO Crash Output
11 NC - 27 NC -
12 NC - 28 NC -
13 NC - 29 NC -
14 NC - 30 NC -
15 NC - 31 NC -
16 GND Ground 32 NC -

 Use the X-431 3G diagnostic tester to record and clear the DTCs stored in the supplemental restraint
system.
 Turn the ignition switch to ON and then select Read Code.
 If the DTC is detected, the malfunction indicated by the DTC is current.
Go to the diagnosis procedure - Step 1.
 If the DTC is not detected, the malfunction indicated by the DTC is intermittent.


 Wiggle the related wire harness and connector and observe if the signal is interrupt in the related circuit.
 Look for broken, bent, protruded or corroded terminals. 30
 Inspect the airbag components and mounting areas for damage, foreign matter, etc. that will cause
incorrect signals.
 Remove the SRS control module assembly from the malfunctioning vehicle and install it to a new vehicle
and perform a test. If the DTC cannot be cleared, the SRS control module assembly is malfunctioning. If
the DTC can be cleared, reinstall the SRS control module assembly to the original vehicle.
Ground Inspection
Ground points are very important to the proper operation of electrical equipment and circuits. Ground points
are often exposed to moisture, dirt and corrosive elements. Corrosion (rust) can increase resistance which will
change the way in which a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can affect
the electronically controlled circuit. Perform the following operations when checking the ground points:
1. Remove the ground nut.
2. Check all the matching surfaces for tarnish, dirt and rust, etc.
4. Reinstall the ground nut securely.
ground path.

Diagnosis Procedure
HINT:
Use the following procedures to troubleshoot the supplemental restraint system (SRS).
NEXT
30
NEXT
3 Check SRS warning light
NEXT
4 Check for DTCs (current DTC and history DTC)
DTC
For current DTC, go to step 5
occurs
No
For history DTC, go to step 6
DTC
5 Diagnostic Trouble Code (DTC) chart
NEXT
6 Circuit inspection
HINT:
 An activation prevention mechanism is built in the airbag system connector. When the connector is
disconnected, this mechanism cuts off the circuit by bringing the short spring plate into contact with the
terminals, thus insulating the circuit from external power sources to prevent accidental airbag activation.
 To release the activation prevention mechanism, insert a piece of paper with the same thickness as the
male terminal between the terminals and the short spring plate to disconnect the connection.
WARNING
 DO NOT release the activation prevention mechanism unless specially directed by the troubleshooting
procedure.

During circuit troubleshooting for the airbag system, make sure to cut off the battery power source, and wait
for at least 90 seconds to discharge the system condenser.
While performing the electrical diagnosis and testing, always refer to the relevant circuit diagram for the
special circuit and component information.
NEXT
7 Repair
30
NEXT
8 Clear DTCs (current DTC and history DTC)
NEXT
DTC
output Go to step 5
NO DTC
Go to next step
output
NEXT
10 Confirmation test
NEXT
11 End

SRS Control Module Assembly DTC List

B0026 Driver Frontal Deployment Loop Open
B0022 Driver Frontal Deployment Loop Resistance Low
B0024 Driver Frontal Deployment Loop Short to GND or Cross Coupling
B0025 Driver Frontal Deployment Loop Short to Battery
30 B0017 Passenger Frontal Deployment Loop Open

B0016 Passenger Frontal Deployment Loop Resistance Low
B0018 Passenger Frontal Deployment Loop Short to GND or Cross Coupling
B0019 Passenger Frontal Deployment Loop Short to Battery
B0049 Crash Output Short to Battery
B0048 Crash Output Short to GND or open
B0051 Front Airbag Deployment Commanded
B0052 Airbag ECU Reaches the Maximum Usage, and It Cannot Be Reusable
B0090 Passenger Deactivation Switch Performance Fault
B0091 Passenger Deactivation Switch Undefined
B0671 System Warning Lamp Short to GND or Open
B0673 System Warning Lamp Short to Battery
B0681 Passenger Airbag Disabled Indicator Short to GND or Open
B0683 Passenger Airbag Disabled Indicator Short to Battery
B1000 Electronic Control Unit (ECU) Internal Fault
B1001 Option Configuration Error
B1328 Power Supply Voltage is Too High
B1327 Power Supply Voltage is Too Low

DTC B0026 Driver Frontal Deployment Loop Open
DTC B0022 Driver Frontal Deployment Loop Resistance Low
Driver Frontal Deployment Loop Short to GND or Cross

DTC B0024
Coupling
DTC B0025 Driver Frontal Deployment Loop Short to Battery 30

IGNITION SWITCH
ON OR START
INSTRUMENT
30 RF02
PANEL FUSE
AND RELAY
10A BOX
I-005
2
RW
1
SRS
CONTROL
MODULE
I-023
6 5 B 16
GW
WY
1 2
FRONT I-024
PASSENGER
AIRBAG
I-034
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
87
85 86 86 86
87 30 87 30
30 85 85 I-023
G
I-005
B
1 2
I-034
G
EA19300040

Self-diagnosis Detection Logic
DTC Detection Warning Light

Condition Condition
Driver Frontal
B0026 Deployment Loop
Open
Driver Frontal  Driver airbag
 Spiral cable
Resistance Low 30
Ignition switch ON ON  Wire harness and
Driver Frontal connector
Deployment Loop
B0024  SRS control
Short to GND or Cross
Coupling module assembly
Driver Frontal
Short to Battery
HINT:
Diagnosis Procedure
1 Check driver airbag
a. Turn the ignition switch to LOCK, disconnect the negative battery cable and wait for at least 90 seconds.
b. Disconnect the driver airbag connector, and connect the new driver airbag to the connector I-051.
WARNING
 Never measure the driver airbag directly; otherwise, it may cause serious personal injury due to
accidental deployment of the airbag.
c. Reconnect the negative battery cable and wait for a few seconds.
d. Turn the ignition switch to ON and wait for at least 90 seconds.
e. Use the X-431 3G diagnostic tester to clear the DTCs.
f. Turn the ignition switch to LOCK.
g. Turn the ignition switch to ON and wait for at least 90 seconds.
h. Use the X-431 3G diagnostic tester to check if the DTCs are still output.
NO Replace driver airbag
YES

 Turn the ignition switch to LOCK, disconnect the negative battery cable and wait for at least 90 seconds.
 Disconnect the driver airbag connector I-051 and the SRS control module assembly connector I-023.

 Disconnect the spiral cable wire harness connector I-048 and the instrument panel wire harness connector
I-018.
 Check if the related connector terminal contact pins are in good condition.
NG Repair or replace instrument panel/spiral

cable wire harnesses and connector
OK
30
3 Check driver airbag control circuit
a. Turn the ignition switch to LOCK, disconnect the negative

battery cable and wait for at least 90 seconds.
b. Disconnect the SRS control module assembly connector
I-023. V
+ -
c. Disconnect the driver airbag connector I-051.
d. Connect the negative battery cable and wait for a few
seconds.
f. Using a digital multimeter, measure the voltage between
driver airbag connector I-051 and body ground to check 1 2
for a short circuit to the power supply according to the

table below. I-051
Standard Voltage
Condition
RA19300160
I-051-1 - Body
Ignition switch ON Below 1 V
ground
I-051-2 - Body
ground
g. Turn the ignition switch to LOCK, disconnect the negative

h. Using a digital multimeter, check for continuity between
driver airbag connector I-051 and body ground to check
for a short circuit to the body ground according to the + -
table below.
Standard Condition
Condition
I-051-1 - I-051-2 Always Continuity I-051

I-051-1 - Body
ground
I-051-2 - Body
ground
RA19300170

i. Release the activation prevention mechanism built into

the SRS control module assembly connector I-023.
j. Using a digital multimeter, check for continuity between
the terminals of driver airbag connector I-051 according
to the table below. + -
Standard Condition
Condition
I-051-1 - I-051-2 Always No continuity
30
1 2
OK Replace SRS control module assembly
I-051
RA19300180
NG
Check airbag wire harness and connector (SRS control module assembly - spiral cable
4 connector)

b. Disconnect the instrument panel wire harness connector
I-018 and the SRS control module assembly connector 
I-023. + -
c. Using a digital multimeter, check for continuity between

the terminals of connector I-018 and connector I-023
2 1
Standard Condition
Multimeter Specified I-018

Condition
I-018-1 - I-023-3 Always Continuity 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-018-2 - I-023-4 Always Continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

RA19300190

d. Release the activation prevention mechanism built into

according to the table below. + -
Standard Condition
Condition

30 I-018
I-018-2 - I-023-3 Always No continuity 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-018-1 - I-023-4 Always No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-018-1 - I-018-2 Always No continuity I-023

RA19300190
NG Replace instrument panel wire harness

and connector
OK
Replace spiral cable

DTC B0017 Passenger Frontal Deployment Loop Open
DTC B0016 Passenger Frontal Deployment Loop Resistance Low
Passenger Frontal Deployment Loop Short to GND or

DTC B0018
Cross Coupling
DTC B0019 Passenger Frontal Deployment Loop Short to Battery 30

IGNITION SWITCH
ON OR START
INSTRUMENT
PANEL FUSE
30 RF02
10A
AND RELAY
BOX
I-005
2
RW
1
SRS
CONTROL
MODULE
I-023
6 5 B 16
GW
WY
1 2
FRONT I-024
PASSENGER
AIRBAG
I-034
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
87
85 86 86 86
87 30 87 30
30 85 85 I-023
G
I-005
B
1 2
I-034
G
EA19300040


Condition Condition
Passenger Frontal
Open
Passenger Frontal
 Front passenger
airbag
Resistance Low
 Wire harness and
30
Passenger Frontal Ignition switch ON ON
connector
Deployment Loop
B0018  SRS control
Short to GND or Cross
module assembly
Coupling
Passenger Frontal
Short to Battery
HINT:
Diagnosis Procedure
1 Check front passenger airbag
a. Turn the ignition switch to LOCK, disconnect the negative battery cable and wait for at least 90 seconds.
b. Disconnect the front passenger airbag connector, and connect the new front passenger airbag to the
connector I-034.
WARNING
 Never measure the front passenger airbag directly; otherwise, it may cause serious personal injury due
to accidental deployment of the airbag.
c. Reconnect the negative battery cable and wait for a few seconds.
d. Turn the ignition switch to ON and wait for at least 90 seconds.
e. Use the X-431 3G diagnostic tester to clear the DTCs.
f. Turn the ignition switch to LOCK.
g. Turn the ignition switch to ON and wait for at least 90 seconds.
h. Use the X-431 3G diagnostic tester to check if the DTCs are still output.
NO Replace front passenger airbag
YES


 Disconnect the front passenger airbag connector I-034 and the SRS control module assembly connector 
I-023.
NG Repair or replace instrument panel wire

harness and connector
OK
30
3 Check front passenger airbag control circuit

I-023. V
+ -
c. Disconnect the front passenger airbag connector I-034.
d. Connect the negative battery cable and wait for a few
seconds.
f. Using a digital multimeter, measure the voltage between
front passenger airbag connector I-034 and body ground 1 2
to check for a short circuit to the power supply according

to the table below. I-034
Standard Voltage
Condition
RA19300200
I-034-1 - Body
ground
I-034-2 - Body
ground
g. Turn the ignition switch to LOCK, disconnect the negative

front passenger airbag connector I-034 and body ground
to check for a short circuit to the body ground according + -
to the table below.

Standard Condition
Condition
1 2

I-034-1 - Body I-034
ground
I-034-2 - Body
ground
RA19300210

i. Release the activation prevention mechanism built into

the terminals of front passenger airbag connector I-034
Standard Condition
Condition
I-034-1 - I-034-2 Always No continuity 1 2 30
OK Replace SRS control module assembly I-034
RA19300220
NG
Check airbag wire harness and connector (SRS control module assembly - front passenger
4 airbag)

b. Disconnect the SRS control module connector I-023 and
the front passenger airbag connector I-034.
+ -
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Standard Condition 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Multimeter Specified I-023

Condition
1 2

I-034
I-023-6 - I-034-2 Always Continuity RA19300230


d. Release the activation prevention mechanism built into

Standard Condition
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Condition

30
I-023-6 - I-034-2 Always No continuity 1 2
I-023-5 - I-023-6 Always No continuity I-034

RA19300230

and connector

DTC B0049 Crash Output Short to Battery
DTC B0048 Crash Output Short to GND or open
IGNITION SWITCH
ON OR START
30
INSTRUMENT
PANEL FUSE
RF02 AND RELAY
10A BOX
I-005
BCM 2
I-006
B13
RW
PW
26 1
SRS
CONTROL
MODULE
I-023
16
B
I-024
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
25 26
87 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
85 86 86 86
87 30 87 30
30 85 85
I-023
G
I-005
B
I-006
L
EA19300050


Condition Condition
Crash Output Short to  Wire harness and
B0049
Battery connector
Ignition switch ON ON
Crash Output Short to  SRS control
B0048 module assembly
GND or open
30 HINT:
Diagnosis Procedure
1 Check wire harness and connector (SRS control module assembly - body control module)

 Disconnect the SRS control module assembly connector I-023 and body control module (BCM) connector
I-006.

OK
2 Check collision output control circuit (SRS control module assembly side)

I-023.
+ -
SRS control module assembly connector I-023 and body
ground to check if the collision output circuit is short to
the ground according to the table below.
Standard Condition
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Condition
I-023
I-023-26 - Body
ground
RA19300240

d. Turn the ignition switch to ON.

e. Using a digital multimeter, check the voltage between
ground to check if the collision output circuit is short to V
the power supply according to the table below. + -
Standard Condition
Condition
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-023-26 - Body
ground
Ignition switch ON Below 1 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
30
I-023
RA19300250
OK
3 Check collision output control circuit (body control module side)

battery cable.
b. Disconnect the body control module (BCM) connector 
I-006.
c. Using a digital multimeter, check for continuity between + -
body control module (BCM) connector I-006 and body

ground to check if the collision output circuit is short to
the ground according to the table below.
Standard Condition B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Condition
Connection Condition I-006
I-006-B13 - Body
ground
RA19300260


e. Using a digital multimeter, check the voltage between
body control module (BCM) connector I-006 and body
ground to check if the collision output circuit is short to V
the power supply according to the table below. + -
Standard Condition
Condition
Connection Condition B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
I-006-B13 - Body
30 ground
I-006

RA19300270
OK
Check collision output control circuit (SRS control module assembly - body control
4 module)

I-023.
c. Disconnect the body control module (BCM) connector  + -
I-006.
the connector I-006 and connector I-023 to check for an B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
open in the collision output circuit according to the table B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
below.
Standard Condition I-006
Condition
I-006-B13 -
Always Continuity I-023
I-023-26
RA19300280

OK

5 Reconfirm DTCs
a. Reconnect the SRS control module assembly connector I-023 securely.

b. Reconnect the body control module (BCM) connector I-006 securely.
c. Connect the negative battery cable.
e. Use the X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the
supplemental restraint system.
f. Turn the ignition switch to LOCK and wait for a few seconds. 30
g. Turn the ignition switch to ON.
h. Use the X-431 3G diagnostic tester to read the DTCs stored in the supplemental restraint system again.
i. Check if the same DTCs are still output.
No System operates normally
Yes
Replace SRS control module assembly

DTC B0051 Front Airbag Deployment Commanded
Airbag ECU Reaches the Maximum Usage, and It Cannot

DTC B0052
Be Reusable
DTC B1000 Electronic Control Unit (ECU) Internal Fault
30 Self-diagnosis Detection Logic

Condition Condition
Front Airbag
B0051 Deployment
Commanded
Airbag ECU Reaches
 SRS control
the Maximum Usage, Ignition switch ON ON
and It Cannot Be
Reusable
Electronic Control Unit
B1000
(ECU) Internal Fault
HINT:
Diagnosis Procedure
1 Check SRS control module assembly

b. Disconnect the negative battery cable and wait for at least 90 seconds.
f. Turn the ignition switch to LOCK and wait for a few seconds.
g. Turn the ignition switch to ON and then select Read Code.
NG Replace SRS control module assembly
OK
Malfunction has been solved and system operates normally

DTC B1001 Option Configuration Error

Condition Condition
 Outside option
Option Configuration configuration error
B1001
Error
 SRS control 30
module assembly
HINT:
Diagnosis Procedure
1 Check for DTCs
a. Use the X-431 3G diagnostic tester (the latest software) to clear and read the DTCs stored in the
supplemental restraint system again.
b. Refer to DTC Confirmation Procedure.
c. Check if the same DTC is output.
No Malfunction indicated by DTC is

intermittent problem
Yes
2 Check configuration of SRS Control Module Assembly

b. Use the X-431 3G diagnostic tester (the latest software) to check whether the setting of SRS control
module assembly matches the actual configuration of the vehicle.
No Reset SRS control module assembly
Yes
3 Reconfirm DTCs

b. Disconnect the negative battery cable and wait for at least 90 seconds.
f. Turn the ignition switch to LOCK and wait for a few seconds.
g. Turn the ignition switch to ON and then select Read Code.

NG Replace SRS control module assembly
OK
Malfunction has been solved and system operates normally
30

DTC B0671 System Warning Lamp Short to GND or Open
DTC B0673 System Warning Lamp Short to Battery
IGNITION SWITCH
BATTERY
ON OR START
30
ENGINE INSTRUMENT
COMPARTMENT PANEL FUSE
EF33 RF01 AND RELAY
FUSE AND
15A RELAY BOX 10A BOX
B-014 I-005
A11 1
R
RW
B-050
30 I-003
R
11 13
INSTRUMENT
AIRBAG
CLUSTER
17 3
B
GrL
I-026
17
SRS
CONTROL
MODULE
I-023
42 41 40 39 38 37 36 35 34 33 32 31 30 29
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
28 27 26 25 24 23 22 21 20 19 18 17 16 15 I-023
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 G
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-050
W
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-043
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 L
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26
87
85 86 86 86
87 30 87 30
30 85 85
A1 A2 A3 A4 A5 A6 B-014
A10 A11 A12 A13
I-005 A7 A8 A9 A14 A15 A16 W
B
EA19300060


Condition Condition
System Warning Lamp  Wire harness and
B0671
Short to GND or Open connector
System Warning Lamp  SRS control
Short to Battery
30 HINT:
Diagnosis Procedure
1 Check wire harness and connector (SRS control module assembly - instrument cluster)

 Disconnect the SRS control module assembly connector I-023 and the instrument cluster connector I-043.

OK
2 Check airbag malfunction indicator control circuit (instrument cluster side)

b. Disconnect the instrument cluster connector I-043.
+ -
instrument cluster connector I-043 and body ground to
check for a short circuit to the ground according to the
table below.
Standard Condition
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-043-17 - Body I-043
ground
RA19300290


e. Using a digital multimeter, measure the voltage between
instrument cluster connector I-043 and body ground to
check for a short circuit to the power supply according to V
the table below. + -
Standard Condition
Condition
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-043-17 - Body
ground
Ignition switch ON Below 1 V 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 30
I-043

RA19300300
OK
3 Check airbag malfunction indicator control circuit (SRS control module assembly side)

I-023.
c. Using a digital multimeter, check for continuity between + -

ground to check for a short circuit to the ground
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Condition
I-023-17 - Body
ground
RA19300310


e. Using a digital multimeter, measure the voltage between
ground to check for a short circuit to the power supply V
Standard Condition
Condition
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
I-023-17 - Body
30 ground
Ignition switch ON Below 1 V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-023

RA19300320
OK
4 Reconfirm DTCs
a. Reconnect the SRS control module assembly connector I-023 and the instrument cluster connector I-043
securely.
b. Connect the negative battery cable.
c. Turn the ignition switch to ON.
d. Use the X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the
e. Turn the ignition switch to LOCK and wait for a few seconds.
f. Turn the ignition switch to ON.
g. Use the X-431 3G diagnostic tester to read the DTCs stored in the supplemental restraint system again.
h. Check if the same DTCs are still output.
Yes

DTC B1328 Power Supply Voltage is Too High
DTC B1327 Power Supply Voltage is Too Low
IGNITION SWITCH
ON OR START
30
INSTRUMENT
PANEL FUSE
RF02 AND RELAY
10A BOX
I-005
2
RW
1
SRS
CONTROL
MODULE
I-023
16
B
I-024
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
25 26
87 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
85 86 86 86
87 30 87 30
30 85 85
I-023
G
I-005
B
EA19300070


Condition Condition
Power Supply Voltage  Battery
B1328
is Too High  Charging system
Ignition switch ON ON  Wire harness and
Power Supply Voltage connector
B1327
is Too Low  SRS control
30 module assembly
HINT:
Diagnosis Procedure
1 Check battery
a. Using a digital multimeter, check the battery voltage.

NG Check charging system (See page 16-6)
OK
Check wire harness and connector (SRS control module assembly - instrument panel fuse
2 and relay box)

 Disconnect the SRS control module assembly connector I-023 and instrument panel fuse and relay box
connector I-005.

OK

3 Check wire harness and connector (SRS control module assembly - battery)

I-023. V
c. Connect the negative battery cable and wait for a few + -
seconds.
30
e. Using a digital multimeter, measure the power supply
voltage of SRS control module assembly connector I-023 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
to check if the system power supply is normal according 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

to the table below.
I-023
Standard Condition
Condition
I-023-1 - Body
Ignition switch ON 11 V to 14 V RA19300330
ground

OK
4 Check wire harness and connector (SRS control module assembly - body ground)

I-023.
+ -
c. Using a digital multimeter, measure the ground circuit of
SRS control module assembly connector I-023 to check if
the system ground is normal according to the table
below.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Condition
I-023-16 - Body
Always Continuity
ground
NG Repair or replace instrument panel wire RA19300340

OK

5 Reconfirm DTCs
a. Reconnect the SRS control module assembly connector I-023 securely.

b. Reconnect the instrument panel fuse and relay box wire harness connector I-005 securely.
30 f. Turn the ignition switch to LOCK and wait for a few seconds.
g. Turn the ignition switch to ON.
h. Use the X-431 3G diagnostic tester to read the DTCs stored in the supplemental restraint system again.
i. Check if the same DTCs are still output.
Yes

ON-VEHICLE SERVICE
Driver Airbag
1. Check the driver airbag (vehicle is not involved in a collision and airbag is not deployed).
a. Perform a diagnosis system inspection.
b. Perform visual inspection with the driver airbag on the
vehicle: 30
 Check for cuts, cracks or discoloration on the outer
surface of driver airbag and in the grooved portion.
 If any defect above is found, replace the driver
airbag with a new one.
STORAGE BOX
RA19300010
2. Check the driver airbag (vehicle is involved in a collision but airbag is not deployed).
b. Perform visual inspection with the driver airbag
removed from the vehicle:
 Check for cuts, cracks or discoloration on the outer
surface of driver airbag and in the grooved portion.
 Check the wire harness for cuts and cracks, and if
the connectors are chipped.
 Check the steering wheel for deformation. SRS
AIRBAG
RA19300020
WARNING
 Be sure to follow the correct procedures to remove and install the driver airbag.
HINT:
 If the driver airbag contact plate is deformed, never repair
it. Always replace the driver airbag with a new one.
 There should not be any contact between driver airbag
and steering wheel, and keep an even clearance all
around when installing the new driver airbag onto the
steering wheel.
RA19300030

Removal
CAUTION
 Handle the airbag and airbag control module assembly carefully, and never tap or strike them fiercely.
 Removal, inspection and installation of airbag system must meet the relevant requirements and
specifications, and never perform operation casually.
 The removed airbag should be kept properly with the face up. Store the airbag in a place with enough
spare space to prevent accidental airbag deployment.
30
WARNING
 Wait at least 90 seconds after disconnecting the negative battery cable to disable the supplemental
restraint system.
3. Remove the driver airbag.

a. Set the front wheels straight ahead.
b. Using a proper tool, loosen the fixing bolts (arrow) on
both sides of the driver airbag. 
RA19300040
c. Pull out the driver airbag from the steering wheel, and support the driver airbag smoothly by hands.
d. Disconnect the driver airbag wire harness connector
(1) and the horn wire harness connector (2).
RA19300050
WARNING
 DO NOT damage the airbag wire harness when handling the airbag wire harness connector.

CAUTION
 DO NOT pull the airbag wire harness when removing the driver airbag.
e. Remove the driver airbag.
Installation
30
CAUTION
 Make sure to tighten the fixing bolts to the specified torque during installation.
 Check that the horn operates normally after installation.
 Check the SRS warning light after installation, and make sure that the supplemental restraint system
operates normally.
Disposal
Always dispose of the airbag together with the vehicle which is equipped with supplemental restraint system.
Otherwise, the airbag will be in chemical and physical dangerous state. Failure to handle it properly will cause
personal injury. Do not dispose of the airbag on your own, and always contact the professional service
department to perform the disposal.

Spiral Cable
Removal
WARNING
30 restraint system.
3. Position the front wheels straight ahead.

5. Remove the steering column upper/lower cover (See page 27-12).
6. Remove the spiral cable.
a. Disconnect the spiral cable wire harness connectors
(1) and (2).
2
RA19300060
b. Disconnect the spiral cable (steering wheel quick

button) wire harness connector (arrow) (if equipped).
RA19300070
c. Remove 4 fixing screws (arrow) between spiral cable

and steering column.
RA19300080
d. Detach and remove the spiral cable from the positioning hole of steering column.

Inspection
1. Check the spiral cable.
a. Check that there are no scratches or cracks on the
connectors, and/or no cracks, dents or chipping on
the cable.
b. If there are scratches, cracks, dents or cuts on the
connectors or the spiral cable, replace the spiral cable
with a new one.
30
RA19300090
Installation
HINT:
Always install the spiral cable correctly according to the
matchmarks on spiral cable and steering column (fully turn
the spiral cable clockwise slowly, then rotate it
counterclockwise by approximately 3.2 turns to align the
arrow marks), otherwise, the spiral cable may be damaged. PB
T
PB
T
RA19300100
CAUTION
 Always install the spiral cable correctly according to the specified operating instructions.
 DO NOT rotate the spiral cable over specified turns to prevent it from breaking.
 Always align the locating pin of spiral cable with the positioning hole of steering column when installing
the spiral cable.
 Check that the horn operates normally after installation.
operates normally.


1. Check the front passenger airbag (vehicle is involved in a collision but airbag is not deployed).
b. Perform visual inspection with the front passenger
airbag removed from the vehicle:
 Check for cuts, cracks or wear on the front
passenger airbag.
30  Check for cracks or other damage on the
connector.
 Check the instrument panel or instrument panel
crossmember assembly for deformation or break.
If any defect above is found, replace the front
passenger airbag with a new one. RA19300110
WARNING
 Be sure to follow the correct procedures to remove and install the front passenger airbag.
Removal
CAUTION
 Handle the airbag and airbag control module assembly carefully, and never tap or strike them fiercely.
 Removal, inspection and installation of airbag system must meet the relevant requirements and
specifications, and never perform operation casually.
 The removed airbag should be kept properly. Store the airbag in a place with enough spare space to
prevent accidental airbag deployment.

WARNING
restraint system.


4. Remove the front passenger airbag.
a. Remove 2 coupling bolts (arrow) between front
passenger airbag and instrument panel crossmember
assembly. 
30
RA19300120
b. Disconnect the front passenger airbag wire harness

connector (arrow).
RA19300130
WARNING
c. Remove the instrument panel upper body assembly (See page 43-16).
d. Using a flat tip screwdriver wrapped with protective
tape, slightly pry the front passenger airbag fixing
bracket all around to separate it from the instrument
panel upper body assembly.
RA19300140
e. Remove the front passenger airbag.

Installation
CAUTION
 Before installing the tightening bolts, always make sure that the airbag wire harness is not hold down or
stuck, perform adjustment if necessary and install it in place.
 When installing the front passenger airbag, first slide the hook on one side into the locating hole, and
30 then press in the hook on the other side firmly, making sure that hooks on both sides enter the
corresponding locating holes correctly.
 Always make sure that the vehicle is powered off during installation, and never install the front passenger
airbag when the vehicle is powered on.
 During the installation of instrument panel upper body assembly, if installation cannot proceed due to
contact of front passenger airbag bracket and instrument panel crossmember assembly, hold the airbag
slightly at the opening of the glove box assembly to install it in place.
operates normally.
Disposal
Always dispose of the airbag together with the vehicle which is equipped with supplemental restraint system.
Otherwise, the airbag will be in chemical and physical dangerous state. Failure to handle it properly will cause
personal injury. Do not dispose of the airbag on your own, and always contact the professional service
department to perform the disposal.

SRS Control Module Assembly

Removal
WARNING
restraint system. 30
3. Remove the auxiliary fascia console body assembly (See page 43-10).
4. Remove the SRS control module assembly.
a. Disconnect the SRS control module assembly wire
harness connector (1).
1
b. Remove 2 fixing bolts (arrow) between SRS control
module assembly and body.
RA19300150
WARNING
c. Remove the SRS control module assembly.
Installation
CAUTION
 Always install the SRS control module assembly correctly in the direction indicated by the arrow on the
SRS control module assembly.
 DO NOT put any object between the SRS control module assembly and the installation surface.
 After installing the tightening bolts, connect the SRS control module assembly securely. Always keep the
vehicle power off during installation.
operates normally.

- MEMO -

SEAT BELT
GENERAL INFORMATION 31-3 Height Adjuster Assembly 31-13
Specifications 31-5 Rear Seat Belt Assembly 31-14
Tool 31-5 Removal 31-14
Circuit Diagram 31-6 Inspection 31-15
Installation 31-15
Center Seat Belt Assembly 31-16
Seat Belt Inspection 31-7 31
Removal 31-16
Front Seat Belt Assembly 31-8 Installation 31-17
Removal 31-8 Double Buckle Belt Assembly 31-18
Front Seat Belt Buckle Assembly 31-11 Rear Seat Belt Buckle Assembly 31-19
On-vehicle Inspection 31-11 Removal 31-19
Installation 31-12

31

31 - SEAT BELT
GENERAL INFORMATION
SEAT BELT
Description
Front Seat Belt Assembly
31
RA19310010
1 - B-pillar Upper Protector Assembly 2 - Height Adjuster Cover

3 - Front Seat Belt Assembly 4 - Seat Belt Lower Bolt Protective Cap
5 - B-pillar Lower Protector Assembly 6 - Front Seat Belt Buckle
7 - Height Adjuster Assembly

31 - SEAT BELT
Rear Seat Belt Assembly
31 3
4
2
RA19310020
1 - Tonneau Cover Assembly 2 - Rear Left Seat Belt Assembly

3 - Center Seat Belt Assembly 4 - Rear Right Seat Belt Assembly
5 - Double Buckle Assembly 6 - Rear Seat Belt Buckle Assembly
The front seat belt is a pretensioner 3 point type belt. The driver seat belt is equipped with the seat belt
reminder. The reminder works when the ignition switch is turned to ON. The reminder will continue flashing to
inform the driver to fasten the seat belt. The seat belt reminder will go off immediately if the seat belt is
fastened.
Both rear left and right seat belts are pretensioner 3 point type belts, and the center seat belt is a 2 point type
belt.

31 - SEAT BELT
Operation
In the event of a collision, the seat belt retractor starts to work. The seat belt is locked securely and cannot be
pulled out from the retractor freely, so that the passenger will be restricted to the seat to prevent the head and
chest from hitting the steering wheel, instrument panel, windshield or front seat, which can reduce the risk of
second collision.
Specifications

Height Adjuster Fixing Bolt 50 ± 5 31
Front Seat Belt Assembly Fixing Bolt 50 ± 5
Front Seat Belt Assembly Fixing Screw 3 ± 0.5
Rear Seat Belt Assembly Fixing Bolt 50 ± 5
Center Seat Belt Assembly Fixing Bolt 50 ± 5
Double Buckle Belt Assembly Fixing Bolt 50 ± 5
Front Seat Belt Buckle Fixing Bolt 50 ± 5
Tool
General Tool
Digital Multimeter
RCH0000002

31 - SEAT BELT
Circuit Diagram
Seat Belt System Circuit Diagram

31
BATTERY
ON OR START ON OR ACC
POWER INSTRUMENT PANEL

EF12 FUSE RF03 RF16 FUSE AND
BOX RELAY BOX
80A 10A 10A
B-009 I-005
3 16
RW
RY
R
F1 B31 B15
BCM
I-006
B-048
B11
VB
I-004
22 B-053
VB
DRIVER SEAT
BELT SWITCH
CLOSE B-024
OPEN
2
B
B-023
1 2 3 4 5 6 7 8 9 10 11 12
1 1
13 14 15 16 17 18 19 20 21 22 23 24
1 2
25 26
87
B-048 B-024
85 86 86 86
Gr B-009 W 87 30 87 30
30 85 85
I-005
B
29 30 31 32 33 34 35 36 37 38 39 40 41 42 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-006
L
I-004
L
EA19310010

31 - SEAT BELT
DIAGNOSIS & TESTING

Seat Belt Inspection
1. When pulling the seat belt downward slowly by hand, the seat belt should be pulled out smoothly from the
retractor and can return back after releasing. If not as specified, replace the seat belt.
The seat belt should be locked automatically as it is pulled out quickly. If not, replace the seat belt.
2. Check if the seat belt has cut, wear and looseness. If damaged, replace the seat belt assembly.
3. Check if the seat had been stretched excessively (for example after accident). If damaged, replace the
seat belt assembly or related components.
4. Tighten the seat belt and release the seat belt striker repeatedly to check the engagement between them.
If those conditions (difficult operation, excessive sliding resistance and sticking etc.) occur, replace the 31
seat belt assembly or seat belt striker assembly.
WARNING
 The seat belt system should be checked regularly to reduce the possibility and serious level of injury
caused by accident.
 When checking the impacted vehicle, be sure to check the seat belt system to reduce the possibility and
serious level of injury caused by accident.

31 - SEAT BELT
ON-VEHICLE SERVICE
Front Seat Belt Assembly
Removal
HINT:
CAUTION
31
 Make sure to wear safety equipment to prevent accidents when removing the front seat belt assembly.
 Appropriate force should be applied when removing the front seat belt assembly, and avoid operating
roughly.
 DO NOT scratch the interior when removing the front seat belt assembly.

3. Remove the front left doorsill pressure plate assembly (See page 47-8).
4. Remove the front left door opening weatherstrip (See page 47-23).
5. Remove the rear left doorsill pressure plate assembly (See page 47-9).
6. Remove the rear left door opening weatherstrip (See page 47-24).
7. Remove the front left seat belt assembly.
the lower bolt protective cap of front seat belt
assembly.
RA19310030
b. Remove the fixing bolt (arrow) from the lower part of

the front seat belt assembly.
RA19310040
c. Remove the left B-pillar lower protector assembly (See page 47-13).

31 - SEAT BELT
d. Press the height adjuster button on both sides as

shown in the illustration, and using a screwdriver
wrapped with protective tape, remove the height
adjuster cover.
RA19310050
e. Remove the fixing bolt (1) from the upper part of the 31
front seat belt assembly.
f. Remove 2 fixing screws from the center of the front 1
seat belt assembly.
RA19310060
g. Remove the fixing bolt (arrow) from the front seat belt
retractor.
RA19310070
h. Remove the front left seat belt assembly.
Inspection
Inspect the front seat belt retractor.
CAUTION
 DO NOT disassemble the front seat belt assembly retractor.

31 - SEAT BELT
HINT:
When the inclination of the front seat belt retractor is 15° or
less, check that the front seat belt can be pulled out from the 45°
front seat belt retractor. When the inclination of the front seat
belt retractor is over 45°, check that the front seat belt locks.
If the result is not as specified, replace the front seat belt
assembly.
lock
Unlock Retractor
RA19310080
31 Installation
CAUTION
 Keep the seat belt assembly clean, avoid attaching oil and check the seat belt assembly for damage
when installing the front seat belt assembly.
 Make sure to tighten all the fixing bolts and fixing screws according to the specified torque when
installing the front seat belt assembly.

31 - SEAT BELT
Front Seat Belt Buckle Assembly

1. Check the front seat belt buckle assembly (for driver side seat).
a. Disconnect the front seat belt buckle connector
(arrow).
31
RA19440090
b. Using a digital multimeter, measure the resistance

between terminals 1 and 2 of the front seat belt buckle
assembly connector.
Under normal conditions, the measured resistance is
∞ Ω (no continuity) when the front seat belt assembly
is fastened; the measured resistance is less than 0 Ω
(continuity) when the front seat belt assembly is
unfastened.
If the result is not as specified, replace the front seat
belt buckle assembly.
2 1
RA19310090
Removal
HINT:
 Use the same procedures for the front passenger seat belt buckle assembly and driver seat belt buckle
assembly.
 The procedures listed below are for the driver seat belt buckle assembly.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front seat belt buckle
assembly.
 Avoid scratch to the interior when removing the front seat belt buckle assembly.
 Avoid damage to the wire harness and connector when removing the front seat belt buckle assembly.

3. Remove the front seat belt buckle assembly.
HINT:
Only the driver seat belt buckle assembly is equipped with connector.

31 - SEAT BELT
a. Disconnect the front seat belt buckle connector

(arrow).
RA19440090
31 b. Remove the fixing bolt (arrow) from the front seat belt
buckle assembly.
RA19310091
c. Remove the front seat belt buckle assembly.
Installation
CAUTION
 Make sure to tighten all the fixing bolts according to the specified torque when installing the front seat
belt buckle assembly.

31 - SEAT BELT
Height Adjuster Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the height adjuster assembly.
 When removing the height adjuster assembly, prevent scratching the interior.
31
3. Remove the left B-pillar lower protector assembly (See page 47-13).
4. Remove the left B-pillar upper protector assembly (See page 47-15).
5. Remove the height adjuster assembly.
a. Remove 2 fixing bolts (arrow) from the height adjuster
assembly.
RA19310100
b. Remove the height adjuster assembly.
Installation
CAUTION
 Make sure to tighten all the fixing bolts according to the specified torque when installing the height
adjuster assembly.

31 - SEAT BELT
Rear Seat Belt Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear seat belt assembly.
 DO NOT use excessive force when removing the rear seat belt assembly. Rough operation is strictly
31 forbidden.
 DO NOT scratch the interior when removing the rear seat belt assembly.

3. Remove the rear seat cushion assembly (See page 44-14).
4. Remove the rear left seat belt assembly.
a. Remove the fixing bolt (arrow) from the lower part of
the rear seat belt assembly. 
RA19310110
b. Remove the rear seatback assembly (See page 44-15).

c. Remove the left C-pillar lower protector assembly (See page 47-17).
d. Remove the left C-pillar upper protector assembly (See page 47-19).
e. Remove the tonneau cover assembly (See page 47-34).
f. Remove the fixing bolt (arrow) from the rear seat belt
retractor.
RA19310120
g. Remove the rear left seat belt assembly.

31 - SEAT BELT
Inspection
Check the rear seat belt retractor.
CAUTION
 DO NOT disassemble the rear seat belt retractor.
HINT:
When the inclination of the rear seat belt retractor is 15° or
less, check that the rear seat belt can be pulled out from the
rear seat belt retractor. When the inclination of the rear seat 45° 31
belt assembly retractor is over 45°, check that the rear seat
belt locks.
If the result is not as specified, replace the rear seat belt
assembly. Unlock
lock
RA19310130
Installation
CAUTION
 Keep the seat belt assembly clean, avoid attaching oil and check the seat belt assembly for damage
when installing the rear seat belt assembly.
 Make sure to tighten the fixing bolt according to the specified torque when installing the rear seat belt
assembly.

31 - SEAT BELT
Center Seat Belt Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the center seat belt assembly.
 DO NOT scratch the interior when removing the center seat belt assembly.

31 2. Disconnect the negative battery cable.
3. Remove the rear seat assembly (See page 44-14).
4. Remove the tonneau cover assembly (See page 47-34).
5. Remove the center seat belt assembly.
a. Remove the fixing bolt (arrow) from the lower part of
center seat belt assembly.
RA19310160
b. Remove the fixing bolt (arrow) from the center seat

belt retractor, then remove the center seat belt
assembly.
RA19310121
Inspection
Check the center seat belt retractor.
CAUTION
 DO NOT disassemble the rear seat belt retractor.

31 - SEAT BELT
HINT:
When the inclination of the center seat belt retractor is 15° or
less, check that the center seat belt can be pulled out from
the center seat belt retractor.  45°
When the inclination of the center seat belt retractor is over
45°, check that the center seat belt locks.
If the result is not as specified, replace the center seat belt
assembly. Unlock
lock
RA19310130
Installation 31
CAUTION
 Make sure to tighten all the fixing bolts and fixing screws according to the specified torque when
installing the center seat belt assembly.

31 - SEAT BELT
Double Buckle Belt Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the double buckle belt
assembly.
 DO NOT scratch the interior when removing the double buckle belt assembly.
31 1. Turn off all the electrical equipment and ignition switch.

4. Remove the double buckle belt assembly.
a. Remove the fixing bolt (arrow) from the double buckle
belt assembly.
RA19310150
b. Remove the double buckle belt assembly.
Installation
CAUTION
 Make sure to tighten all the fixing bolts according to the specified torque when installing the double
buckle belt assembly.

31 - SEAT BELT
Rear Seat Belt Buckle Assembly

Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing the rear seat belt buckle
assembly.
 DO NOT scratch the interior when removing the rear seat belt buckle assembly.
1. Turn off all the electrical equipment and ignition switch. 31

4. Remove the rear seat belt buckle assembly.
a. Remove the fixing bolt (arrow) from the rear seat belt
buckle assembly.
RA19310140
b. Remove the rear seat belt buckle assembly.
Installation
CAUTION
 Make sure to tighten all the fixing bolts according to the specified torque when installing the rear seat belt
buckle assembly.

- MEMO -

ENGINE IMMOBILIZER
GENERAL INFORMATION 32-3 DIAGNOSIS & TESTING 32-6
Description 32-3 Problem Symptoms Table 32-6
Operation 32-3
Circuit Diagram 32-4
Immobilizer Control Module 32-7
Immobilizer Control Module 
Removal 32-7
Terminal List 32-5
Installation 32-7
32

32

32 - ENGINE IMMOBILIZER
GENERAL INFORMATION
ENGINE IMMOBILIZER
Description
32
MUTE
MODE
+ VOL -
SEEK
3
4
STORAGE BOX
ON S
CC T
A
AR
LOCK
1
T
RA19320010
1 - Ignition Switch (Built-in Immobilizer Coil) 2 - Ignition Key (Built-in Transponder)

3 - Immobilizer Control Module 4 - Engine Control Module (ECM)
The vehicle is equipped with engine immobilizer system. The anti-theft features of vehicle have improved due
to the integration technology of ignition key identification and engine start-up. When the engine is started with
unprogrammed ignition key, the engine immobilizer sends the detected signal to the engine control module
and the engine control module outputs the prohibit starting command, thus effectively reduces the possibility
of being stolen.
Operation
When the ignition key is inserted into the ignition switch, the immobilizer coil can detect the data information of
the ignition key, and sends the data information to the immobilizer control module. The immobilizer control
module communicates with the engine control module (ECM) via CAN BUS system, realizing codes
verification and mutual certification. The battery and ignition switch supply power to the immobilizer control
module continuously, allowing the immobilizer to save the trigger memory that has been generated and the
malfunctioning content.

Circuit Diagram
IGNITION SWITCH
ON OR START
INSTRUMENT
RF04 PANEL FUSE
10A AND RELAY BOX
I-005
4
32 IMMOBILIZER
R
COIL
Br
W
4 B1 B2 B3
IG-SW ANT A ANT B GND IMMOBILIZER
CONTROL
MODULE
CAN-H CAN-L GND I-032
6 8 2
G
I-004
11 25
G
I-026
B-053
G
14 6
17 1 DATA LINK
CONNECTOR
ECM I-013
B-001
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
29 30 31 32 33 34 35 36 37 38 39 40 41 42 1 3 5 7
25 26
15 16 17 18 19 20 21 22 23 24 25 26 27 28 2 4 6 8
87
85 86 86 86 1 2 3 4 5 6 7 8 9 10 11 12 13 14
87 30 87 30
30 85 85
I-032
I-005 I-004 W
B L
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 B1 B2 B3
8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 IMMOBILIZER COIL
I-013
B
B-001
B
EA19320010

Immobilizer Control Module Terminal List

1 - -
2 GND Ground
3 - -
4 IG-SW Ignition Switch Power Supply
5 - -
6 CAN-L CAN-L
7 - -
32
8 CAN-H CAN-H
B1 ANT A Coil (ANT A)
B2 ANT B Coil (ANT B)
B3 GND Coil (GND)

DIAGNOSIS & TESTING

HINT:
Symptoms Possible Cause See page

Ignition key (transponder) -
Immobilizer coil -
32 Immobilizer system causes the engine Wire harness or connector -
cannot start or immobilizer system has
failed Immobilizer control module 32-7
Electronic fuel injection system -
ECM 06-209

ON-VEHICLE SERVICE
Immobilizer Control Module
Removal
1. Turn off all the electrical devices and ignition switch.
3. Remove the left lower instrument panel protector assembly (See page 43-16).
4. Disconnect the connectors (arrow) and remove the fixing
bolt (1) of immobilizer control module with a wrench.
32
1
RA19320020
Installation
CAUTION
 Install the connectors in place.

 Tighten the fixing bolt in place.

- MEMO -

LIGHTING SYSTEM
GENERAL INFORMATION 33-3 Removal 33-61
Light Position Diagram 33-3 Inspection 33-62
System Assembly Diagram 33-5 Installation 33-64
Description 33-6 Headlight Leveling Switch 33-65
Front Combination Light 33-67
Removal 33-67
Installation 33-67
High Beam Light/Low Beam Light/
Adjustment 33-67
Front Fog Light Relay Inspection 33-21
Rear Combination Light 33-71 33
Removal 33-71
Installation 33-71
Diagnostic Trouble Code Chart 33-22
License Plate Light 33-72
System Diagnostic 33-22
Removal 33-72
Installation 33-72
B1001-18 33-26
Side Turn Signal Light 33-73
B1001-19 33-26
Removal 33-73
B1002-18 33-26
Installation 33-73
B1002-19 33-26
Front Fog Light 33-74
B1003-11 33-33
Removal 33-74
B1003-13 33-33
Installation 33-74
B1005-12 33-39
High Mounted Stop Light 33-75
B1005-13 33-39
Removal 33-75
B1006-12 33-39
Installation 33-75
B1006-13 33-39
Dome Light Assembly 33-76
B100A-12 33-43
Removal 33-76
B100A-13 33-43
Inspection 33-77
B1007-12 33-47
Installation 33-77
B1007-13 33-47
Back-up Light Switch 33-78
B1008-12 33-51
Removal 33-78
B1008-13 33-51
Inspection 33-78
B103E-18 33-55
Installation 33-79
B103E-19 33-55
Hazard Warning Light Switch 33-80
B103F-18 33-58
Removal 33-80
B103F-19 33-58
Inspection 33-80
Combination Switch 33-61

33

33 - LIGHTING SYSTEM
GENERAL INFORMATION
LIGHTING SYSTEM
Light Position Diagram
33
3
5
6
7
RA19330010

1 - Interior Front Dome Light 2 - Front Combination Light (Low Beam Light, High
Beam Light, Position Light, Turn Signal Light)
3 - Front Fog Light 4 - Side Turn Signal Light
5 - Instrument Panel Backlight 6 - High Mounted Stop Light
7 - Luggage Compartment Light 8 - License Plate Light
9 - Rear Combination Light (Including Turn Signal
Light, Position Light, Brake Light, Rear Fog Light,
Back-up Light)
33

System Assembly Diagram
6 33
3
RA19330020
1 - Interior Front Dome Light Switch 2 - Engine Compartment Fuse and Relay Block
3 - Hazard Warning Light Switch 4 - Body Control Module (BCM)
5 - Headlight Leveling Switch 6 - Combination Switch
7 - Instrument Panel Fuse and Relay Block

Description
The lighting system on this model consists of vehicle lighting device and light signal device, which are used for
normal operation of vehicle to ensure safety when driving at night or in fog.
The lighting system consists of front combination light (including low beam light, high beam light, position light,
turn signal light), rear combination light (including turn signal light, position light, brake light, rear fog light,
back-up light), license plate light, side turn signal light, high mounted stop light, interior front dome light and
instrument panel backlight. The combination lights use semi-closed structure for easy inspection and repair.
Specifications
Bulb Specifications
Bulb Name Nominal Light Source (Model/Type)

Headlight H1
33 Front Position Light LED
Front Turn Signal Light HY21
Brake Light LED
Rear Fog Light P21W
License Plate Light C5W
High Mounted Stop Light LED
Rear Position Light LED
Rear Turn Signal Light PY21W
Back-up Light P21W
Side Turn Signal Light WY5W

Front Combination Light Fixing Bolt 3.5 ± 0.5
Rear Combination Light Fixing Nut 3.5 ± 0.5
Dome Light Fixing Screw 2±1

Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
33
Digital Multimeter
RCH0000002

Circuit Diagram
High/Low Beam Light (Page 1 of 2)
BATTERY
30 86 30 86
ENGINE
LOW BEAM HIGH BEAM
COMPARTMENT
RELAY RELAY
FUSE AND
33 87 85 87 85 RELAY BOX
E-039
EF03 EF01 EF04 EF02
B-014
15A 10A 15A 10A
B3 A16 B2 B12 B1 A2
BrW
WR
RG
RB
Gr
D
WR
YW
RB
RB
YW
RG
RG
W
7 9 8 4 7 9 4 8
FRONT LEFT FRONT RIGHT
M COMBINATION M COMBINATION
LIGHT LIGHT
E-037 E-022
5 6 5 6
B
B
B
E-036 E-026
2 4 6 8 10 2 4 6 8 10
A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 1 3 5 7 9
A10 A11 A12 A13 B8 B9 B10 B11 1 3 5 7 9
A7 A8 A9 A14 A15 A16 B6 B7 B12 B13 B14
B-014 E-039 E-037 E-022

W W B B
EA19330010

High/Low Beam Light (Page 2 of 2)
1 2 3 4 5 6 7 8 9 10 11 12 13 COMBINATION
LOW BEAM LIGHT SWITCH
I-045
HIGH BEAM
B
I-012
1 3
A12 B12
BCM
I-046 HEADLIGHT 33
ADJUSTMENT
I-006
SWITCH
A24 A25 4
I-014
2 6
BrW
P
TO ILLUMINATION
YW
RB
Gr
I-004
26 37 9 5
B-053
YW
RB
Gr B-008
B 10 6 E-038
BrW
A
YW
D
RB
C
42 41 40 39 38 37 36 35 34 33 32 31 30 29
8 7 6 5 4 3 2 1 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
9 10 11 12 13 14 15 16 13 12 11 10 9 8 7 6 5
14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-045
E-038 W
B-053
B L

2 1 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
6 5 4 3 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
I-006 I-014 I-046

L Gr G
EA19330020

Position Light
BATTERY
5
POWER COMBINATION
EF12 FUSE LIGHT SWITCH
BOX
80A I-045
B-009
8
R
F1 A1
PARKING
33 LAMP BCM
RELAY I-006
B-048
I-015
F2 F3
5A 7.5A
D12 D10
RB
L
I-003 I-004
9 B-050 30 B-053
RB
L
RB
B-008 B-008
RB
L
5 4
E-038 E-038
RB
3 1 3 1
FRONT LEFT REAR LEFT FRONT RIGHT REAR RIGHT
COMBINATION COMBINATION COMBINATION COMBINATION
LIGHT LIGHT LIGHT LIGHT
E-037 B-037 E-022 B-045
2 2 2 2
B
E-036 B-034 E-026 B-030
29 30 31 32 33 34 35 36 37 38 39 40 41 42
4 3 2 1 2 4 6 8 10
15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 3 5 7 9
13 12 11 10 9 8 7 6 5
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-045 E-022 E-037

I-003 W B B
W
29 30 31 32 33 34 35 36 37 38 39 40 41 42
1 2 1
15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4 5 6 7 8 6 5 4 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 B-048
16 15 14 13 12 11 10 9
Gr
B-037 B-045
I-004 W W
B-008
L
B
B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 1

D1 D2 D3 D4 D5 I-015
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 W
D6 D7 D8 D9 D10 D11 D12 B-009
I-006
L EA19330060

Turn Signal Light
BATTERY
B
I-012
12
POWER RH LH COMBINATION
BOX
80A I-045
B-009
11 13
BW
VB
R F1 A23 A9
BCM
8-F1 B-048
15A I-006
I-046
B-049
C4 C5 A6 33
GL
YR
RY
RY RY ILLUMINATION
17
RY
B-050 I-003
P
GL
RY
5 5
GL
REAR REAR 1 6 4
RY
TURN TURN
RIGHT
SIGNAL SIGNAL LEFT
COMBIN- B-008 COMBINATION
LIGHT LIGHT
ATION E-038 LIGHT
LIGHT 12 11 HAZARD
B-037
B-045 SWITCH
2 2
B
I-033
B
RY
GL
302 G301
2 5
GL
1 RIGHT 1 1 1
LEFT
B
B
FRONT RIGHT FRONT LEFT
SIDE SIDE COMBINATION
TURN COMBINATION
LIGHT TURN LIGHT
LIGHT LIGHT
E-022 E-037
2 E-021 2 2 E-040 2
B
E-026 E-036 I-028
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 4 3 2 1
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 13 12 11 10 9 8 7 6 5
I-046 I-045
G W
E-037
E-040 2 4 6 8 10
42 41 40 39 38 37 36 35 34 33 32 31 30 29 B
1 2
W 1 3 5 7 9
E-021 28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-050 E-022
W W B
14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 B-009
1 4
2 5 I-033
1 2 3 4 5 6 7 8 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B B-048
B-008 1
B I-006 3 6 Gr
16 15 14 13 12 11 10 9 B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
L
B-045
42 41 40 39 38 37 36 35 34 33 32 31 30 29 1 2 W
C1 C2 C3 C4 C5 C6 C7 C8 C9 6 5 4 3
28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-037
B-049 B-050
W
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W 14 13 12 11 10 9 8 7 6 5 4 3 2 1 W
EA19330050

Fog Light (Page 1 of 2)

BATTERY
POWER ENGINE INSTRUMENT

FUSE COMPARTMENT PANEL
EF12 EF31 RF03 RF22 RF16 FUSE AND
BOX FUSE AND
80A B-009 20A 10A 10A 10A RELAY BOX
RELAY BOX
I-005
3 22 16
33
B
R
I-012
RY
RW
REAR STEERING
OFF FOG WHEEL
SWITCH 1
I-045
FRONT
FOG
3 2
GB
GL
F1 B9 B8 B31 B15
BCM
B-048
I-006
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
4 3 2 1
25 26 I-045 B-048
13 12 11 10 9 8 7 6 5 1
87 W Gr
85 86 86 86
87 30 87 30
30 85 85
I-005
B B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 I-006
L
EA19330030

Fog Light (Page 2 of 2)
86 30 ENGINE 86 30 INSTRUMENT
FRONT COMPARTMENT REAR PANEL
FOG FUSE AND FOG FUSE AND
RELAY RELAY BOX RELAY RELAY BOX
85 87 B-014 85 87 I-005
E-039
A9 B8
WB
33
G
40 B-050
I-003
BrB
G
G
G
2 2 6 6
FRONT FRONT REAR REAR
B-053 RIGHT LEFT RIGHT LEFT
23 FOG COMBINATION
FOG
BG
I-004 COMBINATION
LIGHT LIGHT LIGHT
1 1 2 LIGHT 2
E-025 B-045 B-037
E-034
B
B
E-026 E-036 B-030 B-034
BrB
A11 A27
BCM
I-046
1 2 3 4 5 6 7 8 9 10 11 12
42 41 40 39 38 37 36 35 34 33 32 31 30 29
13 14 15 16 17 18 19 20 21 22 23 24 1 2
28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-050
25 26 I-005 6 5 4 3
14 13 12 11 10 9 8 7 6 5 4 3 2 1 W
87 B
85 86 86 86 B-045
87 30 87 30
30 85 85 W
I-046 1 2 B-037
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 W
G 6 5 4 3
A1 A2 A3 A4 A5 A6 B-014
A10 A11 A12 A13
A7 A8 A9 A14 A15 A16 W
1 2
42 41 40 39 38 37 36 35 34 33 32 31 30 29
1 2
E-039 28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-053
B1 B2 B3 B4 B5 W E-025
B8 B9 B10 B11 14 13 12 11 10 9 8 7 6 5 4 3 2 1 L
E-034 B
B6 B7 B12 B13 B14
B EA19330040

Interior Light

BATTERY
INSTRUMENT
PANEL
EF12 POWER RF03 RF16 FUSE AND
FUSE BOX RELAY BOX
80A B-009 10A 10A
I-005
3 16
RW
RY
R
F1 B31 B15
BCM
F4 F5 I-006
10A 10A B-048
33 DOUAL RLY
GND
I-007
B-049
C02 C19 E1
LW
LW
B-053
2 3 I-004
B
LW
LW
5 I-001
2
C-002
LW
1 I-012
3
DOME
RELE- RELE-
PRE- PRE- LIGHT
ASED SSED DOOR ON ASED SSED C-001
5
B
C-002
9 I-001
B
I-012
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42
13 14 15 16 17 18 19 20 21 22 23 24 5 6 7 8 9 10
15 16 17 18 19 20 21 22 23 24 25 26 27 28
25 26 I-001
1 2 3 4 5 6 7 8 9 10 11 12 13 14
87 W
85 86 86 86
87 30 87 30
30 85 85
I-004
L I-007
I-005 E1
B
B
C1 C2 C3 C4 C5 C6 C7 C8 C9
2 1
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C-001
I-006 W
6 5 4 3
L
B-049
1 B-048 1 B-009 W
Gr EA19330100

License Plate Light

BATTERY

BOX RELAY BOX
80A 10A 10A
B-009 I-005
3 16
RW
RY
R
F1 B31 B15
PARKING BCM 33
LAMP I-006
RELAY
B-048
F3 I-015
7.5A
D10
L
I-004
30
B-053
L
B-031
3 T-005
L
L
L
2 2
LEFT RIGHT
LICENSE LICENSE
PLATE PLATE
LIGHT LIGHT
1 T-004 1 T-007
B
7 T-005
B-031
B-034
1 2 3 4 5 6 7 8 9 10 11 12
29 30 31 32 33 34 35 36 37 38 39 40 41 42
13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4
15 16 17 18 19 20 21 22 23 24 25 26 27 28
25 26
1 2 3 4 5 6 7 8 9 10 11 12 13 14 5 6 7 8
87
85 86 86 86
87 30 87 30
30 85 85
I-004 B-031
L B
I-005
B
B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 D1 D2 D3 D4 D5
1 2 T-007 T-004
D6 D7 D8 D9 D10 D11 D12 L L
I-006
L I-015
W
1 B-048 1 B-009
Gr
EA19330070

Ignition Illumination

BATTERY
ENGINE
POWER COMPARTMENT INSTRUMENT
EF12 FUSE EF05 RF21 PANEL
FUSE AND RF03 RF16 FUSE AND
80A BOX 80A RELAY BOX
B-009 10A 10A 10A RELAY BOX
B-010 I-005
E3
21 3 16
R
R
8
R
B-021 I-047
4
KEY
R
33 SWITCH
I-017
RW
RY
3
Gr
F1 B10 B31 B15

BCM
I-006
F4 F5 B-049
10A 10A I-046
DOUAL RLY B-048
GND I-007
A26 C19 E1
G
1
IGNITION
B
SWITCH 3 B-053
LIGHT I-004
I-016
2
R
I-012
1 2 3 4 5 6 7 8 9 10 11 12
29 30 31 32 33 34 35 36 37 38 39 40 41 42
13 14 15 16 17 18 19 20 21 22 23 24
15 16 17 18 19 20 21 22 23 24 25 26 27 28 I-007
E1
25 26 B
1 2 3 4 5 6 7 8 9 10 11 12 13 14
87
85 86 86 86
87 30 87 30
30 85 85
I-004
L B-010
I-005
E4 E3 E2 E1
B W
C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 1 2 3 4 B-021
I-006 5 6 7 8 W
L
B-049
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 W
3 4
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 1 B-009 1 B-048
1 2 1 2
Gr
I-046 I-016 I-017
G W W EA19330110

Back-up Light

BATTERY

80A BOX 10A 10A RELAY BOX
B-009 I-005
3 16
RW 33
RY
R
F1 B31 B15
BCM
I-006
B-048
I-015
D3
RGr
I-003
42
B-050
Gr
Gr
Gr
3 3
REAR LEFT REAR RIGHT
COMBINATION COMBINATION
LIGHT LIGHT
B-037 B-045
2 2
B
B-034 B-030
D1 D2 D3 D4 D5 I-015 B-037 B-045

1 B-048 1 B-009 1 2
Gr D6 D7 D8 D9 D10 D11 D12 W W W
6 5 4 3
1 2 3 4 5 6 7 8 9 10 11 12
29 30 31 32 33 34 35 36 37 38 39 40 41 42 13 14 15 16 17 18 19 20 21 22 23 24
15 16 17 18 19 20 21 22 23 24 25 26 27 28 25 26
1 2 3 4 5 6 7 8 9 10 11 12 13 14 87
85 86 86 86
87 30 87 30
30 85 85
I-003
W I-005
B
I-006
L
EA19330080

Brake Light

BATTERY

BOX RELAY BOX
80A 10A 10A
B-009 I-005
3 16
33 RW
RY
R
F1 B31 B15
BCM
I-006
B-048
B-049
C14
GBr
GBr
GBr
GBr
4 2 4
REAR LEFT HIGH REAR RIGHT
COMBINATION MOUNTED COMBINATION
LIGHT STOP LIGHT LIGHT
B-037 B-043 B-045
2 1 2
B
B-034 B-034 B-030
1 1 2 B-037 B-045 B-043

1 B-048 B-009 1 2
W W W
Gr 6 5 4 3
1 2 3 4 5 6 7 8 9 10 11 12
C1 C2 C3 C4 C5 C6 C7 C8 C9 13 14 15 16 17 18 19 20 21 22 23 24
25 26
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 87
85 86 86 86
87 30 87 30
30 85 85
B-049
W
I-005
B
I-006
L
EA19330090

DIAGNOSIS & TESTING

HINT:
Position Light, Low Beam Light, High Beam Light

Fuse 49-27
"Low beam" does not come on (one side) Low beam bulb -
33
Fuse 49-27
Low beam bulb -
Combination switch 33-61
"Low beam" does not come on (both sides)
Low beam relay 33-21
Wire harness -
Body Control Module (BCM) -
Bulb -
"High beam" does not come on (one side) Fuse 49-27
Bulb -
Fuse 49-27
"High beam" does not come on (both Combination switch 33-61

sides) High beam relay 33-21
Wire harness -
Fuse 49-29
Position light bulb (both sides) -
Position light does not come on (both
sides)
Fuse 49-29
Position light does not come on (one side) Position light bulb -

Rear Fog Light

Fuse 49-28
Rear fog light bulb -
Rear fog light does not come on Combination switch 33-61
Turn Signal Light and Hazard Warning Light

33 Bulb -
Hazard warning light and turn signal light Wire harness or connector -
do not come on Hazard warning light switch 33-80
Hazard warning light does not come on Hazard warning light switch 33-80
(turn signal light is normal) Wire harness or connector -
Turn signal light does not come on (hazard Combination switch 33-61
warning light is normal) Wire harness or connector -
Brake Light

Bulb -
Brake light does not come on (all) Brake light switch 25-22
Bulb -
Only one brake light does not come on
Interior Front Dome Light (w/Map Light)

Dome light bulb -
Dome light does not come on Fuse 49-29
Dome light assembly 33-76

Back-up Light

Back-up light bulb -
Back-up light does not come on (all) Back-up light switch 33-78
High Beam Light/Low Beam Light/Front Fog Light Relay Inspection

1. Remove the integration relay from the engine compartment fuse and relay box.
2. Measure the resistance according to the table below.
+ -
Multimeter Measurement Specified 3

33
5
When battery 2 4 1
FRONT FOG
10
voltage is not
40
RELAY
Terminal 3 -
LOW BEAM
RELAY
30
10
10
applied between No continuity
20
30
30
Terminal 5
15
terminal 2 and
20
15
HIGH BEAM
40
RELAY
15
15
terminal 1
40
10
15
10
15
15
40
When battery RA19330430
Terminal 3 - voltage is applied

Continuity
Terminal 5 between terminal
2 and terminal 1
If the result is not as specified, replace the integration relay.

 Wiggle the related wire harness and connector and observe if the signal is interrupt in the related circuit
during testing.
 Check the installation of components such as the combination switch and each light assembly for damage,
foreign matter, etc. that will cause incorrect signals.
Ground Inspection
A good connection to the ground is necessary to ensure the circuits operate normally. If the ground point in
circuit is usually exposed to a corrosive environment where it is wet and full of dust, the metal corrosion will
affect the continuity of circuit, resulting in various electrical system malfunctions.
As the control circuit is very sensitive, a loose or corroded line can affect the transmission of various signals in
the electronically controlled circuit seriously. Perform the followings when checking the ground connection:
2. Check all the matching surfaces for tarnish, dirt, rust, etc.

ground path.
Diagnostic Trouble Code Chart

B1001-18 Left Turn Lights Control Circuit Current Below Threshold
B1001-19 Left Turn Lights Control Circuit Current Above Threshold
B1002-18 Right Turn Lights Control Circuit Current Below Threshold
B1002-19 Right Turn Lights Control Circuit Current Above Threshold
B1003-11 Park Light Control Circuit Short to Ground
B1003-13 Park Light Control Circuit Open
33 B1005-12 Low Beam Control Circuit Short to Battery

B1005-13 Low Beam Control Circuit Open
B1006-12 High Beam Control Circuit Short to Battery
B1006-13 High Beam Control Circuit Open
B1007-12 Front Fog Control Circuit Short to Battery
B1007-13 Front Fog Control Circuit Open
B1008-12 Rear Fog Control Circuit Short to Battery
B1008-13 Rear Fog Control Circuit Open
B100A-12 Dome Lights Control Circuit Short to Battery
B100A-13 Dome Lights Control Circuit Open
B103E-18 Brake Light Control Circuit Current Below Threshold
B103E-19 Brake Light Control Circuit Current Above Threshold
B103F-18 Reverse Light Control Circuit Current Below Threshold
B103F-19 Reverse Light Control Circuit Current Above Threshold
System Diagnostic
1. Description
a. Lighting system data and Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
(DLC) of vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for
malfunctions and repair.
2. Check the battery voltage.
Standard voltage:
11 to 14 V
If the voltage is below 11 V, replace or recharge the battery before proceeding to the next step.
DTC Check/Clear
1. Check the DTCs.
a. Connect the intelligent tester to the DLC.
b. Turn the ignition switch to ON (IG) and turn the intelligent tester on.
c. Select the following menu items to read the current malfunctions: A19/BCM/Read fault code/Read
present fault code.
d. Read the DTCs by following the prompts on the tester screen.

2. Clear the DTCs.

a. Connect the intelligent tester to the DLC3.
c. Select the following menu items: A19/BCM/Erase fault code.
d. Clear the DTCs by following the directions on the tester screen.
Data List/Active Test

1. Read the Data List.
HINT:
Using the intelligent tester Data List to perform Active Tests allows the values or states of item to be read
without removing any parts. This non-intrusive inspection can be very useful because intermittent
problems or signals may be discovered before parts or wiring is disturbed. Reading the Data List
information early in troubleshooting is one way to save diagnostic time.
CAUTION 33
 In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely
on these reference values when deciding whether a part is faulty or not.

c. Select the following menu items: A19/BCM/Read datastream/Input status (Light).
d. Read the Data List according to the display on the tester.
Tester Display Measurement Item/Range Normal Condition

Left turn signal On: Active
Left Hand Turn Light Left turn signal On or Off
Left turn signal Off: Inactive
Right turn signal On: Active
Right Hand Turn Light Right turn signal On or Off
Right turn signal Off: Inactive
Front fog light signal On: Active
Front Fog Light Front fog light signal On or Off
Front fog light signal Off: Inactive
Rear fog light signal On: Active
Rear Fog Light Rear fog light signal On or Off
Rear fog light signal Off: Inactive
Position light signal On: Active
Position Light Position light signal On or Off
Position light signal Off: Inactive
Low beam light signal On: Active
Low Beam Low beam light signal On or Off
Low beam light signal Off: Inactive
High beam light signal On: Active
High Beam High beam light signal On or Off High beam light signal Off:
Inactive
2. Perform the Active Test.

HINT:
Using the intelligent tester to perform Active Tests allows items to be tested without removing any parts.
This non-intrusive functional inspection can be very useful because intermittent problems may be
discovered before parts or wiring is disturbed. Perform the Active Test early in troubleshooting is one way
to save diagnostic time. The Data List information can be displayed when performing the Active Test.


c. Select the following menu items: A19/BCM/Action Test.
d. Perform the Active Test according to the tester display.
Test Part Control Range

Left Hand Turn Light Active/Inactive
Right Hand Turn Light Active/Inactive
Position Light Active/Inactive
Low Beam Active/Inactive
High Beam Active/Inactive
Front Fog Light Active/Inactive
33 Rear Fog Light Active/Inactive
Dome Lamp Active/Inactive
Security Indicator Active/Inactive
Diagnosis Procedure
HINT:
Perform troubleshooting according to the procedures below.
NEXT
If the voltage is below 11 V, recharge or replace the battery before proceeding to next step.
NEXT
DTC
No

NEXT
NEXT
6 Repair or replace
NEXT
33
NEXT
DTC
output Go to step 4
NO DTC
Go to the next step
output
9 Confirmation test
NEXT
10 End

Left Turn Lights Control Circuit Current Below

DTC B1001-18
Threshold
Left Turn Lights Control Circuit Current Above

DTC B1001-19
Threshold
Right Turn Lights Control Circuit Current Below

DTC B1002-18
Threshold
Right Turn Lights Control Circuit Current Above

DTC B1002-19
Threshold
33

BCM
B-049
C4 C5
RY
GL
RY
GL
33
RY
GL
5 5
REAR REAR
TURN TURN
RIGHT
SIGNAL SIGNAL LEFT
COMBIN- B-008 COMBINATION
LIGHT LIGHT
ATION E-038 LIGHT
LIGHT 12 11
B-037
B-045
2 2
B
B
RY
GL
302 G301
RY
GL
1 RIGHT 1 1 1
FRONT RIGHT LEFT FRONT LEFT
SIDE SIDE COMBINATION
TURN COMBINATION
LIGHT TURN LIGHT
LIGHT LIGHT
E-022 E-037
2 E-021 2 2 E-040 2
RY
GL
E-026 E-036
2 4 6 8 10 1 2
1 2 C1 C2 C3 C4 C5 C6 C7 C8 C9
1 3 5 7 9 6 5 4 3
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
E-022 E-037 E-040 E-021 B-037 B-045
B B W W W W B-049
W
1 2 3 4 5 6 7 8
B-008
16 15 14 13 12 11 10 9 B
EA19330850

DTC Detection
Condition
Left Turn Lights
B1001-18 Control Circuit Current
Below Threshold
Left Turn Lights
 Bulb
Above Threshold
Ignition switch ON  Wire harness or connector
Right Turn Lights
 BCM
Below Threshold
Right Turn Lights
33 Above Threshold
1 Check turn signal light bulb
a. Remove the turn signal light bulb, and check if the turn signal light bulb filament is blown.
NG Replace turn signal light bulb
OK
2 Check interior wire harness
a. Turn the ignition switch off.

c. Disconnect the BCM connector B-049 and interior wire
harness connector B-008.
+ -
d. Check for continuity between the terminals C4 and C5 of
BCM connector B-049 and the terminals 12 and 11 of
interior wire harness connector B-008 according to the C1 C2 C3 C4 C5 C6 C7 C8 C9
table below.
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Condition B-049
B-049 (C4) -
Always Continuity
B-008 (12) 1 2 3 4 5 6 7 8
B-049 (C5) - 16 15 14 13 12 11 10 9
Always Continuity
B-008 (11)
B-008
RA19330500

e. Disconnect the BCM connector B-049 and interior wire

harness connectors B-045 and B-037.
f. Check for continuity between the terminal C4 of BCM
connector B-049 and the terminal 5 of interior wire
harness connector B-045, and between the terminal C5 + -
of BCM connector B-049 and the terminal 5 of interior
wire harness connector B-037 according to the table
below.
C1 C2 C3 C4 C5 C6 C7 C8 C9
Condition C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-049
B-049 (C4) -
Always Continuity
B-045 (5)
1 2
B-049 (C5) -
Always Continuity 6 5 4 3
B-037 (5)
B-045 33
RA19330510
NG Replace interior wire harness
+ -
C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-049
1 2
6 5 4 3
B-037
RA19330520
OK

3 Check engine compartment wire harness

c. Disconnect the engine compartment wire harness
connectors E-038, E-022, E-040, E-021 and E-037.
+ -
d. Check for continuity between the terminal 12 of engine
compartment wire harness connector E-038 and the
terminal 1 of engine compartment wire harness 8 7 6 5 4 3 2 1
connector E-022 according to the table below. 9 10 11 12 13 14 15 16
Condition E-038
E-038 (12) -
33 E-022 (1)
Always Continuity
2 4 6 8 10
1 3 5 7 9
E-022
RA19330530
e. Check for continuity between the terminal 12 of engine

terminal 1 of engine compartment wire harness
connector E-021 according to the table below.
+ -
Condition
E-038 (12) - 8 7 6 5 4 3 2 1
Always Continuity
E-021 (1) 9 10 11 12 13 14 15 16
E-038
1 2
E-021
RA19330540

f. Check for continuity between the terminal 11 of engine

+ -
Condition
E-038 (11) -
E-040 (1) 9 10 11 12 13 14 15 16
E-038
1 2
E-040
33
RA19330550
g. Check for continuity between the terminal 11 of engine

+ -
Condition
E-038 (11) - E-
037 (1) 9 10 11 12 13 14 15 16
NG Replace engine compartment wire E-038

harness
2 4 6 8 10
1 3 5 7 9
E-037
RA19330560
OK
4 Reconfirm DTCs
a. Connect the disconnected wire harness connectors.

d. Use the X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the control
unit system (BCM).
g. Use the X-431 3G diagnostic tester to read the DTCs in the control unit system (BCM) again.

Result Proceed to
DTC B1001-18, B1001-19, B1002-18, B1002-19 are
NG
output
No DTC is output OK
NG Replace BCM
OK
System is normal
33

DTC B1003-11 Park Light Control Circuit Short to Ground
DTC B1003-13 Park Light Control Circuit Open
BATTERY
5
POWER COMBINATION
BOX
80A I-045
B-009
8
R
33
F1 A1
PARKING
LAMP BCM
RELAY I-006
B-048
I-015
F2 F3
5A 7.5A
D12 D10
RB
I-003 I-004
9 B-050 30 B-053
RB
L
RB
B-008 B-008
RB
L
5 4
E-038 E-038
RB
3 1 3 1
FRONT LEFT REAR LEFT FRONT RIGHT REAR RIGHT
COMBINATION COMBINATION COMBINATION COMBINATION
LIGHT LIGHT LIGHT LIGHT
E-037 B-037 E-022 B-045
2 2 2 2
B
E-036 B-034 E-026 B-030
29 30 31 32 33 34 35 36 37 38 39 40 41 42
4 3 2 1 2 4 6 8 10
15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 3 5 7 9
13 12 11 10 9 8 7 6 5
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-045 E-022 E-037

I-003 W B B
W
29 30 31 32 33 34 35 36 37 38 39 40 41 42
1 2 1
15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4 5 6 7 8 6 5 4 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 B-048
16 15 14 13 12 11 10 9
Gr
B-037 B-045
I-004 W W
B-008
L
B

D1 D2 D3 D4 D5 I-015
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 W
D6 D7 D8 D9 D10 D11 D12 B-009
I-006
L EA19330060

DTC Detection
Condition
Park Light Control
B1003-11  Fuse
Circuit Short to Ground
Park Light Control
B1003-13  BCM
Circuit Open
1 Check fuse

c. Remove the BCM fuses F2 and F3.
33 d. Check the BCM fuses F2 and F3 (See page 49-29).
NG Replace fuses F2 and F3
OK
2 Check instrument panel wire harness

c. Disconnect the BCM connector I-015 and instrument
panel wire harness connectors I-003 and I-004.
+ -
d. Check for continuity between the terminal D12 of BCM
connector I-015 and the terminal 9 of instrument panel
wire harness connector I-003 according to the table D1 D2 D3 D4 D5
below. D6 D7 D8 D9 D10 D11 D12
I-015
Condition
I-015 (D12) - 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Always Continuity
I-003 (9) 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003
RA19330570

e. Check for continuity between the terminal D10 of BCM

connector I-015 and the terminal 30 of instrument panel
wire harness connector I-004 according to the table
below.
+ -
Condition
D1 D2 D3 D4 D5
I-015 (D10) -
Always Continuity D6 D7 D8 D9 D10 D11 D12
I-004 (30)
I-015
29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-004 33
RA19330580
f. Check for continuity between the terminal D10 of BCM

connector I-015 and the body ground according to the
table below.
Condition + -
I-015 (D10) -
Always Continuity D1 D2 D3 D4 D5
Body ground
D6 D7 D8 D9 D10 D11 D12
I-015
RA19030590
g. Check for continuity between the terminal D12 of BCM

connector I-015 and the body ground according to the
table below.
.
Condition + -
I-015 (D12) -
Always Continuity
Body ground D1 D2 D3 D4 D5
D6 D7 D8 D9 D10 D11 D12

I-015
RA19330600

OK

c. Disconnect the interior wire harness connectors B-050,
B-053, B-008, B-037 and B-045.
+ -
d. Check for continuity between the terminal 9 of interior
wire harness connector B-050 and the terminal 5 of
interior wire harness connector B-008 according to the 42 41 40 39 38 37 36 35 34 33 32 31 30 29
table below. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
33 Multimeter
Connection
Condition
Specified
Condition
B-050
B-050 (9) -
Always Continuity
B-008 (5) 1 2 3 4 5 6 7 8
16 15 14 13 12 11 10 9
B-008
RA19330610
e. Check for continuity between the terminal 9 of interior

interior wire harness connector B-037 according to the
table below.
+ -
Condition
B-050 (9) - 42 41 40 39 38 37 36 35 34 33 32 31 30 29
Always Continuity
B-037 (1) 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-050
1 2
6 5 4 3
B-037
RA19330620

f. Check for continuity between the terminal 30 of interior

table below.
+ -
Condition
42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-053 (30) -
B-008 (4)
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-053
1 2 3 4 5 6 7 8
16 15 14 13 12 11 10 9
33
B-008 RA19330630
g. Check for continuity between the terminal 30 of interior

table below.
+ -
Condition
B-053 (30) -
B-045 (1) 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1

B-053
1 2
6 5 4 3
B-045
RA19330640
OK
4 Reconfirm DTCs

unit system (BCM).

Result Proceed to
DTC B1003-11, B1003-13 are output NG
No DTC is output OK
NG Replace BCM
OK
System is normal
33

DTC B1005-12 Low Beam Control Circuit Short to Battery
DTC B1005-13 Low Beam Control Circuit Open
DTC B1006-12 High Beam Control Circuit Short to Battery
DTC B1006-13 High Beam Control Circuit Open
33

BATTERY
30 86 30 86
ENGINE
LOW BEAM HIGH BEAM
COMPARTMENT
RELAY RELAY
FUSE AND
87 85 87 85 RELAY BOX
E-039
EF03 EF01 EF04 EF02
B-014
10A 10A 10A 10A
B3 A16 B2 B12 B1 A2
33
BrW
WR
RG
RB
Gr
W
BrW
Gr
26 37 B-053
I-004
BrW
WR
Gr
RB
RG
7 9 7 9 A24 A25
FRONT LEFT FRONT RIGHT
COMBINATION COMBINATION BCM
LIGHT LIGHT I-046
E-037 E-022
5 5
B
B
E-036 E-026
2 4 6 8 10
B1 B2 B3 B4 B5
A1 A2 A3 A4 A5 A6 B8 B9 B10 B11 1 3 5 7 9
A10 A11 A12 A13 B6 B7 B12 B13 B14
A7 A8 A9 A14 A15 A16
B-014 E-039 E-022 E-037

W W B B
42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-046 B-053
G L
EA19330870

DTC Detection
Condition
Low Beam Control
B1005-12
Circuit Short to Battery
Low Beam Control
B1005-13
Circuit Open  Wire harness or connector
Ignition switch ON
High Beam Control  BCM
B1006-12
High Beam Control
B1006-13
Circuit Open
1 Check instrument panel wire harness 33

c. Disconnect the instrument panel wire harness connector
I-004 and BCM connector I-046.
+ -
d. Check for continuity between the terminals 26 and 37 of
instrument panel wire harness connector I-004 and the
terminals A24 and A25 of BCM connector I-046
according to the table below. 29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
Multimeter Specified 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Condition
I-004
I-004 (26) - I-046
Always Continuity
(A24) A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32

I-004 (37) - I-046
Always Continuity
(A25) I-046
RA19330650
OK


c. Disconnect the interior wire harness connectors B-014
and B-053.
+ -
d. Check for continuity between the terminals A16 and A2 of
interior wire harness connector B-014 and the terminals
26 and 37 of interior wire harness connector B-053 42 41 40 39 38 37 36 35 34 33 32 31 30 29
according to the table below. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition
B-014 (A16) -
33 B-053 (26)
Always Continuity
A1 A2 A3 A4 A5 A6
A10 A11 A12 A13
B-014 (A2) - A7 A8 A9 A14 A15 A16
Always Continuity
B-053 (37) B-014
RA19330660
OK
3 Reconfirm DTCs

unit system (BCM).
Result Proceed to
DTC B1005-12, B1005-13, B1006-12, B1006-13 are
NG
output
No DTC is output OK
NG Replace BCM
OK
System is normal

DTC B100A-12 Dome Lights Control Circuit Short to Battery
DTC B100A-13 Dome Lights Control Circuit Open
BATTERY
EF12 POWER
FUSE BOX
80A B-009
R
F1
33
F5 BCM
10A B-048
B-049
DOUAL RLY
C02 C19
LW
LW
B-053
2 3 I-004
LW
LW
5 I-001
2
C-002
LW
3 1
DOME
RELE- RELE-
PRE- PRE- LIGHT
ASED SSED DOOR ON ASED SSED C-001
5
B
C-002
9 I-001
B
I-012
29 30 31 32 33 34 35 36 37 38 39 40 41 42
2 1
15 16 17 18 19 20 21 22 23 24 25 26 27 28 I-004 1 2 3 4 I-001 C-001
L 5 6 7 8 9 10 W 6 5 4 3 W
1 2 3 4 5 6 7 8 9 10 11 12 13 14
C1 C2 C3 C4 C5 C6 C7 C8 C9
1 1
B-049 B-009
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W
B-048
Gr
EA19330880

DTC Detection
Condition
Dome Lights Control
B100A-12  Fuse
Dome Lights Control
B100A-13  BCM
Circuit Open
1 Check fuse

c. Remove the BCM fuse F5.
33 d. Check the BCM fuse F5 (See page 49-29).
NG Replace fuse
OK

and B-053.
+ -
d. Check for continuity between the terminals C2 and C19
of interior wire harness connector B-049 and the
terminals 2 and 3 of interior wire harness connector  42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-053 according to the table below. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition
B-049 (C2) -
Always Continuity
B-053 (2) C1 C2 C3 C4 C5 C6 C7 C8 C9
B-049 (C19) - C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Always Continuity
B-053 (3)
B-049
RA19330670
OK


c. Disconnect the instrument panel wire harness connectors
I-004 and I-001.
+ -
terminals 2 and 5 of instrument panel wire harness
connector I-001 according to the table below. 29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
Condition
I-004
I-004 (2) -
I-001 (2)
Always Continuity
1 2 3 4
33
5 6 7 8 9 10
I-004 (3) -
Always Continuity
I-001 (5) I-001
RA19330680
OK
4 Check roof wire harness

c. Disconnect the roof wire harness connectors C-002 and
C-001.
+ -
roof wire harness connector C-002 and the terminals 3
and 1 of roof wire harness connector C-001 according to
the table below. 4 3 2 1
10 9 8 7 6 5
Condition
Connection Condition C-002
C-002 (2) -
Always Continuity
C-001 (3) 2 1
C-002 (5) -
Always Continuity 6 5 4 3
C-001 (1)
C-001
RA19330690
NG Replace roof wire harness
OK
5 Reconfirm DTCs


unit system (BCM).
Result Proceed to
No DTC is output OK
NG Replace BCM
OK
33
System is normal

LIGHTING SYSTEM
DTC B1007-12 Front Fog Control Circuit Short to Battery
DTC B1007-13 Front Fog Control Circuit Open
BATTERY
ENGINE
POWER 86 30 COMPARTMENT
FUSE EF31 FRONT FUSE AND
EF12
BOX 20A FOG RELAY BOX
80A B-009 RELAY B-014
85 87 (ERY10) E-039
33
A9 B8
G
BrB
R
G
B
I-012
1 2 2
FRONT FRONT
RIGHT LEFT
STEERING B-053 FOG FOG
REAR 23
OFF WHEEL I-004 LIGHT LIGHT
FOG 1 1
SWITCH 1 E-025 E-034
I-045
B
B
FRONT
FOG
3 2
E-026 E-036
BrB
GB
GL
F1 B9 B8 A11
BCM
B-048
I-006
I-046
4 3 2 1
42 41 40 39 38 37 36 35 34 33 32 31 30 29 1 2
B-053 13 12 11 10 9 8 7 6 5 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 L
14 13 12 11 10 9 8 7 6 5 4 3 2 1 I-045 B-048 E-025 E-034
W Gr B B

I-006
A1 A2 A3 A4 A5 A6 B-014
L A10 A11 A12 A13
A7 A8 A9 A14 A15 A16 W B-009
I-046 B1 B2 B3 B4 B5
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 B8 B9 B10 B11 E-039
G B6 B7 B12 B13 B14 W
EA19330890

DTC Detection
Condition
Front Fog Control
B1007-12
Circuit Short to Battery  Wire harness or connector
Ignition switch ON
Front Fog Control  BCM
B1007-13
Circuit Open

33 I-045 and I-006.
+ -
terminals B8 and B9 of instrument panel wire harness
connector I-006 according to the table below. 4 3 2 1
13 12 11 10 9 8 7 6 5
Condition I-045
I-045 (2) - I-006 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Always Continuity
(B8) B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
I-045 (3) - I-006

(B9)
RA19330700
e. Disconnect the instrument panel wire harness connectors

I-004 and I-046.
f. Check for continuity between the terminal 23 of
terminal A11 of instrument panel wire harness connector + -
I-046 according to the table below.
Condition
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-004 (23) - I-046
Always Continuity
(A11)
I-004
NG Replace instrument panel wire harness A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
I-046
RA19330710
OK


and B-014.
+ -
wire harness connector B-053 and the terminal A9 of
table below. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition
B-053 (23) -
B-014 (A9)
Always Continuity 33
A1 A2 A3 A4 A5 A6
A10 A11 A12 A13
A7 A8 A9 A14 A15 A16
B-014
RA19330720
OK
3 Check engine compartment wire harness

c. Disconnect the engine compartment wire harness
connectors E-039, E-025 and E-034.
+ -
d. Check for continuity between the terminal B8 of engine
B1 B2 B3 B4 B5
Multimeter Specified B8 B9 B10 B11
Condition B6 B7 B12 B13 B14
E-039
E-039 (B8) -
Always Continuity
E-025 (2)
1 2
E-025
RA19330730

e. Check for continuity between the terminal B8 of engine

+ -
Condition
E-039 (B8) -
Always Continuity
E-034 (2)
B1 B2 B3 B4 B5
B8 B9 B10 B11
B6 B7 B12 B13 B14
E-039
1 2
33 E-034
RA19330740
OK
4 Reconfirm DTCs

unit system (BCM).
Result Proceed to
No DTC is output OK
NG Replace BCM
OK
System is normal

DTC B1008-12 Rear Fog Control Circuit Short to Battery
DTC B1008-13 Rear Fog Control Circuit Open
IGNITION SWITCH
BATTERY
ON OR START
RF03 RF22
POWER 10A 10A
EF12 FUSE
BOX INSTRUMENT
80A PANEL
B-009
33
FUSE AND
85 30 RELAY BOX
REAR
FOG I-005
RELAY
(RRY2)
86 87
3 22
WB
B-050
R
40 I-003
B
I-012 G
RW
1
G
G
REAR STEERING
OFF FOG WHEEL 6 6
SWITCH 1 REAR REAR
RIGHT LEFT
I-045
FRONT COMBINATION
BG
COMBINATION
FOG LIGHT
2 LIGHT 2
B-045 B-037
3 2
B
B-030 B-034
GB
GL
F1 B9 B8 B31 A27
BCM
B-048
I-006
I-046
42 41 40 39 38 37 36 35 34 33 32 31 30 29 4 3 2 1
1 2
28 27 26 25 24 23 22 21 20 19 18 17 16 15 13 12 11 10 9 8 7 6 5 1 1
6 5 4 3
B-050
14 13 12 11 10 9 8 7 6 5 4 3 2 1 W I-045 B-048 B-009 B-037 B-045
W Gr W W

I-006
L 1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26
87
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 85 86 86 86
87 30 87 30
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 I-046 30 85 85
G
I-005
B EA19330900

DTC Detection
Condition
Rear Fog Control
B1008-12
Circuit Short to Battery  Wire harness or connector
Ignition switch ON
Rear Fog Control  BCM
B1008-13
Circuit Open

33 I-045 and I-006.
+ -
terminals B8 and B9 of instrument panel wire harness
connector I-006 according to the table below. 4 3 2 1
13 12 11 10 9 8 7 6 5
Condition I-045
I-045 (2) - I-006 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Always Continuity
(B8) B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
I-045 (3) - I-006

(B9)
RA19330700

I-005, I-046 and I-003.
f. Check for continuity between the terminal 85 of
terminal A27 of instrument panel wire harness connector + -
Multimeter Specified A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
Condition
Connection Condition A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
I-046
I-005 (85) - I-046
Always Continuity
(A27) 1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26
87
85 86 86 86
87 30 87 30
30 85 85
I-005
RA19330750

g. Check for continuity between the terminal 87 of

terminal 40 of instrument panel wire harness connector 
+ -
Condition
29 30 31 32 33 34 35 36 37 38 39 40 41 42
I-005 (87) - I-003 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Always Continuity
(40) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003
NG Replace instrument panel wire harness 1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26
87
85 86 86 86
87 30 87 30
30 85 85
I-005 33
RA19330760
OK

B-045 and B-037.
+ -
table below. 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition
B-050 (40) -
Always Continuity
B-045 (6)
1 2
6 5 4 3
B-045
RA19330770


table below.
+ -
Condition
B-050 (40) - 42 41 40 39 38 37 36 35 34 33 32 31 30 29
Always Continuity
B-037 (6) 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
NG Replace interior wire harness B-050
1 2
6 5 4 3
33 B-037
RA19330780
OK
3 Reconfirm DTCs

unit system (BCM).
Result Proceed to
No DTC is output OK
NG Replace BCM
OK
System is normal

DTC B103E-18 Brake Light Control Circuit Current Below Threshold
DTC B103E-19 Brake Light Control Circuit Current Above Threshold
BCM
B-049
C14
GBr
33
GBr
GBr
4 2 GBr 4
REAR LEFT HIGH REAR RIGHT
COMBINATION MOUNTED COMBINATION
LIGHT STOP LIGHT LIGHT
B-037 B-043 B-045
2 1 2
B
B-034 B-034 B-030
C1 C2 C3 C4 C5 C6 C7 C8 C9
1 2 1 2
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 1 2
6 5 4 3 6 5 4 3
B-049 B-045 B-037 B-043

W W W W
EA19330910

DTC Detection
Condition
Brake Light Control
B103E-18 Circuit Current Below
Threshold  Wire harness or connector
Ignition switch ON
Brake Light Control  BCM
B103E-19 Circuit Current Above
Threshold

33 b. Disconnect the negative battery cable.
B-037, B-043 and B-045.
+ -
d. Check for continuity between the terminal C14 of interior
table below. C1 C2 C3 C4 C5 C6 C7 C8 C9
Multimeter Specified C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Condition
B-049
B-049 (C14) -
Always Continuity
B-037 (4)
1 2
6 5 4 3
B-037
RA19330790
e. Check for continuity between the terminal C14 of interior

table below.
+ -
Condition
B-049 (C14) -
Always Continuity
B-043 (2) C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-049
1 2
B-043
RA19330800

f. Check for continuity between the terminal C14 of interior

table below.
+ -
Condition
B-049 (C14) -
Always Continuity C1 C2 C3 C4 C5 C6 C7 C8 C9
B-045 (4)
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
1 2
6 5 4 3
B-045
33
RA19330810
OK
2 Reconfirm DTCs

unit system (BCM).
Result Proceed to
DTC B103E-18, B103E-19 are output NG
No DTC is output OK
NG Replace BCM
OK
System is normal

DTC B103F-18 Reverse Light Control Circuit Current Below Threshold
DTC B103F-19 Reverse Light Control Circuit Current Above Threshold
BCM
I-015
D3
RGr
33
I-003
42
B-050
Gr
Gr
Gr
3 3
REAR LEFT REAR RIGHT
COMBINATION COMBINATION
LIGHT LIGHT
B-037 B-045
2 2
B
B-034 B-030
29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 D1 D2 D3 D4 D5
1 2
D6 D7 D8 D9 D10 D11 D12 6 5 4 3
I-003 I-015 B-037 B-045

W W W W
EA19330920

DTC Detection
Condition
Reverse Light Control
B103F-18 Circuit Current Below
Threshold  Wire harness or connector
Ignition switch ON
Reverse Light Control  BCM
B103F-19 Circuit Current Above
Threshold

b. Disconnect the negative battery cable. 33
I-015 and I-003.
+ -
d. Check for continuity between the terminal D3 of
terminal 42 of instrument panel wire harness connector  D1 D2 D3 D4 D5
I-003 according to the table below. D6 D7 D8 D9 D10 D11 D12
I-015
Condition
I-015 (D3) - I-003 29 30 31 32 33 34 35 36 37 38 39 40 41 42
(42)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
NG Replace instrument panel wire harness I-003

RA19330840
OK

B-037 and B-045.
+ -
42 41 40 39 38 37 36 35 34 33 32 31 30 29
table below.
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition
B-050
B-050 (42) -
Always Continuity
B-037 (3)
1 2
6 5 4 3
B-037
RA19330820


table below.
+ -
Condition
B-050 (42) - 42 41 40 39 38 37 36 35 34 33 32 31 30 29
Always Continuity
B-045 (3) 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2
6 5 4 3
33 B-045
RA19330830
OK
3 Reconfirm DTCs

unit system (BCM).
Result Proceed to
DTC B103F-18, B103F-19 are output NG
No DTC is output OK
NG Replace BCM
OK
System is normal

ON-VEHICLE SERVICE
Combination Switch
Removal
4. Remove the combination switch.
a. Disconnect the combination switch wire harness
connector (arrow).
00 120 140
160
33
R 1
L 0
<
BEEK
+ VOL -
<
MUTE
RA19330030
b. Press the claw of combination switch in the direction

of arrow, and remove the combination switch by
sliding it outward slightly. 00 120 140
160
R 1
L 0
<
BEEK
+ VOL -
<
MUTE
RA19330040

Inspection
1. Check the headlight combination switch assembly.
continuity between the terminals as shown in the
+ -
table. OF
F
Combination Light Switch (Position Light/Low Beam OF

F
Light/High Beam Light Switch)

1 2 3 4
Multimeter Switch Specified 5 6 7 8 9 10 11 12 13

Each pin Switch OFF No continuity
RA19330050
Terminal 5 - Switch in position
Continuity
Terminal 8 light
Terminal 5 - Switch in low
33 Terminal 8 beam
Continuity
Terminal 7 - Switch in low

Continuity
Terminal 10 beam
Terminal 5 - Switch in high
Continuity
Terminal 8 beam
Terminal 7 - Switch in high
Continuity
Terminal 9 beam
Terminal 7 - Switch in passing
Continuity
Terminal 9 light
If the result is not as specified, replace the

combination switch assembly.
Combination Light Switch (Front Fog Light Switch)

+ -
OF
F
OF
F
Switch in (position
Terminal 5 -
light) front fog Continuity 1 2 3 4
Terminal 8
light on position
5 6 7 8 9 10 11 12 13
Switch in (position
Terminal 1 -
light) front fog Continuity
Terminal 3
light on position RA19330050
Switch in (position
Terminal 1 -
light) front fog Continuity
Terminal 3
light on position
Switch in (low
Terminal 5 - beam light) front
Continuity
Terminal 8 fog light on
position
Switch in (low
Continuity
position


Switch in (low
Continuity
position
Switch in (high
Continuity
position
Switch in (high
Continuity
position
Switch in (high 33
Continuity
position

Combination Light Switch (Rear Fog Light Switch)

+ -
OF
F
OF
F
Switch in (position
Terminal 5 -
light) rear fog light Continuity 1 2 3 4
Terminal 8
on position
5 6 7 8 9 10 11 12 13
Switch in (position
Terminal 1 -
light) rear fog light Continuity
Terminal 2
on position RA19330050
Switch in (position
Terminal 1 -
light) rear fog light Continuity
Terminal 3
on position
Switch in (low
Terminal 5 - beam light) rear
Continuity
position
Switch in (low
Continuity
position
Switch in (low
Continuity
position
Switch in (low
Continuity
position


Switch in (high
Continuity
position
Switch in (high
Continuity
position
Switch in (high
Continuity
position
33 Switch in (high
Continuity
position

Combination Light Switch (Turn Signal Light Switch)

+ -
OF
F
OF
F
Terminal 11 - Switch in left turn

Continuity
Terminal 12 position 1 2 3 4
5 6 7 8 9 10 11 12 13
Terminal 12 - Switch in right

Continuity
Terminal 13 turn position
If the result is not as specified, replace the RA19330050

Installation

Headlight Leveling Switch

Removal
3. Remove the headlight leveling switch.
both ends of headlight leveling switch carefully to
remove it.
33
RA19420080
b. Disconnect the headlight leveling switch wire harness

connector.
RA19330080
c. Press the fixing clips on both sides and remove the

headlight leveling switch as shown in the illustration.
RA19330090

Inspection
1. Check the headlight leveling switch.
a. Turn the digital multimeter to ohm band, and connect
the red probe of multimeter to terminal 5, and black
+ -
probe to terminal 6.
1 2
Observe the resistance change on the multimeter 3 4 5 6
while turning the leveling switch.
Multimeter
Switch Position Resistance (KΩ)
Connection
Terminal 2 -
0 1.015
Terminal 2 -
1 1.443
Terminal 4
33 Terminal 2 -
2 1.872
Terminal 4
Terminal 2 -
3 2.301
Terminal 4
Terminal 2 -
4 2.729
Terminal 4
Terminal 2 -
5 3.158
Terminal 4
If the result is not as specified, replace the headlight

leveling switch.
2. Check the headlight leveling switch backlight.
a. Connect the positive battery lead to terminal 6 and
negative battery lead to terminal 3 of the headlight + -
leveling switch. Check if the backlight comes on.

1 2
OK: it comes on. 3 4 5 6
If the result is not as specified, replace the headlight

leveling switch.
RA19330101
Installation

Front Combination Light

Removal
HINT:
 Use the same procedures for front right combination light and front left combination light.
 The procedures listed below are for front left combination light.
4. Remove the front combination light.
a. Remove 4 fixing bolts and 1 clip from the front
combination light. 
33
RA19330110
b. Disconnect the front combination light wire harness

connector and remove the front combination light.
RA19330120
Installation
CAUTION
 When installing the front combination light, make sure the fitting clearance between the front combination
light and the hood, front fender, front bumper is appropriate. Adjust it as necessary.
Adjustment
1. Preparations:
a. The tire inflation pressure comes up to standard.
b. The vehicle is unloaded (besides spare tire, fuel, water, lubricant and tools supplied with the vehicle).
c. Park the vehicle on a level ground or factory.
d. Keep the lens surface of front combination light free from dirt.
e. Check if the power supply operates normally and the bulbs are installed correctly.

The headlight beam can be adjusted up and down, left and right by using the headlight leveling switch
or the adjustment nut at the rear of headlight. Always perform adjustment according to the international
standard.
No. Item Standard

Up and down offset of left/right low
1 526.4 mm (0.700H) - 652.0 mm (0.867H)
beam
2 Left and right offset of left low beam 170 mm
3 Left and right offset of right low beam 350 mm
Up and down offset of left/right high
4 652.0 mm (0.881H) - 703.0 mm (0.950H)
beam
5 Left and right offset of left high beam 170 mm
6 Left and right offset of right high beam 350 mm
33 7 High beam light intensity ≥ 18000 cd
2. The headlight leveling can be adjusted according to the

number of passengers and loading condition. There are 6
adjustment bands to select on the headlight leveling
knob: 0, 1, 2, 3, 4 and 5.
Turn up: Raise the headlight beam.
Turn down: Lower the headlight beam.
Adjust the light according to the table below.
Passenger and Luggage Loading

Knob Position
Luggage
Passenger
Loading
Driver None 0
Driver + Front
None 1
Passenger
Full Occupied None 2/3
Full Luggage
Full Occupied 4
Loading
Full Luggage
Driver 5
Loading
CAUTION
 Whether the headlight leveling is correct or not will directly affects the driving safety. Be sure to adjust it
according to the related specification.

3. Manually headlight leveling: the headlight leveling can be changed by adjusting the following areas
manually as shown in the illustration.
Adjustment method for left headlight
a. Low beams left/right adjustment
When you rotate the screwdriver clockwise, the
beams move to left; when you rotate the screwdriver
counterclockwise, the beams move to right.
RA19330161
b. Low beams up/down adjustment

33
beams move downward; when you rotate the
screwdriver counterclockwise, the beams move
upward.
RA19330160
c. High beams left/right adjustment

beams move to left; when you rotate the screwdriver
counterclockwise, the beams move to right.
RA19330170
d. High beams up/down adjustment

upward.
RA19330171

Adjustment method for right headlight

a. Low beams left/right adjustment
beams move to right; when you rotate the screwdriver
counterclockwise, the beams move to left.
RA19330140
b. Low beams up/down adjustment

33 beams move downward; when you rotate the
upward.
RA19330141
c. High beams left/right adjustment

beams move to right; when you rotate the screwdriver
counterclockwise, the beams move to left.
RA19330151
d. High beams up/down adjustment

upward.
RA19330150

Rear Combination Light

Removal
HINT:
 Use the same procedures for rear right combination light and rear left combination light.
 The procedures listed below are for rear left combination light.
3. Remove the left luggage compartment trim assembly (See page 47-33).
4. Remove the rear combination light.
a. Disconnect the rear combination light wire harness
connector and remove the rear combination light.
33
RA19330180
b. Remove the rear combination light fixing nuts. 

RA19330190
Installation
CAUTION
 When installing the rear combination light, make sure the fitting clearance between the rear combination
light and the luggage compartment door, rear bumper is appropriate. Adjust it as necessary.

License Plate Light

Removal
3. Remove the license plate light.
a. Using a screwdriver wrapped with tape, pry out the
license plate light.
33
RA19330270
b. Disconnect the license plate light connector (arrow)

and remove the license plate light (1).
RA19330280
Installation

Side Turn Signal Light

Removal
Use the same procedures for right side turn signal light and left side turn signal light.
The procedures listed below are for left side turn signal light.
3. Remove the side turn signal light.
a. Pry out the light cover with a screwdriver wrapped
with protective tape while pushing the left side turn
signal light cover forward.
33
RA19460150
b. Disconnect the left side turn signal light wire harness

connector, and remove the left side turn signal light.
RA19460160
Installation

Front Fog Light

Removal
3. Remove the front wheel house protector assembly (See page 46-15).
4. Remove the front fog light.
a. Disconnect the front fog light connector.
33
RA19330281
b. Remove 3 fixing screws from the front fog light, and

remove the front fog light. 
RA19330282
Installation

High Mounted Stop Light

Removal
4. Remove the high mounted stop light.
a. Remove 2 fixing screws (arrow) from the high
mounted stop light.
33
RA19470273
Installation

Dome Light Assembly

Removal
3. Remove the interior front dome light assembly.
remove the interior front dome light cover.
33
RA19470220
b. Remove 2 fixing screws from the interior front dome

light assembly.
RA19470230
c. Disconnect the interior front dome light connector

(arrow), and remove the interior front dome light
assembly.
RA19470240

Inspection
1. Check the dome light.
continuity between the terminals of dome light as
+ -
shown in the table. 1 2
3
Terminal 1 -
OFF Continuity
Terminal 2
Terminal 2 -
OFF No continuity
Ground RA19330360
Terminal 1 -
DOOR Continuity
Terminal 2
Terminal2 -
33
DOOR No continuity
Ground
Terminal 2 -
ON Continuity
Ground
Terminal 1 -
ON No continuity
Terminal 2
If the result is not as specified, replace the dome light

assembly.
Installation

Back-up Light Switch

Removal
1. Stop the vehicle on the lifter, and support it with the lifter.
4. Raise the vehicle with the lifter.
WARNING

 Check if the safety lock of lifter is locked when repairing or inspecting the lifted vehicle.
33 5. Disconnect the back-up light switch connector.
RA19170070

HINT:
The transmission fluid may flow out when removing the back-up light switch. Use a container to collect the
fluid.
 The drained transmission fluid should be collected with a container.
Inspection
Check the back-up light switch
+ -
Switch Condition Specified Condition
1 2
Push Continuity
Not push No continuity
RA19330361

Installation
1. Apply thread locker to the threads of back-up light before installing the back-up light switch, and clean the
transmission fluid on the transmission area where the back-up light will be installed. And then install the
back-up light switch and tighten it. 
2. Check if the transmission fluid level is in the proper position after installation.
a. It is not necessary to do anything, if it is in the proper position.
b. It is necessary to fill the transmission fluid to the specified position, if it is not in the proper position (fill
the fluid until it flows out of retaining plug).
33

Hazard Warning Light Switch

Removal
3. Remove the hazard warning light switch.
a. Disengage the console panel assembly (See page 29-22).
b. Disconnect the hazard warning light connector and MENU
remove the console panel assembly (arrow).

A/C
1 2
3 4
0
P
33 2
4
R
RA19330390
c. Press the claws on both ends of the hazard warning

light switch by hand, and push outward forcefully to
remove it.
RA19330400
Inspection
1. Check the hazard warning light switch.
continuity between the terminals of hazard warning
+ -
light switch as shown in the table.
4 1
5 2
Multimeter Switch Specified 6 3

Terminal 1 -
Terminal 5 Switch not
No continuity
Terminal 4 - pushed
Terminal 1 -
Terminal 5
Terminal 1 -
Switch pushed Continuity
Terminal 4
Terminal 4 -
Terminal 5
If the result is not as specified, replace the hazard

warning light switch.

2. Check the switch illumination.

a. Connect the positive (+) battery lead to terminal 2 and
+ -
negative (-) battery lead to terminal 6, then check that
the switch illumination comes on.
OK: LED comes on. 4 1
5 2
6 3
If the result is not as specified, replace the hazard
warning light switch.
RA19330420
Installation
33

- MEMO -

WIPER AND WASHER
Description 34-3 Front Washer Nozzle 34-15
Tool 34-5 Inspection 34-16
Washer Pump 34-17
Removal 34-17
Installation 34-18
Wiper Switch Assembly 34-8 Washer Fluid Reservoir Assembly 34-19
Installation 34-9 Installation 34-20 34
Wiper Arm Assembly 34-10 Front Washer Line Assembly 34-21
Wiper Motor 34-12 Rain Gutter Front End Plate Assembly 34-23

34

34 - WIPER AND WASHER
GENERAL INFORMATION
WIPER AND WASHER
Description
4
1
2
5 3
7 34
8
×3
×2
×10
11
12 ×3
10
13
14
RA19340010

1 - Wiper Arm Main Blade 2 - Wiper Arm Trim Cap

3 - Main Wiper Arm 4 - Wiper Arm Sub Blade
5 - Front Washer Nozzle 6 - Sub Wiper Arm
7 - Front Windshield Lower Garnish Assembly 8 - Wiper Link Rod
9 - Wiper Motor 10 - Rain Gutter Front End Plate Assembly
11 - Front Washer Line Assembly 12 - Guide Pipe Assembly
13 - Washer Pump 14 - Washer Fluid Reservoir
The wiper and washer are the important devices for cleaning the front windshield assembly. The wiper and
washer systems are controlled by the wiper and washer switch assembly. The wiper and washer systems can
operate only when the ignition switch is turned to ON. The driver controls all the operations of the wiper and
washer by moving the switch control lever.
34

Specifications

Wiper Arm Assembly Fixing Nut 25 ± 4
Wiper Motor and Link Rod Assembly Fixing Bolt 7 ± 1.5
Wiper Motor Fixing Bolt 8±2
Wiper Motor Fixing Nut 8±2
Guide Pipe Assembly Fixing Bolt 7 ± 1.5
Washer Fluid Reservoir Assembly Fixing Bolt 7 ± 1.5
Rain Gutter Front End Plate Assembly Fixing Bolt 10 ± 1.5
ECM (Engine Control Module) Fixing Bolt 7±1
34
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Wiper and Washer Systems
IGNITION SWITCH
ON
INSTRUMENT
PANEL FUSE
RF08 RF07 AND RELAY
BOX
10A 20A I-005
8 7
RL
RL
I-003
25 I-003 B-050
B-050
1
RL
34
B-008
8
E-038
RL
2
RL
1
FRONT
WASHER
M
G
MOTOR
E-023
RL
G
2
B
I-027
RY
PIN NO. 2 3 4 5 6 7 8 9 10 B-016
B
9 E-038
MIST
B-008 2 5 4
0FF
LOW FRONT
INT WIPER
RY
FRONT HIGH
WIPER
MOTOR
LO M
WIPER B-019
HI
SWITCH
1 B-053 I-041 1 6
WASH
I-004
WASH
W
0FF
WASHER
RY
ON
16 15 B-050
WASH
I-003
W
1 2 3 4 5 6 7 8 9 10 11 12
42 41 40 39 38 37 36 35 34 33 32 31 30 29
13 14 15 16 17 18 19 20 21 22 23 24
28 27 26 25 24 23 22 21 20 19 18 17 16 15 1 2 3 4 5 6 7 8
25 26
87 14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9
85 86 86 86
87 30 87 30 I-005
30 85 85 B-050
B B-008
W B
1 2 3 42 41 40 39 38 37 36 35 34 33 32 31 30 29
10 9 8 7 6 5 4 3 2 1
1 2
28 27 26 25 24 23 22 21 20 19 18 17 16 15
4 5 6
14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-041
E-023 B-019 B-053 B
Gr B EA19340010
L

DIAGNOSIS & TESTING

HINT:

Fuse 49-27
Both wiper and washer systems do not
Wiper switch assembly 34-8
operate
Wiper system does not operate in LO or HI Wiper motor 34-12
34
Wiper system does not operate in INT Wiper motor 34-12
Fuse 49-27
Wiper system does not operate
Wiper motor 34-12
Fuse 49-27
Washer system does not operate
Washer pump 34-17
Wiper arm and blade do not return to
Wiper motor 34-12
original position when wiper switch is off

ON-VEHICLE SERVICE
Wiper Switch Assembly
Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the wiper switch
assembly.
 Appropriate force should be applied when removing the wiper switch assembly, and avoid operating
roughly.
 Try to prevent the interior and body paint surface from being scratched when removing the wiper switch
assembly.
34
4. Remove the wiper switch assembly.
a. Disconnect the wiper switch assembly connector
(arrow).
RA19340020
b. Press and hold the claws on the wiper switch

assembly with a screwdriver wrapped with protective
tape, and slide the wiper switch assembly outward
slightly to remove it.
RA19340030

Inspection
1. Check the wiper switch assembly.
a. Using the digital multimeter, check for continuity
between the terminals of wiper switch assembly
F
OF
07
IH
Connection Condition Condition 1 2 3 4 5 6 7 8 9 10
Terminal 3 -
MIST Continuity
Terminal 4
Terminal 4 -
OFF Continuity
Terminal 4 -
INT Continuity
Terminal 5
Terminal 3 -
LO Continuity
Terminal 4
34
Terminal 2 -
HI Continuity
Terminal 3
If the result is not as specified, replace the wiper

switch assembly.
Installation
CAUTION
 Always operate carefully to prevent components from being damaged when installing the wiper switch
assembly.
 Install the connector in place when installing the wiper switch assembly.
 Check the wiper switch assembly for proper operation after installation.

Wiper Arm Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the wiper arm
assembly.
 Appropriate force should be applied when removing the wiper arm assembly, and avoid operating
roughly.
 Try to prevent the front windshield assembly from being scratched when removing the wiper arm
assembly.

34 3. Remove the wiper arm blade.
a. Lift the wiper arm assembly and make the wiper arm assembly and the wiper arm blade at a right angle.
b. Pull out the wiper arm blade from the wiper arm
assembly in the direction of arrow as shown in the
illustration.
RA19340050
4. Remove the wiper arm assembly.

remove the wiper arm trim caps (1).
b. Remove the fixing nuts (2) from the wiper arm 1
assembly. 
2
RA19340060
c. Remove the wiper arm assembly.

Installation
CAUTION
 Always operate carefully to prevent other components from being damaged when installing the wiper
arm assembly.
 Make sure to tighten the fixing nuts to the specified torque when installing the wiper arm assembly.
 Check the wiper arm assembly for proper operation after installation.
HINT:
Always adjust the wiper arm assembly to the proper position when installing it.
Pay attention to the locating point on the front windshield
assembly when assembling. The wiper arm blade should be
pressed against the locating point as shown in the
illustration. 34
RA19340070

Wiper Motor
Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the wiper motor.
 Appropriate force should be applied when removing the wiper motor, and avoid operating roughly.
 Try to prevent the body paint surface from being scratched when removing the wiper motor.

3. Remove the wiper arm assembly (See page 34-10).
4. Remove the front windshield lower garnish assembly (See page 46-31).
34 5. Remove the wiper motor and link rod assembly.
a. Using a screwdriver wrapped with protective tape, pry the clip on the wire harness.
b. Disconnect the connector (1) from the wiper motor
and link rod assembly.
1
c. Remove 2 fixing bolts (arrow) from the wiper motor
and link rod assembly. 
RA19340080
d. Remove the wiper motor and link rod assembly in the

direction of arrow as shown in the illustration.
RA19340090
6. Remove the wiper motor.

a. Remove 3 fixing bolts (arrow) from the wiper motor. 
b. Remove the fixing nut (1) from the wiper motor. 
1
RA19340100

c. Separate the wiper motor and wiper link rod.
Inspection
1. Check the wiper motor.
a. Check the LO operation.
Measurement Condition Specified Condition

Battery positive (+) → Terminal 5
Motor low speed (LO) running
Battery negative (-) → Terminal 4
If the result is not as specified, replace the wiper motor.

b. Check the HI operation.
Measurement Condition Specified Condition

Motor high speed (HI) running
Battery negative (-) → Terminal 4 34
If the result is not as specified, replace the wiper motor.
c. Check the automatic return function.
- Connect the positive (+) battery lead to terminal 5 or 6 and the negative (-) battery lead to terminal 4.
When the motor is running at low speed (LO) or high speed (HI), disconnect the positive (+) battery
to stop the wiper motor at any position other than the original position.
- Connect terminals 1 and 5 with a lead, and connect the positive (+) battery lead to terminal 2, and
the negative (-) battery lead to terminal 4 to run the motor to the original position at low speed.
- Check if the wiper motor can stop automatically after running to the original position.
OK: The motor stops automatically after running
to the original position, which indicates that the + -
motor can return automatically.

3 2 1
If the result is not as specified, replace the wiper 6 5 4
motor.
RA19340110
2. Check the wiper link rod.

a. Check the link pin (1) for looseness or falling off, link
rod (2) for deformation or break, and rotation shaft (3) 2
for sticking. If necessary, replace the wiper link rod. 3
1
RA19340120

Installation
CAUTION
 Always operate carefully to prevent other components from being damaged when installing the wiper
motor.
 Apply grease to the crank arm pivot when installing the wiper motor.
 Adjust and make sure the wiper motor and wiper link rod are at the original position before installing the
wiper motor. Otherwise, the wiper system will not operate normally.
 Install the connector in place and tighten the fixing bolts and nuts to the specified torque when installing
the wiper motor.
 Check the wiper system for proper operation after installing the wiper motor.
34

Front Washer Nozzle

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the front washer
nozzle.
 Appropriate force should be applied when removing the front washer nozzle, and avoid operating
roughly.
 Try to prevent the front windshield lower garnish surface from being scratched when removing the front
washer nozzle.

34
4. Remove the front washer nozzle.
the clips (arrow) on the front washer nozzle.
RA19340150
b. Disconnect the front washer line and front washer

nozzle joint (arrow) to separate the front washer
nozzle.
RA19340160

Inspection
1. Check the front washer nozzle.
a. Check the front washer nozzle for blockage,
deformation or damage. If necessary, replace the front
washer nozzle.
RA19340170
Installation
34 CAUTION
 Always operate carefully to prevent other components from being damaged when installing the front
washer nozzle.
 Install the washer line port in place when installing the front washer nozzle.
 Check the front washer nozzle for proper operation after installation.

Washer Pump
Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the washer pump.
 Appropriate force should be applied when removing the washer pump, and avoid operating roughly.
 Try to prevent the body paint surface from being scratched when removing the washer pump.

4. Remove the washer pump.
CAUTION
34
 Put a container under the washer pump to collect the washer fluid before removing the washer pump.
a. Disconnect the washer pump connector (1).

b. Disconnect the port (2) between washer line and
washer pump, and collect the washer fluid with a 1
container.
RA19340210
c. Using a screwdriver wrapped with protective tape,

remove the washer pump.
RA19340220

Installation
CAUTION
 Always operate carefully to prevent the components from being damaged when installing the washer
pump.
 Install the washer line port in place when installing the washer pump.
 Install the connector in place and tighten the fixing bolts to the specified torque when installing the
washer pump.
 Check the washer system for proper operation after installing the wiper pump.
Inspection
1. Check the washer pump.
34 a. Fill the washer fluid reservoir assembly with washer fluid.
b. Connect the positive (+) battery lead to terminal 1 of the washer pump and the negative (-) battery lead
to terminal 2.
c. Check that the washer fluid flows out of the washer
pump.
OK: Washer fluid flows out of the front washer
pump. 2 1
If the result is not as specified, replace the washer

pump.
RA19340230

Washer Fluid Reservoir Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the washer fluid
reservoir assembly.
 Appropriate force should be applied when removing the washer fluid reservoir assembly, and avoid
operating roughly.
 Try to prevent the body paint surface from being scratched when removing the washer fluid reservoir
assembly.

34
4. Collect the washer fluid with a container.
5. Remove the washer pump (See page 34-17).
6. Remove the guide pipe assembly.
a. Remove the fixing bolt (arrow) from the guide pipe
assembly. 
RA19340180
b. Remove the guide pipe assembly from the washer fluid reservoir assembly.
7. Remove the washer fluid reservoir assembly.
a. Disconnect the washer pump connector (1).
b. Disconnect the port (2) between washer line and front
washer pump, and collect the washer fluid with a 1
container.
RA19340210

c. Remove 3 fixing bolts (arrow) from the washer fluid

reservoir, and remove the washer fluid reservoir. 
RA19340190
Inspection
1. Check the washer fluid reservoir assembly.
a. Check the washer fluid reservoir assembly for
leakage, deformation or damage. Replace the washer
fluid reservoir assembly if necessary.
34 b. Check the internal and external sides of washer fluid
reservoir for dirt. Remove the dirt or replace the
washer fluid reservoir assembly if necessary.
c. Check the grommet for damage. Replace the
grommet if necessary.
RA19340200
Installation
CAUTION
 Always operate carefully to prevent the components from being damaged when installing the washer
fluid reservoir assembly.
 Tighten the fixing bolts to the specified torque when installing the washer fluid reservoir assembly.
 Install the washer line port in place when installing the washer fluid reservoir assembly.

Front Washer Line Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the front washer
line assembly.
 Appropriate force should be applied when removing the front washer line assembly, and avoid operating
roughly.
 Try to prevent the body paint surface from being scratched when removing the front washer line
assembly.

34
6. Remove the front washer line assembly.
a. Disconnect the port (arrow) between front washer line
and washer pump, and collect the washer fluid with a
container.
RA19340240
b. Disconnect the front washer line from the nozzle

(arrow).
RA19340250

c. Remove the front washer line from the clips (arrow)

and pull it out of the clip (1).
RA19460421
d. Using a screwdriver wrapped with protective tape,

remove the clips from the front washer line.
34
RA19340260
e. Remove the front washer line assembly.
Installation
CAUTION
 Always operate carefully to prevent the components from being damaged when installing the front
washer line assembly.
 Install the washer line port in place when installing the front washer line assembly.
 Check the washer system for proper operation after installing the front washer line assembly.

Rain Gutter Front End Plate Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the rain gutter front
end plate assembly.
 Try to prevent the body paint surface from being scratched when removing the rain gutter front end plate
assembly.

34
5. Remove the wiper motor (See page 34-12).
6. Remove the right sealing block.
a. Remove 2 plastic clamps (arrow) from the right
sealing block.
RA19340270
b. Remove the right sealing block.

7. Remove the middle sealing block.
a. Remove 2 plastic clamps (arrow) from the middle
sealing block.
RA19340280
b. Remove the middle sealing block.

8. Remove the rain gutter front end plate assembly.

a. Disconnect the ECM connectors (arrow).
RA19340290
b. Disconnect the clips (arrow) between body wire

harness and engine wire harness.
34
RA19340300
c. Remove 10 fixing bolts (arrow) from the rain gutter

front end plate assembly. 
RA19340310
d. Loosen the rubber bush (arrow) with a screwdriver

wrapped with protective tape, and remove the rain
gutter front end plate assembly.
RA19340320

e. Remove 4 fixing bolts (arrow) from the ECM.

RA19340330
f. Separate the ECM from the rain gutter front end plate assembly.
Installation
CAUTION
34
 Always operate carefully to prevent other components from being damaged when installing the rain
 Install the connector in place and tighten the fixing bolts to the specified torque when installing the rain

- MEMO -

DOOR LOCK
GENERAL INFORMATION 35-3 Front Door Lock Assembly 35-41
Circuit Diagram 35-10 Front Door Key Cylinder 35-44
Removal 35-44
Installation 35-45
Front Door Lock Striker 35-46
Diagnosis Tool 35-15
Removal 35-46
DTC Confirmation Procedure 35-15
Installation 35-46
Rear Door Lock Assembly 35-47
Removal 35-47
Inspection 35-49
Diagnostic Trouble Code (DTC) Chart 35-18
Installation 35-49
B101B-18 35-19
Rear Door Lock Striker 35-50 35
B101B-19 35-19
Removal 35-50
B101B-71 35-19
Installation 35-50
B101C-18 35-19
Luggage Compartment Lock 
B101C-19 35-19 Assembly 35-51
B101C-71 35-19 Removal 35-51
B101D-18 35-31 Inspection 35-52
B101D-19 35-31 Installation 35-53
B101F-11 35-34 Luggage Compartment Lock Latch 35-54
B101F-13 35-34 Removal 35-54
Engine Hood Lock Assembly 35-40 Wireless Key 35-55

35

35 - DOOR LOCK
GENERAL INFORMATION
DOOR LOCK
Description
3 6
4
35
RA19350010
1 - Engine Hood Lock Assembly 2 - Front Right Door Lock Assembly

3 - Rear Right Door Lock Assembly 4 - Front Left Door Lock Assembly
5 - Luggage Compartment Lock Assembly 6 - Rear Left Door Lock Assembly
1. Power door lock system function description

a. The power door lock system can lock/unlock all doors by wireless key operation.
 Wireless key sends the lock/unlock request signals to Body Control Module (BCM). Then, Body
Control Module (BCM) sends these request signals to the lock fastener of each door in order to lock/
unlock all doors simultaneously.
 After inserting the key into the driver side door key cylinder, all doors can be locked/unlocked by
turning the key clockwise or counterclockwise, but body anti-theft function cannot be set.

35 - DOOR LOCK
 Function active: effective at any time even when the engine starts.
 Lock success: when all the doors are closed fully, input the lock signal from the center control
switch, and execute the lock command.
 Lock failure: when at least one door is not closed fully, input the lock signal from the center control
switch, execute the lock command, and then execute the lock command after 1 second delay.
 Unlock success: input the unlock signal from the center control switch and execute the lock
command, regardless of whether the doors are closed fully.
 Door lock protection: lock and unlock the doors 4 times within 10 seconds. Once it is activated,
locking and unlocking cannot be operated for 15 seconds. Before the disable function is activated,
make sure that the final command is unlock, rather than lock.
 Door lock response: when the protection is not activated, Body Control Module (BCM) responses to
each input of lock or unlock.
b. Function
Component Function
Power Door Unlock/Lock Switch Button Lock/unlock all doors.
Lock/Unlock the front left door with fastener.
35 Front Left Door Lock Assembly It has built-in door unlock/lock switch and sends the
unlock/lock signal to Body Control Module (BCM) to
unlock/lock each door.
Front Right Door Lock Assembly Lock/Unlock the front right door with fastener.
Rear Left Door Lock Assembly Lock/Unlock the rear left door with fastener.
Rear Right Door Lock Assembly Lock/Unlock the rear right door with fastener.
2. Wireless door lock system

a. Wireless door lock function
Feature of buttons on remote controller:
 When turning the ignition switch to LOCK, each button on wireless key can operate.
 When turning the ignition switch to ACC, only unlock button on wireless key can operate.
 When turning the ignition switch to ON, each button on wireless key cannot operate.
When the wireless door lock function is valid:
 When all the doors, engine hood and luggage compartment door are closed fully, press the lock
button on wireless key, all door locks perform the locking operation (enter the locking mode at this
time); press the unlock button on wireless key, Body Control Module (BCM) performs the unlocking
operation.
 When all the doors are closed fully, but either of the engine hood and luggage compartment door is
not closed fully, press the lock button on wireless key, all door locks perform locking operation (enter
the lock deactivation mode at this time), press the unlock button on the wireless key, Body Control
Module (BCM) performs the unlocking operation.
 When any door is not closed fully, press the lock button on the wireless key, all door lock perform the
locking operation first, and then perform the unlocking operation after 1 second, press the unlock
button on the wireless key, Body Control Module (BCM) performs the unlocking operation.
b. Wireless luggage compartment function
 When turning the ignition switch to LOCK, press the luggage button on wireless key for more than
1.5 seconds, to open the luggage compartment door.
 When the luggage compartment door is opened, the luggage compartment light will come on; when
the luggage compartment door is closed, the luggage compartment light will go off immediately. If
the luggage compartment door is opened all the time, the luggage compartment light comes on for
15 minutes and then goes off.
c. This system locks/unlocks all doors remotely. The wireless door lock system has the following features:

35 - DOOR LOCK
 A key-integrated type transmitter is used which contains the following 2 switches: door lock switch
and door unlock switch.
 A LED is built in the transmitter to check the battery condition.
d. System function
Function Description
Press the lock switch on wireless key to lock all
All doors lock function
doors.
Press the unlock switch on wireless key to unlock all
All doors unlock function
doors.
Lock: turn signal lights blink once and the 
anti-theft horn sounds once with door locked.
Answer-back function Unlock: turn signal lights blink twice with the door
unlocked to indicate that the corresponding
operation has been completed.
With door locked, if the door is not opened within 30
Auto lock function seconds after the door is unlocked by wireless key,
the door will lock again automatically. 35
e. Wireless key match
If the wireless key is lost, damaged or the Body Control Module (BCM) is replaced, the wireless key
needs to be matched again. The detailed operation procedures are as follows:
 Connect the X-431 3G diagnostic tester (the latest
software) to the Data Link Connector (DLC), and Menu
make it communicate with the vehicle electronic ENG
module by the data network. Then select ABS
corresponding model (A19) from X-431 3G

SRS
BCM
diagnostic tester (the latest software) to enter the ICM
system and select "BCM" system. TPMS
APM
RA19350020
 "Please select [special function]" is displayed on

the screen. SELECT FUNCTION
Read fault code
Erase fault code
Read data stream
System information
Action Test
write data
special function
RA19350030

35 - DOOR LOCK
 "Please select [Key learning]" is displayed on the

screen. special function
Key learning
Shipping Mode
Fault code set
Communication control
RA19350040
 After entering the "Communicating, please wait…"

screen, the hazard warning lights flash once. Communication Information
Press and hold any button on wireless key for

more than 1 second, until the hazard warning lights
flash once.
Communicating,please wait...
35
RA19350050
 "Routine Complete" is displayed on the screen,

and then click "OK". Key Learning
Routine Complete
OK
RA19350060
 Key match is completed.

f. Wireless key
The wireless key controls the doors to lock and unlock.
Wireless lock: with all doors closed, press the lock button on wireless key, all doors will be locked, turn
signal lights blink once and anti-theft horn sounds once. The security indicator will also blink normally to
indicate the system in armed state and the body anti-theft system is started. When any door is not
closed or not fully closed, press the lock button on wireless key, then all door are locked immediately
after performing the unlocking operation, the turn signal lights blink twice while the anti-theft horn does
not sound to, inform the driver that the vehicle is not in locking mode.
Wireless unlock: press the unlock button on wireless key, all doors will be unlocked; the turn signal
lights blink twice and anti-theft horn does not sound, which indicates that the body anti-theft system
becomes deactivated, and then the security indicator will go off. Open any door within 30 seconds after
unlocking the doors by wireless key. If any door does not open within 30 seconds, the door will lock
again automatically.
g. The vehicle security has 7 modes:
Locking mode
 Enter the locking mode when the following conditions are met:
- Remove the key.
- All doors, engine hood and luggage compartment door are closed.

35 - DOOR LOCK
- All doors are locked by the lock button on wireless key.

 When the vehicle is in locking mode, the following conditions will occur:
- The turn signal lights blink once, anti-theft horn sounds once and the anti-theft indicator on
instrument cluster blinks normally, which indicate that the vehicle is in locking mode.
- In the locking mode, if any door does not open within 30 seconds after unlocking the door by
wireless key, the door will lock again automatically.
Lock failure mode
 Lock failure mode occurs under the following conditions:
- If any door, engine hood and luggage compartment door are not closed fully.
 When the vehicle is in lock failure mode, the following conditions will occur:
- The turn signal lights blink twice, anti-theft horn does not sound and the anti-theft indicator does
not blink.
- If all doors are not closed, the central control lock performs the locking operation first, and then
performs the unlocking operation, regardless of the condition of engine hood and luggage
compartment door
- If all doors are closed, all doors are locked with the engine hood and luggage compartment door
are not closed fully.
Lock deactivation mode 35
 In the intrusion mode, the locking mode of entire vehicle will be deactivated if the following condition
occurs:
- Press the unlock button on wireless key.
- Press the luggage button on wireless key for more than 1.5 seconds.
- Open the door with key.
 The following conditions occur in lock deactivation mode (by wireless key, mechanical key, luggage
compartment button):
- All doors are unlocked.
- The turn signal lights blink twice, anti-theft horn does not sound and the anti-theft indicator stops
blinking.
 If the following conditions occur within 30s after the doors are unlocked by wireless key, the vehicle
will not return to the locking state, also not lock automatically:
- Turn the ignition switch to ON.
- Any door is open.
- Open the engine hood.
- Open the luggage compartment door.
Re-locking mode
 Enter the re-locking when the following conditions are met:
- After the vehicle is in locking mode, the locking mode of entire vehicle will be deactivated by
wireless key.
- The condition of all doors, engine hood and luggage compartment door do not change.
- If the key is not in the ignition key cylinder or the ignition switch is not turned to ACC or ON, the
system will be relocked after 30 seconds.
 The following conditions occurs in re-locking mode:
- All doors are locked, the turn signal lights do not blink, anti-theft horn does not sound and the
anti-theft indicator blinks normally, which indicate that the system has been re-locked.
Alarm mode
 When the vehicle is in locking mode, the alarm will be triggered if any following condition occurs:
- Open any door, engine hood and luggage compartment door manually.
- Turn the ignition switch to ON.
 When the vehicle is in alarm mode, the following condition occurs:

35 - DOOR LOCK
- After the alarm is triggered, the turn signal lights blink for 28 seconds and the anti-theft horn
sounds for 28 seconds. The condition will occur again after an interval of 2 seconds. This
process will repeat for 8 times. At the same time, the security indicator blinks quickly to indicate
that the system is in a non-secure state. If all doors/engine hood are fully closed or the ignition
switch is turned off during the cycle, the turn signal lights will complete the blink cycle and all
doors will lock again automatically after an interval of 5 seconds. At this time, the vehicle body
anti-theft system is reactivated.
Alarm deactivation mode
 The following operations will deactivate the alarm mode:
- Press the unlock button on wireless key.
- Open the door with key.
- Press the luggage compartment button on wireless key for more than 1.5 seconds.
Luggage compartment door open mode
 In locking mode, if the luggage compartment opener switch is pressed for 1.5 seconds, the luggage
compartment is opened and the turn signal lights blink twice at 1-second interval. Enter the luggage
compartment door open mode.
- If the luggage compartment is opened, the alarm mode will not be triggered.
- If the luggage compartment is closed, the entire vehicle enters the locking mode again without
35 any sound or light feedback.
- If pressing the lock button on wireless key with luggage compartment door open, the vehicle will
enter the lock failure mode. If pressing the unlock button on wireless key, the vehicle will enter
the lock deactivation mode.
- The vehicle will enter the alarm mode when all doors and engine hood are opened, regardless of
the luggage compartment is opened or closed.
Specifications

Front Power Door Lock Assembly Fixing Screw 7 ± 1.5
7 ± 1.5
Screw
Front Door Lock Striker Fixing Screw 7 ± 1.5
Rear Power Door Lock Assembly Fixing Screw 7 ± 1.5
Luggage Compartment Lock Assembly Fixing Screw 7 ± 1.5
Luggage Compartment Lock Latch Fixing Screw 12 ± 2
Engine Hood Lock Assembly Fixing Nut 7 ± 1.5
Wireless Key Upper Cover Fixing Screw 1.5 ± 0.5

35 - DOOR LOCK
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
35
Digital Multimeter
RCH0000002

35 - DOOR LOCK
Circuit Diagram
Power Door Lock System (Page 1 of 4)

BATTERY
INSTRUMENT
ENGINE PANEL
COMPARTMENT FUSE AND
EF12 POWER EF05 RF03 RF16 RF21 RELAY BOX
FUSE FUSE AND
80A BOX 40A 10A 10A 10A I-005
RELAY BOX
E3 B-010 3 16 21
R
R
A
8
R
R
B-021 I-047 ILLUMINTION
B
I-010 9 5 9 I-011 I-010 5
35 F-007 R G203
F-006 F-007 G-203
B
P
9 11 13 2
FRONT
LEFT
FRONT LEFT POWER
RW
RY
DOOR
WINDOW SWITCH
LOCK UNLOCK LOCK
F-004 ACTUATOR
F-002
2 1 1 3 4
GrG
GrG
GrR
GrR
GrL
GrR
GrG
F-006
6 5 8
I-011
GrG
GrR
GrL
F1 B31 B15 B4 B5 B30
BCM
B I-006
B-048
1 2 3 4 4 3 2 1 F-002
B-021 1
B-010 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 E4 E3 E2 E1 W Gr
W
B-048
13 14 15 16 17 18 19 20 21 22 23 24
Gr
25 26 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 I-010
I-011 16 15 14 13 12 11 10 9 W
87 14 13 12 11 10 9 8 W
85 86 86 86
87 30 87 30
30 85 85

8 7 6 5 4 3 2 1
I-005 B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 F-004
B 16 15 14 13 12 11 10 9 Br
I-006
L EA19350010

35 - DOOR LOCK
F7
15A
BCM
I-046
B-049
DOUAL RLY
BOOT-AJAR LOCK UNLOCK

A19 C15 C13 C12
A
GrB
LW
R
I-003 I-004
B-050 6 31
B-053
B-050
R
LUGGAGE 1 39 I-003
COMPARTMENT
LIGHT 2
B-041 1
LW
LW
GY
35
L
L
GrB
B
I-010 I-029 B-029 B-052

12 F-007 11 H-004 14 L-005 14 R-001
LY
GR
L
L
1 2 2 2 2 2
FRONT FRONT REAR REAR
LUGGAGE RIGHT LEFT
LEFT RIGHT
COMPARTMENT DOOR
LOCK M DOOR M LOCK
M DOOR
LOCK
M DOOR
LOCK LOCK
B-042 MOTOR MOTOR
MOTOR MOTOR
3 1 F-003 1 H-007 1 L-002 1 R-004
GR
G
3 F-007 H-003 8 L-005 8 R-001

8
B
I-010 I-030 B-029 B-052

GR
GR
G
G
42
B-034 I-004 B-053
C1 C2 C3 C4 C5 C6 C7 C8 C9
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 B-049
I-046
W
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 G C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
42 41 40 39 38 37 36 35 34 33 32 31 30 29
42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-053
14 13 12 11 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8 7 6 5 4 3 2 1 L
B-042
W
B-050
W
4 3 2 1
7 6 5 4 3 2 1 B-052
7 6 5 4 3 2 1 I-029 I-030
8 7 6 5 4 3 2 1 10 9 8 7 6 5 14 13 12 11 10 9 8 W
I-010 14 13 12 11 10 9 8 W W
16 15 14 13 12 11 10 9 W
F-003 H-007 L-002 R-004 1 B-041

7 6 5 4 3 2 1 B-029
14 13 12 11 10 9 8 W 2 1 B B B B G
EA19350020

35 - DOOR LOCK
BCM
I-006
I-046
B7 B6 A20 A4 B14
GRB
GRR
GRL
BW
I-010 I-030 I-004

14 6 18 4 B-053
F-007 H-003
LR
LGR
LGB
GRB
GRB
ILLUMINTION
B-029 B-052
12 L-005 12 R-001
P
35
GRB
GRB
4 1 1 3
FRONT FRONT 4 1
REAR REAR
LEFT RIGHT LUGGAGE
LEFT RIGHT
DOOR DOOR COMPARTMENT
DOOR DOOR
LOCK CONTACT OPENER
CONTACT CONTACT
ACTUATOR SWITCH SWITCH
SWITCH SWITCH
F-002 H-008 I-009
2 3 L-001 R-005
2 4
B
2 4
B
L-005 B
B
5 F-007 H-004 6 6 R-001
6 B-029
I-010 I-029 B-052
B
B
I-012 I-028 B-023 I-012

I-046 I-006
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 G L
4 3 2 1
42 41 40 39 38 37 36 35 34 33 32 31 30 29
10 9 8 7 6 5
8 7 6 5 4 3 2 1 I-010 28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-053
16 15 14 13 12 11 10 9 W 14 13 12 11 10 9 8 7 6 5 4 3 2 1 L
I-030
W
4 3 2 1 F-002 H-008 L-001 R-005 7 6 5 4 3 2 1 B-029 7 6 5 4 3 2 1 B-052

GR B B B 14 13 12 11 10 9 8 W 14 13 12 11 10 9 8 W
7 6 5 4 3 2 1 1 2
I-029 I-009
14 13 12 11 10 9 8 3 4 5 6 7 8
W B
EA19350030

35 - DOOR LOCK

BATTERY

BOX RELAY BOX
80A 10A 10A
B-009 I-005
3 16
RW
RY
R
F1 B31 B15
35
BCM
I-006
B-048
B-049
C18 C03
RG
BR
B-053
17 16 I-004
RG
ANTI-THEFT
BR
INDICATOR
I-039
1
1
1 2
B-048 1 2 3 4 5 6 7 8 9 10 11 12
Gr B-009 I-039
Lg 13 14 15 16 17 18 19 20 21 22 23 24
25 26
87
C1 C2 C3 C4 C5 C6 C7 C8 C9 85 86 86 86
B-049 85
87 30
85
87 30
30
W
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
I-005
B

42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-053 B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
28 27 26 25 24 23 22 21 20 19 18 17 16 15
L
14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-006
L
EA19350040

35 - DOOR LOCK
DIAGNOSIS & TESTING

HINT:
Power Door Lock Control System:

Body Control Module (BCM) fuse 49-29
Power door unlock/lock switch button -
All doors lock/unlock functions do not Front left door lock assembly 35-41
operate Other door lock assemblies -
35 Body Control Module (BCM) -
Power door unlock/lock switch button -
Only driver side door lock/unlock functions Front left door lock assembly 35-41
do not operate Wire harness or connector -
Front right door lock assembly 35-41
Only passenger side door lock/unlock
functions do not operate
Rear left door lock assembly 35-47
Only rear left door lock/unlock functions do
not operate
Rear right door lock assembly 35-47
Only rear right door lock/unlock functions
do not operate
Luggage compartment lock assembly 35-51
Only luggage compartment door open/
close functions do not operate

35 - DOOR LOCK
Wireless Door Lock Control System:

Wireless key battery 35-55
Only wireless control function does not Anti-theft match 35-5

operate Wire harness or connector -
Turn signal light -
Only no answer-back
Diagnosis Tool
When connecting the X-431 3G diagnostic tester:
 Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC) for
communication with the vehicle. 35
 DLC is located at the driver side instrument panel crossmember.
 DLC uses a trapezoidal design which can hold 16 terminals.
Digital Multimeter
When using the digital multimeter:
 Troubleshoot the electrical malfunctions and wire harness system.
 Troubleshoot the basic malfunction.
 Measure the voltage, current and resistance.

 Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC), and make
 Using the X-431 3G diagnostic tester to record and clear the DTCs stored in the Body Control Module
(BCM).
 Turn the ignition switch to ON, and then select Read Code.
 If the DTC is not detected, the malfunction indicated by the DTC is intermittent. Please refer to the
"Intermittent DTC Troubleshooting".

 Wiggle the related wire harness and connector and observe if the signal is interrupted in the related circuit.

35 - DOOR LOCK
 Check if the installation of components (power door lock assembly, wire harness or wire harness
connector, etc.) exist some conditions (damage, foreign matter, etc.) that will cause incorrect signals.
 Remove the Body Control Module (BCM) from the malfunctioning vehicle and install it to a new vehicle and
perform a test. If the DTC cannot be cleared, the Body Control Module (BCM) is malfunctioning. If the DTC
can be cleared, reinstall the Body Control Module (BCM) to the original vehicle.
Ground Inspection
moisture, dirt and other corrosive environments. Corrosion (rust) can increase load resistance. This situation
may change the way in which a circuit works. Electronically controlled circuits are very sensitive to proper
grounding. A loose, corroded ground or oxidation can affect the electronically controlled circuit.
Perform the following operations when checking the ground points:
35 2. Check all the contact surfaces for tarnish, dirt and rust, etc.
3. Clean as necessary to ensure that the contacting is in good condition.
6. If several wire harnesses are secured to a eyelet terminal, check if they are installed correctly. Make sure
all the wire harnesses are clean, securely fastened and providing a good ground path.
Diagnosis Procedure
HINT:
Use the following procedure to troubleshoot the power door lock control system.
NEXT
NEXT
NEXT

35 - DOOR LOCK
DTC
No
5 Problem repair (for no DTC), then go to step 8
NEXT
NEXT 35
NEXT
8 Adjust, repair or replace
NEXT
9 Confirm troubleshooting and perform test
NEXT
10 End

35 - DOOR LOCK

B101B-18 Central Unlock Control Circuit Current Below Threshold
B101B-19 Central Unlock Control Circuit Current Above Threshold
B101B-71 Central Unlock Control Circuit Actuator Stuck
B101C-18 Central Lock Control Circuit Current Below Threshold
B101C-19 Central Lock Control Circuit Current Above Threshold
B101C-71 Central Lock Control Circuit Actuator Stuck
B101D-18 Siren Control Circuit Current Below Threshold
B101D-19 Siren Control Circuit Current Above Threshold
B101F-11 Trunk Control Circuit Short to Ground
B101F-13 Trunk Control Circuit Open
35

35 - DOOR LOCK
DTC B101B-18 Central Unlock Control Circuit Current Below Threshold
DTC B101B-19 Central Unlock Control Circuit Current Above Threshold
DTC B101B-71 Central Unlock Control Circuit Actuator Stuck
DTC B101C-18 Central Lock Control Circuit Current Below Threshold
DTC B101C-19 Central Lock Control Circuit Current Above Threshold
DTC B101C-71 Central Lock Control Circuit Actuator Stuck
35

35 - DOOR LOCK
BATTERY
EF12 POWER
FUSE
80A BOX
R
F1
F7
15A BCM
B-048
DOUAL RLY B-049
I-006
LOCK UNLOCK
C13 C12 B4 B5 B30
BCM(BODY CONTROLLER CONNECTOR)
LW
GrG
GrR
GrL
35
B-050 I-011
39 6 5 8
I-003 F-006
GrG
GrR
GrL
1 3 4
LW
LW
L
FRONT
I-010 I-029 B-029 B-052 LEFT
12 11 14 14 LOCK UNLOCK DOOR
F-007 H-004 L-005 R-001
GR
LOCK
L
2 2 2 2 ACTUATOR
FRONT FRONT REAR REAR F-002
LEFT RIGHT LEFT RIGHT 2
DOOR
M DOOR M M DOOR M DOOR
B
LOCK LOCK LOCK LOCK
MOTOR MOTOR MOTOR MOTOR
1 F-003 1 H-007 1 L-002 1 R-004
F-007
GR
G
5 I-010
3 F-007 H-003 8 L-005 8 R-001
I-010 8 I-030 B-029 B-052
B
GR
GR
G
G
42
I-004 B-053 G-203

B-053 I-006 1 B-048
L L Gr
14 13 12 11 10 9 8 7 6 5 4 3 2 1
4 3 2 1
C1 C2 C3 C4 C5 C6 C7 C8 C9
42 41 40 39 38 37 36 35 34 33 32 31 30 29 B-049
B-050 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W F-002
28 27 26 25 24 23 22 21 20 19 18 17 16 15
W Gr
14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-011 4 3 2 1
7 6 5 4 3 2 1 W I-030
14 13 12 11 10 9 8 I-029 10 9 8 7 6 5 W
B-052 W
7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
W I-010
14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 W
B-029 F-003 H-007 L-002 R-004
W 2 1
B B B B
EA19350050

35 - DOOR LOCK

Condition Condition
Central Unlock Control
B101B-18 Circuit Current Below
Threshold
Central Unlock Control
B101B-19 Circuit Current Above
Threshold  Fuse
Central Unlock Control  Front left door lock
B101B-71 assembly
Circuit Actuator Stuck
Ignition switch ON ON  Wire harness or
Central Lock Control connector
B101C-18 Circuit Current Below
Threshold  Body Control
Module (BCM)
Central Lock Control
B101C-19 Circuit Current Above
Threshold 35
Central Lock Control
B101C-71
CAUTION
 When performing the circuit diagnosis and test, always refer to the circuit diagram for specific circuit and
the component information.
Diagnosis Procedure
1 Check Body Control Module (BCM) fuse F7 (15 A)

c. Remove the Body Control Module (BCM) fuse F7 (15 A).
NG Replace Body Control Module (BCM) fuse

F7 (15 A)
OK
2 Check front left door lock assembly
a. Check the front left door lock assembly (See page 35-41).
NG Replace front left door lock assembly
OK

35 - DOOR LOCK
3 Check instrument panel wire harness and connector

I-006 and I-011.
+ -
the instrument panel wire harness connectors I-006 and
I-011 according to the value(s) in the table below.
Condition B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
I-006
I-006 (B4) -
Always Continuity
I-011 (6)
I-006 (B5) - 7 6 5 4 3 2 1
Always Continuity 14 13 12 11 10 9 8
I-011 (5)
I-006 (B30) -
35
I-011
Always Continuity
I-011 (8) RA19350300

I-003 and I-010.
I-010 according to the value(s) in the table below. + -
Condition
I-003 (39) - 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Always Continuity
I-010 (12) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
I-010
RA19350310

35 - DOOR LOCK
g. Disconnect the instrument panel wire harness connectors

I-003 and I-029.
Condition
29 30 31 32 33 34 35 36 37 38 39 40 41 42
I-003 (39) - 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Always Continuity
I-029 (11) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003
7 6 5 4 3 2 1
14 13 12 11 10 9 8
I-029
RA19350320
i. Disconnect the instrument panel wire harness connectors

I-004 and I-030.
35
Condition
I-004 (42) - 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Always Continuity
I-030 (8) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-004
4 3 2 1
10 9 8 7 6 5
I-030
RA19350321
k. Disconnect the instrument panel wire harness connectors

I-004 and I-010.
l. Using a digital multimeter, check for continuity between
Condition
29 30 31 32 33 34 35 36 37 38 39 40 41 42
I-004 (42) -
I-010 (3) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-004
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
I-010
RA19350330

35 - DOOR LOCK
m. Disconnect the instrument panel wire harness connector

I-010 and ground G-203.
n. Using a digital multimeter, check for continuity between
the instrument panel wire harness connector I-010 and
ground G-203 according to the value(s) in the table + -
below.
Condition 8 7 6 5 4 3 2 1
Connection Condition 16 15 14 13 12 11 10 9
I-010 (5) - G-203 Always Continuity I-010

G-203
RA19350390
OK
35
4 Check body wire harness and connector

c. Disconnect the body wire harness connectors B-049 and
B-050.
+ -
the body wire harness connectors B-049 and B-050
according to the value(s) in the table below. C1 C2 C3 C4 C5 C6 C7 C8 C9
Multimeter Specified C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Condition
B-049
B-049 (C13) -
Always Continuity
B-050 (39) 42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-050
RA19350410

35 - DOOR LOCK
e. Disconnect the body wire harness connectors B-049 and

B-052.
according to the value(s) in the table below. + -
Condition
Connection Condition C1 C2 C3 C4 C5 C6 C7 C8 C9
B-049 (C13) -
Always Continuity C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-052 (14)
B-049
B-049 (C12) -
Always Continuity
B-052 (8)
7 6 5 4 3 2 1
14 13 12 11 10 9 8
B-052 RA19350420
g. Disconnect the body wire harness connectors B-029 and

B-049.
35
Condition
Connection Condition 7 6 5 4 3 2 1
14 13 12 11 10 9 8
B-029 (14) -
Always Continuity
B-049 (C13)
B-029
B-029 (8) -
Always Continuity
B-049 (C12) C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-049
RA19350421
i. Disconnect the body wire harness connectors B-049 and

B-053.
Condition
Connection Condition C1 C2 C3 C4 C5 C6 C7 C8 C9
B-049 (C12) - C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Always Continuity
B-053 (42)
B-049
42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-053
RA19350440

35 - DOOR LOCK
k. Disconnect the body wire harness connectors B-029 and

B-053.
Condition
14 13 12 11 10 9 8
B-029 (12) -
Always Continuity
B-053 (18)
B-029
42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-053
RA19350450
m. Disconnect the body wire harness connectors B-052 and

35 B-053.
Condition
14 13 12 11 10 9 8
B-052 (12) -
Always Continuity
B-053 (4)
B-052

connector 42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-053
RA19350460
OK

35 - DOOR LOCK
5 Check front left door wire harness and connector

c. Disconnect the front left door wire harness connectors
F-003 and F-007.
+ -
the front left door wire harness connectors F-003 and
F-007 according to the value(s) in the table below.
Condition
Connection Condition F-003
F-003 (2) -
Always Continuity
F-007 (12) 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
F-003 (1) -
Always Continuity
F-007 (3) F-007
RA19350500 35
e. Disconnect the front left door wire harness connectors

F-002 and F-006.
F-006 according to the value(s) in the table below. + -
Condition
F-002 (1) - 4 3 2 1
Always Continuity
F-006 (6) F-002
F-002 (3) -
Always Continuity
F-006 (5) 1 2 3 4 5 6 7
8 9 10 11 12 13 14
F-002 (4) -
Always Continuity
F-006 (8) F-006
RA19350511

35 - DOOR LOCK
g. Disconnect the front left door wire harness connectors

F-002 and F-007.
Condition
F-002 (2) - F-002

Always Continuity
F-007 (5)
NG Repair or replace front left door wire 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16
F-007
RA19350510
OK
35
6 Check front right door wire harness and connector

c. Disconnect the front right door wire harness connectors
H-003 and H-007.
+ -
the front right door wire harness connectors H-003 and
H-007 according to the value(s) in the table below.
1 2 3 4
Multimeter Specified 5 6 7 8 9 10
Condition
Connection Condition H-003
H-003 (8) -
Always Continuity
H-007 (1)
2 1
H-007
RA19350520

35 - DOOR LOCK
e. Disconnect the front right door wire harness connectors

H-004 and H-007.
H-007 according to the value(s) in the table below. + -
Condition
H-004 (11) - 1 2 3 4 5 6 7
Always Continuity
H-007 (2) 8 9 10 11 12 13 14
H-004
NG Repair or replace front right door wire

2 1
H-007
RA19350530
OK
35
7 Check rear left door wire harness and connector

c. Disconnect the rear left door wire harness connectors
L-002 and L-005.
+ -
the rear left door wire harness connectors L-002 and 
L-005 according to the value(s) in the table below.
2 1
Condition
Connection Condition L-002
L-002 (1) -
Always Continuity
L-005 (8)
1 2 3 4 5 6 7
L-002 (2) - 8 9 10 11 12 13 14
Always Continuity
L-005 (14) L-005
NG Repair or replace rear left door wire RA19350560
OK

35 - DOOR LOCK
8 Check rear right door wire harness and connector

c. Disconnect the rear right door wire harness connectors
R-001 and R-004.
+ -
the rear right door wire harness connectors R-001 and
R-004 according to the value(s) in the table below.
2 1
Condition
Connection Condition R-004
R-001 (14) -
Always Continuity
R-004 (2)
1 2 3 4 5 6 7
R-001 (8) - 8 9 10 11 12 13 14
Always Continuity
R-004 (1)
R-001
35
NG Repair or replace rear right door wire RA19350580
OK
9 Reconfirm DTCs
a. Connect all connectors.

d. Use the X-431 3G diagnostic tester (the latest software) to record and clear the DTCs stored in the Body
Control Module (BCM).
g. Use the X-431 3G diagnostic tester (the latest software) to read the DTCs stored in the Body Control
Module (BCM) again.
Result Proceed to
DTC B101B-18, B101B-19, B101B-71, B101C-18,
NG
B101C-19, B101C-71 are output
No DTC output OK
NG Replace Body Control Module (BCM)
OK
System is normal

35 - DOOR LOCK
DOOR LOCK
DTC B101D-18 Siren Control Circuit Current Below Threshold
DTC B101D-19 Siren Control Circuit Current Above Threshold
BCM
B-049
C10
WB
35
1
ANTI-THEFT
HORN
B-002
2
B
B-016
C1 C2 C3 C4 C5 C6 C7 C8 C9
1 2
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-002
B-049
B
W
EA19350060

35 - DOOR LOCK

Condition Condition
Siren Control
B101D-18 Circuit Current  Wire harness or
Below Threshold connector
Siren Control  Body Control
B101D-19 Circuit Current Module (BCM)
Above Threshold
CAUTION
 When performing the circuit diagnosis and test, always refer to the circuit diagram for specific circuit and
the component information.
35
1 Check anti-theft horn
a. Check the anti-theft horn.
NG Replace anti-theft horn
OK

B-049.
+ -
according to the value(s) in the table below.
1 2
Condition
B-002
B-002 (1) -
Always Continuity
B-049 (C10)
C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-049
RA19350610

35 - DOOR LOCK
e. Disconnect the body wire harness connector B-002 and

ground B-016.
the body wire harness connector B-002 and ground B-
016 according to the value(s) in the table below. + -
Condition
B-002 (2) - B-016 Always Continuity 1 2
B-002
connector
B-016
RA19350620
OK
35
3 Reconfirm DTCs

Module (BCM) again.
Result Proceed to
B101D-18 and B101D-19 are output NG
No DTC output OK
OK
System is normal

35 - DOOR LOCK
DTC B101F-11 Trunk Control Circuit Short to Ground
DTC B101F-13 Trunk Control Circuit Open
BATTERY
INSTRUMENT
ENGINE PANEL
COMPARTMENT FUSE AND
EF12 POWER EF05 RF21 RELAY BOX
FUSE FUSE AND
80A BOX 40A 10A I-005
RELAY BOX
E3 B-010 21
R
R
R
F1
8
F7
15A
BCM
35 I-046 I-003
6 B-050
B-049
B-048
BOOT-AJAR
R
C15 A19 1 LUGGAGE
COMPARTMENT
LIGHT 2
I-004 1 B-041
31
B-053
B
GY
LY
2 1
TAIL DOOR LOCK

B-042
3
B
B-034
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 C1 C2 C3 C4 C5 C6 C7 C8 C9
I-046 B-049
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 G W
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
42 41 40 39 38 37 36 35 34 33 32 31 30 29 42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-050 B-053
28 27 26 25 24 23 22 21 20 19 18 17 16 15 28 27 26 25 24 23 22 21 20 19 18 17 16 15
W L
14 13 12 11 10 9 8 7 6 5 4 3 2 1 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 8 7 6 5 4 3 2 1
I-010 1 B-048
16 15 14 13 12 11 10 9
13 14 15 16 17 18 19 20 21 22 23 24 W Gr
I-005
25 26
87 B
85 86 86 86
87 30 87 30 1
30 85 85 3 2 1 B-042 B-041
W G
EA19350070

35 - DOOR LOCK

Condition Condition
Trunk Control  Luggage
B101F-11 Circuit Short to compartment
Ground lock assembly
Ignition switch ON ON  Wire harness or
Trunk Control connector
B101F-13
Circuit Open  Body Control
Module (BCM)
CAUTION
35
Diagnosis Procedure
1 Check luggage compartment lock assembly
a. Check the luggage compartment lock assembly (See page 35-51).
NG Replace luggage compartment lock

assembly
OK

I-004 and I-046.
+ -
29 30 31 32 33 34 35 36 37 38 39 40 41 42
Condition
I-004 (31) -
I-046 (A19)
I-046
RA19350630

35 - DOOR LOCK

I-003 and I-005.
Condition 29 30 31 32 33 34 35 36 37 38 39 40 41 42
I-003 (6) - 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Always Continuity
I-005 (21) I-003
1 2 3 4 5 6 7 8 9 10 11 12
NG Repair or replace instrument panel wire 13 14 15 16 17 18 19 20 21 22 23 24
harness and connector 25 26
87
85 86 86 86
87 30 87 30
30 85 85
I-005
RA19350631
OK
35

B-042.
+ -
C1 C2 C3 C4 C5 C6 C7 C8 C9
Condition
Connection Condition C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
B-049 (C15) - B-049

Always Continuity
B-042 (2)
3 2 1
B-042
RA19350640

35 - DOOR LOCK

B-042.
Condition
42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-053 (31) -
B-042 (1) 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-053
3 2 1
B-042
RA19350650
g. Disconnect the body wire harness connectors B-053 and

B-041.
35
Condition
42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-053 (31) -
B-041 (1) 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-053
B-041
RA19350651
i. Disconnect the body wire harness connectors B-041 and

B-042.
Condition
B-041 (1) -
Always Continuity 1
B-042 (1)
B-041
3 2 1
B-042
RA19350670

35 - DOOR LOCK
k. Disconnect the body wire harness connectors B-041 and

B-050.
Condition
B-041 (1) - 28 27 26 25 24 23 22 21 20 19 18 17 16 15
Always Continuity
B-050 (6) 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-050
B-041
RA19350671
m. Disconnect the body wire harness connector B-042 and

35 ground B-034.
body wire harness connector B-042 and ground B-034
Condition
3 2 1
B-042 (3) - B-034 Always Continuity
B-042

connector
B-034
RA19350680
OK
4 Reconfirm DTCs

Module (BCM) again.

35 - DOOR LOCK
Result Proceed to
B101F-11 and B101F-13 are output NG
No DTC output OK
OK
System is normal
35

35 - DOOR LOCK
ON-VEHICLE SERVICE
Engine Hood Lock Assembly
Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the engine hood
lock assembly.
 Try to prevent the body paint surface from being scratched when removing the engine hood lock
assembly.

3. Remove the engine hood lock assembly.
35 a. Remove 3 fixing nuts (arrow) from the engine hood
lock assembly.
RA19450110
b. Disconnect the engine hood cable (arrow) assembly.
RA19450120
c. Remove the engine hood lock assembly.
Installation
CAUTION
 Check if the engine hood operates properly after installing the engine hood lock assembly.

35 - DOOR LOCK
Front Door Lock Assembly

Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the front door lock
assembly.
 Try to prevent the body paint surface from being scratched when removing the front door lock assembly.

3. Remove the front left door inner protector assembly (See page 45-19).
4. Remove the front left door protector bracket (See page 45-24). 35
5. Remove the front left door protective film assembly (See page 45-24).
6. Remove the front left door lock cable.
a. Disengage the front door lock cable from the slot in
b. Disconnect the clip (1) from the front door lock cable
and remove the front left door lock cable (2).
2
RA19350091

35 - DOOR LOCK
7. Remove the front left door inner open cable.

a. Disengage the front door inner open cable from the
slot in the direction of arrow as shown in the
illustration.
b. Disconnect the clip (1) from the front door inner open
cable, and remove the front left door inner open cable 2
(2).
RA19350090
8. Remove the front left door lock assembly.

35 a. Disconnect the connectors (arrow) from the front door
lock assembly.
RA19350080
b. Disconnect the clip (1) from the front door outside

lever and the clip (2) from the front door key cylinder
lever.
RA19350071

35 - DOOR LOCK
c. Remove 3 fixing screws (arrow) from the front door

lock assembly, and remove the front door lock
assembly.
RA19350070
Inspection
1. Check the front left door lock assembly (fastener assembly).
a. Apply battery voltage to the terminals of front door 35
lock assembly (fastener assembly) connector and + -
check the operation of front door lock assembly UNLOCK

OK
LOCK
Specified
Measurement Condition
Condition 1 2
Battery positive (+) - Terminal 2

Lock
Battery negative (-) - Terminal 1 RA19350100

Unlock
Battery negative (-) - Terminal 2
If the result is not as specified, replace the front left door lock
assembly.
Installation
CAUTION
 Check if the connectors are installed correctly when installing the front door lock assembly.
 Install the clips on the lever in place when installing the front door lock assembly.
 Check if the front door lock operates properly after installing the front door lock assembly.

35 - DOOR LOCK
Front Door Key Cylinder

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the front door key
cylinder.
 Try to prevent the body paint surface from being scratched when removing the front door key cylinder.

4. Remove the front left door protector bracket (See page 45-24).
6. Remove the front left door key cylinder protective cover.
35 a. Disconnect the clip (arrow) from the front door key
cylinder protective cover lever.
RA19350270
b. Using a screwdriver wrapped with protective tape,

remove the front door key cylinder protective cover
block cover (1).
2
c. Remove the fixing screw (2) from the front door key
cylinder protective cover.
RA19350260
d. Remove the front door key cylinder protective cover.

35 - DOOR LOCK
7. Remove the front left door key cylinder.

a. Disconnect the clip (arrow) from the front door key
RA19450280

disengage the clips (arrow) and separate the front
door key cylinder protective cover from the front door
key cylinder.
35
RA19350110
Installation
CAUTION
 Install the clips on the lever in place when installing the front door key cylinder.
 Check if the front door key cylinder operates properly after installing the front door key cylinder.

35 - DOOR LOCK
Front Door Lock Striker

Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the front door lock
striker.
 Try to prevent the body paint surface from being scratched when removing the front door lock striker.

2. Remove the front left door lock striker.
a. Remove 2 fixing screws (arrow) from the front door
35 lock striker.
RA19350120
b. Remove the front left door lock striker.
Installation
CAUTION
 Try to prevent the body paint surface from being scratched when installing the front door lock striker.

35 - DOOR LOCK
Rear Door Lock Assembly

Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the rear door lock
assembly.
 Try to prevent the body paint surface from being scratched when removing the rear door lock assembly.

3. Remove the rear left door inner protector assembly (See page 45-34).
4. Remove the rear left door protector bracket. (See page 45-38). 35
5. Remove the rear left door protective film assembly (See page 45-38).
a. Disengage the rear door inner open cable (1) and rear
door lock cable (2) from the clips in the direction of 1
arrow as shown in the illustration.
RA19350221
6. Remove the rear left door lock cable.

a. Disengage the front door lock cable from the slot in
b. Disconnect the clip (1) from the rear door lock cable,
and remove the rear left door lock cable (2).
RA19350150

35 - DOOR LOCK
7. Remove the rear left door inner open cable.

a. Disengage the rear door inner open cable from the
slot in the direction of arrow as shown in the
illustration.
b. Disconnect the clip (1) from the rear door inner open
cable, and remove the rear left door inner open cable
2
(2).
RA19350151
8. Remove the rear left door lock assembly.

35 a. Disconnect the connectors (arrow) from the rear door
lock assembly.
RA19350140
b. Disconnect the clip (arrow) from the rear door outside

lever.
RA19450500

35 - DOOR LOCK
c. Remove 3 fixing screws (arrow) from the rear door

lock assembly, and remove the rear door lock
assembly.
RA19350130
Inspection
1. Check the rear left door lock assembly (fastener assembly).
a. Apply battery voltage to the terminals of rear door lock 35
assembly (fastener assembly) connector and check + -
UNLOCK
the operation of rear door lock assembly according to
the table below.
OK LOCK
Specified
Condition 1 2

Lock

Unlock
Battery negative (-) - Terminal 2
If the result is not as specified, replace the rear left door lock
assembly.
Installation
CAUTION
 Check if the connectors are installed correctly when installing the rear door lock assembly.
 Install the clip on the lever in place when installing the rear door lock assembly.
 Check if the rear door lock operates properly after installing the rear door lock assembly.

35 - DOOR LOCK
Rear Door Lock Striker

Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the rear door lock
striker.
 Try to prevent the body paint surface from being scratched when removing the rear door lock striker.

2. Remove the rear left door lock striker.
a. Remove 2 fixing screws (arrow) from the rear door
35 lock striker.
RA19350170
b. Remove the rear left door lock striker.
Installation
CAUTION
 Try to prevent the body paint surface from being scratched when installing the rear door lock striker.

35 - DOOR LOCK
Luggage Compartment Lock Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the luggage
compartment lock assembly.
 Try to prevent the body paint surface from being scratched when removing the luggage compartment
lock assembly.

3. Remove the luggage compartment door opener handle.
a. Remove the luggage compartment door opener handle.
b. Disconnect the cable in the direction of arrow as
shown in the illustration. 35
RA19350280
c. Remove the luggage compartment door opener handle.

4. Remove the luggage compartment door protector assembly.
a. Remove the clips (arrow) from the luggage
compartment door protector assembly.
RA19350180
b. Remove the luggage compartment door protector assembly.

35 - DOOR LOCK
5. Remove the luggage compartment lock assembly.

a. Disengage the luggage compartment door inner open
cable from the slot in the direction of arrow as shown 1
b. Disengage the luggage compartment door inner open
cable (1).
c. Remove the luggage compartment door inner open
cable (2).
2
RA19350190
d. Disconnect the connector (1) from the luggage

compartment lock assembly.
e. Remove 2 fixing bolts (arrow) from the luggage
compartment lock assembly.
35
1
RA19350200
f. Remove the luggage compartment lock assembly.
Inspection
1. Check the luggage compartment lock assembly.
a. Using a digital multimeter, measure the continuity
between each terminal of the luggage compartment
+ -
lock assembly according to the table below.
Multimeter Specified 1 2 3
Condition
On Continuity
1-3
On No continuity
If the result is not as specified, replace the left outside rear RA19350191
view mirror assembly.

35 - DOOR LOCK
2. Check the luggage compartment lock assembly.

a. Apply battery voltage to the terminals of luggage
compartment lock assembly connector and check the + -
operation of luggage compartment lock assembly

1 2 3
OK
Specified
Condition
On
Installation
CAUTION
 Check if the connectors are installed correctly when installing the luggage compartment lock assembly.
 Install the cable clip in place when installing the luggage compartment lock assembly. 35
 Check if the luggage compartment lock operates properly after installing the luggage compartment lock
assembly.

35 - DOOR LOCK
Luggage Compartment Lock Latch

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the luggage
compartment lock latch.
lock latch.

2. Remove the rear luggage compartment trim assembly (See page 47-21).
3. Remove the luggage compartment lock latch.
a. Remove 2 fixing screws (arrow) from the luggage
compartment lock latch.
35 (Tightening torque: 12 ± 2 N·m)
RA19350210
b. Remove the luggage compartment lock latch.
Installation
CAUTION
 Try to prevent the body paint surface from being scratched when installing the luggage compartment lock
latch.

35 - DOOR LOCK
Wireless Key
Removal
CAUTION
 DO NOT push the terminals with your hands when removing the wireless key cover.
 Install the battery positive and negative correctly when removing the wireless key cover.
 DO NOT pry up the battery forcibly when removing the wireless key cover; otherwise, the terminals may
be damaged.
 DO NOT touch the battery with wet hands when removing the wireless key cover; otherwise, the water
may cause rust.
 DO NOT touch or move any components inside the transmitter when removing the wireless key cover.
Failure to do so may interfere with proper operation.
1. Remove the wireless key.

a. Using a flat tip screwdriver wrapped with protective 35
tape, pry out the wireless key cover.
RA19350220
b. Remove the wireless key battery in the direction of

RA19350230
c. Remove 3 fixing screws (arrow) from the wireless key

upper cover.
RA19350240
d. Remove the wireless key upper cover.

35 - DOOR LOCK
e. Remove the wireless key billet (1).

f. Remove the wireless key chip (2).
RA19350250
Installation
CAUTION
 Check that the wireless key operates properly after installing the wireless key.
35

INSTRUMENT CLUSTER
GENERAL INFORMATION 36-3 B1101-11 36-19
Description 36-3 B1101-15 36-19
Operation 36-4 B1103-00 36-24
Specification 36-4 B1104-41 36-27
Tools 36-4 U0073-88 36-28
Circuit Diagram 36-5 U0100-87 36-28
Instrument Cluster Terminal List 36-9 U0101-87 36-28
U0129-87 36-28
U0140-87 36-28
U1130-55 36-33
Diagnosis Tools 36-12
DTC Confirmation Procedure 36-12 ON-VEHICLE SERVICE 36-34
Intermittent DTC Troubleshooting 36-12 Instrument Cluster 36-34
Ground Inspection 36-13 Removal 36-34
Diagnosis Procedure 36-13 Installation 36-35
Diagnostic Trouble Code (DTC)  Instrument Cluster Adjustment 
Chart 36-14 Button 36-36 36
B1100-16 36-15 Removal 36-36
B1100-17 36-15 Installation 36-36

36

36 - INSTRUMENT CLUSTER
GENERAL INFORMATION
INSTRUMENT CLUSTER
Description
Instrument Cluster
20 21 22 23 1 2 3 4 5 6 7
C H E F
100 120 3 4
80 140
19 60 160 2 5 8
08:30
+ -
28.6
40 180 9
18 EPC
1
1 6
20 200 10
0 220 0 7 36
TRIPA 123.5 km
in
km
/h 0r
/m
00
x1
17 16 15 14 13 12 11
RA19360010
1 - Left Turn Signal Indicator 2 - Coolant Temperature Gauge

3 - Fuel Gauge 4 - Right Turn Signal Indicator
5 - Front Fog Indicator 6 - Charging System Warning Light
7 - Rear Fog Indicator 8 - Tachometer
9 - SRS Warning Light 10 - Engine Malfunction Warning Light
11 - Brake System Malfunction Warning Light 12 - Park Brake Warning Light
13 - EPS Warning Light 14 - LCD Display
15 - Driver Seat Belt Reminder Light 16 - Low Fuel Level Warning Light
17 - Low Engine Oil Pressure Warning Light 18 - ABS Warning Light
19 - Position Indicator 20 - Speedometer
21 - High Coolant Temperature Warning Light 22 - Maintenance Indicator
23 - High Beam Indicator

This vehicle is equipped with the pointer type instrument cluster. The instrument cluster is a highly integrated
electronic instrument display system and mainly consists of coolant temperature gauge, tachometer, fuel
gauge, speedometer, comprehensive information display center and warning indication symbols. The
comprehensive information display center mainly displays the vehicle information, which contains the
following: clock, door/luggage compartment door hint information, trip, total mileage, driving range,
instantaneous fuel consumption, average fuel consumption and warning information.
Operation
The instrument cluster is located above the upper left of instrument panel assembly, which is used to monitor
and display the operation status of each system and component in the vehicle. Instrument cluster receives
signals from each sensor and switch, and displays the operation status of each system through the meter,
display, indicator and warning lights. It also reminds and informs the driver by flashing the light and sounding
the buzzer. As a result, it will be helpful for the driver to eliminate possible troubles in time, thus avoiding the
malfunction or accidents efficiently.
Specification

36 Instrument Cluster Fixing Screw 2 ± 0.2
Tools
Special Tool
ཽ⪔⊳䖜
RCH0000001
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Instrument Cluster (Page 1 of 4)
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT ENGINE
PANEL FUSE COMPARTMENT
RF01 EF33
AND RELAY FUSE AND
I-005 B-014
1 A11
R
B-050
RW
30 I-003
R
13 11
SRS
LCD BUZZER
INSTRUMENT
CLUSTER
36
17 3 7 12
GrL
YL
P
B
ILLUMINATION
17
12
AUDIO
I-037
SRS
CONTROL
MODULE I-026
I-023
1 2 3 4 5 6 7 8 9 10 11 12 8 7 6 5 4 3 2 1
A1 A2 A3 A4 A5 A6
A10 A11 A12 A13 16 15 14 13 12 11 10 9
13 14 15 16 17 18 19 20 21 22 23 24 A7 A8 A9 A14 A15 A16
25 26
B-014 I-037
87
W B
85 86 86 86
87 30 87 30
30 85 85
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-005
B
I-043
L
42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B-050
W I-023
G
EA19360010

INSTRUMENT
UNIFIED METER CONTROL UNIT CLUSTER
I-043
LOW CHARGING
OIL
23 24 25 9 16
L
I-003
LB
B-050 38
RG
I-003
37 B-008
B-050 15
E-038
GY
GL
L
36 B-020
L
GENERATOR
10 E-030
E-012
LB
4 3 2 1
OIL PRESSURE
CLOSE SWITCH
E-005
ADJUSTMENT OPEN
SWITCH
I-038
42 41 40 39 38 37 36 35 34 33 32 31 30 29
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
1 2 3 4
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-038
I-043 B B-050
L W
29 30 31 32 33 34 35 36 37 38 39 40 41 42 1 2 3 4 5 6 7 8
1 1
15 16 17 18 19 20 21 22 23 24 25 26 27 28 16 15 14 13 12 11 10 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14
E-005 B-038
B G
B-020
I-003 B
W
EA19360020

INSTRUMENT
CLUSTER
I-043
31 29 30
Gr
Y
B12 B2
BCM
I-006 TO CAN
Y
SYSTEM
36
B16 B1
4 I-004
B-053
Y
24 21 17 1
DRIVER
SEAT BELT ECM
SWITCH B-001
ABS
B-007
B
14 15 16 17 18 19 20 21 22 23 24 25 26
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-043 B-007
L B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
I-006
L
B-001
B
EA19360030

FUEL
GAUGE INSTRUMENT
CLUSTER
I-043
UNIFIED METER CONTROL UNIT
lOW FUEL
BRAKE PARKING LEVEL
BRAKE
26 18 5 22 21
LW
VB
RL
V
I-004 I-003 I-004
6 21 10 32 20
B-053 B-050 B-053
36
LW
YB
RL
V
1 1 2 4 3
FUEL LEVEL
BRAKE PARKING SENSOR AND
FLUID BRAKE FUEL PUMP
CLOSE LEVEL APPLIED SWITCH
B-027
SENSOR RELEASED B-022
OPEN 1
B-018
B
2
B
B-016 B-035
42 41 40 39 38 37 36 35 34 33 32 31 30 29
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-043 28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-053
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
L 14 13 12 11 10 9 8 7 6 5 4 3 2 1
L
42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
1 1 2 3 4 5
14 13 12 11 10 9 8 7 6 5 4 3 2 1 2 1
B-050 B-018 B-022 B-027

W W W B
EA19360040

Instrument Cluster Terminal List

Terminal No. Definition Terminal No. Definition
1 - 17 Airbag Indication Signal
2 - 18 Parking Brake Switch Signal
3 Power Ground 19 -
4 - 20 -
5 Fuel Sensor Ground 21 Fuel Signal Input
6 - 22 Fuel Assist Signal Input
7 Speed Output 23 Adjustment Switch Input
8 - 24 Adjustment Switch Input
Engine Oil Pressure Indication
9 25 Adjustment Switch Ground
Signal
10 - 26 Brake Fluid Level Sensor
11 Battery Power Supply 27 -
12 Illumination Input 28 - 36
13 Ignition Switch Power Supply 29 CAN-L
14 - 30 CAN-H
15 - 31 BCM
Charging System Indication
16 32 -
Signal

DIAGNOSIS & TESTING

HINT:

Fuse 49-28
Entire instrument cluster does not operate Wire harness or connector -
LCD display abnormal
Vehicle speed sensor -
Speedometer display abnormal Wire harness or connector -
36 Instrument cluster 36-34

Engine speed sensor -
Wire harness and connector -
Tachometer display abnormal
Engine Control Module (ECM) 06-209
Fuel level sensor 36-20
Fuel gauge display abnormal Wire harness or connector -
Position light switch (combination switch) 33-61
Position indicator abnormal Wire harness or connector -
Turn light switch (combination switch) 33-61
Turn signal indicator abnormal Wire harness or connector -
High beam switch (combination switch) 33-61
High beam indicator abnormal Wire harness or connector -
Front fog switch (combination switch) 33-61
Front fog indicator abnormal Wire harness or connector -
Rear fog switch (combination switch) 33-61
Rear fog indicator abnormal Wire harness or connector -


Generator 16-9
Charging system warning light abnormal Wire harness or connector -
Engine oil level -
Low engine oil pressure warning light Oil pressure switch 13-15
abnormal Wire harness or connector -
Communication line or connector -
ABS warning light abnormal Instrument cluster 36-34
ABS control unit assembly 24-58
Fuel amount in tank -
Fuel level sensor 36-20
Low fuel level warning light abnormal
Instrument cluster 36-34 36
High engine coolant temperature -
Coolant temperature sensor -
Coolant temperature warning light
abnormal
Engine malfunction warning light abnormal Instrument cluster 36-34
SRS warning light abnormal Instrument cluster 36-34
SRS control unit assembly 30-49
Driver seat belt buckle switch 31-11
Driver seat belt reminder light abnormal Wire harness or connector -
Low brake fluid level -
Low brake fluid level warning light Brake system -

abnormal Wire harness or connector -
Parking brake switch assembly -
Parking brake warning light abnormal Wire harness or connector -

Diagnosis Tools
communication with the vehicle.
 DLC is Located on the instrument panel crossmember.
 DLC uses trapezium design and can accommodate up to 16 terminals.
Digital Multimeter
 Troubleshoot the electrical problems and wiring systems.
 Look for the basic fault.

36 it communicate with the vehicle electronic module by the data network.
 Using the X-431 3G diagnostic tester to record and clear the DTCs stored in Body Control Module (BCM).
 Turn the ignition switch to ON and select "Read Trouble Code "
1.
 If the DTC is not detected, the malfunction indicated by the DTC is intermittent. Please refer to the
"Intermittent DTC Troubleshooting".

circuit.
 Look for the data that has changed or the DTCs to be reset during the wiggle test.
 Inspect the mounting areas of door lock assembly, wire harness or wire harness connector and so on for
damage, foreign matter, etc. that will cause incorrect signals.
 Check and clean all the wire harness connectors and grounding parts related to the current DTC.
 Remove the instrument cluster from the malfunctioning vehicle and install it to a new vehicle and perform a
test. If the DTC cannot be cleared, the instrument cluster is malfunctioning. If the DTC can be cleared,
reinstall the instrument cluster to the original vehicle.
 If multiple trouble codes were set, use the circuit diagrams and look for any common ground circuit or

Ground Inspection
Ground points are very important to the entire circuit system, and the grounding condition can seriously affect
the entire circuit system. Ground points are often exposed to moisture, dirt and other corrosive environments.
Corrosion (rust) and oxidation can increase load resistance. This situation will seriously affect the normal
operation of the circuit. The operations to check the ground points are as follows:
4. Reinstall the ground bolt securely.
6. If several wire harnesses are crimped into one ground eyelet terminal, check if they are installed correctly.
Make sure all the wire harnesses are clean, securely fastened and providing a good ground path.
Diagnosis Procedure
NEXT
36
NEXT
NEXT
DTC
For current DTC, go to step 6
occurs
No
5 If no DTC occurs, go to step 8
NEXT

NEXT
NEXT
NEXT
9 Conduct test and confirm malfunction has repaired
36
NEXT
10 End

DTC DTC Definition
B1100-16 Power Supply Under Volt
B1100-17 Power Supply Over Volt
B1101-11 Fuel Sensor Connected to Ground
B1101-15 Fuel Sensor Fault-Circuit Short to Battery or Open
B1103-00 LED Air Bag Fault
B1104-41 EEPROM Checksum Error
U0073-88 CAN Bus OFF
U0100-87 Lost Communication With EMS
U0101-87 Lost Communication With TCM
U0129-87 Lost Communication With BSM
U0140-87 Lost Communication With BCM
U1130-55 Software Configuration Error

DTC B1100-16 Power Supply Under Volt
DTC B1100-17 Power Supply Over Volt
IGNITION SWITCH
BATTERY
ON OR START
INSTRUMENT ENGINE
PANEL FUSE COMPARTMENT
RF01 EF33
AND RELAY FUSE AND
I-005 B-014
1 A11
R
B-050
RW
30 I-003
36
R
13 11
INSTRUMENT
CLUSTER
3
B
I-026
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 A1 A2 A3 A4 A5 A6
A10 A11 A12 A13
A7 A8 A9 A14 A15 A16
25 26
87
85 86 86 86
87 30 87 30 B-014
30 85 85
W
I-005
B
42 41 40 39 38 37 36 35 34 33 32 31 30 29
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-050 I-043
W L
EA19360050

DTC Detection
DTC DTC Definition Possible Cause
Condition
Power Supply Under
B1100-16  Charging system
Volt
Power Supply Over
B1100-17  Instrument cluster
Volt
CAUTION
Diagnosis Procedure
1 Check battery
36
a. Using a digital multimeter, measure the voltage between the positive battery terminal and negative battery
terminal.
b. The battery voltage should be between 11 and 14 V.
NG Recharge or replace battery
OK
2 Check instrument cluster wire harness and connector

c. Disconnect the instrument cluster wire harness connector
I-043. V
+ -
d. Connect the negative battery cable.
f. Using a digital multimeter, measure the supply voltage
between the instrument cluster wire harness connector 
I-043 and the body ground according to the value(s) in 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
the table below to check if the system power source 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
control circuit is normal.

I-043
Standard Voltage
Condition
I-043 (11) - Body RA19360100
Ignition switch ON 11 to 14V
ground
I-043 (13) - Body
Ignition switch ON 11 to 14V
ground

g. Turn the ignition switch to LOCK.

h. Disconnect the negative battery cable.
i. Disconnect the instrument cluster wire harness connectors
I-003 and I-043.
+ -
instrument cluster wire harness connectors I-003 and 
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition
I-043
I-003 (30) -
Always Continuity
I-043 (11) 29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003
RA19360110
k. Disconnect the instrument cluster wire harness connectors

I-005 and I-043.
l. Using a digital multimeter, check for continuity between 36
I-043 according to the table below. + -
Condition 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-005 (1) -
I-043 (13)
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26
87
85 86 86 86
87 30 87 30
30 85 85
I-005
RA19360131
m. Disconnect the instrument cluster wire harness connector

I-043 and ground I-026.
instrument cluster wire harness connector I-043 and
ground I-026 according to the table below. + -
Condition
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-043 (3) -
I-026
I-043
NG Repair or replace instrument cluster wire

I-026
RA19360120

OK

B-050.
+ -
body wire harness connectors B-014 and B-050
A1 A2 A3 A4 A5 A6
A10 A11 A12 A13
Multimeter Specified A7 A8 A9 A14 A15 A16
Condition
B-014 (A11) -
Always Continuity
B-050 (30) 42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 connector B-050
RA19360130
OK
4 Reconfirm DTCs
a. Connect all the connectors.

instrument cluster control system.
g. Use the X-431 3G diagnostic tester (the latest software) to record the DTCs in the instrument cluster
control system again.
h. Read the DTCs.
Result Proceed to
DTC B1100-16 and B1100-17 are output NG
No DTC output OK
NG Replace instrument cluster
OK
System is normal

DTC B1101-11 Fuel Sensor Connected to Ground
DTC B1101-15 Fuel Sensor Fault-Circuit Short to Battery or Open
FUEL
GAUGE INSTRUMENT
CLUSTER
I-043
lOW FUEL
LEVEL
5 22 21
VB
B
I-003 I-004
10 32 20
B-050 B-053
36
YB
B
2 4 3
FUEL LEVEL
SENSOR AND
FUEL PUMP
B-027
1
B
B-035
42 41 40 39 38 37 36 35 34 33 32 31 30 29
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
28 27 26 25 24 23 22 21 20 19 18 17 16 15
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
14 13 12 11 10 9 8 7 6 5 4 3 2 1
I-043
L
B-053
L
42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
1 2 3 4 5
14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-027
B-050 B
W
EA19360070

DTC Detection
Condition
Fuel Sensor
B1101-11
Connected to Ground  Fuel level sensor
Fuel Sensor  Ignition switch ON  Wire harness or connector
B1101-15 Fault-Circuit Short to  Instrument cluster
Battery or Open
CAUTION
Diagnosis Procedure
36 1 Check fuel level sensor wire harness and connector

c. Disconnect the fuel level sensor and fuel pump assembly
connector B-027.
d. Check the wire harness, connector and terminals for
deformation, bend or damage.
NG Repair or replace fuel level sensor wire

RA19360290
OK

2 Check fuel level sensor
a. Connect the negative battery cable.

c. Check the remaining oil amount segments from fuel + -
gauge in the instrument cluster .
d. Turn the ignition switch to LOCK.
5 4 3 2 1
e. Disconnect the negative battery cable.
f. Disconnect the fuel level sensor and fuel pump assembly
connector B-027.
g. Using a digital multimeter, measure the resistance value RA19360280
between terminal 2 and terminal 3 of fuel level sensor.
h. Check if the fuel level sensor is normal according to the
correspondence between the oil amount segments and
the standard resistance of fuel level sensor shown in the
table below.
Pointer Fuel Level

Fuel Gauge
Indicating Sensor
Position
Angle (°) Resistance (Ω) 36
E (alarm) 0 (normal on) 275 ± 5
1/4 22.5 165 ± 5
1/2 45 97 ± 4
3/4 67.5 79 ± 3
F 90 32 ± 3

c. Disconnect the instrument cluster wire harness connectors
I-043 and I-004.
+ -
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition
I-043
I-043 (5) -
Always Continuity
I-004 (10) 29 30 31 32 33 34 35 36 37 38 39 40 41 42
I-043 (22) - 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Always Continuity
I-004 (32) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-043 (21) -
I-004 (20) RA19360140
NG Repair or replace instrument cluster wire


OK

B-027.
+ -
body wire harness connectors B-053 and B-027
1 2 3 4 5
Condition
B-053 (10) -
Always Continuity
B-027 (2) 42 41 40 39 38 37 36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21 20 19 18 17 16 15
B-053 (32) -
B-027 (4)
36 B-053 (20) - B-053
Always Continuity
B-027 (3) RA19360150
e. Disconnect the body wire harness connector B-027 and

ground B-035.
body wire harness connector B-027 and ground B-035
Condition
B-027 (1) - B-035 Always Continuity 1 2 3 4 5
B-027

connector
B-035
RA19360160
OK
5 Reconfirm DTCs


system again.
h. Read the DTCs.
Result Proceed to
DTC B1101-11 and B1101-15 are output NG
No DTC output OK
OK
System is normal
36

DTC B1103-00 LED Air Bag Fault
IGNITION SWITCH
ON OR START
INSTRUMENT
PANEL FUSE
RF01
AND RELAY
10A BOX
1 I-005
RW
13
INSTRUMENT
36 SRS
CLUSTER
I-043
17
GrL
17
SRS
CONTROL
MODULE
I-023
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
I-043
25 26 L
87
85 86 86 86
87 30 87 30
30 85 85
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-005
B
I-023
G
EA19360060

DTC Detection
Condition
 Airbag system
B1103-00 LED Air Bag Fault Ignition switch ON  Wire harness or connector
 Instrument cluster
CAUTION
Diagnosis Procedure
1 Check driver airbag
a. Check the driver airbag (See page 30-41). 36

NG Repair or replace driver airbag
OK

I-043 and I-023.
+ -
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Condition 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-043
I-043 (17) -
Always Continuity
I-023 (17)
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
I-023
RA19360170

e. Disconnect the instrument cluster wire harness connectors

I-005 and I-043.
Condition 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-005 (1) -
I-043 (13)
1 2 3 4 5 6 7 8 9 10 11 12
NG Repair or replace instrument cluster wire 13 14 15 16 17 18 19 20 21 22 23 24
harness and connector 87

25 26
85 86 86 86
87 30 87 30
30 85 85
I-005
RA19360131
OK
36 3 Reconfirm DTCs

g. Use the X-431 3G diagnostic tester (the latest software) to reocrd the DTCs in the instrument cluster
h. Read the DTCs.
Result Proceed to
DTC B1103-00 is output NG
No DTC output OK
OK
System is normal

DTC B1104-41 EEPROM Checksum Error
DTC Detection
Condition
EEPROM Checksum
B1104-41 Ignition switch ON  Instrument cluster
Error
CAUTION
Diagnosis Procedure
1 Reconfirm DTCs 36
a. Use the X-431 3G diagnostic tester (the latest software) to clear the DTCs stored in the instrument cluster
control system.
b. Turn the ignition switch to LOCK and wait for a few seconds.
d. Use the X-431 3G diagnostic tester (the latest software) to record the DTCs in the instrument cluster
e. Read the DTCs.
Result Proceed to
DTC B1104-41 is output NG
No DTC output OK
OK
System is normal

DTC U0073-88 CAN Bus OFF
DTC U0100-87 Lost Communication With EMS
DTC U0101-87 Lost Communication With TCM
DTC U0129-87 Lost Communication With BSM
DTC U0140-87 Lost Communication With BCM
36

INSTRUMENT
CLUSTER
I-043
31 29 30
Gr
Y
B2
BCM
I-006 TO CAN
SYSTEM
B16 B1
36
24 21 17 1
ECM
B-001
ABS
B-007
14 15 16 17 18 19 20 21 22 23 24 25 26
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 1 2 3 4 5 6 7 8 9 10 11 12 13
I-043 B-007
L B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
I-006
L
B-001
B
EA19360080

DTC Detection
Condition
U0073-88 CAN Bus OFF
Lost Communication
U0100-87
With EMS
 Engine Control Module (ECM)
Lost Communication  Body Control Module (BCM)
U0101-87
With TCM Ignition switch ON
 Control module assembly (ABS )
Lost Communication  CAN line communication
U0129-87
With BSM
Lost Communication
U0140-87
With BCM
CAUTION
36 and the component information.
Diagnosis Procedure
1 Check connector and terminal

c. Disconnect the Engine Control Module (ECM) connector
(arrow).
d. Check the wire harness, connector and terminals for
RA19360300
e. Disconnect the Body Control Module (BCM) connector

(arrow).
f. Check the wire harness, connector and terminals for
RA19360260

g. Disconnect the control module assembly (ABS)

connector (arrow).
h. Check the wire harness, connector and terminals for
NG Repair or replace connector and terminal
RA19360270
OK

I-043 and B-001.
36
+ -
B-001 according to the table below. 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Condition I-043
I-043 (29) -
B-001 (17) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-043 (30) - 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33
B-001 (1)
B-001 RA19360212
e. Disconnect the instrument cluster wire harness connectors

I-043 and I-006.
Condition
I-043 (29) - 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Always Continuity
I-006 (B1) 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
I-043 (30) -
I-006 (B16)
I-006
RA19360210

g. Disconnect the instrument cluster wire harness connectors

I-043 and B-007.
B-007 according to the table below. + -
Condition
I-043 (29) - 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Always Continuity
B-007 (21)
I-043
I-043 (30) -
Always Continuity
B-007 (24) 14 15 16 17 18 19 20 21 22 23 24 25 26
1 2 3 4 5 6 7 8 9 10 11 12 13
NG Repair or replace wire harness and

connector B-007
RA19360211
OK
36 3 Reconfirm DTCs

h. Read the DTCs.
Result Proceed to
DTC U0073-88, U0100-87, U0101-87, U0129-87
NG
and U0140-87 are output
No DTC output OK
OK
System is normal

DTC U1130-55 Software Configuration Error
DTC Detection
Condition
Software Configuration
U1130-55 Ignition switch ON  Instrument cluster
Error
CAUTION
Diagnosis Procedure
1 Reconfirm DTCs 36
a. Use the X-431 3G diagnostic tester (the latest software) to clear the DTCs stored in the instrument cluster
control system.
b. Turn the ignition switch to LOCK and wait for a few seconds.
d. Use the X-431 3G diagnostic tester (the latest software) to record the DTCs in the instrument cluster
e. Read the DTCs.
Result Proceed to
DTC U1130-55 is output NG
No DTC output OK
OK
System is normal

ON-VEHICLE SERVICE
Instrument Cluster
Removal
CAUTION
 Be sure to wear the safety equipment to prevent accidents when removing the instrument cluster.
 Try to prevent the instrument panel assembly from being scratched when removing the instrument
cluster.
 Operate gently and carefully to prevent damage to the component during removal.

3. Remove the instrument cluster cover assembly.
36 the clips on the instrument cluster cover assembly.
RA19360020
b. Remove the instrument cluster cover assembly.

4. Remove the instrument cluster lower garnish assembly.
the clips on the instrument cluster lower garnish
assembly.
RA19360030
b. Remove the instrument cluster lower garnish assembly.

5. Remove the instrument cluster.

a. Remove 4 fixing screws (arrow) from the instrument

cluster.
RA19360040
b. Disconnect the instrument cluster wire harness connector

(arrow) and remove the instrument cluster.
RA19360050 36
Installation
CAUTION
 When installing the instrument cluster, be sure to align the instrument cluster positioning hole with the
instrument panel assembly dowel pin, and install it in place.
 When installing the instrument cluster, be sure to tighten the fixing screws in place.
 When installing the instrument cluster, be sure to install the connector in place.
 After installing the instrument cluster, check if the instrument cluster operates normally.

Instrument Cluster Adjustment Button

Removal
CAUTION
 Be sure to wear the safety equipment to prevent accidents when removing the instrument cluster
adjustment button.
 Try to prevent the instrument panel assembly from being scratched when removing the instrument
cluster adjustment button.

3. Remove the instrument cluster adjustment button.
the clips (arrow) on the instrument cluster adjustment
button.
36
MUTE
+ VOL
-
SEEK
MODE
RA19360060
b. Disconnect the instrument cluster adjustment button

connector (arrow) and remove the instrument cluster
adjustment button.
MUTE
+ VOL
-
SEEK
MODE
RA19360070
Installation
CAUTION
 When installing the instrument cluster adjustment button, be sure to install the connector in place.
 When installing the instrument cluster adjustment button, be careful not to damage other components.
 After installing the instrument cluster adjustment button, check if the instrument cluster adjustment button
operate normally.

AUDIO SYSTEM
GENERAL INFORMATION 37-3 Front Speaker 37-15
Operation 37-4 Inspection 37-15
Tool 37-5 Rear Speaker 37-17
Audio System Control Module  Inspection 37-18
Terminal List 37-8 Installation 37-18
Antenna Assembly 
(w/ Antenna Amplifier) 37-19
Removal 37-19
Single Disc CD Player + USB  Installation 37-20
Assembly 37-11 AUX/USB Interface 37-21
Installation 37-12 Steering Wheel Quick Button 
Electrical Modulation Radio  (if equipped) 37-23
37
Receiver + USB Assembly 37-13 Removal 37-23
Installation 37-14

37

37 - AUDIO SYSTEM
GENERAL INFORMATION
AUDIO SYSTEM
Description
1
2
MUTE
+ VOL
-
SEEK
MODE
37
4
6
5
RA19370010

37 - AUDIO SYSTEM
1 - Steering Wheel Quick Button (if equipped) 2 - Single Disc CD Player/Electrical Modulation
Radio Receiver + USB Assembly
3 - Antenna Assembly (w/ Antenna Amplifier) 4 - Rear Right Speaker
5 - Front Right Speaker 6 - Rear Left Speaker
7 - Front Left Speaker
The audio system mainly indicates radio receiver assembly. The primary function of the radio receiver
assembly is to receive the frequency modulation and amplitude modulation broadcast signals sent from the
broadcast station, and convert the broadcast signal into audio signal.
The radio receiver assembly consists of amplitude modulation tuner (AM) that receives amplitude modulation
broadcast signal and frequency modulation tuner (FM) that receives frequency modulation broadcast signal.
This model uses two types of radio receiver assemblies: single disc CD player + USB assembly and electrical
modulation radio receiver + USB assembly. The single disc CD player + USB assembly provides with radio
receiver function and single disc CD playing function.
4-speaker is equipped for this model. The 4-speaker consists of 2 front speakers and 2 rear speakers.
Operation
Essentially, the radio receiver is a tuner. The radio receiver demodulates the radio frequency signal received
from the antenna, and outputs the low power audio signal, which is amplified by the inner amplifier circuit and
37 converted into original sound.
Specifications

Single Disc CD Player + USB Fixing Screw 8±1
Electrical Modulation Radio Receiver + USB Fixing
8±1
Screw
Front Speaker Fixing Screw 1.5 ± 0.5
Rear Speaker Fixing Screw 1.5 ± 0.5
Antenna Assembly Fixing Nut 5±1
Steering Wheel Quick Button Cover Fixing Screw 1.5 ± 0.5
Steering Wheel Quick Button Fixing Screw 1 ± 0.5

37 - AUDIO SYSTEM
Tool
General Tool
Digital Multimeter
RCH0000002
37

37 - AUDIO SYSTEM
Circuit Diagram
Audio System (Page 1 of 2)
BATTERY IGNITION SWITCH

ON OR ACC
ENGINE INSTRUMENT
COMPARTMENT PANEL FUSE
EF33 RF16 AND RELAY
FUSE AND
15A RELAY BOX 10A BOX
B-014 I-005
A11 16
R
ANTENNA INSTRUMENT
37 30 B-050
AMPLIFIER CLUSTER
B-047 I-043
RY
I-003 ILLUMINATION
7
VL
11 B-050
YL
P
R
I-003
VL
16 15 11 12 14
AUDIO
I-037
1 2 3 4 5 6 7 8 9 10 11 12 42 41 40 39 38 37 36 35 34 33 32 31 30 29
13 14 15 16 17 18 19 20 21 22 23 24 28 27 26 25 24 23 22 21 20 19 18 17 16 15
8 7 6 5 4 3 2 1
25 26 14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9
87
85 86 86 86
87 30 87 30 I-037
30 85 85 B-050 B
W
I-005
B
A1 A2 A3 A4 A5 A6 1
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A10 A11 A12 A13
A7 A8 A9 A14 A15 A16
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 I-043
B-047
L
B-014 W
W
EA19370010

37 - AUDIO SYSTEM
Audio System (Page 2 of 2)
AUDIO
I-037
10 13 1 2 3 5 4 6 7 8 9
GrW
GW
BrB
YG
Br
W
V
LB
I-010 4 13 I-030 7 7 I-029 I-003

37
13 14 27 28
F-007 H-003 H-004 B-050
1 2
STEERING
GrW
BrW
GW
BrB
WHEEL
YG
W
SWITCH 2
I-040 3 4
1 2 1 2 1 2 1 2
P

ILLUMINATION I-026 I-026 LOW SPEAKER LOW SPEAKER LOW SPEAKER LOW SPEAKER
F-005 H-005 B-040 B-044
4 3 2 1
8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 1 1
16 15 14 13 12 11 10 9 14 13 12 11 10 9 8 10 9 8 7 6 5 2 2
16 15 14 13 12 11 10 9
F-005 H-005
I-037 I-010 I-029 I-030 B B
B W W W
1 1
29 30 31 32 33 34 35 36 37 38 39 40 41 42 2 2
15 16 17 18 19 20 21 22 23 24 25 26 27 28
4 3 2 1 I-040 I-003 B-040 B-044
W 1 2 3 4 5 6 7 8 9 10 11 12 13 14 W B B
EA19370020

37 - AUDIO SYSTEM
Audio System Control Module Terminal List

Terminal No. Terminal Name Terminal Definition
1 GND Power Ground
2 FL+ Front Left Speaker Audio Signal+
3 FL- Front Left Speaker Audio Signal-
4 FR+ Front Right Speaker Audio Signal+
5 FR- Front Right Speaker Audio Signal-
6 RL+ Rear Left Speaker Audio Signal+
7 RL- Rear Left Speaker Audio Signal-
8 RR+ Rear Right Speaker Audio Signal+
9 RR- Rear Right Speaker Audio Signal-
Steering Wheel Quick
10 Steering Wheel Quick Button Operation Power
Button Power
11 AMP Antenna Operation Power
12 Speed Signal Vehicle Speed Signal
Steering Wheel Quick
37 13
Button Signal
Steering Wheel Quick Button Signal
14 Backlight Signal Backlight Adjustment Signal

15 ACC Ignition Switch Power Supply
16 Power Supply Battery Power Supply

37 - AUDIO SYSTEM
DIAGNOSIS & TESTING

HINT:
Use the table below to help determine the cause of the problem. Check each suspected area in sequence.
Repair or replace the faulty components, or adjust them as necessary.

Noise source (interference) -
Speaker (loose installation) 37-15
Noise Single disc CD player + USB assembly

37-11
(malfunction)
Electrical modulation radio receiver + USB
37-13
assembly (malfunction)
Fuse (blown) 49-28
Single disc CD player/Electrical modulation
radio receiver + USB operation panel -
(malfunction)
radio receiver + USB assembly does not Single disc CD player + USB assembly 37
37-11
operate (malfunction)
37-13
Wire harness and connector (malfunction) -
Fuse (blown) 49-28
Speaker (malfunction) 37-15
Single disc CD player + USB assembly
-
(malfunction)
Speaker does not sound Electrical modulation radio receiver + USB

37-11
radio receiver + USB assembly 37-13
(malfunction)
Wire harness and connector (malfunction) -

37 - AUDIO SYSTEM

37-11
(malfunction)
37-13
Optional equipment (interference) -
Radio broadcast signal cannot be received 37-11
(malfunction)
(poor reception)
37-13
Antenna assembly (w/ antenna amplifier)
37-19
(malfunction)
Antenna wire harness and connector
-
(malfunction)
CD (malfunction) -
Single disc CD player + USB operation
-
CD cannot be ejected panel (malfunction)
37-11
37 (malfunction)
CD (dirty) -
CD insertion direction (incorrect) -
CD cannot be inserted or CD is ejected
right after insertion CD (malfunction) -
37-11
(malfunction)
CD (malfunction) -
Sound quality is bad only when CD is
played (volume is too low) Single disc CD player + USB assembly
37-11
(malfunction)
HINT:
When checking the general malfunctions of audio system, perform inspection at spacious area nearby free of
obstacles.

37 - AUDIO SYSTEM
ON-VEHICLE SERVICE
Single Disc CD Player + USB Assembly
Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the single disc CD player +
USB assembly.
 Appropriate force should be applied when removing the single disc CD player + USB assembly, and
avoid operating roughly.
 Try to prevent the interior from being scratched when removing the single disc CD player + USB
assembly.

3. Remove the center control panel assembly.
the fixing clips on the center control panel assembly. 37
4 RDM
3 1 RPT
5 DN
2 UP
6
3
disc
mp3 TUNE
VOL
MUTE
USB CD BAND AST

SET
AUX
SEL
0 1
3
A/C
4
CARD CARD
RA19410510
b. Disconnect the hazard warning light switch connector

(arrow) and remove the center control panel
assembly.
RA19410520
4. Remove the single disc CD player + USB assembly.
CAUTION
 Handle and operate carefully to prevent the components from being scratched or damaged when
removing the single disc CD player + USB assembly.

37 - AUDIO SYSTEM
a. Remove 4 fixing screws (arrow) from the single disc

CD player + USB assembly. 
RA19370020
b. Disconnect the connectors (arrow) and antenna (1)

from the single disc CD player + USB assembly, and
remove the single disc CD player + USB assembly.
RA19370026
37
Inspection
1. Check the single disc CD player + USB assembly connectors and terminals for deformation or damage.
Replace them if necessary.
2. Check the antenna and connectors for damage. Replace them if necessary.
3. Check the single disc CD player + USB assembly house for deformation or damage. Replace it if
necessary.
Installation
CAUTION
 Operate carefully to avoid damaging other components when installing the single disc CD player + USB
assembly.
 Be sure to tighten the fixing screws to the specified torque when installing the single disc CD player +
USB assembly.
 Install each connector in place when installing the single disc CD player + USB assembly.
 Check if the single disc CD player + USB assembly operates normally after installation.

37 - AUDIO SYSTEM
Electrical Modulation Radio Receiver + USB Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the electrical modulation radio
receiver + USB assembly.
 Appropriate force should be applied when removing the electrical modulation radio receiver + USB
assembly, and avoid operating roughly.
 Try to prevent the interior from being scratched when removing the electrical modulation radio receiver +
USB assembly.

the fixing clips on the center control panel assembly.
VOL
1 RPT
2 UP
mp3
disc
4 RDM
5 DN
TUNE
37
MUTE
USB CD BAND AST

SET
AUX
SEL
0 1
3
A/C
4
CARD CARD
RA19410510

(arrow) and remove the center control panel
assembly.
RA19410520
4. Remove the electrical modulation radio receiver + USB assembly.
CAUTION
 Handle and operate carefully to prevent the components from being scratched or damaged when
removing the electrical modulation radio receiver + USB assembly.

37 - AUDIO SYSTEM
a. Remove 4 fixing screws (arrow) from the electrical

modulation radio receiver + USB assembly. 
RA19370020

from the electrical modulation radio receiver + USB
assembly, and remove the electrical modulation radio
RA19370026
37
Inspection
1. Check the electrical modulation radio receiver + USB assembly connectors and terminals for deformation
or damage. Replace them if necessary.
2. Check the antenna and connectors for damage. Replace them if necessary.
3. Check the electrical modulation radio receiver + USB assembly house for deformation or damage.
Replace it if necessary.
Installation
CAUTION
 Operate carefully to avoid damaging other components when installing the electrical modulation radio
 Be sure to tighten the fixing screws to the specified torque when installing the electrical modulation radio
 Install each connector in place when installing the electrical modulation radio receiver + USB assembly.
 Check if the electrical modulation radio receiver + USB operates normally after installation.

37 - AUDIO SYSTEM
Front Speaker
Removal
HINT:
4. Remove the front left speaker.
CAUTION
 Never touch the cone paper and other components of front left speaker during removal; otherwise, it will
affect the sound effect or damage the front left speaker.
a. Disconnect the front left speaker connector (1).

b. Remove 3 fixing screws (arrow) from the front left
speaker.
37
1
RA19450342
c. Remove the front left speaker.
Inspection
1. Check the front speaker assembly.
a. Using a digital multimeter, measure the resistance of
front speaker according to the table below.
+ -
Standard Resistance
1
Multimeter Specified 2
Condition
Terminal 1 - Approximately
Always
Terminal 2 4Ω
If the result is not as specified, replace the front RA19370030

speaker assembly.
2. Check the front speaker cone paper for damage or deformation. Replace it if necessary.
3. Check the front speaker connector for damage and the terminals for bend or poor connection. Replace it if
necessary.

37 - AUDIO SYSTEM
Installation
CAUTION
 Operate carefully to avoid damaging other components when installing the front speaker.
 Be sure to tighten the fixing screws to the specified torque when installing the front speaker.
 Install the connector in place when installing the front speaker.
 Check if the front speaker operates normally after installation.
37

37 - AUDIO SYSTEM
Rear Speaker
Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear speaker.
 Appropriate force should be applied when removing the rear speaker, and avoid operating roughly.
 Never touch the cone paper and other components of the rear speaker during removal; otherwise, it will
affect the sound effect or damage the rear speaker.

4. Remove the rear left speaker.
a. Disconnect the rear left speaker connector (arrow).
37
RA19370040
b. Remove 4 fixing screws (arrow) from the rear left

speaker.
RA19370050
c. Remove the rear left speaker.

37 - AUDIO SYSTEM
Inspection
1. Check the rear speaker assembly.
rear speaker according to the table below.
+ -
Standard Resistance
1
Multimeter Specified 2
Condition
Always
Terminal 2 5.6 Ω
If the result is not as specified, replace the rear RA19370060

speaker assembly.
2. Check the rear speaker cone paper for damage or deformation. Replace it if necessary.
3. Check the rear speaker connector for damage and the terminals for bend or poor connection. Replace it if
necessary.
Installation
CAUTION
37  Operate carefully to avoid damaging other components when installing the rear speaker.
 Be sure to tighten the fixing screws to the specified torque when installing the rear speaker.
 Install the connector in place when installing the rear speaker.
 Check if the rear speaker operates normally after installation.

37 - AUDIO SYSTEM
Antenna Assembly (w/ Antenna Amplifier)

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the antenna assembly.
 Appropriate force should be applied when removing the antenna assembly, and avoid operating roughly.

3. Remove the roof assembly (See page 47-28).
CAUTION
 It is not necessary to completely remove the roof assembly when removing it, but it is necessary to lower
the rear of roof assembly so that the radio antenna assembly can be removed.
4. Remove the antenna assembly (w/ antenna amplifier).

a. Disconnect the antenna (1) and connectors (arrow) 37
from the antenna assembly.
RA19370070
b. Remove the fixing nut (arrow) from the antenna

assembly.
RA19370081

37 - AUDIO SYSTEM
c. Detach the attachment parts (arrow) between antenna

assembly and body.
RA19370080
d. Remove the antenna assembly from the roof.
RA19370090
37 Inspection
1. Check the antenna assembly.
a. Check the antenna assembly for wear, cracks, deformation or damage. Replace it if necessary.
b. Check the antenna assembly for looseness or disengagement. Replace it if necessary.
c. Check the terminals on antenna connector for deformation or bent. Replace it if necessary.
Installation
HINT:
When installing the antenna assembly, align the boss at the
end of antenna assembly and the groove on the fixing nut,
and then firmly install the antenna assembly as shown in the
illustration.
RA19370100
CAUTION
 Operate carefully to avoid damaging other components when installing the antenna assembly.
 Always insert the dowel pin into the body positioning hole and set it in place when installing the antenna
assembly.
 Be sure to tighten the fixing nuts to the specified torque when installing the antenna assembly.
 Install each connector and antenna in place when installing the antenna assembly.
 Check if the audio system operates normally after installing the antenna assembly.

37 - AUDIO SYSTEM
AUX/USB Interface
Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the AUX/USB interface.
 Appropriate force should be applied when removing the AUX/USB interface, and avoid operating
roughly.

3. Loosen the shift lever boot assembly.
the clips on shift lever boot assembly, and loosen the
shift lever boot assembly.
37
RA19370150
4. Remove the AUX/USB interface.

a. Disconnect the AUX/USB interface connector (arrow).
X
AU
RA19370170
b. Press and hold the clip on AUX/USB interface in the

direction of arrow as shown in the illustration and
remove the AUX/USB interface.
X
AU
RA19370160

37 - AUDIO SYSTEM
Installation
CAUTION
 Operate carefully to avoid damaging other components when installing the AUX/USB interface.
 Install the connector in place when installing the AUX/USB interface.
37

37 - AUDIO SYSTEM
Steering Wheel Quick Button (if equipped)

Removal
WARNING
 Be sure to read the precautions for SRS airbag before removing the steering wheel quick button (See
page 30-3).
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the steering wheel quick
button.
 Operate carefully to avoid damage to the clip on steering wheel quick button when removing the steering
wheel quick button.

3. Remove the driver airbag (See page 30-41). 37
4. Remove the steering wheel quick button cover.
a. Disconnect the steering wheel quick button connector
(arrow).
E
MUT
E
MUT
-
OFF OFF + VOL
O
<
BEEK
<
4
3
2
RA19370110
b. Remove 4 fixing screws (arrow) from the steering

wheel quick button cover.
E
MUT
E
MUT
-
OFF OFF + VOL
O
<
BEEK
<
4
3
2
RA19370120

37 - AUDIO SYSTEM
c. Using a screwdriver wrapped with protective tape, pry

the clip on steering wheel quick button cover, and
remove the steering wheel quick button cover.
E
MUT
E
MUT
-
OFF OFF + VOL
O
<
BEEK
<
4
3
2
RA19370140
5. Remove the steering wheel quick button.

a. Disconnect the steering wheel quick button
connectors (1).
b. Remove 2 fixing screws (arrow) from the steering
1 1
wheel quick button, and remove the steering wheel
quick button.
37 RA19370130
Inspection
1. Check the steering wheel quick button.
steering wheel quick button according to the table
+ -
below.
1234
Standard Resistance

Connection Condition Condition SEEK
- VOL +
MUTE
Terminal 2 0.1 kΩ
MODE
RA19370180
SEEK 
Terminal 2 0.4 kΩ
SEEK 
Terminal 2 0.79 kΩ
VOL-
VOL+
MODE
If the result is not as specified, replace the steering

wheel quick button.
2. Check the steering wheel quick button for damage. Replace it if necessary.
3. Check the steering wheel quick button connector for damage or poor terminal connection. Replace it if
necessary.

37 - AUDIO SYSTEM
4. Check for continuity of the wire harness between steering wheel quick button connector and audio unit
(radio receiver assembly). Replace it if necessary.
Installation
CAUTION
 Operate carefully to avoid damaging other components when installing the steering wheel quick button.
 Install each connector in place when installing the steering wheel quick button.
 Tighten the fixing screws to the specified torque when installing the steering wheel quick button.
37

- MEMO -

GENERAL INFORMATION 38-3 DIAGNOSIS & TESTING 38-8
Description 38-3 Problem Symptoms Table 38-8
Operation 38-3 Self-checking Function 38-8
Reversing Radar Normal Alarm 
Display 38-4
Reversing Radar Sensor 38-9
Specification 38-4
Installation 38-10
Reversing Radar Control Module 
Reversing Radar Control Module 
Assembly 38-11
Assembly Terminal List 38-7
Removal 38-11
Installation 38-11
38

38

38 - REVERSING RADAR SYSTEM
GENERAL INFORMATION
Description
4
3
2 1
38
6
RA19380010
1 - Reversing Radar Control Module Assembly 2 - Center Left Reversing Radar Sensor
3 - Center Right Reversing Radar Sensor 4 - Right Reversing Radar Sensor
5 - Instrument Cluster (Built-in Buzzer) 6 - Left Reversing Radar Sensor
Operation
Reversing radar system, an auxiliary system used when driver is reversing, consists of reversing radar sensor
(probe), reversing radar control module assembly and alarm device (instrument cluster built-in buzzer).
Reversing radar system is activated when the shift lever is shifted to reverse range. When the reversing radar
sensor senses obstacles behind, the instrument cluster built-in buzzer will sound. This can help the driver to
eliminate blind corner and blurred vision, thus improving the driving safety when reversing.

Reversing Radar Normal Alarm Display

Reversing radar system consists of four reversing radar sensors and one reversing radar control module
assembly. It is activated when the shift lever is shifted to R and reversing at the speed below 5 km/h.
The response way of reversing radar system is buzzer response. The table below shows the correspondence
between buzzer response frequency and actual obstacle distance:
Alarm Type 1st Section 2nd Section 3rd Section 4th Section 5th Section
Pre-warning
Displayed Area Safe Area Amble Area Park Area Park Area
Area
Alarm Distance
> 150 95 - 150 65 - 90 40 - 60 ≤ 35
(cm)
Sound 1 Hz 2 Hz 4 Hz
No Sound Continuous
Frequency of (ON 500 ms/ (ON 250 ms/ (ON 125 ms/
(OFF) Sound
Buzzer OFF 500 ms) OFF 250 ms) OFF 125 ms)
Specification

Fixing Bolt Between Reversing Radar Control
7 ± 1.5
Module Assembly and Body
38
Tool
General Tool
Digital Multimeter
RCH0000002

Circuit Diagram
Reversing Radar System (Page 1 of 2)

BATTERY
POWER INSTRUMENT
EF12 FUSE RF03 RF16 PANEL
B
BOX FUSE AND
80A 10A 10A RELAY BOX
B-009
I-005 B-020
3 16 2
E-012
B-016
B
BACK-UP
LIGHT
SWITCH
E-007
RW
RY
LB
R
E-012
7
B-020
38
LB
24 B-050
I-003
LB
F1 B31 B15 A21

BCM
B-048
I-046
I-006
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 1
1 2 3 4 5 6 7 8 9 10 11 12 I-046
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 G
13 14 15 16 17 18 19 20 21 22 23 24 B-009
25 26
87
85 86 86 86
87 30 87 30
30 85 85

I-006 B-048
I-005 B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 1
L Gr
B
42 41 40 39 38 37 36 35 34 33 32 31 30 29
B-050 1 2 3 4 5 6 7 8 1 2 E-007
28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-020
W B
14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 B
EA19380010

Reversing Radar System (Page 2 of 2)
BCM
I-046
I-015
D3 A8 A3
RGr
Y
I-003
B-050 42 19 20
RGr
Y
L
1 5 13
REVERSING
RADAR
SENSOR
B-036
7 15 4 8 14 16
GW
VW
V
Lg
38 B-031
T-005
1 5
B-032
T-002
3 1
GW
VW
Lg
B
1 1 CENTER 1 REAR RIGHT 1 CENTER
REAR LEFT
RIGHT RADAR LEFT
RADAR
RADAR SENSOR RADAR
SENSOR
2 2 SENSOR 2 T-009 2 SENSOR
T-001 T-008 T-003
B
B
B
B
7
B
T-005 B-031
B
B-034
42 41 40 39 38 37 36 35 34 33 32 31 30 29
I-046 28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-050
G W
14 13 12 11 10 9 8 7 6 5 4 3 2 1
D1 D2 D3 D4 D5
I-015 1 2 T-003
D6 D7 D8 D9 D10 D11 D12 W L 1 2 3 4 B-031
1 2 3 4 5 6 7 8 B
5 6 7 8
9 10 11 12 13 14 15 16 1 2
1 2
1 2 T-008 1 2 T-009 T-001 B-032
L L B-036 3 4 B
L
W EA19380020

Reversing Radar Control Module Assembly Terminal List

Pin No. Terminal Definition Pin No. Terminal Definition
1 Power Supply (Reversing Signal) 9 -
2 - 10 -
3 - 11 -
Center Right Reversing Radar
4 12 -
Sensor Signal
Clock Signal (to Body Control Data Signal (to Body Control Module
5 13
Module (BCM)) (BCM))
6 - 14 -
Right Reversing Radar Sensor
7 Left Reversing Radar Sensor Signal 15
Signal
Center Left Reversing Radar Sensor
8 16 Ground
Signal
38

DIAGNOSIS & TESTING

HINT:
Use the table below to help determine the cause of the problem. Check each suspected area in sequence.
Repair or replace the faulty components, or adjust them as necessary.

Back-up light switch 33-78
Reversing radar sensor -
Reversing radar system does not
Reversing radar control module
function (buzzer in instrument 38-11
assembly
cluster does not sound)
Wire harness and connector -
Self-checking Function
Reversing radar system has malfunction self-checking function, and the function instructions are as follows:
If the reversing radar sensor wire harness and connector are damaged or there is a malfunction in the
reversing radar sensor, the instrument cluster will alarm after turning the ignition switch to ON and shifting the
38 shift lever to R.
The specific warnings are as follows:
1. When the system is normal, the buzzer does not sound, and the reversing radar system enters normal
operation mode.
2. When there are malfunctions in one or more sensors, relevant reversing radar sensor malfunction will be
displayed on LCD display, other sensors can also enter normal operation mode.

ON-VEHICLE SERVICE
Reversing Radar Sensor
Removal
HINT:
 Use the same procedures for the right, center left, center right and left reversing radar sensor.
 The procedures listed below are for the left reversing radar sensor.
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the reversing radar
sensor.
 Operate carefully to avoid damaging the reversing radar sensors when removing the reversing radar
sensor.

3. Remove the rear bumper assembly (See page 46-22).
4. Remove the reversing radar sensor.
a. Disconnect the reversing radar sensor wire harness
connector (arrow). 38
b. Remove the reversing radar sensor clip in the
RA19460333

disengage the claws (arrow) on reversing radar
sensor.
RA19460334

d. Remove the reversing radar sensor.

e. Press the clip in the direction of arrow and remove the
reversing radar sensor housing.
RA19460335
Installation
HINT:
When installing the reversing radar sensor, align the boss at
the end of reversing radar sensor and the groove on the rear
bumper assembly, and then firmly install the reversing radar
sensor as shown in the illustration.
RA19380030
38
CAUTION
 Install the connectors in place when installing the reversing radar sensors.
 Check the reversing radar system for proper operation after installing the reversing radar sensors.

Reversing Radar Control Module Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the reversing radar
control module assembly.
 Appropriate force should be applied when removing the reversing radar control module assembly, and
operate carefully.

3. Remove the luggage compartment trim cover assembly (See page 47-33).
4. Remove the reversing radar control module assembly.
a. Disconnect the reversing radar control module
assembly connector (1).
b. Remove 2 fixing bolts (arrow) between reversing
radar control module assembly and body. 1
38
RA19380040
c. Remove the reversing radar control module assembly.
Installation
CAUTION
 Tighten the fixing bolts to the specified torque when installing the reversing radar control module
assembly.
 Install the connector in place when installing the reversing radar control module assembly.
 Check the reversing radar system for proper operation after installing the reversing radar control module
assembly.

- MEMO -

HORN
GENERAL INFORMATION 39-3 Diagnosis Flow 39-7
Description 39-3 Diagnostic Trouble Code (DTC) 
Specification 39-4 Chart 39-8
Tool 39-4 B103D-11 39-9
Circuit Diagram 39-5 B103D-13 39-9
Horn Fuse Inspection 39-14
Problem Symptoms Table 39-6 ON-VEHICLE SERVICE 39-15
Diagnostic Help 39-6 Horn 39-15
Ground Inspection 39-7 Inspection 39-16
Installation 39-16
39

39

39 - HORN
GENERAL INFORMATION
HORN
Description
4
3
39
RA19390010
1 - Horn Switch 2 - Body Control Module (BCM)

3 - High Pitched Horn 4 - Low Pitched Horn
This vehicle is equipped with high pitched and low pitched electronic horn system.
The horn system consists of the following components:
 Horn: the high pitched horn and low pitched horn are installed on the tank upper crossmember.
 Horn switch: the horn switch is installed on the steering wheel.
 Horn fuse: the horn fuse is located in Body Control Module (BCM).

39 - HORN
Specification

Horn Fixing Bolt 7 ± 1.5
Tool
General Tool
Digital Multimeter
RCH0000002
39

39 - HORN
Circuit Diagram

BATTERY
INSTRUMENT
PANEL
EF12 POWER RF03 RF16 FUSE AND
FUSE BOX RELAY BOX
80A B-009 10A 10A
I-005
3 16
RY
RW
R
F1 B31 B15
BCM
F4 F5 I-046 I-007
10A 10A I-006 B-048
B-049
DOUAL RLY
GND
C20 A22 C10 E1
WB
WB
RG
B-008
B
7
E-038
1
39
WB
WB
SPIRAL ANTI-THEFT
1 1 CABLE HORN
HIGH LOW B-002
2
BW
HORN HORN
E-033 E-028 I-012
1
B
2 2
HORN
B
SWITCH
I-019
B
E-036 B-016
1 2 3 4 5 6 7 8 9 10 11 12 1
1 1 2
13 14 15 16 17 18 19 20 21 22 23 24
1 E1
B-009
25 26 I-005 B-048
87 B-002
B Gr I-007
85 86 86 86 I-019 B
85
87 30
85
87 30 Lg B
30
1 2
8 7 6 5 4 3 2 1
E-038 1 2 E-028
C1 C2 C3 C4 C5 C6 C7 C8 C9 9 10 11 12 13 14 15 16
B-049 B Gr E-033
W Gr
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 I-046
B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 G
I-006
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 L
EA19390010

39 - HORN
DIAGNOSIS & TESTING

HINT:

Horn fuse (blown) 49-29
Low pitched horn (damaged) 39-15
Horn does not sound High pitched horn (damaged) 39-15
Spiral cable (damaged) 30-44
Wire harness (short or open) 39-15
Diagnostic Help
1. Connect the X-431 3G diagnostic tester (the latest software) to the Data Link Connector (DLC), and make
2. Confirm that the malfunction is current, and carry out the diagnostic test and repair procedures.
3. If the DTC cannot be deleted, the malfunction is current.
4. Visually check the related wire harness and connector.
39 5. Check and clean all the wire harness connectors and grounds related to the current DTC.
6. If multiple trouble codes were set, use the circuit diagrams and look for any common ground circuit or
7. Refer to any Technical Bulletin that may apply to the malfunction.

 Wiggle the related wire harness and connector and observe if the signal is interrupt in the related circuit.
 Look for the data that has changed or the DTC to be reset during the wiggle test.
 Inspect the components such as horn, spiral cable etc. mounting areas for damage, foreign matter, etc.
that will cause incorrect signals.
 Remove the BCM control unit assembly from the malfunctioning vehicle and install it to a new vehicle and
perform a test. If the DTC cannot be cleared, the BCM control unit assembly is malfunctioning. If the DTC
can be cleared, reinstall the BCM control unit assembly to the original vehicle.

39 - HORN
Ground Inspection
Ground points are very important to the proper operation of electrical equipment and circuits. Ground points
are often exposed to moisture, dirt and corrosive elements. Corrosion (rust) can increase resistance which will
change the way a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can affect
the electronically controlled circuit. Perform the following operations when checking the ground points:
ground path.
Diagnosis Flow
HINT:
Perform the troubleshooting according to the following procedures.
NEXT
39
NEXT
DTC
No
NEXT

39 - HORN
CAUTION
 Remove the driver airbag when checking the horn switch wire harnesses. Make sure that the negative
battery cable is disconnected during removal, and wait at least 90 seconds to discharge the capacitor in
the supplemental restraint system. Remove the driver airbag (See page 30-41).
NEXT
6 Repair or replace
NEXT
NEXT
39
DTC
occurs Go to step 4
No
DTC Go to next step
9 Confirmation test
NEXT
10 End

B103D-11 Horn Control Circuit Return Short to Earth
B103D-13 Horn Control Circuit Return Open

39 - HORN
DTC B103D-11 Horn Control Circuit Return Short to Earth
DTC B103D-13 Horn Control Circuit Return Open
DTC Detection
Condition
Horn Control Circuit  Fuse
B103D-11
Return Short to Earth  Spiral cable
Ignition switch ON
Horn Control Circuit  Wire harness or connector
B103D-13
Return Open  BCM control unit assembly
HINT:
special circuit and the component information.
Confirmation Procedure
 Use the X-431 3G diagnostic tester to record and clear the DTCs stored in the body control system. 39
 Turn the ignition switch to ON and then select view DTC.
procedure - Step 1.
Diagnosis Procedure
1 Check horn fuse
Check the horn fuse (See page 39-14).
NG Replace a fuse with same specification as

original fuse
OK

39 - HORN
a. Remove the driver airbag (See page 30-41).

b. Disconnect the horn switch wire harness connector (I-019).
c. Remove the front bumper assembly (See page 46-7).
d. Disconnect the high pitched horn connector (E-033) and low pitched horn connector (E-028).
e. Disconnect the connector (E-038/B-008) between engine compartment wire harness and body wire
harness and BCM connector (B-049, I-045).
f. Check if the wire harnesses are worn, pierced, pinched or partially broken.
g. Look for broken, bent, protruded or corroded terminals.
h. Check if the related connector terminal contact pins are in good condition.
NG Repair or replace related wire harness and

connector
OK
3 Check horn switch control circuit
a. Using a digital multimeter, check the wire harness

between horn switch wire harness connector (I-019) and
BCM connector (I-045).
Open Inspection
39 + -
1
Condition I-019
I-019 (1) - I-045
Always Continuity
(A22)
Short Inspection
Condition A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16
I-046
I-019 (1) - Body
Always No continuity RA19390060
ground
I-045 (A22) -
Body ground
NG Repair or replace wire harness, connector

or spiral cable
OK

39 - HORN
4 Check horn power source circuit

between BCM connector (B-049) and body wire harness
connector (B-008).
Open Inspection
+ -
Multimeter Specified 1 2 3 4 5 6 7 8
Condition
Connection Condition 16 15 14 13 12 11 10 9
B-049 (C20) -
Always Continuity B-008
B-008 (7)
Short Inspection C1 C2 C3 C4 C5 C6 C7 C8 C9
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
Condition
B-049 (C20) -
Body ground
B-008 (7) - Body
ground
b. Using a digital multimeter, check the wire harness

between engine compartment wire harness connector 
(E-038) and high pitched horn connector (E-033).
Open Inspection
+ -
39
Condition 1 2
E-033
E-038 (7) - E-033
Always Continuity
(1)
Short Inspection 8 7 6 5 4 3 2 1
9 10 11 12 13 14 15 16
Condition E-038
E-038 (7) - Body
ground
E-033 (1) - Body
ground

39 - HORN
c. Using a digital multimeter, check the wire harness

between engine compartment wire harness connector 
(E-038) and low pitched horn connector (E-028).
Open Inspection
+ -
Condition 1 2
E-028
E-038 (7) - E-028
Always Continuity
(1)
Short Inspection 8 7 6 5 4 3 2 1
9 10 11 12 13 14 15 16
Condition E-038
E-038 (7) - Body
ground
E-028 (1) - Body
ground

connector
OK
39 5 Check horn ground circuit

between high pitched horn connector (E-033/E-028) and
body ground. E-028
Open Inspection 1 2
E-033
+ -
Condition
E-033 (2) - Body
Always Continuity
ground
RA19390100
E-028 (2) - Body
Always Continuity
ground
Short Inspection
 Connect the connector (E-038/B-008) between engine
compartment wire harness and body wire harness E-028
and BCM connector (B-049). 1 2
E-033
V
+ -
Condition
E-033 (2) - Body
Always Below 1 V
ground
RA19390110
E-028 (2) - Body
Always Below 1 V
ground

39 - HORN

connector
OK
Replace Body Control Module (BCM)
39

39 - HORN
Horn Fuse Inspection

1. Identify the horn fuse on the Body Control Module (BCM).
1 2 3 4 5 6 1 2 3 4 5 6
7.5
25
10
10
25
15
5
RA19390020
2. Check the horn fuse.

a. Using a fuse puller, remove the horn fuses F4 (10 A).
b. Check if the fuse is blown. Replace the fuse if it is blown.
CAUTION
 Use a fuse with the same specification as original fuse to avoid affecting the normal usage of electrical
equipment.
39

39 - HORN
ON-VEHICLE SERVICE
Horn
Removal
3. Remove the front bumper (See page 46-7).
4. Remove the low pitched horn.
a. Disconnect the low pitched horn (right side) wire
b. Remove the fixing bolt (arrow) from the low pitched
horn, and remove the low pitched horn.
1
RA19390030
5. Remove the high pitched horn.

a. Disconnect the high pitched horn (left side) wire
b. Remove the fixing bolt (arrow) from the high pitched 39
horn, and remove the high pitched horn.
1
RA19390040

39 - HORN
Inspection
1. Check the high pitched horn.
+ -
a. Apply battery voltage to the high pitched horn and
check the operation of high pitched horn. 2 1
Measurement Specified
Condition
Condition Condition
Battery positive
(+) - Terminal 1
Always Sounds
Battery negative
(-) - Terminal 2 RA19390050
If the high pitched horn sounds, it is normal. If it does

not sound, replace the high pitched horn.
2. Check the low pitched horn.
+ -
a. Apply battery voltage to the low pitched horn and
check the operation of low pitched horn. 2 1
Measurement Specified
Condition
Condition Condition
Battery positive
(+) - Terminal 1
Always Sounds
Battery negative
(-) - Terminal 2 RA19390050
39 If the low pitched horn sounds, it is normal. If it does

not sound, replace the low pitched horn.
3. Check the wire harness.
a. Using a digital multimeter, check for an open, short or ground failure in the horn system wire harness.
Replace it if necessary.
Installation
CAUTION


OTHER SYSTEM
Description 40-3 Cigarette Lighter Assembly 40-5
Installation 40-6
40

40

40 - OTHER SYSTEM
GENERAL INFORMATION
OTHER SYSTEM
Description
1
4
40
RA19400010
1 - Cigarette Lighter End 2 - Cigarette Lighter Fixing Bush

3 - Cigarette Lighter Housing 4 - Auxiliary Fascia Console Assembly
The cigarette lighter assembly is located on the auxiliary fascia console assembly.
CAUTION
 The rated voltage of cigarette lighter socket is 12 V. DO NOT use electrical equipment with higher rated
voltage.

40 - OTHER SYSTEM
Circuit Diagram
System Circuit Diagram for Cigarette Lighter
IGNITION SWITCH
ON OR ACC
BODY
RF17 FUSE
AND
20A RELAY
17 BOX
RY
I-022
1
I-021
RY
CLOSE
CIGARETTE
LIGHTER
OPEN
I-020
2
40
B
2 I-021
I-022
B
I-027
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 1 1
25 26 2 2
87
85 86 86 86 I-022 I-020
87 30 87 30
30 85 85 W W
I-005
B
EA19400010

40 - OTHER SYSTEM
ON-VEHICLE SERVICE
Cigarette Lighter Assembly
Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the cigarette lighter assembly.
 Appropriate force should be applied when removing the rear trunk trim assembly, and avoid operating
roughly.
 DO NOT scratch the auxiliary fascia console assembly when removing the cigarette lighter assembly.

3. Remove the cigarette lighter assembly.
a. Remove the cigarette lighter end (1).
40
RA19400020
b. Press the clips on the cigarette lighter housing in the

directions of arrows as shown in the illustration, and
using a screwdriver wrapped with protective tape,
release the cigarette lighter fixing bush.
RA19400030
c. Disconnect the cigarette lighter connector (arrow) and

remove the cigarette lighter housing.
RA19400040

40 - OTHER SYSTEM
d. Using a screwdriver wrapped with protective tape, pry

the clips on the cigarette lighter housing and remove
the cigarette lighter housing.
RA19400050
Installation
CAUTION
 Check if the cigarette lighter operates normally after installing the cigarette lighter assembly.
40

Description 41-3 Front Door Glass Assembly 41-51
Circuit Diagram 41-9 Front Door Glass Front Guide Rail 
Assembly 41-53
DIAGNOSIS & TESTING 41-12 Removal 41-53
Problem Symptoms Table 41-12 Installation 41-53
Diagnosis Tools 41-12 Front Door Power Glass Regulator 
DTC Confirmation Procedure 41-12 Assembly 41-54
Ground Inspection 41-13 Inspection 41-54
Diagnosis Procedure 41-14 Installation 41-55
Diagnostic Trouble Code (DTC)  Glass Regulating Control Switch 41-56
Chart 41-15 Removal 41-56
B100C-11 41-16 Inspection 41-57
B100C-13 41-16 Installation 41-58
B100C-71 41-16 Rear Door Glass Assembly 41-59
B100D-18 41-16 Removal 41-59
B100D-19 41-16 Installation 41-59
B100D-71 41-16 Triangular Window Glass Assembly 41-60
B100E-18 41-23 Removal 41-60
B100E-19 41-23 Installation 41-61
B100E-71 41-23 Rear Door Glass Rear Guide Rail 
B100F-18 41-23 Assembly 41-62 41
B100F-19 41-23 Removal 41-62
B100F-71 41-23 Installation 41-62
B1010-18 41-31 Rear Door Power Glass Regulator 
B1010-19 41-31 Assembly 41-63
B1010-71 41-31 Removal 41-63
B1011-18 41-39 Inspection 41-63
B1011-19 41-39 Installation 41-64
B1011-71 41-39 Front Windshield Assembly 41-65
B1012-18 41-39 Removal 41-65
B1012-19 41-39 Installation 41-67
B1012-71 41-39 Rear Windshield Assembly 41-71
B1013-18 41-39 Removal 41-71
B1013-19 41-39 Installation 41-74
B1013-71 41-39 Rear Defroster 41-77
General Information 41-77
Glass Regulating Control Master 
Switch 41-48
Removal 41-48 Removal & Installation - 
Rear Defroster Switch 41-80
Inspection 41-49

41

41 - WINDSHIELD/WINDOW GLASS
GENERAL INFORMATION
Description
41
5
RA19410010

1 - Front Windshield Assembly 2 - Left Triangular Window Glass Assembly

3 - Rear Left Door Glass Assembly 4 - Front Left Door Glass Assembly
5 - Rear Windshield Assembly 6 - Front Right Door Glass Assembly
7 - Rear Right Door Glass Assembly 8 - Right Triangular Window Glass Assembly
2
3 4
1
41 5
RA19410020
1 - Front Right Door Glass Regulating Control Switch 2 - Rear Right Door Glass Regulating Control Switch
3 - Front Left Door Glass Regulating Control Switch 4 - Rear Left Door Glass Regulating Control Switch
5 - Rear Left Door Power Glass Regulator Assembly 6 - Front Left Door Power Glass Regulator Assembly
7 - Rear Right Door Power Glass Regulator 8 - Front Right Door Power Glass Regulator
Assembly Assembly

The power window control system controls the power window glass UP/DOWN function by operating the
power glass regulating control switch on the door inner protector assembly. The main control devices of this
system include: power glass regulating control master switch (built into the driver side door) and power glass
regulating control switches (built into the front passenger side door and rear doors). Press the power glass
regulating control master switch or any power glass regulating control switch to transmit the UP/DOWN signal
to the corresponding power glass regulator motor, thus controlling the UP/DOWN operation of corresponding
power window glass.
Main Components Function
Component Description
Locates on the front left door inner protector
assembly and controls the operations of front and
rear passenger door power window glass.
Power window lock switch When the power window lock switch is in the lock
position, only the driver side power glass regulating
control master switch can control the UP/DOWN
operation of driver side power window glass.
Locates on the door inner protector assembly.
Power glass regulating control switch Each power glass regulating control switch controls
the UP/DOWN operation of corresponding power
window glass.
Receives the switch signal and performs conversion
Power glass regulator motor to activate the power glass regulator motor to
change the power window glass position.
System Function
Function Description
41
All the power glass regulating control switches have
the manual UP function. The power window glass
Manual UP function goes up when the power glass regulating control
switch is pulled up and stops when the switch is
released.
All the power glass regulating control switches have
the manual DOWN function. The power window
Manual DOWN function glass goes down when the power glass regulating
control switch is pressed and held (≥ 300 ms), and
stops when the switch is released.
All the power glass regulating switches have the
automatic DOWN function. The window glass goes
down automatically when the power glass regulating
Automatic DOWN function
switch is pressed (50 ms < T < 300 ms). To stop it
partway, press the power glass regulating switch
again.
When the power window lock switch is pressed, the
corresponding power window glass cannot be
operated with the passenger side power glass
Power window LOCK function regulating control switches. In this case, only the
driver side power window glass can be operated.
This function can be canceled only when the power
window lock switch is pressed again.

Operation Inspection
1. Check the power window lock switch.
a. Check that the front passenger side power window
glass and rear power window glass cannot be
operated by the front passenger side power glass
regulating control switch and rear power glass
regulating control switches when the power window
lock switch is pressed.
OK: Front passenger side power glass regulating
control switch and rear power glass regulating
control switches are disabled.
b. Check that the front passenger side power window RA19410030
glass and rear power window glass can be operated
by the front passenger side power glass regulating
control switch and rear power glass regulating control
switches when the power window lock switch is
pressed again.
OK: Front passenger side power glass regulating
control switch and rear power glass regulating
control switches can be operated.
2. Check the manual UP/DOWN function.
a. Check that the driver side power window glass operates as follows:
OK
Power Glass
Condition Regulating Control Switch Operation Power Window Glass
Switch
Pulled UP (close)
Ignition Switch ON Driver side
41 Pushed DOWN (open)
b. Check that the power window glass other than driver side power window glass operate as follows:
OK
Power Glass
Switch
Pulled UP (close)
Passenger side
Pushed DOWN (open)
 Ignition switch ON Pulled UP (close)
 Window lock switch Rear left side
OFF Pushed DOWN (open)
Pulled UP (close)
Rear right side
Pushed DOWN (open)

3. Check the remote manual UP/DOWN function.

a. Check that the driver side power window glass operates as follows:
OK
Power Glass
Switch
Fully pulled UP (close)
Ignition switch ON Driver side
Fully pushed DOWN (open)
b. Check that the power window glass other than driver side power window glass operate as follows:
OK
Power Glass
Switch
Pulled UP (close)
Passenger side
Pushed DOWN (open)
 Ignition switch ON Pulled UP (close)
 Window lock switch Rear left side
OFF Pushed DOWN (open)
Pulled UP (close)
Rear right side
Pushed DOWN (open)
Specifications
Description Torque (N·m) 41
Glass Regulating Control Master Switch Assembly
1.5 ± 0.5
Fixing Screw
Front Door Glass Front Guide Rail Fixing Bolt 7 ± 1.5
Front Door Glass Rear Guide Rail Fixing Bolt 7 ± 1.5
Rear Door Glass Front Guide Rail Fixing Bolt 7 ± 1.5
Rear Door Glass Rear Guide Rail Fixing Screw 3.5 ± 0.5
Front Door Glass Assembly Fixing Bolt 7 ± 1.5
Rear Door Glass Fixing Bolt 7 ± 1.5
Front Door Power Glass Regulator Fixing Bolt 7 ± 1.5
Rear Door Power Glass Regulator Fixing Bolt 7 ± 1.5
Front Door Glass Outer Weatherstrip Fixing Screw 1.5 ± 0.5
Rear Door Glass Outer Weatherstrip Fixing Screw 1.5 ± 0.5
Blower Speed Switch Fixing Screw 1.5 ± 0.5
Fog Switch Set Fixing Screw 1.5 ± 0.5
Air Spring Hinge Fixing Bolt 7 ± 1.5
7 ± 1.5
Hinge and Rear Windshield Assembly


Luggage Compartment Outside Handle Assembly
7 ± 1.5
Fixing Bolt
Tools
Special Tool
Interior Crow Plate
RCH0000025
General Tool
Digital Multimeter
41 RCH0000002

Circuit Diagram
Power Window Control System (Page 1 of 3)

BATTERY
POWER ENGINE INSTRUMENT

EF12 FUSE EF05 COMPARTMENT RF21 RF03 RF16 PANEL
BOX FUSE AND FUSE AND
80A 40A 10A 10A 10A RELAY BOX
B-009 RELAY BOX
B-010 I-005
E3 21 3 16
RW
RY
R
R
8 A
R
B-021 I-047
F1 B31 B15
BCM
F6 F8 B-048
25A 25A I-015
B-049
DOUAL RLY DOUAL RLY DOUAL RLY DOUAL RLY I-006
D1 D2 D4 D5 C8 C9 C6 C7
WBr
WBr
GW
WR
WR
WY
LW
G
I-010 1 I-029 B-029 B-052
2 1 2 1 2 1 2
F-007 H-004 L-005 R-001
41
GW
WBr
WBr
WY
GW
GW
WR
LW
1 2 1 2 1 2 1 2
M M M M

POWER WINDOW POWER WINDOW POWER WINDOW POWER WINDOW
REGULATOR MOTOR REGULATOR MOTOR REGULATOR MOTOR REGULATOR MOTOR
F-008 H-002 L-004 R-002
D1 D2 D3 D4 D5 8 7 6 5 4 3 2 1
I-015 I-010 1 2 3 4
B-021
E4 E3 E2 E1 B-010 D6 D7 D8 D9 D10 D11 D12 W 16 15 14 13 12 11 10 9 W 5 6 7 8
W
W
C1 C2 C3 C4 C5 C6 C7 C8 C9 7 6 5 4 3 2 1
7 6 5 4 3 2 1
7 6 5 4 3 2 1 14 13 12 11 10 9 8
14 13 12 11 10 9 8
14 13 12 11 10 9 8
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
I-029
B-029 W
B-052 B-049
W W
W
1
1 2 3 4 5 6 7 8 9 10 11 12
B-048
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 13 14 15 16 17 18 19 20 21 22 23 24
Gr
25 26
I-006 87 1
L 85 86 86 86
87 30 87 30
30 85 85
B-009
1 2 F-008 H-002 L-004 R-002
Gr Gr Gr Gr I-005
B EA19410010

BCM I-006
B26 B28 B25 B27 B22 B24 B21 B23 Lg

B
YGr
C
YW
D
YBr
E
LB
F
YB
G
R
BrW
GrR
YGr
YBr
YG
YB
LO
LB
LY
B
G203
I-010 I-011 I-010 I-011

7 8 2 1 3 12 4 13 5 9 14
F-007 F-006 F-007 F-006
ILLUMINTION
LY
I-011
B
GrR
GrR
YGr
YBr
YG
9
YB
LO
LB
F-006
R
41
6 7 5 8 4 15 3 16 11 9 14 P 13
FRONT
DOWN UP DOWN UP DOWN UP DOWN UP PASSENGER LEFT
POWER POWER
FRONT FRONT REAR REAR WINDOW
LEFT RIGHT LEFT RIGHT WINDOW
LOCK SWITCH
POWER POWER POWER POWER SWITCH
WINDOW WINDOW WINDOW WINDOW F-004
SWITCH SWITCH SWITCH SWITCH

8 7 6 5 4 3 2 1 I-010
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 I-006 16 15 14 13 12 11 10 9
L W
8 7 6 5 4 3 2 1 7 6 5 4 3 2 1 I-011
F-004 14 13 12 11 10 9 8
16 15 14 13 12 11 10 9 W
Br
EA19410020

Lg
B
YGr
C
YW
D
YBr
E
LB I-003
F 4 18 8 22
B-050
YB
G
I-029
YGr
YBr
YW
4 3
Lg
H-004
ILLUMINTION
GrR
YB
P
4 I-030 B-029 4 3 7 B-052
4 3 7
H-003 L-005 R-001
GrG
GrG
YGr
YBr
P
P
6 7 1 6 7 1 6 7 1
FRONT REAR REAR
RIGHT LEFT RIGHT
UP POWER DOWN POWER DOWN UP DOOR
DOWN UP
WINDOW WINDOW CONTACT
SWITCH SWITCH SWITCH
H-006 L-003 R-005
9 3 9 3 9 3
41
LY
LY
LY
B
H-003 L-005 R-001 B

9 6 B-029 9 6 9 6
I-030 B-052
LY
LY
LY
B
LY
H 12
I-003 B-050
I-028 B-023
42 41 40 39 38 37 36 35 34 33 32 31 30 29
7 6 5 4 3 2 1 B-029 7 6 5 4 3 2 1 B-052
28 27 26 25 24 23 22 21 20 19 18 17 16 15 B-050 14 13 12 11 10 9 8 14 13 12 11 10 9 8
W W
14 13 12 11 10 9 8 7 6 5 4 3 2 1
W
4 3 2 1 6 7 8 9 10
7 6 5 4 3 2 1 H-006 L-003 R-005
I-030 I-029 1 2 3 4 5
10 9 8 7 6 5
14 13 12 11 10 9 8 B B B
W W
EA19410030

DIAGNOSIS & TESTING

HINT:

Fuse 49-29
Driver side power glass regulating control
41-48
Driver side power window glass cannot be switch
operated with driver side power glass
Driver side power glass regulator motor 41-54
regulating control switch
Fuse 49-29
Passenger side power glass regulating
41-57
control switch
Passenger side power window glass
cannot be operated with passenger side Passenger side power glass regulator
41-54
power glass regulating control switch motor
Ground -
Power window has intermittent problem
41
Diagnosis Tools
communication with the vehicle.
 DLC is located at the driver side instrument panel crossmember.
 DLC is a trapezoidal design which can hold 16 terminals.
Digital Multimeter
 Troubleshoot the electrical problems and wiring systems.
 Look for the basic fault.


 Using the X-431 3G diagnostic tester, record and clear the DTCs stored in the Body Control Module
(BCM).
 Turn the ignition switch to ON, and select Read Code.
procedure - Step 1.
 If the DTC is not detected, the malfunction indicated by the DTC is intermittent. Refer to the Intermittent
DTC Troubleshooting.

circuit.
 Check for conditions that would cause the incorrect signals such as breakage, foreign matter, etc. when
installing the components such as power window assembly, wire harness or connector etc.
 Remove the Body Control Module (BCM) from the malfunctioning vehicle and install it to a new vehicle and
perform a test. If the DTC cannot be cleared, the Body Control Module (BCM) is malfunctioning. If the DTC
can be cleared, reinstall the Body Control Module (BCM) to the original vehicle.
41
Ground Inspection
Ground points in the circuit system are very important to the proper operation of whole circuit system.
Whether grounds are normal or not has serious influence to the whole circuit system. Ground points are often
exposed to moisture, dirt and other corrosive areas. Corrosion (rust) and oxidation may increase load
resistance. This situation will seriously affect the circuit operation.
Ground inspection operation is as follows:
5. Check for add-on accessories which may interfere with the ground circuit.
6. If several wire harnesses are crimped into one ground terminal, check for proper crimps. Make sure all the
wire harnesses are clean, securely fastened and providing a good ground path.

Diagnosis Procedure
HINT:
Use the following procedures to troubleshoot the power window control system.
NEXT
NEXT
NEXT
DTC
41
No
5 Problem repair (for no DTC), then go to step 8
NEXT
NEXT
NEXT

NEXT
9 Conduct confirmation test
NEXT
10 End

B100C-11 FL Window Up Control Circuit Current Below Threshold
B100C-13 FL Window Up Control Circuit Current Above Threshold
B100C-71 FL Window Up Control Circuit Actuator Stuck
B100D-18 FL Window Down Control Circuit Current Below Threshold
B100D-19 FL Window Down Control Circuit Current Above Threshold
B100D-71 FL Window Down Control Circuit Actuator Stuck
B100E-18 FR Window Up Control Circuit Current Below Threshold
B100E-19 FR Window Up Control Circuit Current Above Threshold 41
B100E-71 FR Window Up Control Circuit Actuator Stuck
B100F-18 FR Window Down Control Circuit Current Below Threshold
B100F-19 FR Window Down Control Circuit Current Above Threshold
B100F-71 FR Window Down Control Circuit Actuator Stuck
B1010-18 RL Window Up Control Circuit Current Below Threshold
B1010-19 RL Window Up Control Circuit Current Above Threshold
B1010-71 RL Window Up Control Circuit Actuator Stuck
B1011-18 RL Window Down Control Circuit Current Below Threshold
B1011-19 RL Window Down Control Circuit Current Above Threshold
B1011-71 RL Window Down Control Circuit Actuator Stuck
B1012-18 RR Window Up Control Circuit Current Below Threshold
B1012-19 RR Window Up Control Circuit Current Above Threshold
B1012-71 RR Window Up Control Circuit Actuator Stuck
B1013-18 RR Window Down Control Circuit Current Below Threshold
B1013-19 RR Window Down Control Circuit Current Above Threshold
B1013-71 RR Window Down Control Circuit Actuator Stuck

DTC B100C-11 FL Window Up Control Circuit Current Below Threshold
DTC B100C-13 FL Window Up Control Circuit Current Above Threshold
DTC B100C-71 FL Window Up Control Circuit Actuator Stuck
FL Window Down Control Circuit Current Below

DTC B100D-18
Threshold
FL Window Down Control Circuit Current Above

DTC B100D-19
Threshold
DTC B100D-71 FL Window Down Control Circuit Actuator Stuck
41

BATTERY
POWER
EF12 FUSE
BOX
R 80A B-009
F1
F6 BCM
25A
I-015
DOUAL RLY I-006
D1 D2 B26 B28
G-203
GrR
YG
WR
WR
B
I-010 7 8 5 I-010
2 1
F-007 F-007
GrR
YG
GW
WR
B
1 2 6 7 11
FRONT FRONT
41
LEFT FRONT LEFT
M
POWER LEFT POWER
WINDOW POWER DOWN UP
WINDOW
REGULATOR WINDOW SWITCH
MOTOR SWITCH
F-004
F-008
D1 D2 D3 D4 D5
I-015 8 7 6 5 4 3 2 1 I-010 8 7 6 5 4 3 2 1 F-004
D6 D7 D8 D9 D10 D11 D12 W 16 15 14 13 12 11 10 9 W Br
16 15 14 13 12 11 10 9

I-006 7 6 5 4 3 2 1 I-011
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 L 14 13 12 11 10 9 8 W
1 2 1 1
F-008 B-048 B-009

Gr Gr
EA19410060


Condition Condition
FL Window Up Control
B100C-11 Circuit Current Below
Threshold
B100C-13 Circuit Current Above  Fuse
Threshold  Glass regulating
control master
B100C-71 switch
 Power glass
FL Window Down Ignition switch ON ON
regulator assembly
B100D-18 Control Circuit Current
 Wire harness or
Below Threshold
connector
FL Window Down  Body Control
B100D-19 Control Circuit Current Module (BCM)
Above Threshold
FL Window Down
B100D-71 Control Circuit
Actuator Stuck
CAUTION
41
Diagnosis Procedure
1 Check Body Control Module (BCM) fuse F6 (25A)

c. Pull out the Body Control Module (BCM) fuse F6 (25A).

F6 (25A)
OK

2 Check glass regulating control master switch
a. Check the glass regulating control master switch (See page 41-48).
NG Replace glass regulating control master

switch
OK
3 Check front left door power glass regulator assembly
a. Check the front left door power glass regulator assembly (See page 41-54).
NG Replace front left door power glass

regulator assembly
OK

I-015 and I-010.
+ -
I-010 according to the value(s) in the table below. D1 D2 D3 D4 D5 41
D6 D7 D8 D9 D10 D11 D12
Condition
I-015 (D1) - I-010

Always Continuity
(2) 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
I-015 (D2) - I-010
Always Continuity
(1) I-010
RA19410600


I-006 and I-010.
Condition
I-006 (B26) - B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Always Continuity
I-010 (7) B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
I-006 (B28) - I-006

Always Continuity
I-010 (8)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
I-010
RA19410610
g. Disconnect the instrument panel wire harness connector

below.
Condition
8 7 6 5 4 3 2 1
I-010 (5) - G-203 Always Continuity 16 15 14 13 12 11 10 9
41 NG Repair or replace instrument panel wire

I-010
G-203
RA19410620
OK


c. Disconnect the front left door wire harness connectors 
F-007 and F-008.
+ -
the front left door wire harness connectors F-007 and 
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Condition
Connection Condition F-007
F-007 (2) - F-008

Always Continuity
(1) 1 2
F-007 (1) - F-008

Always Continuity F-008
(2)
RA19410630
e. Disconnect the front left door wire harness connectors 

F-007 and F-004.
Condition
F-007 (7) - F-004
Always Continuity
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
41
(6)
F-007
F-007 (8) - F-004
Always Continuity
(7)
F-007 (5) - F-004 8 7 6 5 4 3 2 1
Always Continuity
(11) 16 15 14 13 12 11 10 9
F-004
NG Repair or replace front left door wire RA19410640
OK

6 Reconfirm DTCs

d. Using the X-431 3G diagnostic tester (the latest software), record and clear the DTCs stored in the Body
g. Use the X-431 3G diagnostic tester (the latest software) to record the DTCs stored in the Body Control
Module (BCM) again.
h. Read the DTCs.
Result Proceed to
DTC B100C-11, B100C-13, B100C-71, B100D-18,
NG
B100D-19 and B100D-71 are output
No DTC output OK
OK
System is normal
41

DTC B100E-18 FR Window Up Control Circuit Current Below Threshold
DTC B100E-19 FR Window Up Control Circuit Current Above Threshold
DTC B100E-71 FR Window Up Control Circuit Actuator Stuck
FR Window Down Control Circuit Current Below

DTC B100F-18
Threshold
FR Window Down Control Circuit Current Above

DTC B100F-19
Threshold
DTC B100F-71 FR Window Down Control Circuit Actuator Stuck
41

BATTERY
POWER
EF12 FUSE
BOX
80A B-009
R
F1
F6 BCM
I-015
25A
I-006
DOUAL RLY
D4 D5 B25 B27
WBr
LW
G-203
I-029
1 2
B
H-004 4 3 I-029
H-004 5 I-010
WBr
LW
F-007
GrR
YB
1 2 6 7
FRONT 11
FRONT
RIGHT RIGHT
M
POWER POWER FRONT
DOWN UP PASSENGER
WINDOW WINDOW LEFT
POWER POWER
REGULATOR SWITCH
WINDOW WINDOW
MOTOR H-006 LOCK
H-002 SWITCH
9 SWITCH
F-004
LY
H-003 14
9
I-030
LY
14
41
I-011 F-006

I-006
L
D1 D2 D3 D4 D5 4 3 2 1 6 7 8 9 10
I-015 I-030 H-006
D6 D7 D8 D9 D10 D11 D12 W 10 9 8 7 6 5 W 1 2 3 4 5 B
8 7 6 5 4 3 2 1 I-010 7 6 5 4 3 2 1 I-029 7 6 5 4 3 2 1 I-011

16 15 14 13 12 11 10 9 W 14 13 12 11 10 9 8 W 14 13 12 11 10 9 8 W
8 7 6 5 4 3 2 1
1 1 1 2
16 15 14 13 12 11 10 9
F-004 B-048 B-009 H-002

Br Gr Gr
EA19410070


Condition Condition
FR Window Up Control
B100E-18 Circuit Current Below
Threshold
FR Window Up Control
B100E-19 Circuit Current Above  Fuse
Threshold
 Glass regulating
FR Window Up Control control switch
B100E-71
Circuit Actuator Stuck  Power glass
FR Window Down Ignition switch ON ON regulator assembly
B100F-18 Control Circuit Current  Wire harness or
Below Threshold connector
FR Window Down  Body Control
B100F-19 Control Circuit Current Module (BCM)
Above Threshold
FR Window Down
B100F-71 Control Circuit
Actuator Stuck
CAUTION
41
Diagnosis Procedure


F6 (25A)
OK

2 Check glass regulating control switch
a. Check the glass regulating control switch (See page 41-56).
NG Replace glass regulating control switch
OK
3 Check front right door power glass regulator assembly
a. Check the front right door power glass regulator assembly (See page 41-54).
NG Replace front right door power glass

regulator assembly
OK

I-015 and I-029.
+ -
41 Multimeter Specified
D1 D2 D3 D4 D5
Condition D6 D7 D8 D9 D10 D11 D12

I-015
I-015 (D4) - I-029
Always Continuity
(1)
7 6 5 4 3 2 1
I-015 (D5) - I-029
(2)
I-029
RA19410660


I-006 and I-029.
Condition
I-006 (B25) - B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Always Continuity
I-029 (4) B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
I-006 (B27) -
I-029 (3)
7 6 5 4 3 2 1
14 13 12 11 10 9 8
I-029
RA19410670
g. Disconnect the instrument panel wire harness connectors

I-030 and I-011.
Condition
4 3 2 1
I-030 (9) - I-011 10 9 8 7 6 5

Always Continuity
(14)
I-030
41
7 6 5 4 3 2 1
14 13 12 11 10 9 8
I-011
RA19410680
i. Disconnect the instrument panel wire harness connector

below.
Condition
8 7 6 5 4 3 2 1
I-010
G-203
RA19410620

OK

F-004 and F-007.
+ -
1 2 3 4 5 6 7 8
Condition 9 10 11 12 13 14 15 16
F-007
F-004 (11) - F-007
Always Continuity
(5)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
F-004
RA19410700
e. Disconnect the front left door wire harness connectors 

F-004 and F-006.
Condition
8 9 10 11 12 13 14
F-004 (14) - F-006
Always Continuity F-006
(14)
NG Repair or replace front left door wire 8 7 6 5 4 3 2 1
harness and connector 16 15 14 13 12 11 10 9
F-004
RA19410701
OK

6 Check front right door wire harness and connector

c. Disconnect the front right door wire harness connectors
H-004 and H-002.
+ -
H-002 according to the value(s) in the table below.
1 2 3 4 5 6 7
Multimeter Specified 8 9 10 11 12 13 14
Condition
Connection Condition H-004
H-004 (1) - H-002

Always Continuity
(1)
1 2
H-004 (2) - H-002
Always Continuity
(2) H-002
RA19410710
e. Disconnect the front right door wire harness connectors

H-004 and H-006.
Condition
H-004 (3) - H-006

Always Continuity
8 9 10 11 12 13 14
41
(7) H-004
H-004 (4) - H-006 6 7 8 9 10

Always Continuity
(6) 1 2 3 4 5
H-006
RA19410720

g. Disconnect the front right door wire harness connectors

H-003 and H-006.
Condition
5 6 7 8 9 10
H-003 (9) - H-006
Always Continuity
(9) H-003
NG Repair or replace front right door wire 6 7 8 9 10
harness and connector 1 2 3 4 5
H-006
RA19410730
OK
7 Reconfirm DTCs

41 f. Turn the ignition switch to ON.
Module (BCM) again.
h. Read the DTCs.
Result Proceed to
DTC B100E-18, B100E-19, B100E-71, B100F-18,
NG
B100F-19 and B100F-71 are output
No DTC output OK
OK
System is normal

DTC B1010-18 RL Window Up Control Circuit Current Below Threshold
DTC B1010-19 RL Window Up Control Circuit Current Above Threshold
DTC B1010-71 RL Window Up Control Circuit Actuator Stuck
41

BATTERY
POWER
EF12 FUSE
BOX
80A B-009
R
F1
F8 BCM
B-049
25A
I-006
DOUAL RLY B-048
C8 C9 B22 B24
WBr
WY
4 18 I-003
B-050
G-203
B-029
1 2 B-052
L-005 4 3
R-001 5 I-010
F-007
WBr
GrR
GW
YBr
B
1 2 6 7
REAR 11
REAR
LEFT LEFT
M FRONT
POWER UP DOOR
DOWN PASSENGER LEFT
WINDOW CONTACT
POWER POWER
REGULATOR SWITCH
WINDOW WINDOW
MOTOR L-003 LOCK
L-004 SWITCH
9 SWITCH
F-004
LY
L-005
9 14
B-029
LY
12 14
41
B-050 I-003 I-011 F-006
42 41 40 39 38 37 36 35 34 33 32 31 30 29
I-006 B-050
28 27 26 25 24 23 22 21 20 19 18 17 16 15
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 L W
14 13 12 11 10 9 8 7 6 5 4 3 2 1
C1 C2 C3 C4 C5 C6 C7 C8 C9
B-049 7 6 5 4 3 2 1 B-052
W 14 13 12 11 10 9 8 W
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20
8 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1
I-010 B-029 I-011
16 15 14 13 12 11 10 9 14 13 12 11 10 9 8 14 13 12 11 10 9 8
W W W
6 7 8 9 10
8 7 6 5 4 3 2 1
1 1 1 2 1 2 3 4 5
16 15 14 13 12 11 10 9
F-004 B-048 B-009 L-004 L-003

Br Gr Gr B
EA19410080


Condition Condition
RL Window Up Control  Fuse
B1010-18 Circuit Current Below  Glass regulating
Threshold control switch
RL Window Up Control  Power glass
B1010-19 Circuit Current Above Ignition switch ON ON regulator assembly
Threshold  Wire harness or
connector
RL Window Up Control
B1010-71  Body Control
Module (BCM)
CAUTION
Diagnosis Procedure

41

F8 (25A)
OK
OK
3 Check rear left door power glass regulator assembly
a. Check the rear left door power glass regulator assembly (See page 41-63).
NG Replace rear left door power glass

regulator assembly

OK

I-006 and I-003.
+ -
Multimeter Specified B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17
Condition
I-006
I-006 (B22) -
Always Continuity
I-003 (4) 29 30 31 32 33 34 35 36 37 38 39 40 41 42
I-006 (B24) - 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Always Continuity
I-003 (18) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003
RA19410740

I-003 and I-011.
Condition 7 6 5 4 3 2 1
I-003 (12) - I-011

(14)
29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003
RA19410750


below.
Condition
8 7 6 5 4 3 2 1
I-010
G-203
RA19410620
OK

B-029.
+ -
C1 C2 C3 C4 C5 C6 C7 C8 C9
41
Condition
B-049 (C8) - B-049

Always Continuity
B-029 (1)
B-049 (C9) - 7 6 5 4 3 2 1
B-029 (2)
B-029
RA19410760


B-029.
Condition
28 27 26 25 24 23 22 21 20 19 18 17 16 15
B-050 (4) - B-029
(4)
B-050 (18) - B-050
Always Continuity
B-029 (3)
B-050 (12) - 7 6 5 4 3 2 1
B-029 (9)
B-029
connector
OK

F-004 and F-006.
+ -
41 the front left door wire harness connectors F-004 and 
F-006 according to the value(s) in the table below. 1 2 3 4 5 6 7
8 9 10 11 12 13 14
Condition F-006
F-004 (14) - F-006
Always Continuity
(14) 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
NG Repair or replace front left door wire F-004

RA19410701
OK

7 Check rear left door wire harness and connector

c. Disconnect the rear left door wire harness connectors 
L-005 and L-004.
+ -
L-004 according to the value(s) in the table below.
1 2
Condition
Connection Condition L-004
L-005 (1) - L-004

Always Continuity
(1)
1 2 3 4 5 6 7
L-005 (2) - L-004
(2)
L-005
RA19410790
e. Disconnect the rear left door wire harness connectors 

L-005 and L-003.
L-003 according to the value(s) in the table below. + -
Condition
L-005 (4) - L-003
Always Continuity
6 7 8 9 10
1 2 3 4 5 41
(6)
L-003
L-005 (3) - L-003
Always Continuity
(7)
L-005 (9) - L-003 1 2 3 4 5 6 7
(9)
L-005
NG Repair or replace rear left door wire RA19410800
OK
8 Reconfirm DTCs


Module (BCM) again.
h. Read the DTCs.
Result Proceed to
DTC B1010-18, B1010-19 and B1010-71 are output NG
No DTC output OK
OK
System is normal
41

RL Window Down Control Circuit Current Below

DTC B1011-18
Threshold
RL Window Down Control Circuit Current Above

DTC B1011-19
Threshold
DTC B1011-71 RL Window Down Control Circuit Actuator Stuck
DTC B1012-18 RR Window Up Control Circuit Current Below Threshold
DTC B1012-19 RR Window Up Control Circuit Current Above Threshold
DTC B1012-71 RR Window Up Control Circuit Actuator Stuck
RR Window Down Control Circuit Current Below

DTC B1013-18
Threshold
RR Window Down Control Circuit Current Above

DTC B1013-19
Threshold
DTC B1013-71 RR Window Down Control Circuit Actuator Stuck
41

BATTERY
POWER
EF12 FUSE
BOX
80A B-009
R
F1
F8 BCM
B-049
25A
I-006
DOUAL RLY B-048
C6 C7 B21 B23
GW
G
8 22 I-003
B-050
G-203
B-052
1 2 B-052
R-001 4 3
R-001 5 I-010
F-007
GrR
GW
YBr
WY
B
1 2 6 7
REAR 11
REAR
RIGHT RIGHT
M FRONT
POWER UP DOOR
DOWN PASSENGER LEFT
WINDOW CONTACT
POWER POWER
REGULATOR SWITCH
WINDOW WINDOW
MOTOR R-003 LOCK
R-002 SWITCH
9 SWITCH
F-004
LY
R-001 14
9
B-052
LY
12 14
41
B-050 I-003 I-011 F-006
B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 42 41 40 39 38 37 36 35 34 33 32 31 30 29

I-006 B-050
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 28 27 26 25 24 23 22 21 20 19 18 17 16 15
L W
14 13 12 11 10 9 8 7 6 5 4 3 2 1
C1 C2 C3 C4 C5 C6 C7 C8 C9 6 7 8 9 10
B-049 7 6 5 4 3 2 1 B-052 R-003
1 2 3 4 5
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 W 14 13 12 11 10 9 8 W B
8 7 6 5 4 3 2 1 I-010 7 6 5 4 3 2 1 I-029 7 6 5 4 3 2 1 I-011

16 15 14 13 12 11 10 9 W 14 13 12 11 10 9 8 W 14 13 12 11 10 9 8 W
8 7 6 5 4 3 2 1
1 1 1 2
16 15 14 13 12 11 10 9
F-004 B-048 B-009 R-002

Br Gr Gr
EA19410090


Condition Condition
RL Window Down
Below Threshold
RL Window Down
Above Threshold
RL Window Down
B1011-71 Control Circuit
Actuator Stuck
 Fuse
RR Window Up Control
B1012-18 Circuit Current Below  Glass regulating
Threshold control switch
 Power glass
Ignition switch ON ON regulator assembly
B1012-19 Circuit Current Above
Threshold  Wire harness or
connector
B1012-71  Body Control
Module (BCM)
RR Window Down
Below Threshold
RR Window Down
Above Threshold
RR Window Down
41
B1013-71 Control Circuit
Actuator Stuck
CAUTION
Diagnosis Procedure
1 Check Body Control Module (BCM) fuse F8 (25 A)

c. Pull out the Body Control Module (BCM) fuse F8 (25 A).

F8 (25 A)

OK
OK
3 Check rear right door power glass regulator assembly
a. Check the rear right door power glass regulator assembly (See page 41-63).
NG Replace rear right door power glass

regulator assembly
OK

I-006 and I-003.
+ -
41 the instrument panel wire harness connectors I-006 and
Condition
I-006 (B21) -
Always Continuity
I-003 (8) 29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
I-006 (B23) -
I-003 (22)
I-003
RA19410810


I-003 and I-011.
Condition
14 13 12 11 10 9 8
I-003 (12) - I-011
Always Continuity
(14) I-011
29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14
I-003
RA19410820

below.
Condition
8 7 6 5 4 3 2 1

I-010
41
G-203
RA19410620
OK


B-052.
+ -
C1 C2 C3 C4 C5 C6 C7 C8 C9
Condition
B-049 (C6) - B-049

Always Continuity
B-052 (1)
B-049 (C7) - 7 6 5 4 3 2 1
B-052 (2)
B-052
RA19410840

B-052.
Condition
41 B-050 (8) - B-052

Always Continuity
28 27 26 25 24 23 22 21 20 19 18 17 16 15
(4) 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B-050 (22) - B-050

Always Continuity
B-052 (3)
B-050 (12) - 7 6 5 4 3 2 1
B-052 (9)
B-052
connector
OK


c. Disconnect the front left door wire harness connectors
F-004 and F-006.
+ -
1 2 3 4 5 6 7
Multimeter Specified 8 9 10 11 12 13 14
Condition
F-006
F-004 (14) - F-006
Always Continuity
(14)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
F-004
RA19410860
e. Disconnect the front left door wire harness connectors

F-004 and F-007.
Condition
F-004 (11) - F-007
Always Continuity
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
41
(5)
F-007
NG Repair or replace front left door wire

harness and connector 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
F-004
RA19410700
OK

7 Check rear right door wire harness and connector

c. Disconnect the rear right door wire harness connectors
R-001 and R-002.
+ -
the rear right door wire harness connectors R-001 and
R-002 according to the value(s) in the table below.
Condition
R-002
R-001 (1) - R-002
Always Continuity
(1)
R-001 (2) - R-002
(2) 8 9 10 11 12 13 14
R-001
RA19410880
e. Disconnect the rear right door wire harness connectors

R-001 and R-003.
the rear right door wire harness connectors R-001 and 
R-003 according to the value(s) in the table below. + -
Condition
6 7 8 9 10
41 R-001 (4) - R-003
Always Continuity
1 2 3 4 5
(6)
R-003
R-001 (3) - R-003
Always Continuity
(7)
R-001 (9) - R-003 1 2 3 4 5 6 7
(9)
R-001
NG Repair or replace rear right door wire RA19410890
OK
8 Reconfirm DTCs


Module (BCM) again.
h. Read the DTCs.
Result Proceed to
DTC B1011-18, B1011-19, B1011-71, B1012-18,
B1012-19, B1012-71, B1013-18, B1013-19 and NG
B1013-71 are output
No DTC output OK
OK
System is normal
41

ON-VEHICLE SERVICE
Glass Regulating Control Master Switch
Removal
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing the glass regulating control
master switch.
 Try to prevent the front door inner protector surface from being damaged when removing the glass
regulating control master switch.

3. Remove the glass regulating control master switch assembly.
a. Remove the rubber pad (1).
b. Remove the fixing screw (2) from the glass regulating
control master switch assembly.
(Tightening torque: 1.5 ± 0.5 N·m) 1
2
RA19410050
41
out the glass regulating control master switch
assembly.
RA19410060
d. Disconnect the glass regulating control master switch

assembly connector (arrow) and remove the glass
regulating control master switch assembly.
RA19410070

4. Remove the glass regulating control master switch.

out the claws (arrow) on the glass regulating control
master switch and remove the glass regulating control
master switch.
RA19410080
Inspection
1. Check the glass regulating control master switch.
a. Using a digital multimeter, check for continuity of glass
regulating control master switch according to the table
+ -
below.
1 2 3 4 5 6 7 8
Multimeter Switch Specified 9 10111213141516
Area
Front left UP Continuity

7 - 11
door glass OFF No continuity
regulating
and control DOWN Continuity RA19410090
6 - 11
switch OFF No continuity
UP Continuity
Front right 8 - 11
regulating DOWN Continuity
41
switch 5 - 11
OFF No continuity
UP Continuity
Rear left 11 - 15
switch 4 - 11
OFF No continuity
UP Continuity
Rear right 11 - 16
switch 3 - 11
OFF No continuity
If the result is not as specified, replace the glass


2. Check the glass regulating control master switch illumination.

a. Apply battery voltage to the terminals of glass
-
regulating control master switch connector and check +
the operation of glass regulating control master switch

according to the table below. 1 2 3 4 5 6 7 8
9 10111213141516
Specified
Battery positive Battery negative Condition
(+) (-)
13 11 LED comes on
RA19410091
Installation
CAUTION
 Check if the connector is correctly installed when installing the glass regulating control master switch.
 Check if the switch operates normally after installing the glass regulating control master switch.
41

Front Door Glass Assembly

Removal
HINT:
3. Remove the front left door glass outer weatherstrip.
out the clip on the front left door glass outer
weatherstrip.
b. Remove the front left door glass outer weatherstrip in
the directions of arrow as shown in the illustration.
RA19410161
7. Remove the front left door glass run.
a. Lower the front left door glass assembly to the proper
position and pull out the front left door glass run from
the slot.
41
RA19410160
8. Remove the front left door glass assembly.
CAUTION
 Try to prevent the window glass from being damaged due to dropping when removing the front door
glass assembly.

a. Raise the front left door glass assembly to the proper

position.
b. Using a screwdriver wrapped with protective tape, pry
out the clip and remove the front left door glass
assembly.
RA19410170
Installation
CAUTION
 Try to prevent the window glass from being damaged due to dropping when installing the front door glass
assembly.
41

Front Door Glass Front Guide Rail Assembly

Removal
HINT:
6. Remove the front left door glass assembly (See page 41-51).
7. Remove the front left door glass front guide rail assembly.
a. Remove 2 fixing bolts (2) from the front left door glass
front guide rail assembly, and remove the front left
door glass front guide rail assembly.
RA19410230
Installation
41
CAUTION
 After the glass regulating system is installed, make sure that the window glass can move up and down
smoothly and freely without any vibration, chattering or shock loading, etc.

Front Door Power Glass Regulator Assembly

Removal
HINT:
6. Remove the front left door glass assembly (See page 41-51).
7. Remove the front left door power glass regulator assembly.
out the clip on the connector.
b. Disconnect the connector (1) from the front left door
power glass regulator assembly.
1
RA19410250
c. Remove 5 fixing bolts (arrow) from the front left door

power glass regulator assembly, and remove the front
left door power glass regulator assembly.
41 (Tightening torque: 7 ± 1.5 N·m)
RA19410260
Inspection
1. Check the front door power glass regulator motor.
a. Apply battery voltage to the terminals of power glass
+ -
regulator motor connector, and check the operation of
power glass regulator motor according to the table
below.
2 1
Specified
(+) (-)
1 2 UP smoothly
RA19410270
2 1 Down smoothly
If the result is not as specified, replace the front door

power glass regulator motor.

Installation
CAUTION
 After the front door power glass regulator is installed, make sure that the window glass can move up and
down smoothly and freely without any vibration, chattering or shock loading, etc.
41

Glass Regulating Control Switch

Removal
HINT:
 Use the same procedures for the front right/rear right side and rear left side.
 The procedures listed below are for the rear left side.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing the glass regulating control
switch.
 Try to prevent the rear door inner protector surface from being damaged when removing the glass
regulating control switch.

3. Remove the left glass regulating control switch assembly.
a. Remove the rubber pad (1).
b. Remove the fixing screw (2) from the glass regulating
control switch assembly.
(Tightening torque: 1.5 ± 0.5 N·m) 1
RA19410100
41
out the glass regulating control switch assembly.
RA19410120
d. Disconnect the glass regulating control switch

assembly connector (arrow) and remove the left glass
regulating control switch assembly.
RA19410130

4. Remove the left glass regulating control switch.

out the claws (arrow) on the glass regulating control
switch and remove the left glass regulating control
switch.
RA19410140
Inspection
1. Check the glass regulating control switch.
a. Using a digital multimeter, check for continuity of glass
regulating control switch according to the table below.
+ -
1 2 3 4 5
Multimeter Switch Specified 6 7 8 9 10
Area
Front right UP Continuity

7-9
regulating
control DOWN Continuity
6-9
switch OFF No continuity RA19410150
UP Continuity
Rear left 7-9
switch 6-9 41
OFF No continuity
UP Continuity
Rear right 7-9
switch 6-9
OFF No continuity

2. Check the glass regulating control switch illumination.
a. Apply battery voltage to the terminals of glass
-
regulating control switch connector and check the +
operation of glass regulating control switch according 1 2 3 4 5

to the table below. 6 7 8 9 10
Specified
(+) (-)
1 3 LED comes on
RA19410151

Installation
CAUTION
 Check if the connector is correctly installed when installing the glass regulating control switch.
 Check if the switch operates normally after installing the glass regulating control switch.
41

Rear Door Glass Assembly

Removal
HINT:
1. Turn off all the electrical equipment and ignition switch
4. Remove the rear left door protector bracket (See page 45-38).
6. Remove the rear left door glass run.
a. Lower the rear left door glass assembly to the proper
position and pull out the rear left door glass run from
the slot.
RA19410180
7. Remove the rear left door glass assembly.
CAUTION
 Try to prevent the window glass from being damaged due to dropping when removing the rear door glass 41
assembly.
a. Raise the rear left door glass assembly to the proper position.
b. Remove 2 fixing screws (arrow) from the rear left door
glass assembly, and remove the rear left door glass
assembly.
RA19410190
Installation
CAUTION
 Try to prevent the window glass from being damaged due to dropping when installing the rear door glass
assembly.

Triangular Window Glass Assembly

Removal
HINT:
3. Remove the rear left door glass outer weatherstrip.
out the clip on the rear left door glass outer
weatherstrip.
b. Remove the rear left door glass outer weatherstrip in
the directions of arrow as shown in the illustration.
RA19410200
7. Remove the rear left door glass assembly (See page 41-59).
8. Remove the rear left door glass rear guide rail assembly (See page 41-62).
9. Remove the triangular window glass assembly.
41 a. Remove the triangular window glass assembly in the
RA19410210
b. Remove the triangular window glass rubber strip (1)

from the triangular window glass assembly.
RA19410220

Installation
CAUTION
 Try to prevent the window glass from being damaged due to dropping when installing the rear door glass
assembly.
41

Rear Door Glass Rear Guide Rail Assembly

Removal
HINT:
7. Remove the rear left door glass rear guide rail assembly.
a. Remove the rear left door opening weatherstrip.
HINT:
It is unnecessary to fully remove the rear left door opening weatherstrip. A fixing screw is inside the rear
left door opening weatherstrip.
b. Remove the fixing screw (arrow) from the rear left
door glass rear guide rail assembly.
c. Remove 2 fixing bolts (1) from the rear left door glass
rear guide rail assembly, and remove the rear left door
glass rear guide rail assembly.
1
41
RA19410240
Installation
CAUTION
 After the glass regulating system is installed, make sure that the window glass can move up and down
smoothly and freely without any vibration, chattering or shock loading, etc.

Rear Door Power Glass Regulator Assembly

Removal
HINT:
7. Remove the rear left door power glass regulator assembly.
out the clip on the connector.
b. Disconnect the connector (1) from the rear left door
power glass regulator assembly.
RA19410280
c. Remove 4 fixing bolts (arrow) from the rear left door

power glass regulator assembly.
1 41
d. Remove 3 fixing nuts (1) from the rear left door power
glass regulator assembly, and remove the rear left
door power glass regulator assembly.
RA19410290
Inspection
1. Check the rear door power glass regulator motor.
a. Apply battery voltage to the terminals of power glass
+ -
regulator motor connector, and check the operation of
power glass regulator motor according to the table
below.
Specified
Battery positive Battery negative Condition 2 1
(+) (-)
1 2 UP smoothly
RA19410300
2 1 Down smoothly
If the result is not as specified, replace the rear door

power glass regulator motor.

Installation
CAUTION
 After the rear door power glass regulator is installed, make sure that the window glass can move up and
down smoothly and freely without any vibration, chattering or shock loading, etc.
41

Front Windshield Assembly

Removal
HINT:
It is unnecessary to fully remove the roof assembly, but the front of the roof assembly needs to be lowered
to remove the front windshield assembly.
4. Remove the inside rear view mirror assembly (See page 42-12).
5. Remove the wiper arms assembly (See page 34-10).
7. Remove the front windshield weatherstrip.
8. Remove the rubber adjusting plates.
remove the rubber adjusting plates.
RA19410310
9. Remove the front windshield assembly.

a. Cut the adhesive with a knife. 41
Cut
RA19410320
CAUTION
 Try to prevent the body paint surface from being scratched when cutting the adhesive.
b. Apply protective tape to the outer surface of the body to prevent scratches.
CAUTION
 To prevent the instrument panel upper body assembly from being scratched, place a plastic sheet
between the piano wire and instrument panel upper body assembly.

c. Pass a piano wire through the seam between the

vehicle body and front windshield assembly.
d. Tie wooden blocks or similar objects to both piano
wire ends, cut off the adhesive by pulling the piano
wire around the front windshield assembly, and
remove the front windshield assembly.
RA19410330
CAUTION
 When removing the front windshield assembly, 2 persons are required.

 DO NOT drop the front windshield assembly when removing it.
 Leave as much adhesive on the body as possible when cutting the adhesive.
 When separating the front windshield assembly from the vehicle, be careful not to damage the body paint
and the interior and exterior ornaments.
10.Clean the vehicle body.

a. Using a knife, cut away any extra adhesive on the
contact surface of vehicle body as shown in the
illustration.
Adhesive
41
RA19410340
CAUTION
b. Clean the contact surface of vehicle body with cleaner.
CAUTION
 Even if all the adhesive has been removed, clean the vehicle body.

11. Clean the removed glass.
CAUTION
 DO NOT touch the glass after cleaning it.

 Even if new glass is used, clean it with glass cleaner.
a. Remove the adhesive sticking to the glass with a

scraper.
b. Clean the outer edges of the glass with glass cleaner.
RA19410350
Installation
1. Position the front windshield assembly.
a. Align the front windshield dowel pin with the
installation positioning hole on the tonneau cover
metal plate.
b. Check if the whole contact surface of the front
windshield rim is perfectly even.
c. Make matchmarks on the front windshield and vehicle
body at the positions shown in the illustration.
41
RA19410360
d. Remove the front windshield assembly.

2. Apply a coat of primer M to the contact surface of vehicle body.
CAUTION
 Allow the primer to dry for at least 3 minutes.

 DO NOT apply primer to the adhesive.
 DO NOT apply too much primer.
 DO NOT keep any opened primer M for later use.

a. Using a brush, apply a coat of primer M to the contact

surface of vehicle body. Primer M Primer M
b. The primer width is 15 - 17 mm.
Primer M Adhesive
RA19410370
3. Clean the contact surface of front windshield assembly.
CAUTION
 DO NOT touch the surface of front windshield after cleaning it.
a. Remove any residue on the contact surface of front

windshield assembly with a piece of clean cloth
soaked with glass cleaner.
RA19410380
41 4. Apply a coat of primer G to the contact surface of front windshield assembly.
CAUTION

 DO NOT keep any of the opened primer G for later use.
a. Using a brush or sponge, apply a coat of primer G to

the windshield rim and contact surface.
b. Use a clean cloth to wipe off the excess primer before
drying. Primer G 8 mm
c. The primer width is 8 mm.
RA19410390

5. Mix the adhesive.
CAUTION
 The adhesive should be mixed thoroughly within 5 minutes.
a. Using solvent, thoroughly clean the mixing board and

scraper.
b. Using a scraper, thoroughly mix the 500 g main
adhesive and 75 g hardener on the mixing board.
RA19410400
6. Apply the adhesive.

a. Cut off the tip of the cartridge nozzle and add the adhesive.
b. Install the cartridge to the sealer gun.
c. Apply adhesive evenly to the front windshield
assembly as shown in the illustration.
Adhesive width: 8 mm
Adhesive thickness: 13 - 14 mm
8 mm
13-14 mm 41
RA19410410
7. Install the front windshield assembly.
CAUTION
 Check that the lower/upper clearance and right/left clearance of front windshield are uniform to ensure
fitting well with the surrounding moulding.
a. Align the matchmarks on the windshield and vehicle

body, and gently press in the windshield along the rim. Matchmarks
RA19410420

b. Uniformly apply adhesive to the windshield rim with a

scraper.
c. Remove any excessive or spilled adhesive with a
scraper.
Adhesive
RA19410430
d. Apply tape around the windshield, and remove it when the adhesive becomes hard.
Adhesive thickness after compressing: 6 mm
8. Install the rubber adjusting plate.
9. Install the front windshield weatherstrip.
10.Check and repair the sealing of glass.
a. Check the glass for leakage after the adhesive has completely hardened.
b. If it leaks, seal the leaks with glass sealer.
12.Remove the wiper arms assembly (See page 34-10).
13.Remove the inside rear view mirror assembly (See page 42-12).
14.Remove the roof assembly (See page 47-28).
15.Disconnect the negative battery cable.
16.Turn off all the electrical equipment and ignition switch.
41

Rear Windshield Assembly

Removal
3. Remove the C-pillar upper protector assembly (See page 47-19).
HINT:
It is unnecessary to fully remove the roof assembly, but the rear of the roof assembly needs to be lowered
to remove the rear windshield assembly.
6. Remove the defroster negative wire harness assembly.
a. Remove the left defroster negative wire harness
connector (arrow).
RA19410440
b. Remove the right defroster positive wire harness

connector (arrow).
41
RA19410450
7. Remove the rear windshield weatherstrip.

8. Remove the rubber adjusting plates.
remove the rubber adjusting plates.
RA19410460

9. Remove the rear windshield assembly.

a. Cut the adhesive with a knife.
CAUTION
b. Apply protective tape to the outer surface of the

vehicle body to prevent scratches.
c. Pass a piano wire through the seam between body Cut
and rear windshield assembly.
RA19410320
d. Tie wooden blocks or similar objects to both piano

wire ends, cut off the adhesive by pulling the piano
wire around the rear windshield assembly, and
remove the rear windshield assembly.
41 RA19410470
CAUTION
 When removing the rear windshield assembly, 2 persons are required.

 DO NOT drop the rear windshield assembly when removing it.
 When separating the rear windshield assembly from the vehicle, be careful not to damage the body paint
or the interior and exterior ornaments.

10.Clean the vehicle body.

a. Using a knife, cut away any extra adhesive on the
contact surface of vehicle body as shown in the
illustration.
Adhesive
RA19410340
CAUTION
b. Clean the contact surface of vehicle body with cleaner.
CAUTION
 Even if all the adhesive has been removed, clean the vehicle body.
11. Clean the removed glass.
CAUTION
41
 DO NOT touch the glass after cleaning it.
 Even if new glass is used, clean it with glass cleaner.
a. Remove the adhesive sticking to the glass with a

scraper.
b. Clean the outer edges of the glass with glass cleaner.
RA19410350

Installation
1. Position the rear windshield assembly.
a. Align the rear windshield dowel pin with the
installation positioning hole on the tonneau cover
metal plate.
b. Check if the whole contact surface of rear windshield
rim is perfectly even.
c. Make matchmarks on the rear windshield and vehicle
body at the positions shown in the illustration.
RA19410480
d. Remove the rear windshield assembly.

2. Apply a coat of primer M to the contact surface of vehicle body.
CAUTION

 DO NOT keep any opened primer M for later use.
a. Using a brush, apply a coat of primer M to the contact

surface of vehicle body. Primer M Primer M
b. The primer width is 15 - 17 mm.

41
Primer M Adhesive
RA19410370
3. Clean the contact surface of rear windshield.
CAUTION
 DO NOT touch the surface of rear windshield after cleaning it.
a. Remove any residue on the contact surface of rear

windshield with a piece of clean cloth soaked with
glass cleaner.
RA19410380

4. Apply a coat of primer G to the contact surface of rear windshield assembly.
CAUTION

 DO NOT keep any of the opened primer G for later use.
a. Using a brush or sponge, apply a coat of primer G to

the windshield rim and contact surface.
b. Use a clean cloth to wipe off the excess primer before
drying. Primer G 8 mm
c. The primer width is 8 mm.
RA19410390
5. Mix the adhesive.
CAUTION
 The adhesive should be mixed thoroughly within 5 minutes.
a. Using solvent, thoroughly clean the mixing board and

scraper.
41
b. Using a scraper, thoroughly mix the 500 g main
adhesive and 75 g hardener on the mixing board.
RA19410400
6. Apply the adhesive.

a. Cut off the tip of the cartridge nozzle and add the adhesive.
b. Install the cartridge to the sealer gun.
c. Apply adhesive evenly to the rear windshield
assembly as shown in the illustration.
Adhesive width: 8 mm
Adhesive thickness: 13 - 14 mm
8 mm
13-14 mm
RA19410410

7. Install the rear windshield assembly.
CAUTION
 Check that the lower/upper clearance and right/left clearance of rear windshield are uniform to ensure
fitting well with the surrounding moulding.
a. Align the matchmarks on the windshield and vehicle

body, and gently press in the windshield along the rim. Matchmarks
RA19410490
b. Uniformly apply adhesive to the windshield rim with a

scraper.
c. Remove any excessive or spilled adhesive with a
scraper.
Adhesive
RA19410430
41
d. Apply tape around the windshield, and remove it when the adhesive becomes hard.
Adhesive thickness after compressing: 6 mm
8. Install the rubber adjusting plate.
9. Install the rear windshield weatherstrip.
10.Check and repair the sealing of glass.
a. Check the glass for leakage after the adhesive has completely hardened.
b. If it leaks, seal the leaks with glass sealer.
12.Remove the tonneau cover assembly (See page 47-34).
13.Remove the C-pillar upper protector assembly (See page 47-19).

Rear Defroster
General Information
Description
Rear Window Defogger Wire
41
RA19410500
Turn the rear defroster switch on, and heat defroster wire to remove the fog, frost or water vapors on the rear
windshield, thus realizing a clear view.
To open the rear defroster, turn the ignition switch to ON and press the rear defroster switch. The rear
defroster switch indicator comes on while the rear defroster operation begins. The rear defroster stops and
the indicator turns off after pressing the rear defroster switch again.

Circuit Diagram
Rear Defroster System

BATTERY
POWER ENGINE
EF12 FUSE EF05 COMPARTMENT RF23 85 30 INSTRUMENT
BOX 40A FUSE AND DEFROST RF03 RF16 PANEL
80A 30A
B-009 RELAY BOX RELAY FUSE AND
10A 10A RELAY BOX
E3 B-010 86 87 I-005
3 16
R
R
8
RB
2
B-021 I-047
RB
1
R
RW
RY
V
REAR
DEFROSTER
B-039
41
F1 A16 B31 B15

BCM
I-046
I-006
B-048
1 2 3 4 1 1 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32
1 E4 E3 E2 E1 5 6 7 8 I-046
G
B-039 B-009
B-048 B-010 B
Gr W B-021
W
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26 I-005
87 B
I-006 85 86 86 86
87 30 87 30
L 30 85 85
EA19410040


HINT:

Fuse 49-27
Rear defroster switch is turned on but does Rear defroster switch 41-80
not operate (indicator on) Rear defroster wire -
Fuse 49-27
Rear defroster switch is turned on but does
Rear defroster switch 41-80
not operate (indicator off)
Ground -
Rear defroster has intermittent problem
41

Removal & Installation - Rear Defroster Switch

Removal
HINT:
The rear defroster switch is installed on the A/C control panel assembly, and cannot be disassembled.
CAUTION
 Be sure to wear safety equipment to prevent accidents when removing the rear defroster switch.
 Appropriate force should be applied when removing the rear defroster switch, and avoid operating
roughly.
 Try to prevent the interior ornament from being scratched when removing the rear defroster switch.

out the clips on the center control panel assembly.
4 RDM
3 1 RPT
5 DN
2 UP
6
3
disc
mp3 TUNE
VOL
MUTE
USB CD BAND AST

SET
AUX
SEL
0 1
3
A/C
4
CARD CARD
RA19410510
41
b. Disconnect the warning light switch connector and
remove the center control panel assembly.
RA19410520
4. Remove the A/C control panel.

a. Remove 2 fixing screws (arrow) from the A/C control
panel.
out the clips on the A/C control panel.
RA19410530

c. Disconnect the connectors (arrow) from the A/C CD
BAN
D
SCA
AST
N
control panel and remove the A/C control panel.

SET
RA19410550
Installation
CAUTION
 Install the connector in place when installing the rear defroster switch.
 Always operate carefully to prevent the components from being damaged when installing the rear
defroster switch.
 Check if the switch operates normally after installing the rear defroster switch.
41

- MEMO -

REAR VIEW MIRROR
Description 42-3 Outside Rear View Mirror 
Specification 42-4 Lens Assembly 42-10
Circuit Diagram 42-5 Inspection 42-11
Installation 42-11
DIAGNOSIS & TESTING 42-7 Inside Rear View Mirror Assembly 42-12
Problem Symptoms Table 42-7 Removal 42-12
Service Precautions 42-7 Installation 42-12
ON-VEHICLE SERVICE 42-8 Outside Rear View Mirror 
Adjustment Switch Assembly 42-13
Outside Rear View Mirror 
Assembly 42-8 Removal 42-13
42

42

42 - REAR VIEW MIRROR
GENERAL INFORMATION
REAR VIEW MIRROR
Description
3
2
RA19420010
42
1 - Left Outside Rear View Mirror 2 - Outside Rear View Mirror Adjustment Switch
Assembly
3 - Inside Rear View Mirror 4 - Right Outside Rear View Mirror
This vehicle is equipped with power outside rear view mirror and inside rear view mirror.
Power outside rear view mirror: the driver can control the rotation of motor by operating the outside rear view
mirror adjustment switch in the vehicle, thus adjusting the mirror surface to achieve the required visual angle.
The power outside rear view mirror adjustment switch is located on the instrument panel left end cover
assembly. With the ignition switch ON, press the outside rear view mirror switch to "L" or "R" position to select
the left or right outside rear view mirror to be adjusted, and then press the rear view mirror up or down and left
or right button to achieve a required visual angle.
When there is fog or frost on the power outside rear view mirror lens, the heat defogger wire in the lens can
remove the fog or frost by heating the lens with the rear window defogger switch being pressed.
It is necessary to adjust the inside rear view mirror manually to the desired direction. When driving at night,
the rear view mirror angle can be adjusted by pulling back the glare-resistant rod to reduce glare.

Specification

Outside Rear View Mirror Assembly Fixing Nut 7 ± 1.5
Tool
General Tool
Digital Multimeter
RCH0000002
42

Circuit Diagram
System Circuit Diagram for Rear View Mirror (Page 1 of 2)

BATTERY
POWER ENGINE
FUSE COMPARTMENT INSTRUMENT
EF12 EF05 85 30 PANEL
BOX FUSE AND DEFROST
80A 40A RF03 RF23 RF26 RF16 FUSE AND
B-009 RELAY BOX RELAY
B-010 10A 30A (RRY3) 10A 10A RELAY BOX
E3 86 87 I-005
R
3 26 16
R
B-021 I-047
RB
A
RW
RY
R
42
F1 B31 A16 B15

BCM
I-046
I-006
A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 B-048 1 2 3 4 B-021
I-046 1 B-010
Gr 5 6 7 8 W E4 E3 E2 E1
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 G W
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 1
25 26 I-005
I-006
B32 B31 B30 B29 B28 B27 B26 B25 B24 B23 B22 B21 B20 B19 B18 B17 87 B B-009
L
85 86 86 86
87 30 87 30
30 85 85
EA19420010

System Circuit Diagram for Rear View Mirror (Page 2 of 2)
IGNITION SWITC
ON
INSTRUMENT
PANEL
RF09 FUSE AND
10A RELAY BOX
I-005
9
ILLUMINATION
RL
P
5 2
REAR VIEW
UP DOWN UP DOWN RH LH RH LH MIRROR
ADJUSTMENT
SWITCH
LH LH RH I-008
RH
MIRROR MIRROR MIRROR MIRROR
4 9 7 1 10 6
RW
WB
GR
PB
Lg
B
I-012
GR
GR
6 15 16 I-010 I-030 10 5 5 I-029
F-007 H-003 H-004
WB
GR
GR
RW
PB
Lg
7 6 8 8 6 7
UP LH LH UP POWER
POWER
REAR VIEW M M REAR VIEW
M M MIRROR
MIRROR
RH MOTOR RH DN MOTOR
DN
F-009 H-001
42
3 10 3 10
RB
RB
B
F-006 F-007 H-004

I-011 7 5 I-029 12 6
I-010
B
B
RB
RB
I-012 I-028
A
5 4 3 2 1 I-010 I-029 4 3 2 1 I-030

I-008 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
10 9 8 7 6 W 14 13 12 11 10 9 8 W 10 9 8 7 6 5 W
B 16 15 14 13 12 11 10 9
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24 5 4 3 2 1 7 6 5 4 3 2 1
F-009 H-001 I-011
I-005 12 11 10 9 8 7 6 W W 14 13 12 11 10 9 8 W
25 26
87 B
85 86 86 86
87 30 87 30
30 85 85
EA19420020

DIAGNOSIS & TESTING

HINT:
sequence. Repair or replace the suspected parts, or adjust it.
Symptom Suspected Area See Page

Fuse 49-28
Outside rear view mirror adjustment switch
42-13
Outside rear view mirror cannot operate assembly
Outside rear view mirror assembly 42-8
Fuse 49-28
Rear defroster switch 41-80
Outside rear view mirror cannot defrost Outside rear view mirror assembly 42-8
Outside rear view mirror intermittent Ground 49-22

malfunction Wire harness or connector -
Service Precautions
Visual inspection can reduce the unnecessary test and diagnostic time, so pay attention to the following
inspection items:
1. Check if the fuse is damaged. 42
2. Check if the wire harnesses and connectors related to the rear view mirror are worn, pierced, pinched or
partially broken.
3. Check if the wire harnesses and connectors related to the rear view mirror are broken, bent, protruded or
corroded terminals.
4. Check if the terminal contact pins of the wire harnesses and connectors related to the rear view mirror are
in good condition.

ON-VEHICLE SERVICE
Outside Rear View Mirror Assembly
Removal
HINT:
CAUTION
 When removing the outside rear view mirror assembly, make sure to wear safety equipment to prevent
accidents.
 When removing the outside rear view mirror assembly, operate carefully to prevent damage to the
components.
 When removing the outside rear view mirror assembly, prevent scratching the interior and body paint
surface.

4. Remove the left outside rear view mirror assembly.
a. Disconnect the outside rear view mirror connector (1).
1
42
RA19420020
b. Remove 3 fixing nuts (arrow) from the outside rear

view mirror assembly.
RA19420030
c. Remove the left outside rear view mirror assembly.

Inspection
1. Check the left outside rear view mirror assembly.
+ -
a. Apply battery voltage to the terminals of outside rear
view mirror connector and check the operation of
outside rear view mirror according to the table below.
Specified 1 2 3 4 5
Condition 6 7 8 9 10 11 12

UP
RA19420040
DOWN
LEFT
RIGHT
If the result is not as specified, replace the left outside

rear view mirror assembly.
Installation
CAUTION
 Connect the connector in place and tighten the fixing nuts to the specified torque when installing the
outside rear view mirror assembly.
 Make sure the outside rear view mirror assembly can move smoothly after installing.
42

Outside Rear View Mirror Lens Assembly

Removal
HINT:
CAUTION
 Avoid breaking the claw when removing the outside rear view mirror lens assembly.
 Avoid damaging the lens due to dropping when removing the outside rear view mirror lens assembly.
 Prevent the body paint surface from being scratched when removing the outside rear view mirror lens
assembly.
1. Remove the left outside rear view mirror lens assembly.

a. Press the outside rear view mirror surface to tilt it.
b. Apply protective tape around the outside rear view mirror.
detach the claws (arrow) of outside rear view mirror
lens.
RA19420050
42 d. Disconnect the connectors (arrow) from the outside

rear view mirror lens.
RA19420051
e. Remove the left outside rear view mirror lens assembly.

Inspection
1. Check the left outside rear view mirror lens assembly
heater. + -
a. Apply battery voltage to the terminals of outside rear

view mirror lens assembly connector and check the +
operation of outside rear view mirror lens assembly -
Specified
Condition
Outside rear view RA19420041
Battery positive Battery negative
mirror lens
(+) (-)
become warm
HINT:
The outside rear view mirror lens become warm in a
short time.
If the result is not as specified, replace the left outside
rear view mirror lens assembly.
Installation
CAUTION
 Connect the connectors in place when installing the outside rear view mirror assembly.
 Make sure the outside rear view mirror lens assembly can move smoothly when installing.
42

Inside Rear View Mirror Assembly

Removal
CAUTION
 Appropriate force should be applied when removing the rear trunk trim assembly, and avoid operating
roughly.
 Prevent the front windshield from being scratched when removing the inside rear view mirror assembly.
1. Remove the inside rear view mirror assembly.

a. Rotate the inside rear view mirror assembly by 90°.
RA19420060
b. Remove the inside rear view mirror assembly in the

42
RA19420070
Installation
CAUTION
 Make sure the inside rear view mirror assembly can move smoothly after installing.

Outside Rear View Mirror Adjustment Switch Assembly

Removal
CAUTION
 Prevent the interior from being scratched when removing the outside rear view mirror adjustment switch
assembly.

3. Remove the outside rear view mirror adjustment switch assembly.
out the headlight adjustment switch unit.
RA19420080
b. Disconnect the outside rear view mirror adjustment

switch connector (arrow).
42
RA19420090

detach the claws of outside rear view mirror
adjustment switch assembly (arrow).
RA19420100
d. Remove the outside rear view mirror adjustment switch assembly.

Inspection
1. Check the outside rear view mirror adjustment switch
assembly.
+ -
a. Adjust the outside rear view mirror adjustment switch 1 2 3 4 5
assembly to "L" position. 6 7 8 9 10
b. Using a multimeter, check for continuity between

terminals of the outside rear view mirror adjustment
switch assembly according to the following table.

Connecting
Condition Condition RA19420110
Terminal
1 - 10 UP Continuity
1-5 OFF No continuity
5 - 10 DOWN Continuity
5-9 LEFT Continuity
10 - 4 OFF No continuity
5 - 10 RIGHT Continuity
If the result is not as specified, replace the outside

rear view mirror adjustment switch assembly.
c. Adjust the outside rear view mirror adjustment switch
assembly to "R" position.
+ -
d. Using a multimeter, check for continuity between 1 2 3 4 5
terminals of the outside rear view mirror adjustment 6 7 8 9 10
switch assembly according to the following table.

42
Connecting
Condition Condition
Terminal
4-6 UP Continuity RA19420110

5-6 DOWN Continuity
5-7 LEFT Continuity
5-6 RIGHT Continuity
If the result is not as specified, replace the outside

rear view mirror adjustment switch assembly.

Installation
CAUTION
 Connect the connectors in place when installing the outside rear view mirror adjustment switch
assembly.
 Operate carefully to prevent damage to other components during installing the outside rear view mirror
adjustment switch assembly.
 Check that the switch can operate normally after installing the outside rear view mirror adjustment switch
assembly.
42

- MEMO -

INSTRUMENT PANEL
GENERAL INFORMATION 43-3 Disassembly 43-24
Tools 43-9 Instrument Panel Lower Body 
Assembly 43-26
Auxiliary Fascia Console Assembly 43-10 Disassembly 43-26
Disassembly 43-13 Installation 43-27
Assembly 43-15 Instrument Panel Crossmember 
Installation 43-15 Assembly 43-28
Instrument Panel Upper Body  Removal 43-28
Assembly 43-16 Installation 43-30
Removal 43-16
43

43

43 - INSTRUMENT PANEL
GENERAL INFORMATION
INSTRUMENT PANEL
Description
Auxiliary Fascia Console Assembly
1 3
5
2 4
6
11 14
3
4
5
×2
13
×2
10
12
6
43
×2
×2
×2
×2
7
9
RA19430010

1 - Shift Knob and Shift Lever Boot Assembly 2 - AUX/USB Interface

3 - Gearshift Cover Plate Assembly 4 - Auxiliary Fascia Console Left Extension Panel
Assembly
5 - Gearshift Front Cover Plate 6 - Auxiliary Fascia Console Right Extension Panel
Assembly
7 - Auxiliary Fascia Console Assembly 8 - Auxiliary Fascia Console Rear Cover Plate
Assembly
9 - Auxiliary Fascia Console Rear Storage Box 10 - Armrest Box Gasket
11 - Armrest Box Cover Assembly 12 - Cigarette Lighter Assembly
13 - Coin Box Assembly 14 - Portable Ashtray Assembly
43

Instrument Panel Assembly
2
24
3
23
22 4
×4 ×6 ×4
21
19 5
20 ×4
17
18
16
×4
×2
9
12 ×11
×2
×3
10
43
STOR
AGE
BOX
7
15 14 13 ×4
8
11
RA19430020

1 - Anti-theft Indicator 2 - Front Defroster Grille

3 - Instrument Panel Upper Body Assembly 4 - Right Outlet Assembly
5 - Instrument Panel Right End Cover Assembly 6 - Instrument Panel Lower Body Assembly
7 - Glove Box Assembly 8 - Glove Box Lock
9 - A/C Control Panel 10 - Instrument Panel Storage Box Panel
11 - Instrument Panel Front Storage Box 12 - Center Console Switch
13 - Instrument Panel Left Lower Protector Assembly 14 - Hood Grip Assembly
15 - Instrument Panel Storage Box 16 - Headlight Adjustment Switch Set
17 - Single Disc CD Player/Electrical Modulation 18 - Center Control Panel Assembly
Radio Receiver + USB
19 - Instrument Cluster Lower Garnish Assembly 20 - Instrument Cluster Adjustment Button
21 - Instrument Cluster 22 - Left Outlet Assembly
23 - Instrument Panel Left End Cover Assembly 24 - Instrument Cluster Cover Assembly
43

×3
2
×12
×3
3
5 6
×4
43
×2
RA19430021
1 - Instrument Panel Upper Body Assembly 2 - Left A/C Duct Assembly

3 - Center Main Duct Cover Plate 4 - Right A/C Duct Assembly
5 - Instrument Panel Lower Body Assembly 6 - Glove Box Upper Trim Board
7 - Glove Box Holder
The instrument panel of this model consists of auxiliary fascia console assembly, instrument panel upper body
assembly, instrument panel lower body assembly and instrument panel crossmember system.

Specifications

9±1
Box Fixing Bolt
2 ± 0.2
Box Fixing Screw
Auxiliary Fascia Console Extension Panel Assembly
2 ± 0.2
Fixing Screw
Auxiliary Fascia Console Rear Cover Plate
2 ± 0.2
Assembly Fixing Screw
Auxiliary Fascia Console Rear Storage Box Fixing
2 ± 0.2
Screw
Armrest Box Cover Assembly Fixing Screw 2 ± 0.2
Gearshift Front Cover Plate Fixing Screw 2 ± 0.2
Instrument Panel Left Lower Protector Assembly
2 ± 0.2
Fixing Screw
Single Disc CD Player/Electrical Modulation Radio
8±1
Receiver + USB Fixing Screw
A/C Control Panel Fixing Screw 1.5 ± 0.5
Instrument Panel Upper Body Assembly Fixing
2 ± 0.2
Screw
Instrument Panel Upper Body Assembly Fixing Bolt 9±1
Instrument Panel Lower Body Assembly Fixing Bolt 9±1
Instrument Panel Lower Body Assembly Fixing Nut 7±1
43 Outlet Assembly Fixing Screw 2 ± 0.2
Instrument Panel Storage Box Fixing Screw 2 ± 0.2
Glove Box Lock Fixing Screw 2 ± 0.2
Instrument Panel Front Storage Box Fixing Screw 2 ± 0.2
Center Main Duct Cover Plate Fixing Screw 2 ± 0.2
A/C Duct Assembly Fixing Screw 2 ± 0.2
Glove Box Upper Trim Board Fixing Screw 2 ± 0.2
Glove Box Holder Fixing Screw 2 ± 0.2
Diagnostic Interface Fixing Screw 2 ± 0.2
Body Control Module Fixing Bolt 7±1
Instrument Panel Fuse and Relay Box Fixing Bolt 7±1
Front Passenger Airbag Fixing Bolt 10 ± 1.5
Steering Column Fixing Bolt 25 ± 3
Steering Column Fixing Nut 25 ± 3
Instrument Panel Crossmember Assembly Fixing
25 ± 4
Bolt

Tools
Special Tools
RCH0000014
Interior Crow Plate
RCH0000025
43

ON-VEHICLE SERVICE
Auxiliary Fascia Console Assembly
Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the auxiliary fascia console
assembly.
 Appropriate force should be applied when removing the auxiliary fascia console assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the auxiliary fascia console assembly.

3. Remove the portable ashtray assembly in the direction of
RA19430030
4. Remove the cigarette lighter assembly (1).
43 1
RA19400020

5. Remove the shift knob and shift lever boot assembly.

up the clips of shift lever boot assembly.
b. Pull out the shift knob in the direction of arrow as
RA19430040
c. Remove the shift knob and shift lever boot assembly.

6. Remove the coin box assembly.
up the clips of coin box assembly.
RA19430060
b. Remove the coin box assembly.

7. Remove the auxiliary fascia console left extension panel assembly (take left side as an example).
a. Remove the fixing screw (arrow) from the auxiliary
fascia console extension panel assembly.
off the clips from the auxiliary fascia console
extension panel assembly. 43
RA19430070
c. Remove the auxiliary fascia console left extension panel assembly.

8. Remove the auxiliary fascia console assembly.
a. Remove 3 fixing screws (arrow) from the side of
auxiliary fascia console assembly (take left side as an
example).
RA19430090

b. Remove 2 fixing screws (arrow) from the front part of

auxiliary fascia console assembly.
AUX
RA19430091
c. Remove the armrest box gasket from the auxiliary

fascia console assembly rear armrest box.
RA19430110
d. Remove 2 fixing bolts (arrow) from the auxiliary fascia

console assembly rear armrest box.
RA19430120
43
e. Disconnect the AUX/USB interface connector (arrow).
AUX
RA19430100

f. Lift up the rear part of auxiliary fascia console

assembly to disconnect the cigarette lighter connector
(arrow) and remove the auxiliary fascia console
assembly.
RA19430130
Disassembly
1. Remove the auxiliary fascia console rear cover plate assembly.
a. Remove 2 fixing screws (arrow) from the auxiliary
fascia console rear cover plate assembly.
RA19430140

up the clips of auxiliary fascia console rear cover plate
assembly.
43
RA19430141
c. Remove the auxiliary fascia console rear cover plate assembly.

2. Remove the auxiliary fascia console rear storage box.
a. Remove the fixing screw (arrow) from the auxiliary
fascia console rear storage box.
RA19430170


up the claws (arrow) on both sides of the auxiliary
fascia console rear storage box.
RA19430160
c. Remove the auxiliary fascia console rear storage box.

3. Remove the armrest box cover assembly.
a. Remove 2 fixing screws (arrow) from the armrest box
cover assembly.
RA19430180
b. Remove the armrest box cover assembly.

4. Remove the AUX/USB interface.
a. Press and hold the clip on the AUX/USB interface in
43
RA19430190
b. Remove the AUX/USB interface.

5. Remove the gearshift cover plate assembly.
off the clips from the gearshift cover plate assembly.
RA19430200
b. Remove the gearshift cover plate assembly.

6. Remove the gearshift front cover plate.

a. Remove 2 fixing screws (arrow) from the gearshift
front cover plate.
RA19430210

off the clip from the gearshift front cover plate.
RA19430220
c. Remove the gearshift front cover plate.
Assembly
Installation
CAUTION
43
 Make sure to tighten the fixing bolts and fixing screws to the specified torque when installing the auxiliary
fascia console assembly.
 Check each electrical equipment for proper operation after installing the auxiliary fascia console
assembly.

Instrument Panel Upper Body Assembly

Removal
WARNING
 Wait at least 60 seconds after disconnecting the negative battery cable to disable the supplementary
restraint system.
 When removing and installing the instrument panel assembly, all components related to airbag should be
operated with the battery power source off. It is forbidden to operate them with the power source on.
Because within 60 seconds after the vehicle stops or fuse removed, there is enough power inside the
airbag control module for activating the airbag, and the airbag can be accidentally activated, causing
personal injury or vehicle damage.
 DO NOT expose airbag components to hot air or flame.
 The removed airbag should be well kept. If triggered accidentally, the airbag may cause personal injury.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the instrument panel upper
body assembly.
 DO NOT scratch the interior and body paint when removing the instrument panel upper body assembly.

3. Remove the headlight adjustment switch set.
out the headlight adjustment switch set.
43
RA19420080
b. Disconnect the outside rear view mirror adjustment

switch connector (1), headlight leveling adjustment
switch connector (2) and luggage compartment door
opener switch connector (3).
2
3
1
RA19430231
c. Remove the headlight adjustment switch set.

4. Remove the front doorsill pressure plate assembly (See page 47-8).
5. Remove the front door opening weatherstrip (See page 47-23).
6. Remove the A-pillar lower protector assembly (See page 47-12).
7. Remove the instrument panel left end cover assembly (take left side as an example).
off the clips from the instrument panel end cover
assembly.
RA19430240
b. Remove the instrument panel left end cover assembly.

8. Remove the left outlet assembly (take left side as an example).
a. Remove the fixing screw (arrow) from the outlet
assembly.
off the clip from the outlet assembly.
RA19430250
c. Remove the left outlet assembly.

9. Remove the instrument panel left lower protector assembly.
a. Remove the hood grip assembly (See page 45-15).
b. Remove 3 fixing screws (arrow) from the instrument
43
panel left lower protector assembly.
RA19430270

c. Using an interior crow plate, pry off the clips from the
instrument panel left lower protector assembly.
RA19430271
d. Remove the instrument panel left lower protector assembly.

10.Remove the instrument panel storage box.
a. Remove the fixing screw (arrow) from the storage
box.
RA19430260
b. Remove the claws (arrow) on both sides of the

storage box.
43
RA19430280
c. Remove the instrument panel storage box from the instrument panel left lower protector assembly.
11. Remove the instrument cluster cover assembly.
off the clips from the instrument cluster cover
assembly.
RA19430290
b. Remove the instrument cluster cover assembly.

12.Remove the instrument cluster lower garnish assembly.

off the clips from the instrument cluster lower garnish
assembly.
RA19430300
b. Remove the instrument cluster lower garnish assembly.

13.Remove the anti-theft indicator.
up the clips (arrow) of anti-theft indicator.
RA19430451
b. Disconnect the anti-theft indicator connector (arrow).
43
RA19430460
c. Remove the anti-theft indicator.

14.Remove the front defroster grille.
up the clips of front defroster grille.
RA19430462
b. Remove the front defroster grille.

15.Remove the driver airbag (See page 30-41).

16.Remove the steering wheel assembly (See page 27-9).
17.Remove the spiral cable (See page 30-44).
18.Remove the combination switch cover (See page 27-12).
19.Remove the headlight, turn light and fog light switch assembly.
20.Remove the wiper switch assembly (See page 34-8).
21.Remove the instrument cluster (See page 36-34).
22.Remove the center control panel assembly.
off the clips from the center control panel assembly.
A/C
RA19430310

(arrow).
RA19430320
c. Remove the center control panel assembly.

43 23.Remove the single disc CD player/electrical modulation radio receiver + USB.
a. Remove 4 fixing screws (arrow) from the single disc
CD player/electrical modulation radio receiver + USB.
A/C
RA19430330


from the single disc CD player/electrical modulation
radio receiver + USB.
RA19430340
c. Remove the single disc CD player/electrical modulation radio receiver + USB.

24.Remove the A/C control panel.
a. Remove 2 fixing screws (arrow) from the A/C control
panel.
off the clips from the A/C control panel.
A/C
RA19430350
c. Disconnect the connectors (arrow) from the A/C

control panel.
43
RA19430360
d. Remove the A/C control panel.

25.Remove the instrument panel storage box panel.
off the clips from the instrument panel storage box
panel.
STORAGE BOX
RA19430370

b. Disconnect the center console switch connector

(arrow).
RA19430380
c. Remove the instrument panel storage box panel.

26.Remove the center console switch.
a. Remove the clips (arrow) from the center console
switch.
STOPAGE BOX
RA19430390
b. Remove the center console switch from the instrument panel storage box panel.
27.Remove the instrument panel front storage box.
a. Remove 4 fixing screws (arrow) from the instrument
panel front storage box.
43
RA19430400
b. Remove the instrument panel front storage box from the instrument panel storage box panel.
28.Remove the instrument cluster adjustment button.
a. Disconnect the instrument cluster adjustment button
connector (arrow).
RA19430450
b. Remove the instrument cluster adjustment button.

29.Remove the glove box lock.

a. Open the glove box assembly.
b. Remove 2 fixing screws (arrow) from the glove box
lock. SRS
RA19430421
c. Remove the glove box lock.

30.Remove the glove box assembly.
a. Disengage the claws on both sides of the glove box
assembly.
SRS
RA19430410
b. Remove the claws (arrow) from the lower part of glove

box assembly. SRS
43
RA19430420
c. Remove the glove box assembly.

31.Remove the A-pillar upper protector assembly (See page 47-10).
32.Remove the instrument panel upper body assembly.
a. Disconnect the front passenger airbag connector (1).
b. Remove 2 fixing bolts (arrow) from the front 1
passenger airbag assembly.
RA19430440

c. Remove 4 fixing bolts (1) and 6 fixing screws (arrow)

from the instrument panel upper body assembly. 1
(Tightening torque for screw: 2 ± 0.2 N·m) 1 1
RA19430430
d. Using an interior crow plate, pry off the clips from the
instrument panel upper body assembly.
RA19430431
e. Remove the instrument panel upper body assembly.
Disassembly
CAUTION
 Make sure to wear safety equipment to prevent accidents when disassembling the instrument panel
upper body assembly.
 DO NOT scratch the instrument panel surface when disassembling the instrument panel upper body
assembly.
43
1. Remove the A/C duct assembly.
a. Remove 6 fixing screws (arrow) from the A/C duct
assembly.
RA19430490
b. Remove the A/C duct assembly.

2. Remove the center main duct cover plate.

a. Remove 12 fixing screws (arrow) from the center main
duct cover plate.
RA19430500
b. Remove the center main duct cover plate.

3. Remove the front passenger airbag.
a. Disengage the clips from the front passenger airbag.
RA19430510
b. Remove the front passenger airbag.
Assembly
Installation
CAUTION
 Make sure to tighten the fixing bolts and fixing screws to the specified torque when installing the
instrument panel upper body assembly.
 Check the airbag for proper installation after installing the instrument panel upper body assembly.
 Check that the horn operates properly after installing the instrument panel upper body assembly.
 Check the SRS warning light and make sure the supplementary restraint system operates properly after
installing the instrument panel upper body assembly.
 Check each electrical equipment for proper operation after installing the instrument panel upper body
assembly.

Instrument Panel Lower Body Assembly

Removal
WARNING
 Wait at least 60 seconds after disconnecting the negative battery cable to disable the supplementary
restraint system.
 When removing and installing the instrument panel assembly, all components related to airbag should be
operated with the battery power source off. It is forbidden to operate them with the power source on.
Because within 60 seconds after the vehicle stops or fuse removed, there is enough power inside the
airbag control module for activating the airbag, and the airbag can be accidentally activated, causing
personal injury or vehicle damage.
 DO NOT expose airbag components to hot air or flame.
 The removed airbag should be well kept. If triggered accidentally, the airbag may cause personal injury.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the instrument panel lower
body assembly.
 DO NOT scratch the interior and body paint when removing the instrument panel lower/upper body
assembly.

3. Remove the instrument panel upper body assembly (See page 43-16).
4. Remove the instrument panel lower body assembly.
a. Remove 11 fixing bolts (arrow) and 4 fixing nuts (1)
43 from the instrument panel lower body assembly. 1
(Tightening torque for nut: 7 ± 1 N·m)
RA19430470
b. Remove the instrument panel lower body assembly.
Disassembly
CAUTION
 Make sure to wear safety equipment to prevent accidents when disassembling the instrument panel
lower body assembly.
 DO NOT scratch the instrument panel surface when disassembling the instrument panel lower body
assembly.

1. Remove the glove box holder.

a. Remove 2 fixing screws (arrow) from the glove box
holder.
RA19430520
b. Remove the glove box holder.

2. Remove the glove box upper trim board.
a. Remove 4 fixing screws (arrow) from the glove box
upper trim board.
RA19430521
b. Remove the glove box upper trim board.
Assembly
Installation
CAUTION
 Make sure to tighten the fixing bolts and fixing nuts to the specified torque when installing the instrument
panel lower body assembly.
 Check the airbag for proper installation after installing the instrument panel lower body assembly.
 Check that the horn operates properly after installing the instrument panel lower body assembly.
installing the instrument panel lower body assembly.
 Check each electrical equipment for proper operation after installing the instrument panel lower body
assembly.


Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the instrument panel
 DO NOT scratch the interior and body paint when removing the instrument panel crossmember
assembly.

3. Remove the instrument panel upper body assembly (See page 43-16).
4. Remove the instrument panel lower body assembly (See page 43-26).
5. Remove the body control module.
a. Disconnect the body control module connectors (1).
b. Remove 2 fixing bolts (arrow) from the body control 1
module.
1
RA19430530
c. Remove the body control module.

6. Remove the instrument panel fuse and relay box.
43 a. Remove 2 fixing bolts (arrow) from the instrument
panel fuse and relay box.
RA19430540
b. Remove the instrument panel fuse and relay box.

7. Remove the diagnostic interface.

a. Remove 2 fixing screws (arrow) from the diagnostic
interface.
RA19430550
b. Remove the diagnostic interface.

8. Disconnect the ignition switch connectors (arrow).
RA19430570
9. Disconnect the brake switch connector (arrow).
43
RA19430580
10.Separate the steering column.

a. Remove 2 fixing nuts (arrow) and 1 fixing bolt (1) from
the steering column.
(Tightening torque for nut: 25 ± 3 N·m)
(Tightening torque for bolt: 25 ± 3 N·m) 1
RA19430560
b. Separate the steering column from the instrument panel crossmember.

11. Separate the instrument panel wire harness.

remove the clips from the instrument panel wire
harness.
RA19430590
b. Separate the instrument panel wire harness from the instrument panel crossmember.
12.Remove the instrument panel crossmember assembly.
a. Remove 12 fixing bolts (arrow) from the instrument
panel crossmember assembly.
RA19430600
b. Remove the instrument panel crossmember assembly.
Installation
CAUTION
43  Make sure to tighten the fixing bolts to the specified torque when installing the instrument panel
 Check the airbag for proper installation after installing the instrument panel crossmember assembly.
 Check that the horn operates properly after installing the instrument panel crossmember assembly.
installing the instrument panel crossmember assembly.
 Check each electrical equipment for proper operation after installing the instrument panel crossmember
assembly.

SEAT
GENERAL INFORMATION 44-3 Disassembly 44-15
Inspection 44-17
Rear Seat Protector Assembly 44-18
Front Seat Assembly 44-7
Removal 44-18
Removal 44-7
Installation 44-19
Disassembly 44-9
Rear Seat Cushion Support 44-20
Assembly 44-12
Removal 44-20
Installation 44-12
Installation 44-20
Inspection 44-12
Rear Seatback Support 44-21
Rear Seat Assembly 44-14
Removal 44-21
Removal 44-14
Installation 44-21
44

44

44 - SEAT
GENERAL INFORMATION
SEAT
Description
Driver Seat Assembly
10 2
3
9
×2
8 4
5
44
6
RA19440010
1 - Driver Seat Headrest Assembly 2 - Driver Seat Headrest Guide w/ Button

3 - Driver Seatback Assembly 4 - Driver Seat Outer Shield
5 - Driver Seat Reclining Adjuster Handle 6 - Driver Seat Height Adjuster Handle (If Equipped)
7 - Driver Seat Cushion Assembly 8 - Driver Seat Belt Buckle Assembly
9 - Driver Seat Inner Shield 10 - Driver Seat Headrest Guide without Button

44 - SEAT
Front Passenger Seat Assembly
2
9
3
5
4
×2
44 7
RA19440020
1 - Front Passenger Seat Headrest Assembly 2 - Front Passenger Seat Headrest Guide w/ Button
3 - Front Passenger Seatback Assembly 4 - Front Passenger Seat Inner Shield
5 - Front Passenger Seat Belt Buckle Assembly 6 - Front Passenger Seat Cushion Assembly
7 - Front Passenger Seat Outer Shield 8 - Front Passenger Seat Reclining Adjuster Handle
9 - Front Passenger Seat Headrest Guide w/o Button

44 - SEAT
Rear Seat Assembly
5
1
6
7
10
15
11
44
14 12
13
RA19440030

44 - SEAT
1 - Rear Right Seatback Assembly 2 - Rear Right Seatback Lock

3 - Rear Seat Headrest Assembly 4 - Rear Seat Headrest Guide w/ Button
5 - Rear Seat Headrest Guide w/o Button 6 - Rear Seat Unlock Handle
7 - Rear Seat Unlock Handle Seat 8 - Rear Left Seatback Lock
9 - Rear Left Seatback Assembly 10 - Rear Seatback Support
11 - Rear Seat Cushion Assembly 12 - Rear Seat Cushion Support
13 - Rear Seat Lower Left Protector Assembly 14 - Rear Seat Lower Center Protector Assembly
15 - Rear Seat Lower Right Protector Assembly
The front seat assemblies can be moved forward and backward by seat adjusting handle, and the seatback
reclining can be adjusted by seat reclining adjuster handle.
The rear seat position is not adjustable; however, the rear seatback can be put down forward by pushing the
seatback unlock handle to help increase the storage space of the luggage compartment.
Specifications

Front Seat Assembly Fixing Bolt 25 ± 4
Front Seat Belt Buckle Assembly 50 ± 5
Seat Inner Shield Fixing Screw 2 ± 0.2
Seat Outer Shield Fixing Screw 2 ± 0.2
Coupling Bolt Between Seatback Assembly and Left
40
Side of Seat Cushion Assembly
Coupling Bolt Between Seatback Assembly and
27
Right Side of Seat Cushion Assembly
Rear Seatback Assembly Fixing Bolt 25 ± 4
44
Rear Seatback Lock Fixing Bolt 27
Rear Seat Cushion Support Fixing Bolt 25 ± 4
Rear Seatback Support Fixing Bolt 25 ± 4

44 - SEAT
ON-VEHICLE SERVICE
Front Seat Assembly
Removal
HINT:
 Use the same procedures for the front passenger seat assembly and driver seat assembly.
 The procedures listed below are for the driver seat assembly.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the seat assembly.
 Avoid scratch or damage to the body paint surface and carpet when installing the seat assembly.

3. Remove the driver seat headrest assembly.
a. Press the seat headrest guide w/ button and remove
the driver seat headrest assembly.
RA19440040
4. Remove the driver seat assembly.

a. Pull up the seat adjusting handle and move the seat
assembly to the rearmost position.
44
RA19440050
b. Remove 2 fixing bolts on the front side of the seat

assembly.
RA19440060

44 - SEAT
c. Pull up the seat adjusting handle and move the seat

assembly to the foremost position.
RA19440070
d. Remove 2 fixing bolts on the rear side of the seat

assembly.
RA19440080
e. Disconnect the wire harness connector (arrow) under

the seat assembly (for driver seat assembly).
RA19440090
44 f. Pull up the driver seat adjusting handle and move the seat assembly to the mid-position. At the same
time, operate the driver seatback reclining adjuster handle and move the seatback to the upright
position, and remove the driver seat assembly.

44 - SEAT
Disassembly
HINT:
 Use the same procedures for the front passenger seat assembly and driver seat assembly.
 The procedures listed below are for the driver seat assembly.
CAUTION
 Make sure to wear safety equipment to prevent accidents when disassembling the seat assembly.
1. Remove the driver seat belt buckle assembly.

a. Remove the fixing bolt (arrow) on the seat belt buckle
assembly.
RA19440100
b. Remove the driver seat belt buckle assembly.

2. Remove the driver seat inner shield.
a. Remove 2 fixing screws from the seat inner shield.
RA19440110 44
b. Remove the driver seat inner shield.
3. Remove the driver seat reclining adjuster handle.
a. Using a screwdriver wrapped with tape to disengage
the clip from the seat reclining adjuster handle.
RA19440120
b. Remove the driver seat reclining adjuster handle.

44 - SEAT
4. Remove the driver seat height adjuster handle (if equipped).

a. Using a screwdriver wrapped with tape to disengage
the clip from the seat height adjuster handle.
RA19440121
b. Remove the driver seat height adjuster handle.

5. Remove the driver seat outer shield.
a. Remove the fixing screw from the seat outer shield.
RA19440130
b. Disengage the clips (arrow) from the seat outer shield

and remove the driver seat outer shield.
44
RA19440140
6. Remove the hooks (arrow) connecting the driver

seatback assembly and driver seat cushion assembly.
RA19440150

44 - SEAT
7. Remove the driver seat headrest guide.

a. Remove 5 hog rings (arrow) from the bottom of
seatback assembly.
RA19440160
b. Press and hold the lower part of seat headrest guide

indicated by the arrow shown in the illustration, and
remove the driver seat headrest guide.
RA19440170
8. Disengage the driver seatback assembly and the driver seat cushion assembly.
a. Remove 2 fixing bolts (arrow) between the seatback
assembly and the left side of seat cushion assembly.
44
RA19440180
b. Remove the fixing bolt (arrow) between the seatback

assembly and the right side of seat cushion assembly.
RA19440190
c. Disengage the driver seatback assembly and the driver seat cushion assembly.

44 - SEAT
Assembly
CAUTION
 Make sure to wear safety equipment to prevent accidents when assembling the seat.
 Be careful not to damage the seat cover during assembly.
 Replace the damaged hog rings during assembly.
 Keep the seat cover clean and tidy, and try to prevent wrinkles during assembly.
Installation
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the seat assembly.
 Be careful not to damage the body paint surface when installing the seat assembly.
 Avoid scratch or damage to the carpet when installing the seat assembly.
Inspection
After completing the installation of the seat assembly, check the basic functions of the seat assembly, and
confirm that the following functions operate normally:
1. Move the seat to the foremost and rearmost positions by
pulling up the seat adjusting handle, and check if the seat
is difficult to move, stuck, has high sliding resistance,
makes noise, etc. If the above conditions occur, repair or
replace it in time.
44
RA19440410

44 - SEAT
2. Adjust the seatback reclining to the maximum and

minimum angle by pulling up the seat reclining adjuster
handle, and check if the seat is difficult to move and
stuck, etc. If the above conditions occur, repair or replace
it in time.
RA19440191
3. Press the headrest guide w/ button and pull the headrest

up and down. Check if the headrest is difficult to move,
stuck, etc. If the above conditions occur, repair or replace
it in time.
RA19440400
4. Pull up the seat height adjuster handle to raise the seat to

the highest and lowest position. Check the seat if there
are faults, such as regulating, stuck, etc. If the above 44
faults ocuur, repair or replace them in time (if equipped).
RA19440192
5. Check if the fixing bolts are set in position. Tighten them to the specified torque as necessary.

44 - SEAT
Rear Seat Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when disassembling the rear seat assembly.
 Avoid scratch or damage to the body paint surface and carpet when removing the rear seat assembly.

2. Remove the rear seat headrest assembly.
a. Press the seat headrest guide w/ button and remove
the rear seat headrest assembly.
RA19440200
3. Remove the rear seat cushion assembly.

a. As shown in the illustration, put your hands around the
hook on one side of the rear seat cushion assembly,
and then raise the rear seat cushion assembly to
disengage the hook. Use the same procedure for
hook on the other side.
44
RA19440210
b. Disengage the hook from the seat cushion assembly

and remove the rear seat cushion assembly.
RA19440220

44 - SEAT
4. Remove the rear seatback assembly.

a. Remove 2 fixing bolts (arrow) from the rear left
seatback assembly, and remove the rear left seatback
assembly.
RA19440230
b. Remove 2 fixing bolts (arrow) from the rear right

seatback assembly, and remove the rear right
seatback assembly.
RA19440240
Disassembly
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when disassembling the rear seat assembly.
1. Remove the rear left seat headrest guide. 44

a. Unzip the rear seatback assembly.
RA19440340

44 - SEAT
b. Press and hold the lower part of the rear seat

headrest guide indicated by the arrow shown in the
illustration, and remove the rear left seat headrest
guide.
RA19440350
2. Remove the rear left seatback lock.

a. Press and hold the lower part of the rear seat unlock
handle seat indicated by the arrow shown in the
illustration, and remove the rear left seat unlock
handle seat.
RA19440360
b. Release the seatback lock lever indicated by the

arrow shown in the illustration, and remove the rear
seat unlock handle.
RA19440370
44
c. Remove 3 fixing bolts from the rear seatback lock and
remove the rear left seatback lock.
RA19440380

44 - SEAT
Assembly
CAUTION
 Make sure to wear safety equipment to prevent accidents when assembling the rear seat assembly.
 Be careful not to damage the seat cover when assembling the rear seat assembly.
 Replace the damaged hog rings when assembling the rear seat assembly.
 Keep the seat cover clean and tidy, and try to prevent wrinkles when assembling the rear seat assembly.
Installation
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the rear seat assembly.
 Be careful not to damage the body paint surface when installing the rear seat assembly.
 Avoid scratch or damage to the carpet when installing the rear seat assembly.
 When installing the rear seat cushion, make sure that the seat belt buckle is not under the seat cushion.
Inspection
After installing the rear seat assembly, check the basic functions of the rear seat assembly, and confirm that
the following functions operate normally:
1. Push down the rear seatback unlock handle and check if
the rear seatback lock is unlock and difficult to lock.
Repair or replace it as necessary.
44
RA19440390
2. Push down the headrest guide w/ button and move the

headrest up and down. Check if the headrest is difficult to
move, stuck, etc. If the above conditions occur, repair or
replace it in time.
RA19440391

44 - SEAT
Rear Seat Protector Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when disassembling the rear seat protector
assembly.
 Avoid scratch or damage to the body and carpet when removing the rear seat protector assembly.

2. Remove the rear doorsill pressure plate assembly (See page 47-9).
3. Remove the rear seat lower left protector assembly.
a. Remove the plastic clamp (arrow) from the rear seat
lower left protector assembly.
RA19440250

the clips on the rear seat lower left protector
assembly, and remove the rear seat lower left
protector assembly.
44
RA19440260
4. Remove the rear seat lower right protector assembly.

a. Remove the plastic clamp (arrow) from the rear seat
lower right protector assembly.
RA19440270

44 - SEAT

the clips on the rear seat lower right protector
assembly, and remove the rear seat lower right
protector assembly.
RA19440280
5. Remove the rear seat lower center protector assembly.

a. Remove the plastic clamps (arrow) from the rear seat
lower center protector assembly.
RA19440290

the clips on the rear seat lower center protector
assembly, and remove the rear seat lower center
protector assembly.
RA19440300
44
Installation
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the rear seat lower protector
assembly.
 Avoid scratch or damage to the body and carpet when installing the rear seat lower protector assembly.

44 - SEAT
Rear Seat Cushion Support

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when disassembling the rear seat cushion
support.
 Avoid scratch or damage to the body and carpet when removing the rear seat cushion support assembly.

3. Remove the rear seat lower protector assembly (See page 44-18).
4. Remove the rear seat cushion support.
a. Remove 6 fixing bolts (arrow) from the rear seat
cushion support and remove the rear seat cushion
support. 
RA19440310
Installation
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the rear seat cushion support.
44  Avoid scratch or damage to the body and carpet when installing the rear seat cushion support assembly.

44 - SEAT
Rear Seatback Support

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when disassembling the rear seatback
support.
 Avoid scratch or damage to the body and carpet when removing the rear seatback support.
1. Remove the luggage compartment carpet assembly (See page 47-32).

2. Take out the front shock pad.
RA19440320
3. Remove the rear seatback assembly (See page 44-14).

4. Remove the C-pillar lower protector assembly (See page 47-17).
5. Remove the rear seatback support.
a. Remove 3 fixing bolts (arrow) from the rear seatback
support and remove the rear seatback support. 
44
RA19440330
Installation
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the rear seatback support.
 Avoid scratch or damage to the body and carpet when installing the rear seatback support.

- MEMO -

ENGINE HOOD/DOOR
GENERAL INFORMATION 45-3 Adjustment 45-31
Description 45-3 Inspection 45-33
Specifications 45-7 Rear Door Inner Protector 
Tool 45-8 Assembly 45-34
Removal 45-34
Hood Assembly 45-9 Rear Door Assembly 45-37
Adjustment 45-11 Adjustment 45-43
Hood Hinge Assembly 45-13 Luggage Compartment Door 
Hood Cable Assembly 45-15 Installation 45-47
Removal 45-15 Adjustment 45-48
Hood Support Rod Assembly 45-17 Luggage Compartment Door 
Removal 45-17 Hinge Assembly 45-50
Front Door Inner Protector  Installation 45-52
Assembly 45-19 Luggage Compartment Door 
Removal 45-19 Opener Switch Assembly 45-53
Front Door Assembly 45-23 Inspection 45-54
Installation 45-30
45

45

45 - ENGINE HOOD/DOOR
GENERAL INFORMATION
ENGINE HOOD/DOOR
Description
Hood Assembly
4
5
×11
7
45
FU
SE
& RE
LAY
BO
X
RA19450010

1 - Hood Assembly 2 - Hood Left Hinge Assembly

3 - Hood Support Rod Assembly 4 - Hood Front Weatherstrip
5 - Hood Upper Adjustment Block 6 - Hood Right Hinge Assembly
7 - Hood Sound-absorbing Pad 8 - Hood Lower Adjustment Block
Front Left Door Assembly
2
1
25
3
26
4
22
23
24
6
×3
×2
7 5
×2 8
21 15
9 ×3
×3 ×2 17
45
10
20 14 16
×4
11
19
×5
13
12
18
RA19450020

1 - Front Door Frame Weatherstrip 2 - Front Door Glass Run

3 - Front Door Glass Assembly 4 - Front Door Assembly
5 - Front Door Glass Front Guide Rail Assembly 6 - Front Door Outside Handle Base Assembly
7 - Front Door Upper Hinge Assembly 8 - Front Door Check Assembly
9 - Front Door Lower Hinge Assembly 10 - Front Speaker
11 - Front Door Power Glass Regulator Assembly 12 - Front Door Protective Film Assembly
13 - Front Door Protector Bracket 14 - Front Door Inside Handle Assembly
15 - Rubber Cushion 16 - Driver Door Glass Regulating Control Switch
Assembly
17 - Front Door Inner Triangular Block Assembly 18 - Front Door Inner Protector Assembly
19 - Front Door Buffer Block 20 - Front Door Lock Assembly
21 - Outside Handle Gasket 22 - Front Door Key Cylinder Protective Cover
23 - Front Door Outside Handle 24 - Outside Handle Rear End Gasket
25 - Front Door Outer Weather Bar 26 - Rear View Mirror Assembly
45

Luggage Compartment Door Assembly
3
×2
×2
×4
×4
×2 7
45
RA19450030

1 - Luggage Compartment Door Assembly 2 - Luggage Compartment Adjustment Block

3 - Luggage Compartment Lock Assembly 4 - Luggage Compartment Door Protector Assembly
5 - Luggage Compartment Door Opener Handle 6 - Luggage Compartment Door Left Hinge
Assembly
7 - Luggage Compartment Door Right Hinge 8 - Luggage Compartment Door Hinge Right Torsion
Assembly Bar
9 - Luggage Compartment Door Hinge Left Torsion
Bar
The vehicle has a structure of four doors & two covers (front left door, rear left door, front right door, rear right
door, luggage compartment door and hood).
Specifications

Fixing Bolt Between Hood and Hood Hinge 32 ± 3
Fixing Bolt Between Hood Hinge and Front Fender 10 ± 1
Fixing Bolt Between Hood Hinge and Body 32 ± 3
32 ± 3
Door
32 ± 3
Body
32 ± 3
Door
32 ± 3
Body
Front Speaker Bracket Fixing Screw 1.5 ± 0.5
Hood Lock Assembly Fixing Nut 7 ± 1.5
Front Door Protector Bracket Fixing Screw 1.5 ± 0.5 45
Rear Door Protector Bracket Fixing Screw 1.5 ± 0.5
7 ± 0.7
Screw
Fixing Screw of Rear Door Protective Cover Without
7 ± 0.7
Key Cylinder
Front Door Outside Handle Base Assembly Fixing
7 ± 0.7
Screw
Rear Door Outside Handle Base Assembly Fixing
7 ± 0.7
Screw
Front Door Lock Striker Fixing Screw 20 ± 2
Luggage Compartment Lock Cylinder Fixing Screw 12 ± 2


Front Door Inner Triangular Block Assembly Fixing
1.5 ± 0.5
Screw
Front Door Inside Handle Assembly Fixing Screw 1.5 ± 0.5
Rear Door Inside Handle Assembly Fixing Screw 1.5 ± 0.5
Front Door Inner Protector Assembly Fixing Screw 1.5 ± 0.5
10 ± 2
and Door
22 ± 3.5
and Body
10 ± 2
Door
22 ± 3.5
Body
Assembly and Luggage Compartment Door Hinge 10 ± 1.5
Assembly
10 ± 1.5
Hinge Assembly and Body
Tool
Special Tool
Interior Crow Plate
45 RCH0000025

ON-VEHICLE SERVICE
Hood Assembly
Removal
WARNING
 When removing the hood assembly, an assistant is needed to hold the hood.
 Prevent the hood from dropping or sudden closing to cause accidents during operation.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the hood assembly.
 Try to prevent the body paint surface from being scratched when removing the hood assembly.

3. Remove the hood upper adjustment block.
a. Turn the hood upper adjustment blocks counterclockwise.
b. Remove the hood adjustment blocks (1).
1 1
4. Remove the hood front weatherstrip. 2
a. Remove the clips from the hood front weatherstrip.
b. Remove the hood front weatherstrip (2).
RA19450050
5. Remove the hood sound-absorbing pad.

a. Remove the clips (arrow) from the hood sound-absorbing
pad, and remove the hood sound-absorbing pad.
45
RA19450052

6. Remove the hood lower adjustment block.

a. Turn the hood lower adjustment blocks counterclockwise.
b. Remove the hood lower adjustment blocks (1).
RA19450051
7. Remove the hood assembly.

a. Remove 4 fixing bolts (arrow) between hood
assembly and hood hinge assembly, and remove the
hood assembly.
RA19450060
Installation
WARNING
 When installing the hood assembly, an assistant is needed to hold the hood.
45 CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the hood assembly.
 Try to prevent the body paint surface from being scratched when installing the hood assembly.

Adjustment
1. Adjust the hood assembly.
a. Loosen the fixing bolts on the hood hinge assembly.
b. Adjust the clearance of the hood assembly to standard range and pre-tighten the fixing bolts on the
hood hinge assembly.
The standard ranges of clearance between the installation positions of hood assembly and each part
are as follows:
Clearance between hood assembly and radiator grille: 7.0 ± 1.5 mm.
Clearance between hood assembly and front bumper assembly: 6.5 ± 1.5 mm.
Clearance between hood assembly and front fender assembly: 4.0 ± 1.0 mm.
4.0±1.0
7.0±1.5
Hood
Front Fender
Hood
Hood
Radiator Grille
6.5±1.5
Front Bumper
45
RA19450070
c. After adjustment, tighten the fixing bolts between hood hinge assembly and hood assembly to the
specified torque.
d. After adjustment, tighten the fixing bolts between hood hinge assembly and body to the specified
torque.

2. Adjust the height of hood front end with the adjustment block.
a. Raise or lower the hood front end by rotating the upper
adjustment blocks clockwise or counterclockwise.
RA19450071
b. Raise or lower the hood front end by rotating the lower

adjustment blocks clockwise or counterclockwise.
RA19450061
c. After adjustment, make sure that the alignment between hood assembly and front fender assembly is
within the standard range.
Standard alignment: 0 ± 1.0 mm
d. After adjustment, make sure that the alignment between hood assembly and front bumper assembly is
Standard alignment: 3.0 ± 1.5 mm
3. Adjust the hood lock assembly.
a. Slightly loosen the fixing nuts of hood lock assembly
and adjust the hood lock assembly in the direction of
45
RA19450072
b. Tighten the hood lock assembly fixing nuts to the specified torque after adjustment.
Inspection
After the hood assembly is adjusted, perform the following inspections:
1. Check the hood for wear or deformation during installation, and repair it as necessary.
2. Check if the fixing bolts and fixing nuts are set in position. Tighten them to the specified torque as
necessary.
3. Check if the clearance and alignment between hood assembly and the front fender assembly, radiator
grille and front bumper assembly are within the specified range, and adjust them as necessary.

Hood Hinge Assembly

Removal
HINT:
WARNING
 When removing the hood hinge assembly, an assistant is needed to hold the hood.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the hood hinge assembly.
 Try to prevent the body paint surface from being scratched when removing the hood hinge assembly.
 When removing the hood hinge assembly, prevent the hood from dropping to damage the body or front
windshield during operation.

3. Remove the front windshield lower garnish left seal block.
up the clips on the front windshield lower garnish left
seal block.
RA19450081
45
b. Remove the front windshield lower garnish left seal block.
4. Remove the front left fender cover plate.
a. Remove 2 plastic clips (arrow) from the fender cover
plate.
RA19450080
b. Remove the front left fender cover plate.

5. Remove the hood left hinge assembly.

a. Remove 2 fixing bolts (arrow) between hood hinge
assembly and hood assembly.
RA19450090
b. Remove the fixing bolt (arrow) between hood hinge

assembly and front fender assembly.
RA19450082
c. Remove 2 fixing bolts (arrow) between hood hinge

assembly and body.
RA19450100
d. Remove the hood hinge assembly.

45
Installation
WARNING
 When installing the hood hinge assembly, an assistant is needed to hold the hood.
CAUTION
 After installing the hood hinge assembly, it is necessary to adjust the hood.
 When installing the hood hinge assembly, prevent the hood from dropping to damage the body or front
windshield during operation.

Hood Cable Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the hood cable assembly.
 Try to prevent the body paint surface from being scratched when removing the hood cable assembly.

3. Remove the front left wheel house protector assembly (See page 46-15).
4. Remove the hood lock assembly.
a. Remove 3 fixing nuts (arrow) from the hood lock
assembly.
RA19450110
b. Disengage the clips (arrow) of hood cable assembly.
RA19450120 45
c. Remove the hood lock assembly.
5. Remove the hood grip assembly.
a. As shown in the illustration, pry up the clip of hood
grip and pry the hood grip assembly to loosen the
hood grip assembly.
RA19450130

b. As shown in the illustration, pull down the hood grip

assembly and move the hood cable to the right to get
the hood cable out of the guide of hood grip assembly.
RA19450140
c. Remove the hood cable (arrow) to separate the hood

cable from the hood grip assembly.
RA19450150
6. Remove the hood cable assembly.

remove the clips from the hood cable assembly.
RA19450160
b. Remove the hood cable assembly.

45
Installation
CAUTION
 Try to prevent the body paint surface from being scratched when installing the hood cable assembly.
 After the installation of hood cable assembly is completed, make sure the hood can be opened smoothly
without sticking.

Hood Support Rod Assembly

Removal
WARNING
 When removing the hood support rod assembly, an assistant is needed to hold the hood.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the hood support rod
assembly.
 Try to prevent the body paint surface from being scratched when removing the hood support rod
assembly.
 When removing the hood support rod assembly, prevent the hood from dropping to cause accidents
during operation.

3. Remove the hood support rod clip.
up the claw.
RA19450180
45
b. Remove the hood support rod clip.
4. Remove the hood support rod assembly.
up the fixing sleeve (arrow) on the hood support rod
assembly lower end, and remove the hood support
rod assembly.
RA19450170

Installation
WARNING
 When removing the hood support rod assembly, an assistant is needed to hold the hood.
CAUTION
 Try to prevent the body paint surface from being scratched when installing the hood support rod
assembly.
 The hood support rod assembly and hood support rod clip should be fitted closely after installing the
hood support rod assembly.
45

Front Door Inner Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front door inner protector
assembly.
 Avoid damage to the surface of front door inner protector when removing the front door inner protector
assembly.

3. Remove the glass regulating control master switch assembly (See page 41-48).
4. Remove the front left door inner triangular block assembly.
a. Remove the fixing screw (arrow) from the front door
inner triangular block assembly.
b. Using an interior crow plate, pry off the fixing clips
from the front door inner triangular block assembly,
RA19450400
c. Remove the front left door inner triangular block assembly.
45

5. Loosen the front left door inside handle assembly.

off the front door inside handle cover (1).
b. Remove the fixing screw (2) from the front door inside
handle assembly.
2 1
RA19450410
6. Remove the front left door inner protector assembly.

a. Remove the fixing screw (arrow) from the front door
inner protector assembly.
RA19450420
45

b. Using an interior crow plate, pry off the clips from the
front door inner protector assembly, and loosen the
front door inner protector assembly in the direction of
RA19450430
c. Disconnect the front door lock cable (1) and front door
inside open cable (2).
2
45
RA19450440
d. Remove the front left door inner protector assembly.

7. Remove the front left door inside handle assembly.

inside handle assembly.
RA19450450
b. Remove the front door inside handle assembly from the front door inner protector assembly.
Installation
CAUTION
 Replace the damaged clips and install the front door inner protector assembly in place when installing
the front door inner protector assembly.
 Check that the inside handle assembly can be used normally after installing the front door inner protector
assembly.
45

Front Door Assembly

Removal
HINT:
WARNING
 When removing the front door assembly, an assistant is needed to hold the front door to prevent the front
door from dropping to cause accidents during operation.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front door assembly.
 Try to prevent the body paint surface from being scratched when removing the front door assembly.

3. Disconnect the front left door connectors (arrow).
RA19450200
4. Remove the front left door buffer block.

remove the front door buffer block (arrow).
45
RA19450210

6. Remove the front left door protector bracket.

protector bracket.
RA19450220
b. Remove the front door protector bracket.

7. Remove the front left speaker.
a. Disconnect the front speaker connector (1).
b. Remove 3 fixing screws (arrow) from the front
speaker.
RA19450342
c. Remove the front speaker.

8. Remove the front left door protective film assembly.
CAUTION
 Avoid damage to the front door protective film when removing the front door protective film assembly.
 Place the front door protective film assembly properly after removal, and avoid the adhesive sticker on
the front door protective film assembly from sticking to other components.
45 a. Disengage the wire harness clip (arrow).
RA19450231

b. Disengage the wire harness clip in the direction of

RA19450240
c. Remove the front left door protective film assembly by

gently pulling it along edges from one corner of the
front left door protective film assembly.
RA19450250
9. Remove the front left door key cylinder protective cover.

a. Disengage the clip (arrow) from the front door key
45
RA19350270


remove the front door key cylinder protective cover
block cover (1).
2
c. Remove the fixing screw (2) from the front door key
cylinder protective cover, and remove the front left
door key cylinder protective cover.
1
RA19350260
d. Disengage the clip (arrow) from the front door key

cylinder protective cover lever, and separate the front
door key cylinder protective cover from the front door
key cylinder protective cover lever.
RA19450280
10.Remove the front left door outside handle.

a. Slide and pull the front door outside handle in the
direction of arrow as shown in the illustration, and
remove it.
45
RA19450290

11. Remove the front left door outside handle base assembly.
a. Disengage the clip (arrow) from the front door outside
handle base lever.
RA19450310
b. Remove the fixing screw (arrow) from the front door

outside handle base assembly.
RA19450300
c. Using the pliers, hold the clip and remove it together

with the front door outside handle base assembly.
45
RA19450301
CAUTION
 Make sure to remove the clip together with outside handle frame. If the clip is still secured to the door
panel, it may be damaged.

d. Separate the outside handle base lever and the front

door outside handle base assembly in the direction of
RA19450320
12.Remove the outside handle gasket.

a. Disengage the claw from the outside handle gasket, and remove the outside handle gasket.
13.Remove the outside handle rear end gasket.
a. Disengage the claw from the outside handle rear end
gasket, and remove the outside handle rear end
gasket.
RA19450330
14.Remove the left outside rear view mirror assembly (See page 42-8).
45 15.Remove the front left door glass assembly (See page 41-51).
16.Remove the front left door glass front guide rail assembly (See page 41-53).
17.Remove the front left door power glass regulator assembly (See page 41-54).
18.Remove the front left door lock assembly (See page 35-41).
19.Remove the front left door check assembly.
a. Remove 2 fixing bolts (arrow) between front door
check assembly and door.
RA19450340

b. Remove the fixing bolt (arrow) between front door

check assembly and body.
RA19450331
c. Remove the front left door check assembly.

20.Remove the front left door frame weatherstrip.
a. Remove the clip from the front door frame
weatherstrip.
RA19450670
b. Remove the front left door frame weatherstrip.

21.Remove the front left door assembly.
off the front door dust boot (1).
b. Remove 4 fixing bolts (arrow) between front door
hinge assembly and door.
1
RA19450341
c. Remove the front left door assembly.

22.Remove the front left door hinge assembly.

a. Remove 4 fixing bolts (arrow) between front door
hinge assembly and body.
b. Remove the front door upper hinge assembly (1) and
front door lower hinge assembly (2). 2
RA19450350
Installation
WARNING
 When installing the front door assembly, make sure to wear safety equipment to prevent accidents.
 When installing the front door assembly, an assistant is needed to hold the front door to prevent the front
CAUTION
 Replace the damaged clips and install the front door protector in place when installing the front door
protector.
 Stick the protective film in specified position, not in a wrong position or a asymmetric position between
the left and right sides or covering the holes of other installation parts.
 DO NOT drag the protective film when assembling it. Assemble it in its original condition and ensure that
the sheet metal is clean before assembly.
 The finished protective film should have no defects, such as wrinkles, bubbles or turnups.
 The finished protective film should have powerful adherence.
 The protective film sticking should be finished at one time. Avoid repeat sticking.
45

Adjustment
1. Adjust the front left door assembly.
a. Loosen the fixing bolts on the front door hinge
assemblies and adjust the front door assembly
position in the direction of arrow as shown in the
illustration.
RA19450360
b. Tighten the fixing bolts on the front door hinge assemblies to the specified torque after adjustment.
c. Loosen the fixing bolts on the front door hinge
assemblies and adjust the front door assembly
illustration.
RA19450370
d. Tighten the fixing bolts on the front door hinge assemblies to the specified torque after adjustment.
45

e. The standard ranges of clearance and alignment between installation positions of front door assembly
and each part are as follows:
Clearance between front door assembly and rear door assembly: 4.0 ± 1.0 mm.
Clearance between front door assembly and lower body outer panel: 5.5 ± 1.5 mm.
Clearance A-B between front door assembly and front fender assembly: 4.3 ± 1.0 mm.
Clearance B-C between front door assembly and front fender assembly: 4.3 - 5.5 ± 1.0 mm.
Clearance between front door assembly and upper body outer panel: 4.0 ± 1.2 mm.
4.0±1.2
Front Door
Upper Body Outer Panel
A-B:4.3±1.0
B-C:4.3-5.5±1.0
Front Fender
Front Door
4.0±1.0
A
Rear Door
5.5±1.5 Front Doort
B
Lower Body Outer Panel
Front Door
C
45
RA19450700
f. After adjustment, make sure that the alignment between front door assembly and rear door assembly is
Standard alignment: 0 + 1.0/-0.5 mm
g. After adjustment, make sure that the alignment between front door assembly and front fender assembly
is within the standard range.
Standard alignment: 0.5 + 0.7/-0.5 mm

2. Adjust the front left door lock striker.

a. Slightly loosen the fixing screws on the front door lock
striker and tap it with a plastic hammer in the direction
of arrow as shown in the illustration to adjust the lock
striker position.
RA19450390
b. Tighten the fixing screws on the front door lock striker to the specified torque after adjustment.
Inspection
After the front left door assembly is adjusted, perform the following inspections:
1. Check the front door assembly for wear or deformation during installation, and repair it as necessary.
2. Check if the fixing bolts and fixing screws are set in position. Tighten them to the specified torque as
necessary.
3. Check if the clearance and alignment between the front door assembly installation position and each part
are within the specified range. Adjust them if necessary.
45

Rear Door Inner Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear door inner protector
assembly.
 Avoid damage to the surface of rear door inner protector when removing the rear door inner protector
assembly.

3. Remove the left glass regulating control switch (See page 41-56).
4. Loosen the rear left door inside handle assembly.
off the rear door inside handle cover (1).
b. Remove the fixing screw (2) from the rear door inside
handle assembly.
2
RA19450550
45
5. Remove the rear left door inner protector assembly.
a. Remove the plastic clip (arrow) from the rear door
inner protector assembly.
RA19450560

rear door inner protector assembly, and loosen the
rear door inner protector assembly in the direction of
RA19450570
c. Disconnect the rear door lock cable (1) and rear door
inside open cable (2).
45
RA19450580
d. Remove the rear left door inner protector assembly.

6. Remove the rear door inside handle assembly.
inside handle assembly.
RA19450590
b. Remove the rear door inside handle assembly from the rear door inner protector assembly.

Installation
CAUTION
 Replace the damaged clips and install the rear door inner protector assembly in place when installing the
rear door inner protector assembly.
 Check that the inside handle assembly can be used normally after installing the rear door inner protector
assembly.
45

Rear Door Assembly

Removal
HINT:
WARNING
 When removing the rear door assembly, an assistant is needed to hold the rear door to prevent the rear
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear door assembly.
 Try to prevent the body paint surface from being scratched when removing the rear door assembly.

3. Remove the B-pillar lower protector assembly (See page 47-13).
4. Disconnect the rear left door connector (arrow).
RA19450460
45

6. Remove the rear left door protector bracket.
protector bracket.
RA19450470
b. Remove the rear door protector bracket.

7. Remove the rear left door protective film assembly.
CAUTION
 Avoid damage to the rear door protective film when removing the rear door protective film assembly.
 Place the rear door protective film assembly properly after removal, and avoid the adhesive sticker on
the rear door protective film assembly from sticking to other components.
a. Remove the rear left door protective film assembly by

rear left door protective film assembly.
45
RA19450480

8. Remove the protective cover without key cylinder from the rear left door.
remove the trim plug of protective cover without key
cylinder from the rear left door.
b. Remove the fixing screw (2) from the protective cover
without key cylinder, and remove the protective cover
without key cylinder. 1
RA19450490
9. Remove the rear left door outside handle.

a. Slide and pull the rear door outside handle in the
direction of arrow as shown in the illustration, and
remove it.
RA19450290
10.Remove the rear left door outside handle base.

a. Disengage the clip (arrow) from the rear door outside
handle base lever.
45
RA19450500

b. Remove the fixing screw (arrow) from the rear door

outside handle base assembly.
RA19450510
c. Using the pliers, hold the clip and remove it together

with the rear door outside handle base assembly.
RA19450301
CAUTION
 Make sure to remove the clip together with outside handle frame. If the clip is still secured to the door
panel, it may be damaged.
d. Separate the outside handle base lever and the rear

door outside handle base in the direction of arrow as
45 shown in the illustration.
RA19450520
11. Remove the outside handle gasket.

a. Disengage the claw from the outside handle gasket, and remove the outside handle gasket.

12.Remove the outside handle rear end gasket.

a. Disengage the claw from the outside handle rear end
gasket, and remove the outside handle rear end
gasket.
RA19450330
13.Remove the rear left door glass assembly (See page 41-59).
14.Remove the rear left door glass rear guide rail assembly (See page 41-62).
15.Remove the triangular window glass assembly (See page 41-60).
16.Remove the rear left door power glass regulator assembly (See page 41-63).
17.Remove the rear left door lock assembly (See page 35-47).
18.Remove the rear left door check assembly.
a. Remove 2 fixing bolts (arrow) between rear door
check assembly and door.
45
RA19450540
b. Remove the fixing bolt (arrow) between rear door

check assembly and body.
RA19450541
c. Remove the rear left door check assembly.

19.Remove the rear left door frame weatherstrip.

a. Remove the clip from the rear door frame
weatherstrip.
RA19450710
b. Remove the rear left door frame weatherstrip.

20.Remove the rear left door assembly.
off the rear door dust boot (1).
b. Remove 4 fixing bolts (arrow) between rear door
hinge assembly and door.
1
RA19450542
c. Remove the rear left door assembly.

21.Remove the rear left door hinge assembly.
a. Remove 4 fixing bolts (arrow) between rear door
hinge assembly and body.
45 b. Remove the rear door upper hinge assembly (1) and
1
rear door lower hinge assembly (2).
RA19450543

Installation
WARNING
 When installing the rear door assembly, make sure to wear safety equipment to prevent accidents.
 When installing the rear door assembly, an assistant is needed to hold the rear door to prevent the rear
CAUTION
 Replace the damaged clips and install the rear door protector in place when installing the rear door
protector.
 Stick the protective film in specified position, not in a wrong position or a asymmetric position between
the left and right sides or covering the holes of other installation parts.
 DO NOT drag the protective film when assembling it. Assemble it in its original condition and ensure that
the sheet metal is clean before assembly.
 The finished protective film should have no defects, such as wrinkles, bubbles or turnups.
 The finished protective film should have powerful adherence.
 The protective film sticking should be finished at one time. Avoid repeat sticking.
Adjustment
1. Adjust the rear left door assembly.
a. Loosen the fixing bolts on the rear door hinge
assemblies and adjust the rear door assembly
illustration.
45
RA19450551
b. Tighten the fixing bolts on the rear door hinge assemblies to the specified torque after adjustment.
c. Loosen the fixing bolts on the rear door hinge
assemblies and adjust the rear door assembly
illustration.
RA19450553

d. Tighten the fixing bolts on the rear door hinge assemblies to the specified torque after adjustment.
e. The standard ranges of clearance between the installation positions of the rear door assembly and
each part are as follows:
Clearance between rear door assembly and front door assembly: 4.0 ± 1.0 mm.
Clearance between rear door assembly and upper body outer panel: 4.0 ± 1.2 mm.
Clearance between rear door assembly and rear body outer panel: 4.0 ± 1.0 mm.
Clearance A-B between rear door assembly and lower body outer panel: 5.5 - 4.0 ± 1.5 mm.
Clearance B-C between rear door assembly and lower body outer panel: 5.5 ± 1.5 mm.
4.0±1.2
Rear Door
Upper Body Outer Panel
4.0±1.0
Rear Door
Rear Body Outer Panel
4.0±1.0
Rear Door
Front Door
C B
A
45
A-B:5.5~4.0±1.5
B-C:5.5±1.5
Lower Body Outer Panel

Rear Door
RA19450690
f. After adjustment, make sure that the alignment between rear door assembly and front door assembly is
g. After adjustment, make sure that the alignment between rear door assembly and rear body outer panel
assembly is within the standard range.

2. Adjust the rear left door lock striker.

a. Slightly loosen the fixing screws on the rear door lock
striker and tap it with a plastic hammer in the direction
of arrow as shown in the illustration to adjust the
striker position.
RA19450552
b. Tighten the fixing screws on the rear door lock striker to the specified torque after adjustment.
Inspection
After the rear left door assembly is adjusted, perform the following inspections:
1. Check the rear door assembly for wear or deformation during installation, and repair it as necessary.
2. Check if the fixing bolts and fixing screws are set in position. Tighten them to the specified torque as
necessary.
3. Check if the clearance and alignment between the rear door assembly installation position and each part
are within the specified range. Adjust them if necessary.
45

Luggage Compartment Door Assembly

Removal
WARNING
 When removing the luggage compartment door assembly, an assistant is needed to hold the luggage
compartment door.
 Prevent the luggage compartment door from dropping or sudden closing to cause accidents during
operation.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the luggage compartment door
assembly.
door assembly.

a. Loosen the luggage compartment door opener handle on the luggage compartment door protector
assembly.
b. Disconnect the luggage compartment door opener
handle cable in the direction of arrow as shown in the
illustration.
45 RA19350280

1
compartment door protector assembly, and remove
the luggage compartment door protector assembly.
b. Turn the luggage compartment upper adjustment
blocks counterclockwise, and remove the luggage
compartment adjustment blocks (1).
RA19450610
5. Remove the luggage compartment lock assembly (See page 35-51).

6. Remove the luggage compartment door assembly.

off the clips (arrow) from the luggage compartment
door.
RA19450621
b. Remove 4 fixing bolts (arrow) from the luggage

compartment door assembly.
RA19450620
c. Remove the luggage compartment door assembly.
Installation
WARNING
 When installing the luggage compartment door assembly, an assistant is needed to hold the luggage
compartment door.
operation.
45
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the luggage compartment door
assembly.
 Try to prevent the body paint surface from being scratched when installing the luggage compartment
door assembly.

Adjustment
1. Adjust the luggage compartment door assembly.
a. Loosen the fixing bolts on the luggage compartment door hinge assembly.
b. Adjust the clearance of luggage compartment door assembly to standard range and pre-tighten the
fixing bolts on the luggage compartment door hinge assembly.
The standard ranges of clearance between the installation positions of luggage compartment door
assembly and each part are as follows:
Clearance between luggage compartment door assembly and body outer panel: 4.0 ± 1.0 mm.
Clearance A-B between luggage compartment door assembly and rear bumper assembly: 
4.0 - 6.0 ± 1.0 mm.
Clearance B-C between luggage compartment door assembly and rear bumper assembly: 
6.0 ± 2.0 mm.
Clearance D-E between luggage compartment door assembly and rear combination light: 
4.0 ± 1.2 mm.
Clearance E-A between luggage compartment door assembly and rear combination light assembly: 
4.0 - 5.0 ± 1.2 mm.
4.0±1.0
Luggage
Compartment Door
Body Outer Panel
Luggage Compartment Door A-B:4.0-6.0±1.0
B-C:6.0±2.0
Rear Bumper
E
45
C
B
D-E:4.0±1.2
Luggage E-A:4.0-5.0±1.2
Compartment
Door
Rear
Combination Light
RA19450680

c. After adjustment, tighten the fixing bolts between luggage compartment door hinge assembly and
luggage compartment door assembly to the specified torque.
d. After adjustment, tighten the fixing bolts between luggage compartment door hinge assembly and body
to the specified torque.
2. Adjust the height of luggage compartment door with the luggage compartment adjustment block.
a. Raise or lower the luggage compartment door by
rotating the luggage compartment adjustment blocks
clockwise or counterclockwise.
RA19450611
3. Adjust the luggage compartment lock cylinder.

a. Slightly loosen the fixing screws on the luggage
compartment lock cylinder and tap it with a plastic
hammer in the direction of arrow as shown in the
illustration to adjust the luggage compartment lock
cylinder position.
RA19450660
b. Tighten the fixing screws on the luggage compartment lock cylinder to the specified torque after
adjustment.
Inspection
After the luggage compartment door assembly is adjusted, perform the following inspections: 45
1. Check the luggage compartment door for wear or deformation during installation, and repair it as
necessary.
3. Check if the clearance and alignment between the luggage compartment door assembly and rear bumper
assembly are within the specified range. Adjust them if necessary.

Luggage Compartment Door Hinge Assembly

Removal
HINT:
WARNING
 When removing the luggage compartment door hinge assembly, an assistant is needed to hold the
luggage compartment door.
operation.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the luggage compartment door
hinge assembly.
door hinge assembly.

4. Remove the luggage compartment door hinge left/right torsion bar.
a. Remove the luggage compartment door hinge left/
right torsion bar from the slots (arrow).
45
RA19450640


a. Loosen the luggage compartment door opener handle on the luggage compartment door protector
assembly.
handle cable in the direction of arrow as shown in the
illustration.
RA19350280

compartment door protector assembly, and remove
the luggage compartment door protector assembly.
RA19450612
7. Remove the left luggage compartment door hinge assembly.

up the clips (arrow) on the luggage compartment door
hinge assembly.
45
RA19450621
b. Remove 2 fixing bolts (arrow) between luggage

compartment door hinge assembly and luggage
compartment door assembly.
RA19450630

c. Remove 4 fixing bolts (arrow) between luggage

compartment door hinge assembly and body.
RA19450650
d. Remove the luggage compartment door hinge assembly.
Installation
CAUTION
 After installing the luggage compartment door hinge assembly, it is necessary to adjust the luggage
compartment door.
 Try to prevent the body paint surface from being scratched when installing the luggage compartment
door hinge assembly.
 When installing the hood hinge assembly, prevent the hood from dropping to damage the body or glass
during operation.
45

Luggage Compartment Door Opener Switch Assembly

Removal
CAUTION
 DO NOT scratch the interior when removing the luggage compartment door opener switch assembly.

3. Remove the luggage compartment door opener switch assembly.
off the headlight adjustment switch set.
RA19420080

switch connector (arrow).
RA19450091
c. Using a screwdriver wrapped with protective tape, 45

disengage the claws (arrow) on the luggage
compartment door opener switch assembly.
RA19450092
d. Remove the luggage compartment door opener switch assembly.

Inspection
1. Check the luggage compartment door opener switch
assembly.
+ -
a. Using the digital multimeter, measure the continuity 2 1
between each terminal of the luggage compartment 8 7 6 5 4 3
door opener switch assembly as shown in the table.

Switch not
1-2 No continuity
pushed RA19450720
1-2 Switch pushed Continuity
If the result is not as specified, replace the luggage

2. Check the luggage compartment door opener switch
-
illumination. +
a. Apply battery voltage to the terminals of luggage 2 1
compartment door opener switch connector, and 8 7 6 5 4 3
check the operation of luggage compartment door

opener switch according to the table below.
Specified
(+) (-) RA19450721
3 4 LED comes on
If the result is not as specified, replace the luggage

Installation
CAUTION
 Install the connector in place when installing the luggage compartment door opener switch assembly.
45
 Always operate carefully to prevent other components from being damaged when installing the luggage
 Check that the switch can be used normally after installing the luggage compartment door opener switch
assembly.

EXTERIOR
GENERAL INFORMATION 46-3 Rear Bumper Assembly 46-22
Specifications 46-6 Disassembly 46-23
Tool 46-6 Assembly 46-25
Installation 46-25
Rear Bumper Bracket Assembly 46-26
Front Bumper Assembly 46-7
Removal 46-26
Removal 46-7
Installation 46-26
Disassembly 46-9
Rear Bumper Anti-collision 
Assembly 46-11 Crossmember Assembly 46-27
Front Bumper Mounting Bracket  Installation 46-27
Assembly 46-12
Rear Wheel Front Fender Apron 46-28
Removal 46-12
Removal 46-28
Installation 46-12
Installation 46-28
Front Bumper Crossmember 
Rear Wheel Rear Fender Apron 46-29
Assembly 46-13
Removal 46-29
Removal 46-13
Installation 46-30
Installation 46-14
Front Windshield Lower Garnish 
Front Wheel House Protector 
Assembly 46-31
Assembly 46-15
Removal 46-31
Removal 46-15
Installation 46-33
Installation 46-15
Oil Filler Cap Assembly 46-34
Fender Assembly 46-16
Removal 46-34
Removal 46-16
Installation 46-35
Installation 46-19
Rear Towing Hook Assembly 46-36
Lower Deflector 46-20
Removal 46-36
Removal 46-20
Installation 46-36
Installation 46-21
Name Plate 46-37
Removal 46-37
Installation 46-37
46

46

46 - EXTERIOR
GENERAL INFORMATION
EXTERIOR
Description
×2
14
13 ×9
16
×2
2
15
×8
×2
×6 12
×6
11
4
3
×4
×9
×5 ×2
×4 10
×8
9 5
8
×8
×8
×6
46
7
6
RA19460010

46 - EXTERIOR
1 - Front Windshield Lower Garnish Assembly 2 - Left Fender Cover Plate

3 - Left Fender Sponge 4 - Front Left Fender
5 - Front Bumper Left Mounting Bracket Assembly 6 - Front Left Wheel House Protector Assembly
7 - Left Lower Deflector 8 - Front Bumper Assembly
9 - Front Bumper Energy Absorber 10 - Front Bumper Crossmember Assembly
11 - Right Lower Deflector 12 - Front Right Wheel House Protector Assembly
13 - Front Right Fender 14 - Right Fender Sponge
15 - Front Bumper Right Mounting Bracket Assembly 16 - Right Fender Cover Plate
46

46 - EXTERIOR
2
×4
×3
×3
×3
8 ×3
×3
×4
×2
7 ×3
4
×3 ×4
×3
5
6
RA19460020
46
1 - Rear Right Wheel Front Fender Apron 2 - Rear Bumper Right Bracket Assembly
3 - Rear Right Wheel Rear Fender Apron 4 - Rear Bumper Anti-collision Crossmember
Assembly
5 - Rear Bumper Assembly 6 - Rear Left Wheel Rear Fender Apron
7 - Rear Bumper Left Bracket Assembly 8 - Rear Left Wheel Front Fender Apron
Bumper assembly and bumper crossmember assembly are safety device to protect the front and rear body,
which mainly absorb and reduce outside shock. The exterior mainly consists of front bumper assembly, front
bumper mounting bracket assembly, front bumper crossmember assembly, front wheel house protector
assembly, fender assembly, lower deflector, rear bumper assembly, rear bumper bracket assembly, rear
bumper anti-collision crossmember assembly, rear wheel fender apron, front windshield lower garnish
assembly and rear towing hook assembly.

46 - EXTERIOR
Specifications

Front Wheel House Protector Assembly Fixing
2.5 ± 0.5
Screw
Front Bumper Assembly Lower Fixing Screw 5±1
Front Bumper Assembly Upper Fixing Bolt 10 ± 2
Radiator Grille Fixing Screw 5
Intake Grille Fixing Screw 5
Front Fog Light Assembly Fixing Screw 2±1
Front Bumper Mounting Bracket Assembly Fixing
10 ± 2
Bolt
Rear Bumper Bracket Assembly Fixing Bolt 10
Oil Filler Cap Assembly Fixing Bolt 10 ± 1.5
Front Bumper Crossmember Assembly Fixing Bolt 7±1
Front Bumper Crossmember Assembly Fixing Nut 30 ± 4.5
23 ± 2
Fixing Nut
Lower Deflector Fixing Screw 7 ± 1.5
Lower Deflector Fixing Screw 2.5 ± 0.5
Fender Fixing Bolt 10 ± 1
Rear Bumper Assembly Fixing Screw 1.5 ± 0.5
Rear Wheel Rear Fender Apron Fixing Screw 2.5 ± 0.5
Rear Wheel Rear Fender Apron Fixing Screw 10 ± 1.5
Camera Fixing Screw 2±1
Front Windshield Lower Garnish Assembly Fixing
5±1
Bolt
Rear Towing Hook Assembly Fixing Bolt 45 ± 7
46
Tool
Special Tool
Interior Crow Plate
RCH0000025

46 - EXTERIOR
ON-VEHICLE SERVICE
Front Bumper Assembly
Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the front bumper
assembly.
 Try to prevent the body paint surface from being scratched when removing the front bumper assembly.

3. Remove the front bumper assembly.
a. Raise the vehicle with a lifter, and remove 2 fixing
screws (arrow) between front bumper assembly and
front wheel house protector assembly (take left side
as an example).
RA19460030
b. Remove 4 fixing screws (arrow) from the lower part of

front bumper assembly.
RA19460050
46
c. Lower the vehicle to the proper position, and remove 4 fixing bolts (arrow) from the upper part of front
bumper assembly.
d. Remove 5 plastic clamps (1) from the upper part of
front bumper assembly.
RA19460040

46 - EXTERIOR
e. Disengage the claws from the front bumper assembly

(take left side as an example).
RA19460060
CAUTION
 Avoid breaking the claws when removing the front bumper assembly.
f. Disconnect the front fog light connector (arrow) (take

left side as an example).
RA19460070
g. Remove the front bumper assembly.
46

46 - EXTERIOR
Disassembly
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when disassembling the front
bumper assembly.
 Appropriate force should be applied when disassembling the front bumper assembly, and avoid
operating roughly.
 Avoid breaking the claws when disassembling the front bumper assembly.
1. Remove the front towing hook cover plate.

remove the front towing hook cover plate claw.
RA19460111
b. Remove the front towing hook cover plate.

2. Remove the intake grill.
a. Remove 4 fixing screws (arrow) from the intake grill.
RA19460090
b. Using a screwdriver wrapped with protective tape, 46

disengage the intake grill claws.
RA19460091
c. Remove the intake grill.

46 - EXTERIOR
3. Remove the radiator grill assembly.

a. Remove 9 fixing screws (arrow) from the radiator grill
assembly.
RA19460080
b. Disengage the claws from the radiator grill assembly.
RA19460081
c. Remove the radiator grill assembly.

4. Remove the front fog light assembly (take left side as an example).
a. Remove 3 fixing screws (arrow) from the front fog light
assembly.
RA19460110
46 b. Remove the front fog light assembly.

5. Remove the fog light garnish (take left side as an example).
disengage the claws from the fog light garnish.
RA19460100
b. Remove the fog light garnish.

46 - EXTERIOR
6. Remove the fog light trim board (take left side as an example).
disengage the claws from the fog light trim board.
RA19460101
b. Remove the fog light trim board.
Assembly
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when assembling the front bumper
assembly.
 Try to prevent the body paint surface from being scratched when assembling the front bumper assembly.
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the front bumper
assembly.
 Try to prevent the body paint surface from being scratched when installing the front bumper assembly.
 Make sure that the front bumper is installed correctly and the fitting clearance between front bumper and
body is appropriate when installing the front bumper assembly.
46

46 - EXTERIOR
Front Bumper Mounting Bracket Assembly

Removal
HINT:
CAUTION
mounting bracket assembly.
 Try to prevent the body paint surface from being scratched when removing the front bumper mounting
bracket assembly.

4. Remove the front bumper left mounting bracket assembly.
a. Remove 2 fixing bolts (arrow) from the front bumper
mounting bracket assembly.
RA19460120
b. Remove the front bumper left mounting bracket assembly.
Installation
CAUTION
46
mounting bracket assembly.
 Try to prevent the body paint surface from being scratched when installing the front bumper mounting
bracket assembly.

46 - EXTERIOR
Front Bumper Crossmember Assembly

Removal
CAUTION
 Try to prevent the body paint surface from being scratched when removing the front bumper

4. Remove the front bumper energy absorber.
RA19460140
5. Remove the front bumper crossmember assembly.

a. Disconnect the wire harness clips (arrow) from the
front bumper crossmember.
46
RA19460130

46 - EXTERIOR
b. Remove 8 fixing nuts (1) from both sides of front

bumper crossmember assembly.
c. Remove 4 fixing bolts (arrow) from the front part of
front bumper crossmember assembly.
1 1
RA19460131
d. Remove the front bumper crossmember assembly.
Installation
CAUTION
 Try to prevent the body paint surface from being scratched when installing the front bumper
 There should be no looseness, shaking and deformation after installing the front bumper crossmember
assembly.
46

46 - EXTERIOR
Front Wheel House Protector Assembly

Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the front wheel
house protector assembly.
 Try to prevent the body paint surface from being scratched when removing the front wheel house
protector assembly.
1. Remove the front left wheel house protector assembly.

a. Remove 8 plastic clamps from the front wheel house assembly.
b. Remove 6 fixing screws from the front wheel house
assembly.
RA19460141
c. Remove the front left wheel house protector assembly.
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the front wheel
house protector assembly.
46
 Try to prevent the body paint surface from being scratched when installing the front wheel house
protector assembly.
 Replace the damaged plastic clamps and install the front wheel house protector assembly in place when
installing the front wheel house protector assembly.

46 - EXTERIOR
Fender Assembly
Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the fender
assembly.
 Try to prevent the body paint surface from being scratched when removing the fender assembly.

3. Remove the front left wheel house protector assembly (See page 46-15).
5. Remove the front bumper left mounting bracket assembly (See page 46-12).
6. Remove the front windshield lower garnish left sealing block.
disengage the clips from the front windshield lower
garnish left sealing block.
RA19450081
b. Remove the front windshield lower garnish left sealing block.

7. Remove the left turn light.
a. Push the turn light cover forward, and then use a
screwdriver wrapped with protective tape to remove
the turn light cover.
46
RA19460150

46 - EXTERIOR
b. Disconnect the turn light connector (arrow).
RA19460160
c. Remove the left turn light.

8. Remove the left outer triangular block assembly.
a. Using an interior crow plate, pry off the clamps from
the outer triangular block assembly.
RA19460180
b. Remove the left outer triangular block assembly.

9. Remove the left fender assembly.
a. Remove the plastic clamp (1) between the upper part
of fender and the body.
b. Remove 2 fixing bolts (arrow) between the upper part
of fender and the body.
RA19460170
46
c. Remove the fixing bolt (arrow) between front fender
and engine hood under front windshield lower garnish.
RA19450082

46 - EXTERIOR
d. Remove the fixing bolt (arrow) between front fender

inside the outer triangular block assembly and the
body.
RA19460200
e. Remove 3 fixing bolts (arrow) between the front part

of front fender and the body.
RA19460190
f. Remove the fixing bolt (arrow) between the inner part

RA19460230
g. Remove the fixing bolt (arrow) between the lower part

46
RA19460220
h. Remover the front left fender.

46 - EXTERIOR
10.Remove the left fender sponge.
RA19460240
11. Remove the left fender cover plate.

a. Remove 2 plastic clamps (arrow) from the fender
cover plate.
RA19460250
b. Remove the left fender cover plate.
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the front fender.
 Try to prevent the body paint surface from being scratched when installing the front fender.
 Make sure that the front fender is installed correctly and the fitting clearance between front fender and
body is appropriate when installing the front fender.
46

46 - EXTERIOR
Lower Deflector
Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the lower deflector.
 Try to prevent the body paint surface from being scratched when removing the lower deflector.
1. Remove the left lower deflector.

a. Remove 2 fixing screws (arrow) from the left lower
deflector.
RA19460270
b. Remove 5 fixing screws (arrow) from the lower part of

lower deflector.
RA19460260
46 c. Remove the fixing screw (arrow) between the lower

part of lower deflector and the front wheel house. 
RA19460261
d. Remove the left lower deflector.

46 - EXTERIOR
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the lower deflector.
 Try to prevent the body paint surface from being scratched when installing the lower deflector.
46

46 - EXTERIOR
Rear Bumper Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the rear bumper
assembly.
 Try to prevent the body paint surface from being scratched when removing the rear bumper assembly.

3. Remove the rear combination light (See page 33-71).
CAUTION
 It is not necessary to completely remove the luggage compartment weatherstrip when removing it, so
that the plastic clamps on the rear bumper assembly can be removed.
4. Remove the luggage compartment weatherstrip (See page 47-25).

5. Remove the rear bumper assembly.
a. Raise the vehicle with a lifter, and remove 2 fixing
screws (arrow) between rear bumper assembly and
rear wheel rear fender apron (take left side as an
example).
1
b. Remove the plastic clamp (1) between rear bumper
assembly and rear wheel rear fender apron (take left
side as an example).
RA19460280
c. Remove 2 plastic clamps (arrow) from the lower part

of rear bumper assembly.
46
RA19460300
d. Lower the vehicle and remove 2 fixing screws (arrow) from the upper part of rear bumper assembly.

46 - EXTERIOR
e. Remove 4 plastic clamps (1) from the upper part of

rear bumper assembly.
1
RA19460290
CAUTION
 Avoid breaking the claws when removing the rear bumper assembly.
f. Disengage the claws from the rear bumper assembly

(take left side as an example).
RA19460310
g. Pry off the clips on the rear bumper assembly connectors.

h. Disconnect the rear bumper assembly connectors
(arrow).
46
RA19460320
i. Remove the rear bumper assembly.
Disassembly
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when dissembling the rear bumper
assembly.
 Appropriate force should be applied when disassembling the rear bumper assembly, and avoid operating
roughly.
 Avoid breaking the claws when dissembling the rear bumper assembly.

46 - EXTERIOR
1. Remove the rear bumper lower trim board.

a. Disengage the claws on the rear bumper lower trim
board.
RA19460331
b. Remove the rear bumper lower trim board.

2. Remove the reversing radar (take left side as an example).
a. Disconnect the reversing radar connector (arrow).
b. Remove the clip from the reversing radar in the
RA19460333

disengage the claws (arrow) on the reversing radar.
RA19460334
46
d. Remove the reversing radar.
e. Press the clip in the direction of arrow and remove the
reversing radar housing.
RA19460335
3. Remove the license plate light.

a. Disconnect the license plate light connector (arrow).

46 - EXTERIOR
b. Disengage the claws on the license plate light.
RA19460330
c. Remove the license plate light.
Assembly
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when assembling the rear bumper
assembly.
 Try to prevent the body paint surface from being scratched when assembling the rear bumper assembly.
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the rear bumper
assembly.
 Try to prevent the body paint surface from being scratched when installing the rear bumper assembly.
 Make sure that the rear bumper is installed correctly and the fitting clearance between rear bumper and
body is appropriate when installing the rear bumper assembly.
46

46 - EXTERIOR
Rear Bumper Bracket Assembly

Removal
HINT:
CAUTION
bracket assembly.
 Try to prevent the body paint surface from being scratched when removing the rear bumper bracket
assembly.

4. Remove the rear bumper left bracket assembly.
a. Remove the plastic clamp (1) from the rear bumper bracket assembly.
b. Remove 4 fixing bolts (arrow) from the rear bumper
bracket assembly. 1
RA19460360
c. Remove the rear bumper left bracket assembly.
Installation
46 CAUTION
bracket assembly.
 Try to prevent the body paint surface from being scratched when installing the rear bumper assembly.

46 - EXTERIOR

Removal
CAUTION
anti-collision crossmember assembly.
 Try to prevent the body paint surface from being scratched when removing the rear bumper anti-collision

4. Remove the rear bumper anti-collision crossmember assembly.
a. Remove 6 fixing nuts (arrow) from the rear bumper
anti-collision crossmember assembly.
RA19460370
b. Remove the rear bumper anti-collision crossmember assembly.
Installation
46
CAUTION
anti-collision crossmember assembly.
 Try to prevent the body paint surface from being scratched when installing the rear bumper anti-collision
 There should be no looseness, shaking and deformation after installing the rear bumper anti-collision

46 - EXTERIOR
Rear Wheel Front Fender Apron

Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the rear wheel
front fender apron assembly.
 Try to prevent the body paint surface from being scratched when removing the rear wheel front fender
apron assembly.
1. Remove the rear left wheel front fender apron.

a. Remove 3 plastic clamps from the rear left wheel front
fender apron.
RA19460380
b. Remove the rear left wheel front fender apron.
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the rear wheel front
fender apron.
 Try to prevent the body paint surface from being scratched when installing the rear wheel front fender
46 apron.
 Replace the damaged plastic clamps and install the rear wheel front fender apron in place when
installing the rear wheel front fender apron.

46 - EXTERIOR
Rear Wheel Rear Fender Apron

Removal
HINT:
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the rear wheel rear
fender apron assembly.
 Try to prevent the body paint surface from being scratched when removing the rear wheel rear fender
apron assembly.
1. Remove the rear left wheel rear fender apron.

a. Remove 3 plastic clamps from the rear wheel rear fender apron.
b. Remove the fixing screw from the inside of rear wheel
rear fender apron.
RA19460390
c. Remove 2 fixing screws from the outside of rear wheel

rear fender apron.
RA19460391
46
d. Remove the rear left wheel rear fender apron.

46 - EXTERIOR
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the rear wheel rear
fender apron.
 Try to prevent the body paint surface from being scratched when installing the rear wheel rear fender
apron.
 Replace the damaged plastic clamps and install the rear wheel rear fender apron in place when installing
the rear wheel rear fender apron.
46

46 - EXTERIOR
Front Windshield Lower Garnish Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the front
windshield lower garnish assembly.
 Try to prevent the body paint surface from being scratched when removing the front windshield lower
garnish assembly.

2. Remove the engine compartment rear weatherstrip.
a. Remove the clips from the engine compartment rear weatherstrip.
b. Remove the engine compartment rear weatherstrip
(1).
RA19460402
3. Remove the front windshield lower garnish center sealing block.

off the clips on the front windshield lower garnish
center sealing block.
RA19460401 46
b. Remove the front windshield lower garnish center sealing block.
4. Remove the front windshield lower garnish left sealing block (take left side as an example).
off the clips on the front windshield lower garnish
center sealing block.
RA19450081

46 - EXTERIOR
b. Remove the front windshield lower garnish left sealing block.

5. Remove the front windshield lower garnish assembly.
a. Remove 4 fixing screws (arrow) from the front
windshield lower garnish assembly.
RA19460400
b. Disconnect the front washer pipe joint (1), and remove

the front washer pipe from the clip (arrow).
RA19460410
c. Remove the front windshield lower garnish assembly.

6. Disengage the front windshield lower garnish assembly.
a. Disconnect the front washer pipe from the nozzle (arrow).
b. Press the claws on the front nozzle in the direction of
46 RA19460420
c. Remove the front nozzle.

d. Remove the front washer pipe from the clips (arrow),
and take it out from the clip (1).
RA19460421

46 - EXTERIOR
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the front windshield
lower garnish assembly.
 Try to prevent the body paint surface from being scratched when installing the front windshield lower
garnish assembly.
46

46 - EXTERIOR
Oil Filler Cap Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the oil filler cap
assembly.
 Try to prevent the body paint surface from being scratched when removing the oil filler cap assembly.
1. Open the oil filler cap assembly as shown in the

illustration.
RA19460450
2. Remove the oil filler cap assembly.

a. Disconnect the connecting wire (1) from the oil filler cap assembly.
b. Remove 2 fixing bolts (arrow) from the oil filler cap
assembly.
46
1
RA19460460
c. Remove the oil filler cap assembly.

46 - EXTERIOR
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the oil filler cap
assembly.
 Try to prevent the body paint surface from being scratched when installing the oil filler cap assembly.
46

46 - EXTERIOR
Rear Towing Hook Assembly

Removal
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when removing the rear towing
hook assembly.
 Try to prevent the body paint surface from being scratched when removing the rear towing hook
assembly.
1. Remove the rear towing hook assembly.

a. Remove 3 fixing bolts (arrow) from the rear towing
hook assembly.
RA19460470
b. Remove the rear towing hook assembly.
Installation
CAUTION
 Be sure to wear the necessary safety equipment to prevent accidents when installing the rear towing
hook assembly.
 Try to prevent the body paint surface from being scratched when installing the rear towing hook
assembly.
46

46 - EXTERIOR
Name Plate
Removal
HINT:
 Use the same operation procedures for front name plate "CAC", rear name plate "CAC", name plate "E3"
and name plate "CHERY".
 The procedures listed below are for the name plate "CHERY".
CAUTION
 If the name plate "CHERY" is to be reused, be careful not to damage it.

 Try to prevent the body paint surface from being scratched when removing the name plate "CHERY".
1. Remove the name plate "CHERY".

a. Attach protective tape around the name plate "CHERY".
b. Insert a piano wire between body and name plate "CHERY".
c. Tie both piano wire ends to objects (such as wooden blocks) that can serve as handles.
d. Pull the piano wire to remove the double-sided tape
on the body where applying name plate.
RA19460480
e. Remove the name plate "CHERY".
Installation
1. Clean the body surface.
a. Using a heat light, heat the body surface, and remove the double-sided tape from the body.
b. Wipe off any remaining tape adhesive residue with cleaner.
2. Clean the name plate "CHERY" (if the name plate "CHERY" is to be reused). 46
a. Using a heat light, heat the name plate, and remove the double-sided tape from the "CHERY" name
plate.
b. Wipe off any remaining tape adhesive residue with cleaner.
c. Apply new double-sided tape to the name plate "CHERY".
3. Install the name plate "CHERY".
a. Using a heat light, heat the body and name plate "CHERY".
b. Remove the release paper from the name plate "CHERY", and install the name plate "CHERY" in place.

46 - EXTERIOR
CAUTION
 DO NOT overheat the body and name plate.

 DO NOT remove the release paper from the name plate in advance.
 DO NOT touch the name plate adhesive surface with hand.
 After removing the release paper, prevent foreign matter from attaching to the outside adhesive.
4. The installation distance ranges for front name plate "CAC" are as follows:
a. Install the front name plate "CAC" to the installation hole.
b. The vertical distance "a" between the right side of
front name plate "CAC" and the right side of hood is
33.0 ± 2 mm
c. The vertical distance "b" between the left side of front
name plate "CAC" and the left side of hood is 
a c b
33.0 ± 2 mm
d. The vertical distance "a" between the upper side of
front name plate "CAC" and the upper side of hood is
5.5 ± 2 mm
RA19460520
5. The installation distance ranges for name plate "CHERY" are as follows:
a. When attaching the name plate "CHERY", keep it horizontal and centered.
b. The vertical distance "a" between the left side of name
plate "CHERY" and the left side of luggage
compartment door is 2.4 ± 2 mm.
a
c. The vertical distance "a" between the lower side of
name plate "CHERY" and the lower side of luggage
c
d. The vertical distance "a" between the lower left side of b
name plate "CHERY" and the lower left side of
luggage compartment door is 4.9 ± 2 mm.
RA19460490
6. The installation distance ranges for rear name plate "CAC" are as follows:
46 a. When attaching the rear name plate "CAC", keep it horizontal and centered.
b. The vertical distance "a" between the left side of rear
name plate "CAC" and the left side of luggage
a b
c. The vertical distance "a" between the right side of rear
name plate "CAC" and the right side of luggage
compartment door is 43.9 ± 2 mm. c
d. The vertical distance "a" between the lower side of
rear name plate "CAC" and the lower side of luggage
RA19460500

46 - EXTERIOR
7. The installation distance ranges for name plate "E3" are as follows:
a. When attaching the name plate "E3", keep it horizontal and centered.
b. The vertical distance "a" between the right side of
name plate "E3" and the right side of luggage
c. The vertical distance "a" between the lower side of a
name plate "E3" and the lower side of luggage
compartment door is 10.4 ± 2 mm. c
d. The vertical distance "a" between the lower right side b
of name plate "E3" and the lower right side of luggage
RA19460510
46

- MEMO -

INTERIOR
GENERAL INFORMATION 47-3 Rear Door Opening Weatherstrip 47-24
Tool 47-7 Luggage Compartment 
Weatherstrip 47-25
Front Doorsill Pressure Plate  Installation 47-25
Assembly 47-8
Sun Visor Assembly 47-26
Removal 47-8
Removal 47-26
Installation 47-8
Installation 47-26
Rear Doorsill Pressure Plate 
Passenger Grip Assembly 47-27
Assembly 47-9
Removal 47-27
Removal 47-9
Installation 47-27
Installation 47-9
Roof Assembly 47-28
A-pillar Upper Protector Assembly 47-10
Removal 47-28
Removal 47-10
Installation 47-29
Installation 47-11
Front Floor Carpet Assembly 47-30
A-pillar Lower Protector Assembly 47-12
Removal 47-30
Removal 47-12
Installation 47-31
Installation 47-12
Luggage Compartment Carpet 
B-pillar Lower Protector Assembly 47-13
Assembly 47-32
Removal 47-13
Removal 47-32
Installation 47-14
Installation 47-32
B-pillar Upper Protector Assembly 47-15
Luggage Compartment Trim Cover 
C-pillar Lower Protector Assembly 47-17 Installation 47-33
Removal 47-17 Tonneau Cover Assembly 47-34
C-pillar Upper Protector Assembly 47-19 Installation 47-35
Removal 47-19 Rear Seat Cover Assembly 47-36
Rear Luggage Compartment Trim  Installation 47-36
Assembly 47-21
Fuel Filler Cap Cable Assembly 47-37
Removal 47-21
Removal 47-37 47
Installation 47-22
Installation 47-38
Front Door Opening Weatherstrip 47-23
Removal 47-23
Installation 47-23

47

47 - INTERIOR
GENERAL INFORMATION
INTERIOR
Description
×2
×2 ×2
×2
6
9
4
5
22
7
×2
×2 8 21
10
11
19
15 20
18
16
12
14
47
17
13
RA19470010

47 - INTERIOR
1 - Roof Assembly 2 - Tonneau Cover Assembly

3 - Right C-pillar Upper Protector Assembly 4 - Right C-pillar Lower Protector Assembly
5 - Rear Right Doorsill Pressure Plate Assembly 6 - Right B-pillar Upper Protector Assembly
7 - Right B-pillar Lower Protector Assembly 8 - Front Right Doorsill Pressure Plate Assembly
9 - Right A-pillar Upper Protector Assembly 10 - Protector Fixing Screw Cover
11 - Right A-pillar Lower Protector Assembly 12 - Left A-pillar Upper Protector Assembly
13 - Left A-pillar Lower Protector Assembly 14 - Front Left Doorsill Pressure Plate Assembly
15 - Left B-pillar Upper Protector Assembly 16 - Left B-pillar Lower Protector Assembly
17 - Rear Left Doorsill Pressure Plate Assembly 18 - Left C-pillar Lower Protector Assembly
19 - Left C-pillar Upper Protector Assembly 20 - Rear Luggage Compartment Trim Assembly
21 - Rear Seat Left Cover Assembly 22 - Rear Seat Right Cover Assembly
47

47 - INTERIOR
9 10
2
3
5
×2 ×2
8
×2
7
4
RA19470020
1 - Roof Assembly 2 - Rear Left Passenger Grip Assembly

3 - Left Sun Visor Holder B 4 - Left Sun Visor Assembly
5 - Rear Right Passenger Grip Assembly 6 - Interior Front Dome Light Assembly
7 - Interior Front Dome Light Cover 8 - Right Sun Visor Assembly
9 - Right Sun Visor Holder B 10 - Front Right Passenger Grip Assembly
47

47 - INTERIOR
7 9
2
3
RA19470030
1 - Luggage Compartment Weatherstrip 2 - Left Luggage Compartment Trim Cover Assembly

3 - Luggage Compartment Carpet Assembly 4 - Rear Left Door Opening Weatherstrip
5 - Front Left Door Opening Weatherstrip 6 - Front Floor Carpet Assembly
47 7 - Front Right Door Opening Weatherstrip 8 - Rear Right Door Opening Weatherstrip
9 - Right Luggage Compartment Trim Cover
Assembly
The interior consists of the following parts: roof assembly, sun visor assembly, door opening weatherstrip,
passenger grip assembly, doorsill pressure plate assembly, pillar protector assembly and carpet assembly,
etc.

47 - INTERIOR
Specifications

Sun Visor Assembly Fixing Screw 3 ± 0.5
Sun Visor Holder B Fixing Screw 3 ± 0.5
Passenger Grip Assembly Fixing Screw 5±1
Interior Front Dome Light Assembly Fixing Screw 2±1
A-pillar Upper Protector Assembly Fixing Screw 5±1
B-pillar Upper Protector Assembly Fixing Screw 5±1
C-pillar Upper Protector Assembly Fixing Screw 5±1
Fuel Tank Opening Bracket Assembly Fixing Bolt 10 ± 1.5
Tool
Special Tool
Interior Crow Plate
RCH0000025
47

47 - INTERIOR
ON-VEHICLE SERVICE
Front Doorsill Pressure Plate Assembly
Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front doorsill pressure plate
assembly.
 Appropriate force should be applied when removing the front doorsill pressure plate assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the front doorsill pressure plate assembly.
1. Remove the front left doorsill pressure plate assembly.

a. Using an interior crow plate, pry off the clips from the
front doorsill pressure plate assembly.
RA19470130
b. Remove the front left doorsill pressure plate assembly.
Installation
CAUTION
47  DO NOT scratch the interior and body paint when installing the front doorsill pressure plate assembly.
 Make sure the front doorsill pressure plate assembly is installed in place during installation.
 Make sure to check the fitting gap between the front doorsill pressure plate assembly and the B-pillar
lower protector assembly, A-pillar lower protector assembly for uniformity after installing the front doorsill
pressure plate assembly.

47 - INTERIOR
Rear Doorsill Pressure Plate Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear doorsill pressure plate
assembly.
 Appropriate force should be applied when removing the rear doorsill pressure plate assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the rear doorsill pressure plate assembly.
1. Remove the rear left doorsill pressure plate assembly.

rear doorsill pressure plate assembly.
RA19470140
b. Remove the rear left doorsill pressure plate assembly.
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the rear doorsill pressure plate assembly.
 Make sure the rear doorsill pressure plate assembly is installed in place when installing.
 Make sure to check the fitting gap between the rear doorsill pressure plate assembly and the B-pillar
lower protector assembly, C-pillar lower protector assembly for uniformity after installing the rear doorsill 47
pressure plate assembly.

47 - INTERIOR
A-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the A-pillar upper protector
assembly.
 Appropriate force should be applied when removing the A-pillar upper protector assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the A-pillar upper protector assembly.
2. Remove the left A-pillar upper protector assembly.
remove the protector fixing screw cover (1).
b. Remove the fixing screw (2) from the A-pillar upper
protector assembly.
1
RA19470040
c. Using an interior crow plate, pry off the clip from the 
A-pillar upper protector assembly.
d. Pull out the snap-fits on the A-pillar upper protector
from the installation holes on the instrument panel.
47 RA19470050
e. Remove the left A-pillar protector assembly.

47 - INTERIOR
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the A-pillar upper protector assembly.
 Make sure the damaged clip is replaced and the A-pillar upper protector assembly is installed in place
when installing the A-pillar upper protector assembly.
 The A-pillar upper protector assembly and the front door opening weatherstrip should be fitted closely
after installing the A-pillar upper protector assembly.
 The A-pillar upper protector assembly and the instrument panel and roof headlining should be fitted
closely after installing the A-pillar upper protector assembly.
47

47 - INTERIOR
A-pillar Lower Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the A-pillar lower protector
assembly.
 Appropriate force should be applied when removing the A-pillar lower protector assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the A-pillar lower protector assembly.
3. Remove the left A-pillar lower protector assembly.
A-pillar lower protector assembly.
RA19470060
b. Remove the left A-pillar lower protector assembly.
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the A-pillar lower protector assembly.
47  Make sure the A-pillar lower protector assembly is installed in place during installation.
 The A-pillar lower protector assembly and the front door opening weatherstrip should be fitted closely
after installing the A-pillar lower protector assembly.

47 - INTERIOR
B-pillar Lower Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the B-pillar lower protector
assembly.
 Appropriate force should be applied when removing the B-pillar lower protector assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the B-pillar lower protector assembly.
5. Remove the left B-pillar lower protector assembly.
off the front seat belt assembly lower bolt cover.
RA19310030
b. Remove the fixing bolt (arrow) from the lower part of

the front seat belt assembly.
47
RA19310040

47 - INTERIOR
B-pillar lower protector assembly.
RA19470090
d. Remove the left B-pillar lower protector assembly.
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the B-pillar lower protector assembly.
 Make sure the damaged clips are replaced and the B-pillar lower protector assembly is installed in place
when installing the B-pillar lower protector assembly.
 The B-pillar lower protector assembly and the front and rear door opening weatherstrips should be fitted
closely after installing the B-pillar lower protector assembly.
 The B-pillar lower protector assembly and the front and rear doorsill pressure plate assemblies should be
fitted closely after installing the B-pillar lower protector assembly.
47

47 - INTERIOR
B-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the B-pillar upper protector
assembly.
 Appropriate force should be applied when removing the B-pillar upper protector assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the B-pillar upper protector assembly.
5. Remove the left B-pillar lower protector assembly (See page 47-13).
6. Remove the left B-pillar upper protector assembly.
remove the vertical adjuster cover while pressing the
vertical adjuster button on both sides as shown in the
illustration.
RA19310050
b. Remove the fixing bolt (arrow) from the upper part of

the front seat belt assembly.
47
RA19470071

47 - INTERIOR

d. Remove the fixing screw (2) from the B-pillar upper
RA19470070
e. Using an interior crow plate, pry off the clip from the 
B-pillar upper protector assembly.
RA19470080
f. Remove the left B-pillar upper protector assembly.
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the B-pillar upper protector assembly.
 Make sure the damaged clip is replaced and the B-pillar upper protector assembly is installed in place
when installing the B-pillar upper protector assembly.
 The B-pillar upper protector assembly and the front and rear door opening weatherstrips should be fitted
closely after installing the B-pillar upper protector assembly.
 The B-pillar upper protector assembly and the B-pillar lower protector assembly and roof headlining
should be fitted closely after installing the B-pillar upper protector assembly.
47

47 - INTERIOR
C-pillar Lower Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the C-pillar lower protector
assembly.
 Appropriate force should be applied when removing the C-pillar lower protector assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the C-pillar lower protector assembly.
4. Remove the left C-pillar lower protector assembly.
a. Remove the plastic clip (arrow) from the C-pillar lower
protector assembly.
RA19470120
C-pillar lower protector assembly.
47
RA19470121
c. Remove the left C-pillar lower protector assembly.

47 - INTERIOR
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the C-pillar lower protector assembly.
 Make sure the damaged clips are replaced and the C-pillar lower protector assembly is installed in place
when installing the C-pillar lower protector assembly.
 The C-pillar lower protector assembly and the C-pillar upper protector and rear door opening
weatherstrip should be fitted closely after installing the C-pillar lower protector assembly.
47

47 - INTERIOR
C-pillar Upper Protector Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the C-pillar upper protector
assembly.
 Appropriate force should be applied when removing the C-pillar upper protector assembly, and avoid
operating roughly.
 DO NOT scratch the interior and body paint when removing the C-pillar upper protector assembly.
4. Remove the left C-pillar lower protector assembly (See page 47-17).
5. Remove the left C-pillar upper protector assembly.
b. Remove the fixing screw (2) from the C-pillar upper 2
1
RA19470100
C-pillar upper protector assembly.
d. Pull out the snap-fits on the C-pillar upper protector
from the installation holes on the tonneau cover.
47
RA19470110
e. Remove the left C-pillar upper protector assembly.

47 - INTERIOR
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the C-pillar upper protector assembly.
 Make sure the damaged clips are replaced and the C-pillar upper protector assembly is installed in place
when installing the C-pillar upper protector assembly.
 The C-pillar upper protector assembly and the rear door opening weatherstrip should be fitted closely
after installing the C-pillar upper protector assembly.
 The C-pillar upper protector assembly and the C-pillar lower protector assembly and roof headlining
should be fitted closely after installing the C-pillar upper protector assembly.
47

47 - INTERIOR
Rear Luggage Compartment Trim Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear luggage compartment
trim assembly.
 Appropriate force should be applied when removing the rear luggage compartment trim assembly, and
avoid operating roughly.
 DO NOT scratch the interior and body paint when removing the rear luggage compartment trim
assembly.

3. Take out the spare tire.
4. Remove the left shock pad (the left side is shown as an
example).
RA19470290
5. Remove the rear luggage compartment trim assembly.

a. Remove the plastic clips (arrow) from the rear
luggage compartment trim assembly.
RA19470150 47
rear luggage compartment trim assembly.
RA19470151

47 - INTERIOR
c. Remove the rear luggage compartment trim assembly.
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the rear luggage compartment trim assembly.
 Make sure the damaged clips are replaced and the rear luggage compartment trim assembly is installed
in place when installing the rear luggage compartment trim assembly.
47

47 - INTERIOR
Front Door Opening Weatherstrip

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the front door opening
weatherstrip.
 DO NOT damage the front door opening weatherstrip when removing it.
2. Remove the front left door opening weatherstrip.
a. Remove the front left door opening weatherstrip by
front door opening weatherstrip.
RA19470160
Installation
CAUTION
 The fitting between the front door opening weatherstrip and the body should be tightened properly and
the weatherstrip should not fall off easily when installing the front door opening weatherstrip.
 When installing the front door opening weatherstrip, tap all around uniformly with a rubber hammer to
install it in place. The surface of the weatherstrip should have no defects, such as tapped dents,
deformation and warpage after installation.
 After installing the front door opening weatherstrip, do not remove or install it unless it is necessary; or
the weatherstrip holding force of installation may be reduced. 47

47 - INTERIOR
Rear Door Opening Weatherstrip

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear door opening
weatherstrip.
 DO NOT damage the rear door opening weatherstrip when removing it.
2. Remove the rear left door opening weatherstrip.
a. Remove the rear left door opening weatherstrip by
rear door opening weatherstrip.
RA19470170
Installation
CAUTION
 The fitting between the rear door opening weatherstrip and the body should be tightened properly and
the weatherstrip should not fall off easily when installing the rear door opening weatherstrip.
 When installing the rear door opening weatherstrip, tap all around uniformly with a rubber hammer to
 After installing the rear door opening weatherstrip, do not remove or install it unless it is necessary; or the
47 weatherstrip holding force of installation may be reduced.

47 - INTERIOR
Luggage Compartment Weatherstrip

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the luggage compartment
weatherstrip.
 Avoid damage to the luggage compartment weatherstrip when removing it.
1. Remove the luggage compartment weatherstrip.

a. Remove the luggage compartment weatherstrip by
luggage compartment weatherstrip.
RA19470180
Installation
CAUTION
 The fitting between the luggage compartment weatherstrip and the body should be tightened properly
and the weatherstrip should not fall off easily when installing the luggage compartment weatherstrip.
 When installing the luggage compartment weatherstrip, tap all around uniformly with a rubber hammer to
 After installing the luggage compartment weatherstrip, do not remove or install it unless it is necessary;
or the weatherstrip holding force of installation may be reduced.
47

47 - INTERIOR
Sun Visor Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the sun visor assembly.
 Avoid damage to the interior and the roof when removing the sun visor assembly.
1. Remove the left sun visor assembly.

a. Disengage one side of the sun visor assembly from
the holder B (1).
1
b. Remove 2 fixing screws (arrow) from the sun visor
assembly.
RA19470190
c. Remove the left sun visor assembly.

2. Remove the left sun visor holder B.
a. Remove the fixing screw from the sun visor holder B.
RA19470200
47 b. Remove the left sun visor holder B.
Installation
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the sun visor assembly.
 Avoid damage to the interior and roof when installing the sun visor assembly.

47 - INTERIOR
Passenger Grip Assembly

Removal
HINT:
 Use the same procedures for the rear left/rear right side and front right side.
 The procedures listed below are for the front right side.
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the passenger grip assembly.
 Avoid damage to the interior and roof when removing the passenger grip assembly.
1. Remove the front right passenger grip assembly.

loosen the passenger grip covers (arrow).
RA19470211
b. Remove 2 fixing screws (arrow) from the passenger

grip assembly.
RA19470210
c. Remove the front right passenger grip assembly.
Installation 47
CAUTION
 Make sure to wear safety equipment to prevent accidents when installing the passenger grip assembly.
 Avoid damage to the interior and roof when installing the passenger grip assembly.

47 - INTERIOR
Roof Assembly
Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the roof assembly.
 Avoid damage to the interior and body paint when removing the roof assembly.

3. Remove the sun visor assembly (See page 47-26).
4. Remove the passenger grip assembly (See page 47-27).
8. Remove the rear door opening weatherstrip (See page 47-24).
9. Remove the A-pillar upper protector assembly (See page 47-10).
10.Remove the B-pillar upper protector assembly (See page 47-15).
12.Remove the interior front dome light assembly.
remove the interior front dome light cover.
RA19470220
b. Remove 2 fixing screws from the interior front dome

light assembly.
47
RA19470230

47 - INTERIOR
c. Disconnect the interior front dome light connector

(arrow).
RA19470240
d. Remove the interior front dome light assembly.

13.Remove the roof assembly.
a. Remove 2 clips (arrow) from the roof assembly.
RA19470250
b. Remove the roof assembly from the rear door.
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the roof assembly.
 Make sure the damaged clips are replaced and the roof assembly is installed in place when installing the
roof assembly.
 The roof assembly and the pillar upper protectors should be fitted closely when installing the roof
assembly.
 The roof assembly and the door opening weatherstrip should be fitted closely after installing the roof
assembly.
47

47 - INTERIOR
Front Floor Carpet Assembly

Removal
CAUTION
 Please wear protective gloves when removing the front floor carpet assembly.
 Avoid damage to the interior and body paint when removing the front floor carpet assembly.

4. Remove the front seat assembly (See page 44-7).
10.Remove the rear door opening weatherstrip (See page 47-24).
11. Remove the A-pillar lower protector assembly (See page 47-12).
12.Remove the B-pillar lower protector assembly (See page 47-13).
13.Remove the C-pillar lower protector assembly (See page 47-17).
14.Remove the front floor carpet assembly.
a. Remove the tightening shim (arrow) on the left side of
front floor carpet assembly.
RA19470260
b. Remove the tightening shim (arrow) on the right side

47 of front floor carpet assembly.
RA19470270

47 - INTERIOR
c. Remove the application sheet (arrow) on the center of

front floor carpet assembly.
RA19470274
d. Remove the front floor carpet assembly.

15.Remove the front floor shock pad (the left side is shown
1
as an example).
a. Remove the front left shock pad (1) from the front floor
3
(for the left side).
b. Remove the front shock pad (2) from the front floor. 4
c. Remove the center shock pad (3) from the front floor.
d. Remove the rear shock pad (4) from the front floor. 2
RA19470275
Installation
CAUTION
 Always pay attention to the flatness around front floor carpet assembly and the routing of relative body
wire harness when installing the front floor carpet assembly.
 Spread the front floor carpet assembly according to the bottom shape without obvious bumps and
unevenness. Expose the seat installation holes, and the front floor carpet should be firmly abutted
against the bottom.
 Replace the damaged clips when installing the front floor carpet assembly.
47

47 - INTERIOR
Luggage Compartment Carpet Assembly

Removal
1. Remove the luggage compartment carpet assembly.

a. Lift up the band in the middle of the rear part of
luggage compartment carpet and remove the luggage
compartment carpet assembly by pulling it outward.
RA19470280
Installation
CAUTION
 Make sure that the left and right sides of luggage compartment carpet are fitted in place after installing
the luggage compartment carpet assembly.
47

47 - INTERIOR
Luggage Compartment Trim Cover Assembly

Removal
HINT:
CAUTION
 Make sure to wear safety equipment when removing the luggage compartment trim assembly.
 Avoid damage to the interior and body paint when removing the luggage compartment trim assembly.

2. Remove the left shock pad (the left side is shown as an
example).
RA19470290

4. Remove the rear luggage compartment trim assembly (See page 47-21).
5. Remove the left luggage compartment trim assembly.
a. Remove the plastic clips (arrow) from the luggage
compartment trim assembly.
47
RA19470300
b. Remove the left luggage compartment trim assembly.
Installation
CAUTION
 The luggage compartment trim assembly, rear luggage compartment trim assembly and luggage
compartment weatherstrip should be fitted closely when installing the luggage compartment trim
assembly.

47 - INTERIOR
Tonneau Cover Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the tonneau cover assembly.
 Appropriate force should be applied when removing the tonneau cover assembly, and avoid operating
roughly.
 DO NOT scratch the interior and body paint when removing the tonneau cover assembly.
3. Remove the C-pillar lower protector assembly (See page 47-17).
5. Remove the tonneau cover assembly.
tonneau cover assembly.
RA19470271
b. Disconnect the high mounted stop light connector

(arrow).
47 RA19470272
c. Remove the tonneau cover assembly and high mounted stop light.
d. Remove 2 fixing screws (arrow) from the high
mounted stop light.
RA19470273

47 - INTERIOR
e. Remove the high mounted stop light from the tonneau cover assembly.
Installation
CAUTION
 DO NOT scratch the interior and body paint when installing the tonneau cover assembly.
 Make sure the damaged clips are replaced and the tonneau cover assembly is installed in place when
installing the tonneau cover assembly.
 The tonneau cover assembly and C-pillar upper protector assembly should be fitted closely when
installing the tonneau cover assembly.
47

47 - INTERIOR
Rear Seat Cover Assembly

Removal
CAUTION
 Make sure to wear safety equipment to prevent accidents when removing the rear seat cover assembly.
 Appropriate force should be applied when removing the rear seat cover assembly, and avoid operating
roughly.
 DO NOT scratch the interior and body paint when removing the rear seat cover assembly.

2. Remove the C-pillar lower protector (See page 47-17).
3. Remove the rear seat cover assembly.
a. Remove the clips (arrow) from the rear seat right
cover assembly.
RA19440241
b. Remove the rear seat right cover assembly.

c. Remove the clips (arrow) from the rear seat left cover
assembly.
RA19440242
47
d. Remove the rear seat left cover assembly.
Installation
CAUTION
 Make sure the damaged clips are replaced and the rear seat cover assembly is installed in place when
installing the rear seat cover assembly.

47 - INTERIOR
Fuel Filler Cap Cable Assembly

Removal
CAUTION
 Be sure to wear safety equipment when removing the fuel filler cap cable assembly.
 Avoid damage to the interior and body paint when removing the fuel filler cap cable assembly.
5. Remove the B-pillar lower protector assembly (See page 47-13).
8. Remove the right C-pillar lower protector assembly (See page 47-17).
9. Remove the right C-pillar upper protector assembly (See page 47-19).
10.Remove the fuel filler cap cable assembly.
a. Remove the fixing bolt (arrow) from the fuel tank
opening bracket assembly.
RA19470310
b. Remove the fuel filler cap cable from the fuel tank
opening bracket assembly in the direction of arrow as
47
RA19470320

47 - INTERIOR

off the clips (arrow) on the front part of fuel filler cap
cable.
RA19470330
d. Using a screwdriver wrapped with protective tape, pry

off the clip (arrow) on the rear part of fuel filler cap
cable.
RA19470340
e. Rotate the other end of fuel filler cap cable by 90°.
RA19470350
f. Remove the fuel filler cap cable.
Installation
CAUTION
47
 DO NOT scratch the interior and body paint when installing the fuel filler cap cable.
 Make sure the damaged clips are replaced and the fuel filler cap cable is installed in place when
installing the fuel filler cap cable.
 Check that the fuel filler cap cable can be used normally after installing the fuel filler cap cable.

BODY DIMENSIONS
GENERAL INFORMATION 48-3 Distances Between A-pillar Hinges 
Description 48-3 and B-pillar Hinges 48-10
Engine Compartment Dimensions 48-4 Distances Between B-pillars and 
C-pillars 48-11
Body Opening Dimensions (Front View) 48-5
Body Assembly Dimensions 48-13
Body Opening Dimensions (Side View) 48-6
Body Opening Dimensions (Rear View) 48-7 Front Body Assembly Dimensions 48-14
Side Body Assembly Dimensions 48-19
Body Opening Dimensions (Top View) 48-8
Rear Body Assembly Dimensions 48-23
Body Frame Dimensions 48-9
Sub Assembly Dimensions 48-28
48

48

48 - BODY DIMENSIONS
GENERAL INFORMATION
BODY DIMENSIONS
Description
 All measurements should be made from the bare metal. Remove the trim and bumper covers as
necessary.
 Repair the badly damaged areas before taking measurements for underbody alignment.
 Monitor the upper body structure for excessive stress or movement while making any corrections to the
underbody structure.
 Remove all the glasses as necessary to prevent breakage.
 All dimensions are shown in millimeters (mm).
48

Engine Compartment Dimensions
mm
1406
1155 mm
28
m 1402
m
9m
mm
737
RA19480010
48

Body Opening Dimensions (Front View)
142
9 mm 9m
1 42 m
RA19480030
48

Body Opening Dimensions (Side View)
13
8m
29
11
104
m
42
m
mm
m
9
m
1 00
811 mm 980 mm
RA19480020
48

Body Opening Dimensions (Rear View)
1101 mm
m
m
15
11
11
15
m
m
1205 mm
RA19480021
48

Body Opening Dimensions (Top View)
1087 mm
18
m
85
m
85
m
m
18
1105 mm
48
RA19480031

Body Frame Dimensions
499 mm
876 mm
873 mm
1068 mm
1247 mm
1105 mm
48
909 mm
1278 mm
RA19480032

Distances Between A-pillar Hinges and B-pillar Hinges
357mm
319 mm
RA19480060
48

Distances Between B-pillars and C-pillars
1487 mm
1372 mm
1119 mm
RA19480040
48

1497 mm
RA19480050
48

Body Assembly Dimensions

1. Gap is indicated by the standard distance measurement symbol .
2. Alignment measurement method and instructional symbol description:
a. Reference surface is indicated by .
b. The pointed surface is indicated by .
c. If the level is higher than the reference surface, the number is positive, whereas negative.
48

Front Body Assembly Dimensions
A 2
A 3
4
A
A 13
A 5
A
A 6
A
7
8 A 12
A 10 11
48 RA19480070

The clearance between side body and fender at A-1: 

3.0 ± 1.0 mm 0±1.0
The alignment between side body and fender at A-1: 
1.0
0 ± 1.0 mm 3.0±
SIDE BODY
FENDER
RA19480110
The clearance between front windshield lower garnish and

sealing block at A-2: 0.5 ± 0.5 mm 0±0.5
The alignment between front windshield lower garnish and
sealing block at A-2: 0 ± 0.5 mm
.5
0.5±0
SEALING BLOCK
FRONT WINDSHIELD LOWER GARNISH
RA19480150
The clearance between hood and fender at A-3: 4.0 ± 1.0 mm

The alignment between hood and fender at A-3: 0 ± 1.0 mm 0±1.0
4.0±1.0
FENDER HOOD
RA19480100
The clearance between headlight and hood at A-4: 

4.5 ± 1.2 mm
4.5±1.2
HOOD
HEADLIGHT 48
RA19480190


4.5 ~ 6.5 ± 1.2 mm
4.5~6.5±1.2
HOOD
HEADLIGHT
RA19480191

6.5 ± 1.2 mm
6.5±1.2
HOOD
HEADLIGHT
RA19480192
The clearance between front bumper and hood at A-7: 

6.5 ± 1.5 mm
The alignment between front bumper and hood at A-7: 
3.0
3.0 ± 1.5 mm
±1
HOOD
.5
6.5±1.5
FRONT BUMPER
RA19480090
The clearance between radiator grille and hood at A-8: 

7.0 ± 1.5 mm
HOOD
7.0±1.5
RADIATOR GRILLE
48
RA19480080

The clearance between radiator grille and front bumper at 

A-9: 1.0 ± 0.5 mm
RADIATOR GRILLE
1.0±0.5
FRONT BUMPER
RA19480140
The clearance between front bumper and headlight at A-10: 

3.0 ± 1.2 mm
HEADLIGHT
3.0±1.2
FRONT BUMPER
RA19480180
The clearance between front bumper and headlight at A-11: 

3.0 ± 1.2 mm
HEADLIGHT
3.0±1.2
FRONT BUMPER
RA19480170
The clearance between front bumper and fender at A-12: 

0.5 ± 0.5 mm
The alignment between front bumper and fender at A-12:  -0.7±0.7
-0.7 ± 0.7 mm
0.5±0.5
48
FRONT
FENDER BUMPER
RA19480130

The clearance between headlight and fender at A-13: 

2.0 ± 1.0 mm
-1.0±1.0
The alignment between headlight and fender at A-13:  2.0±1.0
-1.0 ± 1.0 mm
FENDER HEADLIGHT
RA19480120
48

Side Body Assembly Dimensions
B 4
B
B 5
3
B
B 1 9
B 6
B 12
B B B
B 11
10 7
8
RA19480200
The clearance between fender and front door at B-1: 

4.3 ± 1.0 mm 0.5+0.7/-0.5
The alignment between fender and front door at B-1:  4.3±1.0
0.5 + 0.7/-0.5 mm
FENDER
FRONT DOOR
RA19480282
48
The clearance between front door and side body at B-2: 
4.0 ± 1.2 mm -1.0~-2.0±1.0
The alignment between front door and side body at B-2: 
4.0±1.2
-1.0 ~ -2.0 ± 1.0 mm
SIDE BODY
FRONT DOOR
RA19480210


4.0 ± 1.2 mm -2.0±1.0
The alignment between front door and side body at B-3: 
4.0±1.2
-2.0 ± 1.0 mm
SIDE BODY
FRONT DOOR
RA19480211
The clearance between rear door and side body at B-4: 

4.0 ± 1.2 mm
The alignment between rear door and side body at B-4:  -2.0±1.0
-2.0 ± 1.0 mm 4.0±1.2
SIDE BODY
REAR DOOR
RA19480230

4.0 ± 1.2 mm
The alignment between rear door and side body at B-5:  -2.0±1.0~0+1.0/-0.5
-2.0 ± 1.0 ~ 0 + 1.0/-0.5 mm 4.0±1.2
SIDE BODY
REAR DOOR
RA19480231

4.0 ± 1.0 mm 0+1.0/-0.5
The alignment between rear door and side body at B-6: 
4.0±1.0
0 + 1.0/-0.5 mm
SIDE BODY
48
REAR DOOR
RA19480240


5.5 ~ 4.0 ± 1.5 mm
5.5~4.0±1.5
SIDE BODY
FRONT DOOR
RA19480251

5.5 ± 1.5 mm
5.5±1.5
SIDE BODY
FRONT DOOR
RA19480250
The clearance between front door and rear door at B-9: 

4.0 ± 1.0 mm
The alignment between front door and rear door at B-9:  0+1.0/-0.5
0 + 1.0/-0.5 mm
4.0±1.0
FRONT DOOR REAR DOOR
RA19480220

5.5.± 1.5 mm
5.5±1.5
FRONT DOOR
SIDE BODY
48
RA19480260

The clearance between fender and side body at B-11: 

3.0 ± 1.5 mm
The alignment between fender and side body at B-11: 
0 ± 1.5 mm FENDER SIDE BODY
3.0±1.5
0±1.5
RA19480270
The clearance between fender and front door at B-12: 

4.3 ~ 5.5 ± 1.0 mm
0.5+0.7/-0.5
The alignment between fender and front door at B-12:  4.3~5.5±1.0
0.5 + 0.7/-0.5 mm
FENDER
FRONT DOOR
RA19480280
48

Rear Body Assembly Dimensions
C C
2
1
C
C
C 3
4
5 C
6
C
7
14
C
C
12
C
8
C
C
C
C
9 11
13
10
RA19480281
The clearance between rear windshield and roof at C-1: N/A

The alignment between rear windshield and roof at C-1: 
48
-3.9±1.5
-3.9 ± 1.5 mm
N/A
ROOF
REAR WINDSHIELD
RA19480370

The alignment between roof side trim and roof at C-2: 

3.0 ± 0.5 mm
3.0±0.5
ROOF SIDE TRIM
ROOF
RA19480390
The alignment between roof edge and roof at C-2: 

0 ± 1.0 mm
ROOF
SIDE BODY
±1.0
RA19480590
The clearance between trunk lid and side body at C-3: 

4.0 ± 1.0 mm -2.0±1.0
The alignment between trunk lid and side body at C-3:  4.0±1.0
-2.0 ± 1.0 mm
TRUNK LID SIDE BODY
RA19480301

4.0 ± 1.0 mm -2.0~1.0±1.0
-2.0 ~ -1.0 ± 1.0 mm
48 TRUNK LID SIDE BODY
RA19480300


4.0 ± 1.0 mm -1.0+0/-1.0
-1.0 + 0/-1.0 mm
TRUNK LID SIDE BODY
RA19480302
The clearance between tail light and side body at C-6: 

2.0 ± 1.2 mm
-1.0±1.0
The alignment between tail light and side body at C-6: 
-1.0 ± 1.0 mm 2.0±1.2
TAIL LIGHT
SIDE BODY
RA19480290
The clearance between tail light and trunk lid at C-7: 

4.0 ± 1.2 mm 0±1.0~1.0±1.0
The alignment between tail light and trunk lid at C-7:  4.0±1.2
0 ± 1.0 ~ 1.0 ± 1.0 mm
TRUNK LID
TAIL LIGHT
RA19480321
The clearance between tail light and trunk lid at C-8: 

4.0 ~ 5.0 ± 1.2 mm 5.0±1.0
The alignment between tail light and trunk lid at C-8:  4.0~5.0±1.2
5.0 ± 1.0 mm
TRUNK LID
TAIL LIGHT 48
RA19480322

The clearance between trunk lid and rear bumper at C-9: 

6.0 ± 2.0 mm
TRUNK LID
6.0±2.0
REAR BUMPER
RA19480310
The clearance between rear bumper and trunk lid at C-10: 

4.0 ~ 6.0 ± 1.0 mm
TRUNK LID
4.0~6.0±1.0
REAR BUMPER
RA19480311
The clearance between tail light and rear bumper at C-11: 

2.0 ± 1.2 mm
TAIL LIGHT
2.0±1.2
REAR BUMPER
RA19480350
The clearance between tail light and side body at C-12: 

2.0 ± 1.2 mm
SIDE BODY
TAIL LIGHT
2.0±1.2
48
RA19480330

The clearance between rear bumper and side body at C-13: 

0.5 ± 0.5 mm
The alignment between rear bumper and side body at C-13:  REAR BUMPER
SIDE BODY
-0.7 ± 0.7 mm
0.5±0.5
-0.7±0.7
RA19480340
The clearance between fuel filler cap and side body at C-14:
3.0 ± 0.7 mm
The alignment between fuel filler cap and side body at C-14: -0.5±0.7
-0.5 ± 0.7 mm
3.0±0.7
FUEL
FILLER CAP
SIDE BODY
RA19480380
48

Sub Assembly Dimensions
D
2
D
3
8
D
4
D
D 6
D 5
7
D
RA19480410
The clearance between front windshield and roof at D-1: N/A

The alignment between front windshield and roof at D-1:  -3.9±1.5
48 -3.9 ± 1.5 mm
N/A
ROOF
FRONT WINDSHIELD
RA19480360

The clearance between front windshield and side body at 

D-2: 5.6 ± 2.0 mm
5.6±2.0
SIDE BODY
FRONT WINDSHIELD
RA19480400
The clearance between rear view mirror seat and front door
at D-3: 1.0 ± 1.0 mm
REAR VIEW MIRROR SEAT
1.0±1.0
FRONT DOOR
RA19480440
The clearance between outer triangular block and side body

at D-4: 1.0 ± 1.0 mm OUTER TRIANGULAR BLOCK
1.0±1.0
SIDE BODY
RA19480430
The clearance between fender and outer triangular block at

D-5: 1.0 ± 1.0 mm
FENDER
1.0±1.0
OUTER TRIANGULAR BLOCK
48
RA19480420

The clearance between rear view mirror seat and outer

triangular block at D-6: 4.3 ± 1.5 mm
The alignment between rear view mirror seat and outer 4.3±1.5
triangular block at D-6: -0.5 ± 1.0 mm REAR VIEW MIRROR SEAT
-0.5±1.0
OUTER TRIANGULAR BLOCK
RA19480450
The alignment between front door and fender at D-7: 

0 ± 1.0 mm
FRONT DOOR
±1.0
FENDER
RA19480500
The alignment between side body and fender at D-8: 

0 ± 1.0 mm
±1.0
SIDE BODY
FENDER
RA19480490
48

WIRE HARNESS
WIRE HARNESS INFORMATION 49-3 VEHICLE FUSE & RELAY 49-26
General Information 49-3 General Information 49-26
Description 49-3 Description 49-26
Circuit Diagram Information 49-3 Fuse & Relay 49-27
Circuit Diagram Instruction 49-4 Engine Compartment Fuse and 
Electrical Troubleshooting 49-7 Relay Box 49-27
Wire Harness Troubleshooting 49-7 Instrument Panel Fuse and Relay Box 49-28
Voltage Test 49-7 BCM Fuse Box 49-29
Circuit Continuity Test 49-7 VEHICLE WIRE HARNESS LAYOUT 49-30
Short Circuit Test 49-7
Electrical Troubleshooting Tools 49-8 Description 49-30
Electrical Repair 49-9
Vehicle Wire Harness Layout 49-31
Wire Harness Repair 49-9
Entire Vehicle Wire Harness Layout 49-31
Fuse Replacement 49-9 Engine Wire Harness 49-32
Electrical Components 49-10
Engine Compartment Wire Harness 49-34
VEHICLE POWER DISTRIBUTION 49-12 Instrument Panel Wire Harness 49-36
General Information 49-12 Body Wire Harness 49-39
Description 49-12 Front Left Door Wire Harness 49-42
Circuit Diagram 49-13 Front Right Door Wire Harness 49-43
Power Distribution 49-13 Rear Left Door Wire Harness 49-44
Rear Right Door Wire Harness 49-45
VEHICLE GROUND DISTRIBUTION 49-21 Rear Bumper Wire Harness 49-46
A/C Wire Harness 49-47
Description 49-21
Battery Positive/Negative 
Circuit Diagram 49-22 Wire Harness 49-48
Ground Distribution 49-22 Roof Wire Harness 49-49
Defroster Negative Wire Harness 49-50
49

49

49 - WIRE HARNESS
WIRE HARNESS INFORMATION

WIRE HARNESS
General Information
Description
The wire harness information contains basic introductions of circuit diagrams, inspection methods of cables
and connectors, as well as layout of connector positions and wire harness positions, etc.
Circuit Diagram Information

The circuit diagrams are classified into each chapter in Service Manual. If a component appears in a specific
system, its related information (such as wire harness, connector and terminal, etc.) will appear in the circuit
diagram and be introduced in detail. For example, the information of Engine Control Module (ECM) is mainly
introduced in chapter 6. If the component wire harnesses involve other systems, the component information
will also appear in the corresponding systems.
Chery automobile offers related circuit diagram information of the vehicle electrical equipment to help the
technicians determine and detect the vehicle malfunction effectively.
Functions and features of the circuit diagram:
 The power supply circuit is on the top of the page, while the ground circuit is at the bottom.
 Components (such as switches and fuses) are displayed on the circuit diagram in the form of simple icon.
49

49 - WIRE HARNESS
Circuit Diagram Instruction
EXAMPLE
[1] BATTERY
IGNITION SWITCH
ON OR START [13]
B+ ENGINE
COMPARTMENT
SB5 FUSE AND RELAY BOX [14]
[2] E-014
30A
E-049
D3
[3] A
A11 A13
2 3
INSTRUMENT
[4] MAIN
RELAY EF14 PANEL FUSE [15]
AND RELAY BOX
10A
1 5 I-004
EF19
15A
A4 A3 A1 [12]
VR
SENSOR
I-003
RW
1 2
BW
G
[5]
B
I-013
[6] 2 3 E-010
[8] [16]
10 13 3 4
1 CONTROL
MODULE
I-001
MOTOR 5 7
[7] M E-011
GR
O
TO BACKLIGHT [17]
V
POWER
I-006
2 6 1 6
B-008 SWITCH
[9]
B
I-009
5 [19]
[18]
[10] LIGHT
E-014 [11]
B-003 3 5
4
B-002 I-006
D1 D2 D3 D4 D5
1 2 3 4 5 6 7 8 9 10 11 12 13 A16 A15 A14 A9 A8 A7
14 15 16 17 18 19 20 21 22 23 24 25 26
A6 A5 A4
A13 A12 A11 A10
A3 A2 A1
[20] D6 D7 D8 D9 D10 D11 D12
49
E-049
I-001 I-004 [21] W
W W
2 1
1 2 3 4 5 6 7 8 4 5 6 1 2 B+
8 7 6 5 4 3 2 1 1 2 1 2 3 6 5 4 3
9 10 11 12 13 14 15 16
16 15 14 13 12 11 10 9
E-014
I-009 I-003
B-008 I-013 B-003
E-011 W W
W W W
Gr
EA19490000
The connector pin layout is shown at the bottom of the circuit diagram.

49 - WIRE HARNESS
The following is a list of the symbols defined in the circuit diagram.

It indicates the power supply from the battery positive to the
1 Battery
electrical equipment.
This symbol indicates a fuse; "SB5" indicates the fuse number;
2 Fuse
"30A" indicates the rated amperage of the fuse.
The solid circle indicates that each intersecting wire is
3 Splice Point
interconnected.
This symbol indicates a relay; "MAIN RELAY" indicates the relay
4 Relay
name; "1, 2, 3 and 5" indicate the terminal numbers of the relay.
It indicates the color of this wire. The color codes are as follows:
B = Black; W = White; R = Red; G = Green; L = Blue; Y = Yellow;
5 Color Br = Brown; O = Orange; Gr = Gray; P = Pink; V = Violet; Lg = Light
Green.
For example: "BrR" indicates that the main color is brown in the wire
color, and the second color is red.
It indicates the plug-in connector. "Λ" is the female connector, and 
"I-013" is the applicable number; "◊" is the male connector, and 
"E-010" is the applicable number. The number "2" inside the male
6 Connector
connector symbol indicates the used terminal number. "----"
indicates different terminals come from the same junction
connectors.
7 Motor This symbol indicates a motor.
8 Component Name It indicates the name of a component.
"E-011" indicates the connector number of the component. The letter
"E" indicates the wire harness code in which the connector is
located. The connector codes are as follows:
E = Engine Wire Harness, Engine Compartment Wire Harness;
I = Instrument Panel Wire Harness;
B = Body Wire Harness;
F = Front Left Door Wire Harness;
9 Connector No. H = Front Right Door Wire Harness;
L = Rear Left Door Wire Harness;
R = Rear Right Door Wire Harness;
T = Rear Bumper Wire harness;
K = A/C Wire Harness;
P = Battery Positive/Negative Wire Harness;
C = Roof Wire Harness.
49
10 Ground Point It indicates the ground connection.
11 Bulb This symbol indicates a bulb.
12 Terminal No. It indicates the terminal number in the connector of the component.
It indicates the power supply from the ignition switch to the electrical
13 Ignition Switch
equipment.
It indicates that the wire harness is connected to the circuit diagram
14 Connected to … on the next page. The letter "A" is connected with "A" in the circuit
diagram on the next page.

49 - WIRE HARNESS

15 Fuse and Relay Box Name It indicates the name of the fuse and relay box.
16 Twisted-pair It indicates that the two wires are twisted.
It indicates the backlight illumination power supply output from the
17 Backlight Power Supply
fuse of the front position light.
It is used for indicators, warning lights or illuminations in the
18 LED
switches or instrument cluster.
19 Switch This symbol indicates a switch.
It indicates the cross section of the connector and description of the
20 Connector View
terminal number.
The letter "W" indicates the color of the connector. The color codes
21 Connector Color
are the same as above.
49

49 - WIRE HARNESS
Electrical Troubleshooting
Wire Harness Troubleshooting
The following 6 steps help to troubleshoot the wire harness. Be sure to check the non-original components
added to the vehicle before performing any diagnosis. If the vehicle is equipped with these components,
disconnect them to verify these added components are not the cause of the problem.
Perform the following steps when troubleshooting the wire harness:
1. Verify the problem.
2. Look for any related symptom (by inspecting the components in the same circuit).
3. Analyze the symptom (use the wire harness diagram to determine the layout of the circuit, the area where
the problems most likely occur and the area where the diagnosis will continue).
4. Isolate the problem area.
5. Repair the problem area.
6. Check for proper operation (in this step, check all the items in the repaired circuit for proper operation).
Voltage Test
1. The negative probe (black) of the voltmeter is grounded.
2. Connect the positive probe (red) of the voltmeter to the selected measuring point (turn the ignition switch
on as necessary). Check the voltage value displayed on the voltmeter.
Circuit Continuity Test

1. Turn off all the electrical equipment and ignition switch, and disconnect the negative battery cable.
2. Remove the circuit to be tested.
3. Connect the two probes of the ohmmeter to the two ends of the circuit to be tested respectively, and check
the circuit continuity (low resistance means there is good continuity in the circuit).
Short Circuit Test

1. Measure and record the battery voltage.
2. Pull out the fuse of the circuit to be tested or disconnect the power supply end of the test circuit.
3. Connect the positive probe (red) of the voltmeter to the positive battery terminal and the negative probe
(black) to the power supply end of the circuit.
4. Check the voltage value displayed on the voltmeter. If the voltage value of the battery is displayed, it
indicates that the test circuit is shorted to ground.
49

49 - WIRE HARNESS
Electrical Troubleshooting Tools

1. Jumper Wire
a. The jumper wire is used to create a temporary circuit.
Connect the jumper wire between the terminals of a
circuit to bypass the switch.
RA19490010
CAUTION
 DO NOT connect a jumper wire from power supply end to body ground, as this may damage the wire
harnesses or electrical components.
2. Voltmeter
Power circuit
a. The voltmeter is used to measure the circuit voltage. Voltmeter
The measurement range should be higher than 15 V.
Measure the voltage by connecting the positive probe Black
V
- +
(red) of the voltmeter to the positive lead of the test
component and the negative probe (black) to the
negative lead or body ground.
Ground Red RA19490020
3. Ohmmeter
The ohmmeter is used to measure the resistance
between two points in a circuit, or check the circuit for an Power Supply
Line
open or short.
Ground Line
- +
Ohmmeter
RA19490030
49
CAUTION
 DO NOT connect the ohmmeter to the circuit when applying voltage to the circuit, as this may result in
inaccurate measured data or even damaging the ohmmeter.

49 - WIRE HARNESS
Electrical Repair
Wire Harness Repair
CAUTION
 Measure the length of the lead to be repaired and select a proper substitute lead before servicing.
 If there are several leads to be repaired, please stagger the repaired parts.
1. Peel off 0.5 inch insulating layer from the lead to be repaired and the substitute lead.
2. Connect the original lead to the substitute lead with the heat shrink tube and compress the metal core of
the heat shrink tube with a tool, so that the original lead and the substitute lead can be connected firmly.
3. Heat the heat shrink tube to shrink the outer rubber layer and ensure that the sealing of repaired area is in
good condition.
4. Wrap the repaired lead with insulating tape.
Fuse Replacement
CAUTION
 The energizing test should be performed after replacing the fuse. If the fuse is blown again, check the
corresponding circuit for short. If any electrical equipment or additional device which exceeds the rated
current is installed, replace it with the fuse with higher amperes.
1. Turn off all the electrical equipment and ignition switch before servicing.
2. Remove the blown fuse with a fuse puller.
3. Replace the fuse with a new one which has the same
specification. Pull
Puller
Fuse
RA19490040
49

49 - WIRE HARNESS
Electrical Components
1. Battery cable
a. Disconnect the negative battery cable (arrow) before
servicing the electrical components.
RA19490050
2. Sensor, switch and relay

a. Do not drop or tap the sensor, switch or relay to avoid
damaging the components during servicing.
RA19490060
CAUTION
 Use the relay of the same specification with the original one during replacement.
3. Connector
a. Disconnect the connector.
 Hold the connector by hand and press the
connector clip to disconnect it.
49 RA19490090
CAUTION
 DO NOT pull the wire harness forcibly to avoid damaging the components when disconnecting the
connector.

49 - WIRE HARNESS
 There are a variety of ways to fix the connector

clip, and the common disconnection methods are
RA19490100
b. Install the connector.

 A "click" can be heard when the connector is
installed in place.
ick
Cl
RA19490110
c. Replace the connector terminal.

 As shown in the illustration (1), insert a suitable
tool into the terminal to lift up the fixing clip, and 1
then pull out the terminal from behind.
 During installation, push the terminal from the back
of the connector to ensure that the fixing clip is
installed in place as shown in the illustration (2). 2
RA19490070
d. Check the connector terminal.

 Pull a single wire harness terminal gently to check
if it is installed in place.
49
RA19490120

49 - WIRE HARNESS
VEHICLE POWER DISTRIBUTION

General Information
Description
The power distribution system provides secure, reliable and efficient power for all electrical equipment on the
entire vehicle.
The power distribution system consists of the following components:
 Battery
 Engine compartment fuse and relay box
 Instrument panel fuse and relay box
 Ignition switch
 Fuse
 Relay
49

49 - WIRE HARNESS
Circuit Diagram
Power Distribution
Power Distribution (Page 1 of 8)
BATTERY
- +
BODY TRANSMISSION
POWER
BF01 FUSE BOX
150A P-002
5 4 6
GENERATOR STARTER POWER SUPPLY
49
P-002
EA19490010

49 - WIRE HARNESS
A A
EF13
30 86 30 86
HIGH LOW 30A
BEAM BEAM
RELAY RELAY
ENGINE
87 85 87 85 30 86 COMPARTMENT
STARTER FUSE AND
RELAY RELAY BOX
B-012
87 85 B-013
EF01 EF02 EF03 EF04
B-014
10A 10A 15A 15A E-039
B2 B1 A2 B3 B12 A16 D13 C3 A8
ECM
FRONT COMBINATION LIGHT BCM STARTER STARTER SWITCH
D13 D14 D15 D16
49
C11 C12 C13 C14
B-012 B-013
W W
A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5
A10 A11 A12 A13 B8 B9 B10 B11
A7 A8 A9 A14 A15 A16 B6 B7 B12 B13 B14
B-014 E-039
W W EA19490020

49 - WIRE HARNESS
A A
EF23 EF22
30 86 EF18
30A 40A
10A
ECU ENGINE
MAIN C COMPARTMENT
RELAY FUSE AND
87 85 RELAY BOX
30 86 30 86
HIGH B-013
LOW
FAN B-017
FAN
RELAY RELAY E-039
87 85 87 85
C17 K6 B11 C15 B9 C9
ECM CANISTER SOLENOID VALVE COOLING FAN
B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 C6 C7 H1 H2 H3 H4 H5 H6 H7
B6 B7
B8 B9 B10 B11
B12 B13 B14 C8 C9 C10
C11 C12 C13 C14
C15 C16 C17 C18 H8 H9 H10 H11H12H13H14 49
E-039 B-013 B-017
W W W
EA19490030

49 - WIRE HARNESS
A A
EF21 EF22
ENGINE
15A 40A
COMPARTMENT
EF16 EF17 EF20 EF15
C FUSE AND
15A 15A 10A 15A RELAY BOX
30 86 30 86
FUEL B-012
A/C
PUMP CLUTCH B-013
RELAY RELAY B-014
87 85 87 85 B-017
A15 C5 D14 C16 K4 D6 C6 C4 D5
FUEL LEVEL SENSOR AND ECM A/C PRESSURE IGNITION INJECTOR 1 UPSTREAM DOWN-
FUEL PUMP SWITCH COIL INJECTOR 2 OXYGEN STREAM
INJECTOR 3 SENSOR OXYGEN
INJECTOR 4 SENSOR
49 D9 D10 D11D12
D13 D14 D15 D16
D17 D18 D19 D20 C8 C9 C10
C11 C12 C13 C14
C15 C16 C17 C18
B-012 B-013
W W
A1 A2 A3 A4 A5 A6 H1 H2 H3 H4 H5 H6 H7
A10 A11 A12 A13
A7 A8 A9 A14 A15 A16 H8 H9 H10 H11H12H13H14
B-014 B-017
W W EA19490040

49 - WIRE HARNESS
A A
EF31
20A
ENGINE
COMPARTMENT
EF06 EF35 EF33
FUSE AND
40A 10A 15A RELAY BOX
30 86
B-010
FRONT
FOG B-013
RELAY B-014
87 85 E-039
B8 A9 E4 C1 A11
FRONT FOG LIGHT BCM ABS CONTROL MODULE ECM AUDIO

INSTRUMENT CLUSTER
C1 C2 C3 C4 C5 C6 C7 A1 A2 A3 A4 A5 A6
C8 C9 C10
C11 C12 C13 C14
C15 C16 C17 C18 A7 A8 A9
A10 A11 A12 A13
A14 A15 A16 49
B-013 B-014
W W
B1 B2 B3 B4 B5
B8 B9 B10 B11
B6 B7 B12 B13 B14 E4 E3 E2 E1
E-039 B-010
W W EA19490050

49 - WIRE HARNESS
7
B-021 I-047
IG1 IG2 B1 B2 ACC ST KEY IN SW
12A 12A 15A 15A
IGNITION
LOCK
SWITCH
ACC
I-042
ON
START
A D
RF16
ENGINE 10A
COMPARTMENT
FUSE AND 87 85
EF09 EF05 EF07 INSTRUMENT
RELAY BOX
40A 40A 30A BLOWER PANEL FUSE
B-010
RELAY AND RELAY
B-011 BOX
30 86
I-005
RF25
E1 E3 F2
5A
8 25 16
5
B-021 I-047
BLOWER AUDIO
BCM
HVAC CONTROL PANEL AND BLOWER SWITCH
F1 1 2 3 4 5 6 7 8 9 10 11 12
E4 E3 E2 E1
49 F2
13 14 15 16 17 18 19 20 21 22 23 24
B-010 B-011 25 26
W Lg 87
85 86 86 86
87 30 87 30
30 85 85
1 2 3 4
3 2 1
5 6 7 8 I-005
6 5 4
B
B-021 I-042
W L
EA19490060

49 - WIRE HARNESS
E E
D D
INSTRUMENT
RF17 RF07 RF08 RF09 RF05 RF04 RF03 PANEL FUSE
20A 20A 10A 10A 10A 10A 10A AND RELAY
BOX
I-005
17 7 8 9 5 4 3
FRONT WIPER REAR VIEW MIRROR ECM

MOTOR ADJUSTMENT SWITCH
CIGARETTE FRONT WASHER ABS CONTROL BCM

LIGHTER MOTOR MODULE DIAGNOSTIC INTERFACE
REVERSING RADAR SENSOR
HVAC Control Panel
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26
49
87
85 86 86 86
87 30 87 30
30 85 85
I-005
B
EA19490070

49 - WIRE HARNESS
RF22 RF23
10A 30A
INSTRUMENT
RF02 RF01 RF21 PANEL FUSE
85 30 85 30
10A 10A REAR DEFROST 10A AND RELAY
FOG RELAY BOX
RELAY I-005
RF26
86 87 86 87
10A
2 1 26 21
BRAKE SWITCH REAR FOG LIGHT POWER REAR VIEW

INSTRUMENT CLUSTER MIRROR HEAT
SRS CONTROL BCM REAR DEFROSTER BRAKE SWITCH

MODULE KEY SWITCH
DIAGNOSTIC INTERFACE
FRONT LEFT POWER
WINDOW SWITCH
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
49 87
25 26
85 86 86 86
87 30 87 30
30 85 85
I-005
B
EA19490080

49 - WIRE HARNESS
VEHICLE GROUND DISTRIBUTION

General Information
Description
The ground distribution system provides the centralized and convenient information about the ground
positions for the electrical equipment on the entire vehicle. Technicians can find the relevant electrical
equipment quickly through the ground points and solve the problem accurately and efficiently.
49

49 - WIRE HARNESS
Circuit Diagram
Ground Distribution
Ground Distribution (Page 1 of 4)
47
ECU 2
E-001
48
E-002
2 A/C PRESSURE SWITCH

E-027
E-026 2 RIGHT SIDE TURN LIGHT

E-021
1 FRONT RIGHT FOG LIGHT

E-025
5 RIGHT COMBINATION LIGHT

E-022
6
2 FRONT RIGHT RADAR SENSOR

E-024
1 COOLING FAN 1
E-031
E-036 1 COOLING FAN 2

E-032
2 HIGH HORN
E-033
5 LEFT COMBINATION LIGHT

E-037
6
1 FRONT LEFT FOG LIGHT

E-034
49
2 LEFT SIDE TURN LIGHT
E-040
2 LOW HORN
E-028
2 FRONT LEFT RADAR SENSOR

E-035
EA19490110

49 - WIRE HARNESS
4
DIAGNOSTIC INTERFACE
5 I-013
I-012
4 REAR VIEW MIRROR ADJUSTMENT SWITCH
I-008
1 STEERING WHEEL SWITCH 1

I-045
1 HEADLIGHT ADJUSTMENT SWITCH

I-014
2
LUGGAGE COMPARTMENT
OPENER SWITCH
4 I-009
11 FRONT LEFT POWER WINDOW SWITCH

5
F-004
I-010 F-007
2 FRONT LEFT DOOR LOCK ACTUATOR

F-002
10 POWER REAR VIEW MIRROR MOTOR

F-009
2 FRONT LEFT DOOR CONTACT SWITCH

F-001
2 CEILING LIGHT
9
C-001
I-001 C-002
16 SRS CONTROL MODULE

I-023
I-024
2 IMMOBILIZER CONTROL MODULE

I-032
I-026 1 AUDIO
I-037
4 STEERING WHEEL SWITCH 2

I-040
49
A5
2
HVAC Control Panel
K-008
A6
3
I-031 K-003
EA19490120

49 - WIRE HARNESS
2 CIGARETTE LIGHTER
I-020
I-027 5 WIPER SWITCH

I-041
2 HAZARD SWITCH
I-033
5
I-028
3 FRONT RIGHT DOOR CONTACT SWITCH

6
H-008
I-029 H-004
10 POWER REAR VIEW MIRROR MOTOR

H-001
3 FRONT RIGHT POWER WINDOW SWITCH

H-006
63
ECU 1
B-001
64
B-003
26 ABS CONTROL MODULE

B-007
B-006
2 BRAKE FLUID LEVEL SENSOR

B-018
B-016 4 FRONT WIPER MOTOR

B-019
2 ANTI-THEFT HORN
B-002
2 BACK-UP LIGHT SWITCH

2 E-007
B-020 E-012
2 REAR RIGHT COMBINATION LIGHT

B-045
49 B-030
1 FUEL LEVEL SENSOR AND FUEL PUMP
B-027
B-035
B6 BLOWER SWITCH
K-007
K-001
EA19490130

49 - WIRE HARNESS
2 DRIVER SEAT BELT SWITCH

B-024
B-023 2 CLUTCH SWITCH

B-054
3 REAR RIGHT POWER WINDOW SWITCH

6
R-003
B-052 R-001
3 REAR RIGHT DOOR CONTACT SWITCH

R-005
3 REAR LEFT POWER WINDOW SWITCH

6 L-003
B-029 L-005
2 REAR LEFT DOOR CONTACT SWITCH

L-001
1 HIGH MOUNTED STOP LIGHT

B-043
B-034 3 TAIL DOOR LOCK

B-042
3 REAR LEFT COMBINATION LIGHT

B-037
14
REVERSING RADAR SENSOR
B-036
16
3 CAMERA
2
T-006
2 LEFT CENTER RADAR SENSOR

7 T-003
B-031 T-005
2 REAR LEFT RADAR SENSOR
T-001
2 RIGHT CENTER RADAR SENSOR

T-008
2 REAR RIGHT RADAR SENSOR 49

T-009
1 LEFT LICENSE PLATE LIGHT

T-004
1 RIGHT LICENSE PLATE LIGHT

T-007
EA19490140

49 - WIRE HARNESS
VEHICLE FUSE & RELAY

General Information
Description
Each system should be equipped with fuses and relays to ensure the normal operation of vehicle electrical
system. The fuses and relays are integrated into the fuse and relay boxes which are installed in the following
specific positions of vehicle:
Engine compartment fuse and relay box: located on the left side of engine compartment and the rear side of
front left combination light.
Instrument panel fuse and relay box: located on the lower left side of instrument panel.
BCM fuse box: located on lower side of instrument panel.
49

49 - WIRE HARNESS
Fuse & Relay

Engine Compartment Fuse and Relay Box
EF16 15A
EF15 15A
EF18 10A
EF17 15A
EF20 10A
EF09
EF34
ECU A/C
40A
Main Clutch Spare
relay relay
EF05
40A
Low Fuel
EF03 15A
EF04 15A
beam pump
EF21 15A
EF24 20A
EF06
EF14
relay relay EF32
40A
Low
speed fan
EF33 15A relay
EF13 30A
EF31 20A
EF23
EF08
EF10
30A
EF01 10A
EF02 10A
High
beam Spaer EF07
relay 30A
Front EF12 80A
High
Starter
EF35 10A
fog speed fan

EF25
EF26
EF28
relay EF22
relay relay
40A
RA19490130
No. Description No. Description

EF01 Left Headlight High Beam EF17 ECU EMS
Canister/Fuel Pump/High-speed Fan
EF02 Right Headlight High Beam EF18
Relay/Low-speed Fan Relay Coil
EF03 Left Headlight Low Beam EF20 Injector
EF04 Right Headlight Low Beam EF21 Fuel Pump
EF05 Instrument Panel Fuse and Relay Box EF22 High-speed Fan
EF06 ABS Pump EF23 Low-speed Fan
EF07 Blower EF24 A/C
EF08 Reserve EF25 Reserve 49
EF09 Ignition Switch EF26 Reserve
EF10 Reserve EF28 Reserve
EF12 BCM EF31 Front Fog Light
EF13 Starter EF32 Reserve
EF14 Reserve EF33 Instrument Cluster/Audio System
EF15 Upstream/Downstream Oxygen Sensor EF34 Reserve
EF16 Ignition Coil EF35 ECU

49 - WIRE HARNESS
Instrument Panel Fuse and Relay Box
RF01 10A
RF02 15A
RF03 10A
RF04 10A
RF06 10A
RF07 20A
RF08 10A
RF09 10A
RF05 5A
RF10
RF11
RF12
RF21 10A
RF22 10A
RF23 30A
RF24 10A
RF16 10A
RF17 20A
RF20 30A
RF19 5A
RF13
RF14
RF15
RF18
RF26 10A
RF25 5A
Blower
relay
Defrost relay Rear fog relay
RA19490140
No. Description No. Description

RF01 Instrument Cluster RF14 -
RF02 Airbag RF15 -
Audio System/Sunroof Switch (If equipped)/
RF03 Diagnosis/Radar/A/C Control Panel/BCM RF16
Blower Relay Coil/BCM
RF04 ECU RF17 Cigarette Lighter
RF05 ABS RF18 -
RF06 TCU (If equipped) RF19 TCU (If equipped)
RF07 Front Wiper RF20 Sunroof (If equipped)
Key in Switch/Diagnosis/Stop Switch/Ignition
RF08 Front Washer RF21
Switch
RF09 Power Outside Rear View Mirror RF22 Rear Fog Light
RF10 - RF23 RF23
49 RF11 - RF24 Position Switch (If equipped)

RF12 - RF25 A/C Control Panel
RF13 - RF26 Rear View Mirror Heating (If equipped)

49 - WIRE HARNESS
BCM Fuse Box
1 2 3 4 5 6 1 2 3 4 5 6
7.5 A
25 A
10 A
10 A
15 A
25 A
5A
5A
RA19490150
No. No.
Description Description
(Left) (Right)
1 Reserve 1 Trunk Lock/Door Lock Motor
Front Left Position Light/Rear Left Position
2 Rear Left Lifter/Rear Right Lifter 2
Light
Front Right Position Light/Rear Right
3 Reserve 3 Position Light/Left License Plate Light/Right
License Plate Light
4 High Pitched Horn/Low Pitched Horn 4 Reserve
Dome Light/Front Left Map Light/Front Right
5 5 Reserve
Map Light/Key Light
6 Reserve 6 Front Left Lifter/Front Right Lifter
49

49 - WIRE HARNESS
VEHICLE WIRE HARNESS LAYOUT

General Information
Description
The wire harness layout introduces the location information of vehicle wire harness and electrical components
in the form of graphic. The entire vehicle wire harnesses are divided into the following parts:
 Entire Vehicle Wire Harness Layout
 Engine Wire Harness
 Engine Compartment Wire Harness
 Instrument Panel Wire Harness
 Body Wire Harness
 Front Left Door Wire Harness
 Front Right Door Wire Harness
 Rear Left Door Wire Harness
 Rear Right Door Wire Harness
 Rear Bumper Wire harness
 A/C Wire Harness
 Battery Positive/Negative Wire Harness
 Roof Wire Harness
 Defogger Negative Wire Harness
49

49 - WIRE HARNESS
Vehicle Wire Harness Layout

Entire Vehicle Wire Harness Layout
Engine Compartment Defroster Negative

Wire Harness A/C Wire Harness Roof Wire Harness Wire Harness
Front Right Door Rear Right Door Rear Bumper

Engine Wire Harness Wire Harness Wire Harness Wire Harness
Front Left Door

Wire Harness
Battery Positive Battery Negative Instrument Panel Body Rear Left Door
Wire Harness Wire Harness Wire Harness Wire Harness Wire Harness
EA19490150
49

49 - WIRE HARNESS
Engine Wire Harness
E-020 E-019 E-018 E-017 E-016 E-015 E-014 E-013
E-012
E-001
B-020
E-002
E-003 E-011
E-004 E-010
E-005
E-009
R-003
E-006 R-003
E-007 R-003
E-008
EA19490160
Connector Code Connector Color/Pin Connector Name

E-001 B/48 ECU 1
E-002 - Ground
E-003 B/3 Knock Sensor
E-004 B/2 Injector 1
49
E-005 B/1 Oil Pressure Switch
E-006 B/4 Upstream Oxygen Sensor
E-007 B/2 Back-up Light Switch
E-008 B/4 Downstream Oxygen Sensor
E-009 B/3 Camshaft Position Sensor
E-010 B/4 Ignition Coil
E-011 B/1 Starter Solenoid Switch

49 - WIRE HARNESS

E-012 B/16 to Body Wire Harness Connector B-020
E-013 B/3 Engine Speed Sensor
E-014 B/2 Coolant Temperature Sensor
E-015 B/6 Throttle Position Sensor
E-018 B/2 Canister Solenoid Valve
E-019 B/4 Intake Pressure/Temperature Sensor
49

49 - WIRE HARNESS
Engine Compartment Wire Harness
E-040
E-021
E-039
B-008
E-038
E-022 E-037
E-023
E-036
E-024 E-035
E-025 E-034
E-026
R-003 R-003
E-027 R-003
E-028 R-003
E-029 R-003
E-030 R-003
E-031 R-003
E-032 R-003
E-033
EA19490170

E-021 W/2 Right Side Turn Light
E-022 B/10 Right Combination Light
E-023 Gr/2 Front Washer Motor
E-024 Lg/2 Front Right Radar Sensor
E-025 B/2 Front Right Fog Light
49 E-026 - Ground
E-027 B/2 A/C Pressure Switch
E-028 Gr/2 Low Horn
E-029 G/1 Power Steering Pump Switch
E-030 - Generator
E-031 B/3 Cooling Fan 1
E-032 B/3 Cooling Fan 2

49 - WIRE HARNESS

E-033 Gr/2 High Horn
E-034 B/2 Front Left Fog Light
E-035 Lg/2 Front Left Radar Sensor
E-036 - Ground
E-037 B/10 Left Combination Light
E-038 B/16 to Body Wire Harness Connector B-008
E-039 W/14 Engine Compartment Fuse and Relay Box (B)
E-040 W/2 Left Side Turn Light
49

49 - WIRE HARNESS
Instrument Panel Wire Harness
I-047 B-021 I-046 I-045 I-044 I-043 I-042 I-018 I-041 I-039 I-019 I-040 I-038 I-053
C-002
I-001
I-002 I-037
I-003 I-036
B-050 I-035
B-053 I-034
I-004 I-033
I-005 I-032
I-006 I-031
K-003
I-007 I-030
I-008 H-003
I-009
STORAGE BOX
H-004
F-007 I-029
I-010 I-028
F-006
I-011
I-012
I-052
I-051
I-050
R-003
I-013 R-003
I-014 R-003
I-015 R-003
I-016 R-003
I-017 R-003
I-048 I-049 R-003
I-020 R-003
I-021 R-003
I-022 R-003
I-023 R-003
I-024 R-003
I-025 R-003
I-026 R-003
I-027
EA19490180

I-001 W/10 to Roof Wire Harness C-002
I-002 Gr/1 Antenna
I-003 W/42 to Body Wire Harness Connector B-050
I-004 L/42 to Body Wire Harness Connector B-053
I-005 B Instrument Panel Fuse and Relay Box
I-006 L/32 BCM (B)
49
I-007 B/1 BCM (E)
I-008 B/10 Rear View Mirror Adjustment Switch
I-009 B/8 Luggage Compartment Opener Switch
I-010 W/16 to Front Left Door Wire Harness Connector F-007
I-011 W/14 to Front Left Door Wire Harness Connector F-006
I-012 - Ground
I-013 B/16 Diagnostic Interface

49 - WIRE HARNESS

I-014 Gr/6 Headlight Adjustment Switch
I-015 W/12 BCM (D)
I-016 W/2 Ignition Switch Light
I-017 W/4 Key Switch
I-018 Y/2 to Spiral Cable Connector I-048
I-019 Lg/1 to Spiral Cable Connector I-049
I-020 W/2 Cigarette Lighter
I-021 W/2 to Instrument Panel Wire Harness Connector I-022
I-022 W/2 to Cigarette Lighter Wire Harness Connector I-021
I-023 G/32 SRS Control Module
I-024 - Ground
I-025 B/8 USB 1
I-026 - Ground
I-027 - Ground
I-028 - Ground
I-029 W/14 to Front Right Door Wire Harness Connector H-004
I-030 W10 to Front Right Door Wire Harness Connector H-003
I-031 W/15 to A/C Wire Harness Connector K-003
I-032 B/8 Immobilizer Control Module
I-033 B/6 Hazard Switch
I-034 G/2 Front Passenger Airbag
I-035 B/1 Antenna
I-036 B/8 USB 2
I-037 B/16 Audio
I-038 B/4 Adjustment Switch
I-039 Lg/2 Anti-theft Indicator
I-040 W/4 to Spiral Cable Connector I-050
I-041 B/10 Wiper Switch
I-042 L/6 Ignition Switch
I-043 L/32 Instrument Cluster
49
I-044 Lg/4 Brake Switch
I-045 W/13 Combination Light Switch
I-046 G/32 BCM (A)
I-047 W/8 to Body Wire Harness Connector B-021
I-048 Y/2 to Instrument Panel Wire Harness Connector I-018
I-049 Lg/1 to Instrument Panel Wire Harness Connector I-019
I-050 W/4 to Instrument Panel Wire Harness Connector I-040

49 - WIRE HARNESS

I-051 Y/2 Driver Airbag
I-052 Lg/1 Horn Switch
I-053 W/4 Remote Audio System Controls
49

49 - WIRE HARNESS
Body Wire Harness
E-012 B-020 B-019 B-018 B-017 B-016
B-001
B-002
B-003
B-004
B-005
B-006
B-007
E-038
B-008
B-009 B-010 B-011 B-012 B-013 B-014 B-015

EA19490190

B-001 B/64 ECU 2
B-002 B/2 Anti-theft Horn
B-003 - Ground
B-004 B/4 A/C High/Low Pressure Switch
B-005 B/2 Front Right Wheel Speed Sensor
B-006 - Ground
B-007 B/26 ABS Control Module
B-008 B/16 to Engine Compartment Wire Harness Connector E-038
B-009 - Fuse Box 49
B-010 W/4 Engine Compartment Fuse and Relay Box (E)
B-011 Lg/2 Engine Compartment Fuse and Relay Box (F)
Engine Compartment Fuse and Relay Box (D)B-013W/
B-012 W/20
18 Engine Compartment Fuse and Relay Box (C)
B-014 W/16 Engine Compartment Fuse and Relay Box (A)
B-015 B/2 Front Left Wheel Speed Sensor
B-016 - Ground

49 - WIRE HARNESS

Ground W/14 Engine Compartment Fuse and Relay Box (K)
B-018 W/2 Brake Fluid Level Sensor
B-019 B/6 Front Wiper Motor
B-020 B/16 to Engine Wire Harness Connector E-012
B-058 B-054 B-053 B-052 R-001 B-051 B-050 B-049 B-048 B-047 B-026 B-046 B-045
B-044
B-043
B-042
B-041
B-040
B-039
B-038
B-037
B-036
B-035
B-034
B-033
T-002
B-032
T-005
B-031
B-030
B-025
I-004 I-003 I-047 B-021 B-022 B-023 B-024 B-027 B-029 L-005
EA19490200

B-021 W/8 to Instrument Panel Wire Harness Connector I-047
B-022 W/1 Parking Brake Switch
49 B-023 - Ground
B-024 W/2 Driver Seat Belt Switch
B-025 - Ground
B-026 Gr/1 Antenna
B-027 B/5 Fuel Level Sensor and Fuel Pump
B-029 W/14 to Rear Left Door Wire Harness Connector L-005
B-030 - Ground
B-031 B/8 to Rear Bumper Wire Harness Connector T-005

49 - WIRE HARNESS

B-032 B/4 to Rear Bumper Wire Harness Connector T-002
B-033 W/2 Rear Left Wheel Speed Sensor
B-034 - Ground
B-035 - Ground
B-036 W/16 Reversing Radar Sensor
B-037 W/6 Rear Left Combination Light
B-038 G/1 Luggage Compartment Light 1
B-039 B/1 Rear Defroster
B-040 B/2 Rear Left Low Speaker
B-041 G/1 Luggage Compartment Light 2
B-042 W/3 Tail Door Lock
B-043 W/2 High Mounted Stop Light
B-044 B/2 Rear Right Low Speaker
B-045 W/6 Rear Right Combination Light
B-046 W/2 Rear Right Wheel Speed Sensor
B-047 W/1 Antenna Amplifier
B-048 Gr/1 BCM (F) Power Supply
B-049 W/20 BCM (C)
B-050 W/42 to Instrument Panel Wire Harness Connector I-003
B-051 Gr/1 Antenna
B-052 W/14 to Rear Right Door Wire Harness Connector R-001
B-053 L/42 to Instrument Panel Wire Harness Connector I-004
B-054 B/2 Clutch Switch
B-058 B/6 Electronic Accelerator Pedal
49

49 - WIRE HARNESS
Front Left Door Wire Harness
F-009
F-008
F-007
F-001
I-010
F-002
I-011
F-003
F-006
F-004 F-005
EA19490210

F-001 B/4 Front Left Door Contact Switch
F-002 Gr/4 Front Left Door Lock Actuator
F-003 B/2 Front Left Door Lock Motor
F-004 Br/16 Front Left Power Window Switch
F-005 B/2 Front Left Low Speaker
49 F-006 W/14 to Instrument Panel Wire Harness Connector I-011
F-007 W/16 to Instrument Panel Wire Harness Connector I-010
F-008 Gr/2 Front Left Power Window Regulator Motor
F-009 W/12 Power Rear View Mirror Motor

49 - WIRE HARNESS
Front Right Door Wire Harness
H-001
H-002
H-003
H-008
I-030
I-029
H-007
H-004
H-005 H-006
EA19490220

H-001 W/12 Power Rear View Mirror Motor
H-002 Gr/2 Front Right Power Window Regulator Motor
H-003 W/10 to Instrument Panel Wire Harness Connector I-030
H-004 W/14 to Instrument Panel Wire Harness Connector I-029
H-005 B/2 Front Right Low Speaker
H-006 B/10 Front Right Power Window Switch
49
H-007 B/2 Front Right Door Lock Motor
H-008 B/4 Front Right Door Contact Switch

49 - WIRE HARNESS
Rear Left Door Wire Harness
L-005
L-001
B-029
L-002
L-003 R-003
L-004
EA19490230

L-001 B/4 Rear Left Door Contact Switch
L-002 B/2 Rear Left Door Lock Motor
L-003 B/10 Rear Left Power Window Switch
L-004 Gr/2 Rear Left Power Window Regulator Motor
L-005 W/14 to Body Wire Harness Connector B-029
49

49 - WIRE HARNESS
Rear Right Door Wire Harness
R-001
R-005
B-052
R-004
R-002 R-003
EA19490240

R-001 W/14 to Body Wire Harness Connector B-052
R-002 Gr/2 Rear Right Power Window Regulator Motor
R-003 B/10 Rear Right Power Window Switch
R-004 B/2 Rear Right Door Lock Motor
R-005 B/4 Rear Right Door Contact Switch
49

49 - WIRE HARNESS
Rear Bumper Wire Harness
T-001 T-009
T-002 B-032 T-003 T-004 T-005 T-006 B-031 T-007 T-008
EA19490250

T-001 L/2 Rear Left Radar Sensor
T-002 B/4 to Body Wire Harness Connector B-032
T-003 L/2 Left Center Radar Sensor
T-004 B/2 Left License Plate Light
T-005 B/8 to Body Wire Harness Connector B-031
T-006 B/4 Camera
49 T-007 B/2 Right License Plate Light
T-008 L/2 Right Center Radar Sensor
T-009 L/2 Rear Right Radar Sensor

49 - WIRE HARNESS
A/C Wire Harness
K-009 K-008 K-007
K-006
K-005
STORAGE BOX
K-004
K-003
I-031
K-002
K-001
EA19490260

K-001 - Ground
K-002 W/2 Evaporator Temperature Sensor
K-003 W/15 To Instrument Panel Wire Harness Connector I-031
K-004 W/2 Blower
K-005 W/4 Speed Resistor
K-006 L/6 Inner and Outer Circulation Motor
K-007 W/6 Blower Switch
49
K-008 B/20 HVAC Control Panel
K-009 W/7 Mode Damper Motor

49 - WIRE HARNESS
Battery Positive/Negative Wire Harness
N-001
N-002
P-001
P-002
P-004 P-003
N-003
EA19490270

P-001 - Engine Compartment Fuse Box Power Supply
P-002 - Power Fuse Box
P-003 - Starter Power Supply
49 P-004 - Generator
N-001 - Body Ground
N-002 - Battery Negative
N-003 - Transmission Ground

49 - WIRE HARNESS
Roof Wire Harness
C-001
C-002
I-001
EA19490280

C-001 W/6 Ceiling Light
C-002 W/10 to Instrument Panel Wire Harness Connector I-001
49

49 - WIRE HARNESS
Defroster Negative Wire Harness
G-001
G-002
EA19490290

G-001 B/1 Defroster Negative
G-002 - Ground
49

INDEX
A D
Abbreviation Table,  Diagnosis & Testing, 
Introduction..................................................02-26 Air Conditioning ...........................................29-12
Adjustment Item,  Diagnosis & Testing, 
Maintenance ..................................................05-7 Audio System.................................................37-9
Air Conditioning................................................29-1 Diagnosis & Testing, 
Air Conditioning,  Axle................................................................21-9
Preparation ..................................................03-32 Diagnosis & Testing, 
Air Conditioning,  Brake .............................................................25-9
Service Specifications..................................04-35 Diagnosis & Testing, 
Audio System ...................................................37-1 Brake Control System..................................24-13
Audio System,  Diagnosis & Testing, 
Preparation ..................................................03-39 Clutch.............................................................18-7
Audio System,  Diagnosis & Testing, 
Service Specifications..................................04-43 Differential......................................................20-6
Axle ..................................................................21-1 Diagnosis & Testing, 
Door Lock ....................................................35-14
Axle, 
Engine Immobilizer ........................................32-6
Axle, 
Hydraulic Assist Steering ...............................28-7
B Diagnosis & Testing, 
Instrument Cluster .......................................36-10
Body Dimensions .............................................48-1 Diagnosis & Testing, 
Brake................................................................25-1 Lighting System ...........................................33-19
Brake Control System ......................................24-1 Diagnosis & Testing, 
Parking Brake ................................................26-6
Brake Control System, 
QR515MHA Transmission ...........................17-10
Brake Control System, 
Rear View Mirror............................................42-7
Brake, 
Reversing Radar System...............................38-8
Brake, 
Seat Belt ........................................................31-7
C Diagnosis & Testing, 
SQR477F Charging System ..........................16-6
Circuit Diagnosis Information,  Diagnosis & Testing, 
Introduction..................................................02-14 SQR477F Cooling System........................... 12-11
Circuit Information,  Diagnosis & Testing, 
Introduction..................................................02-21 SQR477F Emission Control System..............09-6
Clutch ...............................................................18-1 Diagnosis & Testing, 
Clutch,  SQR477F Engine Management System......06-18
Clutch,  SQR477F Engine Mechanical .....................07-17
SQR477F Exhaust System............................ 11-6
Diagnosis & Testing, 
SQR477F Fuel Supply System....................08-10
Chery Automobile Co., Ltd. ID–1

INDEX

SQR477F Ignition System .............................14-6 G
General Information, 
SQR477F Intake System...............................10-8
Air Conditioning .............................................29-3
SQR477F Lubrication System .......................13-8
Audio System.................................................37-3
SQR477F Starting System ............................15-6
Axle................................................................21-3
Steering Column ............................................27-6
Body Dimensions...........................................48-3
Supplemental Restraint System ....................30-8
Brake .............................................................25-3
Suspension....................................................22-9
Brake Control System....................................24-3
Tire and Wheel ..............................................23-6
Clutch.............................................................18-3
Windshield/Window Glass ...........................41-12
Differential......................................................20-3
Wiper and Washer .........................................34-7
Door Lock ......................................................35-3
Horn...............................................................39-6
Drive Shaft .....................................................19-3
Differential ........................................................20-1
Differential,  Engine Hood/Door .........................................45-3
Preparation ..................................................03-23
Differential,  Engine Immobilizer ........................................32-3
Service Specifications..................................04-23
Door Lock.........................................................35-1 Exterior ..........................................................46-3
Door Lock,  General Information, 
Preparation ..................................................03-37 Hydraulic Assist Steering ...............................28-3
Door Lock,  General Information, 
Service Specifications..................................04-41 Instrument Cluster .........................................36-3
Drive Shaft .......................................................19-1 General Information, 
Drive Shaft,  Instrument Panel............................................43-3
Service Specifications..................................04-22 General Information, 
Interior............................................................47-3
E General Information, 
Lighting System .............................................33-3
Engine Hood/Door............................................45-1
Engine Hood/Door,  Other System.................................................40-3
Preparation ..................................................03-45
Engine Hood/Door,  Parking Brake ................................................26-3
Engine Immobilizer...........................................32-1 QR515MHA Transmission .............................17-3
Engine Unit Repair,  General Information, 
SQR477F Engine Mechanical .....................07-62 Rear View Mirror............................................42-3
Exterior.............................................................46-1 General Information, 
Exterior,  Reversing Radar System...............................38-3
Preparation ..................................................03-46 General Information, 
Exterior,  Seat ...............................................................44-3
ID–2 Chery Automobile Co., Ltd.

INDEX
Seat Belt ........................................................31-3 I
Inspection Items, 
SQR477F Charging System ..........................16-3
Maintenance ..................................................05-8
Instrument Cluster ............................................36-1
SQR477F Cooling System ............................12-3
Instrument Cluster, 
Preparation ..................................................03-38
SQR477F Emission Control System .............09-3
Instrument Cluster, 
SQR477F Engine Management System .......06-3
Instrument Panel ..............................................43-1
SQR477F Engine Mechanical .......................07-3 Instrument Panel, 
Preparation ..................................................03-44
SQR477F Exhaust System............................ 11-3 Instrument Panel, 
SQR477F Fuel Supply System......................08-3 Interior ..............................................................47-1
General Information,  Interior, 
SQR477F Ignition System .............................14-3 Preparation ..................................................03-47
General Information,  Interior, 
SQR477F Intake System...............................10-3 Service Specifications..................................04-54
General Information,  Introduction ......................................................02-1
SQR477F Lubrication System .......................13-3
General Information,  L
SQR477F Starting System ............................15-3
Lighting System................................................33-1
Steering Column ............................................27-3 Lighting System, 
Preparation ..................................................03-35
Supplemental Restraint System ....................30-3 Lighting System, 
Suspension....................................................22-3
M
Tire and Wheel ..............................................23-3 Maintenance.....................................................05-1
General Information,  Maintenance Items, 
Windshield/Window Glass .............................41-3 Maintenance ..................................................05-3
Wiper and Washer .........................................34-3 O
Horn...............................................................39-3 On-vehicle Service, 
Air Conditioning ...........................................29-15
H On-vehicle Service, 
Audio System............................................... 37-11
Horn .................................................................39-1 On-vehicle Service, 
Horn,  Axle..............................................................21-10
Preparation ..................................................03-41 On-vehicle Service, 
Horn,  Brake ...........................................................25-12
Service Specifications..................................04-45 On-vehicle Service, 
Hydraulic Assist Steering .................................28-1 Brake Control System..................................24-57
Hydraulic Assist Steering,  On-vehicle Service, 
Preparation ..................................................03-31 Clutch.............................................................18-8
Hydraulic Assist Steering,  On-vehicle Service, 
Service Specifications..................................04-34 Differential......................................................20-7

INDEX
On-vehicle Service,  On-vehicle Service, 

Door Lock ....................................................35-40 SQR477F Lubrication System ..................... 13-11
Drive Shaft.....................................................19-5 SQR477F Starting System.............................15-8
Engine Hood/Door .........................................45-9 Steering Column ............................................27-9
Engine Immobilizer ........................................32-7 Supplemental Restraint System ..................30-41
Exterior ..........................................................46-7 Suspension .................................................. 22-11
Hydraulic Assist Steering.............................28-12 Tire and Wheel ..............................................23-8
Instrument Cluster .......................................36-34 Windshield/Window Glass ...........................41-48
Instrument Panel .........................................43-10 Wiper and Washer .........................................34-8
Interior ...........................................................47-8 Horn .............................................................39-15
On-vehicle Service,  Other System ...................................................40-1
Lighting System ...........................................33-61
On-vehicle Service,  P
Other System.................................................40-5
On-vehicle Service,  Parking Brake...................................................26-1
Parking Brake ................................................26-7 Parking Brake, 
On-vehicle Service,  Preparation ..................................................03-29
QR515MHA Transmission ...........................17-12 Parking Brake, 
On-vehicle Service,  Service Specifications..................................04-32
Rear View Mirror............................................42-8 Preparation.......................................................03-1
On-vehicle Service, 
Reversing Radar System...............................38-9 Q
Seat ...............................................................44-7 QR515MHA Transmission................................17-1
On-vehicle Service,  QR515MHA Transmission, 
Seat Belt ........................................................31-8 Preparation ..................................................03-20
On-vehicle Service,  QR515MHA Transmission, 
SQR477F Charging System ..........................16-7 Service Specifications..................................04-19
SQR477F Cooling System ..........................12-14 R
On-vehicle Service,  Rear View Mirror ..............................................42-1
SQR477F Emission Control System .............09-7
Rear View Mirror, 
On-vehicle Service,  Preparation ..................................................03-43
SQR477F Engine Management System ...06-196
Rear View Mirror, 
On-vehicle Service,  Service Specifications..................................04-47
SQR477F Engine Mechanical .....................07-21
Replacement Instruction, 
On-vehicle Service,  Maintenance ..................................................05-6
SQR477F Exhaust System............................ 11-7
Reversing Radar System .................................38-1
Reversing Radar System, 
SQR477F Fuel Supply System....................08-13
Preparation ..................................................03-40
Reversing Radar System, 
SQR477F Ignition System .............................14-8
SQR477F Intake System...............................10-9

INDEX
SQR477F Ignition System, 

S Preparation ..................................................03-17
SQR477F Ignition System, 
Seat..................................................................44-1
Seat Belt ..........................................................31-1
SQR477F Intake System..................................10-1
Seat Belt, 
SQR477F Intake System, 
Preparation ..................................................03-34
Preparation ..................................................03-13
Seat Belt, 
SQR477F Intake System, 
Seat, 
SQR477F Lubrication System..........................13-1
SQR477F Lubrication System, 
Service Information, 
Preparation ..................................................03-16
Introduction....................................................02-3
SQR477F Lubrication System, 
Service Specifications ......................................04-1
SQR477F Charging System.............................16-1
SQR477F Starting System ...............................15-1
SQR477F Charging System, 
SQR477F Starting System, 
Preparation ..................................................03-19
Preparation ..................................................03-18
SQR477F Charging System, 
SQR477F Starting System, 
SQR477F Cooling System ...............................12-1
Steering Column...............................................27-1
SQR477F Cooling System, 
Steering Column, 
Preparation ..................................................03-15
Preparation ..................................................03-30
SQR477F Cooling System, 
Steering Column, 
SQR477F Emission Control System ................09-1
Supplemental Restraint System .......................30-1
SQR477F Emission Control System, 
Supplemental Restraint System, 
Preparation ..................................................03-12
Preparation ..................................................03-33
SQR477F Emission Control System, 
Supplemental Restraint System, 
Service Specifications.................................. 04-11
SQR477F Engine Management System ..........06-1
Suspension ......................................................22-1
SQR477F Engine Management System, 
Suspension, 
Preparation ....................................................03-3
Preparation ..................................................03-26
SQR477F Engine Management System, 
Suspension, 
Service Specifications....................................04-3
SQR477F Engine Mechanical..........................07-1
SQR477F Engine Mechanical,  T
Preparation ....................................................03-5
SQR477F Engine Mechanical,  Tire and Wheel .................................................23-1
Service Specifications....................................04-4 Tire and Wheel, 
SQR477F Exhaust System .............................. 11-1 Service Specifications..................................04-28
SQR477F Exhaust System, 
Preparation ..................................................03-14 V
SQR477F Exhaust System, 
Service Specifications..................................04-13 Vehicle Fuse & Relay, 
Wire Harness ...............................................49-26
SQR477F Fuel Supply System ........................08-1
Vehicle Ground Distribution, 
SQR477F Fuel Supply System, 
Wire Harness ...............................................49-21
Preparation .................................................. 03-11
Vehicle Information, 
SQR477F Fuel Supply System, 
Introduction ..................................................02-10
Vehicle Power Distribution, 
SQR477F Ignition System................................14-1
Wire Harness ...............................................49-12

INDEX
Vehicle Wire Harness Layout, 

Wire Harness...............................................49-30
W
Wheel Alignment, 
Suspension..................................................22-40
Windshield/Window Glass................................41-1
Windshield/Window Glass, 
Preparation ..................................................03-42
Windshield/Window Glass, 
Wiper and Washer ...........................................34-1
Wiper and Washer, 
Preparation ..................................................03-36
Wiper and Washer, 
Wire Harness ...................................................49-1
Wire Harness Information, 
Wire Harness.................................................49-3

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CHERY A19 CAUTION:

This manual is only for specialized

2014 without proper equipment and tools, it may

In order to prevent dangerous operation and

All Rights Reserved © 2014

VEHICLE INFORMATION 02-10

Chery Automobile Co., Ltd. 02–1

02–2 Chery Automobile Co., Ltd.

How to Use This Manual

Chery Automobile Co., Ltd. 02–3

02–4 Chery Automobile Co., Ltd.

 Always wear a clean uniform.

Chery Automobile Co., Ltd. 02–5

2. Jacking up and supporting vehicle

02–6 Chery Automobile Co., Ltd.

b. Precautions for using a plate type lifter

Chery Automobile Co., Ltd. 02–7

8. Lubrication and seal

02–8 Chery Automobile Co., Ltd.

Seal Lock Adhesive 02

11. Rubber parts and rubber hoses

- Cool the exhaust pipe with a fan.

Chery Automobile Co., Ltd. 02–9

The code can also be found on the body bottom board

Vehicle Identification Number (VIN)

WMI VDS VIS

ƶƶƶ ƶƶƶƶƶƶ ƶƶƻƻƻƻƻƻ

□: represents a letter or a number (letters I, O and Q cannot be used); ○: represents a number.

02–10 Chery Automobile Co., Ltd.

 The first three digits of VIN represent world manufacturer identifier.

No. WMI Code Vehicle Category

 The fourth digit of VIN represents vehicle type.

marked with chassis number and engine number.

Chery Automobile Co., Ltd. 02–11

02–12 Chery Automobile Co., Ltd.

1 - Seat Belt Reminder Light 2 - ABS Warning Light

Chery Automobile Co., Ltd. 02–13

CIRCUIT DIAGNOSIS INFORMATION

ECM Control System Troubleshooting

Diagnosis and Troubleshooting

Procedure Types Details Troubleshooting Methods

2. Detailed troubleshooting steps

02–14 Chery Automobile Co., Ltd.

Circuit Simulation Test

Chery Automobile Co., Ltd. 02–15

 DO NOT heat the components to a temperature higher than 60°C (140°F).

02–16 Chery Automobile Co., Ltd.

6. Cold/hot start test

Chery Automobile Co., Ltd. 02–17

Precautions for Control Module and Electrical Components Inspection

02–18 Chery Automobile Co., Ltd.

How to Check Connector

1. Check connector with a digital multimeter

Chery Automobile Co., Ltd. 02–19

02–20 Chery Automobile Co., Ltd.

 The terminal side view in the circuit diagram is shown

Connector Symbol Connector

MANUAL TRANSMISSION AUTO TRANSMISSION

Chery Automobile Co., Ltd. 02–21

3. Circuit diagram example

02–22 Chery Automobile Co., Ltd.

The following is a list of symbols defined in the circuit diagram.

No. Definition Description